For the rear brake caliper [A], change the brake

For the rear brake caliper [A], change the brake
VULCAN 1700 NOMAD
VN1700 CLASSIC TOURER
Motorcycle
Service Manual
Quick Reference Guide
This quick reference guide will assist
you in locating a desired topic or procedure.
•Bend the pages back to match the
black tab of the desired chapter number with the black tab on the edge at
each table of contents page.
•Refer to the sectional table of contents
for the exact pages to locate the specific topic required.
General Information
1 j
Periodic Maintenance
2 j
Fuel System (DFI)
3 j
Cooling System
4 j
Engine Top End
5 j
Clutch
6 j
Engine Lubrication System
7 j
Engine Removal/Installation
8 j
Crankshaft/Transmission
9 j
Wheels/Tires
10 j
Final Drive
11 j
Brakes
12 j
Suspension
13 j
Steering
14 j
Frame
15 j
Electrical System
16 j
Appendix
17 j
VULCAN 1700 NOMAD
VN1700 CLASSIC TOURER
Motorcycle
Service Manual
All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise,
without the prior written permission of Quality Assurance Division/Consumer Products & Machinery
Company/Kawasaki Heavy Industries, Ltd., Japan.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible
care has been taken to make it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incurring an obligation
to make such changes to products manufactured previously. See your Motorcycle dealer for the latest
information on product improvements incorporated after this publication.
All information contained in this publication is based on the latest product information available at the time
of publication. Illustrations and photographs in this publication are intended for reference use only and may
not depict actual model component parts.
© 2009 Kawasaki Heavy Industries, Ltd.
First Edition (1) : Jan. 30, 2009 (M)
LIST OF ABBREVIATIONS
A
ampere(s)
ABDC
AC
ATDC
BBDC
BDC
BTDC
°C
DC
F
°F
ft
g
h
L
after bottom dead center
alternating current
lb
m
min
pound(s)
after top dead center
before bottom dead center
bottom dead center
before top dead center
degree(s) Celsius
direct current
farad(s)
degree(s) Fahrenheit
foot, feet
gram(s)
N
Pa
PS
psi
r
rpm
TDC
TIR
V
W
meter(s)
minute(s)
newton(s)
pascal(s)
horsepower
pound(s) per square inch
revolution
revolution(s) per minute
top dead center
total indicator reading
volt(s)
watt(s)
hour(s)
liter(s)
Ω
ohm(s)
COUNTRY AND AREA CODES
AT
AU
CA
CAL
CH
Austria
Australia
Canada
California
Switzerland
DE
Germany
EUR
GB
SEA
US
WVTA
(FULL H)
GB WVTA
(FULL H)
Europe
United Kingdom
Southeast Asia
United States
WVTA Model with Honeycomb
Catalytic Converter (Full Power)
WVTA Model with Honeycomb Catalytic
Converter (Left Side Traffic Full
Power)
EMISSION CONTROL INFORMATION
To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of
the United States Environmental Protection Agency and California Air Resources Board. Additionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance
with applicable regulations of the California Air Resources Board on vehicles sold in California
only.
1. Crankcase Emission Control System
This system eliminates the release of crankcase vapors into the atmosphere. Instead, the vapors
are routed through an oil separator to the inlet side of the engine. While the engine is operating,
the vapors are drawn into combustion chamber, where they are burned along with the fuel and air
supplied by the fuel injection system.
2. Exhaust Emission Control System
This system reduces the amount of pollutants discharged into the atmosphere by the exhaust
of this motorcycle. The fuel, ignition, and exhaust systems of this motorcycle have been carefully
designed and constructed to ensure an efficient engine with low exhaust pollutant levels.
The exhaust system of this model motorcycle manufactured primarily for sale in California includes a catalytic converter system.
3. Evaporative Emission Control System
Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. Instead, fuel vapors are routed into the running engine to be burned, or stored in a canister when
the engine is stopped. Liquid fuel is caught by a vapor separator and returned to the fuel tank.
The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is
commonly referred to as the Act’s “tampering provisions”.
“Sec. 203(a) The following acts and the causing thereof are prohibited...
(3)(A) for any person to remove or render inoperative any device or element of design installed
on or in a motor vehicle or motor vehicle engine in compliance with regulations under this
title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer
knowingly to remove or render inoperative any such device or element of design after such
sale and delivery to the ultimate purchaser.
(3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading
motor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles knowingly to remove or render inoperative any device or element of design installed on or in a
motor vehicle or motor vehicle engine in compliance with regulations under this title following its sale and delivery to the ultimate purchaser...”
NOTE
The
phrase
“remove
or
render
inoperative
any
device or element of design” has been generally
○
interpreted as follows.
1. Tampering does not include the temporary removal or rendering inoperative of devices or elements of design in order to perform maintenance.
2. Tampering could include.
a.Maladjustment of vehicle components such that the emission standards are exceeded.
b.Use of replacement parts or accessories which adversely affect the performance
or durability of the motorcycle.
c.Addition of components or accessories that result in the vehicle exceeding the standards.
d.Permanently removing, disconnecting, or rendering inoperative any component or
element of design of the emission control systems.
WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL
LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING
$10 000 PER VIOLATION.
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED
Federal law prohibits the following acts or the causing thereof. (1) The removal or rendering
inoperative by any person other than for purposes of maintenance, repair, or replacement, of any
device or element of design incorporated into any new vehicle for the purpose of noise control
prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the
vehicle after such device or element of design has been removed or rendered inoperative by
any person.
Among those acts presumed to constitute tampering are the acts listed below.
Replacement of the original exhaust system or muffler with a component not in compliance
with Federal regulations.
Removal of the muffler(s) or any internal portion of the muffler(s).
Removal of the air box or air box cover.
Modifications to the muffler(s) or air inlet system by cutting, drilling, or other means if such
modifications result in increased noise levels.
•
•
•
•
Foreword
This manual is designed primarily for use by
trained mechanics in a properly equipped shop.
However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and
repair work. A basic knowledge of mechanics,
the proper use of tools, and workshop procedures must be understood in order to carry out
maintenance and repair satisfactorily. Whenever the owner has insufficient experience or
doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics.
In order to perform the work efficiently and
to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures
before starting work, and then do the work carefully in a clean area. Whenever special tools or
equipment are specified, do not use makeshift
tools or equipment. Precision measurements
can only be made if the proper instruments are
used, and the use of substitute tools may adversely affect safe operation.
For the duration of the warranty period,
we recommend that all repairs and scheduled
maintenance be performed in accordance with
this service manual. Any owner maintenance or
repair procedure not performed in accordance
with this manual may void the warranty.
To get the longest life out of your vehicle.
Follow the Periodic Maintenance Chart in the
Service Manual.
Be alert for problems and non-scheduled
maintenance.
Use proper tools and genuine Kawasaki Motorcycle parts. Special tools, gauges, and
testers that are necessary when servicing
Kawasaki motorcycles are introduced by the
Service Manual. Genuine parts provided as
spare parts are listed in the Parts Catalog.
Follow the procedures in this manual carefully. Don’t take shortcuts.
Remember to keep complete records of maintenance and repair with dates and any new
parts installed.
•
•
•
•
•
How to Use This Manual
In this manual, the product is divided into
its major systems and these systems make up
the manual’s chapters. The Quick Reference
Guide shows you all of the product’s system
and assists in locating their chapters. Each
chapter in turn has its own comprehensive Table of Contents.
For example, if you want ignition coil information, use the Quick Reference Guide to locate
the Electrical System chapter. Then, use the
Table of Contents on the first page of the chapter to find the Ignition Coil section.
Whenever you see these WARNING and
CAUTION symbols, heed their instructions!
Always follow safe operating and maintenance
practices.
WARNING
This warning symbol identifies special
instructions or procedures which, if not
correctly followed, could result in personal injury, or loss of life.
CAUTION
This caution symbol identifies special
instructions or procedures which, if not
strictly observed, could result in damage to or destruction of equipment.
This manual contains four more symbols (in
addition to WARNING and CAUTION) which will
help you distinguish different types of information.
NOTE
○This note symbol indicates points of particular interest for more efficient and convenient operation.
a procedural step or work to be
• Indicates
done.
○Indicates a procedural sub-step or how to do
the work of the procedural step it follows. It
also precedes the text of a NOTE.
Indicates a conditional step or what action to
take based on the results of the test or inspection in the procedural step or sub-step it follows.
In most chapters an exploded view illustration
of the system components follows the Table of
Contents. In these illustrations you will find the
instructions indicating which parts require specified tightening torque, oil, grease or a locking
agent during assembly.
GENERAL INFORMATION 1-1
General Information
Table of Contents
Before Servicing .....................................................................................................................
Model Identification.................................................................................................................
General Specifications............................................................................................................
Electrical Throttle Valve (ETV) System...................................................................................
Unit Conversion Table ............................................................................................................
1
1-2
1-7
1-9
1-12
1-15
1-2 GENERAL INFORMATION
Before Servicing
Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever
necessary. This section explains the items that require particular attention during the removal and
reinstallation or disassembly and reassembly of general parts.
Especially note the following.
Battery Ground
Before completing any service on the motorcycle, disconnect the battery cables from the battery to prevent the engine from accidentally turning over. Disconnect the ground
cable (–) first and then the positive (+). When completed
with the service, first connect the positive (+) cable to the
positive (+) terminal of the battery then the negative (–) cable to the negative terminal.
Edges of Parts
Lift large or heavy parts wearing gloves to prevent injury
from possible sharp edges on the parts.
Solvent
Use a high-flash point solvent when cleaning parts. High
-flash point solvent should be used according to directions
of the solvent manufacturer.
Cleaning Vehicle before Disassembly
Clean the vehicle thoroughly before disassembly. Dirt or
other foreign materials entering into sealed areas during vehicle disassembly can cause excessive wear and decrease
performance of the vehicle.
GENERAL INFORMATION 1-3
Before Servicing
Arrangement and Cleaning of Removed Parts
Disassembled parts are easy to confuse. Arrange the
parts according to the order the parts were disassembled
and clean the parts in order prior to assembly.
Storage of Removed Parts
After all the parts including subassembly parts have been
cleaned, store the parts in a clean area. Put a clean cloth
or plastic sheet over the parts to protect from any foreign
materials that may collect before re-assembly.
Inspection
Reuse of worn or damaged parts may lead to serious accident. Visually inspect removed parts for corrosion, discoloration, or other damage. Refer to the appropriate sections
of this manual for service limits on individual parts. Replace
the parts if any damage has been found or if the part is beyond its service limit.
Replacement Parts
Replacement parts must be KAWASAKI genuine or
recommended by KAWASAKI. Gaskets, O-rings, oil seals,
grease seals, circlips, cotter pins or locknuts must be
replaced with new ones whenever disassembled.
Assembly Order
In most cases assembly order is the reverse of disassembly, however, if assembly order is provided in this Service
Manual, follow the procedures given.
1-4 GENERAL INFORMATION
Before Servicing
Tightening Sequence
Generally, when installing a part with several bolts, nuts,
or screws, start them all in their holes and tighten them to
a snug fit. Then tighten them according to the specified sequence to prevent case warpage or deformation which can
lead to malfunction. Conversely when loosening the bolts,
nuts, or screws, first loosen all of them by about a quarter turn and then remove them. If the specified tightening
sequence is not indicated, tighten the fasteners alternating
diagonally.
Tightening Torque
Incorrect torque applied to a bolt, nut, or screw may
lead to serious damage. Tighten fasteners to the specified
torque using a good quality torque wrench.
Force
Use common sense during disassembly and assembly,
excessive force can cause expensive or hard to repair damage. When necessary, remove screws that have a non
-permanent locking agent applied using an impact driver.
Use a plastic-faced mallet whenever tapping is necessary.
Gasket, O-ring
Hardening, shrinkage, or damage of both gaskets and
O-rings after disassembly can reduce sealing performance.
Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains.
Install the new gaskets and replace the used O-rings when
re-assembling.
Liquid Gasket, Non-permanent Locking Agent
For applications that require Liquid Gasket or a
Non-permanent Locking Agent, clean the surfaces so
that no oil residue remains before applying liquid gasket or
non-permanent locking agent. Do not apply them excessively. Excessive application can clog oil passages and
cause serious damage.
GENERAL INFORMATION 1-5
Before Servicing
Press
For items such as bearings or oil seals that must be
pressed into place, apply small amount of oil to the contact area. Be sure to maintain proper alignment and use
smooth movements when installing.
Ball Bearing and Needle Bearing
Do not remove pressed ball or needle unless removal is
absolutely necessary. Replace with new ones whenever
removed. Press bearings with the manufacturer and size
marks facing out. Press the bearing into place by putting
pressure on the correct bearing race as shown.
Pressing the incorrect race can cause pressure between
the inner and outer race and result in bearing damage.
Oil Seal, Grease Seal
Do not remove pressed oil or grease seals unless removal
is necessary. Replace with new ones whenever removed.
Press new oil seals with manufacture and size marks facing
out. Make sure the seal is aligned properly when installing.
Apply specified grease to the lip of seal before installing
the seal.
Circlips, Cotter Pins
Replace the circlips or cotter pins that were removed with
new ones. Take care not to open the clip excessively when
installing to prevent deformation.
1-6 GENERAL INFORMATION
Before Servicing
Lubrication
It is important to lubricate rotating or sliding parts during
assembly to minimize wear during initial operation. Lubrication points are called out throughout this manual, apply
the specific oil or grease as specified.
Direction of Engine Rotation
When rotating the crankshaft by hand, the free play
amount of rotating direction will affect the adjustment. Rotate the crankshaft to positive direction (clockwise viewed
from output side).
Electrical Leads
A two-color lead is identified first by the primary color and
then the stripe color. Unless instructed otherwise, electrical
leads must be connected to those of the same color.
Instrument
Use a meter that has enough accuracy for an accurate
measurement. Read the manufacture’s instructions thoroughly before using the meter. Incorrect values may lead
to improper adjustments.
GENERAL INFORMATION 1-7
Model Identification
VN1700C9F (US and CA Models) Left Side View
VN1700C9F (US and CA Models) Right Side View
1-8 GENERAL INFORMATION
Model Identification
VN1700C9F (EUR Models) Left Side View
VN1700C9F (EUR Models) Right Side View
Frame Number
Engine Number
GENERAL INFORMATION 1-9
General Specifications
Items
Dimensions
Overall Length
Overall Width
Overall Height
Wheelbase
Road Clearance
Seat Height
Curb Mass:
Front
Rear
Fuel Tank Capacity
Performance
Minimum Turning Radius
Engine
Type
Cooling System
Bore and Stroke
Displacement
Compression Ratio
Maximum Horsepower
Maximum Torque
Carburetion System
Starting System
Ignition System
Timing Advance
Ignition Timing
Spark Plug
Cylinder Numbering Method
Firing Order
Valve Timing:
Inlet:
Open
Close
Duration
Exhaust:
Open
Close
Duration
VN1700C9F
2 500 mm (98.43 in.)
1 025 mm (40.35 in.),
(AU) 995 mm (39.17 in.)
1 465 mm (57.68 in.)
1 665 mm (65.55 in.)
140 mm (5.51 in.)
730 mm (28.7 in.)
378 kg (833 lb)
168 kg (370 lb)
210 kg (463 lb)
20 L (5.3 US gal)
3.3 m (10.8 ft)
4-stroke, SOHC, V2-cylinder
Liquid-cooled
102 × 104 mm (4.02 × 4.09 in.)
1700 cm³ (103.7 cu in.)
9.5:1
54 kW (73.4 PS) @5 000 r/min (rpm),
(CA), (CAL), (US) – – –
136 N·m (13.9 kgf·m, 100.3 ft·lb) @2 750 r/min (rpm),
(CA), (CAL), (US) – – –
FI (Fuel Injection), MIKUNI EACW42 × 2
Electric starter
Battery and coil (transistorized)
Electronically advanced (IC igniter in ECU)
From 0° BTDC @ 950 r/min (rpm)
to 32° BTDC @ 4 250 r/min (rpm)
NGK ILZKAR7B11
Front to rear, 1-2
2-1
30° (BTDC)
50° (ABDC)
260°
55° (BBDC)
25° (ATDC)
260°
1-10 GENERAL INFORMATION
General Specifications
Items
Lubrication System
Engine Oil:
Type
Viscosity
Capacity
Drive Train
Primary Reduction System:
Type
Reduction Ratio
Clutch Type
Transmission:
Type
Gear Ratios:
1st
2nd
3rd
4th
5th
6th
Final Drive System:
Type
Reduction Ratio
Overall Drive Ratio
Frame
Type
Caster (Rake Angle)
Trail
Front Tire:
Type
Size
Rim Size
Rear Tire:
Type
Size
Rim Size
Front Suspension:
Type
Wheel Travel
Rear Suspension:
Type
Wheel Travel
VN1700C9F
Forced lubrication (semi-dry sump)
API SE, SF or SG
API SH, SJ, SL or SM with JASO MA, MA1 or MA2
SAE 10W-40
5.0 L (5.3 US qt)
Chain
1.515 (50/33)
Wet multi disc
6-speed, constant mesh, return shift
3.077
1.900
1.407
1.143
0.967
0.806
(40/13)
(38/20)
(38/27)
(32/28)
(29/30)
(29/36)
Belt
2.250 (72/32)
2.746 @Top gear
Tubular, double cradle
30°
169 mm (6.7 in.)
Tubeless
130/90 B16 M/C (67 H)
16 × 3.50
Tubeless
170/70 B16 M/C (75 H)
16 × 4.50
Telescopic fork
140 mm (5.5 in.)
Swingarm
80 mm (3.2 in.)
GENERAL INFORMATION 1-11
General Specifications
Items
Brake Type:
Front
Rear
Electrical Equipment
Battery
Headlight:
Type
Bulb
Tail/Brake Light
Alternator:
Type
Rated Output
VN1700C9F
Dual discs
Single disc
12 V 18 Ah
Semi-sealed beam
12 V 60/55 W (quartz-halogen)
LED
Three-phase AC
46.8 A/14 V @5 000 r/min (rpm)
Specifications are subject to change without notice, and may not apply to every country.
1-12 GENERAL INFORMATION
Electrical Throttle Valve (ETV) System
General Description
VN1700 series is equipped with the electronically-controlled throttle valve system called the Electrical Throttle Valve (ETV) system. The throttle pulley and the throttle valves of this system are not
connected mechanically, and the throttle valves are electrically operated. On the other hand, the throttle grip and the throttle pulley are connected with two throttle cables in the same way as that for the
conventional mechanically-operated throttle valve system to ensure the throttle operation feel without
any strangeness. The accelerator position sensors (APS) that detect the throttle grip opening angle
are installed to the throttle body, located near the center of the motorcycle to minimize the direct impact to the sensors when the motorcycle falls. The ETV system also features high durability thanks
to the adoption of highly-durable contact-free throttle position sensors (TPS) and the duplex circuitry
for the critical sensors, APS and TPS.
Some models of VN1700 series are equipped with an auto cruise control system as an auxiliary
function of this system.
Construction and Function
1. Throttle Grip
2. Right Handle Switch Housing
3. Throttle Cable
4. Throttle Pulley
5. Throttle Valve
6. Accelerator Position Sensor
7. Throttle Position Sensor
8. Actuator (DC Motor)
9. FI ECU
10. Throttle Body Assembly
GENERAL INFORMATION 1-13
Electrical Throttle Valve (ETV) System
System Diagram
1. Accelerator Position Sensor #1 and #2
The accelerator position sensor senses the rider’s intention on throttle operation and transmits it
to the ECU as an electrical signal. Each incorporating a built-in variable resistor, the two sensors
independently work to detect the position of the pulley shaft.
2. Throttle Position Sensor #1 and #2
The two contact-free, Hall-element type sensors independently work to detect the opening angle
of the throttle valves.
3. Actuator (DC Motor)
In response to the signal from the ECU, the actuator (DC motor) moves the throttle valves quickly
to the target position via three gears.
4. FI ECU
Receiving the accelerator position sensor signals, the ECU operates the actuator to move the
throttle valves to the target opening angle, and verifies that the valves are in the target position
by the throttle position sensor signals. The ECU performs the fail-safe control in case of a system
failure. It also performs the cruise control function in the models equipped with cruise control
system.
The FI ECU has a large-scale integrated circuit (LSI) to monitor its central processing unit (CPU),
and the CPU also has the function to monitor the LSI – they mutually monitor with each other for
their correct operations.
CPU (Central Processing Unit)
LSI (Large-scale Integrated Circuit for Monitoring CPU)
A. Fuel Injection Control Section
B. Cruise Control Section
C. Fail-safe Control and LSI Monitoring Section
1-14 GENERAL INFORMATION
Electrical Throttle Valve (ETV) System
D. Throttle Valve Opening Control Section
E. Motor Drive Section
F. CPU Monitoring Section
5. Partial Opening Holding Device
When the actuator (DC motor) becomes
incapable of throttle valve control, this device
holds the throttle valve at a predetermined
partially-open position by balancing the forces of
the return spring and the open spring which pulls
the throttle valve in the opening direction.
A. Partial Opening Holding Device
B. Open and Return Springs
6. Right Handle Switch Housing
In the models equipped with cruise control system, the switches of the system are collectively
installed to the right handle switch housing to facilitate the activation of the system during running.
Fail-safe System against System Failure
There are three fail-safe modes in accordance with the failure conditions: power limitation mode,
limp-home mode, and idle mode.
1) Power Limitation Mode
If the ECU judges that one of the sensor signals from the accelerator position sensors or the
throttle position sensors is incorrect but the ECU can control the ETV system using the other
(correct) sensor signal, the ECU limits the engine output and flashes the warning light to warn the
rider of the system failure.
2) Limp Home Mode
If the ECU cannot control the throttle valves correctly due to the failure of the actuator, both
throttle position sensors or the like, the ECU cuts off the power to the actuator and fix the throttle
valves at a partially-open position using the partial opening holding device to maintain the minimum driving capability.
3) Idle Mode
If the ECU judges that both of the accelerator position sensor signals are incorrect and therefore
it cannot notice the rider’s intension on throttle operation, the ECU flashes the warning light and
fixes the engine speed to the idling speed.
GENERAL INFORMATION 1-15
Unit Conversion Table
Prefixes for Units:
Prefix
mega
kilo
centi
milli
micro
Units of Length:
Symbol
M
k
c
m
µ
×
×
×
×
×
Power
1 000 000
1 000
0.01
0.001
0.000001
Units of Mass:
kg
g
×
×
2.205
0.03527
=
=
lb
oz
Units of Volume:
L
L
L
L
L
L
mL
mL
mL
×
×
×
×
×
×
×
×
×
0.2642
0.2200
1.057
0.8799
2.113
1.816
0.03381
0.02816
0.06102
×
×
×
×
×
×
×
0.6214
3.281
0.03937
=
=
=
mile
ft
in
=
=
=
=
=
=
kgf·m
ft·lb
in·lb
N·m
ft·lb
in·lb
=
=
=
=
=
=
kgf/cm²
psi
cmHg
kPa
psi
kPa
=
mph
=
=
=
=
PS
HP
kW
HP
Units of Torque:
N·m
N·m
N·m
kgf·m
kgf·m
kgf·m
×
×
×
×
×
×
0.1020
0.7376
8.851
9.807
7.233
86.80
Units of Pressure:
=
=
=
=
=
=
=
=
=
gal (US)
gal (imp)
qt (US)
qt (imp)
pint (US)
pint (imp)
oz (US)
oz (imp)
cu in
=
=
=
=
kg
lb
N
lb
Units of Force:
N
N
kg
kg
km
m
mm
0.1020
0.2248
9.807
2.205
Units of Temperature:
kPa
kPa
kPa
kgf/cm²
kgf/cm²
cmHg
×
×
×
×
×
×
0.01020
0.1450
0.7501
98.07
14.22
1.333
Units of Speed:
km/h
×
0.6214
Units of Power:
kW
kW
PS
PS
×
×
×
×
1.360
1.341
0.7355
0.9863
PERIODIC MAINTENANCE 2-1
Periodic Maintenance
Table of Contents
Periodic Maintenance Chart ...................................................................................................
Torque and Locking Agent......................................................................................................
Specifications .........................................................................................................................
Special Tools ..........................................................................................................................
Periodic Maintenance Procedures..........................................................................................
Fuel System (DFI)................................................................................................................
Throttle Control System Inspection...................................................................................
Idle Speed Inspection .......................................................................................................
Idle Speed Adjustment......................................................................................................
Fuel Hose Inspection (fuel leak, damage, installation condition) ......................................
Evaporative Emission Control System Inspection (CAL and SEA Models) ......................
Cooling System....................................................................................................................
Coolant Level Inspection...................................................................................................
Radiator Hose and Pipe Inspection (Coolant Leak, Damage, Installation Condition).......
Engine Top End ...................................................................................................................
Air Suction System Damage Inspection............................................................................
Clutch...................................................................................................................................
Clutch Operation Inspection..............................................................................................
Clutch Fluid Level Inspection ............................................................................................
Clutch Fluid Leak (Clutch Hose and Pipe) ........................................................................
Clutch Hose and Pipe Damage and Installation Condition Inspection..............................
Wheels and Tires .................................................................................................................
Tire Air Pressure Inspection..............................................................................................
Wheel/Tire Damage Inspection.........................................................................................
Tire Tread Wear Inspection...............................................................................................
Wheel Bearing Damage Inspection ..................................................................................
Final Drive............................................................................................................................
Drive Belt Deflection Inspection .......................................................................................
Drive Belt Deflection Adjustment ......................................................................................
Wheel Alignment Inspection/Adjustment ..........................................................................
Drive Belt Wear and Damage Inspection..........................................................................
Brakes..................................................................................................................................
Brake Fluid Leak (Brake Hose and Pipe) Inspection ........................................................
Brake Hose and Pipe Damage and Installation Condition Inspection...............................
Brake Operation Inspection ..............................................................................................
Brake Fluid Level Inspection.............................................................................................
Brake Pad Wear Inspection ..............................................................................................
Brake Light Switch Operation Inspection ..........................................................................
Suspension ..........................................................................................................................
Front Forks/Rear Shock Absorber Operation Inspection ..................................................
Front Fork Oil Leak Inspection..........................................................................................
Rear Shock Absorber Oil Leak Inspection ........................................................................
Swingarm Pivot Lubrication ..............................................................................................
Steering ...............................................................................................................................
Steering Play Inspection ...................................................................................................
Steering Play Adjustment..................................................................................................
Steering Stem Bearing Lubrication ...................................................................................
Electrical System .................................................................................................................
Spark Plug Condition Inspection.......................................................................................
Lights and Switches Operation .........................................................................................
2-3
2-7
2-13
2-15
2-16
2-16
2-16
2-17
2-17
2-20
2-21
2-22
2-22
2-23
2-23
2-23
2-24
2-24
2-24
2-24
2-25
2-25
2-25
2-25
2-25
2-26
2-27
2-27
2-28
2-30
2-30
2-33
2-33
2-34
2-34
2-34
2-35
2-35
2-36
2-36
2-37
2-37
2-37
2-38
2-38
2-38
2-40
2-40
2-40
2-41
2
2-2 PERIODIC MAINTENANCE
Headlight Aiming Inspection .............................................................................................
Sidestand Switch Operation Inspection ............................................................................
Engine Stop Switch Operation Inspection.........................................................................
Others ..................................................................................................................................
Chassis Parts Lubrication ................................................................................................
Bolts, Nuts and Fasteners Tightness Inspection...............................................................
Replacement Parts ..............................................................................................................
Air Cleaner Element Replacement....................................................................................
Fuel Hose Replacement ...................................................................................................
Coolant Change ................................................................................................................
Radiator Hose and O-ring Replacement...........................................................................
Engine Oil Change............................................................................................................
Oil Filter Replacement ......................................................................................................
Brake Hose and Pipe Replacement..................................................................................
Brake Fluid Change ..........................................................................................................
Master Cylinder Rubber Parts Replacement ....................................................................
Caliper Rubber Parts Replacement ..................................................................................
Clutch Hose and Pipe Replacement .................................................................................
Clutch Fluid Change .........................................................................................................
Clutch Master Cylinder Rubber Parts Replacement .........................................................
Clutch Slave Cylinder Piston Seal Replacement ..............................................................
Spark Plug Replacement ..................................................................................................
2-44
2-46
2-47
2-47
2-47
2-48
2-50
2-50
2-51
2-52
2-54
2-55
2-56
2-57
2-57
2-59
2-61
2-64
2-65
2-66
2-67
2-67
PERIODIC MAINTENANCE 2-3
Periodic Maintenance Chart
Dummy Page
2-4 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
ITEM
Fuel System
Throttle control system (play,
smooth return, no drag)-inspect
* ODOMETER READING
× 1 000 km
(× 1 000 mile) See
Page
1
6
12
18
24
30
36
Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
year
Idle speed-inspect
Fuel leak (fuel hose and
pipe)-inspect
year
Fuel hose and pipe damage-inspect
year
Fuel hose and pipe installation
condition-inspect
Evaporative emission control
system function-inspect (CAL and
SEA Models)
Cooling System
year
•
Coolant level-inspect
Coolant leak (radiator hose and
pipe)-inspect
year
Radiator hose damage-inspect
year
Radiator hose installation
condition-inspect
Engine Top End
•
•
•
•
•
year
•
•
•
•
•
•
•
•
•
•
Air suction system damage-inspect
Clutch
Clutch operation (play,
disengagement, engagement)
-inspect
Clutch fluid level-inspect
Clutch fluid leak (clutch hose and
pipe)-inspect
Clutch hose and pipe
damage-inspect
Clutch hose installation
condition-inspect
Wheels and Tires
Tire air pressure-inspect
•
6
months
year
year
year
year
Wheel/tire damage-inspect
Tire tread wear, abnormal
wear-inspect
Wheel bearing damage-inspect
year
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
2–16
•
2–21
2–17
2–20
2–20
2–20
•
•
•
•
•
•
•
•
•
•
•
•
2–22
•
•
•
2–23
•
•
•
2–24
•
•
•
•
2–24
•
•
•
•
2–25
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
2–23
2–23
2–23
2–24
2–25
2–25
2–25
2–25
2–26
PERIODIC MAINTENANCE 2-5
Periodic Maintenance Chart
FREQUENCY Whichever
comes
first
ITEM
Final Drive
* ODOMETER READING
× 1 000 km
(× 1 000 mile) See
Page
1
6
12
18
24
30
36
Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)
Drive belt deflection-inspect
Drive belt wear-inspect
Brakes
Brake fluid leak (brake hose and
pipe)-inspect
Brake hose and pipe
damage-inspect
Brake hose installation
condition-inspect
Brake operation (effectiveness,
play, no drag)-inspect
Brake fluid level-inspect
year
year
year
year
6
months
•
•
•
•
•
•
•
•
•
•
•
•
•
•
2–27
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
2–33
Brake pad wear-inspect #
•
Brake light switch operation-inspect
Suspension
Front forks/rear shock absorber
operation (damping and smooth
stroke)-inspect
Front forks/rear shock absorber oil
leak-inspect
year
2–30
2–34
2–34
2–34
2–34
2–35
2–35
•
•
•
2–36
•
•
•
•
2–37
2–37
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
2–40
•
•
•
•
•
•
2–47
Swingarm pivot-lubricate
2–37
Steering
Steering play-inspect
year
Steering stem bearings-lubricate
2
years
•
•
2–38
2–40
Electrical System
Spark plug condition-inspect
Lights and switches
operation-inspect
year
Headlight aiming-inspect
year
Sidestand switch operation-inspect
year
Engine stop switch operation
-inspect
Others
Chassis parts-lubricate
Bolts and nuts tightness-inspect
year
year
•
2–41
2–44
2–46
2–47
2–48
*: For higher odometer readings, repeat at the frequency interval established here.
#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or
frequent starting/stopping.
2-6 PERIODIC MAINTENANCE
Periodic Maintenance Chart
Periodic Replacement Parts
FREQUENCY Whichever
come
first
ITEM
Air cleaner element-replace #
Every
1
(0.6)
12
(7.5)
24
36
48
(15) (22.5) (30)
Every 18 000 km (11 250 mile)
Fuel hose-replace
4 years
Coolant-change
3 years
Radiator hose and O-ring-replace
3 years
Engine oil-change #
year
Oil filter-replace
year
Brake hose and pipe-replace
4 years
Brake fluid-change
2 years
Rubber parts of brake master cylinder and
caliper-replace
4 years
Clutch hose and pipe-replace
4 years
Clutch fluid-change
2 years
Rubber parts of clutch master cylinder and
slave cylinder-replace
Spark plug-replace
* ODOMETER READING
× 1 000 km
(× 1 000 mile)
•
•
•
•
•
•
•
•
•
•
•
•
4 years
Every 48 000 km (30 000 mile)
•
See
Page
2–50
2–51
2–52
2–54
•
•
•
•
•
•
•
•
2–55
2–56
2–57
2–57
2–59
2–61
2–64
2–65
2–66
2–67
*: For higher odometer readings, repeat at the frequency interval established here.
#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or
frequent starting/stopping.
PERIODIC MAINTENANCE 2-7
Torque and Locking Agent
The following tables list the tightening torque for the major fasteners requiring use of a
non-permanent locking agent or silicone sealant etc.
Letters used in the “Remarks” column mean:
AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.
L: Apply a non-permanent locking agent.
Lh: Left-hand Threads
M: Apply molybdenum disulfide grease.
MO: Apply molybdenum disulfide oil solution.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1)
O: Apply 2-stroke oil.
R: Replacement Parts
S: Follow the specified tightening sequence.
Si: Apply silicone grease (ex. PBC grease).
SS: Apply silicone sealant.
Fastener
Fuel System
Air Cleaner Housing Cover Bolts
Air Cleaner Element Bolt
Air Cleaner Housing Bolts
Crankshaft Sensor Bolts
Delivery Joint Bolts
Fuel Pump Bolts
Gear Position Switch Bolts
Inlet Manifold Bolts
Right Air Cleaner Housing Center Bolts
Speed Sensor Mounting Bolt
Throttle Body Assy Holder Bolts
Throttle Cable Holder Plate Screw
Water Temperature Sensor
Cruise Control Cancel Switch (Throttle)
Mounting Nut
Oxygen Sensor (Equipped Models)
Cooling System
Cross Pipe Bolts
Radiator Fan Bolts
Radiator Hose Clamp Screws
Thermostat Housing Cover Bolts
Water Pipe Bolts
Water Pump Impeller Bolt
Water Separator Inner Cover Bolts
Water Separator Outer Cover Bolts
Water Temperature Sensor
Engine Top End
Breather Check Valve Cover Bolts
Cylinder Head Nuts (M12) (First)
Cylinder Head Nuts (M12 New Nuts) (Final)
N·m
Torque
kgf·m
ft·lb
4.9
4.9
9.8
5.9
9.8
9.8
4.9
9.8
9.8
9.8
9.8
2.0
12
0.50
0.50
1.0
0.60
1.0
1.0
0.50
1.0
1.0
1.0
1.0
0.20
1.2
43 in·lb
43 in·lb
87 in·lb
52 in·lb
87 in·lb
87 in·lb
43 in·lb
87 in·lb
87 in·lb
87 in·lb
87 in·lb
18 in·lb
106 in·lb
0.28
0.03
2.5
25
2.5
18
34
8.3
2.0
9.8
12
12
12
12
12
3.5
0.85
0.20
1.0
1.2
1.2
1.2
1.2
1.2
25
73 in·lb
18 in·lb
87 in·lb
106 in·lb
106 in·lb
106 in·lb
106 in·lb
106 in·lb
9.8
39
70
1.0
4.0
7.1
87 in·lb
29
52
Remarks
L
L, S
L
L
L
L
L
Lh
MO, S
MO, S
2-8 PERIODIC MAINTENANCE
Torque and Locking Agent
Fastener
Cylinder Head Nuts (M12 Used Nuts) (Final)
Cylinder Head Nuts (M10) (First)
Cylinder Head Nuts (M10) (Final)
Cylinder Head Outer Cover Bolts
Cylinder Head Inner Cover Bolts
Plugs
Rocker Case Bolts (M8)
Rocker Case Bolts (M6)
Spark Plugs
Water Pipe Fitting Bolts
Camshaft Chain Tensioner Bolts
Camshaft Sprocket Bolts
Exhaust Pipe Holder Nuts
Muffler Body Mounting Bolt
Rear Camshaft Chain Guide Retainer Bolts
Clutch
Cam Damper Bolt
Clutch Cover Bolts
Clutch Hose Banjo Bolt
Clutch Hub Nut
Clutch Lever Pivot Bolt
Clutch Lever Pivot Bolt Locknut
Clutch Master Cylinder Clamp Bolts
Clutch Reservoir Cap Screws
Clutch Slave Cylinder Bleed Valve
Clutch Slave Cylinder Bolts
Clutch Spring Bolts
Front Outer Clutch Cover Bolts
Primary Chain Guide Bolts
Rear Outer Clutch Cover Bolts
Starter Lockout Switch Screw
Cruise Control Cancel Switch (Clutch) Screw
Clutch Pipe Bracket Bolt
Engine Lubrication System
Breather Check Valve Cover Bolts
Engine Oil Drain Bolts
Inside Oil Pipe Retainer Bolt
Oil Filter
Oil Filter Pipe
Oil Passage Plug (PT1/8)
Oil Pressure Relief Valve
Oil Pressure Switch
Oil Pressure Switch Terminal Bolt
77
20
39
9.8
9.8
20
20
9.8
18
9.8
12
15
17
25
9.8
Torque
kgf·m
7.8
2.0
4.0
1.0
1.0
2.0
2.0
1.0
1.8
1.0
1.2
1.5
1.7
2.5
1.0
ft·lb
57
15
29
87 in·lb
87 in·lb
15
15
87 in·lb
13
87 in·lb
106in·lb
11
12
18
87 in·lb
69
12
25
185
1.0
7.0
1.2
2.5
19.0
0.10
51
106 in·lb
18
136
8.8 in·lb
5.9
11
1.5
7.8
12
12
9.8
9.8
9.8
1.2
1.2
12
0.60
1.1
0.15
0.80
1.2
1.2
1.0
1.0
1.0
0.12
0.12
1.2
52 in·lb
97 in·lb
13 in·lb
69 in·lb
106 in·lb
106 in·lb
87 in·lb
87 in·lb
87 in·lb
11 in·lb
11 in·lb
106 in·lb
9.8
20
9.8
18
25
15
15
15
-
1.0
2.0
1.0
1.8
2.5
1.5
1.5
1.5
-
87 in·lb
14
87 in·lb
13
18
11
11
11
-
N·m
Remarks
MO, S
MO, S
MO, S
L
L
S
S
L
L
MO, R
Si
S
L
L
L
L
L
L
L
L
SS
Hand-tighten
PERIODIC MAINTENANCE 2-9
Torque and Locking Agent
Fastener
Oil Pump Cover Bolts
Oil Pump Drive Gear Bolt
Oil Screen Plugs
Out Side Oil Pipe Bolts
Torque Limiter Bearing Retainer Bolt
Engine Removal/Installation
Cross Pipe Bolts
Downtube Bolts
Engine Mounting Adjusting Bolt
Engine Mounting Adjusting Bolt Locknut
Engine Mounting Bolt (M10)
Engine Mounting Bracket Bolts (M6)
Engine Mounting Bracket Bolts (M8)
Engine Mounting Bracket Bolts (M10)
Engine Mounting Bracket Nuts (M10)
Engine Mounting Nut (M10)
Engine Mounting Nut (M12)
Crankshaft/Transmission
Balancer Chain Tensioner Bolts
Balancer Sprocket Bolts
Ball Bearing Retainer Bolts
Ball Bearing Retainer Screws
Connecting Rod Big End Bolts
Crankcase Bolts (M10)
Crankcase Bolts (M6)
Engine Pulley Plate Bolts
Oil Nozzles
Oil Passage Plugs (PT1/2)
Oil Passage Plug (PT3/8)
Oil Passage Plugs (PT1/8)
Piston Oil Jet Bolts
Race Retainer Screw
Upper Balancer Chain Guide Bolts
Lower Balancer Chain Guide Bolts
External Shift Mechanism Cover Bolts (L = 50
mm)
External Shift Mechanism Cover Bolts (L = 22
mm)
Gear Positioning Lever Nut
Shift Drum Bearing Retainer Bolts
Shift Drum Cam Bolt
Shift Lever Bolts
Shift Pedal Pad Screw
N·m
12
42
20
9.8
9.8
Torque
kgf·m
1.2
4.3
2.0
1.0
1.0
ft·lb
106 in·lb
31
15
87 in·lb
87 in·lb
34
59
9.8
49
44
9.8
25
44
59
44
3.5
6.0
1.0
5.0
4.5
1.0
2.5
4.5
6.0
4.5
25
44
87 in·lb
36
32
87 in·lb
18
32
43
32
R
R
59
6.0
43
R, S
12
83
9.8
9.8
60
39
12
12
3.9
20
20
15
6.9
9.8
12
12
1.2
7.0
1.0
1.0
6.1
4.0
1.2
1.2
0.40
2.0
2.0
1.5
0.70
1.0
1.2
1.2
106 in·lb
51
87 in·lb
87 in·lb
44
29
106 in·lb
106 in·lb
34 in·lb
15
15
11
61 in·lb
87 in·lb
106 in·lb
106 in·lb
12
1.2
106 in·lb
12
1.2
106 in·lb
7.8
9.8
0.80
1.0
69 in·lb
87 in·lb
12
12
6.9
1.2
1.2
0.70
106 in·lb
106 in·lb
61 in·lb
Remarks
MO
M
S
S
S
S
L
L
MO
S
S
L
L
L
L
L
L
L
2-10 PERIODIC MAINTENANCE
Torque and Locking Agent
Fastener
Shift Shaft Return Spring Pin
Tie-Rod Locknuts
Wheels/Tires
Front Axle
Front Axle Clamp Bolts
Rear Axle Nut
Rear Air Valve Nuts
Final Drive
Engine Pulley Mounting Nut
Engine Pulley Inner Cover Bolts
Engine Pulley Outer Cover Bolts
Rear Axle Nut
Rear Coupling Stud Bolts
Rear Pulley Mounting Nuts
Rear Pulley Plate Bolts
Brakes
Bleed Valves
Brake Hose Banjo Bolts
Brake Lever Pivot Bolt
Brake Lever Pivot Bolt Locknut
Front Brake Disc Mounting Bolts
Front Brake Light Switch Screw
Front Brake Reservoir Cap Screws
Front Caliper Mounting Bolts
Front Master Cylinder Clamp Bolts
Brake Pedal Bolt
Rear Brake Disc Mounting Bolts
Rear Caliper Mounting Bolts
Rear Master Cylinder Mounting Bolts
Rear Master Cylinder Push Rod Locknut
Suspension
Upper Front Fork Clamp Bolts
Lower Front Fork Clamp Bolts
Fork Cover Clamp Bolts
Front Fork Bottom Allen Bolts
Front Axle Clamp Bolts
Rear Shock Absorber Nuts
Rear Shock Absorber Air Valve
Swingarm Pivot Shaft Nut
Steering
Handlebar Clamp Bolts
Handlebar Holder Nuts
Lower Front Fork Clamp Bolts
39
9.8
Torque
kgf·m
4.0
1.0
ft·lb
29
87 in·lb
127
20
108
1.5
13.0
2.0
11.0
0.15
94
15
80
13 in·lb
175
12
9.8
108
44
59
6.9
18.0
1.2
1.0
11.0
4.5
6.0
0.70
129
106 in·lb
87 in·lb
80
33
44
61 in·lb
7.8
25
1.0
5.9
27
1.2
1.5
34
11
8.8
27
34
25
17.2
0.80
2.5
0.10
0.60
2.8
0.12
0.15
3.5
1.1
0.90
2.8
3.5
2.5
1.8
69 in·lb
18
8.9 in·lb
52 in·lb
20
11 in·lb
13 in·lb
25
97 in·lb
78 in·lb
20
25
18
13
20
30
2.0
3.0
15
22
AL
4.2
20
20
0.43
2.0
2.0
37 in·lb
15
15
L
S
34
5.5
108
3.5
0.56
11.0
25
49 in·lb
80
34
59
30
3.5
6.0
3.0
25
44
22
N·m
Remarks
L
Lh (1)
S
M
L
R
L
Si
L
S
L
O, S
R
AL
PERIODIC MAINTENANCE 2-11
Torque and Locking Agent
Fastener
Steering Stem Head Nut
Steering Stem Nut
Upper Front Fork Clamp Bolts
Frame
Cross Pipe Bolts
Downtube Bolts
Front Footboard Bracket Bolts
Rear Footboard Bracket Bolts
Sidestand Mounting Bolt
Sidestand Mounting Nut
Sidestand Switch Mounting Bolt
Rear Fender Allen Bolts
Cross Bar Mounting Bolts
Front Guard Mounting Bolts
Rear Guard Mounting Bolts
Saddlebag Stay Bolts
Electrical System
Alternator Cover Bolts
Alternator Harness Clamp Bolt
Alternator Rotor Bolt
Alternator Stator Coil Lead Connector Stay Bolt
Alternator Stator Coil Mounting Bolts
Crankshaft Sensor Bolts
Crankshaft Sensor Lead Holding Plate Bolt
Gear Position Switch Lead Holding Plate Bolt
Gear Position Switch Bolts
Oil Pressure Switch
Oil Pressure Switch Terminal Bolt
Oxygen Sensor (Equipped Models)
Spark Plugs
Speed Sensor Mounting Bolt
Starter Motor Mounting Bolts
Starter Motor Terminal Locknut
Starter Motor Terminal Nut
Starter Motor Through Bolts
Stator Lead Holding Plate Bolts
Engine Ground Mounting Bolt
Front Brake Light Switch Screw
Fuel Pump Bolts
Sidestand Switch Mounting Bolt
Starter Lockout Switch Screw
Cruise Control Cancel Switch (Clutch) Screw
N·m
88
29
20
Torque
kgf·m
9.0
3.0
2.0
ft·lb
65
22
15
34
59
34
25
44
44
3.5
6.0
3.5
2.5
4.5
4.5
25
44
25
18
32
32
8.8
25
25
0.90
2.5
2.5
78 in·lb
18
18
34
25
25
3.5
2.5
2.5
25
18
18
12
9.8
150
9.8
12
5.9
5.9
4.9
1.2
1.0
15.3
1.0
1.2
0.60
0.60
0.50
106 in·lb
87 in·lb
111
87 in·lb
106 in·lb
52 in·lb
52 in·lb
43 in·lb
3.9
15.0
25
18.0
9.8
9.8
11
5.9
5.0
5.9
9.8
0.40
1.5
2.5
1.8
1.0
1.0
1.1
0.60
0.51
0.60
1.0
35 in·lb
11
18
13
87 in·lb
87 in·lb
97 in·lb
52 in·lb
44 in·lb
52 in·lb
87 in·lb
1.2
9.8
8.8
1.2
1.2
0.12
1.0
0.90
0.12
0.12
11
87
78
11
11
in·lb
in·lb
in·lb
in·lb
in·lb
Remarks
L
R
L
MO
L
L
L
L
SS
Hand-tighten
L
L
L
L, S
L
2-12 PERIODIC MAINTENANCE
Torque and Locking Agent
Fastener
Water Temperature Sensor
Licence Plate Light Lens Screws
N·m
12
0.9
Torque
kgf·m
1.2
0.09
ft·lb
106 in·lb
8 in·lb
Remarks
The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and
nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the
values are for use with dry solvent-cleaned threads.
Basic Torque for General Fasteners
Threads dia. (mm)
5
6
8
10
12
14
16
18
20
N·m
3.4 ∼ 4.9
5.9 ∼ 7.8
14 ∼19
25 ∼ 34
44 ∼ 61
73 ∼ 98
115 ∼ 155
165 ∼ 225
225 ∼ 325
Torque
kgf·m
0.35 ∼ 0.50
0.60 ∼ 0.80
1.4 ∼1.9
2.6 ∼ 3.5
4.5 ∼ 6.2
7.4 ∼ 10.0
11.5 ∼ 16.0
17.0 ∼ 23.0
23.0 ∼ 33.0
ft·lb
30 ∼ 43 in·lb
52 ∼ 69 in·lb
10 ∼ 13.5
19 ∼ 25
33 ∼ 45
54 ∼ 72
83 ∼ 115
125 ∼ 165
165 ∼ 240
PERIODIC MAINTENANCE 2-13
Specifications
Item
Fuel System (DFI)
Throttle Grip Free Play
Idle Speed
Air Cleaner Element
Cooling System
Coolant:
Type (Recommended)
Color
Mixed Ratio
Freezing Point
Total Amount
Engine Top End
Valve Clearance
Clutch
Clutch Fluid:
Grade
Engine Lubrication System
Engine Oil:
Grade
Viscosity
Capacity
Level
Wheels/Tires
Tread Depth:
Front
Rear
Air Pressure: (when Cold)
Front
Rear
Standard
Service Limit
2 ∼ 3 mm (0.08 ∼ 0.12 in.)
950 ±50 r/min (rpm)
Viscous paper element
– – –
– – –
– – –
Permanent type antifreeze
Green
Soft water 50%, Coolant 50%
–35°C (–31°F)
2.4 L (2.5 US qt)
– – –
– – –
Non-adjustable (HLA Type)
– – –
DOT4
– – –
API SE, SF or SG
API SH, SJ, SL or SM with JASO MA, MA1 or
MA2
SAE 10W-40
4.1 L (4.3 US qt, when filter is not removed)
4.3 L (4.5 US qt, when filter is removed)
5.0 L (5.3 US qt, when engine is completely dry)
Between upper and lower level lines (Wait 2 ∼ 3
minutes after idling or running)
– – –
4.3 mm (0.17 in.)
7.2 mm (0.28 in.)
Up to 180 kg (397 lb) load:
200 kPa (2.00 kgf/cm², 28 psi)
Up to 97.5 kg (215 lb) load:
250 kPa (2.50 kgf/cm², 36 psi)
97.5 ∼ 180 kg (215 ∼ 397 lb) load:
280 kPa (2.80 kgf/cm², 40 psi)
– – –
– – –
– – –
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
1 mm (0.04 in.)
(AT, CH, DE): 1.6
mm (0.06 in.)
Up to 130 km/h
(80 mph): 2 mm
(0.08 in.)
Over 130 km/h
(80 mph): 3 mm
(0.1 in.)
– – –
– – –
– – –
2-14 PERIODIC MAINTENANCE
Specifications
Item
Final Drive
Drive Belt Deflection:
(45 N, 4.6 kgf, 10 lb force)
(When installing new belt
or engine is remounted)
Brakes
Brake Fluid:
Grade
Brake Pad Lining Thickness:
Front
Rear
Brake Light Timing:
Front
Rear
Electrical System
Spark Plug:
Type
Gap
Standard
Service Limit
3.0 ∼ 4.5 mm (0.12 ∼ 0.18 in.)
3.0 mm (0.12 in.)
– – –
– – –
DOT4
– – –
4.5 mm (0.18 in.)
7.0 mm (0.28 in.)
1 mm (0.04 in.)
1 mm (0.04 in.)
Pulled ON
ON after about 10 mm (0.39 in.) of pedal travel
– – –
– – –
NGK ILZKAR7B11
1.0 ∼ 1.1 mm (0.031 ∼ 0.035 in.)
– – –
– – –
PERIODIC MAINTENANCE 2-15
Special Tools
Inside Circlip Pliers:
57001-143
Oil Filter Wrench:
57001-1249
Steering Stem Nut Wrench:
57001-1100
Tension Gauge:
57001-1585
2-16 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Fuel System (DFI)
Throttle Control System Inspection
• Check the throttle grip free play [A].
Throttle Grip Free Play
Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)
If the free play is incorrect, adjust the throttle grip free play
as follows.
the dust cover [A].
• Slide
Loosen
locknut [B].
• Turn thetheaccelerator
cable adjuster [C] until 2 ∼ 3 mm
• (0.08 ∼ 0.12 in.) of throttle
grip play is obtained.
Tighten
the
locknut.
• Slide the dust cover to the original position.
• If the free play cannot be adjusted by using the accelerator cable adjuster, use the decelerator cable adjuster [D]
and accelerator cable adjuster make the necessary free
play.
If the free play cannot be adjusted with the adjusters, replace the cables.
If the throttle grip free play is adjusted, confirm the following inspections.
Full Throttle Pulley Position Inspection (see Cable Installation in the Fuel System (DFI) chapter)
Cruise Control Cancel Switch (Throttle) Operation Inspection (see Cable Installation in the Fuel System (DFI)
chapter)
that the throttle grip [A] moves smoothly from full
• Check
open to close, and the throttle closes quickly and com-
•
pletely by the return spring in all steering positions.
If the throttle grip does not return properly, check the throttle cables routing, grip free play and cable damage. Then
lubricate the throttle cable.
Run the engine at the idle speed, and turn the handlebar
all the way to the right and left to ensure that the idle speed
does not change.
If the idle speed increases, check the throttle cable free
play and the cable routing.
PERIODIC MAINTENANCE 2-17
Periodic Maintenance Procedures
Idle Speed Inspection
the engine and warm it up thoroughly.
•○Start
At first the engine will run fast to decrease warm up time
(fast idle).
○Gradually the fast idle will lower to a certain RPM auto-
•
matically. This is the idle speed.
With the engine idling, turn the handlebar to both sides
[A].
If handlebar movement changes the idle speed, the
throttle cables may be improperly adjusted or incorrectly
routed or damaged. Be sure to correct any of these
conditions before riding (see Cable, Wire, and Hose
Routing section in the Appendix chapter).
WARNING
Operation with improperly adjusted, incorrectly
routed or damaged cables could result in an unsafe
riding condition.
the idle speed.
• Check
If the idle speed is out of the specified range, adjust it (see
Idle Speed Adjustment).
Idle Speed
Standard: 950 ±50 r/min (rpm)
Idle Speed Adjustment
NOTE
○This motorcycle is equipped with the ETV (Electrical
Throttle Valve) system to control the throttle valves electrically. The idle speed is adjusted automatically at the
specified value (950 r/min (rpm)) by the ETV system.
Therefore, it is not necessary to adjust the idle speed
normally.
○The idle speed can be adjusted by operating the right
switch housing.
the gear position in the neutral.
• Set
Start
the engine and warm it up thoroughly until the water
• temperature
goes up 60°C (140°F) or more.
• Wait until fast idle speed lowers to a certain value.
2-18 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
the “S” button [A] of the right switch housing for more
• Push
than two seconds to display the clock setting mode [B] on
the LCD (Liquid Crystal Display).
PERIODIC MAINTENANCE 2-19
Periodic Maintenance Procedures
the “S” button to display the idle speed adjusting
• Push
mode [A].
NOTE
○The display change to the clock setting mode [B], average fuel consumption unit setting mode [C], idle speed
adjusting mode each time the “S” button is pressed.
○The initial setting value of the idle speed adjusting mode
is the “0” (this shows 950 r/min (rpm)).
○The idle adjusting mode is displayed with following conditions.
1. The gear position is neutral.
2. The water temperature is 60°C (140°F) or more.
3. The engine is running and the speedometer is the 0
km/h.
4. The fast idle was finished.
the idle speed by pushing the “MODE-A” switch
• Adjust
(left position) [A] or “MODE-B” switch (right position) [B]
of the right switch housing as follows.
2-20 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
○The idle speed goes up 50 r/min (rpm) at one time by
pushing the “MODE-A” switch.
○When pushing the “MODE-A” switch, the value on the
display shows the “+50” [A] (this shows 1 000 r/min (rpm)).
○The idle speed goes down 50 r/min (rpm) at one time by
pushing the “MODE-B” switch.
○When pushing the “MODE-B” switch, the value on the
display shows the “–50” [B] (this shows 900 r/min (rpm)).
NOTE
○When pushing the “MODE-B” switch for more than two
seconds, the value on the display shows the “0” [C] (initial setting value).
○The idle speed can be set with 850 ∼ 1 100 r/min (rpm).
○Open and close the throttle a few times to make sure that
the idle speed is within the specified range. Readjust if
necessary.
of the following procedures ends idle speed adjusting
• Any
mode.
○Push the “S” button for more than two seconds.
○When the engine is stopped.
Fuel Hose Inspection (fuel leak, damage,
installation condition)
○If the motorcycle is not properly handled, the high pressure inside the fuel line can cause fuel to leak [A] or the
hose to burst. Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) and check the
fuel hoses.
Replace the fuel hose if any fraying, cracks [B] or bulges
[C] are noticed.
PERIODIC MAINTENANCE 2-21
Periodic Maintenance Procedures
that the fuel hose [A] are routed according to
• Check
Cable, Wire, and Hose Routing section in the Appendix
chapter.
Replace the hose if it has been sharply bent or kinked.
that the fuel hose joints are securely connected.
•○Check
Push and pull [A] the fuel hose joint [B] back and forth
more than two times, and make sure it is locked.
○Check the other hose joint in the same way.
WARNING
Make sure the hose joint is installed correctly on the
delivery pipe by sliding the joint, or the fuel could
leak.
If it does not locked, reinstall the hose joint.
Evaporative Emission Control System Inspection
(CAL and SEA Models)
the canister as follows.
•○Inspect
Remove:
Band [A]
Canister/Separator Bracket Bolts [B]
○Disconnect the hoses from the canister [C], and remove
the canister.
○Visually inspect the canister for cracks or other damage.
If the canister has any cracks or bad damage, replace it
with a new one.
NOTE
○The canister is designed to work well through the motorcycle’s life without any maintenance if it is used under
normal conditions.
2-22 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
the liquid/vapor separator as follows.
•○Check
Remove:
Canister
Band [A]
○Disconnect the hoses from the separator [B], and remove
the separator.
○Visually inspect the separator for cracks and other damage.
If the separator has any cracks or damage, replace it with
a new one.
○To prevent the gasoline from flowing into or out of the
canister, hold the separator perpendicular to the ground.
Check the hoses of the evaporative emission control system as follows.
○Check that the hoses are securely connected and clips
are in position.
○Replace any kinked, deteriorated or damaged hoses.
○Route the hoses according to Cable, Wire, and Hose
Routing section in the Appendix chapter.
○When installing the hoses, avoid sharp bending, kinking,
flattening or twisting, and route the hoses with a minimum
of bending so that the emission flow will not be obstructed.
•
Cooling System
Coolant Level Inspection
NOTE
○Check the level when the engine is cold (room or ambient temperature).
the coolant level in the reserve tank with the motor• Check
cycle held upright. The coolant level should be between
the “F” (full) level and the “L” (low) level (In the photo, the
right side cover has been removed for clarity).
Front [A]
Reserve Tank [B]
“F” Level [C]
“L” Level [D]
If the coolant level is lower than the “L” level, remove
the right side cover and the reserve tank cap, then add
coolant to the ”F” level.
CAUTION
For refilling, add the specified mixture of coolant
and soft water. Adding water alone dilutes the
coolant and degrades its anticorrosion properties.
The diluted coolant can attack the aluminum engine
parts. In an emergency, soft water can be added,
but the diluted coolant must be returned to the correct mixture ratio within a few days.
If coolant must be added often or the reserve tank
has run completely dry, there is probably leakage in
the cooling system. Check the system for leaks.
Coolant ruins painted surfaces. Immediately wash
away any coolant that spills on the frame, engine,
wheels, or other painted parts.
PERIODIC MAINTENANCE 2-23
Periodic Maintenance Procedures
Radiator Hose and Pipe Inspection (Coolant Leak,
Damage, Installation Condition)
○The
•
high pressure inside the radiator hose can cause
coolant to leak [A] or the hose to burst if the line is not
properly maintained. Visually inspect the hoses for signs
of deterioration. Squeeze the hoses. A hose should not
be hard and brittle, nor should it be soft or swollen.
Replace the hose if any fraying, cracks [B] or bulges [C]
are noticed.
Check that the hoses are securely connected and clamps
are tightened correctly.
Torque - Radiator Hose Clamp Screws: 2.0 N·m (0.20 kgf·m,
18 in·lb)
Engine Top End
Air Suction System Damage Inspection
the fuel tank (see Fuel Tank Removal in the Fuel
• Remove
System (DFI) chapter).
the air switching valve hose [A] from the right
• Separate
air cleaner housing.
the following parts temporarily.
• Connect
Fuel Pump/Fuel Level Sensor Lead Connector [A]
Fuel Hose [B] (see Fuel Tank Installation in the Fuel System (DFI) chapter)
the engine and run it at idle speed.
• Start
Plug
the
air switching valve hose end [A] with your finger
• and feel vacuum
pulsing in the hose.
If there is no vacuum pulsation, check the hose line for
leak. If there is no leak, check the air switching valve
(see Air Switching Valve Unit Test in the Electrical System chapter) or air suction valve (see Air Suction Valve
Inspection in the Engine Top End chapter).
2-24 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Clutch
Clutch Operation Inspection
the engine and check that the clutch does not slip
• Start
and that it releases properly.
If the clutch operation is insufficiency, inspect the clutch
system.
WARNING
When inspecting by running the vehicle, note a
surrounding traffic situation enough in the place of
safety.
Clutch Fluid Level Inspection
the clutch fluid reservoir horizontal.
• Hold
Check
clutch fluid level of the clutch reservoir is
• betweenthatthethelower
[A] and the upper [B] level lines.
If the fluid level is lower than the lower level line, fill the
reservoir to the upper level line in the reservoir.
○Since the clutch fluid is the same as the brake fluid, refer
to the Brake Fluid Level Inspection in this chapter for further details.
Torque - Clutch Reservoir Cap Screws:
kgf·m, 13 in·lb)
1.5 N·m (0.15
WARNING
Change the fluid in the clutch line completely if the
fluid must be refilled but the type and brand of the
fluid that already is in the reservoir are unidentified.
After changing the fluid, use only the same type and
brand of fluid thereafter. Mixing different types and
brands of fluid lowers the fluid boiling point and
could cause the clutch to be ineffective. It may also
cause the rubber clutch parts to deteriorate.
Clutch Fluid Leak (Clutch Hose and Pipe)
the clutch lever and inspect the clutch fluid leak
• Apply
from the clutch hose [A], pipe [B] and fitting.
If the clutch fluid leaked from any position, inspect or replace the problem part.
PERIODIC MAINTENANCE 2-25
Periodic Maintenance Procedures
Clutch Hose and Pipe Damage and Installation
Condition Inspection
high pressure inside the clutch line can cause fluid
• The
to leak [A] or the hose to burst if the line is not properly
•
maintained. Bend and twist the rubber hose while examining it.
Replace it if any fraying, cracks [B] or bulges [C] are noticed.
Check that the hoses are securely connected and banjo
bolts are tightened correctly.
Torque - Clutch Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
installing the clutch hose, route the hoses accord• When
ing to Cable, Wire, and Hose Routing section in the Appendix chapter.
Replace the hose if it has been sharply bent or kinked.
Wheels and Tires
Tire Air Pressure Inspection
the air valve cap.
• Remove
Measure
tire air pressure with an air pressure gauge
• [A] when the
the tires are cold (that is, when the motorcycle
has not been ridden more than a mile during the past 3
hours).
Adjust the tire air pressure according to the specifications
if necessary.
Air Pressure (when Cold)
Front: Up to 180 kg (397 lb)
200 kPa (2.00 kgf/cm², 28 psi)
Rear:
Up to 97.5 kg (215 lb)
250 kPa (2.50 kgf/cm², 36 psi)
97.5 ∼ 180 kg (215 ∼ 397 lb)
280 kPa (2.80 kgf/cm², 40psi)
• Install the air valve cap.
Wheel/Tire Damage Inspection
any imbedded stones [A] or other foreign parti• Remove
cles [B] from tread.
inspect the tire for cracks and cuts, and replace
• Visually
the tire if necessary. Swelling or high spots indicate inter-
•
nal damage, requiring tire replacement.
Visually inspect the wheel for cracks, cuts and dents damage.
If any damage is found, replace the wheel if necessary.
Tire Tread Wear Inspection
As the tire tread wears down, the tire becomes more susceptible to puncture and failure. An accepted estimate is
that 90% of all tire failures occur during the last 10% of tread
life (90% worn). So it is false economy and unsafe to use
the tires until they are bald.
2-26 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
the tread depth at the center of the tread with a
• Measure
depth gauge [A]. Since the tire may wear unevenly, take
measurement at several places.
If any measurement is less than the service limit, replace
the tire (see Tire Removal/Installation in the Wheels/Tires
chapter).
Tread Depth
Standard:
Front
4.3 mm (0.17 in.)
Rear
7.2 mm (0.28 in.)
Service Limit:
Front
1 mm (0.04 in.)
(AT, CH, DE) 1.6 mm (0.06 in.)
Rear
Up to 130 km/h (80 mph): 2 mm (0.08 in.)
Over 130 km/h (80 mph): 3 mm (0.12 in.)
WARNING
To ensure safe handling and stability, use only the
recommended standard tires for replacement, inflated to the standard pressure.
NOTE
○Most countries may have their own regulations a minimum tire tread depth; be sure to follow them.
○Check and balance the wheel when a tire is replaced
with a new one.
Wheel Bearing Damage Inspection
the front wheel off the ground (see Front Wheel
• Raise
Removal in the Wheels/Tires chapter).
the handlebar all the way to the right or left.
• Turn
Inspect
roughness of the front wheel bearing by push• ing and the
pulling [A] the wheel.
Spin
the
wheel lightly, and check for smoothly turn,
• roughness,frontbinding
or noise.
If roughness, binding or noise is found, remove the front
wheel and inspect the wheel bearing (see Front Wheel
Removal, Hub Bearing Inspection in the Wheels/Tires
chapter).
the rear wheel off the ground (see Rear Wheel Re• Raise
moval in the Wheels/Tires chapter).
the roughness of the rear wheel bearing by push• Inspect
ing and pulling the wheel to be both side.
[A] the rear wheel lightly, and check for smoothly
• Spin
turn, roughness, binding or noise.
If roughness, binding or noise is found, remove the rear
wheel and inspect the wheel bearing (see Rear Wheel Removal, Hub Bearing Inspection in the Wheels/Tires chapter) and coupling (see Coupling Bearing Inspection in the
Final Drive chapter).
PERIODIC MAINTENANCE 2-27
Periodic Maintenance Procedures
Final Drive
Drive Belt Deflection Inspection
NOTE
○Belt deflection must be checked and adjusted when the
belt is cold (at room temperature).
○Belt deflection also should be checked at first 1000 km
(621.4 mile) ride after belt replacement.
to see if wheel alignment is properly adjusted.
•○Check
The left and right notches [A] on the belt adjusters [B]
should point to the same marks or positions [C] on the
swingarm.
If they do not, adjust the wheel alignment (see Wheel
Alignment Inspection/Adjustment).
the rear wheel off the ground (see Rear Wheel Re• Raise
moval in the Wheels/Tires chapter).
inspect the belt for damage (see Drive Belt Wear
• Visually
and Damage Inspection).
If the belt is damaged, replace it with a new one.
the initial belt position [A] on the front of the belt
• Mark
cover [B].
the tension gauge [C], push up the belt at the win• Using
dow [D] of the belt cover with 45 N of force.
Special Tool - Tension Gauge: 57001-1585
the pushed up belt position [E].
• Mark
the deflection (length between mark [E] and [A])
• Measure
of the belt.
○The length between the mark line (front side and window)
of the belt cover is the 5 mm (0.19 in).
NOTE
○Push the belt by the gauge until the top surface [A] of
the stopper comes to the 45 N loaded scale [B], marked
“45N”.
○Push up on the middle of the belt width. An inaccurate
reading will occur if the edge of the belt is pushed up.
○Look parallel to the belt during inspection. An inaccurate reading will occur if looking from any other angle.
the belt deflection at two positions by rotating the
• Inspect
rear wheel.
2-28 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
the drive belt deflection at arbitrary position, and
• Inspect
record the value [A].
• Turn the rear wheel 90 degrees.
• Inspect the drive belt deflection, and record the value [B].
the belt deflection at the position [C] of one where
• Decide
deflection is large.
Drive Belt Deflection (with 45 N, 4.6 kgf, 10 lb force)
Standard: 3.0 ∼ 4.5 mm (0.12 ∼ 0.18 in.)
Drive Belt Deflection (with 45 N, 4.5 kgf, 10 lb force,
when installing new belt or engine remounted)
Standard: 3.0 mm (0.12 in.)
If the deflection is out of the specification, adjust it.
Drive Belt Deflection Adjustment
• Remove:
Saddlebag (see Saddlebag Removal in the Frame chapter)
PERIODIC MAINTENANCE 2-29
Periodic Maintenance Procedures
the axle cotter pin [A], and loosen the axle nut
• Remove
[B].
the rear wheel off the ground (see Rear Wheel Re• Raise
moval in the Wheels/Tires chapter).
the belt adjuster locknuts [C] on the both sides.
• Loosen
If the belt is too tight, back out the left and right belt adjuster nuts [D], and kick the wheel forward until the belt is
too loose.
Turn in the left and right belt adjuster nuts evenly until the
drive belt has the correct amount of deflection.
○To keep the belt and wheel aligned, the notch on the belt
adjuster should align with the same swingarm mark [E]
that the other side notch aligns with.
•
• Tighten both belt adjuster locknuts.
WARNING
Misalignment of the wheel will result in abnormal
wear, and may result in an unsafe riding condition.
Tighten both belt adjuster locknuts, and make sure
the axle stays aligned.
• Tighten the axle nut.
Torque - Rear Axle Nut: 108 N·m (11.0 kgf·m, 80 ft·lb)
the drive belt deflection (see Belt Deflection In• Inspect
spection).
Readjust if necessary.
• Insert a new cotter pin [A].
NOTE
○When inserting the cotter pin, if the slots in the nut do
not align with the cotter pin hole in the axle, tighten the
nut clockwise [B] up to next alignment.
○It should be within 30°.
○Loosen once and tighten again when the slot goes past
the nearest hole.
• Bend the cotter pin [A] over the nut.
WARNING
If the rear axle nut is not securely tightened or the
cotter pin is not installed, an unsafe riding condition may result.
the rear brake for weak braking power and brake
• Check
drag.
2-30 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Wheel Alignment Inspection/Adjustment
that the notch [A] on the belt adjuster [B] aligns with
• Check
the same swingarm mark [C] or position that the other side
notch aligns with.
If they do not, adjust the belt deflection (see Belt Deflection Adjustment) and align the wheel alignment.
○Wheel
NOTE
alignment can be also checked using the
straightedge or string method.
WARNING
Misalignment of the wheel will result in abnormal
wear, and may result in an unsafe riding condition.
Drive Belt Wear and Damage Inspection
the rear wheel off the ground (see Rear Wheel Re• Raise
moval in the Wheels/Tires chapter).
the left side cover (see Left Side Cover Removal
• Remove
in the Frame chapter).
inspect the belt [A] for wear and damage.
• Visually
If the nylon fabric facing of any portion is worn off, and the
•
polyurethane compound is exposed, or belt is damaged,
replace the belt immediately with a new one.
Otherwise, refer to the Drive Belt Tooth Wear and Damage Patterns and perform the according to the table of
Drive Belt Wear and Damage Analysis.
Whenever the belt is replaced, inspect the engine and
rear pulleys (see Pulley Wear Inspection in the Final Drive
chapter).
WARNING
A belt worn past the nylon fabric facing must be
replaced. Such a worn belt may cause a serious
accident.
PERIODIC MAINTENANCE 2-31
Periodic Maintenance Procedures
Drive Belt Tooth Wear and Damage Patterns
A. Belt Cross Section
B. Edge Bevel Wear
C. Rub Wear
D. Stone
2-32 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Drive Belt Wear and Damage Analysis
Pattern
Condition
1
Internal tooth cracks (slight)
2
Scuffing to side of teeth
3
Fraying edge cord
4
Beveled wear
5
6
External tooth cracks (severe)
7
Tooth hook wear
8
Stone damage
Severe fractured or missing teeth
Required Action
O.K. for continued use, but inspect the belt
periodically.
O.K. for continued use, but inspect the belt
periodically. Also check the pulley flange.
O.K. for continued use, but inspect the belt
periodically (replace the belt if excessive).
O.K. for continued use, check the pulley
alignment and flange condition.
Replace the drive belt.
Replace the drive belt.
Replace the drive belt. Inspect the pulley for
wear.
Remove stone, O.K. for continued use it not near
edge of the belt. Inspect the pulley for damage.
PERIODIC MAINTENANCE 2-33
Periodic Maintenance Procedures
Brakes
Brake Fluid Leak (Brake Hose and Pipe) Inspection
the brake lever or pedal and inspect the brake fluid
• Apply
leak from the brake hoses [A] and fittings [B].
If the brake fluid leaked from any position, inspect or replace the problem part.
2-34 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Brake Hose and Pipe Damage and Installation
Condition Inspection
the brake hoses and fittings for deterioration,
• Inspect
cracks and signs of leakage.
○The high pressure inside the brake line can cause fluid to
•
leak [A] or the hose to burst if the line is not properly maintained. Bend and twist the rubber hose while examining
it.
Replace the hose if any crack [B], bulge [C] or leakage is
noticed.
Tighten any brake hose banjo bolts.
Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
the brake hose routing.
• Inspect
If any brake hose routing is incorrect, run the brake hose
according to Cable, Wire, and Hose Routing section in the
Appendix chapter.
Brake Operation Inspection
the operation of the front and rear brake by run• Inspect
ning the vehicle on the dry road.
If the brake operation is insufficiency, inspect the brake
system.
WARNING
When inspecting by running the vehicle, note a
surrounding traffic situation enough in the place of
safety.
Brake Fluid Level Inspection
that the brake fluid level in the front brake reservoir
• Check
[A] is above the lower level line [B].
NOTE
○Hold the reservoir horizontally by turning the handlebar
when checking brake fluid level.
If the fluid level is lower than the lower level line, fill the
reservoir to the upper level line [A] in the reservoir [B].
PERIODIC MAINTENANCE 2-35
Periodic Maintenance Procedures
that the brake fluid level in the rear brake reservoir
• Check
[A] is above the lower level line [B].
If the fluid level is lower than the lower level line, fill the
reservoir to the upper level line [C].
WARNING
Do not mix two brands of fluid. Change the brake
fluid in the brake line completely if the brake fluid
must be refilled but the type and brand of the brake
fluid that is already in the reservoir are unidentified.
After changing the fluid, use only the same type and
brand of fluid thereafter.
the front
• Install
screws.
brake reservoir cap, and tighten the
Torque - Front Brake Reservoir Cap Screws: 1.5 N·m (0.15
kgf·m, 13 in·lb)
the procedure below to install the rear brake fluid
• Follow
reservoir cap correctly.
○First, tighten the rear brake fluid reservoir cap [B] clockwise [C] by hand until slight resistance is felt indicating
that the cap is seated on the reservoir body, then tighten
the cap an additional 1/6 turn [D] while holding the brake
reservoir body [A].
Brake Pad Wear Inspection
the brake pads (see Front/Rear Brake Pad Re• Remove
moval in the Brakes chapter).
the lining thickness [A] of the pads in each caliper.
• Check
If the lining thickness of either pad is less than the service
limit [B], replace both pads in the caliper as a set.
Pad Lining Thickness
Standard:
Front
4.5 mm (0.18 in.)
Rear
7.0 mm (0.28 in.)
Service Limit: 1 mm (0.04 in.)
Brake Light Switch Operation Inspection
on the ignition switch.
• Turn
The
brake
[A] should go on when the brake lever
• is applied orlights
after the brake pedal is depressed about 10
mm (0.39 in.).
2-36 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
•
•
If it does not, adjust the brake light switch.
Remove the front guard mounting bolt [A] and front footboard bracket bolts [B].
Slide the front guard forward.
holding the switch body, turn the adjusting nut to
• While
adjust the switch.
Switch Body [A]
Adjusting Nut [B]
Light sooner as the body rises [C]
Light later as the body lowers [D]
CAUTION
To avoid damaging the electrical connections inside of the switch, be sure that the switch body does
not turn during adjustment.
If it does not go on, inspect or replace the following items.
Battery (see Charging Condition Inspection in the Electrical System chapter)
Brake Light (LED) (see Tail/Brake Light (LED) Removal
in the Electrical System chapter)
Main Fuse 30 A and Taillight Fuse 10 A (see Fuse Inspection in the Electrical System chapter)
Front Brake Light Switch [A] (see Switch Inspection in
the Electrical System chapter)
Rear Brake Light Switch (see Switch Inspection in the
Electrical System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)
Suspension
Front Forks/Rear Shock Absorber Operation
Inspection
the forks down and up [A] 4 or 5 times, and inspect
• Pump
the smooth stroke.
If the forks does not smoothly or noise is found, inspect
the fork oil level or fork clamps (see Front Fork Oil Change
in the Suspension chapter).
PERIODIC MAINTENANCE 2-37
Periodic Maintenance Procedures
the rear seat down and up [A] 4 or 5 times, and
• Pump
inspect the smooth stroke.
If the shock absorber does not smoothly or noise is found,
inspect the oil leak (see Rear Shock Absorber Oil Leak
Inspection).
Front Fork Oil Leak Inspection
inspect the front forks [A] for oil leakage.
• Visually
Replace or repair any defective parts, if necessary.
Rear Shock Absorber Oil Leak Inspection
inspect the shock absorber [A] for oil leakage.
• Visually
If the oil leakage is found on it, replace the shock absorber
with a new one.
Swingarm Pivot Lubrication
the swingarm (see Swingarm Removal in the
• Remove
Suspension chapter).
the old grease out of the bearings.
• Clean
Apply
grease
to the inner surface of the needle bearings
• [A].
a thin coat of grease to the lips [B] of the grease
• Apply
seals.
the swingarm (see Swingarm Installation in the
• Install
Suspension chapter).
2-38 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Steering
Steering Play Inspection
the front wheel off the ground (see Front Wheel
• Raise
Removal in the Wheels/Tires chapter).
the front wheel pointing straight ahead, alternately
• With
tap each end of the handlebar. The front wheel should
•
swing fully left and right from the force of gravity until the
fork hits the stop.
If the wheel binds or catches before the stop, the steering
is too tight.
Feel for steering looseness by pushing and pulling [A] the
forks.
If you feel looseness, the steering is too loose.
NOTE
○The cables and wiring will have some effect on the motion of the fork which must be taken into account.
○Be sure the leads and cables are properly routed.
○The bearings must be in good condition and properly
lubricated in order for any test to be valid.
Steering Play Adjustment
• Remove:
Windshield
(see Windshield Removal in the Frame
chapter)
• Remove:
Bolt [A]
Holder [B]
the handlebar (see Handlebar Removal in the
• Remove
Steering chapter).
CAUTION
Take care not to bend the hoses sharply.
the upper front fork clamp bolts [A].
• Loosen
• Remove:
Steering Stem Head Nut [B] and Washer
Steering Stem Head [C]
PERIODIC MAINTENANCE 2-39
Periodic Maintenance Procedures
• Remove the lock washer [A].
the steering using the steering stem nut wrench
• Adjust
[A].
Special Tool - Steering Stem Nut Wrench: 57001-1100
If the steering is too tight, loosen the stem nut [B] a fraction
of a turn.
If the steering is too loose, tighten the stem nut a fraction
of a turn.
NOTE
○Turn the stem nut 1/8 turn at time maximum.
the claw [A] of the lock washer to the groove [B] of the
• Fit
stem nut.
the steering stem head.
• Install
Tighten:
•
Torque - Steering Stem Head Nut: 108 N·m (11.0 kgf·m, 80
ft·lb)
Upper Front Fork Clamp Bolts: 20 N·m (2.0 kgf·m,
15 ft·lb)
• Install:
Handlebar (see Handlebar Installation in the Steering
chapter)
Holder [A]
the steering again.
• Check
If the steering is still too tight or loose, repeat the adjustment.
2-40 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Steering Stem Bearing Lubrication
the steering stem (see Steering, Stem Bearing
• Remove
Removal in the Steering chapter).
a high-flash point solvent, wash the upper and
• Using
lower ball bearings in the cages, and wipe the upper and
•
•
•
•
lower outer races, which are press-fitted into the frame
head pipe, clean off grease and dirt.
Visually check the outer races and the ball bearings.
Replace the bearing assemblies if they show wear or
damage.
Pack the upper and lower ball bearings [A] in the cages
with grease, and apply a light coat of grease to the upper
and lower outer races.
Install the steering stem (see Steering, Stem Bearing Installation in the Steering chapter).
Adjust the steering (see Steering Play Adjustment).
Electrical System
Spark Plug Condition Inspection
• Remove:
Spark Plugs (see Spark Plug Removal in the Electrical
•
•
System chapter)
Visually inspect the spark plugs.
If the spark plug center electrode [A] and/or side electrode [B] are corroded or damaged, or if the insulator [C]
is cracked, replace the plug.
If the spark plug is dirtied or the carbon is accumulated,
replace the spark plug.
Measure the gap [D] with a wire-type thickness gauge.
If the gap is incorrect, replace the spark plug.
Spark Plug Gap:
1.0 ~ 1.1 mm (0.039 ~0.043 in.)
• Use the standard spark plug or its equivalent.
Standard Spark Plug:
Type:
NGK ILZKAR7B11
PERIODIC MAINTENANCE 2-41
Periodic Maintenance Procedures
Lights and Switches Operation
First Step
Turn the ignition switch ON.
The following lights should go on according to below table.
•
•
Models
Position Lights
(Equipped Models) [A]
City Light (Equipped
Models) [B]
United
Canada Europe
States
go on
go on
–
–
–
–
goes on
–
Fuel Level Warning
Indicator Light (LED) [C]
goes on on (for 3 seconds)
CRUISE Indicator Light
(LED) [D]
goes on (for 3 seconds)
SET Indicator Light
(LED) [E]
goes on (for 3 seconds)
Neutral Indicator Light
(LED) [F]
goes on
Oil Pressure Warning
Symbol [G] and Warning go on
Indicator Light (LED) [H]
Meter Panel LCD [I]
Australia
goes on
Meter Panel Illumination
go on
Lights (LED) [J]
Taillight (LED) [K]
go on
License Plate Light [L]
goes on
2-42 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
•
•
If the light does not go on, inspect or replace the following
parts.
Battery (see Charging Condition Inspection in the Electrical System chapter)
Position Light Bulb (see Position Light Bulb Replacement in the Electrical System chapter)
City Light Bulb (see City Light Bulb Replacement in the
Electrical System chapter)
Fuel Level Warning Indicator Light (LED) (see Meter Unit
Inspection in the Electrical System chapter)
CRUISE Indicator Light (LED) (see Meter Unit Inspection in the Electrical System chapter)
SET Indicator Light (LED) (see Meter Unit Inspection in
the Electrical System chapter)
Neutral Indicator Light (LED) (see Meter Unit Inspection
in the Electrical System chapter)
Warning Indicator Light (LED) (Oil Pressure Warning)
(see Meter Unit Inspection in the Electrical System chapter)
Meter Panel LCD (see Meter Unit Inspection in the Electrical System chapter)
Meter Panel Illumination Light (LED) (see Meter Unit Inspection in the Electrical System chapter)
Tail/Brake Light (LED) (see Taillight (LED) Replacement
in the Electrical System chapter)
License Plate Light Bulb (see License Plate Light Bulb
Replacement in the Electrical System chapter)
ECU (see ECU Power Supply Inspection in the Fuel System (DFI) chapter)
Main Fuse 30 A and Taillight Fuse 10 A (see Fuse Inspection in the Electrical System chapter)
Ignition Switch (see Switch Inspection in the Electrical
System chapter)
Oil Pressure Switch (see Switch Inspection in the Electrical System chapter)
Gear Position Switch (see Gear Position Switch Inspection in the Electrical System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)
Turn the ignition switch OFF.
The all lights should go off.
If the light does not go off, replace the ignition switch.
PERIODIC MAINTENANCE 2-43
Periodic Maintenance Procedures
Second Step
Turn the ignition switch ON.
Push the turn signal switch [A] ON (left or right position).
The left or right turn signal lights [B] (front and rear) according to the switch position should flash.
The turn signal indicator light (LED) [C] in the meter unit
should flash.
If the lights do not flash, inspect or replace the following
part.
Turn Signal Light Bulb (see Turn Signal Light Bulb Replacement in the Electrical System chapter)
Turn Signal Indicator Light (LED) (see Meter Unit Inspection in the Electrical System chapter)
Turn Signal Relay Fuse 10 A (see Fuse Inspection in the
Electrical System chapter)
Turn Signal Switch (see Switch Inspection in the Electrical System chapter)
Turn Signal Control Relay (see Turn Signal Control Relay Inspection in the Electrical System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)
Push the turn signal switch.
The turn signal lights and indicator light (LED) should go
off.
If the light does not go off, inspect or replace the following
part.
Turn Signal Switch (see Switch Inspection in the Electrical System chapter)
•
•
•
•
•
•
NOTE
○Refer to the Electrical System chapter for the automatic
turn signal canceling system.
the hazard button [A].
• Push
The
left
• flash. and right turn signal lights (front and rear) should
turn signal indicator lights (LED) in the meter unit
• The
should flash.
•
•
If the lights do not flash, inspect or replace the following
parts.
Hazard Button (see Switch Inspection in the Electrical
System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)
Push the hazard button.
The turn signal lights and indicator lights (LED) should go
off.
If the lights do not go off, inspect or replace the following
part.
Hazard Button (see Switch Inspection in the Electrical
System chapter)
2-44 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Third Step
Turn the ignition switch to ACC position.
Push the turn signal switch [A] ON (left or right position).
The left or right turn signal lights (front and rear) according
to the switch position should flash.
The turn signal indicator light (LED) in the meter unit
should flash.
If the lights do not flash, inspect or replace the ignition
switch (see Switch Inspection in the Electrical System
chapter).
•
•
•
•
Fourth Step
Set the dimmer switch to low beam position [A].
Start the engine.
The low beam headlight should go on.
If the low beam headlight does not go on, inspect or replace the following parts.
Headlight Bulb (see Headlight Bulb Replacement in the
Electrical System chapter)
Headlight Fuse 10 A (see Fuse Inspection in the Electrical System chapter)
Dimmer Switch (see Switch Inspection in the Electrical
System chapter)
Headlight Relay (see Relay Circuit Inspection in the
Electrical System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)
•
•
•
the dimmer switch to high beam position [A].
• Set
The
high beam headlight should go on.
• The high
indicator light (LED) [B] should go on.
• If the highbeam
beam headlight and/or high beam indicator light
•
•
(LED) does not go on, inspect or replace the following
parts.
Headlight Bulb (see Headlight Bulb Replacement in the
Electrical System chapter)
Dimmer Switch (see Switch Inspection in the Electrical
System chapter)
Push the engine stop switch to stop position.
The headlight should stay going on.
If the headlight and high beam indicator light (LED) does
go off, inspect or replace the headlight relay (see Relay
Circuit Inspection in the Electrical System chapter).
Headlight Aiming Inspection
the headlight beam for aiming.
• Inspect
If the headlight beam points to one side rather than
straight ahead, adjust the horizontal beam.
PERIODIC MAINTENANCE 2-45
Periodic Maintenance Procedures
Headlight Beam Horizontal Adjustment
Turn the horizontal adjuster [A] on the headlight with a
screwdriver in or out until the beam points straight ahead.
○Turn the adjuster clockwise to face the headlight to the
left.
If the headlight beam points too low or high, adjust the
vertical beam.
•
Headlight Beam Vertical Adjustment
Turn the vertical adjuster [A] in the headlight in or out with
a screwdriver to adjust the headlight vertically.
○Turn the adjuster clockwise to face the headlight to the
left.
•
NOTE
○On high beam, the brightest points should be slightly
below horizontal with the motorcycle on its wheels and
the rider seated. Adjust the headlight to the proper angle according to local regulations.
NOTE
○For the United States model, the proper angle is 0.4 degrees below horizontal. This is 50 mm (2.0 in.) drop at
7.6 m (25 ft) measured from the center of the headlight
with the motorcycle on its wheels and the rider seated.
50 mm (2.0 in.) [A]
Center of Brightest Spot [B]
7.6 m (25 ft) [C]
Height of Headlight Center [D]
2-46 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Sidestand Switch Operation Inspection
the rear wheel off the ground with the jack (see
• Raise
Rear Wheel Removal in the Wheels/Tires chapter).
the sidestand switch [A] operation accordance to
• Inspect
below table.
Sidestand Switch Operation
Sidestand
Gear
Position
Clutch
Lever
Engine
Start
Engine Run
Up
Neutral
Released
Starts
Continue
running
Up
Neutral
Pulled in
Starts
Continue
running
Up
In Gear
Released
Doesn’t
start
Continue
running
Up
In Gear
Pulled in
Starts
Continue
running
Down
Neutral
Released
Starts
Continue
running
Down
Neutral
Pulled in
Starts
Continue
running
Down
In Gear
Released
Doesn’t
start
Stops
Down
In Gear
Pulled in
Doesn’t
start
Stops
If the sidestand switch operation does not work, inspect
or replace the following parts.
Battery (see Charging Condition Inspection in the Electrical System chapter)
Main Fuse 30 A (see Fuse Inspection in the Electrical
System chapter)
Ignition Fuse 10 A (see Fuse Inspection in the Electrical
System chapter)
Ignition Switch (see Switch Inspection in the Electrical
System chapter)
Sidestand Switch (see Switch Inspection in the Electrical
System chapter)
Starter Lockout Switch (see Switch Inspection in the
Electrical System chapter)
Engine Stop Switch (see Switch Inspection in the Electrical System chapter)
Starter Button (see Switch Inspection in the Electrical
System chapter)
Gear Position Switch (see Gear Position Switch Inspection in the Electrical System chapter)
Starter Relay (see Starter Relay Inspection in the Electrical System chapter)
Relay Box (see Relay Circuit Inspection in the Electrical
System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)
If the all parts are good condition, replace the ECU (see
ECU Removal/Installation in the Fuel System (DFI) chapter).
PERIODIC MAINTENANCE 2-47
Periodic Maintenance Procedures
Engine Stop Switch Operation Inspection
First Step
Set the gear position in the neutral position.
Turn the ignition switch ON.
Push the engine stop switch to stop position [A].
Push the starter button.
The engine does not start.
If the engine starts, inspect or replace the engine stop
switch (see Switch Inspection in the Electrical System
chapter).
•
•
•
•
•
Second Step
Set the gear position in the neutral position.
Turn the ignition switch ON.
Push the engine stop switch to run position [A].
Push the starter button and start the engine.
Push the engine stop switch to stop position.
Immediately the engine should be stop.
If the engine does not stop, inspect or replace the engine
stop switch (see Switch Inspection in the Electrical System chapter).
•
•
•
•
•
•
Others
Chassis Parts Lubrication
lubricating each part, clean off any rusty spots with
• Before
rust remover and wipe off any grease, oil, dirt, or grime.
• Lubricate the points listed below with indicated lubricant.
NOTE
○Whenever the vehicle has been operated under
wet or rainy conditions, or especially after using a
high-pressure water spray, perform the general lubrication
Pivots: Lubricate with Grease.
Brake Lever
Brake Pedal
Clutch Lever
Rear Master Cylinder Push Rod Joint Pin
Sidestand
Points: Lubricate with Grease.
Throttle Inner Cable Upper and Lower Ends [A]
2-48 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Cables: Lubricate with Rust Inhibitor
Throttle Cables
Lubricate the cables by seeping the oil between the cable
and housing.
○The cable may be lubricated by using a commercially
available pressure cable lubricator with an aerosol cable
lubricant.
•
the cable disconnected at both ends, the inner cable
• With
should move freely [A] within the cable housing.
If cable movement is not free after lubricating, if the cable
is frayed [B], or if the cable housing is kinked [C], replace
the cable.
Bolts, Nuts and Fasteners Tightness Inspection
the tightness of the bolts and nuts listed here. Also,
• Check
check to see that each cotter pin is in place and in good
condition.
NOTE
○For the engine fasteners, check the tightness of them
when the engine is cold (at room temperature).
If there are loose fasteners, retorque them to the specified torque following the specified tightening sequence.
Refer to the appropriate chapter for torque specifications.
If torque specifications are not in the appropriate chapter,
see the Standard Torque Table. For each fastener, first
loosen it by 1/2 turn, then tighten it.
If cotter pins are damaged, replace them with new ones.
PERIODIC MAINTENANCE 2-49
Periodic Maintenance Procedures
Bolt, Nut and Fastener to be checked
Engine:
Radiator Bolt
Exhaust Pipe Holder Nuts
Left and Right Muffler Body Mounting Bolts
Clutch Lever Pivot Bolt Nut
Clutch Master Cylinder Clamp Bolts
Clutch Slave Cylinder Bolts
Engine Mounting Bolts and Nuts
Engine Bracket Bolts
Wheels:
Front Axle Clamp Bolts
Front Axle
Rear Axle Nut
Rear Axle Nut Cotter Pin
Brakes:
Brake Lever Pivot Bolt and Nut
Brake Pedal Bolt
Rear Master Cylinder Push Rod Joint Cotter Pin
Caliper Mounting Bolts
Front Master Cylinder Clamp Bolts
Rear Master Cylinder Mounting Bolts
Suspension:
Front Fork Clamp Bolts
Rear Shock Absorber Nuts
Swingarm Pivot Shaft Nut
Steering:
Handlebar Clamp Bolts
Steering Stem Head Nut
Others:
Front and Rear Footboard Bracket Bolts
Front and Rear Fender Mounting Bolts
Sidestand Bolt
Cross Pipe Bolts
Downtube Bolts
Windshield Bolts
Saddlebag Bolts
Front and Rear Engine Guard Bolts
2-50 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Replacement Parts
Air Cleaner Element Replacement
NOTE
○In dusty areas, the element should be replaced more
frequently than the recommended interval.
○After riding through rain or on muddy roads, the element
should be replaced immediately.
WARNING
If dirt or dust is allowed to pass through into the
throttle body assy, the throttle may become stuck,
possibly causing an accident.
CAUTION
If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur.
• Remove:
Left Air Cleaner Housing Cover Bolts [A]
Left Air Cleaner Housing Cover [B]
the air cleaner element bolt [A].
• Remove
Discard
the
air cleaner element [B].
•
a new element [A] so that the screen side [B] faces
• Install
inward.
CAUTION
Use only the recommended air cleaner element
(Kawasaki part number 11013-0031). Using another
air cleaner element will wear the engine prematurely or lower the engine performance.
• Tighten:
Torque - Air Cleaner Element Bolt : 4.9 N·m ( 0.50 kgf·m,
43 in·lb)
PERIODIC MAINTENANCE 2-51
Periodic Maintenance Procedures
• Tighten:
Torque - Left Air Cleaner Housing Cover Bolts : 4.9 N·m (
0.50 kgf·m, 43 in·lb)
L = 10 mm (0.39 in.) [A]
L = 25 mm (0.98 in.) [B]
Fuel Hose Replacement
the fuel tank (see Fuel Tank Removal in the Fuel
• Remove
System (DFI) chapter).
sure to place a piece of cloth [A] around the fuel hose
• Be
joint.
a thin blade screwdriver [B] into the slit [C] on the
• Insert
joint lock [D].
[A] the driver to disconnect the joint lock [B].
• Turn
Pull
the
fuel hose joint [C] out of the delivery pipe.
•
WARNING
Be prepared for fuel spillage; any spilled fuel must
be completely wiped up immediately.
When the fuel hose is disconnected, fuel spills out
from the hose and the pipe. Cover the hose connection with a clean shop towel to prevent fuel spillage.
the fuel hose [A] with a new one.
• Replace
Run
the
fuel
hose correctly (see Cable, Wire, and Hose
• Routing section
in the Appendix chapter).
[B] the fuel hose joint [C] straight onto the delivery
• Insert
pipe until the hose joint clicks.
• Push [D] the joint lock [E].
and pull [A] the fuel hose joint [B] back and forth
• Push
more than two times and make sure it is locked and does
not come off.
WARNING
Make sure the fuel hose joint is installed correctly
on the delivery pipe or the fuel could leak.
•
•
If it comes off, reinstall the hose joint.
Install the fuel tank (see Fuel Tank Installation in the Fuel
System (DFI) chapter).
Start the engine and check the fuel hose for leaks.
2-52 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Coolant Change
WARNING
To avoid burns, do not remove the radiator cap or
try to change the coolant when the engine is still
hot. Wait until it cools down.
Coolant on tires will make them slippery, and can
cause an accident and injury.
Since coolant is harmful to the human body, do not
use for drinking.
the cross pipe (see Radiator Removal in the
• Remove
Cooling System chapter).
a container [A] under the radiator, then remove the
• Place
hose [B] from the radiator.
the fuel tank (see Fuel Tank Removal in the Fuel
• Remove
System (DFI) chapter).
the radiator cap [A] in two steps. First turn the
• Remove
cap counterclockwise to the first stop. Then push and turn
it further in the same direction and remove the cap.
○The coolant will drain from the radiator and engine.
Front [B]
• Remove:
Left Side Cover (see Left Side Cover Removal in the
•
Frame chapter)
Coolant Reserve Tank Bolts [A]
Remove the cap [B] and poor the coolant into a container.
CAUTION
Soft or distilled water must be used with the antifreeze (see Specifications in this chapter) in the
cooling system.
If hard water is used in the system, it causes scale
accumulation in the water passages, and considerably reduces the efficiency of the cooling system.
PERIODIC MAINTENANCE 2-53
Periodic Maintenance Procedures
Water and Coolant Mixture Ratio (Recommended)
: 50%
Soft Water
Coolant
: 50%
Freezing Point
: –35°C (–31°F)
Total Amount
: 2.4 L (2.5 US qt)
• Fill the coolant into the radiator.
○Choose
NOTE
a suitable mixture ratio by referring to the
coolant manufacturer’s directions.
○Fill in the coolant slowly so that it can expel the air from
the engine and radiator.
• Check the cooling system for leaks.
the radiator hoses to force any air bubbles caught
• Tap
inside.
the radiator up to the filler neck [A] with coolant.
• Fill
• Install the radiator cap.
the reserve tank up to the “F” (full) level line [A] with
• Fill
coolant and install the cap.
the fuel tank (see Fuel Tank Installation in the Fuel
• Install
System (DFI) chapter).
the engine and warm it up thoroughly until the radi• Start
ator fan turns on and then stop the engine.
the coolant level in the reserve tank several times
• Check
while the engine is cooling down, and replenish as necessary.
If the coolant level is lower than the “L” level line, add
coolant to the “F” level line.
CAUTION
Do not add more coolant above the “F” level line.
2-54 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Radiator Hose and O-ring Replacement
the coolant (see Coolant Change).
• Drain
Remove:
• Thermostat Housing [A] with Bracket [B] (see Thermo-
•
•
•
•
•
stat Removal in the Cooling System chapter)
Alternator Cover (see Alternator Removal in the Electrical System chapter)
Left Side Cover (see Left Side Cover Removal in the
Frame chapter)
Replace the hoses [C] and O-rings with new ones.
Apply grease to the new O-rings [D].
Apply soap and water solution to the new O-rings [E].
Run the new hoses according to Cable, Wire and Hose
Routing section in the Appendix chapter.
Tighten the water pipe bolts [F] and radiator hose clamp
screws.
Torque - Water Pipe Bolts: 12 N·m (1.2 kgf·m, 106 in·lb)
Radiator Hose Clamp Screws: 2.0 N·m (0.20 kgf·m,
18 in·lb)
the removed parts (see appropriate chapters).
• Install
Fill
the
coolant (see Coolant Change).
• Check the
cooling system for leaks.
•
PERIODIC MAINTENANCE 2-55
Periodic Maintenance Procedures
Engine Oil Change
the motorcycle so that it is vertical after warming
• Situate
up the engine.
• Remove the oil filler cap [A] on the crankcase.
the front [A] and rear [B] engine oil drain bolts
• Remove
and drain the oil.
○The oil in the filter can be drained by removing the filter
•
•
(see Oil Filter Replacement).
Replace the drain bolt gaskets with new ones.
Tighten the drain bolts.
Torque - Engine Oil Drain Bolts (Front and Rear): 20 N·m
(2.0 kgf·m, 14 ft·lb)
2-56 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
• Pour in the specified grade and amount of oil.
Recommended Engine Oil
Grade:
API SE, SF or SG
API SH, SJ, SL or SM with JASO MA, MA1,
or MA2
Viscosity:
SAE 10W-40
Amount:
4.1 L (4.3 US qt) (when filter is not
removed)
4.3 L (4.5 US qt) (when filter is removed)
5.0 L (5.3 US qt) (when engine is
completely disassembled and dry)
NOTE
○Do not add any chemical additive to the oil. Oils fulfilling
the above requirements are fully formulated and provide
adequate lubrication for both the engine and the clutch.
○Although 10W-40 engine oil is the recommended oil
for most conditions, the oil viscosity may need to be
changed to accommodate atmospheric conditions in
your riding area.
the oil filler cap.
• Install
the oil level (see Oil Level Inspection in the Engine
• Check
Lubrication System chapter).
NOTE
○Because of the semi-dry sump lubrication system, the
engine oil level indicated on the dipstick will fluctuate
depending on the motorcycle’s position and engine
speed when the engine is shut off. To ensure a proper
reading of the engine oil level, follow the Oil Level
Inspection procedures closely.
Oil Filter Replacement
the engine oil (see Engine Oil Change in this chap• Drain
ter).
the oil filter [A] with the oil filter wrench [B] and
• Remove
discard the oil filter.
Special Tool - Oil Filter Wrench: 57001-1249
NOTE
○The filter has an oil filter bypass valve which can not be
removed.
the oil filter with a new one.
• Replace
Apply
engine
• installation. oil to the gasket [A] of the new filter before
• Tighten the filter with the oil filter wrench.
Special Tool - Oil Filter Wrench: 57001-1249
Torque - Oil Filter: 18 N·m (1.8 kgf·m, 13 ft·lb)
in the specified grade and amount of oil (see Engine
• Pour
Oil Change in this chapter).
PERIODIC MAINTENANCE 2-57
Periodic Maintenance Procedures
Brake Hose and Pipe Replacement
CAUTION
Brake fluid quickly ruins painted plastic surfaces;
any spilled fluid should be completely washed away
immediately.
the right saddlebag (see Saddlebag Removal in
• Remove
the Frame chapter).
the brake hose banjo bolts [A], clamps [B], bolt
• Remove
[C] and grommets [D].
removing the brake hose, take care not to spill the
• When
brake fluid on the painted or plastic parts.
removing the brake hoses [E], temporarily secure
• When
the end of the brake hose to some high place to keep fluid
•
loss to a minimum.
Immediately wash away any brake fluid that spills.
Brake Fluid Change
NOTE
○The procedure to change the front brake fluid is as follows. Changing the rear brake fluid is the same as for
the front brake.
the brake fluid reservoir.
• Level
Remove:
• Screws [A]
Reservoir Cap [B]
Diaphragm Plate [C]
Diaphragm [D]
Protector [E]
2-58 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
the rubber cap from the bleed valve [A] on the
• Remove
caliper [B].
a clear plastic hose [C] to the bleed valve, and run
• Attach
the other end of the hose into a container.
• Fill the reservoir with fresh specified brake fluid.
NOTE
○For the rear brake caliper [A], change the brake fluid for
two bleed valves [B].
the brake fluid as follows.
•○Change
Repeat this operation until fresh brake fluid comes out
1.
2.
3.
4.
from the plastic hose or the color of the fluid changes.
Open the bleed valve [A].
Apply the brake and hold it [B].
Close the bleed valve [C].
Release the brake [D].
NOTE
○The fluid level must be checked often during the changing operation and replenished with fresh brake fluid. If
the fluid in the reservoir runs out any time during the
changing operation, the brakes will need to be bled
since air will have entered the brake line.
○Front Brake: Repeat the above steps for the other
caliper.
the clear plastic hose.
• Remove
Install:
• Protector
•
Diaphragm
Diaphragm Plate
Reservoir Cap
Tighten:
Torque - Front Brake Reservoir Cap Screws: 1.5 N·m (0.15
kgf·m, 13 in·lb)
• Tighten the bleed valves, and install the rubber caps.
Torque - Bleed Valves: 7.8 N·m (0.80 kgf·m, 69 in·lb)
PERIODIC MAINTENANCE 2-59
Periodic Maintenance Procedures
the procedure below to install the rear brake fluid
• Follow
reservoir cap correctly.
○First, tighten the rear brake fluid reservoir cap [B] clockwise [C] by hand until slight resistance is felt indicating
that the cap is seated on the reservoir body, then tighten
the cap an additional 1/6 turn [D] while holding the brake
fluid reservoir body [A].
changing the fluid, check the brake for good braking
• After
power, no brake drag, and no fluid leakage.
If necessary, bleed the air from the lines.
Master Cylinder Rubber Parts Replacement
Front Master Cylinder Disassembly
Remove the front master cylinder (see Front Master Cylinder Removal in the Brakes chapter).
Remove the reservoir cap [A], plate [B] and diaphragm
[C].
Unscrew the locknut [D] and pivot bolt [E], and remove
the brake lever.
Pull the dust cover [F] out of place, and remove the circlip
[G].
•
•
•
•
Special Tool - Inside Circlip Pliers: 57001-143
• Pull out the piston assy [H].
CAUTION
Do not remove the secondary cup from the piston
since removal will damage it.
• Replace:
Piston Assy
Circlip
Dust Cover
Diaphragm
2-60 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Rear Master Cylinder Disassembly
Remove the rear master cylinder (see Rear Master Cylinder Removal in the Brakes chapter).
Remove the reservoir cap [A], plate [B] and diaphragm
[C].
Remove the circlip [D], connector [E] and O-ring [F].
•
•
•
Special Tool - Inside Circlip Pliers: 57001-143
the dust cover [G] out of place, and remove the cir• Slide
clip [H].
out the push rod assy [I].
• Pull
• Take off the piston assy [J] and return spring [K].
CAUTION
Do not remove the secondary cup from the piston
since removal will damage it.
• Replace:
Diaphragm
Circlip
O-ring
Circlip
Push Rod Assy
Piston Assy
Master Cylinder Assembly
Before assembly, clean all parts including the master
cylinder with brake fluid or alcohol.
•
CAUTION
Except for the disc pads and disc, use only disc
brake fluid, isopropyl alcohol, or ethyl alcohol for
cleaning brake parts. Do not use any other fluid for
cleaning these parts. Gasoline, engine oil, or any
other petroleum distillate will cause deterioration of
the rubber parts. Oil spilled on any part will be difficult to wash off completely, and will eventually deteriorate the rubber used in the disc brake.
brake fluid to the new parts and to the inner wall of
• Apply
the cylinder.
care not to scratch the piston or the inner wall of the
• Take
cylinder.
silicone grease.
• Apply
Brake Lever Pivot Bolt
•
Brake Lever Pivot Contact
Push Rod Contact
Dust Cover
Tighten the brake lever pivot bolt and the locknut.
Torque - Brake Lever Pivot Bolt: 1.0 N·m (0.10 kgf·m, 8.9
in·lb)
Brake Lever Pivot Bolt Locknut: 5.9 N·m (0.60
kgf·m, 52 in·lb)
PERIODIC MAINTENANCE 2-61
Periodic Maintenance Procedures
Caliper Rubber Parts Replacement
Front Caliper Disassembly
Remove:
Front Caliper (see Front Caliper Removal in the Brakes
chapter)
Front Brake Pads (see Front Brake Pad Removal in the
Brakes chapter)
Caliper Holder [A]
Pad Spring [B]
•
compressed air, remove the pistons.
• Using
remove the pistons is as follows.
One way to
○Cover the caliper opening with a clean, heavy cloth [A].
○Remove the piston by lightly applying compressed air [B]
to where the brake line fits into the caliper.
WARNING
To avoid serious injury, never place your fingers or
palm inside the caliper opening. If you apply compressed air into the caliper, the piston may crush
your hand or fingers.
○Pull out the pistons by hand.
the dust seals [A] and fluid seals [B].
• Remove
• Remove the bleed valve [C] and rubber cap [D].
NOTE
○If compressed air is not available, do as follows with the
brake hose connected to the caliper.
○Prepare a container for brake fluid, and perform the
work above it.
○Remove the brake pads (see Front Brake Pad Removal
in the Brakes chapter).
○Pump the brake pedal to remove the caliper piston.
Front 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 valves and rubber caps.
Torque - Bleed Valves: 7.8 N·m (0.80 kgf·m, 69 in·lb)
2-62 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
the fluid seals [A] with new ones.
•○Replace
Apply silicone grease to the fluid seals, and install them
into the cylinders by hand.
Replace the dust seals [B] with new ones.
○Apply silicone grease to the dust seals, and install them
into the cylinders by hand.
•
brake fluid to the outside of the pistons, and push
• Apply
them into each cylinder by hand.
the friction boot [A] and dust boot [B] with new
• Replace
ones.
silicone grease to the sliding surface of the caliper
• Apply
holder shafts [C].
• Check that the guide [D] is in place on the caliper holder.
the pad spring [A] on the caliper as shown in the
• Install
figure.
the brake pads (see Front Brake Pad Installation in
• Install
the Brakes chapter).
up any spilled brake fluid on the caliper with wet
• Wipe
cloth.
Rear Caliper Disassembly
Remove:
Rear Caliper (see Rear Caliper Removal in the Brakes
chapter)
Rear Brake Pads (see Rear Brake Pad Removal in the
Brakes chapter)
Caliper Holder [A]
Pad Spring [B]
•
compressed air, remove the pistons.
• Using
remove the pistons is as follows.
One way to
○Cover the caliper opening with a clean, heavy cloth [A].
○Remove the piston by lightly applying compressed air [B]
to where the brake line fits into the caliper.
WARNING
To avoid serious injury, never place your fingers or
palm inside the caliper opening. If you apply compressed air into the caliper, the piston may crush
your hand or fingers.
PERIODIC MAINTENANCE 2-63
Periodic Maintenance Procedures
○Pull out the pistons by hand.
the dust seals [A] and fluid seals [B].
• Remove
Remove
the
bleed valves [C] and rubber caps [D].
•
NOTE
○If compressed air is not available, do as follows with the
brake hose connected to the caliper.
○Prepare a container for brake fluid, and perform the
work above it.
○Remove the brake pads (see Rear Brake Pad Removal
in the Brakes chapter).
○Pump the brake pedal to remove the caliper piston.
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 valves and rubber caps.
Torque - Bleed Valves: 7.8 N·m (0.80 kgf·m, 69 in·lb)
the fluid seals [A] with new ones.
•○Replace
Apply silicone grease to the fluid seals, and install them
into the cylinders by hand.
Replace the dust seals [B] with new ones.
○Apply silicone grease to the dust seals, and install them
into the cylinders by hand.
•
brake fluid to the outside of the pistons, and push
• Apply
them into each cylinder by hand .
the friction boot [A] and dust boot [B] with new
• Replace
ones.
silicone grease to the sliding surface of the caliper
• Apply
holder shafts [C].
• Check that the guide [D] is in place on the caliper holder.
the pad spring [A] on the caliper as shown in the
• Install
figure.
the brake pads (see Rear Brake Pad Installation in
• Install
the Brakes chapter).
up any spilled brake fluid on the caliper with wet
• Wipe
cloth.
2-64 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Clutch Hose and Pipe Replacement
CAUTION
Clutch fluid quickly ruins painted plastic surfaces;
any spilled fluid should be completely washed away
immediately.
removing the clutch hose, take care not to spill the
• When
clutch fluid on the painted or plastic parts.
• Remove:
Front Footboard Left (see Front Footboard Removal/Installation)
Banjo Bolt [A] and washers
Clamp [B]
the banjo bolt [A] and washers.
• Remove
Pull
out
the
damper [B] outward.
•
the clamps [A]
• Open
Pull
out
the clutch hose [B] from the holder [C].
•
wash away any clutch fluid that spills.
• Immediately
are washers on each side of the clutch hose fittings.
• There
Replace them with new ones when installing.
• Tighten:
Torque - Clutch Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
installing the hoses, avoid sharp bending, kinking,
• When
flatting or twisting, and route the hoses according to Ca-
•
ble, Wire, and Hose Routing section in Appendix chapter.
Fill the clutch line after installing the clutch hose (see
Clutch Fluid Change).
PERIODIC MAINTENANCE 2-65
Periodic Maintenance Procedures
Clutch Fluid Change
the clutch fluid reservoir and remove the reservoir
• Level
cap.
the engine pulley outer cover (see Engine Pulley
• Remove
Outer Cover Removal in the Final Drive chapter.) and
the rubber cap from the bleed valve on the clutch slave
cylinder.
Attach a clear plastic hose [A] to the bleed valve and run
the other end of the hose into a container.
Fill the reservoir with fresh fluid.
Change the clutch fluid as follows.
○Repeat this operation until fresh fluid comes out from the
plastic hose or the color of the fluid changes.
1. Open [B] the bleed valve, using a wrench.
2. Pump the clutch lever and hold [C] it.
3. Close [D] the bleed valve.
4. Release [E] the clutch lever.
•
•
•
NOTE
○The fluid level must be checked often during the charging operation and replenihed with fresh fluid. If the fluid
in the reservoir runs completely out any time during fluid
changing, the bleeding operation must be done over
again from the beginning since air will have entered the
line.
WARNING
Do not mix two brands of fluid.
changing the fluid, check the clutch for good clutch
• After
power and no fluid leakage.
•
•
•
If necessary, bleed the air from the lines (see Clutch Line
Bleeding in the Clutch chapter).
Remove the clear plastic hose.
Install the reservoir cap.
Tighten the bleed valve, and install the rubber cap.
Torque - Clutch Reservoir Cap Screws: 1.5 N·m (0.15
kgf·m, 13 in·lb)
Clutch Slave Cylinder Bleed Valve: 7.8 N·m (0.80
kgf·m, 69 in·lb)
2-66 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Clutch Master Cylinder Rubber Parts Replacement
the clutch master cylinder (see Clutch Master
• Remove
Cylinder Removal in the Clutch chapter).
the reservoir cap [A], plate [B] and diaphragm
• Remove
[C], and pour the clutch fluid into a container.
the locknut [D] and pivot bolt [E], and remove
• Unscrew
the clutch lever.
the dust cover [F] out of place, and remove the circlip
• Pull
[G].
Special Tool - Inside Circlip Pliers: 57001-143
out the piston assy [H] (primary cup [I], piston [J],
• Pull
secondary cup [K], and return spring [L]).
• Replace:
Piston Assy
Dust Cover
Diaphragm
Circlip
CAUTION
Do not remove the secondary cup from the piston
since removal will damage it.
the parts of the clutch master cylinder (see Clutch
• Check
Master Cylinder Inspection in the Clutch chapter).
If any part shows signs of damage, replace it.
assembly, clean all parts including the master
• Before
cylinder with clutch fluid or alcohol.
CAUTION
Use only disc brake fluid, isopropyl alcohol or ethyl
alcohol, for cleaning parts. Do not use any other
fluid for cleaning these parts.
Gasoline, motor oil or any other petroleum distillate will cause deterioration of the rubber parts. Oil
spilled on any part will be difficult to wash off completely, and will eventually deteriorate the rubber
used in the cylinder.
clutch fluid to the parts removed and to the inner
• Apply
wall of the cylinder.
care not to scratch the piston or the inner wall of the
• Take
cylinder.
the push rod with the dust seal fitted into the
• Install
groove.
○The push rod round end must be faced inwards.
Torque - Clutch Lever Pivot Bolt: 1.0 N·m (0.10 kgf·m, 8.9
in·lb)
Clutch Lever Pivot Bolt Locknut: 5.9 N·m (0.60
kgf·m, 52 in·lb)
the clutch master cylinder (see Clutch Master Cylin• Install
der Installation in the Clutch chapter).
PERIODIC MAINTENANCE 2-67
Periodic Maintenance Procedures
Clutch Slave Cylinder Piston Seal Replacement
the engine pulley outer cover (see Engine Pulley
• Remove
Outer Cover Removal in the Final Drive).
the banjo bolt [A] at the clutch pipe lower end, and
• Loosen
tighten it loosely.
the slave cylinder bolts [B] and detach the slave
• Unscrew
cylinder with the pipe installed from the engine.
the clutch lever until the piston comes out of the
• Pump
cylinder.
• Unscrew the banjo bolt and remove the slave cylinder [C].
CAUTION
Immediately wash away any clutch fluid that spills.
It may damage painted surfaces.
NOTE
○If the clutch slave cylinder is removed and left alone, the
piston will be pushed out by spring force.
• Remove:
Piston [A]
Piston Seal [B]
Spring [C]
the piston seal with a new one.
• Replace
Apply
clutch
fluid to the outer surface of the piston and
• the piston seal.
the following as shown.
• Assemble
Cylinder [A]
Piston [B]
Piston Seal [C]
Spring [D]
Spark Plug Replacement
• Remove:
Fuel Tank (see Fuel Tamk Removal in the Fuel System
(DFI) chapter)
Spark Plug Caps [A]
2-68 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
the spark plug using a 14 mm (0.55 in.)
• Remove
wrench [A] vertically.
plug
CAUTION
The insulator [A] of the spark plug may break if
when the wrench is inclined during loosening.
Inclined Spark Plug Wrench [B]
Contact (Spark Plug and Plug Wrench) [C]
Bad [D]
Vertically Spark Plug Wrench [E]
Good [F]
• Replace the spark plug with a new one.
Standard Spark Plug
Type:
NGK ILZKAR7B11
the new spark plug [A] and plug wrench [B] in the
• Insert
plug hole, and finger-tighten it first.
• Using the plug wrench vertically, tighten the plug.
CAUTION
The insulator of the spark plug may break if when
the wrench is inclined during tightening.
Torque - Spark Plugs: 18 N·m (1.8 kgf·m, 13 ft·lb)
the spark plug caps securely.
• Install
Be
sure
• lightly. the spark plug caps are installed by pulling up it
FUEL SYSTEM (DFI) 3-1
Fuel System (DFI)
Table of Contents
Exploded View........................................................................................................................
Specifications .........................................................................................................................
Special Tools and Sealant ......................................................................................................
DFI System.............................................................................................................................
DFI Parts Location..................................................................................................................
DFI Servicing Precautions ......................................................................................................
DFI Servicing Precautions ...................................................................................................
Troubleshooting the DFI System ............................................................................................
Outline .................................................................................................................................
Inquiries to Rider..................................................................................................................
DFI System Troubleshooting Guide .......................................................................................
Self-Diagnosis ........................................................................................................................
Self-diagnosis Outline..........................................................................................................
Self-diagnosis Procedures...................................................................................................
Service Code Reading ......................................................................................................
Service Code Erasing .......................................................................................................
Backups ...............................................................................................................................
Throttle Position Sensor (Service Code 11) ...........................................................................
Throttle Position Sensor Removal ....................................................................................
Throttle Position Sensor Output Voltage Inspection .........................................................
Throttle Position Sensor Input Voltage Inspection ............................................................
Inlet Air Pressure Sensor (Service Code 12)..........................................................................
Inlet Air Pressure Sensor Removal...................................................................................
Inlet Air Pressure Sensor Installation................................................................................
Inlet Air Pressure Sensor Input Voltage Inspection...........................................................
Inlet Air Pressure Sensor Output Voltage Inspection........................................................
Inlet Air Temperature Sensor (Service Code 13)....................................................................
Inlet Air Temperature Sensor Removal/Installation...........................................................
Inlet Air Temperature Sensor Output Voltage Inspection ..................................................
Inlet Air Temperature Sensor Resistance Inspection ........................................................
Water Temperature Sensor (Service Code 14) ......................................................................
Water Temperature Sensor Removal/Installation .............................................................
Water Temperature Sensor Output Voltage Inspection.....................................................
Water Temperature Sensor Resistance Inspection...........................................................
Accelerator Position Sensor (Service Code 18) .....................................................................
Accelerator Position Sensor Removal ..............................................................................
Accelerator Position Sensor Output Voltage Inspection ...................................................
Accelerator Position Sensor Input Voltage Inspection ......................................................
Accelerator Position Sensor Resistance Inspection .........................................................
Crankshaft Sensor (Service Code 21)....................................................................................
Crankshaft Sensor Removal/Installation...........................................................................
Crankshaft Sensor Resistance Inspection ........................................................................
Crankshaft Sensor Peak Voltage Inspection.....................................................................
Speed Sensor (Service Code 24)...........................................................................................
Speed Sensor Removal/Installation..................................................................................
Speed Sensor Input Voltage Inspection............................................................................
Speed Sensor Output Voltage Inspection .........................................................................
Gear Position Switch (Service Code 25) ................................................................................
Gear Position Switch Removal/Installation .......................................................................
Gear Position Switch Resistance Inspection ....................................................................
3-4
3-8
3-10
3-12
3-18
3-20
3-20
3-22
3-22
3-26
3-29
3-34
3-34
3-34
3-38
3-38
3-40
3-42
3-42
3-42
3-43
3-45
3-45
3-45
3-45
3-46
3-51
3-51
3-51
3-52
3-54
3-54
3-54
3-55
3-56
3-56
3-56
3-57
3-57
3-59
3-59
3-59
3-59
3-61
3-61
3-61
3-62
3-64
3-64
3-64
3
3-2 FUEL SYSTEM (DFI)
Gear Position Switch Output Voltage Inspection ..............................................................
Vehicle-down Sensor (Service Code 31)................................................................................
Vehicle-down Sensor Removal .........................................................................................
Vehicle-down Sensor Installation ......................................................................................
Vehicle-down Sensor Input Voltage Inspection.................................................................
Vehicle-down Sensor Output Voltage Inspection ..............................................................
Oxygen Sensor - not activated (Service Code 33, Equipped Models) ...................................
Oxygen Sensor Removal/Installation................................................................................
Oxygen Sensor Inspection................................................................................................
Fuel Pump Relay (Service Code 46) ......................................................................................
Fuel Pump Relay Removal/Installation .............................................................................
Fuel Pump Relay Inspection .............................................................................................
Return Spring (Service Code 49) ...........................................................................................
Return Spring Removal.....................................................................................................
Return Spring Inspection ..................................................................................................
Ignition Coils #1, #2 (Service Code 51, 52) ............................................................................
Ignition Coil Removal/Installation......................................................................................
Ignition Coil Primary Winding Resistance Inspection........................................................
Ignition Coil Input Voltage Inspection................................................................................
Radiator Fan Relay (Service Code 56)...................................................................................
Radiator Fan Relay Removal/Installation..........................................................................
Radiator Fan Relay Inspection..........................................................................................
ETV Acutuator (Service Code 58) ..........................................................................................
ETV Actuator Removal .....................................................................................................
ETV Actuator Input Voltage Inspection .............................................................................
ETV Actuator Resistance Inspection ................................................................................
Air Switching Valve (Service Code 64) ...................................................................................
Air Switching Valve Removal/Installation ..........................................................................
Air Switching Valve Inspection ..........................................................................................
Oxygen Sensor Heater (Service Code 67, Equipped Models) ...............................................
Oxygen Sensor Heater Removal/Installation ....................................................................
Oxygen Sensor Heater Resistance Inspection .................................................................
Oxygen Sensor Heater Power Source Voltage Inspection ...............................................
Battery Voltage (Service Code 97) .........................................................................................
Battery Voltage Inspection ................................................................................................
ETV Control Circuit (Service Code 98)...................................................................................
ETV Control Circuit Inspection..........................................................................................
Warning Indicator Light (LED) ................................................................................................
Light (LED) Inspection ......................................................................................................
ECU ........................................................................................................................................
ECU Identification .............................................................................................................
ECU Removal ...................................................................................................................
ECU Installation ................................................................................................................
ECU Power Supply Inspection..........................................................................................
DFI Power Source ..................................................................................................................
ECU Fuse Removal ..........................................................................................................
ECU Fuse Installation .......................................................................................................
ECU Fuse Inspection ........................................................................................................
ECU Main Relay Removal/Installation ..............................................................................
ECU Main Relay Inspection ..............................................................................................
Fuel Line.................................................................................................................................
Fuel Pressure Inspection ..................................................................................................
Fuel Flow Rate Inspection ................................................................................................
Fuel Pump ..............................................................................................................................
Fuel Pump Removal .........................................................................................................
Fuel Pump Installation ......................................................................................................
Fuel Pump Operation Inspection ......................................................................................
3-64
3-66
3-66
3-67
3-67
3-68
3-71
3-71
3-71
3-74
3-74
3-74
3-75
3-75
3-75
3-76
3-76
3-76
3-76
3-78
3-78
3-78
3-79
3-79
3-79
3-80
3-81
3-81
3-81
3-82
3-82
3-82
3-83
3-85
3-85
3-86
3-86
3-87
3-87
3-88
3-88
3-88
3-88
3-89
3-91
3-91
3-91
3-91
3-91
3-91
3-92
3-92
3-93
3-95
3-95
3-96
3-96
FUEL SYSTEM (DFI) 3-3
Fuel Pump Operating Voltage Inspection .........................................................................
Pressure Regulator Removal............................................................................................
Fuel Filter Cleaning...........................................................................................................
Fuel Injectors ..........................................................................................................................
Fuel Injector Removal .......................................................................................................
Fuel Injector Installation ....................................................................................................
Fuel Injector Audible Inspection .......................................................................................
Fuel Injector Resistance Inspection ..................................................................................
Fuel Injector Output Voltage Inspection ............................................................................
Fuel Injector Input Voltage Inspection...............................................................................
Fuel Injector Fuel Line Inspection .....................................................................................
Throttle Grip and Cables ........................................................................................................
Free Play Inspection .........................................................................................................
Free Play Adjustment........................................................................................................
Cable Installation ..............................................................................................................
Cable Lubrication ..............................................................................................................
Throttle Body Assy .................................................................................................................
Idle Speed Inspection/Adjustment ....................................................................................
Throttle Body Assy Removal.............................................................................................
Throttle Body Assy Installation..........................................................................................
Throttle Body Assy Disassembly .....................................................................................
Throttle Body Assy Assembly ...........................................................................................
Inlet Manifold ..........................................................................................................................
Inlet Manifold Removal .....................................................................................................
Inlet Mnifold Installation ....................................................................................................
Air Cleaner..............................................................................................................................
Air Cleaner Element Removal/Installation ........................................................................
Air Cleaner Element Inspection ........................................................................................
Air Cleaner Oil Draining ....................................................................................................
Left Air Cleaner Housing Removal....................................................................................
Left Air Cleaner Housing Installation.................................................................................
Right Air Cleaner Housing Removal .................................................................................
Right Air Cleaner Housing Installation ..............................................................................
Fuel Tank ................................................................................................................................
Fuel Tank Removal ...........................................................................................................
Fuel Tank Installation ........................................................................................................
Fuel Tank Inspection .........................................................................................................
Fuel Tank Cleaning ...........................................................................................................
Evaporative Emission Control System (CAL and SEA Models) .............................................
Parts Removal/Installation ................................................................................................
Hose Inspection ................................................................................................................
Separator Inspection.........................................................................................................
Separator Operation Test..................................................................................................
Canister Inspection ..........................................................................................................
3-96
3-97
3-98
3-99
3-99
3-100
3-100
3-100
3-101
3-102
3-103
3-105
3-105
3-105
3-105
3-106
3-107
3-107
3-107
3-108
3-110
3-111
3-112
3-112
3-112
3-113
3-113
3-113
3-113
3-113
3-114
3-114
3-115
3-117
3-117
3-119
3-121
3-121
3-122
3-122
3-122
3-122
3-123
3-123
3-4 FUEL SYSTEM (DFI)
Exploded View
FUEL SYSTEM (DFI) 3-5
Exploded View
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Fastener
Air Cleaner Housing Cover Bolts
Air Cleaner Element Bolt
Air Cleaner Housing Bolts
Crankshaft Sensor Bolts
Delivery Joint Bolts
Fuel Pump Bolts
Gear Position Switch Bolts
Inlet Manifold Bolts
Right Air Cleaner Housing Center Bolts
Speed Sensor Mounting Bolt
Throttle Body Assy Holder Bolts
Throttle Cable Holder Plate Screw
Water Temperature Sensor
Cruise Control Cancel Switch (Throttle)
Mounting Nut
15. CAL and SEA Models
16. Crankshaft Sensor
17. ECU
18. Gear Position Sensor
19. Inlet Air Pressure Sensor
20. Inlet Air Temperature Sensor
21. Relay Box
22. Speed Sensor
23. Throttle Body Assy
24. Vehicle-down Sensor
CL: Apply cable lubricant.
EO: Apply engine oil.
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
S: Follow the specified tightening sequence.
4.9
4.9
9.8
5.9
9.8
9.8
3.9
9.8
9.8
9.8
9.8
2.0
12
Torque
kgf·m
0.50
0.50
1.0
0.60
1.0
1.0
0.40
1.0
1.0
1.0
1.0
0.20
1.2
ft·lb
43 in·lb
43 in·lb
87 in·lb
52 in·lb
87 in·lb
87 in·lb
35 in·lb
87 in·lb
87 in·lb
87 in·lb
87 in·lb
18 in·lb
106 in·lb
0.28
0.03
2.5 in·lb
N·m
Remarks
L
L, S
L
L
L
L
L
3-6 FUEL SYSTEM (DFI)
Exploded View
FUEL SYSTEM (DFI) 3-7
Exploded View
No.
1
Fastener
Oxygen Sensor (Equipped Models)
2. CAL and SEA Models
3. Canister
4. Separator
N·m
25
Torque
kgf·m
2.5
ft·lb
18
Remarks
3-8 FUEL SYSTEM (DFI)
Specifications
Item
Digital Fuel Injection System
Idle Speed
Throttle Body Assy:
Type
Bore
ECU:
Make
Type
Fuel Pressure (High Pressure Line)
Fuel Pump:
Type
Discharge
Fuel Injectors:
Type
Nozzle Type
Resistance
Throttle Position Sensor:
Output Voltage (1)
Output Voltage (2)
Input Voltage
Inlet Air Pressure Sensor:
Input Voltage
Output Voltage
Inlet Air Temperature Sensor:
Output Voltage
Resistance
Water Temperature Sensor:
Output Voltage
Accelerator Position Sensor:
Output Voltage (1)
Output Voltage (2)
Input Voltage
Resistance
Speed Sensor:
Input Voltage
Output Voltage
Standard
950 ±50 r/min (rpm)
Two barrel type
42 mm (1.65 in.)
MITSUBISHI ELECTRIC
Digital memory type, with built in IC igniter, sealed with resin
294 kPa (3.0 kgf/cm², 43 psi) with engine idling
In-tank, friction pump
29 mL (0.98 US oz.) or more for 3 seconds
INP-284
Fine atomizing type with 12 holes
About 11.7 ∼ 12.3 Ω at 20°C (68°F)
DC 3.50 ∼ 3.90 V at full throttle opening (for reference)
DC 4.50 ∼ 4.80 V at full throttle opening (for reference)
DC 4.75 ∼ 5.25 V
DC 4.75 ∼ 5.25 V
DC 3.80 ∼ 4.20 V at standard atmospheric pressure (see
this text for details)
About DC 2.25 ∼ 2.50 V at inlet air temperature 20°C (68°F)
5.4 ∼ 6.6 kΩ at 0°C (32°F)
0.29 ∼ 0.39 kΩ at 80°C (176°F)
About DC 2.80 ∼ 2.97 V at 20°C (68°F)
DC 0.50 ∼ 0.90 V at ordinary throttle position
DC 3.85 ∼ 4.75 V at full throttle opening (for reference)
DC 0.35 ∼ 1.05 V at ordinary throttle position
DC 3.85 ∼ 4.75 V at full throttle opening (for reference)
DC 4.75 ∼ 5.25 V
4 ∼ 6 kΩ
DC 4.75 ∼ 5.25 V
About DC 0.05 ∼ 0.09 V or DC 4.5 ∼ 4.9 V at ignition switch
ON and 0 km/h
FUEL SYSTEM (DFI) 3-9
Specifications
Item
Vehicle-down Sensor:
Input Voltage
Output Voltage
Oxygen Sensor (Equipped Models):
Output Voltage (Rich)
Output Voltage (Lean)
Heater Resistance
ETV Actuator
Input Voltage
Can Communication Line
Resistance (at ECU)
Throttle Grip and Cables
Throttle Grip Free Play
Air Cleaner
Element
Standard
DC 4.75 ∼ 5.25 V
With sensor tilted 40 ∼ 50° or more right or left: DC 0.65
∼ 1.35 V
With sensor arrow mark pointed up: DC 3.55 ∼ 4.45 V
DC 0.8 V or more
DC 0.24 V or less
6.7 ∼ 10.5 Ω at 20°C (68°F)
About DC 1 ∼ 2 V
122 ∼ 126 Ω
2 ∼ 3 mm (0.08 ∼ 0.12 in.)
Viscous paper element
3-10 FUEL SYSTEM (DFI)
Special Tools and Sealant
Oil Pressure Gauge, 5 kgf/cm²:
57001-125
Needle Adapter Set:
57001-1457
Jack:
57001-1238
Fuel Pressure Gauge Adapter:
57001-1593
Fork Oil Level Gauge:
57001-1290
Fuel Hose:
57001-1607
Vacuum Gauge:
57001-1369
Speed Sensor Measuring Adapter:
57001-1667
Hand Tester:
57001-1394
Measuring Adapter:
57001-1700
FUEL SYSTEM (DFI) 3-11
Special Tools and Sealant
Kawasaki Bond (Silicone Sealant):
56019-120
3-12 FUEL SYSTEM (DFI)
DFI System
DFI System
FUEL SYSTEM (DFI) 3-13
DFI System
1. Fuel Tank
2. FI Indicator LED Light
3. ECU
4. Battery 12 V 18 Ah
5. Pressure Regulator
6. Fuel Pump
7. Water Temperature Sensor
8. Inlet Air Pressure Sensor
9. Delivery Joint
10. Fuel Injector #1
11. Fuel Injector #2
12. Air Switching Valve
13. Inlet Air Temperature Sensor
14. Vehicle-down Sensor
15. Oxygen Sensor (Equipped Models)
16. Throttle Position Sensor/ETV Actuator
17. Accelerator Position Sensor
18. Speed Sensor
19. Crankshaft Sensor
20. Gear Position Switch
21. Fuel Flow
22. Air Flow
3-14 FUEL SYSTEM (DFI)
DFI System
DFI System Wiring Diagram
FUEL SYSTEM (DFI) 3-15
DFI System
Part Names
1. ECU
2. Oxygen Sensor (Equipped Models)
3. Speed Sensor
4. Gear Position Switch
5. ETV Actuator Relay
6. Throttle Position Sensor/ETV Actuator
7. ETV Actuator
8. Throttle Position Sensor 2
9. Throttle Position Sensor 1
10. Accelerator Position Sensor
11. Accelerator Position Sensor 2
12. Accelerator Position Sensor 1
13. Fuel Injector #2
14. Fuel Injector #1
15. Air Switching Valve
16. Inlet Air Temperature Sensor
17. Water Temperature Sensor
18. Inlet Air Pressure Sensor
19. Ignition Coil #2 (Rear Cylinder)
20. Ignition Coil #1 (Front Cylinder)
21. Right Handlebar Switch Housing
22. Engine Stop Switch
23. Ignition Switch
24. Frame Ground 6
25. Frame Ground 3
26. Relay Box
27. Fuel Pump Relay
28. Fuse Box 1
29. Ignition Fuse 10 A
30. Fuse Box 2
31. Oxygen Sensor Heater Fuse 10 A (Equipped Models)
32. ETV Actuator Relay Fuse 10 A
33. ECU Fuse 10A
34. Engine Ground
35. Battery
36. Starter Relay
37. Main Fuse 30 A
38. Vehicle-down Sensor
39. Crankshaft Sensor
40. Fuel Pump
41. Meter Unit
42. Kawasaki Diagnostic System Connector
○Color Codes:
BK: Black
BL: Blue
BR: Brown
CH: Chocolate
DG: Dark Green
G: Green
GY: Gray
LB: Light Blue
LG: Light Green
O: Orange
P: Pink
PU: Purple
R: Red
V: Violet
W: White
Y: Yellow
3-16 FUEL SYSTEM (DFI)
DFI System
Terminal Numbers of ECU Connectors
Terminal Names
1. Ignition Coil #2 (Rear Cylinder): BK
2. Fuel Injector #2 (Rear Cylinder): BL/Y
3. Unused
4. Ground for ETV Actuator (to Battery): BK/Y
5. Power Supply to ETV Actuator (from ETV Actuator Relay): G/O
6. ETV Actuator (+): GY/BK
7. ETV Actuator (–): LG
8. ETV Actuator Relay: Y/BL
9. Fuel Pump Relay: BR/Y
10. Engine Ground: BK/Y
11. Unused
12. Unused
13. Unused
14. Unused
15. Unused
16. Starter Lockout Switch: Y/G
17. Radiator Fan Relay: BR/W
18. Engine Ground: BK/Y
19. Sidestand Switch: G/BK
20. Unused
21. Unused
22. Cruise Control Cancel Switch (Rear Brake): BL
23. Cruise Control Cancel Switch (Throttle): BK/BL
24. Cruise Control Switch (SET/–): R/G
25. Starter Button: BK/R
26. Ignition Coil #1 (Front Cylinder): BK/O
27. Fuel Injector #1 (Front Cylinder): BL/O
28. Oxygen Sensor Heater (Equipped Models): P/BL
29. Air Switching Valve: G/Y
30. Front/Rear Brake Light Switch (for Cruise Control Cancel): BL
31. Cruise Control Cancel Switch (Clutch): V
32. Cruise Control Switch (RES/+): GY/BL
33. Cruise Control ON/OFF Button: BL/R
34. Ground for Control System: BK/Y
FUEL SYSTEM (DFI) 3-17
DFI System
35. Battery Monitor Voltage: W/R
36. Inlet Air Temperature Sensor: R
37. Unused
38. Crankshaft Sensor (+): Y
39. Speed Sensor: LG/R
40. Gear Position Switch: G
41. Unused
42. Unused
43. Power Supply to Accelerator Position Sensor 2: BL/BK
44. Power Supply to ECU (from Ignition Switch): BR/W
45. Unused
46. Inlet Air Pressure Sensor: O/G
47. Crankshaft Sensor (–): BK
48. Power Supply to Sensors: BL
49. Power Supply to Throttle Position Sensor 1/2: BL/R
50. Accelerator Position Sensor 2: G/BK
51. CAN Communication Line (Low): LB
52. Vehicle-down Sensor: Y/R
53. Water Temperature Sensor: O
54. Oxygen Sensor (Equipped Models): GY/R
55. Ground for Sensors: BR/Y
56. Ground for Throttle Position Sensor 1/2: O/BK
57. Throttle Position Sensor 2: G/Y
58. Ground for Accelerator Position Sensor 2: BR
59. CAN Communication Line (High): GY/BL
60. Power Supply to ECU (from Battery): W/BK
61. Unused
62. Unused
63. Unused
64. External Communication Line (*KDS): LG
65. Ground for Accelerator Position Sensor 1: BK/O
66. Accelerator Position Sensor 1: G/W
67. Power Supply to Accelerator Position Sensor 1: BL/W
68. Throttle Position Sensor 1: G/R
*: KDS (Kawasaki Diagnostic System)
3-18 FUEL SYSTEM (DFI)
DFI Parts Location
Ignition Coil #1 (Front Cylinder) [A]
Air Switching Valve [B]
Ignition Coil #2 (Rear Cylinder) [A]
Inlet Air Pressure Sensor [B]
Water Temperature Sensor [A]
Fuel Injector #1 (Front Cylinder) [B]
Fuel Injector #2 (Rear Cylinder) [C]
Inlet Air Temperature Sensor [D]
Throttle Position Sensor [A]
ETV Actuator [B]
Accelerator Position Sensor [C]
Crankshaft Sensor [A]
FUEL SYSTEM (DFI) 3-19
DFI Parts Location
Gear Position Switch [A]
Speed Sensor [A]
Kawasaki Diagnostic System Connector (6 Pins Connector) [B]
ETV Actuator Relay [A] (R/BL, Y/BL, R/BL, G/O Leads)
Vehicle-down Sensor [B]
Fuse Box 1 [C] (Oxygen Sensor Heater Fuse 10 A
(Equipped Models))
Fuse Box 2 [D] (ECU Fuse 10 A, ETV Actuator Relay
Fuse 10 A)
Battery [E]
Relay Box [F] (Fuel Pump Relay, Radiator Fan Relay)
ECU [G]
Fuel Pump [A]
Oxygen Sensor [A] (Equipped Models)
3-20 FUEL SYSTEM (DFI)
DFI Servicing Precautions
DFI Servicing Precautions
There are a number of important precautions that should
be followed servicing the DFI system.
○This DFI system is designed to be used with a 12 V sealed
battery as its power source. Do not use any other battery
except for a 12 V sealed battery as a power source.
○Do not reverse the battery cable connections. This will
damage the ECU.
○To prevent damage to the DFI parts, do not disconnect the
battery cables or any other electrical connections when
the ignition switch is on or while the engine is running.
○Take care not to short the leads that are directly connected to the battery positive (+) terminal to the chassis
ground.
○When charging, remove the battery from the motorcycle.
This is to prevent ECU damage by excessive voltage.
○Whenever the DFI electrical connections are to be disconnected, first turn off the ignition switch, and disconnect
the battery (–) terminal. Do not pull the lead, only the connector. Conversely, make sure that all the DFI electrical
connections are firmly reconnected before starting the engine.
○Connect these connectors until they click [A].
○Do not turn the ignition switch ON while any of the DFI
electrical connectors are disconnected. The ECU memorizes service codes.
○Do not spray water on the electrical parts, DFI parts, connectors, leads and wiring.
○If a transceiver is installed on the motorcycle, make sure
that the operation of the DFI system is not influenced by
electric wave radiated from the antenna. Check operation
of the system with the engine at idle. Locate the antenna
as far as possible away from the ECU.
○When any fuel hose is disconnected, do not turn on the
ignition switch. Otherwise, the fuel pump will operate and
fuel will spout from the fuel hose.
○Do not operate the fuel pump if the pump is completely
dry. This is to prevent pump seizure.
○Before removing the fuel system parts, blow the outer surfaces of these parts clean with compressed air.
○When any fuel hose is disconnected, fuel may spout out
by residual pressure in the fuel line. Cover the hose joint
with a piece of clean cloth to prevent fuel spillage.
○When installing the fuel hoses, avoid sharp bending, kinking, flattening or twisting, and route the fuel hoses with a
minimum of bending so that the fuel flow will not be obstructed.
○Run the hoses according to Cable, Wire, and Hose Routing section in the Appendix chapter.
○To prevent corrosion and deposits in the fuel system, do
not add to fuel any fuel antifreeze chemicals.
FUEL SYSTEM (DFI) 3-21
DFI Servicing Precautions
○If the motorcycle is not properly handled, the high pressure inside the fuel line can cause fuel to leak or the hose
to burst. Remove the fuel tank (see Fuel Tank Removal)
and check the fuel hose [A].
Replace the fuel hose if any fraying, cracks or bulges are
noticed.
○To maintain the correct fuel/air mixture (F/A), there must
be no inlet air leaks in the DFI system. Be sure to install
the oil filler cap [A] after filling the engine oil.
3-22 FUEL SYSTEM (DFI)
Troubleshooting the DFI System
The warning indicator light (LED) [A] is used for the
FI/ETV (Electrical Throttle Valve) indicator, oil pressure
warning indicator and water temperature warning indicator.
Outline
When problem occurs with DFI system, the warning indicator light (LED) [A] goes on and the “Error” segments [B],
service code [C] and FI warning symbol [D] are displayed
on the LCD (Liquid Crystal Display) to alert the rider. The
service code is displayed by the number of two digits.
When problem occurs with ETV (Electrical Throttle Valve)
system, the warning indicator light (LED) [A] blinks and the
“Error” segments [B], service code [C] and FI warning symbol [D] are displayed on the LCD (Liquid Crystal Display) to
alert the rider. The service code is displayed by the number
of two digits.
FUEL SYSTEM (DFI) 3-23
Troubleshooting the DFI System
If the problem is with the following parts, the ECU can not
recognize these problem. Therefore, the warning indicator
light (LED) does not go on and the “Error” segments, service
code and FI warning symbol are not displayed.
LCD for Meter Unit
Fuel Pump
Fuel Injectors
Ignition Coil Secondary Wiring and Ground Wiring
ECU Power Source Wiring and Ground Wiring
When the service code [A] is displayed, for first ask the
rider about the conditions [B] of trouble, and then start to
determine the cause [C] of problem.
As a pre-diagnosis inspection, check the ECU for ground
and power supply, the fuel line for no fuel leaks, and for correct pressure. The pre-diagnosis items can not be detected
by the DFI self-diagnosis function.
Don’t rely solely on the DFI self-diagnosis function, use
common sense.
Even when the DFI system is operating normally, the
warning indicator light (LED) goes on and the “Error”
segments, service code and FI warning symbol may be
displayed under strong electrical interface. In this case,
additional measures are not required. Turn the ignition
switch OFF to go off the indicator light, segments, code
and symbol.
If the "Error" segments, service code and FI warning symbol of the motorcycle brought in for repair still are displayed,
check the content of the service code.
When repair has been done, the "Error" segments, service code and FI warning symbol go off (return to the normal display). But the service codes stored in memory of the
ECU are not erased to preserve the problem history. The
problem history can be referred using the KDS (Kawasaki
Diagnostic System) when solving unstable problems.
When the motorcycle is down, the vehicle-down sensor
operates and the ECU shuts off the fuel pump relay, fuel injectors and ignition system. The ignition switch is left ON. If
the starter button is pushed, the electric starter turns but the
engine does not start. When the starter button is pushed,
the warning indicator light (LED) blinks and the FI warning
symbol is displayed on the LCD but the “Error” segments
and the service code are not displayed. To start the engine
again, raise the motorcycle, turn the ignition switch OFF,
and then ON.
3-24 FUEL SYSTEM (DFI)
Troubleshooting the DFI System
Much of the DFI system troubleshooting work consists
of confirming continuity of the wiring. The DFI parts are
assembled and adjusted with precision, and it is impossible
to disassemble or repair them.
checking the DFI parts, use a digital meter which
• When
can be read two decimal place voltage or resistance.
○The DFI part connectors [A] have seals [B], including the
•
ECU.
When measuring the input or output voltage with the connector joined, use the needle adapter set [C].
Special Tool - Needle Adapter Set: 57001-1457
the needle adapter inside the seal until the needle
• Insert
adapter reaches the terminal.
CAUTION
Insert the needle adapter straight along the terminal
in the connector to prevent short-circuit between
terminals.
sure that measuring points are correct in the con• Make
nector, noting the position of the lock [D] and the lead
•
•
color before measurement. Do not reverse connections
of a digital meter.
Be careful not to short-circuit the leads of the DFI or electrical system parts by contact between adapters.
Turn the ignition switch ON and measure the voltage with
the connector joined.
CAUTION
Incorrect, reverse connection or short circuit by
needle adapters could damage the DFI or electrical
system parts.
○After measurement, remove the needle adapters and apply silicone sealant to the seals [A] of the connector [B]
for waterproofing.
Sealant - Kawasaki Bond (Silicone Sealant): 56019-120
check battery condition before replacing the DFI
• Always
parts. A fully charged battery is a must for conducting
•
•
accurate tests of the DFI system.
Trouble may involve one or in some cases all items.
Never replace a defective part without determining what
CAUSED the problem. If the problem was caused by
some other item or items, they too must be repaired or
replaced, or the new replacement part will soon fail again.
Measure coil winding resistance when the DFI part is cold
(at room temperature).
FUEL SYSTEM (DFI) 3-25
Troubleshooting the DFI System
sure all connectors in the circuit are clean and tight,
• Make
and examine wires for signs of burning, fraying, short,
etc. Deteriorated wires and bad connections can cause
reappearance of problems and unstable operation of the
DFI system.
If any wiring is deteriorated, replace the wiring.
each connector [A] apart and inspect it for corrosion,
• Pull
dirt, and damage.
If the connector is corroded or dirty, clean it carefully. If it
is damaged, replace it. Connect the connectors securely.
Check the wiring for continuity.
○Use the wiring diagram to find the ends of the lead which
is suspected of being a problem.
○Connect the hand tester between the ends of the leads.
•
Special Tool - Hand Tester: 57001-1394
○Set the tester to the × 1 Ω range, and read the tester.
If the tester does not read 0 Ω, the lead is defective. Replace the lead or the main harness or the subharness.
○If both ends of a harness [A] are far apart, ground [B] the
one end [C], using a jumper lead [D] and check the continuity between the end [E] and the ground [F]. This enables to check a long harness for continuity. If the harness
is open, repair or replace the harness.
○When checking a harness [A] for short circuit, open one
end [B] and check the continuity between the other end
[C] and ground [D]. If there is continuity, the harness has
a short circuit to ground, and it must be repaired or replaced.
down suspicious locations by repeating the con• Narrow
tinuity tests from the ECU connectors.
If no abnormality is found in the wiring or connectors, the
DFI parts are the next likely suspects. Check the part,
starting with input and output voltages. However, there is
no way to check the ECU itself.
If an abnormality is found, replace the affected DFI part.
If no abnormality is found in the wiring, connectors, and
DFI parts, replace the ECU.
3-26 FUEL SYSTEM (DFI)
Troubleshooting the DFI System
DFI Diagnosis Flow Chart
Inquiries to Rider
○Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms
the rider has encountered.
○Try to find out exactly what problem occurred under exactly what conditions by asking the rider;
knowing this information may help you reproduce the problem.
○The following sample diagnosis sheet will help prevent you from overlooking any areas, and will
help you decide if it is a DFI system problem, or a general engine problem.
FUEL SYSTEM (DFI) 3-27
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, □ always, □ other:
Temperature □ hot, □ warm, □ cold, □ very cold, □ always, □ other:
Problem
□ chronic, □ often, □once
frequency
Road
□ street, □ highway, □ mountain road (□ uphill, □ downhill), □ bumpy, □ pebble
Altitude
□ normal, □ high (about 1 000 m or more)
Motorcycle conditions when problem occurred.
Warning
□ Goes on immediately after ignition switch ON, and goes off after engine pressure
becomes high enough (with engine running).
indicator light
(LED)
□ Goes on immediately after ignition switch ON, and “Error” segments, service
code and FI warning symbol are displayed on the LCD (DFI system problem).
□ Start blinks after ignition switch ON, and “Error” segments, service code and FI
warning symbol are displayed on the LCD (ETV system problem).
□ Does not go on or blink after ignition switch ON.
Starting
□ starter motor not rotating.
difficulty
□ starter motor rotating but engine do not turn over.
□ starter motor and engine do not turn over.
□ no fuel flow (□ no fuel in tank, □ no fuel pump sound).
□ no spark.
□ other:
Engine stalls □ right after starting.
□ when opening throttle grip.
□ when closing throttle grip.
□ when moving off.
□ when stopping the motorcycle.
□ when cruising.
□ other:
Poor running □ very low idle speed, □ very high idle speed, □ rough idle speed.
at low speed □ battery voltage is low (charge the battery).
□ spark plug loose (tighten it).
□ spark plug dirty, broken, or gap maladjusted (remedy it).
□ backfiring.
□ afterfiring.
□ hesitation when acceleration.
□ engine oil viscosity too high.
□ brake dragging.
□ engine overheating.
□ clutch slipping.
□ other:
3-28 FUEL SYSTEM (DFI)
Troubleshooting the DFI System
Poor running
or no power at
high speed
□ spark plug loose (tighten it).
□ spark plug dirty, broken, or gap maladjusted (remedy it).
□ spark plug incorrect (replace it).
□ knocking (fuel poor quality or incorrect, → use high-octane gasoline).
□ brake dragging.
□ clutch slipping.
□ engine overheating.
□ engine oil level too high.
□ engine oil viscosity too high.
□ other:
FUEL SYSTEM (DFI) 3-29
DFI System Troubleshooting Guide
NOTE
○This is not an exhaustive list, giving every possible cause for each problem listed.
It is meant
simply as a rough guide to assist the troubleshooting for some of the more common difficulties in
DFI system.
○The ECU may be involved in the DFI electrical, ETV and ignition system troubles. If these parts
and circuits are checked out good, be sure to check the ECU for ground and power supply. If the
ground and power supply are checked good, replace the ECU.
Engine Won’t Turn Over
Symptoms or possible Causes
Actions (chapter)
Gear Position, starter lockout or sidestand switch Inspect each switch (see chapter 16).
trouble
Vehicle-down sensor operated
Turn ignition switch OFF (see chapter 3).
Vehicle-down sensor trouble
Inspect (see chapter 3).
Crankshaft sensor trouble
Inspect (see chapter 16).
Ignition coil shorted or not in good contact
Inspect or Reinstall (see chapter 16).
Ignition coil trouble
Inspect (see chapter 16).
Spark plug dirty, broken or gap maladjusted
Inspect and replace (see chapter 2).
Spark plug incorrect
Replace it with the correct plug (see chapter 2).
ECU ground and power supply trouble
Inspect (see chapter 3).
ECU trouble
Inspect (see chapter 3).
No or little fuel in tank
Supply fuel (see Owner’s Manual).
Fuel injector trouble
Inspect and replace (see chapter 3).
Fuel pump not operating
Inspect (see chapter 3).
Fuel pump relay trouble
Inspect and replace (see chapter 3).
Fuel filter clogged
Fuel pressure regulator trouble
Fuel line clogged
Inspect and replace fuel pump (see chapter 3).
Inspect fuel pressure and replace fuel pump (see
chapter 3).
Inspect and repair (see chapter 3).
Poor Running at Low Speed
Symptoms or Possible Causes
Spark weak:
Ignition coil shorted or not in good contact
Ignition coil trouble
Spark plug dirty, broken or gap maladjusted
Spark plug incorrect
ECU trouble
Fuel/air mixture incorrect:
Little fuel in tank
Air cleaner clogged, poorly sealed, or missing
Inlet Manifold loose
Throttle body assy loose
Throttle body assy dust seal damage
Fuel injector O-ring damage
Fuel filter clogged
Actions (chapter)
Inspect or reinstall (see chapter 16).
Inspect (see chapter 16).
Inspect and replace (see chapter 2).
Replace it with the correct plug (see chapter 2).
Inspect (see chapter 3).
Supply fuel (see Owner’s Manual).
Clean element or inspect sealing (see chapter 2).
Reinstall (see chapter 3).
Reinstall (see chapter 3).
Replace (see chapter 3).
Replace (see chapter 3).
Inspect and replace fuel pump (see chapter 3).
3-30 FUEL SYSTEM (DFI)
DFI System Troubleshooting Guide
Symptoms or Possible Causes
Fuel pressure regulator trouble
Fuel line clogged
Inlet air pressure sensor trouble
Water temperature sensor trouble
Inlet air temperature sensor trouble
Accelerator position sensor trouble
Throttle position sensor trouble
ETV actuator trouble
Unstable (rough) idling:
Fuel pressure too low or too high
Fuel injector trouble
Accelerator position sensor trouble
Throttle position sensor trouble
ETV actuator trouble
Inlet air pressure sensor trouble
Water temperature sensor trouble
Inlet air temperature sensor trouble
Engine stalls easily:
Spark plug dirty, broken or gap maladjusted
Ignition coil trouble
Accelerator position sensor trouble
Throttle position sensor trouble
ETV actuator trouble
Inlet air pressure sensor trouble
Water temperature sensor trouble
Inlet air temperature sensor trouble
Fuel pump trouble
Fuel injector trouble
Fuel pressure too low or too high
Fuel pressure regulator trouble
Fuel line clogged
Poor acceleration:
Fuel pressure too low
Water or foreign matter in fuel
Fuel filter clogged
Fuel pump trouble
Fuel injector trouble
Accelerator position sensor trouble
Throttle position sensor trouble
ETV actuator trouble
Inlet air pressure sensor trouble
Water temperature sensor trouble
Actions (chapter)
Inspect fuel pressure and replace fuel pump (see
chapter 3).
Inspect and repair (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect
Inspect
Inspect
Inspect
(see
(see
(see
(see
chapter
chapter
chapter
chapter
3).
3).
3).
3).
Inspect
Inspect
Inspect
Inspect
Inspect
Inspect
Inspect
(see
(see
(see
(see
(see
(see
(see
chapter
chapter
chapter
chapter
chapter
chapter
chapter
3).
3).
3).
3).
3).
3).
3).
Inspect (see chapter 3).
Inspect and replace (see chapter 2).
Inspect (see chapter 16).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect fuel pressure and replace fuel pump (see
chapter 3).
Inspect and repair (see chapter 3).
Inspect (see chapter 3).
Change fuel. Inspect and clean fuel system (see
chapter 3).
Inspect and replace fuel pump (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
FUEL SYSTEM (DFI) 3-31
DFI System Troubleshooting Guide
Symptoms or Possible Causes
Inlet air temperature sensor trouble
Spark plug dirty, broken or gap maladjusted
Ignition coil trouble
Stumble:
Fuel pressure too low
Fuel injector trouble
Accelerator position sensor trouble
Throttle position sensor trouble
ETV actuator trouble
Inlet air pressure sensor trouble
Water temperature sensor trouble
Inlet air temperature sensor trouble
Surge:
Unstable fuel pressure
Fuel injector trouble
Water temperature sensor trouble
Backfiring when deceleration:
Spark plug dirty, broken or gap maladjusted
Fuel pressure too low
Fuel pump trouble
Accelerator position trouble
Throttle position sensor trouble
ETV actuator trouble
Inlet air pressure sensor trouble
Water temperature sensor trouble
Inlet air temperature sensor trouble
Air switching valve trouble
Air suction valve trouble
After fire:
Spark plug burned or gap maladjusted
Fuel injector trouble
Inlet air pressure sensor trouble
Water temperature sensor trouble
Inlet air temperature sensor trouble
Other:
Intermittent any DFI fault and its recovery
Actions (chapter)
Inspect (see chapter 3).
Inspect and replace (see chapter 2).
Inspect (see chapter 16).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect
Inspect
Inspect
Inspect
Inspect
Inspect
(see
(see
(see
(see
(see
(see
chapter
chapter
chapter
chapter
chapter
chapter
3).
3).
3).
3).
3).
3).
Fuel pressure regulator trouble (Inspect and
replace fuel pump) or kinked fuel line (Inspect
and replace fuel pump) (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect
Inspect
Inspect
Inspect
Inspect
and replace (see chapter 2).
(see chapter 3).
(see chapter 3).
(see chapter 3).
(see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect and replace (see chapter 16).
Inspect and replace (see chapter 5).
Replace (see chapter 2).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Check that DFI connectors are clean and tight,
and examine leads for signs of burning or fraying
(see chapter 3).
Poor Running or No Power at High Speed:
Symptoms or Possible Causes
Firing incorrect:
Ignition coil shorted or not in good contact
Actions (chapter)
Inspect or Reinstall (see chapter 16).
3-32 FUEL SYSTEM (DFI)
DFI System Troubleshooting Guide
Symptoms or Possible Causes
Ignition coil trouble
Spark plug dirty, broken or gap maladjusted
Spark plug incorrect
ECU trouble
Fuel/air mixture incorrect:
Air cleaner clogged, poorly sealed, or missing
Inlet manifold loose
Throttle body assy loose
Throttle body assy dust seal damage
Actions (chapter)
Inspect (see chapter 16).
Inspect and replace (see chapter 2).
Replace it with the correct plug (see chapter 2).
Inspect (see chapter 3).
Clean element or inspect sealing (see chapter 2).
Reinstall (see chapter 3).
Reinstall (see chapter 3).
Replace (see chapter 3).
Water or foreign matter in fuel
Change fuel. Inspect and clean fuel system (see
chapter 3).
Fuel injector O-ring damage
Replace (see chapter 3).
Fuel injector clogged
Inspect and repair (see chapter 3).
Fuel line clogged
Inspect and repair (see chapter 3).
Fuel pump operates intermittently and often DFI Fuel pump bearings may wear. Replace the fuel
fuse blows.
pump (see chapter 3).
Fuel pump trouble
Inspect (see chapter 3).
Inlet air pressure sensor trouble
Inspect (see chapter 3).
Cracked or obstructed inlet air pressure sensor Inspect and repair or replace (see chapter 3).
vacuum hose
Water temperature sensor trouble
Inspect (see chapter 3).
Inlet air temperature sensor trouble
Inspect (see chapter 3).
Accelerator position sensor trouble
Inspect (see chapter 3).
Throttle position sensor trouble
Inspect (see chapter 3).
ETV actuator trouble
Inspect (see chapter 3).
Knocking:
Fuel poor quality or incorrect
Fuel change (Use the gasoline recommended in
the Owner’s Manual).
Spark plug incorrect
Replace it with the correct plug (see chapter 2).
Ignition coil trouble
Inspect (see chapter 16).
ECU trouble
Inspect (see chapter 3).
Engine vacuum not synchronizing
Inspect and adjust (see chapter 2).
Inlet air pressure sensor trouble
Inspect (see chapter 3).
Water temperature sensor trouble
Inspect (see chapter 3).
Inlet air temperature sensor trouble
Inspect (see chapter 3).
Miscellaneous:
Speed sensor trouble
Inspect (see chapter 3).
Throttle valves will not fully open
Inspect throttle cables and ETV system (see
chapter 3).
Engine overheating - Water temperature sensor, (see Overheating of Troubleshooting Guide in
crankshaft sensor or speed sensor trouble
chapter 17)
Air switching valve trouble
Inspect and replace (see chapter 16).
Air suction valve trouble
Inspect and replace (see chapter 5).
Exhaust Smokes Excessively:
(Black smokes)
FUEL SYSTEM (DFI) 3-33
DFI System Troubleshooting Guide
Symptoms or Possible Causes
Air cleaner element clogged
Fuel pressure too high
Fuel injector trouble
Water temperature sensor trouble
Inlet air temperature sensor trouble
(Brown smoke)
Air duct loose
Fuel pressure too low
Water temperature sensor trouble
Inlet air temperature sensor trouble
Actions (chapter)
Clean element (see chapter 2).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Reinstall (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
Inspect (see chapter 3).
3-34 FUEL SYSTEM (DFI)
Self-Diagnosis
The warning indicator light (LED) [A] is used for the
FI/ETV (Electrical Throttle Valve) indicator, oil pressure
warning indicator and water temperature warning indicator.
Self-diagnosis Outline
The ECU notifies the rider of troubles in DFI system, ignition system and EVT system by lighting up or blinking the
warning indicator light (LED) [A] and displaying the “Error”
segments [B], service code [C] and FI warning symbol [D]
on the LCD (Liquid Crystal Display) when DFI, ignition and
ETV system parts are faulty, and initiates fail-safe function.
In case of serious troubles ECU stops the injection/ignition/starter motor operation.
Self-diagnosis Procedures
○When problem occurs with DFI system, the warning indicator light (LED) [A] goes on and the “Error” segments [B],
service code [C] and FI warning symbol [D] are displayed
on the LCD (Liquid Crystal Display) to alert the rider. The
service code is displayed by the number of two digits.
FUEL SYSTEM (DFI) 3-35
Self-Diagnosis
○When problem occurs with ETV (Electrical Throttle Valve)
system, the warning indicator light (LED) [A] blinks and
the “Error” segments [B], service code [C] and FI warning
symbol [D] are displayed on the LCD (Liquid Crystal Display) to alert the rider. The service code is displayed by
the number of two digits.
the ignition switch ON.
• Turn
The
service
code [A] is displayed by the number of two
• digits.
pushing the “S” button [B] of the right switch hous• When
ing for more than two seconds while the “Error” segments
[C], service code and FI warning symbol [D] are displayed
on the LCD, the display on the LCD is switched to the
normal display. But, the warning indicator light (LED) [E]
goes on or blinks and the FI warning symbol is displayed.
3-36 FUEL SYSTEM (DFI)
Self-Diagnosis
switching to the normal display, the service code can
• After
be displayed again by the following procedures.
○Push the “S” button of the right switch housing for more
than two seconds to display the clock setting mode [A] on
the LCD.
○Push the “S” button to display the service code [B].
NOTE
○The display change to the clock setting mode, average
fuel consumption unit setting mode [C], service code
display each time the “S” button is pressed.
of the following procedures ends self-diagnosis.
•○Any
Push the “S” button for more than two seconds.
○When the ignition switch is turned OFF.
FUEL SYSTEM (DFI) 3-37
Self-Diagnosis
Self-Diagnosis Flow Chart
3-38 FUEL SYSTEM (DFI)
Self-Diagnosis
Service Code Reading
○The service code(s) is displayed on the LCD by the number of two digits.
○When there are a number of problems, all the service codes can be stored and the display will begin
starting from the lowest number service code in the numerical order.
○Then after completing all codes, the display is repeated until the ignition switch is pushed OFF or
“S” button is pushed for more than two seconds.
○For example, if three problems occurred in the order of 31, 11, 21, the service codes are
displayed (each two seconds) from the lowest number in the order listed as shown below.
(11→21→31)→(11→21→31)→· · ·(repeated)
○If there is no problem or when the repair has been done, when repair has been done, the "Error"
segments, service code and FI warning symbol go off (return to the normal display).
Service Code Erasing
○When repair has been done, the "Error" segments, service code and FI warning symbol go off (return
to the normal display).
But the service codes stored in memory of the ECU are not erased to preserve the problem history.
In this model, the problem history can not be erased.
FUEL SYSTEM (DFI) 3-39
Self-Diagnosis
Service Code Table
Service
Code
11
12
13
14
18
21
24
System
ETV
DFI
DFI
DFI
ETV
DFI
DFI
25
31
33
46
49
51
52
56
58
64
DFI
DFI
DFI
DFI
ETV
DFI
DFI
DFI
ETV
DFI
67
DFI
97
98
ETV
ETV
Problems
Throttle position sensor malfunction, wiring open or short.
Inlet air pressure sensor malfunction, wiring open or short.
Inlet air temperature sensor malfunction, wiring open or short.
Water temperature sensor malfunction, wiring open or short.
Accelerator position sensor malfunction, wiring open or short.
Crankshaft sensor malfunction, wiring open or short.
Speed sensor malfunction, wiring open or short.
Gear position switch malfunction, wiring open or short.
Vehicle-down sensor malfunction, wiring open or short.
Oxygen sensor inactivation, wiring open or short (Equipped Models).
Fuel pump relay malfunction, relay is stuck.
Return spring malfunction.
Ignition coil #1 (Front Cylinder) malfunction, wiring open or short.
Ignition coil #2 (Rear Cylinder) malfunction, wiring open or short.
Radiator fan relay malfunction, wiring open or short.
ETV actuator malfunction, wiring open or short.
Air switching valve malfunction, wiring open or short.
Oxygen sensor heater malfunction, wiring open or short (Equipped
Models).
Battery monitor voltage is low.
ECU/ETV circuit malfunction, wiring open or short.
Notes:
○The ECU may be involved in these problems. If all the parts and circuits checked out good, be sure
to check the ECU for ground and power supply. If the ground and power supply are checked good,
replace the ECU.
○When no service code is displayed, the electrical parts of the DFI system and ETV system have no
fault, and the mechanical parts of the DFI system or ETV system and the engine are suspect.
3-40 FUEL SYSTEM (DFI)
Self-Diagnosis
Backups
○The ECU takes the following measures to prevent engine damage when the DFI, ignition or ETV
system parts have troubles.
Service
Codes
Parts
Output Signal Usable
Range or Criteria
11
Throttle
Position
Sensor
Output Voltage
(full throttle opening)
(1) 3.50 ∼ 3.90 V
(2) 4.50 ∼ 4.80 V
12
Inlet Air
Pressure
Sensor
Inlet Air Pressure
(Absolute)
Pv = 50 ∼ 910 mmHg
13
Inlet Air
Inlet Air Temperature
Temperature
Ta = – 30 ∼ + 120°C
Sensor
14
Water
Water Temperature
Temperature
Tw = – 30 ∼ + 120°C
Sensor
18
Accelerator Output Voltage
Position
(1) 0.50 ∼ 4.75 V
Sensor
(2) 0.35 ∼ 4.75 V
21
Crankshaft
Sensor
24
25
31
33
46
49
Backups by ECU
If both throttle position sensor 1 and 2 fail,
the ECU sets the DFI in the D-J method(*1)
and sets to the Limp Home Mode(*2). If
either sensor fails, the ECU sets to the Power
Limitation Mode(*3).
If the inlet air pressure sensor system fails (the
signal is out of the usable range, wiring short
or open), the ECU sets the DFI in the α-N
method (*4).
If the inlet air temperature sensor system fails
(the signal is out of the usable range, wiring
short or open), the ECU sets Ta at 30°C.
If the water temperature sensor system fails
(the signal is out of the usable range, wiring
short or open), the ECU sets Tw at 80°C and
the radiator fan operates.
If both accelerator position sensor 1 and 2 fail,
the ECU sets to the idle speed. If either sensor
fails, the ECU sets to the Power Limitation
Mode.
Crankshaft sensor must
If the crankshaft sensor fails, the engine stops
send 18 signals to the ECU
by itself.
at the 1 cranking.
Speed sensor must send
If the speed sensor system fails (no signal,
29 signals to the ECU at
wiring short or open), the speedometer shows
the 1 rotation of the output
0.
shaft.
Gear
If the gear position switch system fails (no
Output Voltage
Position
signal, wiring short or open), the ECU set the
0.2 ∼ 4.8 V
Switch
top (6th) gear position.
If the vehicle-down sensor system has failures
(the output voltage is out of the usable range,
Vehicle
Output Voltage
wiring short or open), the ECU shuts off the
-down
0.2 ∼ 4.8 V
fuel pump relay, the fuel injectors and the
Sensor
ignition system.
The oxygen sensor is
Oxygen
active and sensor must
If the oxygen sensor is not activated, the ECU
Sensor
send signals (output
stops the current to the heater and feedback
(Equipped
voltage) continuously to
mode of the oxygen sensor.
Models)
the ECU.
When the relay ON
Fuel Pump
condition, battery monitor –
Relay
voltage 5 V or more
TPS Output Voltage
(default position of the
Return
throttle valve by learning
–
Spring
function)
4 V or more
Speed
Sensor
FUEL SYSTEM (DFI) 3-41
Self-Diagnosis
Service
Codes
Parts
51
Ignition Coil
#1 (Front
Cylinder)
—
52
Ignition Coil
#2 (Rear
cylinder)
—
56
58
64
67
Output Signal Usable
Range or Criteria
When the relay OFF
Radiator Fan
condition, the fan relay is
Relay
open.
The actuator operates
open and close of the
ETV
throttle valve by the pulse
Actuator
signal from the ECU.
The air switching valve
controls the flow of the
Air Switching
secondary air by opening
Valve
and shutting the solenoid
valve.
Oxygen
Sensor
Heater
(Equipped
Models)
97
Battery
98
ETV Control
Circuit
Backups by ECU
If the ignition coil #1 primary winding has
failures (wiring short or open), the ECU shuts
off the injector #1 to stop fuel to the cylinder
#1, though the engine keeps running.
If the ignition coil #2 primary winding has
failures (wiring short or open), the ECU shuts
off the injector #2 to stop fuel to the cylinder
#2, though the engine keeps running.
If the radiator fan relay fails, the ECU shuts
off the relay.
If the ETV actuator fails (the signal is out to the
usable range, wiring short or open), the ECU
stops the current to the actuator, and sets to
the Limp Home Mode.
If the air switching valve fails, the ECU stops
the air switching valve control.
The oxygen sensor heater
raises temperature of
the sensor for its earlier
activation.
If the oxygen sensor heater fails (wiring short
or open), the ECU stops the current to the
heater and the feedback mode of the oxygen
sensor.
The ECU monitors the
battery voltage when the
fuel pump operates.
Detection Voltage: less
than 6.3 V
The ECU sets to the Limp Home Mode.
—
The ECU sets to the Limp Home Mode.
Note:
(*1) D-J method: When the engine load is light like at idling or low speed, the ECU determines
the injection quantity by calculating from the throttle vacuum (inlet air pressure sensor output
voltage) and engine speed (crankshaft sensor output voltage).
(*2) Limp Home Mode: ETV is not operational. Power controls by ignition timing.
(*3) Power Limitation Mode: ETV is operational condition by redundant system.
(*4) α-N method: As the engine speed increases, and the engine load turns middle to heavy, the
ECU determines the injection quantity by calculating from the throttle opening (throttle position
sensor output voltage) and the engine speed.
3-42 FUEL SYSTEM (DFI)
Throttle Position Sensor (Service Code 11)
Throttle Position Sensor Removal
CAUTION
Do not remove throttle position sensor in the gear
case [A] since it has been adjusted and set with precision at the factory.
Never drop the throttle body assy, especially on a
hard surface. Such a shock to the throttle position
sensor can damage it.
Throttle Position Sensor Output Voltage
Inspection
NOTE
○Be sure the battery is fully charged.
the ignition switch OFF.
• Turn
• Remove:
Front Seat (see Front Seat Removal in the Frame chapter)
Battery Case Cover (see Battery Removal in the Electrical System chapter)
the digital meter to the connector [A] with the
• Connect
needle adapter set.
Special Tool - Needle Adapter Set: 57001-1457
Throttle Position Sensor Output Voltage
Connection:
(1)
Digital Meter (+) → G/R lead (ECU terminal 68)
Digital Meter (−) → O/BK lead (ECU terminal 56)
(2)
Digital Meter (+) → G/Y lead (ECU terminal 57)
Digital Meter (−) → O/BK lead (ECU terminal 56)
the ignition switch ON.
• Turn
Measure
the output voltage with full throttle opened.
•
Output Voltage
Standard: (1)
(2)
○Open
DC 3.50 ~ 3.90 V at full throttle
opening (for reference)
DC 4.50 ~ 4.80 V at full throttle
opening (for reference)
NOTE
the throttle, confirm the output voltage will be
raise.
○When the throttle is ordinary position, the standard
value is not determined because there is some uncertain elements, e.g. water temperature, throttle valve
initial opening, etc.
the ignition switch OFF.
• Turn
If the reading is out of the standard, check the input voltage (see Throttle Position Sensor Input Voltage Inspection).
If the reading is within the standard, replace the ECU (see
ECU Removal/Installation).
FUEL SYSTEM (DFI) 3-43
Throttle Position Sensor (Service Code 11)
Throttle Position Sensor Input Voltage Inspection
NOTE
○Be sure the battery is fully charged.
the ignition switch OFF.
• Turn
• Remove:
Front Seat (see Front Seat Removal in the Frame chapter)
Battery Case Cover (see Battery Removal in the Electrical System chapter)
the digital meter to the connector [A] with the
• Connect
needle adapter set.
Special Tool - Needle Adapter Set: 57001-1457
Throttle Position Sensor Input Voltage
Connection:
Digital Meter (+) → BL/R lead (ECU terminal 49)
Digital Meter (−) → O/BK lead (ECU terminal 56)
the ignition switch ON.
• Turn
Measure
the input voltage.
•
Input Voltage
Standard:
DC 4.75 ~ 5.25 V
the ignition switch OFF.
• Turn
If the reading is out of the standard, replace the ECU (see
•
ECU Removal/Installation).
If the reading is within the standard, check the wiring for
continuity between the main harness connectors according to the following procedure.
Remove:
Right Air Cleaner Housing (see Right Air Cleaner Housing Removal)
the throttle position sensor connector [A].
• Disconnect
Set
the
hand
• for continuity.tester to the × 1 Ω range and check the wiring
Special Tool - Hand Tester: 57001-1394
If the wiring is good, replace the throttle body assy (see
Throttle Body Assy Removal/Installation).
If the wiring is not good, replace the main harness.
3-44 FUEL SYSTEM (DFI)
Throttle Position Sensor (Service Code 11)
Throttle Position Sensor Circuit
1. ECU
2. Throttle Position Sensor/ETV Actuator
3. Throttle Position Sensor 1
4. Throttle Position Sensor 2
FUEL SYSTEM (DFI) 3-45
Inlet Air Pressure Sensor (Service Code 12)
Inlet Air Pressure Sensor Removal
CAUTION
Never drop the inlet air pressure sensor, especially
on a hard surface. Such a shock to the sensor can
damage it.
• Remove:
Fuel Tank (see Fuel TankRemoval)
•
Inlet Air Pressure Sensor Connector [A]
Inlet Air Pressure Sensor Bolt [B]
Separate the vacuum hose [C] and remove the inlet air
pressure sensor [D].
Inlet Air Pressure Sensor Installation
• Installation is basically the reverse of removal.
Inlet Air Pressure Sensor Input Voltage Inspection
NOTE
○Be sure the battery is fully charged.
the ignition switch OFF.
• Turn
the fuel tank (see Fuel Tank Removal).
• Remove
Disconnect
inlet air pressure sensor connector and
• connect the the
measuring adapter [A] between these connectors as shown in the figure.
Main Harness [B]
Inlet Air Pressure Sensor [C]
Special Tool - Measuring Adapter: 57001-1700
a digital meter [D] to the measuring adapter
• Connect
leads.
Inlet Air Pressure Sensor Input Voltage
Connections to Adapter:
Digital Meter (+) → R (main harness BL) lead
Digital Meter (–) → BK (main harness BR/Y) lead
the input voltage with the engine stopped and
• Measure
with the connector joined.
• Turn the ignition switch ON.
Input Voltage
Standard: DC 4.75 ∼ 5.25 V
the ignition switch OFF.
• Turn
If the reading is within the standard, check the output voltage (see Inlet Air Pressure Sensor Output Voltage Inspection).
3-46 FUEL SYSTEM (DFI)
Inlet Air Pressure Sensor (Service Code 12)
If the reading is out of the standard, remove the ECU
and check the wiring for continuity between main harness
connectors.
Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Inlet Air Pressure Sensor Connector [B]
BL lead (ECU terminal 48) [C]
BR/Y lead (ECU terminal 55) [D]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
Inlet Air Pressure Sensor Output Voltage
Inspection
the output voltage at the inlet air pressure sen• Measure
sor in the same way as input voltage inspection, note the
following.
○Disconnect the inlet air pressure sensor connector and
connect the measuring adapter [A] between these connectors as shown in the figure.
Main Harness [B]
Inlet Air Pressure Sensor [C]
Special Tool - Measuring Adapter: 57001-1700
Inlet Air Pressure Sensor Output Voltage
Connections to Adapter:
Digital Meter (+) → W (main harness O/G) lead
Digital Meter (–) → BK ( main harness BR/Y) lead
the output voltage with the engine stopped, and
• Measure
with the connector joined.
• Turn the ignition switch ON.
Output Voltage
Usable Range:
DC 3.80 ∼ 4.20 V at standard
atmospheric pressure (101.32 kPa,
76 cmHg)
NOTE
○The output voltage changes according to local atmospheric pressure.
the ignition switch OFF.
• Turn
If the reading is out of the usable range, replace the sensor.
FUEL SYSTEM (DFI) 3-47
Inlet Air Pressure Sensor (Service Code 12)
If the reading is within the usable range, remove the ECU
and check the wiring for continuity between main harness
connector.
Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Inlet Air Pressure Sensor Connector [B]
O/G lead (ECU terminal 46) [C]
BR/Y lead (ECU terminal 55) [D]
If the wiring is good, check the sensor for various vacuum.
Remove the inlet air pressure sensor [A] and disconnect
the vacuum hose from the sensor.
Connect an auxiliary hose [B] to the inlet air pressure sensor.
Temporarily install the inlet air pressure sensor.
○Connect a digital meter [C], vacuum gauge [D], the fork
oil level gauge [E] and the measuring adapter to the inlet
air pressure sensor.
•
•
•
Special Tools - Fork Oil Level Gauge: 57001-1290
Vacuum Gauge: 57001-1369
Measuring Adapter: 57001-1700
Inlet Air Pressure Sensor Output Voltage
Connections to Adapter:
Digital Meter (+) → W (main harness O/G) lead
Digital Meter (–) → BK (main harness BR/Y) lead
○Turn the ignition switch ON.
○Measure the inlet air pressure sensor output voltage from
various vacuum readings, while pulling the handle of the
fork oil level gauge.
○Check the inlet air pressure sensor output voltage, using
the following formula and chart.
Suppose:
Pg: Vacuum Pressure (Gauge) of Throttle Body
Pl: Local Atmospheric Pressure (Absolute) measured by
a barometer
Pv: Vacuum Pressure (Absolute) of Throttle Body
Vv: Sensor Output Voltage (V)
3-48 FUEL SYSTEM (DFI)
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 Meter Reading)
then
Pv = 70 – 8 = 62 cmHg (Absolute)
Plot this Pv (62 cmHg) at a point [1] on the chart and draw a
vertical line through the point. Then, you can get the usable
range [2] of the sensor output voltage.
Usable range = 3.08 ∼ 3.48 V
Plot Vv (3.2 V) on the vertical line. → Point [3].
Results: In the chart, Vv is within the usable range and
the sensor is normal.
If the reading is out of the usable range, replace the sensor.
If the reading is within the usable range, check the ECU
for its ground and power supply (see ECU Power Supply
Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
FUEL SYSTEM (DFI) 3-49
Inlet Air Pressure Sensor (Service Code 12)
ID: Idling
Ps: Standard Atmospheric Pressure (Absolute)
Pv: Throttle Vacuum Pressure (Absolute)
ST: Standard of Sensor Output Voltage (V)
TO: Throttle Full Open
UR: Usable Range of Sensor Output Voltage (V)
Vv: Inlet Air Pressure Sensor Output Voltage (V) (Digital Meter Reading)
3-50 FUEL SYSTEM (DFI)
Inlet Air Pressure Sensor (Service Code 12)
Inlet Air Pressure Sensor Circuit
1. ECU
2. Inlet Air Pressure Sensor
FUEL SYSTEM (DFI) 3-51
Inlet Air Temperature Sensor (Service Code 13)
Inlet Air Temperature Sensor Removal/Installation
CAUTION
Never drop the inlet air temperature sensor, especially on a hard surface. Such a shock to the sensor
can damage it.
• Remove:
Right Air Cleaner Housing (see Air Cleaner Housing Removal)
Screw [A]
Pull out the inlet air temperature sensor [B].
•
that the O-ring [A] is in place on the inlet air tem• Check
perature sensor [B].
• Tighten the screw securely.
Inlet Air Temperature Sensor Output Voltage
Inspection
NOTE
○Be sure the battery is fully charged.
the ignition switch OFF.
• Turn
Remove:
• Right Air Cleaner Housing (see Air Cleaner Housing Re-
•
moval)
Disconnect the inlet air temperature sensor connector
and connect the measuring adapter [A] between these
connectors as shown in the figure.
Main Harness [B]
Inlet Air Temperature Sensor [C]
Special Tool - Measuring Adapter: 57001-1700
a digital meter [D] to the measuring adapter
• Connect
leads.
Inlet Air Temperature Sensor Output Voltage
Connections to Adapter:
Digital Meter (+) → R (main harness R) lead
Digital Meter (–) → BK (main harness BR/Y) lead
the output voltage with the engine stopped and
• Measure
the connector joined.
• Turn the ignition switch ON.
Output Voltage
Standard: About DC 2.25 ∼ 2.50 V at inlet air
temperature 20°C (68°F)
NOTE
○The output voltage changes according to the inlet air
temperature.
3-52 FUEL SYSTEM (DFI)
Inlet Air Temperature Sensor (Service Code 13)
the ignition switch OFF.
• Turn
If the reading is within the standard, check the ECU for
its ground and power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
If the reading is out of the standard, remove the ECU
and check the wiring for continuity between main harness
connectors.
Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Inlet Air Temperature Sensor Connector [B]
R lead (ECU terminal 36) [C]
BR/Y lead (ECU terminal 55) [D]
If the wiring is good, check the inlet air temperature sensor
resistance (see Inlet Air Temperature Sensor Resistance
Inspection).
Inlet Air Temperature Sensor Resistance
Inspection
the inlet air temperature sensor (see Inlet Air
• Remove
Temperature Sensor Removal/Installation).
the sensor [A] in a container of machine oil so
• Suspend
that the heat-sensitive portion is submerged.
a thermometer [B] with the heat-sensitive por• Suspend
tion [C] located in almost the same depth with the sensor.
NOTE
○The sensor and thermometer must not touch the container side or bottom.
the container over a source of heat and gradually
• Place
raise the temperature of the oil while stirring the oil gently
•
for even temperature.
Using a digital meter, measure the internal resistance
of the sensor across the terminals at the temperatures
shown in the following.
Inlet Air Temperature Sensor Resistance
Standard: 5.4 ∼ 6.6 kΩ at 0°C (32°F)
0.29 ∼ 0.39 kΩ at 80°C (176°F)
If the reading is out of the standard, replace the sensor.
If the reading is within the standard, but the problem still
exists, replace the ECU (see ECU Removal/Installation).
FUEL SYSTEM (DFI) 3-53
Inlet Air Temperature Sensor (Service Code 13)
Inlet Air Temperature Sensor Circuit
1. ECU
2. Inlet Air Temperature Sensor
3-54 FUEL SYSTEM (DFI)
Water Temperature Sensor (Service Code 14)
Water Temperature Sensor Removal/Installation
CAUTION
Never drop the water temperature sensor, especially on a hard surface. Such a shock to the sensor
can damage it.
• Remove:
Fuel Tank (see Fuel Tank Removal)
Drain
the coolant (see Coolant Change in the Periodic
• Maintenance
chapter).
Remove:
• Connector [A]
Water Temperature Sensor [B]
the O-ring [A] with a new one.
• Replace
Tighten:
•
Torque - Water Temperature Sensor: 12 N·m (1.2 kgf·m, 106
in·lb)
the engine with coolant and bleed the air from the cool• Fill
ing system (see Coolant Change in the Periodic Maintenance chapter).
Water Temperature Sensor Output Voltage
Inspection
NOTE
○Be sure the battery is fully charged.
the ignition switch OFF.
• Turn
Remove:
• Fuel Tank (see Fuel Tank Removal)
the water temperature sensor connector and
• Disconnect
connect the measuring adapter [A] between these connectors as shown in the figure.
Main Harness [B]
Water Temperature Sensor [C]
Special Tool - Measuring Adapter: 57001-1700
a digital meter [D] to the measuring adapter
• Connect
leads.
Water Temperature Sensor Output Voltage
Connections to Adapter:
Digital Meter (+) → R (main harness O) lead
Digital Meter (–) → BK (main harness BR/Y) lead
the output voltage with the engine stopped and
• Measure
the connector joined.
• Turn the ignition switch ON.
Output Voltage
Standard: About DC 2.80 ∼ 2.97 V at 20°C (68°F)
NOTE
○The output voltage changes according to the coolant
temperature in the engine.
FUEL SYSTEM (DFI) 3-55
Water Temperature Sensor (Service Code 14)
the ignition switch OFF.
• Turn
If the reading is within the standard, check the ECU for
its ground, and power supply (see ECU Power Supply
Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
If the reading is out of the standard, remove the ECU
and check the wiring for continuity between main harness
connectors.
Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Water Temperature Sensor Connector [B]
O lead (ECU terminal 53) [C]
BR/Y lead (ECU terminal 55) [D]
If the wiring is good, check the water temperature sensor
resistance (see Water Temperature Sensor Resistance
Inspection).
Water Temperature Sensor Resistance Inspection
to the Water Temperature Sensor Inspection in the
• Refer
Electrical System chapter.
If the reading is within the standard, but the problem still
exists, replace the ECU (see ECU Removal/Installation).
Water Temperature Sensor Circuit
1. ECU
2. Water Temperature Sensor
3-56 FUEL SYSTEM (DFI)
Accelerator Position Sensor (Service Code 18)
Accelerator Position Sensor Removal
CAUTION
Do not remove accelerator position sensor [A]
since it has been adjusted and set with precision
at the factory.
Never drop the throttle body assy, especially on a
hard surface. Such a shock to the accelerator position sensor can damage it.
Accelerator Position Sensor Output Voltage
Inspection
NOTE
○Be sure the battery is fully charged.
the ignition switch OFF.
• Turn
• Remove:
Front Seat (see Front Seat Removal in the Frame chapter)
Battery Case Cover (see Battery Removal in the Electrical System chapter)
the digital meter to the connector [A] with the
• Connect
needle adapter set.
Special Tool - Needle Adapter Set: 57001-1457
Accelerator Position Sensor Output Voltage
Connection:
(1)
Digital Meter (+) → G/W lead (ECU terminal 66)
Digital Meter (−) → BK/O lead (ECU terminal 65)
(2)
Digital Meter (+) → G/BK lead (ECU terminal 50)
Digital Meter (−) → BR lead (ECU terminal 58)
the ignition switch ON.
• Turn
Measure
output voltage with the ordinary throttle po• sition andthe
full throttle opened.
Output Voltage
Standard: (1)
(2)
DC 0.50 ~ 0.90 V at ordinary throttle
position
DC 3.85 ~ 4.75 V at full throttle
opening (for reference)
DC 0.35 ~ 1.05 V at ordinary throttle
position
DC 3.85 ~ 4.75 V at full throttle
opening (for reference)
NOTE
○Open the throttle, confirm the output voltage will be
raise.
the ignition switch OFF.
• Turn
If the reading is out of the standard, check the input voltage (see Accelerator Position Sensor Input Voltage Inspection).
If the reading is within the standard, replace the ECU (see
ECU Removal/Installation).
FUEL SYSTEM (DFI) 3-57
Accelerator Position Sensor (Service Code 18)
Accelerator Position Sensor Input Voltage
Inspection
NOTE
○Be sure the battery is fully charged.
the ignition switch OFF.
• Turn
Remove:
• Front Seat (see Front Seat Removal in the Frame chapter)
Battery Case Cover (see Battery Removal in the Electrical System chapter)
the digital meter to the connector [A] with the
• Connect
needle adapter set.
Special Tool - Needle Adapter Set: 57001-1457
Accelerator Position Sensor Input Voltage
Connection:
(1)
Digital Meter (+) → BL/W lead (ECU terminal 67)
Digital Meter (−) → BK/O lead (ECU terminal 65)
(2)
Digital Meter (+) → BL/BK lead (ECU terminal 43)
Digital Meter (−) → BR lead (ECU terminal 58)
the ignition switch ON.
• Turn
• Measure the input voltage.
Input Voltage
Standard:
(1) and (2) DC 4.75 ∼ 5.25 V
the ignition switch OFF.
• Turn
If the reading is out of the standard, replace the ECU (see
ECU Removal/Installation).
If the reading is within the standard, check the accelerator position sensor resistance (see Accelerator Position
Sensor Resistance).
If the resistance is the standard, check the wiring for continuity between the main harness connectors using the
Accelerator Position Sensor Circuit.
Special Tool - Hand Tester: 57001-1394
If the wiring is not good, replace the main harness.
If the wiring is good, replace the ECU (see ECU Removal/Installation).
Accelerator Position Sensor Resistance
Inspection
the ignition switch OFF.
• Turn
Remove:
• Right Air Cleaner Housing (see Right Air Cleaner Hous-
•
ing Removal)
Disconnect the accelerator position sensor connector [A].
3-58 FUEL SYSTEM (DFI)
Accelerator Position Sensor (Service Code 18)
the digital meter [A] to the terminals of the accel• Connect
erator position sensor connector [B].
Accelerator Position Sensor Resistance
Connection:
(1) BL/W lead terminal → BK/O lead terminal
(2) BL/BK lead terminal → BR lead terminal
• Measure the accelerator position sensor resistance.
Accelerator Position Sensor Resistance
Standard: (1) and (2) 4 ~ 6 kΩ
If the reading is out of the standard, replace the throttle
body assy (see Throttle Body Assy Removal/Installation).
Accelerator Position Sensor Circuit
1. ECU
2. Accelerator Position Sensor
3. Accelerator Position Sensor 1
4. Accelerator Position Sensor 2
FUEL SYSTEM (DFI) 3-59
Crankshaft Sensor (Service Code 21)
The crankshaft sensor has no power source, and when
the engine stops, the crankshaft sensor generates no signals.
Crankshaft Sensor Removal/Installation
to the Crankshaft Sensor Removal/Installation in
• Refer
the Electrical System chapter.
Crankshaft Sensor Resistance Inspection
to the Crankshaft Sensor Inspection in the Electrical
• Refer
System chapter.
If the reading is within the standard, check the peak voltage (see Crankshaft Sensor Peak Voltage Inspection).
Crankshaft Sensor Peak Voltage Inspection
to the Crankshaft Sensor Peak Voltage Inspection
• Refer
in the Electrical System chapter.
If the reading is within the standard, remove the ECU and
check the wiring for continuity between main harness connectors.
Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Crankshaft Sensor Connector [B]
Y lead (ECU terminal 38) [C]
BK lead (ECU terminal 47) [D]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
3-60 FUEL SYSTEM (DFI)
Crankshaft Sensor (Service Code 21)
Crankshaft Sensor Circuit
1. ECU
2. Crankshaft Sensor
FUEL SYSTEM (DFI) 3-61
Speed Sensor (Service Code 24)
Speed Sensor Removal/Installation
to the Speed Sensor Removal/Installation in the
• Refer
Electrical System chapter.
Speed Sensor Input Voltage Inspection
NOTE
○Be sure the battery is fully charged.
the ignition switch OFF.
• Turn
• Disconnect the speed sensor connector [A].
the speed sensor measuring adapter [A] be• Connect
tween these connectors as shown in the figure.
Main Harness [B]
Speed Sensor [C]
Special Tool - Speed Sensor Measuring Adapter: 57001
-1667
a digital meter [D] to the speed sensor measuring
• Connect
adapter leads.
Speed Sensor Input Voltage
Connections to Adapter:
Digital Meter (+) → BL (main harness BL) lead
Digital Meter (–) → BK/Y (main harness BR/Y) lead
the input voltage with the engine stopped and
• Measure
with the connector joined.
• Turn the ignition switch ON.
Input Voltage
Standard: DC 4.75 ∼ 5.25 V
the ignition switch OFF.
• Turn
If the reading is within the standard, check the output voltage (see Speed Sensor Output Voltage Inspection).
If the reading is out of the standard, remove the ECU
and check the wiring for continuity between main harness
connectors.
Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Speed Sensor Connector [B]
BL lead (ECU terminal 48) [C]
BR/Y lead (ECU terminal 55) [D]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
3-62 FUEL SYSTEM (DFI)
Speed Sensor (Service Code 24)
Speed Sensor Output Voltage Inspection
the jack, raise the rear wheel off the ground (see
• Using
Rear Wheel Removal in the Wheels/Tires chapter).
Special Tool - Jack: 57001-1238
the output voltage at the speed sensor in the
• Measure
same way as input voltage inspection, note the following.
○Disconnect the speed sensor connector and connect the
speed sensor measuring adapter [A] between these connectors as shown in the figure.
Main Harness [B]
Speed Sensor [C]
Special Tool - Speed Sensor Measuring Adapter: 57001
-1667
Speed Sensor Output Voltage
Connections to Adapter:
Digital Meter (+) → BL/Y (main harness LG/R) lead
Digital Meter (–) → BK/Y (main harness BR/Y) lead
the output voltage with the engine stopped and
• Measure
with the connector joined.
• Turn the ignition switch ON.
Output Voltage
Standard: About DC 0.05 ∼ 0.09 V or DC 4.5 ∼ 4.9 V at
ignition switch ON and 0 km/h
NOTE
○Rotate the rear wheel by hand, confirm the output voltage will be raise or lower.
the ignition switch OFF.
• Turn
If the reading is out of the standard, replace the sensor.
If the reading is within the standard, remove the ECU and
check the wiring for continuity between main harness connectors.
Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Speed Sensor Connector [B]
LG/R lead (ECU terminal 39) [C]
BR/Y lead (ECU terminal 55) [D]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
FUEL SYSTEM (DFI) 3-63
Speed Sensor (Service Code 24)
Speed Sensor Circuit
1. ECU
2. Speed Sensor
3-64 FUEL SYSTEM (DFI)
Gear Position Switch (Service Code 25)
Gear Position Switch Removal/Installation
to the Gear Position Switch Removal/Installation in
• Refer
the Electrical System chapter.
Gear Position Switch Resistance Inspection
to the Gear Position Switch Inspection in the Elec• Refer
trical System chapter.
If the reading is as the specified, check the output voltage
(see Gear Position Switch Output Voltage Inspection).
Gear Position Switch Output Voltage Inspection
NOTE
○Be sure the battery is fully charged.
the ignition switch OFF.
• Turn
Disconnect
the gear position switch lead connector [A].
•
the measuring adapter [A] between these con• Connect
nectors as shown in the figure.
Main Harness [B]
Gear Position Switch Lead Connector [C]
Special Tool - Measuring Adapter: 57001-1700
a digital meter [D] to the measuring adapter
• Connect
leads.
Gear Position Switch Output Voltage
Connections to Adapter:
Digital Meter (+) → R (switch BL) lead
Digital Meter (–) → Battery (–) terminal
the switch output voltage with the engine
• Measure
stopped and with the connector joined.
the ignition switch ON.
•○Turn
When changing the gear position from lower gear to
higher gear, raise the rear wheel off the ground with
the jack (see Rear Wheel Removal in the Wheels/Tires
chapter) and rotate the rear wheel by hand.
Special Tool - Jack: 57001-1238
Output Voltage at 1 ∼ 6 Gear Positions
Standard:
1st
About 3.0 V
2nd
About 2.5 V
3rd
About 2.0 V
4th
About 1.5 V
5th
About 1.1 V
6th
About 0.7 V
FUEL SYSTEM (DFI) 3-65
Gear Position Switch (Service Code 25)
the ignition switch OFF.
• Turn
If the reading is out of the standard, check the wiring for
continuity, using the wiring diagram in this section.
Special Tool - Hand Tester: 57001-1394
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
Gear Position Switch Circuit
1. ECU
2. Gear Position Switch
3. Battery
4. Engine Ground
3-66 FUEL SYSTEM (DFI)
Vehicle-down Sensor (Service Code 31)
This sensor has a weight [A] with two magnets inside,
and sends a signal to the ECU. But when the motorcycle
banks 60 ∼ 70° or more to either side (in fact falls down),
the weight turns and the signal changes. The ECU senses
this change, and stops the fuel pump relay, the fuel injectors
(primary and secondary) and the ignition system.
Hall IC [B]
When the motorcycle is down, the ignition switch is left
ON. If the starter button is pushed, the electric starter turns
but the engine does not start. To start the engine again,
raise the motorcycle, turn the ignition switch OFF, and then
ON.
Vehicle-down Sensor [A]
Ground Terminal [B]: BR/Y
Output Terminal [C]: Y/R
Power Source Terminal [D]: BL
Vehicle-down Sensor Removal
CAUTION
Never drop the vehicle-down sensor, especially on
a hard surface. Such a shock to the sensor can
damage it.
• Remove:
Battery Case Cover (see Battery Removal in the Electrical System chapter)
Fuse Box 1 [A]
Fuse Box 2 [B]
○Push the stopper [C] of the fuse box and pull out it upward.
• Remove:
Connector [A]
Bolts [B]
Vehicle-down Sensor [C]
FUEL SYSTEM (DFI) 3-67
Vehicle-down Sensor (Service Code 31)
Vehicle-down Sensor Installation
UP mark [A] of the sensor should face upward.
• The
Tighten
the vehicle-down senor bolts securely.
•
WARNING
Incorrect installation of the vehicle-down sensor
could cause sudden loss of engine power. The
rider could lose balance during certain riding situations like leaning over in a turn with the potential
for an accident resulting in injury or death. Ensure
that the vehicle-down sensor is held in place by the
battery case.
Vehicle-down Sensor Input Voltage Inspection
NOTE
○Be sure the battery is fully charged.
the vehicle-down sensor (see Vehicle-down
• Remove
Sensor Removal).
the measuring adapter [A] between the main har• Connect
ness connector and vehicle-down sensor connector as
shown in the figure.
Main Harness [B]
Vehicle-down Sensor [C]
Special Tool - Measuring Adapter: 57001-1700
a digital meter [D] to the measuring adapter
• Connect
leads.
Vehicle-down Sensor Input Voltage
Connections to Adapter:
Digital Meter (+) → R (main harness BL) lead
Digital Meter (–) → BK (main harness BR/Y) lead
the input voltage with the engine stopped and
• Measure
with the connector joined.
• Turn the ignition switch ON.
Input Voltage
Standard: DC 4.75 ∼ 5.25 V
the ignition switch OFF.
• Turn
If the reading is within the standard, check the output voltage (see Vehicle-down Sensor Output Voltage Inspection).
3-68 FUEL SYSTEM (DFI)
Vehicle-down Sensor (Service Code 31)
If the reading is out of the standard, remove the ECU
and check the wiring for continuity between main harness
connectors.
Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Vehicle-down Sensor Connector [B]
BL lead (ECU terminal 48) [C]
BR/Y lead (ECU terminal 55) [D]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
Vehicle-down Sensor Output Voltage Inspection
the output voltage at the vehicle-down sensor in
• Measure
the same way as input voltage inspection, note the following.
○Connect the measuring adapter [A] between the main harness connector and vehicle-down sensor connector as
shown in the figure.
Special Tool - Measuring Adapter: 57001-1700
•
Main Harness [B]
Vehicle-down Sensor [C]
Connect a digital meter [D] to the measuring adapter
leads.
Vehicle-down Sensor Output Voltage
Connections to Adapter:
Digital Meter (+) → W (main harness Y/R) lead
Digital Meter (–) → BK (main harness BR/Y) lead
FUEL SYSTEM (DFI) 3-69
Vehicle-down Sensor (Service Code 31)
the sensor vertically.
• Hold
Measure
the output voltage with the engine stopped, and
• with the connector
joined.
the ignition switch ON.
• Turn
Tilt
the
sensor 40 ∼ 50° or more [A] right or left, then hold
• the sensor
almost vertical with the arrow mark pointed up
[B], and measure the output voltage.
Output Voltage
Standard: With sensor tilted 40 ∼ 50° or more right or
left: DC 0.65 ∼ 1.35 V
With sensor arrow mark pointed up: DC
3.55 ∼ 4.45 V
NOTE
○If you need to test again, turn the ignition switch OFF,
and then ON.
the ignition switch OFF.
• Turn
If the reading is out of the standard, replace the sensor.
If the reading is within the standard, remove the ECU and
check the wiring for continuity between main harness connectors.
Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Vehicle-down Sensor Connector [B]
Y/R lead (ECU terminal 52) [C]
BR/Y lead (ECU terminal 55) [D]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
3-70 FUEL SYSTEM (DFI)
Vehicle-down Sensor (Service Code 31)
Vehicle-down Sensor Circuit
1. ECU
2. Vehicle-down Sensor
FUEL SYSTEM (DFI) 3-71
Oxygen Sensor - not activated (Service Code 33, Equipped Models)
Oxygen Sensor Removal/Installation
to the Oxygen Sensor Removal/Installation
• Refer
(Equipped Models) in the Electrical System chapter.
Oxygen Sensor Inspection
up the engine thoroughly until the radiator fan
• Warm
starts.
the ignition switch OFF.
• Turn
Remove:
• Right Side Cover (see Side Cover Removal in the Frame
chapter)
Oxygen Sensor Connector [A]
the measuring adapter [A] between the main
• Connect
harness connector and oxygen sensor lead connector as
shown in the figure.
Main Harness [B]
Oxygen Sensor [C]
Special Tool - Measuring Adapter: 57001-1700
• Connect a digital meter [D] to the harness adapter leads.
Oxygen Sensor Output Voltage
Connections to Adapter:
Digital Meter (+) → R (sensor BK) lead
Digital Meter (–) → BK (sensor GY) lead
the fuel tank (see Fuel Tank Removal).
• Remove
Separate
the air switching valve hoses [A] from the air
• switching valve.
3-72 FUEL SYSTEM (DFI)
Oxygen Sensor - not activated (Service Code 33, Equipped Models)
○Do not disconnect the air switching valve connector [A].
the air switching valve hose ends [A], and shut off
• Plug
the secondary air.
the following parts temporarily.
• Connect
Fuel Pump/Fuel Level Sensor Lead Connector [A]
Fuel Hose (see Fuel Tank Installation)
the engine, and let it idle.
• Start
Measure
the output voltage with the connector joined.
•
Output Voltage (with Plugs)
Standard: DC 0.8 V or more
remove the plugs from the air switching valve hoses
• Next,
[A] with idling.
• Measure the output voltage with the connector joined.
Output Voltage (without Plugs)
Standard: DC 0.24 V or less
• Turn the ignition switch OFF.
FUEL SYSTEM (DFI) 3-73
Oxygen Sensor - not activated (Service Code 33, Equipped Models)
If the reading is out of the standard (with plugs: 0.8 V
or more, without plugs: 0.24 V or less), remove the ECU
and check the wiring for continuity between main harness
connectors.
Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Oxygen Sensor Connector [B]
GY/R lead (ECU terminal 54) [C]
BR/Y lead (ECU terminal 55) [D]
If the wiring is good, replace the sensor.
If the reading is within the standard (with plugs: 0.8 V
or more, without plugs: 0.24 V or less), check the ECU
for its ground and power supply (see ECU Power Supply
Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
Oxygen Sensor Circuit
1. ECU
2. Oxygen Sensor
3. Oxygen Sensor Heater Fuse 10 A
4. Ignition Switch
5. Main Fuse 30 A
6. Battery
7. Engine Ground
8. Frame Ground 3
3-74 FUEL SYSTEM (DFI)
Fuel Pump Relay (Service Code 46)
Fuel Pump Relay Removal/Installation
○The fuel pump relay is built in the relay box [A].
to the Relay Box Removal in the Electrical System
• Refer
chapter.
Fuel Pump Relay Inspection
to the Relay Circuit Inspection in the Electrical Sys• Refer
tem chapter.
If the fuel pump relay is normal, check the wiring for continuity (see wiring diagram in this section).
Special Tool - Hand Tester: 57001-1394
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
Fuel Pump Relay Circuit
1. ECU
2. Engine Stop Switch
3. Ignition Switch
4. Frame Ground 3
5. Relay Box
6. Fuel Pump Relay
7. Ignition Fuse 10 A
8. ECU Fuse 10 A
9. Fuel Pump
10. Main Fuse 30 A
11. Battery
12. Engine Ground
FUEL SYSTEM (DFI) 3-75
Return Spring (Service Code 49)
Return Spring Removal
CAUTION
Do not remove return spring in the gear case [A]
since it has been set with precision at the factory.
Return Spring Inspection
the ignition switch OFF.
• Turn
Remove
• Right Air Cleaner Housing (see Right Air Cleaner Hous-
•
ing Removal)
Check that the throttle valves [A] move lightly by pushing
finger without the spring force.
If the throttle valves move lightly, the return spring is broken, replace the throttle body assy.
If the throttle valves move hardly and return them by the
return spring, check the output voltage of the throttle position sensor 1 (see Throttle Position Sensor Output Voltage Inspection).
If the output voltage is good, replace the ECU (see ECU
Removal/Installation).
3-76 FUEL SYSTEM (DFI)
Ignition Coils #1, #2 (Service Code 51, 52)
Ignition Coil #1 (Front Cylinder): Service Code 51
Ignition Coil #2 (Rear Cylinder): Service Code 52
Ignition Coil Removal/Installation
to the Ignition Coil Removal/Installation in the Elec• Refer
trical System chapter.
Ignition Coil Primary Winding Resistance
Inspection
to the Ignition Coil Inspection in the Electrical Sys• Refer
tem chapter.
If the reading is within the standard, check the input voltage (see Ignition Coil Input Voltage Inspection).
Ignition Coil Input Voltage Inspection
NOTE
○Be sure the battery is fully charged.
the ignition switch OFF.
• Turn
Remove:
• Front Seat (see Front Seat Removal in the Frame chap-
•
ter)
Battery Case Cover (see Battery Removal in the Electrical System chapter)
Connect the digital meter to the connector [A] with the
needle adapter set.
Special Tool - Needle Adapter Set: 57001-1457
Ignition Coil Input Voltage
Connections:
For Ignition Coil #1
Digital Meter (+) → BK/O lead (terminal 26)
Digital Meter (–) → Battery (–) terminal
For Ignition Coil #2
Digital Meter (+) → BK lead (terminal 1)
Digital Meter (–) → Battery (–) terminal
the input voltage to each primary winding of the
• Measure
ignition coils with the engine stopped, and with the con-
•
•
nectors joined.
Turn the engine stop switch to run position.
Turn the ignition switch ON.
Input Voltage
Standard: about Battery Voltage
the ignition switch OFF.
• Turn
If
the
input voltage is within the standard, replace the ECU
• (see ECU
Removal/Installation).
If the input voltage is out of the standard, check the wiring
for continuity (see Ignition Coil Circuit).
Special Tool - Hand Tester: 57001-1394
If the wiring is good, replace the ECU (see ECU Removal/Installation).
If the wiring is not good, replace the main harness.
FUEL SYSTEM (DFI) 3-77
Ignition Coils #1, #2 (Service Code 51, 52)
Ignition Coil Circuit
1. ECU
2. Ignition Coil #2 (Rear Cylinder)
3. Ignition Coil #1 (Front Cylinder)
4. Engine Stop Switch
5. Ignition Switch
6. Main Fuse 30 A
7. Ignition Fuse 10 A
8. Battery
9. Engine Ground
10. Frame Ground 3
3-78 FUEL SYSTEM (DFI)
Radiator Fan Relay (Service Code 56)
Radiator Fan Relay Removal/Installation
○The radiator fan relay is built in the relay box [A].
to the Relay Box Removal in the Electrical System
• Refer
chapter.
Radiator Fan Relay Inspection
to the Relay Circuit Inspection in the Electrical Sys• Refer
tem chapter.
If the radiator fan relay is normal, check the wiring for
continuity (see wiring diagram in this section).
Special Tool - Hand Tester: 57001-1394
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
Radiator Fan Relay Circuit
1. Ignition Switch
2. Joint Connector 1
3. Frame Ground 1
4. Fan Motor
5. Water Temperature Sensor
6. ECU
7. Fan Relay
8. Relay Box
9. Ignition Fuse 10 A
10. Fan Fuse 10 A
11. Engine Ground
12. Battery
13. Main Fuse 30 A
14. Frame Ground 3
FUEL SYSTEM (DFI) 3-79
ETV Acutuator (Service Code 58)
ETV Actuator Removal
CAUTION
Do not remove ETV actuator in the gear case [A]
since it has been set with precision at the factory.
ETV Actuator Input Voltage Inspection
NOTE
○Be sure the battery is fully charged.
the ignition switch OFF.
• Turn
• Remove:
Front Seat (see Front Seat Removal in the Frame chapter)
Battery Case Cover (see Battery Removal in the Electrical System chapter)
the digital meter to the connector [A] with the
• Connect
needle adapter set.
Special Tool - Needle Adapter Set: 57001-1457
ETV Actuator Input Voltage
Connection:
Digital Meter (+) → GY/BK lead (ECU terminal 6)
Digital Meter (−) → LG lead (ECU terminal 7)
the ignition switch ON.
• Turn
Measure
the voltage.
•
Input Voltage
Standard: about DC 1 ~ 2 V
the ignition switch OFF.
• Turn
If the reading is out of the standard, check the following
items.
ETV Actuator Relay (see ETV Actuator Relay Inspection)
Wiring (using the ETV Actuator Circuit)
If the above items are good, replace the throttle body assy
(see Throttle Body Assy Removal/Installation) and/or the
ECU (see ECU Removal/Installation).
3-80 FUEL SYSTEM (DFI)
ETV Acutuator (Service Code 58)
ETV Actuator Resistance Inspection
• Remove:
Front Seat (see Front Seat Removal in the Frame chapter)
ETV Actuator Relay [A]
the hand tester [A] and a 12 V battery [B] to the
• Connect
relay [C] as shown in the figure.
Special Tool - Hand Tester: 57001-1394
If the relay does not work as specified, the relay is defective. Replace the relay.
Testing Relay
Hand Tester Range: × 1 Ω
Criteria:
When battery is connected ⇒ 0 Ω
When battery is disconnected ⇒ ∞Ω
Relay Coil Terminals: [1] and [2]
Relay Switch Terminals: [3] and [4]
ETV Actuator Circuit
1. ECU
2. ETV Actuator Relay
3. Throttle Position Sensor/ETV Actuator
4. ETV Actuator
5. ETV Actuator Relay Fuse 10 A
6. Main Fuse 30 A
7. Battery
FUEL SYSTEM (DFI) 3-81
Air Switching Valve (Service Code 64)
Air Switching Valve Removal/Installation
to the Air Switching Valve Removal/Installation in
• Refer
the Engine Top End chapter.
Air Switching Valve Inspection
to the Air Switching Valve Unit Test in the Electrical
• Refer
System chapter.
If the air switching valve is normal, check the wiring for
continuity, using the wiring diagram in this section.
Special Tool - Hand Tester: 57001-1394
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
Air Switching Valve Circuit
1. ECU
2. Air Switching Valve
3. Engine Stop Switch
4. Ignition Switch
5. Ignition Fuse 10 A
6. ECU Fuse 10 A
7. Main Fuse 30 A
8. Battery
9. Engine Ground
10. Relay Box
11. Fuel Pump Relay
12. Frame Ground 3
3-82 FUEL SYSTEM (DFI)
Oxygen Sensor Heater (Service Code 67, Equipped Models)
Oxygen Sensor Heater Removal/Installation
The oxygen sensor heater is built in the oxygen sensor.
So, the heater itself can not be removed. Remove the oxygen sensor (see Oxygen Sensor Removal (Equipped Models) in the Electrical System chapter).
Oxygen Sensor Heater Resistance Inspection
the ignition switch OFF.
• Turn
• Remove:
Right Side Cover (see Side Cover Removal in the Frame
chapter)
Oxygen Sensor Connector [A]
CAUTION
Do not pull strongly, twist, or bend the oxygen sensor lead. This may cause the wiring open.
a digital meter [A] to the terminals in each oxygen
• Connect
sensor lead connector [B].
• Measure the oxygen sensor heater resistance.
Oxygen Sensor Heater Resistance
Connections: W lead [C] ←→ W lead [D]
Standard: 6.7 ∼ 10.5 Ω at 20° (68°F)
If the reading is out of the standard, replace the sensor.
If the reading is within the standard, check the power
source voltage (see Oxygen Sensor Heater Power
Source Voltage Inspection).
FUEL SYSTEM (DFI) 3-83
Oxygen Sensor Heater (Service Code 67, Equipped Models)
Oxygen Sensor Heater Power Source Voltage
Inspection
NOTE
○Be sure the battery is fully charged.
the ignition switch OFF.
• Turn
Disconnect
the oxygen sensor lead connector and con• nect the measuring
adapter [A] between these connectors as shown in the figure.
Main Harness [B]
Oxygen Sensor [C]
Special Tool - Measuring Adapter: 57001-1700
a digital meter [D] to the measuring adapter
• Connect
leads.
Oxygen Sensor Heater #1 and #2 Power Source Voltage
Connections to Adapter:
Digital Meter (+) → R (main harness W/G) lead
Digital Meter (–) → Battery (–) terminal
the power source voltage with
• Measure
stopped and with the connector joined.
• Turn the ignition switch ON.
the engine
Power Source Voltage
Standard: Battery Voltage
the ignition switch OFF.
• Turn
If the reading is in specification, but the problem still exists, replace the ECU (see ECU Removal/Installation).
If the reading is out of the standard, check the following.
Oxygen Sensor Heater Fuse 10 A (see Fuse Inspection
in the Electrical System chapter)
Power Source Wiring (see wiring diagram in this section)
If the fuse and wiring are good, remove the ECU and
check the wiring for continuity between main harness connectors.
Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Oxygen Sensor Connector [B]
P/BL lead (ECU terminal 28) [C]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
3-84 FUEL SYSTEM (DFI)
Oxygen Sensor Heater (Service Code 67, Equipped Models)
Oxygen Sensor Circuit
1. ECU
2. Oxygen Sensor
3. Oxygen Sensor Heater Fuse 10 A
4. Ignition Switch
5. Main Fuse 30 A
6. Battery
7. Engine Ground
8. Frame Ground 3
FUEL SYSTEM (DFI) 3-85
Battery Voltage (Service Code 97)
Battery Voltage Inspection
to the Charging Condition Inspection in the Electri• Refer
cal System chapter for battery voltage inspection.
If the battery voltage is good condition, replace the ECU
(see ECU Removal/Installation).
Battery Monitor Circuit
1. ECU
2. Engine Stop Switch
3. Ignition Switch
4. Frame Ground 3
5. Relay Box
6. Fuel Pump Relay
7. Ignition Fuse 10 A
8. ECU Fuse 10 A
9. Fuel Pump
10. Main Fuse 30 A
11. Battery
12. Engine Ground
3-86 FUEL SYSTEM (DFI)
ETV Control Circuit (Service Code 98)
ETV Control Circuit Inspection
○The ETV control circuit is controlled in the ECU [A].
•
So, the ETV control circuit cannot be inspected.
When the service code 98 is displayed on the LCD, replace the ECU (see ECU Removal/Installation).
FUEL SYSTEM (DFI) 3-87
Warning Indicator Light (LED)
Light (LED) Inspection
○The warning indicator light (LED) [A] is used for the FI indicator, ETV (Electrical Throttle Valve) indicator, oil pressure warning indicator and battery warning indicator.
○In this model, the warning indicator light (LED) goes on or
blinks by the data sent from the ECU.
Refer to the Meter Unit Inspection in the Electrical System
chapter.
•
Warning Indicator Light (LED) Circuit
1. ECU
2. Oil Pressure Switch
3. Meter Unit
4. Warning Indicator Light (LED)
3-88 FUEL SYSTEM (DFI)
ECU
ECU Identification
○Most countries have their own regulations, so each ECU
has different characteristic. So, do not confuse ECU with
each other and use only the ECU for your model. Otherwise, the motorcycle can not clear the regulation.
ECU Identification
Part Number [A]
Specification
US
21175-0176
CA
CAL
WVTA (FULL H)
21175-0186
GB WVTA (FULL H)
AU
SEA
ECU Removal
CAUTION
Never drop the ECU, especially on a hard surface.
Such a shock to the ECU can damage it.
• Remove:
Front Seat (see Front Seat Removal in the Frame chapter)
Battery Case Cover (see Battery Removal in the Electrical System chapter)
Turn Signal Control Relay [A]
Remove the ECU [B] with bracket [C].
•
the ECU connectors [A].
• Disconnect
Remove
the
ECU [B] from the rubber protector [C].
•
ECU Installation
• Install:
ECU (in Rubber Protector)
•
•
ECU Connectors
Fit the hooks [A] of the bracket [B] into the recesses [C]
of the battery case.
Install the removed parts.
NOTE
○When the ECU was replaced with a new one, do not
remove the battery, fuse or ECU for 6 seconds for the
learning control of the ECU after the ignition switch is
turned off.
○The ECU does the learning control that is to memorize
the full closing position and full opening position of the
throttle valve for 6 seconds after the ignition switch is
turned OFF.
FUEL SYSTEM (DFI) 3-89
ECU
ECU Power Supply Inspection
• Remove:
Front Seat (see Front Seat Removal in the Frame chap•
•
•
ter)
Battery Case Cover (see Battery Removal in the Electrical System chapter)
Visually inspect the ECU connectors.
If the connector is clogged with mud or dust, blow it off
with compressed air.
Remove the ECU (see ECU Removal).
Visually inspect the terminals [A] of the ECU connectors.
If the terminals of the main harness connectors are damaged, replace the main harness.
If the terminals of the ECU connectors are damaged, replace the ECU.
the ignition switch OFF.
• Turn
Disconnect
ECU connectors [A].
• Set the handthetester
[B] to the × 1 Ω range and check the
• following wiring for continuity.
Special Tool - Hand Tester: 57001-1394
ECU Grounding Inspection
Connections:
(I) BK/Y leads (ECU
terminal 10, 18 or 34)
←→ Battery (–) Terminal
(II) Engine Ground
←→ Battery (–) Terminal
Criteria:
Both: 0 Ω
If no continuity, check the connectors, the engine ground
lead, or main harness, and repair or replace them if necessary.
If the wiring is good, check the power source voltage of
the ECU.
NOTE
○Be sure the battery is fully charged.
the ECU connectors.
• Connect
Connect
a digital meter [A] to the connector [B] with the
• needle adapter
set.
Special Tool - Needle Adapter Set: 57001-1457
ECU Power Supply Inspection
Connections:
(I) Digital Meter (+) → Terminal 44 (BR/W)
Digital Meter (–) → Battery (–) terminal
(II) Digital Meter (+) → Terminal 60 (W/BK)
Digital Meter (–) → Battery (–) terminal
Ignition Switch OFF:
Terminal 44 (BR/W): 0 V
Terminal 60 (W/BK): Battery Voltage
Ignition Switch ON:
Both: Battery Voltage
3-90 FUEL SYSTEM (DFI)
ECU
If the reading is out of the specification, check the following.
Main Fuse 30 A (see Fuse Inspection in the Electrical
System chapter)
ECU Fuse 10 A (see Fuse Inspection Electrical System
chapter)
Power Source Wiring (see ECU Power Source Circuit)
If the fuse and wiring are good, replace the ECU (see ECU
Removal/Installation).
ECU Power Source Circuit
1. Ignition Switch
2. Ignition Fuse 10A
3. ECU Fuse 10 A
4. Main Fuse 30 A
5. Battery
6. Engine Ground
7. Frame Ground 3
8. Frame Ground 6
9. ECU
FUEL SYSTEM (DFI) 3-91
DFI Power Source
ECU Fuse Removal
to the 10 A ECU Fuse Removal in the Electrical
• Refer
System chapter.
ECU Fuse Installation
•
If a fuse fails during operation, inspect the DFI system to
determine the cause, and then replace it with a new fuse
of proper amperage.
Refer to the Fuse Installation in the Electrical System
chapter.
ECU Fuse Inspection
to the Fuse Inspection in the Electrical System
• Refer
chapter.
ECU Main Relay Removal/Installation
○The ECU main relay function is included in the ECU [A]
and can not be removed.
ECU Main Relay Inspection
○The ECU main relay function is included in the ECU [A]
and can not be inspected.
3-92 FUEL SYSTEM (DFI)
Fuel Line
Fuel Pressure Inspection
NOTE
○Be sure the battery is fully charged.
• Remove:
Fuel Hose (see Fuel Hose Replacement in the Periodic
Maintenance chapter)
○Be sure to place a piece of cloth around the fuel outlet
pipe of the fuel pump and the delivery pipe of the throttle
body assy.
WARNING
Be prepared for fuel spillage; any spilled fuel must
be completely wiped up immediately.
When the fuel hose is disconnected, fuel spills out
from the hose and the pipe because of residual
pressure. Cover the hose connection with a piece
of clean cloth to prevent fuel spillage.
the fuel pressure gauge adapter [A] and fuel hoses
• Install
(Special Tool: 57001-1607) [B] between the fuel outlet
•
•
pipe and delivery pipe.
Secure the fuel hoses with the clamps.
Connect the pressure gauge [C] to the fuel pressure
gauge adapter.
Special Tools - Oil Pressure Gauge, 5 kgf/cm²: 57001-125
Fuel Pressure Gauge Adapter: 57001-1593
Fuel Hose: 57001-1607
WARNING
Do not try to start the engine with the fuel hoses
disconnected.
the engine stop switch run position.
• Turn
Turn
the ignition switch ON.
•○The fuel
pump should operate for 3 seconds, and then
should stop.
○After
NOTE
turning on the engine stop switch and ignition
switch, inspect the fuel leakage from the connected
portion of the special tools.
CAUTION
Do not drive the fuel pump 3 seconds or more without the fuel in the fuel tank. If the fuel pump is driven
without the fuel, it may be damaged.
the engine, and let it idle.
• Start
• Measure the fuel pressure with the engine idling.
Fuel Pressure (with Engine Idling)
Standard: 294 kPa (3.0 kgf/cm², 43 psi)
FUEL SYSTEM (DFI) 3-93
Fuel Line
NOTE
○The gauge needle will fluctuate.
Read the pressure at
the average of the maximum and minimum indications.
the ignition switch OFF.
• Turn
If the fuel pressure is much higher than specified, replace
•
•
•
•
the fuel pump because the fuel pressure regulator in the
fuel pump have been clogged or stuck.
If the fuel pressure is much lower than specified, check
the following.
Fuel Line Leakage (see Fuel Injector Fuel Line Inspection)
Amount of Fuel Flow (see Fuel Flow Rate Inspection)
After above checks, measure the fuel pressure again.
Remove the fuel pressure gauge, hoses and adapter.
Install:
Fuel Hose (see Fuel Hose Replacement in the Periodic
Maintenance chapter)
Fuel Tank (see Fuel Tank Installation)
Start the engine and check for fuel leakage.
Fuel Flow Rate Inspection
WARNING
Gasoline is extremely flammable and can be explosive under certain conditions. Make sure the area
is well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light. Do not smoke. Turn the ignition switch OFF.
Be prepared for fuel spillage; any spilled fuel must
be completely wiped up immediately.
NOTE
○Be sure the battery is fully charged.
the ignition switch OFF.
• Turn
until the engine cools down.
• Wait
Prepare
hose (Special Tool:
• measuringa fuel
cylinder.
57001-1607) and a
Special Tool - Fuel Hose: 57001-1607
• Remove the fuel tank bolts.
the fuel tank cap [A] to lower the pressure in the
• Open
tank.
the fuel hose from the fuel pump (see Fuel Tank
• Remove
Removal).
○Be sure to place a piece of cloth around the fuel outlet
pipe of the fuel pump.
WARNING
Be prepared for fuel spillage; any spilled fuel must
be completely wiped up immediately.
When the fuel hose is disconnected, fuel spills out
from the hose and the pipe because of residual
pressure. Cover the hose connection with a piece
of clean cloth to prevent fuel spillage.
3-94 FUEL SYSTEM (DFI)
Fuel Line
the prepared fuel hose [A] to the fuel outlet pipe.
• Connect
Secure
the
hose with a clamp.
• Insert the fuelfuelhose
into the measuring cylinder [B].
•
WARNING
Wipe off spilled out fuel immediately.
Be sure to hold the measuring cylinder vertical.
the fuel tank cap.
• Close
Turn
the
stop switch to run position.
• Turn the engine
ignition
switch ON.
•○The fuel pump should
operate for 3 seconds, and then
should stop.
CAUTION
Do not drive the fuel pump 3 seconds or more without the fuel in the fuel tank. If the fuel pump is driven
without the fuel, it may be damaged.
the discharge for 3 seconds.
•○Measure
Repeat this operation several times.
Amount of Fuel Flow
Standard: 29 mL (0.98 US oz.) or more for 3 seconds
the ignition switch OFF.
• Turn
If the fuel flow is much less than the specified, replace the
•
•
fuel pump (see Fuel Pump Removal/Installation).
Install the fuel tank (see Fuel Tank Installation).
Start the engine and check for fuel leakage.
FUEL SYSTEM (DFI) 3-95
Fuel Pump
Fuel Pump Removal
WARNING
Gasoline is extremely flammable and can be explosive under certain conditions. Make sure the area
is well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light. Do not smoke. Turn the ignition switch OFF
and disconnect the battery (–) terminal.
To make fuel spillage minimum, draw the fuel out
from the fuel tank when the engine is cold. Be
prepared for fuel spillage; any spilled fuel must be
completely wiped up immediately.
CAUTION
Never drop the fuel pump, especially on a hard surface. Such a shock to the pump can damage it.
the fuel out from the fuel tank with a commercially
• Draw
available electric pump.
the fuel tank (see Fuel Tank Removal).
•○Remove
Be careful of fuel spillage from the fuel tank since fuel still
remains in the fuel tank and fuel pump. Plug the fuel pipe
of the fuel tank.
the fuel tank upside down.
• Turn
Unscrew
• pump [B].the fuel pump bolts [A], and take out the fuel
CAUTION
Do not pull the leads of the fuel pump. If they are
pulled, the lead terminals may be damaged.
• Discard the fuel pump gasket [A].
3-96 FUEL SYSTEM (DFI)
Fuel Pump
Fuel Pump Installation
dirt or dust from the fuel pump [A] by lightly ap• Remove
plying compressed air.
• Replace the fuel pump gasket with a new one.
that the fuel pump terminal [A] and band [B] are in
• Check
place.
•
•
200 ±10 mm (7.87 ±0.39 in.) [C]
Connector [D]
Front [E]
Apply a non-permanent locking agent to the threads of
the fuel pump bolts.
Following the tightening sequence as shown in the figure,
tighten the fuel pump bolts to the specified torque.
Torque - Fuel Pump Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
the pump bolts again to check the tightness in the
• Tighten
order shown.
Fuel Pump Operation Inspection
NOTE
○Be sure the battery is fully charged.
the engine stop switch to run position.
• Turn
Turn
ignition switch ON and make sure that the fuel
• pumptheoperates
(make light sounds) for 3 seconds, and
•
then stops.
Turn the ignition switch OFF.
If the pump does not operate as described above, check
the operating voltage (see Fuel Pump Operating Voltage
Inspection).
Fuel Pump Operating Voltage Inspection
NOTE
○Be sure the battery is fully charged.
• Turn the ignition switch OFF.
• Remove:
Front Seat (see Front Seat Removal in the Frame chap•
ter)
Fuel Tank Mounting Bolts [A]
Bracket [B]
Lift up the rear end of the fuel tank, using a suitable wood
block.
FUEL SYSTEM (DFI) 3-97
Fuel Pump
the fuel pump lead connector and connect
• Disconnect
the measuring adapter [A] between these connectors as
shown in the figure.
Main Harness [B]
Fuel Pump [C]
Special Tool - Measuring Adapter: 57001-1700
a digital meter [D] to the measuring adapter
• Connect
leads.
Fuel Pump Operating Voltage
Connections to Adapter:
Digital Meter (+) → R (pump BK/Y) lead
Digital Meter (–) → BK (pump BK/W) lead
the operating voltage with engine stopped and
• Measure
with the connector joined.
the engine stop switch run position.
• Turn
Turn
• the ignition switch ON.
Operating Voltage
Standard: Battery Voltage for 3 seconds, and then 0 V
the ignition switch OFF.
• Turn
If the reading is not the standard, check the fuel pump relay (see Relay Circuit Inspection in the Electrical System
chapter).
If the fuel pump relay is normal, check the wiring for continuity (see Fuel Pump Circuit).
Special Tool - Hand Tester: 57001-1394
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
If the reading is in the specification, but the pump does
not operate, replace the fuel pump (see Fuel Pump Removal/Installation).
Pressure Regulator Removal
○The pressure regulator [A] is built into the fuel pump and
can not be removed.
3-98 FUEL SYSTEM (DFI)
Fuel Pump
Fuel Filter Cleaning
○The fuel filter [A] is built into the pump and can not be
cleaned or checked.
If the fuel filter is suspected of clogging or being damaged,
replace it with the fuel pump as a set.
Fuel Pump Circuit
1. ECU
2. Engine Stop Switch
3. Ignition Switch
4. Frame Ground 3
5. Relay Box
6. Fuel Pump Relay
7. Ignition Fuse 10 A
8. ECU Fuse 10 A
9. Fuel Pump
10. Main Fuse 30 A
11. Battery
12. Engine Ground
FUEL SYSTEM (DFI) 3-99
Fuel Injectors
Fuel Injector Removal
• Remove:
Fuel Tank (see Fuel Tank Removal)
Throttle Body Assy (see Throttle Body Assy Removal)
Fuel Injector Connectors [A]
• Remove:
Delivery Joint Bolt [A]
Bracket [B]
• Remove:
Delivery Joint Bolt [A]
Bracket [B]
• Remove:
Delivery Joint Assembly [A]
• Remove:
Fuel Injectors [A]
3-100 FUEL SYSTEM (DFI)
Fuel Injectors
Fuel Injector Installation
installing the fuel injector, blow away dirt or dust
• Before
from the delivery joint by applying compressed air.
the O-rings [A] of each fuel injector with new
• Replace
ones.
engine oil to the new O-rings, insert them to the de• Apply
livery joint assembly [B] and confirm whether the injectors
•
•
•
•
•
•
turn smoothly or not.
Replace the dust seals [C] with new ones.
Apply engine oil to the new dust seals.
Be sure that the pins [D] are in position.
Install the delivery joint assembly and brackets [E] as
shown in the figure.
Apply a non-permanent locking agent to the delivery joint
bolts.
Tighten:
Torque - Delivery Joint Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
the fuel injector lead connectors.
•○Connect
The front fuel injector lead has a tag of “F” mark.
• Install the removed parts.
Fuel Injector Audible Inspection
NOTE
○Be sure the battery is fully charged.
the engine, and let it idle.
• Start
Apply
tip of a screwdriver [A] to the fuel injector. Put
• the griptheend
onto your ear, and listen whether the fuel
injector is clicking or not.
Fuel Injector [B]
A
○ sound scope can also be used.
○The click interval becomes shorter as the engine speed
rises.
Do the same for the other fuel injectors.
If all the fuel injectors click at regular intervals, the fuel
injectors are normal.
Turn the ignition switch OFF.
If any fuel injector does not click, check the fuel injector
resistance (see Fuel Injector Resistance Inspection).
•
•
Fuel Injector Resistance Inspection
the ignition switch OFF.
• Turn
Remove:
• Front Seat (see Front Seat Removal in the Frame chap-
•
ter)
Battery Case Cover (see Battery Removal in the Electrical System chapter)
Disconnect the ECU connectors [A].
FUEL SYSTEM (DFI) 3-101
Fuel Injectors
the digital meter [A] to the harness connectors
• Connect
[B] with the needle adapter set.
Special Tool - Needle Adapter Set: 57001-1457
Fuel Injector Resistance
Connection:
Fuel Injector #1
Digital Meter → BL/O lead (ECU terminal 27)
Digital Meter → W/R lead (ECU terminal 35)
Fuel Injector #2
Digital Meter → BL/Y lead (ECU terminal 2)
Digital Meter → W/R lead (ECU terminal 35)
• Measure the throttle position sensor resistance.
Fuel Injector Resistance
Standard: About 11.7 ∼ 12.3 Ω at 20 °C (68 °F)
If the reading is within the standard, check the output voltage (see Fuel Injector Output Voltage Inspection).
If the reading is out of the standard, replace the fuel injector (see Fuel Injector Removal/Installation) or check the
wiring for continuity (see Fuel Injector Circuit).
Fuel Injector Output Voltage Inspection
NOTE
○Be sure the battery is fully charged.
the ignition switch OFF.
• Turn
Remove:
• Front Seat (see Front Seat Removal in the Frame chapter)
Battery Case Cover (see Battery Removal in the Electrical System chapter)
the hand tester [A] to the connector joined with
• Connect
the needle adapter set.
Special Tools - Hand Tester: 57001-1394
Needle Adapter Set: 57001-1457
Fuel Injector Output Voltage
Connections ECU Connector:
Fuel Injector #1
Digital Meter (+) → BL/O lead (ECU terminal 27)
Digital Meter (−) → Battery (−) terminal [C]
Fuel Injector #2
Digital Meter (+) → BL/Y lead (ECU terminal 2)
Digital Meter (−) → Battery (−) terminal [C]
the engine stop switch to run position.
• Turn
Turn
the ignition switch ON.
• Measure
the output voltage.
•
Output Voltage
Standard: About Battery Voltage for 3 seconds, and
then 0 V
3-102 FUEL SYSTEM (DFI)
Fuel Injectors
the ignition switch OFF.
• Turn
If the reading is in the specification, but the injector does
not operate, replace the ECU (see ECU Removal/Installation).
If the reading is out of the specification, check the input
voltage (see Fuel Injector Input Voltage Inspection).
Fuel Injector Input Voltage Inspection
NOTE
○Be sure the battery is fully charged.
the ignition switch OFF.
• Turn
Remove:
• Fuel Tank (see Fuel Tank Removal)
Right Air Cleaner Housing (see Right Air Cleaner Housing Removal)
the injector connector and connect the mea• Disconnect
suring adapter [A] between these connectors as shown in
the figure.
Main Harness [B]
Fuel Injector #1 [C]
Special Tool - Measuring Adapter Set: 57001-1700
the hand tester [D] to the measuring adapter
• Connect
leads.
Special Tool - Hand Tester: 57001-1394
Fuel Injector Input Voltage
Connections to Adapter:
Fuel Injector #1, #2
Digital Meter (+) → R (main harness W/R) lead
Digital Meter (−) → Battery (−) terminal [C]
the engine stop switch to run position.
• Turn
Turn
the ignition switch ON.
• Measure
the output voltage.
•
Intput Voltage
Standard: About Battery Voltage for 3 seconds, and
then 0 V
the ignition switch OFF.
• Turn
If the reading is in the specification, check the wiring for
continuity to ECU connector (see Fuel Injector Circuit).
If the reading is out of the specification, check the following.
Fuel Pump Relay (see Relay Circuit Inspection in the
Electrical System chapter)
Wiring for Power Source (see Fuel Injector Circuit)
If all parts are good, but the injector does not operate,
replace the ECU (see ECU Removal/Installation).
FUEL SYSTEM (DFI) 3-103
Fuel Injectors
Fuel Injector Fuel Line Inspection
• Remove:
Fuel Tank (see Fuel Tank Removal)
Left Air Cleaner Housing (see Left Air Cleaner Housing
Removal)
Fuel Hoses (see Fuel Hose Replacement in the Periodic
Maintenance chapter)
○Be sure to place a piece of cloth around the fuel outlet
pipe of the fuel pump and the delivery pipe.
WARNING
Be prepared for fuel spillage; any spilled fuel must
be completely wiped up immediately.
When the fuel hose is disconnected, fuel spills out
from the hose and the pipe because of residual
pressure. Cover the hose connection with a piece
of clean cloth to prevent fuel spillage.
the injector fuel line for leakage as follows.
•○Check
Connect a commercially available vacuum/pressure
pump [A] to the nipple of the delivery pipe [B] with the
fuel hose [C] (both ends with the clamps [D]) as shown
in the figure.
Upper View [E]
○Apply soap and water solution to the areas [F] as shown
in the figure.
○Watching the pressure gauge, squeeze the pump lever,
and build up the pressure until the pressure reaches the
maximum pressure.
Injector Fuel Line Maximum Pressure
Standard: 300 kPa (3.06 kgf/cm², 43 psi)
CAUTION
During pressure testing, do not exceed the maximum pressure for which the system is designed.
○Watch the gauge for at least 6 seconds.
If the pressure holds steady, the fuel line is good.
If the pressure drops at once or if bubbles are found in the
area, the fuel line is leaking. Replace the delivery joint
assy and injectors.
○Repeat the leak test, and check the fuel line for no leakage.
Install:
Fuel Hoses (see Fuel Hose Replacement in the Periodic
Maintenance chapter)
Left Air Cleaner Housing (see Left Air Cleaner Housing
Installation)
Fuel Tank (see Fuel Tank Installation)
Start the engine and check for fuel leakage.
•
•
3-104 FUEL SYSTEM (DFI)
Fuel Injectors
Fuel Injector Circuit
1. ECU
2. Engine Stop Switch
3. Fuel Injector #2
4. Fuel Injector #1
5. Ignition Switch
6. Ignition Fuse 10 A
7. ECU Fuse 10 A
8. Main Fuse 30 A
9. Battery
10. Engine Ground
11. Relay Box
12. Fuel Pump Relay
13. Frame Ground 3
FUEL SYSTEM (DFI) 3-105
Throttle Grip and Cables
Free Play Inspection
to the Throttle Control System Inspection in the Pe• Refer
riodic Maintenance chapter.
Free Play Adjustment
to the Throttle Control System Inspection in the Pe• Refer
riodic Maintenance chapter.
Cable Installation
the throttle cables in accordance with the Cable,
• Install
Wire, and Hose Routing section in the Appendix chapter.
the lower ends of the throttle cables in the throttle
• Install
pulley on the throttle body assy after installing the upper
•
ends of the throttle cables in the grip.
After installation, adjust each cable properly (see Throttle
Control System Inspection in the Periodic Maintenance
chapter).
WARNING
Operation with incorrectly routed or improperly adjusted cables could result in an unsafe riding condition.
• Confirm the following inspections.
Cruise Control Cancel Switch (Throttle) Operation Inspection:
Refer to the cruise control cancel switch (throttle) operates (see Cruise Control Cancel Switch Inspection in the
Electrical System chapter)
If the cruise control cancel switch (throttle) function does
not work correctly, adjust the throttle grip free play with
the accelerator cable adjuster [A] and then use the decelerator cable adjuster [B] (see Throttle Control System
Inspection in the Periodic Maintenance chapter).
Confirm the cruise control cancel switch (throttle) operation again.
•
•
Full Throttle Pulley Position Inspection:
Remove:
Right Air Cleaner Housing (see Right Air Cleaner Housing Removal in the Fuel System (DFI) chapter)
Turn and hold the throttle grip to full throttle position.
Confirm that the stopper [A] of the pulley touches the post
[B] of the throttle body.
•
•
•
3-106 FUEL SYSTEM (DFI)
Throttle Grip and Cables
•
•
If the stopper of the pulley does not touch, adjust the
throttle grip free play with the accelerator cable adjuster
[A] and then use the decelerator cable adjuster [B] (see
Throttle Control System Inspection in the Periodic Maintenance chapter).
Confirm the full throttle pulley position again.
Install:
Right Air Cleaner Housing (see Right Air Cleaner Housing Installation)
Cable Lubrication
to the Chassis Parts Lubrication in the Periodic
• Refer
Maintenance chapter.
FUEL SYSTEM (DFI) 3-107
Throttle Body Assy
Idle Speed Inspection/Adjustment
to the Idle Speed Inspection/Adjustment in the Pe• Refer
riodic Maintenance chapter.
Throttle Body Assy Removal
WARNING
Gasoline is extremely flammable and can be explosive under certain conditions. Make sure the area
is well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light. Do not smoke. Turn the ignition switch OFF.
Be prepared for fuel spillage: any spilled fuel must
be completely wiped up immediately.
CAUTION
Never drop the throttle body assy, especially on a
hard surface. Such a shock to the body assy can
damage it.
• Remove:
Fuel Tank (see Fuel Tank Removal)
Right Air Cleaner Housing (see Right Air Cleaner Housing Removal)
Cable Holder Screw [A] and Cable Holder [B]
Right Handlebar Switch Housing Screw [C]
• Remove:
Cap Screws [A]
Cap [B]
Right Handlebar Switch Housing [C]
• Remove:
Throttle Cable Ends [A]
3-108 FUEL SYSTEM (DFI)
Throttle Body Assy
• Remove:
Vacuum Hose [A]
Cruise Control Cancel Switch (Throttle)
Lead Connector [B]
• Remove:
Throttle Position Sensor Connector [A]
Accelerator Position Sensor Connector [B]
Throttle Body Assy Holder Bolts [C]
Throttle Body Assy [D] (from Inlet Manifold)
• Remove:
Throttle Cable Holder Plate Screw [A]
•
Stopper [B]
Throttle Cables [C]
Throttle Body Assy
Stuff a piece of lint-free clean cloth into the inlet ports of
the inlet manifold to keep dirt out of the engine.
CAUTION
If dirt gets into the engine, excessive engine wear
and possibly engine damage will occur.
Throttle Body Assy Installation
the throttle bores [A] for carbon deposits.
• Check
If any carbon accumulates, wipe the carbon off the throttle
bores, using a lint-free cloth [B] penetrated with a high
-flash point solvent.
a thin coat of grease to the throttle cable lower ends.
• Apply
the accelerator cable end [A] and the decelerator cable
• Fit
end [B] into the throttle pulley.
the cables with the stopper plate [C]
• Hold
Tighten:
•
Torque - Throttle Calbe Holder Plate Screw [D] : 2.0 N·m
(0.20 kgf·m, 18 in·lb)
the throttle cables correctly (see Cable, Wire, and
• Run
Hose Routing section in the Appendix chapter).
FUEL SYSTEM (DFI) 3-109
Throttle Body Assy
a thin coat of grease to the throttle cable upper
• Apply
ends.
the upper ends of the throttle cables in the grip.
• Install
the projection [A] of the right switch housing into the
• Fit
hole [B] of the handlebar.
• Install:
Right Switch Housing [A]
•
•
•
•
•
Cap [B]
Tighten the cap screws [C] temporarily.
Tighten the right switch housing screw [D] securely.
Tighten the cap screws securely.
Turn the throttle grip and make sure that the throttle pulley
moves smoothly and return by spring force.
Run the leads and hoses correctly (see Cable, Wire, and
Hose Routing section in the Appendix chapter).
assembly, visually inspect the mating surfaces [A]
• Before
for any damage, like dent, nick, rust, flaw, and crack.
or rust damage can sometimes be repaired by using
• Nick
emery paper (first No. 200, then 400) to remove sharp
•
•
•
edges or raised areas.
If the damage is not repairable, replace the throttle body
and/or the inlet manifold to prevent leakage.
With a high-flash point solvent, clean off the mating surfaces and wipe dry.
Be sure to install the dowel pins [B].
Apply grease to the new O-rings [C] and fit them into the
groove. Be careful not to pinch the gasket between the
mating surfaces.
3-110 FUEL SYSTEM (DFI)
Throttle Body Assy
• Install:
Throttle Body Assy [A]
•
Throttle Body Assy Holder Bolt [B], 75 mm (3.0 in.)
Throttle Body Assy Holder Bolts [C], 60 mm (2.4 in.)
Tighten:
Torque - Throttle Body Assy Holder Bolts: 9.8 N·m (1.0
kgf·m, 87 in·lb)
• Install:
Cruise Control Cancel Switch (Throttle) Lead Connector
•
Vacuum Hose
Install the removed parts (see appropriate chapters).
NOTE
○When the throttle body was replaced with a new one, do
not remove the battery, fuse or ECU for 6 seconds for
the learning control of the ECU after the ignition switch
is turned off.
○The ECU does the learning control that is to memorize
the full closing position and full opening position of the
throttle valve for 6 seconds after the ignition switch is
turned OFF.
• Adjust:
Throttle Grip Free Play (see Throttle Control System Inspection in the Periodic Maintenance chapter)
Idle Speed (see Idle Speed Adjustment in the Periodic
Maintenance chapter)
Throttle Body Assy Disassembly
CAUTION
Do not remove, disassemble or adjust the throttle
position sensor/ETV actuator [A], accelerator position sensor [B], bypass screws [C], tempering
screw [D], throttle link mechanism [E] and throttle body assy [F], because they are adjust or set
surely at the manufacturer. Adjustment of these
parts could result in poor performance, requiring
replacement of the throttle body assy.
• Remove:
Throttle Body Assy (see Throttle Body Assy Removal)
Cruise Control Cancel Switch (Throttle) Mounting Nut [A]
Spring Washer and Plane Washer
Cruise Control Cancel Switch (Throttle) [B]
FUEL SYSTEM (DFI) 3-111
Throttle Body Assy
Throttle Body Assy Assembly
a non-permanent locking agent to the cruise control
• Apply
cancel switch (throttle) bolt [A].
the switch so that the projection [B] into the hole
• Install
[C] of the bracket.
• Install:
Plane Washer [A]
•
Spring Washer [B]
Cruise Control Cancel Switch (Throttle) Mounting Nut [C]
Tighten:
Torque - Cruise Control Cancel Switch (Throttle) Mounting
Nut: 0.28 N·m (0.03 kgf·m, 2.5 in·lb)
the throttle body assy (see Throttle Body Assy In• Install
stallation).
3-112 FUEL SYSTEM (DFI)
Inlet Manifold
Inlet Manifold Removal
• Remove:
Throttle Body Assy (see Throttle Body Assy Removal)
Fuel Injectors (Fuel Injector Removal)
Inlet Manifold Bolts [A]
Inlet Manifold [B]
Inlet Mnifold Installation
any carbon off the bores [A] around the inlet man• Wipe
ifold, using a piece of lint-free cloth penetrated with a
•
high-flash point solvent.
With a high-flash point solvent, clean off the flange surface of the cylinder head and wipe dry.
the flange seal [A] with a new one.
• Replace
Install
the
flange [B] and seal in the direction shown. Po• sition the wide
diameter [C] to outside [D].
seal should be centered on the flange.
• The
Apply
• bolts. a non-permanent locking agent to the inlet manifold
• Tighten:
Torque - Inlet Manifold Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
FUEL SYSTEM (DFI) 3-113
Air Cleaner
Air Cleaner Element Removal/Installation
to the Air Cleaner Element Replacement in the Pe• Refer
riodic Maintenance chapter.
Air Cleaner Element Inspection
• Remove:
Air Cleaner Element (see Air Cleaner Element Replace•
ment in the Periodic Maintenance chapter)
Visually check the element [A] for tears or breaks.
If the element has any tears or breaks, replace the element.
Air Cleaner Oil Draining
A drain tube is connected to the bottom of the air cleaner
to drain water or oil accumulated in the air cleaner housing.
Remove:
Left Air Cleaner Housing (see Left Air Cleaner Housing
Removal)
Visually check the drain tube [A] if the water or oil accumulates.
If any water or oil accumulates in the tube, remove the
tube from the housing and drain it.
After draining, be sure to install the tube and clamp [B]
firmly.
•
•
•
WARNING
Be sure to reinstall the tube after draining. Oil on
tires will make them slippery and can cause an accident and injury.
Left Air Cleaner Housing Removal
• Remove:
Front Seat (see Front Seat Removal in the Frame chap•
ter)
Fuel Tank Mounting Bolts [A]
Bracket [B]
Lift up the rear end of the fuel tank, using a suitable wood
block.
• Remove:
Air Cleaner Element (see Air Cleaner Element Replacement in the Periodic Maintenance chapter)
Air Cleaner Housing Bolts [A] and Washers
Left Air Cleaner Housing [B]
3-114 FUEL SYSTEM (DFI)
Air Cleaner
• Remove:
Breather Hose [A]
Left Air Cleaner Housing Installation
installing the damper [A] and collar [B], install them
• When
as shown in the figure.
Air Cleaner Housing [C]
Engine Side [D]
Big Side [E]
the breather hose [A] into the grommet [B] as shown
• Insert
in the figure.
○Reach the round portion [C] to the grommet.
Air Cleaner Housing [D]
Cylinder Head [E]
• Install:
Left Air Cleaner Housing
•
Air Cleaner Housing Bolts and Washers
Tighten:
Torque - Air Cleaner Housing Bolts: 9.8 N·m (1.0 kgf·m, 87
in·lb)
• Install the removed parts.
Right Air Cleaner Housing Removal
• Remove:
Front Seat (see Front Seat Removal in the Frame chap•
ter)
Fuel Tank Mounting Bolts [A]
Bracket [B]
Lift up the rear end of the fuel tank, using a suitable wood
block.
FUEL SYSTEM (DFI) 3-115
Air Cleaner
• Remove:
Right Air Cleaner Housing Cover Bolts [A]
Right Air Cleaner Housing Cover [B]
• Remove:
Inlet Air temperature Sensor Connector [A]
Air Switching Valve Hose [B]
• Remove:
Air Cleaner Housing Bolts [A] and Washers
Right Air Cleaner Housing Center Bolts [B]
Right Air Cleaner Housing [C]
Right Air Cleaner Housing Installation
installing the damper [A] and collar [B], install them
• When
as shown in the figure.
Air Cleaner Housing [C]
Engine Side [D]
Big Side [E]
a high-flash point solvent, clean off the mating sur• With
faces [A] and wipe dry.
• Install:
Inlet Air temperature Sensor Connector
Air Switching Valve Hose
3-116 FUEL SYSTEM (DFI)
Air Cleaner
• Install:
Right Air Cleaner Housing
•
•
Air Cleaner Housing Bolts [A] and Washers
Apply a non-permanent locking agent to the right air
cleaner housing center bolts [B].
Tighten:
Torque - Right Air Cleaner Housing Center Bolts: 9.8 N·m
(1.0 kgf·m, 87 in·lb)
Air Cleaner Housing Bolts: 9.8 N·m (1.0 kgf·m, 87
in·lb)
the right air clearner housing cover.
• Install
Tighten:
•
Torque - Right Air Cleaner Housing Cover Bolts: 4.9 N·m
(0.50 kgf·m, 43 in·lb)
• Install the removed parts.
FUEL SYSTEM (DFI) 3-117
Fuel Tank
Fuel Tank Removal
WARNING
Gasoline is extremely flammable and can be explosive under certain conditions. Make sure the area
is well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light. Do not smoke. Turn the ignition switch OFF
and disconnect the battery (–) terminal.
To avoid fire, do not remove the fuel tank when the
engine is still hot. Wait until it cools down.
To make fuel spillage minimum, draw the fuel out
from the fuel tank when the engine is cold.
Be prepared for fuel spillage; any spilled fuel must
be completely wiped up immediately.
the ignition switch OFF.
• Turn
Wait
until
cools down.
• Disconnectthetheengine
battery
terminal (see Battery Removal
• in the Electrical System(–)chapter).
the fuel tank cap [A] to lower the pressure in the
• Open
tank.
the fuel out from the fuel tank with a commercially
• Draw
available pump [A].
○Use a soft plastic hose [B] as a pump inlet hose in order
to insert the hose smoothly.
○Put the hose through the filler opening [C] into the tank
and draw the fuel out.
WARNING
The fuel could not be removed completely from the
fuel tank. Be careful for remained fuel spillage.
the meter cover together with the meter unit (see
• Remove
Meter Unit Removal in the Electrical System chapter).
• Remove:
Fuel Tank Bolts [A]
Bracket [B]
3-118 FUEL SYSTEM (DFI)
Fuel Tank
• Disconnect:
Fuel Pump Lead Connector [A]
sure to place a piece of cloth [A] around the fuel hose
• Be
joint.
a thin blade screwdriver [B] into the slit [C] on the
• Insert
joint lock [D].
[A] the driver to disconnect the joint lock [B].
• Turn
Pull
the
fuel hose joint [C] out of the outlet pipe.
•
WARNING
Be prepared for fuel spillage; any spilled fuel must
be completely wiped up immediately.
When the fuel hose is disconnected, fuel spills out
from the hose and the pipe. Cover the hose connection with a clean shop towel to prevent fuel spillage.
• Remove:
Breather Hose [A]
the CAL and SEA models, remove the following.
• For
Fuel Return Hose [A] (right side, red)
the fuel tank, and place it on a flat surface.
•○Remove
Do not apply the load to the fuel outlet pipe of the fuel
pump.
FUEL SYSTEM (DFI) 3-119
Fuel Tank
• For the CAL and SEA models, note the following.
CAUTION
For the California and Southeast Asia models, if
gasoline, solvent, water or any other liquid enters
the canister, the canister’s vapor absorbing capacity is greatly reduced. If the canister does become
contaminated, replace it with a new one.
○Be sure to plug the evaporative fuel return hose to prevent
fuel spilling before fuel tank removal.
○Be careful of fuel spillage from the fuel tank, if the fuel still
remains in the fuel tank and fuel pump.
WARNING
For the California and Southeast Asia models, be
careful not to spill the gasoline through the return
hose. Spilled fuel is hazardous.
If liquid or gasoline flows into the breather hose, remove
the hose and blow it clean with compressed air.
WARNING
Store the fuel tank in an area which is well
-ventilated and free from any source of flame
or sparks. Do not smoke in this area. Place the
fuel tank on a flat surface and plug the fuel pipes
to prevent fuel leakage.
Fuel Tank Installation
the above WARNING (see Fuel Tank Removal).
• Note
Run
the
hoses correctly (see Cable, Wire, and Hose Rout• ing section
in the Appendix chapter).
Check
that
the
[A] are in place on the fuel tank.
• If the dampersdampers
are damaged or deteriorated, replace
them.
installing the damper [A], position the thick side [B]
• When
to frame side [C].
3-120 FUEL SYSTEM (DFI)
Fuel Tank
that the dampers [A] are in place on the frame.
• Check
If the dampers are damaged or deteriorated, replace
them.
the fuel pump so that the stoppers [A] fit to the
• Install
dampers [B].
the CAL and SEA models, note the following.
•○For
To prevent the gasoline from flowing into or out of the
canister, hold the separator perpendicular to the ground.
○Connect the hoses according to the diagram of the evaporative emission control system. Make sure they do not
get pinched or kinked.
○Run the hoses with a minimum of bending so that the air
or vapor will not be obstructed.
[A] the fuel hose joint [B] straight onto the fuel outlet
• Install
pipe until the hose joint clicks.
• Push [C] the joint lock [D] until the hose joint clicks.
and pull [A] the fuel hose joint [B] back and forth
• Push
more than two times, and make sure it is locked and does
not come off.
WARNING
Make sure the hose joint is installed correctly on the
delivery pipe or the fuel could leak.
•
If it comes off, reinstall the hose joint.
Connect the fuel pump lead connector and the battery (–)
terminal (see Battery Installation in the Electrical System
chapter).
FUEL SYSTEM (DFI) 3-121
Fuel Tank
Fuel Tank Inspection
inspect the gasket [A] on the tank cap for any
• Visually
damage.
•
Replace the gasket if it is damaged.
Check to see if the fuel breather pipe [B] in the tank are
not clogged. Check the tank cap breather also.
If they are clogged, remove the tank and drain it, and then
blow the breather free with compressed air.
CAUTION
Do not apply compressed air to the air vent holes
[C] in the tank cap. This could cause damage and
clogging of the labyrinth in the cap.
Fuel Tank Cleaning
WARNING
Clean the tank in a well-ventilated area, and take
care that there are no sparks or flame anywhere
near the working area. Because of the danger or
highly flammable liquids, do not use gasoline or
low-flash point solvents to clean the tank.
• Remove:
Fuel Tank (see Fuel Tank Removal)
•
•
•
•
Fuel Pump (see Fuel Pump Removal)
Pour some high-flash point solvent into the fuel tank and
shake the tank to remove dirt and fuel deposits.
Draw the solvent out of the fuel tank.
Dry the tank with compressed air.
Install:
Fuel Pump (see Fuel Pump Installation)
Fuel Tank (see Fuel Tank Installation)
3-122 FUEL SYSTEM (DFI)
Evaporative Emission Control System (CAL and SEA Models)
The Evaporative Emission Control System routes fuel vapors from the fuel system into the running engine or stores
the vapors in a canister when the engine is stopped. Although no adjustments are required, a thorough visual inspection must be made at the intervals specified by the Periodic Maintenance Chart.
Parts Removal/Installation
WARNING
Gasoline is extremely flammable and can be explosive under certain conditions. Make sure the area
is well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light. Do not smoke. Turn the ignition switch OFF.
CAUTION
If gasoline, solvent, water or any other liquid enters
the canister, the canister’s vapor absorbing capacity is greatly reduced. If the canister does become
contaminated, replace it with a new one.
prevent the gasoline from flowing into or out of the
• To
canister, hold the separator perpendicular to the ground.
the hoses according to the diagram of the sys• Connect
tem (see Cable, Wire, and Hose Routing section in the
Appendix chapter). Make sure they do not get pinched or
kinked.
Hose Inspection
to the Evaporative Emission Control System In• Refer
spection (CAL and SEA Models) in the Periodic Maintenance chapter.
Separator Inspection
to the Evaporative Emission Control System In• Refer
spection (CAL and SEA Models) in the Periodic Maintenance chapter.
FUEL SYSTEM (DFI) 3-123
Evaporative Emission Control System (CAL and SEA Models)
Separator Operation Test
WARNING
Gasoline is extremely flammable and can be explosive under certain conditions. Do not smoke.
Turn the ignition switch OFF. Make sure the area is
well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light.
the hoses to the separator, and install the sepa• Connect
rator on the motorcycle.
the breather hose from the separator, and in• Disconnect
ject about 20 mL (0.68 US oz.) of gasoline [A] into the
•
•
•
separator [B] through the hose fitting.
Disconnect the fuel return hose [C] from the fuel tank [D].
Run the open end of the return hose into the container
and hold it level with the tank top [E].
Start the engine, and let it idle.
If the gasoline in the separator comes out of the hose, the
separator works well. If it does not, replace the separator
with a new one.
Canister Inspection
to the Evaporative Emission Control System In• Refer
spection (CAL and SEA Models) in the Periodic Maintenance chapter.
3-124 FUEL SYSTEM (DFI)
Evaporative Emission Control System (CAL and SEA Models)
1. Fuel Tank
2. Canister
3. Blue Hose (Breather)
4. Green Hose (Purge)
5. Band (for Canister)
6. Bracket (for Canister)
7. Separator
8. Band (for Separator)
9. Fittings
10. Red Hose (Return)
11. White Hose (Vacuum)
12. Throttle Body Assy
13. Check Valve
COOLING SYSTEM 4-1
Cooling System
Table of Contents
Exploded View........................................................................................................................
Coolant Flow Chart.................................................................................................................
Specifications .........................................................................................................................
Special Tools ..........................................................................................................................
Coolant ...................................................................................................................................
Coolant Deterioration Inspection.......................................................................................
Coolant Level Inspection...................................................................................................
Coolant Draining ...............................................................................................................
Coolant Filling ...................................................................................................................
Pressure Testing ...............................................................................................................
Cooling System Flushing ..................................................................................................
Coolant Reserve Tank Removal/Installation .....................................................................
Water Pump............................................................................................................................
Water Pump Removal .......................................................................................................
Water Pump Installation ....................................................................................................
Water Pump Inspection.....................................................................................................
Water Pump Impeller Disassembly/Assembly ..................................................................
Water Pump Impeller Inspection .......................................................................................
Mechanical Seal Inspection ..............................................................................................
Mechanical Seal Replacement .........................................................................................
Radiator ..................................................................................................................................
Radiator Removal .............................................................................................................
Radiator Installation ..........................................................................................................
Radiator Inspection ...........................................................................................................
Radiator Cap Inspection ...................................................................................................
Radiator Filler Neck Inspection .........................................................................................
Thermostat .............................................................................................................................
Thermostat Removal.........................................................................................................
Thermostat Installation......................................................................................................
Thermostat Inspection ......................................................................................................
Hoses and Pipes ....................................................................................................................
Water Separator Cover Removal ......................................................................................
Water Separator Cover Installation ...................................................................................
Hose Installation ...............................................................................................................
Hose Inspection ................................................................................................................
Water Temperature Sensor ....................................................................................................
Water Temperature Sensor Removal/Installation .............................................................
Water Temperature Sensor Inspection .............................................................................
4-2
4-4
4-6
4-7
4-8
4-8
4-8
4-8
4-8
4-8
4-9
4-9
4-10
4-10
4-10
4-10
4-10
4-10
4-11
4-11
4-13
4-13
4-14
4-15
4-15
4-16
4-17
4-17
4-17
4-18
4-19
4-19
4-19
4-20
4-20
4-21
4-21
4-21
4
4-2 COOLING SYSTEM
Exploded View
COOLING SYSTEM 4-3
Exploded View
No.
1
2
3
4
5
6
7
8
9
Fastener
Cross Pipe Bolts
Radiator Fan Bolts
Radiator Hose Clamp Screws
Thermostat Housing Cover Bolts
Water Pipe Bolts
Water Pump Impeller Bolt
Water Separator Inner Cover Bolts
Water Separator Outer Cover Bolts
Water Temperature Sensor
10. Double Seal Bearing
11. Mechanical Seal
12. Oil Seal
13. Radiator
14. Radiator Cap
15. Sealing Seat
16. Thermostat
G: Apply grease.
LH: Left-hand threads
R: Replacement Parts
WL: Apply soap and water solution.
N·m
34
8.3
2.0
9.8
12
12
12
Torque
kgf·m
3.5
0.85
0.20
1.0
1.2
1.2
1.2
ft·lb
25
73 in·lb
18 in·lb
87 in·lb
106 in·lb
106 in·lb
106 in·lb
12
12
1.2
1.2
106 in·lb
106 in·lb
Remarks
Lh
4-4 COOLING SYSTEM
Coolant Flow Chart
COOLING SYSTEM 4-5
Coolant Flow Chart
1. Radiator Fan
2. Radiator
3. Water Separator Cover
4. Water Pump
5. Reserve Tank
6. Reserve Tank Overflow Hose
7. Radiator Overflow Hose
8. Cylinder Jacket
9. Cylinder Head Jacket
10. Thermostat Housing
11. Radiator Cap
12. Hot Coolant Flow
13. Cold Coolant Flow
Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion. When the engine starts, the water pump turns and the coolant circulates.
The thermostat is a wax pellet type which opens or closes as coolant temperature changes. The
thermostat continuously changes its valve opening to keep the coolant temperature at the proper level.
When coolant temperature is below 58 ∼ 62°C (136 ∼ 144°F), the thermostat closes so that the coolant
flow is restricted through the air bleeder hole, causing the engine to warm up more quickly. When
coolant temperature is more than 58 ∼ 62°C (136 ∼ 144°F), the thermostat opens and the coolant
flows.
When the coolant temperature goes up beyond 95°C (203°F), the radiator fan relay conducts to
operate the radiator fan. The radiator fan draws air through the radiator core when there is not sufficient air flow such as at low speeds. This increases up the cooling action of the radiator. When the
temperature is below 90°C (194°F), the fan relay opens and the radiator fan stops.
In this way, this system controls the engine temperature within narrow limits where the engine operates most efficiently even if the engine load varies.
The system is pressurized by the radiator cap to suppress boiling and the resultant air bubbles
which can cause engine overheating. As the engine warms up, the coolant in the radiator and the
water jacket expands. The excess coolant flows through the radiator cap and hose to the reserve tank
to be stored there temporarily. Conversely, as the engine cools down, the coolant in the radiator and
the water jacket contracts, and the stored coolant flows back to the radiator from the reserve tank.
The radiator cap has two valves. One is a pressure valve which holds the pressure in the system
when the engine is running. When the pressure exceeds 93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 13 ∼ 18
psi), the pressure valve opens and releases the pressure to the reserve tank. As soon as pressure
escapes, the valve closes, and keeps the pressure at 93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 13 ∼ 18 psi).
When the engine cools down, another small valve (vacuum valve) in the cap opens. As the coolant
cools, the coolant contracts to from a vacuum in the system. The vacuum valve opens and allows the
coolant from the reserve tank to enter the radiator.
4-6 COOLING SYSTEM
Specifications
Item
Coolant provided when shipping
Type (Recommended)
Color
Mixed Ratio
Freezing Point
Total Amount
Radiator Cap
Relief Pressure
Thermostat
Valve Opening Temperature
Valve Full Opening Lift
Standard
Permanent type antifreeze (soft water and ethylene
glycol plus corrosion and rust inhibitor chemicals
for aluminum engines and radiators)
Green
Soft water 50%, coolant 50%
−35°C (−31°F)
2.4 L (2.5 US qt) (Reserve tank full level, including
radiator and engine)
93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 13.5 ∼ 17.8 psi)
58 ∼ 62°C (136 ∼ 144°F)
8 mm (0.31 in.) or more at 75°C (167°F)
COOLING SYSTEM 4-7
Special Tools
Bearing Driver Set:
57001-1129
Bearing Remover Shaft,
57001-1265
Bearing Remover Head,
57001-1266
9:
10 ×
12:
4-8 COOLING SYSTEM
Coolant
Coolant Deterioration Inspection
the left side cover (see Left Side Cover Removal
• Remove
in the Frame chapter).
inspect the coolant [A] in the reserve tank.
• Visually
If whitish cotton-like wafts are observed, aluminum parts
in the cooling system are corroded. If the coolant is
brown, iron or steel parts are rusting. In either case, flash
the cooling system.
If the coolant gives off an abnormal smell, check for a
cooling system leak. It may be caused by exhaust gas
leaking into the cooling system.
Coolant Level Inspection
to the Coolant Level Inspection in the Periodic Main• Refer
tenance chapter.
Coolant Draining
to the Coolant Change in the Periodic Maintenance
• Refer
chapter .
Coolant Filling
to the Coolant Change in the Periodic Maintenance
• Refer
chapter.
Pressure Testing
the fuel tank (see Fuel Tank Removal in the Fuel
• Remove
System (DFI) chapter).
the radiator cap, and install a cooling system
• Remove
pressure tester [A] on the radiator filler neck [B].
○Remove the radiator cap in two steps.
First turn the cap
counterclockwise to the first stop. Then push and turn it
further in the same direction and remove the cap.
NOTE
○Wet the cap sealing surfaces with water or coolant to
prevent pressure leakage.
up pressure in the system carefully until the pres• Build
sure reaches 123 kPa (1.25 kgf/cm², 17.8 psi).
CAUTION
During pressure testing, do not exceed the pressure for which the system is designed. The maximum pressure is 123 kPa (1.25 kgf/cm², 17.8 psi).
the gauge for at least 6 seconds.
• Watch
If the pressure holds steady, the system is all right.
•
If the pressure drops and no external source is found,
check for internal leakage. Droplets in the engine oil indicate internal leakage. Check the cylinder head and cylinder gaskets and the water pump.
Remove the pressure tester, replenish the coolant, and
install the radiator cap.
COOLING SYSTEM 4-9
Coolant
Cooling System Flushing
Over a period of time, the cooling system accumulates
rust, scale, and lime in the water jacket and radiator. When
this accumulation is suspected or observed, flush the cooling system. If this accumulation is not removed, it will clog
up the water passage and considerably reduce the efficiency of the cooling system.
Drain the cooling system (see Coolant Change in the Periodic Maintenance chapter).
Fill the cooling system with fresh water mixed with a flushing compound.
•
•
CAUTION
Do not use a flushing compound which is harmful to
the aluminum engine and radiator. Carefully follow
the instructions supplied by the manufacturer of the
cleaning product.
up the engine, and run it at normal operating tem• Warm
perature for about ten minutes.
the engine, and drain the cooling system.
• Stop
Fill
the
with fresh water.
• Warm upsystem
the
engine
and drain the system.
• Repeat the previous two
steps once more.
• Fill the system with a permanent
type coolant and bleed
• the air from the system (see Coolant
Change in the Periodic Maintenance chapter).
Coolant Reserve Tank Removal/Installation
coolant reserve tank is removed and installed dur• The
ing coolant change (see Coolant Change in the Periodic
Maintenance chapter).
4-10 COOLING SYSTEM
Water Pump
Water Pump Removal
the coolant (see Coolant Change in the Periodic
• Drain
Maintenance chapter).
• Remove:
Alternator Cover (see Alternator Cover Removal in the
Electrical System chapter)
Impeller Bolt [A] and Washer
Impeller [B]
NOTE
○The impeller bolt has left-hand threads. Turn the bolt
clockwise and remove it.
Water Pump Installation
the washer with a new one.
• Replace
the water pump impeller bolt together with a new
• Tighten
washer by turning the bolt counterclockwise.
• Tighten:
Torque - Water Pump Impeller Bolt: 12 N·m (1.2 kgf·m, 106
in·lb)
Water Pump Inspection
the drainage outlet passage [A] at the bottom of
• Check
the crankcase for coolant leaks.
If the mechanical seal is damaged, the coolant leaks
through the seal and drains through the passage. Replace the mechanical seal unit.
Water Pump Impeller Disassembly/Assembly
the water pump impeller (see Water Pump Re• Remove
moval).
sealing seat [A] and rubber seal [B] may be removed
• The
easily by hand.
coolant around the surfaces of the rubber seal and
• Apply
sealing seat.
the rubber seal and sealing seat into the impeller by
• Install
pressing them by hand until the seat stops at the bottom
•
of the hole.
Install the water pump impeller (see Water Pump Installation).
Water Pump Impeller Inspection
the alternator cover (see Alternator Cover Re• Remove
moval in the Electrical System chapter).
inspect the water pump impeller [A].
• Visually
If the surface is corroded or if the blades are damaged,
replace the impeller.
COOLING SYSTEM 4-11
Water Pump
Mechanical Seal Inspection
the impeller (see Water Pump Removal).
• Remove
Visually
inspect
mechanical seal.
• If any one of thethe
parts is damaged, replace the mechanical seal as a unit.
○The sealing seat and rubber seal may be removed easily
by hand.
Impeller Sealing Seat Surface [A]
Rubber Seal [B]
Mechanical Seal Diaphragm [C]
Mechanical Seal Replacement
the water pump impeller (see Water Pump Re• Remove
moval).
the mechanical seal flange off with a small chisel [A].
• Pry
the mechanical seal out of the right crankcase with
• Pull
needle nose pliers. Discard the mechanical seal.
CAUTION
Be careful not to damage the water pump shaft and
the inner sealing surface of the crankcase.
• Replace the mechanical seal with a new one.
NOTE
○Since the replacement mechanical seal has an adhesive coated body, do not apply a liquid gasket to the
exterior surface of the body.
[A] the mechanical seal [B] by using a suitable 28
• Press
mm socket [C] and a bearing driver [D] until its flange
touches the step [E].
Special Tool - Bearing Driver Set: 57001-1129
•
•
•
If the seal and ball bearing are damaged, replace the mechanical seal, ball bearing, and oil seal by splitting the
crankcase.
Split the crankcase (see Crankcase Splitting in the Crankshaft/Transmission chapter).
Remove the mechanical seal.
Take the bearing [A] out of the left crankcase, using the
bearing remover.
Special Tools - Bearing Remover Shaft, 9 [B]: 57001-1265
Bearing Remover Head, 10 × 12 [C]:
57001-1266
• Using a thin-bladed screwdriver, pry out the oil seal [D].
4-12 COOLING SYSTEM
Water Pump
the oil seal and ball bearing with new ones.
• Replace
Apply
grease
to the oil seal lips.
• Press the oil seal
the hole from the outside of the
• left crankcase with[A]theinto
bearing driver set so that the spring
side of the seal lips is toward the inside of the crankcase.
Special Tool - Bearing Driver Set: 57001-1129
the oil seal in until oil seal surface [B] is 0.5 ∼ 1.5
• Press
mm (0.020 ∼ 0.059 in.) [C] from the step [D] of the hole.
the ball bearing [A] into the hole from the outside of
• Press
the left crankcase with the bearing driver set [B].
the ball bearing in until it stops at the bottom surface
• Press
[C] of the crankcase.
Special Tool - Bearing Driver Set: 57001-1129
• Install the new mechanical seal.
CAUTION
Do not reuse the mechanical seal.
COOLING SYSTEM 4-13
Radiator
Radiator Removal
• Remove:
Bracket Bolt [A]
•
Cross Pipe Bolts [B]
Detach the projections of the radiator from the grommet
[C] of the cross pipe.
the clamp [A] to free the lead.
• Open
Disconnect
regulator connectors [B].
• Remove thethe
cross
pipe [C] together with the regulators.
• Drain the coolant (see
• Maintenance chapter). Coolant Change in the Periodic
• Disconnect the radiator fan connector [A].
• Remove the radiator hose [A].
• Remove:
Bolt [A]
Horn [B]
4-14 COOLING SYSTEM
Radiator
• Remove:
Radiator Bolt [A]
Radiator [B]
CAUTION
Do not touch the radiator core. This could damage
the radiator fins, resulting in loss of cooling efficiency.
• Remove:
Radiator Fan Bolts [A]
Radiator Fan [B]
Radiator Installation
is the reverse of removal, note the following.
•○Installation
Run the radiator fan lead [A] as shown in the figure.
•
Radiator Screen Bracket [B]
Good Route [C]
Tighten:
Torque - Radiator Fan Bolts: 8.3 N·m (0.85 kgf·m, 73 in·lb)
○Insert the projection [A] of the radiator into the grommet
[B] of the cross pipe.
○Install the bracket on the cross pipe so that the hook portion [A] touches the tab [B].
• Tighten:
Torque - Cross Pipe Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb)
• Install the removed parts (see appropriate chapters).
COOLING SYSTEM 4-15
Radiator
Radiator Inspection
the radiator (see Radiator Removal).
• Remove
Check
the
core.
• If there areradiator
obstructions to air flow, remove them.
If the corrugated fins [A] are deformed, carefully
straighten them.
If the air passages of the radiator core are blocked more
than 20% by unremovable obstructions or irreparably deformed fins, replace the radiator with a new one.
CAUTION
When cleaning the radiator with steam cleaner, be
careful of the following to prevent radiator damage.
1.Keep the steam gun [A] away more than 0.5 m (1.6
ft) [B] from the radiator core.
2.Hold the steam gun perpendicular [C] (not oblique
[D]) to the core surface and run the steam gun following the core fin direction.
Radiator Cap Inspection
the radiator cap (see Coolant Change in the Pe• Remove
riodic Maintenance chapter).
the condition of the top and bottom valve seals of
• Check
the radiator cap.
If any one of them shows visible damage, replace the cap.
Bottom Valve Seal [A]
Top Valve Seal [B]
Valve Spring [C]
• Install the cap [A] on a cooling system pressure tester [B].
NOTE
○Wet the cap sealing surfaces with water or coolant to
prevent pressure leakage.
the pressure gauge, pump the pressure tester
• Watching
to build up the pressure until the relief valve opens: the
gauge needle flicks downward. Stop pumping and measure leak time at once. The relief valve must open within
the specified range in the table below and the gauge needle must remain within the same range at least 6 seconds.
Radiator Cap Relief Pressure
Standard: 93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm²,
13.5 ∼ 17.8 psi)
If the cap holds too much pressure or cannot hold the
specified pressure, replace it with a new one.
4-16 COOLING SYSTEM
Radiator
Radiator Filler Neck Inspection
the radiator cap (see Coolant Change in the Pe• Remove
riodic Maintenance chapter).
the radiator filler neck for signs of damage.
• Check
Check
condition of the top and bottom sealing seats
• [A] in thethefiller
neck. They must be smooth and clean for
the radiator cap to function properly.
COOLING SYSTEM 4-17
Thermostat
Thermostat Removal
the coolant (see Coolant Change in the Periodic
• Drain
Maintenance chapter).
• Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)
Water Hoses [A]
Bracket Bolts [B]
Water Temperature Sensor Connector [C]
the water hose [A].
• Remove
Remove
• bracket. the thermostat housing
[B] along with the
the thermostat housing cover bolts [A], take off
• Remove
the thermostat housing cover [B], and take out the thermostat.
Thermostat Installation
the O-ring [A] with a new one.
• Replace
Apply
grease
to the new O-ring.
• Install a new O-ring
the thermostat housing [B].
• Install the thermostantintohousing
along with the bracket.
• Run the leads and hoses correctly
(see cable, wire and
• Hoses Routing section in the Appendix
chapter).
• Tighten:
Torque - Thermostat Housing Cover Bolts: 9.8 N·m (1.0
kgf·m, 87 in·lb)
Radiator Hose Clamp Screws: 2.0 N·m (0.20 kgf·m,
18 in·lb)
the radiator with coolant (see Coolant Change in the
• Fill
Periodic Maintenance chapter).
4-18 COOLING SYSTEM
Thermostat
Thermostat Inspection
the thermostat (see Thermostat Removal).
• Remove
Inspect
the
valve at room temperature.
• If the valve isthermostat
open, replace the valve with a new one.
To
check
valve
temperature, suspend the ther• mostat [A] and anopening
accurate thermometer [B] in a container
of water with the heat-sensitive portions [C] in almost the
same depth.
NOTE
○The thermostat must be completely submerged and the
thermostat and thermometer must not touch the container sides or bottom.
raise the temperature of the water while stirring
• Gradually
the water gently for even temperature.
If the measurement is out of the range, replace the thermostat.
Thermostat Valve Opening Temperature
58 ∼ 62°C (136 ∼ 144°F)
COOLING SYSTEM 4-19
Hoses and Pipes
Water Separator Cover Removal
the coolant (see Coolant Change in the Periodic
• Drain
Maintenance chapter)
• Remove:
Water Separator Outer Cover Bolts [A]
Water Separator Outer Cover [B]
• Remove:
Water Pipe Bolts [A]
Upper Water Pipes [B]
• Remove:
Water Pipe Bolt [A]
•
Water Separator Inner Cover Bolts [B]
Remove the water separator inner cover [C] together with
the lower water pipe [D].
Water Separator Cover Installation
the O-rings [A] of the water pipes with new ones.
• Replace
Apply
soap
and water solution to the new O-rings.
•
sure that the dowel pins [A] and rubber dampers [B]
• Be
are in position.
the water separator inner cover gasket with a
• Replace
new one.
the water separator inner cover together with the
• Install
lower water pipe.
○When installing the lower water pipe, insert the water pipe
•
into the hole of the alternator cover as far as it will go.
Tighten:
Torque - Water Separator Inner Cover Bolts: 12 N·m (1.2
kgf·m, 106 in·lb)
Water Pipe Bolt: 12 N·m (1.2 kgf·m, 106 in·lb)
4-20 COOLING SYSTEM
Hoses and Pipes
the O-rings [A] with new ones.
• Replace
Apply
grease
to the new O-rings.
• Install the upper
water pipes.
•○When installing the
upper water pipes, insert the water
•
pipes into the pipe fitting of the cylinder as far as they will
go.
Tighten:
Torque - Water Pipe Bolts: 12 N·m (1.2 kgf·m, 106 in·lb)
the water separator outer cover.
• Install
Tighten:
•
Torque - Water Separator Outer Cover Bolts: 12 N·m (1.2
kgf·m, 106 in·lb)
Hose Installation
the hoses and pipes being careful to follow bend• Install
ing direction. Avoid sharp bending, kinking, flattening, or
twisting.
Install the clamps [A] as near as possible to the hose end
to clear the raised rib on the fitting. This will prevent the
hoses from working loose.
○The clamp screws should be positioned correctly to prevent the clamps from contacting the other parts.
•
Torque - Radiator Hose Clamp Screws: 2.0 N·m (0.20 kgf·m,
18 in·lb)
Hose Inspection
the radiator or radiator hoses are removed or in
• Whenever
accordance with the Periodic Maintenance Chart, check
the radiator or radiator hoses and their connections. Refer to the Radiator Hose Inspection (Coolant Leak, Damage, Installation Condition) in the Periodic Maintenance
chapter.
COOLING SYSTEM 4-21
Water Temperature Sensor
Water Temperature Sensor Removal/Installation
to the Water Temperature Sensor Removal/Instal• Refer
lation in the Fuel System (DFI) chapter.
Water Temperature Sensor Inspection
to the Water Temperature Sensor Inspection in the
• Refer
Electrical System chapter.
ENGINE TOP END 5-1
Engine Top End
Table of Contents
Exploded View...................................
Exhaust System Identification ...........
Specifications ....................................
Special Tools and Sealant .................
Clean Air System...............................
Air Suction Valve Removal...........
Air Suction Valve Installation........
Air Suction Valve Inspection ........
Air Switching Valve Removal .......
Air Switching Valve Installation ....
Air Switching Valve Operation
Test............................................
Air Switching Valve Unit Test .......
Clean Air System Hose
Inspection..................................
Cylinder Head Covers .......................
Cylinder Head Cover Removal ....
Cylinder Head Cover Installation .
Rocker Cases ....................................
Rocker Case Removal .................
Rocker Case Installation ..............
Rocker Shafts, Rocker Arms .............
Rocker Shaft and Rocker Arm
Removal ....................................
Rocker Shaft and Rocker Arm
Installation .................................
Rocker Arm Assembly .................
Rocker Shaft Diameter
Measurement ............................
Rocker Arm Inspection.................
HLA (Hydraulic Lash Adjuster) ..........
HLA Removal...............................
HLA Installation............................
HLA Air Bleeding..........................
Camshaft Chain Tensioners ..............
Camshaft Chain Tensioner
Removal ....................................
Camshaft Chain Tensioner
Installation .................................
Camshafts, Camshaft Chains,
Camshaft Sprockets .......................
Camshaft Removal ......................
Camshaft Installation ...................
Camshaft, Rocker Case Wear .....
Camshaft Runout .........................
5-2
5-6
5-8
5-10
5-12
5-12
5-12
5-12
5-13
5-13
5-13
5-14
5-14
5-15
5-15
5-15
5-18
5-18
5-20
5-23
5-23
5-23
5-23
5-23
5-24
5-25
5-25
5-25
5-25
5-26
5-26
5-27
5-28
5-28
5-28
5-30
5-30
Cam Wear....................................
Camshaft Chain Removal ............
Camshaft Chain Installation .........
Camshaft Sprocket Removal .......
Camshaft Sprocket Installation ....
KACR (Kawasaki Automatic
Compression Release) ...................
KACR Inspection..........................
KACR Removal............................
KACR Installation.........................
Cylinder Heads ..................................
Cylinder Compression
Measurement ............................
Cylinder Head Removal ...............
Cylinder Head Installation ............
Cylinder Head Warp.....................
Valves ................................................
Valve Clearance Inspection/Adjustment.....................................
Valve Removal .............................
Valve Installation ..........................
Valve Guide Removal ..................
Valve Guide Installation ...............
Valve-to-Guide Clearance
Measurement (Wobble
Method) .....................................
Valve Seat Inspection ..................
Valve Seat Repair ........................
Cylinders, Pistons..............................
Cylinder Removal.........................
Cylinder Installation......................
Piston Removal............................
Piston Installation.........................
Cylinder Wear ..............................
Piston Wear .................................
Piston Ring, Piston Ring Groove
Wear..........................................
Piston Ring Groove Width............
Piston Ring Thickness ................
Piston Ring End Gap ...................
Mufflers..............................................
Muffler Body Removal..................
Muffler Body Installation...............
Exhaust Pipe Removal.................
Exhaust Pipe Installation..............
5-31
5-31
5-31
5-31
5-32
5-33
5-33
5-33
5-34
5-37
5-37
5-38
5-38
5-41
5-42
5-42
5-42
5-42
5-42
5-43
5-43
5-44
5-44
5-49
5-49
5-49
5-50
5-51
5-52
5-52
5-53
5-53
5-53
5-54
5-55
5-55
5-56
5-57
5-60
5
5-2 ENGINE TOP END
Exploded View
ENGINE TOP END 5-3
Exploded View
No.
1
2
3
4
5
6
7
8
9
10
Fastener
Breather Check Valve Cover Bolts
Cylinder Head Nuts (M12) (First)
Cylinder Head Nuts (M12 New Nuts) (Final)
Cylinder Head Nuts (M12 Used Nuts) (Final)
Cylinder Head Nuts (M10) (First)
Cylinder Head Nuts (M10) (Final)
Cylinder Head Outer Cover Bolts
Cylinder Head Inner Cover Bolts
Plugs
Rocker Case Bolts (M8)
Rocker Case Bolts (M6)
Spark Plugs
Water Pipe Fitting Bolts
N·m
9.8
39
70
77
20
39
9.8
9.8
20
20
9.8
18
9.8
Torque
kgf·m
1.0
4.0
7.1
7.8
2.0
4.0
1.0
1.0
2.0
2.0
1.0
1.8
1.0
ft·lb
87 in·lb
29
52
57
15
29
87 in·lb
87 in·lb
15
15
87 in·lb
13
87 in·lb
11. “R” marked side faces up.
12. “RN” marked side faces up.
13. Hollow mark faces exhaust side.
G: Apply grease.
L: Apply a non-permanent locking agent.
MO: Apply molybdenum disulfide oil solution.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1)
R: Replacement Parts
S: Follow the specified tightening sequence.
SS: Apply silicone sealant.
WL: Apply soap and water solution or rubber lubricant.
Remarks
MO, S
MO, S
L
L
S
S
5-4 ENGINE TOP END
Exploded View
ENGINE TOP END 5-5
Exploded View
No.
1
2
3
4
5
Fastener
Camshaft Chain Tensioner Bolts
Camshaft Sprocket Bolts
Exhaust Pipe Holder Nuts
Muffler Body Mounting Bolt
Rear Camshaft Chain Guide Retainer Bolts
N·m
12
15
17
25
9.8
Torque
kgf·m
1.2
1.5
1.7
2.5
1.0
ft·lb
106in·lb
11
12
18
87 in·lb
6. HLA (Hydraulic Lash Adjuster)
7. Oxygen Sensor (Equipped Models)
EO: Apply engine oil.
L: Apply a non-permanent locking agent.
M: Apply molybdenum disulfide grease.
MO: Apply molybdenum disulfide oil solution.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1)
R: Replacement Parts
SS: Apply silicone sealant.
Remarks
L
L
5-6 ENGINE TOP END
Exhaust System Identification
Exhaust Pipe Mark Position [A]
Left Muffler Body Mark Position [A]
ENGINE TOP END 5-7
Exhaust System Identification
Right Muffler Body Mark Position [A]
Right Muffler Body [A] with Hole [B] for Oxygen Sensor [C]
Honeycomb Type Catalyst Positions [A]
Left Muffler Body [B]
Right Muffler Body [C]
5-8 ENGINE TOP END
Specifications
Item
Rocker Shafts, Rocker Arms
Rocker Shaft Diameter
Rocker Arm Inside Diameter
Camshafts
Cam Height:
Exhaust
Inlet
Standard
Service Limit
15.976 ∼ 15.994 mm
(0.6289 ∼ 0.6296 in.)
16.016 ∼ 16.034 mm
(0.6305 ∼ 0.6312 in.)
15.95 mm (0.6279 in.)
34.422 ∼ 34.536 mm
34.32 mm (1.351 in.)
(1.3552 ∼ 1.3597 in.)
34.407 ∼ 34.521 mm
34.31 mm (1.350 in.)
16.07 mm (0.6326 in.)
(1.3546 ∼ 1.3591 in.)
Camshaft Journal/Rocker Case 0.020 ∼ 0.062 mm (0.0008 ∼ 0.0024 in.) 0.15 mm (0.0059 in.)
Clearance
Camshaft Journal Diameter
25.959 ∼ 25.980 mm
25.93 mm (1.021 in.)
(1.0220 ∼ 1.0228 in.)
Rocker Case Bearing Inside
26.000 ∼ 26.021 mm
26.08 mm (1.027 in.)
Diameter
(1.0236 ∼ 1.0244 in.)
Camshaft Runout
TIR 0.02 mm (0.0008 in.) or less
TIR 0.1 mm (0.004 in.)
Cylinder Heads
Cylinder Compression
(Usable Range)
Cylinder Head Warp
Valves
Valve Clearance
Valve Head Thickness:
Exhaust
Inlet
Valve Stem Bend
Valve Stem Diameter:
Exhaust
Inlet
Valve Guide Inside Diameter:
Exhaust
Inlet
Valve/Valve Guide Clearance
(Wobble Method):
Exhaust
Inlet
Valve Seat Cutting Angle
420 ∼ 698 kPa (4.3 ∼ 7.1 kgf/cm2, 61 ∼
101 psi) at 300 r/min (rpm)
–––
Non-adjustable (HLA Type)
1.0 mm (0.039 in.)
0.6 mm (0.024 in.)
TIR 0.01 mm (0.0004 in.) or less
– – –
0.05 mm ( 0.002 in.)
– – –
0.6 mm (0.024 in.)
0.3 mm (0.012 in.)
TIR 0.05 mm (0.002 in.)
5.955 ∼ 5.970 mm (0.2344 ∼ 0.2350 in.)
5.965 ∼ 5.980 mm (0.2348 ∼ 0.2354 in.)
5.94 mm (0.234 in.)
5.95 mm (0.234 in.)
6.000 ∼ 6.012 mm (0.2362 ∼ 0.2367 in.)
6.000 ∼ 6.012 mm (0.2362 ∼ 0.2367 in.)
6.08 mm (0.239 in.)
6.08 mm (0.239 in.)
0.07 ∼ 0.14 mm (0.0028 ∼ 0.0055 in.)
0.04 ∼ 0.10 mm (0.0016 ∼ 0.0039 in.)
32°, 45°, 55°, 60°
0.30 mm (0.012 in.)
0.25 mm (0.010 in.)
– – –
ENGINE TOP END 5-9
Specifications
Item
Valve Seating Surface:
Width:
Exhaust
Inlet
Outside Diameter:
Exhaust
Inlet
Valve Spring Free Length
Cylinders, Pistons
Cylinder Inside Diameter
Piston Diameter
Piston/Cylinder Clearance
Piston Ring/Groove Clearance:
Top
Second
Piston Ring Groove Width:
Top
Second
Piston Ring Thickness:
Top
Second
Piston Ring End Gap:
Top
Second
Standard
0.8 ∼ 1.2 mm (0.031 ∼ 0.047 in.)
0.8 ∼ 1.2 mm (0.031 ∼ 0.047 in.)
34.9 ∼ 35.1 mm (1.374 ∼ 1.382 in.)
38.9 ∼ 39.1 mm (1.531 ∼ 1.539 in.)
49.2 mm (1.937 in.)
102.000 ∼ 102.012 mm
Service Limit
– – –
– – –
– – –
– – –
47.5 mm (1.87 in.)
102.10 mm (4.020 in.)
(4.0157 ∼ 4.0162 in.)
101.942 ∼ 101.957 mm
101.79 mm (4.007 in.)
(4.0135 ∼ 4.0140 in.)
0.043 ∼ 0.070 mm (0.0017 ∼ 0.0028 in.)
– – –
0.04 ∼ 0.07 mm (0.0015 ∼ 0.0027 in.)
0.02 ∼ 0.06 mm (0.0007 ∼ 0.0023 in.)
0.17 mm (0.0067 in.)
0.16 mm (0.0063 in.)
1.23 ∼ 1.24 mm (0.0484 ∼ 0.0488 in.)
1.21 ∼ 1.23 mm (0.0476 ∼ 0.0484 in.)
1.32 mm (0.0520 in.)
1.31 mm (0.0516 in.)
1.17 ∼ 1.19 mm (0.0461 ∼ 0.0469 in.)
1.17 ∼ 1.19 mm (0.0461 ∼ 0.0469 in.)
1.10 mm (0.0433 in.)
1.10 mm (0.0433 in.)
0.25 ∼ 0.35 mm (0.0098 ∼ 0.0138 in.)
0.40 ∼ 0.55 mm (0.0157 ∼ 0.0217 in.)
0.7 mm (0.028 in.)
0.9 mm (0.035 in.)
5-10 ENGINE TOP END
Special Tools and Sealant
Compression Gauge, 20 kgf/cm²:
57001-221
Valve Seat Cutter, 45° 57001-1117
41.5:
Valve Spring Compressor Assembly:
57001-241
Valve Seat Cutter, 32° 57001-1122
38.5:
Valve Spring Compressor Adapter, 28.2:
57001-243
Valve Seat Cutter, 60° 57001-1124
41:
Valve Guide Arbor,
57001-1021
Valve Seat Cutter Holder Bar:
57001-1128
5.5:
Piston Ring Compressor Grip:
57001-1095
Piston Ring Compressor Belt, 95 ∼ 108:
57001-1358
ENGINE TOP END 5-11
Special Tools and Sealant
Valve Seat Cutter, 45° 57001-1496
40:
Valve Seat Cutter Holder,
57001-1576
Valve Seat Cutter, 55° 57001-1497
38.5:
Valve Guide Reamer,
57001-1596
Valve Seat Cutter, 32°57001-1515
44:
Compression Gauge Adapter, M12 × 1.25:
57001-1733
Valve Guide Driver:
57001-1564
Piston Pin Puller:
57001-1568
6:
6:
Kawasaki Bond (Silicone Sealant):
92104-0004
5-12 ENGINE TOP END
Clean Air System
Air Suction Valve Removal
Air Suction Valve of Front Cylinder
Remove:
Cylinder Head Inner Cover (see Cylinder Head Cover
Removal)
Air Suction Valve [A]
•
Air Suction Valve of Rear Cylinder
Remove:
Engine (see Engine Removal in the Engine Removal/Installation chapter)
Cylinder Head Inner Cover (see Cylinder Head Cover
Removal)
Air Suction Valve [A]
•
Air Suction Valve Installation
the air suction valve [A] so that the stopper [B] of
• Install
the reed faces downward.
Air Suction Valve Inspection
the air suction valve (see Air Suction Valve Re• Remove
moval).
inspect the reeds [A] for cracks, folds, warps,
• Visually
heat damage or other damage.
•
If there is any doubt as to the condition of the reeds, replace the air suction valve as an assembly.
Check the reed contact areas [B] of the valve holder for
grooves, scratches, any signs of separation from the
holder or heat damage.
If there is any doubt as to the condition of the reed contact
areas, replace the air suction valve as an assembly.
If any carbon or other foreign particles have accumulated
between the reed and the reed contact area, wash the
valve assembly clean with a high-flash point solvent.
CAUTION
Do not scrape off the deposits with a scraper as this
could damage the rubber, requiring replacement of
the suction valve assembly.
ENGINE TOP END 5-13
Clean Air System
Air Switching Valve Removal
CAUTION
Never drop the air switching valve, especially on
a hard surface. Such a shock to the air switching
valve can damaged it.
the ignition coils (see Ignition Coil Removal in
• Remove
the Electrical System chapter).
• Disconnect the connector [A].
the hoses [A] from the air switching valve [B],
• Separate
and remove the air switching valve.
Air Switching Valve Installation
that the rubber protector [A] is installing on the air
• Check
switching valve [B] correctly.
the air switching valve [A] with hoses as shown in
• Install
the figure.
White Marks [B]
Rubber Damper [C]
Front [D]
Upside View [E]
Front View [F]
Air Switching Valve Operation Test
to the Air Suction System Damage Inspection in the
• Refer
Periodic Maintenance chapter.
5-14 ENGINE TOP END
Clean Air System
Air Switching Valve Unit Test
to the Air Switching Valve Unit Test in the Electrical
• Refer
System chapter.
Clean Air System Hose Inspection
certain that all the hoses are routed without being flat• Be
tened or kinked, and are connected correctly to the air
cleaner housing, air switching valve, and fittings on the
cylinder head covers.
If they are not, correct them. Replace them if they are
damaged.
ENGINE TOP END 5-15
Cylinder Head Covers
Cylinder Head Cover Removal
Front Cylinder Head Cover
Remove:
Air Switching Valve (see Air Switching Valve Removal)
Cylinder Head Outer Cover Bolts [A] with Collars
Cylinder Head Outer Covers [B]
•
• Remove:
Cylinder Head Inner Cover Bolts [A] with Gaskets
Cylinder Head Inner Cover [B]
Rear Cylinder Head Cover
Remove:
Engine (see Engine Removal in the Engine Removal/Installation chapter)
Cylinder Head Outer Cover Bolts [A] with Collars
Plate [B] with Collar
Cylinder Head Outer Covers [C]
•
• Remove:
Cylinder Head Inner Cover Bolts [A] with Gaskets
Cylinder Head Inner Cover [B]
Cylinder Head Cover Installation
installing the cylinder head inner cover, be sure to
• Before
install the following parts.
Dowel Pin [A]
Plug Hole Gasket (Upper) [B]
Air Suction Valve (see Air Suction Valve Cover Installation)
5-16 ENGINE TOP END
Cylinder Head Covers
the cylinder head inner cover gasket [A] with a
• Replace
new one, and install it on the cylinder head inner cover
•
[B].
Apply silicone sealant to the mating surface of the half
-month portion [C], and install the gasket on the cylinder
head.
Sealant - Kawasaki Bond (Silicone Sealant) : 92104-0004
installation, wipe up the silicone sealant that seeps
• After
out around the mating surface.
the gaskets [A] with new ones.
• Replace
Tighten:
•
Torque - Cylinder Head Inner Cover Bolts [B] : 9.8 N·m (1.0
kgf·m, 87 in·lb)
the trim [A] to the cylinder head outer cover [B],
• Install
and fit the trim onto the slot [C] of the cylinder head inner
•
cover [D].
Install the cylinder head outer cover of the other side in
the same way.
NOTE
○The front and rear cylinder head cover installation are
same procedures as until above procedures.
Front Cylinder Head Cover
Install the collars [A] on the seating surfaces (shaded portions) [B] of the cylinder head outer covers [C] as shown
in the figure.
Apply a non-permanent locking agent to the threads of
the cylinder head outer cover bolts [D], and tighten them.
•
•
Torque - Cylinder Head Outer Cover Bolts: 9.8 N·m (1.0
kgf·m, 87 in·lb)
ENGINE TOP END 5-17
Cylinder Head Covers
Rear Cylinder Head Cover
Install the collars [A] on the seating surfaces (shaded portions) [B] of the cylinder head outer covers [C] as shown
in the figure.
Install the plate [D] so that the tabs [E] fit onto the seating
surface of the cylinder head outer cover as shown in the
figure.
Apply a non-permanent locking agent to the threads of
the cylinder head outer cover bolts [F], and tighten them.
•
•
•
Torque - Cylinder Head Outer Cover Bolts: 9.8 N·m (1.0
kgf·m, 87 in·lb)
5-18 ENGINE TOP END
Rocker Cases
Rocker Case Removal
Front Rocker Case
Remove:
Cylinder Head Inner Cover (see Cylinder Head Cover
Removal)
Alternator Cover (see Alternator Cover Removal in the
Electrical System chapter)
•
a wrench on the alternator rotor bolt, turn the
• Using
crankshaft clockwise [A] until the “FRONT” mark line
(TDC mark for front piston) [B] of the alternator rotor [C]
is aligned with the projection [D] of the crankcase.
○Remove the spark plug (see Spark Plug Replacement in
the Periodic Maintenance chapter) to turn the crankshaft
easily.
If the alternator rotor was removed, perform the next procedure.
○Install the alternator bolt [A] together with the washer [B]
on the crankshaft temporary.
○Using
a wrench on the alternator rotor bolt, turn the
crankshaft clockwise [A] until the “F” mark line (TDC
mark for front piston) [B] of the balancer chain sprocket
[C] is aligned with the line [D] of the crankcase.
that the front camshaft chain timing is positioned
• Check
as shown in the figure.
“ ” Mark [A] of Camshaft Sprocket
Timing Marks [B] of Weights
Upper Surface of Cylinder Head [C]
Left Side View [D]
○The timing marks must be aligned with the cylinder head
upper surface.
ENGINE TOP END 5-19
Rocker Cases
the camshaft chain tensioner (see Camshaft
• Remove
Chain Tensioner Removal).
the M6 and M8 rocker case bolts as shown se• Loosen
quence [1 ∼ 6] in the figure, and remove them.
the rocker case [A], and remove the front camshaft
• Lift
chain guide [B] from the pin of the case.
NOTE
○The cylinder head and rocker case are machined in the
assemble state, so they must be used as a set. Be
careful not to mix them up for front and rear cylinders.
Rear Rocker Case
Remove:
Cylinder Head Inner Cover (see Cylinder Head Cover
Removal)
Alternator Cover (see Alternator Cover Removal in the
Electrical System chapter)
•
a wrench on the alternator rotor bolt, turn the crank• Using
shaft clockwise [A] until the “REAR” mark line (TDC mark
for rear piston) [B] of the alternator rotor [C] is aligned with
the projection [D] of the crankcase.
○Remove the spark plug (see Spark Plug Replacement in
the Periodic Maintenance chapter) to turn the crankshaft
easily.
If the alternator rotor was removed, perform the next procedure.
○Install the alternator bolt [A] together with the washer [B]
on the crankshaft temporarily.
5-20 ENGINE TOP END
Rocker Cases
○Using
a wrench on the alternator rotor bolt, turn the
crankshaft clockwise [A] until the “R” mark line (TDC
mark for rear piston) [B] of the balancer chain sprocket
[C] is aligned with the line [D] of the crankcase.
that the rear camshaft chain timing is positioned
• Check
as shown in the figure.
“ ” Mark [A] of Camshaft Sprocket
Timing Marks [B] of Weights
Upper Surface of Cylinder Head [C]
Right Side View [D]
○The timing marks must be aligned with the cylinder head
upper surface.
the camshaft chain tensioner (see Camshaft
• Remove
Chain Tensioner Removal).
the M6 and M8 rocker case bolts as shown se• Loosen
quence [1 ∼ 6] in the figure, and remove them.
the rocker case [A], and remove the front camshaft
• Lift
chain guide [B] from the pin of the case.
NOTE
○The cylinder head and rocker case are machined in the
assemble state, so they must be used as a set. Be
careful not to mix them up for front and rear cylinders.
Rocker Case Installation
installing rocker case, check that the crankshaft
• Before
is positioned at TDC and at the end of the compression
stroke.
ENGINE TOP END 5-21
Rocker Cases
molybdenum disulfide oil solution to all cam parts
• Apply
and journals.
the plug hole gasket [A] so that the cutout portions
• Install
[B] fit onto the ribs [C] of the cylinder head.
• Install the dowel pins [A].
the pin [A] of the rocker case to the hole of the front
• Insert
camshaft chain guide [B].
the rocker case so that the pin [C] fits onto the
• Install
groove [D] of the rear camshaft chain guide [E].
the rocker case bolts following the specified tight• Tighten
ening sequence.
Inlet Side [A]
Torque - Rocker Case Bolts (M8) [1 ∼ 4] : 20 N·m (2.0 kgf·m,
15 ft·lb)
Rocker Case Bolts (M6) [5, 6] : 9.8 N·m (1.0 kgf·m,
87 in·lb)
5-22 ENGINE TOP END
Rocker Cases
the camshaft chain tensioner (see Camshaft Chain
• Install
Tensioner Installation).
installing the camshaft chain tensioner, check to be
• After
sure that the camshaft chain timing is correct.
the crankshaft clockwise and recheck the camshaft
• Turn
chain timing.
ENGINE TOP END 5-23
Rocker Shafts, Rocker Arms
Rocker Shaft and Rocker Arm Removal
• Remove:
Rocker Case (see Rocker Case Removal)
Rocker Shafts [A]
Rocker Arms [B]
Rocker Shaft and Rocker Arm Installation
molybdenum disulfide oil solution to the rocker
• Apply
shafts.
○The rocker shafts are identical.
the rocker shafts into the rocker case and rocker
• Insert
arms so that the notches [A] face to the plug hole side
•
[B].
Align the M8 bolt holes [C] of the rocker case and the
notches of the rocker shaft.
Rocker Arm Assembly
a flat-end bar [A] and a block [B] with a recess
• Prepare
[C].
the oil chamber [D] for the HLA into the rocker arm
• Press
end [E] until the chamber end is even with the step [F] of
the hole.
○Install the oil chamber so that the air bleed hole [G] is
placed as shown in the figure. This makes HLA bleeding
easier.
Rocker Shaft Diameter Measurement
the rocker shaft (see Rocker Shaft and Rocker
• Remove
Arm Removal).
the diameter [A] of the rocker shaft where the
• Measure
rocker arm pivots on it with a micrometer.
If the rocker shaft diameter is smaller than the service
limit, replace it. Also check the rocker arm inside diameter
(see Rocker Arm Inspection).
Rocker Shaft Diameter
Standard:
15.976 ∼ 15.994 mm (0.6289 ∼ 0.6296 in.)
Service Limit: 15.95 mm (0.6279 in.)
5-24 ENGINE TOP END
Rocker Shafts, Rocker Arms
Rocker Arm Inspection
the rocker arm (see Rocker Shaft and Rocker
• Remove
Arm Removal).
the area [A] on the rocker arm where the cam
• Inspect
rubs.
•
If the rocker arm is scored, discolored or otherwise damaged, replace it. Also inspect the camshaft lobes.
Measure the inside diameter [B] of the rocker arm with a
dial bore gauge.
If the rocker arm inside diameter is larger than the service
limit, replace it. Also check the rocker shaft diameter (see
Rocker Shaft Diameter Measurement).
Rocker Arm Inside Diameter
Standard:
16.016 ∼ 16.034 mm (0.6305 ∼ 0.6312 in.)
Service Limit: 16.07 mm (0.6326 in.)
ENGINE TOP END 5-25
HLA (Hydraulic Lash Adjuster)
HLA Removal
the rocker arm (see Rocker Shaft and Rocker
• Remove
Arm Removal).
the HLA (Hydraulic Lash Adjuster) [A] out of the
• Pull
rocker arm with fingers.
CAUTION
Be careful not to damage or deform an HLA by tapping it during removal or installation.
Do not drop the HLA or hit it sharply. If it is damaged, the plunger will not operate smoothly.
HLA Installation
that the HLA plunger is not damaged.
• Check
If the plunger does damage, replace the HLA.
HLA Body [A]
O-ring [B]
Plunger Spring [C]
Pivot Plunger [D]
Check Valve [E]
Check Valve Spring [F]
the HLA (see HLA Air Bleeding).
• Air-bleed
a rocker arm [A] in engine oil, and then insert the
• Soak
HLA [B] into the rocker arm.
○Be careful not to tip the rocker arm having the HLA, and
not to allow engine oil to leak out of the HLA.
HLA Air Bleeding
a container with engine oil.
• Fill
Prepare
thumbtack and cut its needle to 2.1 ∼ 2.3 mm
• (0.0827 ∼a 0.0906
in.) long [A]. Grind its cutting edge [B]
•
smooth.
Push in the check valve of the HLA [D] with the needle of
the tack [C] and move the plunger up and down in the oil
bath.
If the plunger sinks into the HLA body, repeat the air
bleeding procedure and then push the plunger.
After air bleeding, if the plunger sinks into the HLA body
again, replace the HLA.
CAUTION
Do not push the check valve in more than 2.1 ∼ 2.3
mm (0.0827 ∼ 0.0906 in.). Pushing too deep may
cause the damage of the HLA.
5-26 ENGINE TOP END
Camshaft Chain Tensioners
Camshaft Chain Tensioner Removal
CAUTION
Do not turn over the crankshaft while the tensioner
is removed. This could upset the camshaft chain
timing, and damage the valves.
Front Camshaft Chain Tensioner
Remove the alternator rotor (see Alternator Rotor Removal in the Electrical System chapter).
Push the camshaft chain while pushing the stopper [A] to
push the push rod [B] into the interior of tensioner body
[C].
Insert the suitable pin into the hole [D] to hold the rod in
place.
•
•
•
• Remove:
Camshaft Chain Tensioner Bolts [A]
Camshaft Chain Tensioner [B]
After
○ removing the chain tensioner, do not remove the pin
[C].
Rear Camshaft Chain Tensioner
Remove:
Clutch Cover (see Clutch Cover Removal in the Clutch
chapter)
Upper Primary Chain Guide (see Clutch Removal in the
Clutch chapter)
Push the camshaft chain while pushing the stopper [A] to
push the push rod [B] into the interior of tensioner body
[C].
Insert the suitable pin into the hole [D] to hold the rod in
place.
•
•
•
• Remove:
Camshaft Chain Tensioner Bolts [A]
Camshaft Chain Tensioner [B]
After
○ removing the chain tensioner, do not remove the pin
[C].
ENGINE TOP END 5-27
Camshaft Chain Tensioners
Camshaft Chain Tensioner Installation
If the pin was removed, install it as follows.
○Push the push rod [A] into the interior of tensioner body
[B] while pushing the stopper [C].
CAUTION
Be careful the oil remaining in the tensioner body
dashes out.
○Insert the suitable pin [A] into the hole [B] to hold the rod
in place.
a non-permanent locking agent to the threads of
• Apply
the camshaft chain tensioner bolts [A], and tighten them.
Torque - Camshaft Chain Tensioner Bolts : 12 N·m (1.2
kgf·m, 106 in·lb)
tightening the camshaft chain tensioner bolts, pull
• After
out the pin [B] from the tensioner body to free the push
rod.
○Push the push rod (camshaft chain) to pull out the pin.
5-28 ENGINE TOP END
Camshafts, Camshaft Chains, Camshaft Sprockets
Camshaft Removal
NOTE
○The front and rear camshaft removal are same procedures.
• Remove:
Engine (see Engine Removal in the Engine Removal/In•
•
stallation chapter)
Rocker Case (see Rocker Case Removal)
Disengage the camshaft chain [A] from the camshaft
sprocket, and remove the camshaft [B].
Support the camshaft chain using a suitable tool.
CAUTION
The crankshaft may be turned while the camshaft is
removed. Always pull the chain taut while turning
the crankshaft. This avoids kinking the chain on the
lower (crankshaft) sprocket. A kinked chain could
damage both the chain and the sprocket.
Camshaft Installation
NOTE
○The front and rear camshafts are different.
The rear
camshaft [A] has a groove [B] for identification. Be careful not to mix up these shafts.
molybdenum disulfide oil solution to all cam parts
• Apply
and journals.
install the front camshaft as follows.
•○First,
Install the alternator bolt together with the washer on the
crankshaft temporarily (see Rocker Case Removal).
○Using a wrench on the alternator rotor bolt, turn the
crankshaft clockwise [A] until the “F” mark line (TDC
mark for front piston) [B] of the balancer chain sprocket
[C] is aligned with the line [D] of the crankcase.
CAUTION
The crankshaft may be turned while the camshaft is
removed. Always pull the chain taut while turning
the crankshaft. This avoids kinking the chain on the
lower (crankshaft) sprocket. A kinked chain could
damage both the chain and the sprocket.
ENGINE TOP END 5-29
Camshafts, Camshaft Chains, Camshaft Sprockets
If the rear camshaft chain guide [A] was removed, be sure
to install it first.
Torque - Rear Camshaft Chain Guide Retainer Bolt : 9.8
N·m (1.0 kgf·m, 87 in·lb)
Left Side View [B]
○Pull the tension side (inlet side) [C] of the chain taut to
install the chain.
○Face the “ ” mark [D] of the sprocket upward.
○Engage the camshaft chain with the sprocket so that the
timing marks [E] on the weights are aligned with the cylinder head upper surface [F].
○Install:
Front Rocker Case (see Rocker Case Removal)
Front Camshaft Chain Tensioner (see Camshaft Chain
Tensioner Installation)
○After installing the above parts, check to be sure that the
front camshaft chain timing is correct.
install the rear camshaft as follows.
•○Next,
Using a wrench on the alternator rotor bolt, turn the crankshaft clockwise [A] by one rotation (360° turn from the
front piston TDC), and then turn the crankshaft clockwise
(52° turn from the front piston TDC) until the “R” mark
line (TDC mark for rear piston) [B] of the balancer chain
sprocket [C] is aligned with the line [D] of the crankcase.
CAUTION
The crankshaft may be turned while the camshaft is
removed. Always pull the chain taut while turning
the crankshaft. This avoids kinking the chain on the
lower (crankshaft) sprocket. A kinked chain could
damage both the chain and the sprocket.
If the rear camshaft chain guide [A] was removed, be sure
to install it first.
Torque - Rear Camshaft Chain Guide Retainer Bolt : 9.8
N·m (1.0 kgf·m, 87 in·lb)
Right Side View [B]
○Pull the tension side (exhaust side) [C] of the chain taut
to install the chain.
○Face the “ ” mark [D] of the sprocket upward.
○Engage the camshaft chain with the sprocket so that the
timing marks [E] on the weights are aligned with the cylinder head upper surface [F].
○Install:
Rear Rocker Case (see Rocker Case Removal)
Rear Camshaft Chain Tensioner (see Camshaft Chain
Tensioner Installation)
After
installing the above parts, check to be sure that the
○
rear camshaft chain timing is correct.
○Turn the crankshaft clockwise and recheck the front/rear
camshaft chain timing.
5-30 ENGINE TOP END
Camshafts, Camshaft Chains, Camshaft Sprockets
Camshaft, Rocker Case Wear
the rocker cases (see Rocker Case Removal).
• Remove
Cut
strips
of plastigage to journal width. Place a strip
• on each journal
parallel to the camshaft installed in the
•
•
correct position.
Measure each clearance between the camshaft journal
and the rocker case using plastigage (press gauge).
Tighten the rocker case bolts to the specified torque (see
Rocker Case Installation).
NOTE
○Do not turn the camshaft when the plastigage is between the journal and rocker case.
the rocker case again, and measure the plasti• Remove
gage width [A] to determine the clearance between each
journal and the rocker case. Measure the maximum plastigage width.
Camshaft Journal/Rocker Case Clearance
Standard:
0.020 ∼ 0.062 mm (0.0008 ∼ 0.0024 in.)
Service Limit: 0.15 mm (0.0059 in.)
If any clearance exceeds the service limit, measure the
diameter of each camshaft journal with a micrometer.
Camshaft Journal Diameter
Standard:
25.959 ∼ 25.980 mm (1.0220 ∼ 1.0228 in.)
Service Limit: 25.93 mm (1.021 in.)
If the camshaft journal diameter is less than the service
limit, replace the camshaft with a new one and measure
the clearance again.
If the clearance still remains out of the limit, replace the
rocker case and cylinder head as a set.
CAUTION
The rocker case and cylinder head are machined in
the assembled state, so they must be replaced as a
set.
Camshaft Runout
the camshaft (see Camshaft Removal).
• Remove
Set
the
camshaft
in a camshaft alignment jig or on V
• blocks.
runout with a dial gauge at the specified place
• Measure
as shown in the figure.
If the runout exceeds the service limit, replace the shaft.
Camshaft Runout
Standard:
Service Limit:
TIR 0.02 mm (0.0008 in.) or less
TIR 0.1 mm (0.004 in.)
ENGINE TOP END 5-31
Camshafts, Camshaft Chains, Camshaft Sprockets
Cam Wear
the camshaft (see Camshaft Removal).
• Remove
Measure
[A] of each cam with a micrometer.
• If the camstheareheight
worn down past the service limit, replace
the camshaft.
Cam Height
Standard:
Exhaust
34.422 ∼ 34.536 mm (1.3552 ∼ 1.3597 in.)
Inlet
34.407 ∼ 34.521 mm (1.3546 ∼ 1.3591 in.)
Service Limit:
Exhaust
34.32 mm (1.351 in.)
Inlet
34.31 mm (1.350 in.)
Camshaft Chain Removal
Front Camshaft Chain
Remove:
Front Camshaft (see Camshaft Removal)
Balancer Chain Sprocket (see Balancer Mechanism Removal in the Crankshaft/Transmission chapter)
Front Camshaft Chain Guide [A]
Rear Camshaft Chain Guide Retainer Bolt [B] with Retainer [C]
Rear Camshaft Chain Guide [D]
Remove the front camshaft chain [E] from the crankshaft
sprocket, and then pull out the chain to downward.
•
•
Rear Camshaft Chain
Remove:
Rear Camshaft (see Camshaft Removal)
Damper Cam Sprocket (see Clutch Removal in the
Clutch chapter)
Front Camshaft Chain Guide [A]
Rear Camshaft Chain Guide Retainer Bolt [B] with Retainer [C]
Rear Camshaft Chain Guide [D]
Remove the front camshaft chain [E] from the crankshaft
sprocket, and then pull out the chain to downward.
•
•
Camshaft Chain Installation
is reverse of removal, note the following.
•○Installation
Tighten:
Torque - Rear Camshaft Chain Guide Retainer Bolt : 9.8
N·m (1.0 kgf·m, 87 in·lb)
Camshaft Sprocket Removal
NOTE
○The front and rear camshaft sprocket removal are same
procedures.
• Remove:
Camshaft (see Camshaft Removal)
Weights of KACR (see KACR Removal)
Camshaft Sprocket Bolts [A]
Camshaft Sprocket [B]
5-32 ENGINE TOP END
Camshafts, Camshaft Chains, Camshaft Sprockets
Camshaft Sprocket Installation
the camshaft sprockets as shown in the figure.
• Install
Exhaust Cam Positions [A]
Push Rods of KACR [B]
Front Camshaft Sprocket [C]
Rear Camshaft Sprocket [D]
The
○ front and rear camshaft sprockets are identical.
Apply a non-permanent locking agent to the threads of
the camshaft sprocket bolts, and tighten them.
•
Torque - Camshaft Sprocket Bolts : 15 N·m (1.5 kgf·m, 11
ft·lb)
ENGINE TOP END 5-33
KACR (Kawasaki Automatic Compression Release)
KACR Inspection
The KACR (Kawasaki Automatic Compression Release)
momentarily opens the exhaust valves on the compression
stroke at very low speeds. In this model, the KACR is operated at 400 ∼ 500 r/min (rpm). This allows some of the compression pressure to escape, making it easy to turn over the
engine during starting.
Due to the simplicity of the mechanism, no periodic maintenance is needed. There are only two symptoms of problems with the KACR mechanism [A]: compression is not released during starting, and compression is released during
running.
(1) If compression is not released during starting, the
weights are not returning to their rest position.
Remove the camshaft (see Camshaft Removal).
Visually inspect the spring.
If damaged, deformed, or missing, replace the spring.
Remove the spring and move the weights back and forth.
If the weights do not move smoothly, replace the KACR
parts as a set. Also inspect the exhaust rocker arm for
any damage, and replace the rocker arm if necessary.
[A] Rest Position (compression is released) [A]
Weights [B]
Spring [C]
•
•
•
(2) If compression is released while the engine is running,
the weights are not swinging out.
Remove the spring and move the weights back and forth.
If the weights do not move easily from the retracted position, replace the KACR parts as a set. Also inspect the exhaust rocker arm for any damage, and replace the rocker
arm if necessary.
Running Position (compression is not released) [A]
Weights [B]
Spring [C]
•
KACR Removal
NOTE
○The front and rear KACR removal are same procedures.
• Remove:
Camshaft (see Camshaft Removal)
Spring [A]
Circlips [B]
Weights [C]
5-34 ENGINE TOP END
KACR (Kawasaki Automatic Compression Release)
the suitable wire [A] into the hole of the push rod
• Insert
[B] to hold it in place.
out the shaft [A] from the camshaft, and then remove
• Pull
the push rod [B].
○After removing the push rod, do not remove the wire [C].
KACR Installation
If the wire was removed, install it as follows.
○Assemble the following parts.
Holder [A]
Spring [B]
Push Rod [C]
○Push the push rod [A] using a suitable bar from the hole
[B] of the holder bottom.
○Insert the suitable wire [C] into the hole of the push rod to
hold it in place.
NOTE
○The front KACR shaft has a “F” mark [A] and the rear
KACR shaft has a “R” mark [B]. Be careful not to mix up
these shafts.
ENGINE TOP END 5-35
KACR (Kawasaki Automatic Compression Release)
the push rod [A], and then insert the shaft [B] to the
• Install
camshaft.
• Pull out the wire [C] from the hole of the push rod.
front KACR, set the shaft so that the “F” mark [A] is
• For
aligned with the “ ” mark [B] of the camshaft sprocket as
shown in the figure.
rear KACR, set the shaft so that the “R” mark [A] is
• For
aligned with the “ ” mark [B] of the camshaft sprocket as
shown in the figure.
the weight on the camshaft sprocket.
•○Install
Hook the arms [A] on the pins of the KACR shaft.
○The weights are identical.
the circlips [B] with new ones, and install them.
• Replace
Hook
the
[C] from the outside with the open side of
• the hook spring
inwards.
installing the KACR, check that the KACR is oper• After
ated correctly as follows.
○First, pull the weights [A] to outside [B] by hand and check
that the push rod [C] is pulled to inside [D].
If the operation of the KACR is different, reinstall it.
5-36 ENGINE TOP END
KACR (Kawasaki Automatic Compression Release)
○Next, release the hand from the weights [A], and check
that the weights and push rod [B] are returned to original
position.
○When releasing the hand from the weights, the push rod
must be pushed out [C].
If the operation of the KACR is different, reinstall it.
ENGINE TOP END 5-37
Cylinder Heads
Cylinder Compression Measurement
NOTE
○Use the battery which is fully charged.
up the engine thoroughly.
• Warm
the engine.
• Stop
Remove
spark plugs (see Spark Plug Replacement in the
• Periodic Maintenance
chapter).
the compression gauge [A] and adapter [B] firmly
• Attach
into the spark plug hole.
○Using the starter motor, turn the engine over with the throttle fully open until the compression gauge stops rising; the
compression is the highest reading obtainable.
Special Tools - Compression Gauge, 20 kgf/cm²: 57001-221
Compression Gauge Adapter, M12 × 1.25:
57001-1733
Cylinder Compression
Usable Range:
420 ∼ 698 kPa (4.3 ∼ 7.1 kgf/cm²,
61 ∼ 101 psi) at 300 r/min (rpm)
the measurement for the other cylinder.
• Repeat
Install
the
plugs (see Spark Plug Replacement in
• the Periodicspark
Maintenance chapter).
The following table should be consulted if the obtainable compression reading is not within the usable range.
Problem
Diagnosis
Cylinder
compression
is higher than
usable range
Carbon accumulation on piston and in
combustion chamber possibly due to
damaged valve stem oil seal and/or
damaged piston oil rings (This may be
indicated by white exhaust smoke.)
Incorrect cylinder head gasket thickness
Damaged or missing KACR spring
KACR weights do not move smoothly.
Gas leakage around cylinder head
Cylinder
compression
is lower than
usable range
Remedy (Action)
Remove the carbon deposits and replace
damaged parts if necessary.
Replace the gasket with a standard part.
Replace the KACR spring.
Replace the KACR.
Replace damaged gasket and check
cylinder head warp.
Bad condition of valve seating
Repair if necessary.
HLA seizure
Replace the HLA.
Incorrect piston/cylinder clearance
Replace the piston and/or cylinder.
Piston seizure
Inspect the cylinder and replace/repair
the cylinder and/or piston as necessary.
Bad condition of piston ring and/or piston Replace the piston and/or the piston
ring grooves
rings.
KACR weights do not move smoothly.
Replace the KACR.
5-38 ENGINE TOP END
Cylinder Heads
Cylinder Head Removal
NOTE
○The front and rear cylinder head removal are same procedures.
• Remove:
Camshaft (see Camshaft Removal)
Front Camshaft Chain Guide [A]
Rear Camshaft Chain Guide Retainer Bolt [B] with Retainer [C]
Rear Camshaft Chain Guide [D]
the cylinder head nuts, following the specified
• Remove
sequence.
○First, loosen the M10 nuts [A].
○Next, loosen the M12 nuts as shown sequence [1 ∼ 4] in
•
the figure.
Front Cylinder Head [B]
Rear Cylinder Head [C]
Remove the cylinder head.
Cylinder Head Installation
NOTE
○The rocker case is machined with the cylinder head, so
if a new cylinder head is installed, use the case that is
supplied with the new head.
the O-rings [A] of the upper oil pipe with new
• Replace
ones.
• Apply grease to the new O-rings.
ENGINE TOP END 5-39
Cylinder Heads
NOTE
○The front cylinder head gasket has a “F” mark [A] and
the rear cylinder head gasket has a “R” mark [B]. Be
careful not to mix up these gaskets.
the cylinder head gasket with a new one, and
• Replace
install it.
• Install the dowel pins [A].
NOTE
○The front cylinder head has a “F” mark [A] and the rear
cylinder head has a “R” mark [B]. Be careful not to mix
up these heads.
• Install the cylinder head.
5-40 ENGINE TOP END
Cylinder Heads
molybdenum disulfide oil solution to the following
• Apply
portions.
Threads of M10 Cylinder Head Nuts [A]
Threads of M12 Cylinder Head Nuts [B]
Both Sides of Washers [C]
the cylinder head nuts using the following steps.
•○Tighten
First, following the sequence numbers [1 ∼ 4] on the cylinder head, tighten the M12 cylinder head nuts [A].
Torque - Cylinder Head Nuts (M12)
First: 39 N·m (4.0 kgf·m, 29 ft·lb)
Final (New Nuts): 70 N·m (7.1 kgf·m, 52 ft·lb)
Final (Used Nuts): 77 N·m (7.8 kgf·m, 57 ft·lb)
○Next, tighten the M10 cylinder head nuts [B].
Torque - Cylinder Head Nuts (M10)
First: 20 N·m (2.0 kgf·m, 15 ft·lb)
Final: 39 N·m (4.0 kgf·m, 29 ft·lb)
Front Cylinder Head [C]
Rear Cylinder Head [D]
the front and rear camshaft chain guides.
• Install
Tighten:
•
Torque - Rear Camshaft Chain Guide Retainer Bolt : 9.8
N·m (1.0 kgf·m, 87 in·lb)
ENGINE TOP END 5-41
Cylinder Heads
Cylinder Head Warp
the cylinder head.
• Clean
Lay
a
straightedge
across the lower surface of the cylinder
• head at several positions.
a thickness gauge [A] to measure the space between
• Use
the straightedge [B] and the head.
Cylinder Head Warp
–––
Standard:
Service Limit: 0.05 mm (0.002 in.)
If the cylinder head is warped more than the service limit,
replace it.
If the cylinder head is warped less than the service limit,
repair the head by rubbing the lower surface on emery
paper secured to a surface plate (first No. 200, then No.
400).
5-42 ENGINE TOP END
Valves
Valve Clearance Inspection/Adjustment
NOTE
○Since
the HLA (hydraulic lash adjuster) constantly
maintain zero clearance, it is not necessary to inspect
or adjust the valve clearance.
Valve Removal
the cylinder head (see Cylinder Head Removal).
• Remove
the valve spring compressor assembly, remove the
• Using
valve.
Special Tools - Valve Spring Compressor Assembly [A]:
57001-241
Valve Spring Compressor Adapter, 28.2
[B]: 57001-243
Valve Installation
the oil seal with a new one.
• Replace
a thin coat of molybdenum disulfide grease to the
• Apply
valve stem before valve installation.
the springs so that the closed coil end faces down• Install
wards (the side painted in white faces upwards).
Valve Stem [A]
Oil Seal [B]
Spring Seat [C]
Closed Coil End [D]
Valve Spring [E]
Side Painted in White [F]
Retainer [G]
Split Keepers [H]
Valve Guide Removal
• Remove:
Valve (see Valve Removal)
•
Oil Seal
Spring Seat
Heat the area around the valve guide to 120 ∼ 150°C (248
∼ 302°F), and hammer lightly on the valve guide arbor [A]
to remove the guide from the top of the head.
CAUTION
Do not heat the cylinder head with a torch. This will
warp the cylinder head. Soak the cylinder head in
oil and heat the oil.
Special Tool - Valve Guide Arbor,
5.5: 57001-1021
ENGINE TOP END 5-43
Valves
Valve Guide Installation
oil to the valve guide outer surface before installa• Apply
tion.
the area around the valve guide hole to about 120 ∼
• Heat
150°C (248 ∼ 302°F).
CAUTION
Do not heat the cylinder head with a torch. This will
warp the cylinder head. Soak the cylinder head in
oil and heat the oil.
the valve guide driver [A], press and insert the valve
• Using
guide [B] in until its snap ring touches the head surface.
Special Tool - Valve Guide Driver: 57001-1564
until the cylinder head cools down and then ream the
• Wait
valve guide with the valve guide reamer [A] even if the old
guide is reused.
○Turn the reamer in a clockwaise direction until the reamer
turns freely in the guide. Never turn the reamer counterclockwise or it will be dulled.
○Once the guides are reamed they must be cleaned thoroughly.
Special Tool - Valve Guide Reamer, 6: 57001-1596
Valve-to-Guide Clearance Measurement (Wobble
Method)
If a small bore gauge is not available, inspect the valve
guide wear by measuring the valve to valve guide clearance
with the wobble method as indicated below.
Insert a new valve [A] into the guide [B] and set a dial
gauge against the stem perpendicular to it as close as
possible to the cylinder head mating surface.
Move the stem back and forth [C] to measure valve/valve
guide clearance.
Repeat the measurement in a direction at a right angle to
the first.
If the reading exceeds the service limit, replace the guide.
•
•
•
NOTE
○The reading is not actual valve/valve guide clearance
because the measuring point is above the guide.
Valve/Valve Guide Clearance (Wobble Method)
Standard:
Exhaust
0.07 ∼ 0.14 mm (0.0028 ∼ 0.0055 in.)
Inlet
0.04 ∼ 0.10 mm (0.0016 ∼ 0.0039 in.)
Service Limit:
Exhaust
0.30 mm (0.012 in.)
Inlet
0.25 mm (0.010 in.)
5-44 ENGINE TOP END
Valves
Valve Seat Inspection
the valve (see Valve Removal).
• Remove
Check
the
valve seating surface [A] between the valve [B]
• and valve seat
[C].
○Measure the outside diameter [D] of the seating pattern
on the valve seat.
If the outside diameter is too large or too small, repair the
seat (see Valve Seat Repair).
Valve Seating Surface Outside Diameter
Standard:
Exhaust
34.9 ∼ 35.1 mm (1.374 ∼ 1.382 in.)
Inlet
38.9 ∼ 39.1 mm (1.531 ∼ 1.539 in.)
○Measure the seat width [E] of the portion where there is
no build-up carbon (white portion) of the valve seat with a
vernier caliper.
Good [F]
If the width is too wide [G], too narrow [H] or uneven [J],
repair the seat (see Valve Seat Repair).
Valve Seating Surface Width
Standard:
Exhaust
0.8 ∼ 1.2 mm (0.031 ∼ 0.047 in.)
Inlet
0.8 ∼ 1.2 mm (0.031 ∼ 0.047 in.)
Valve Seat Repair
• Repair the valve seat with the valve seat cutters [A].
Special Tools Valve Seat Cutter Holder Bar [B]: 57001-1128
Valve Seat Cutter Holder,
6 [C]: 57001-1576
[For Exhaust Valve Seat]
Valve Seat Cutter, 45° -
40: 57001-1496
Valve Seat Cutter, 32° -
38.5: 57001-1122
Valve Seat Cutter, 55° -
38.5: 57001-1497
[For Inlet Valve Seat]
Valve Seat Cutter, 45° -
41.5: 57001-1117
Valve Seat Cutter, 32° -
44: 57001-1515
Valve Seat Cutter, 60° -
41: 57001-1124
If the manufacturer’s instructions are not available, use
the following procedure.
ENGINE TOP END 5-45
Valves
Seat Cutter Operation Care
1. This valve seat cutter is developed to grind the valve for
repair. Therefore the cutter must not be used for other
purposes than seat repair.
2. Do not drop or shock the valve seat cutter, or the diamond particles may fall off.
3. Do not fail to apply engine oil to the valve seat cutter
before grinding the seat surface. Also wash off ground
particles sticking to the cutter with washing oil.
NOTE
○Do not use a wire brush to remove the metal particles
from the cutter. It will take off the diamond particles.
4. Setting the valve seat cutter holder in position, operate
the cutter in one hand. Do not apply too much force to
the diamond portion.
NOTE
○Prior to grinding, apply engine oil to the cutter and during the operation, wash off any ground particles sticking
to the cutter with washing oil.
5. After use, wash it with washing oil and apply thin layer
of engine oil before storing.
Marks Stamped on the Cutter
The marks stamped on the back of the cutter [A] represent
the following.
60° ........................... Cutter angle [B]
37.5 ....................... Outer diameter of cutter [C]
Operating Procedures
Clean the seat area carefully.
Coat the seat with machinist’s dye.
Fit a 45° cutter into the holder and slide it into the valve
guide.
Press down lightly on the handle and turn it right or left.
Grind the seating surface only until it is smooth.
•
•
•
•
CAUTION
Do not grind the seat too much. Overgrinding will
reduce valve clearance by sinking the valve into the
head. If the valve sinks too far into the head, it will
be impossible to adjust the clearance, and the cylinder head must be replaced.
5-46 ENGINE TOP END
Valves
the outside diameter of the seating surface with
• Measure
a vernier caliper.
If the outside diameter of the seating surface is too small,
repeat the 45° grind until the diameter is within the specified range.
Widened Width [A] of engagement by machining with
45° cutter
Ground Volume [B] by 32° cutter
32° [C]
Correct Width [D]
Ground Volume [E] by 60° or 55° cutter
60° or 55° [F]
the outside diameter of the seating surface with
• Measure
a vernier caliper.
If the outside diameter of the seating surface is too small,
repeat the 45° grind [A] until the diameter is within the
specified range.
Original Seating Surface [B]
NOTE
○Remove all pittings of flaws from 45° ground surface.
○After grinding with 45° cutter, apply thin coat of machinist’s dye to seating surface. This makes seating surface
distinct and 32° and 60° (or 55°) grinding operation easier.
○When the valve guide is replaced, be sure to grind with
45° cutter for centering and good contact.
If the outside diameter [A] of the seating surface is too
large, make the 32° grind described below.
If the outside diameter of the seating surface is within the
specified range, measure the seat width as described below.
Grind the seat at a 32° angle [B] until the seat outside
diameter is within the specified range.
○To make the 32° grind, fit a 32° cutter into the holder, and
slide it into the valve guide.
○Turn the holder one turn at a time while pressing down
very lightly. Check the seat after each turn.
•
CAUTION
The 32° cutter removes material very quickly.
Check the seat outside diameter frequently to prevent overgrinding.
○After making the 32° grind, return to the seat outside di-
•
ameter measurement step above.
To measure the seat width, use a vernier caliper to measure the width of the 45° angle portion of the seat at several places around the seat.
If the seat width is too narrow, repeat the 45° grind until
the seat is slightly too wide, and then return to the seat
outside diameter measurement step above.
ENGINE TOP END 5-47
Valves
If the seat width is too wide, make the 60° or 55° [A] grind
described below.
If the seat width is within the specified range, lap the valve
to the seat as described below.
Grind the seat at a 60° or 55° angle until the seat width is
within the specified range.
○To make the 60° or 55° grind, fit 60° or 55° cutter into the
holder, and slide it into the valve guide.
○Turn the holder, while pressing down lightly.
○After making the 60° or 55° grind, return to the seat width
measurement step above.
Correct Width [B]
•
the valve to the seat, once the seat width and outside
• Lap
diameter are within the ranges specified above.
○Put a little coarse grinding compound on the face of the
valve in a number of places around the valve head.
○Spin the valve against the seat until the grinding compound produces a smooth, matched surface on both the
seat and the valve.
○Repeat the process with a fine grinding compound.
Lapper [A]
Valve Seat [B]
Valve [C]
The seating area should be marked about in the middle
of the valve face.
If the seat area is not in the right place on the valve, check
to be sure the valve is the correct part. If it is, it may have
been refaced too much; replace it.
Be sure to remove all grinding compound before assembly.
•
•
5-48 ENGINE TOP END
Valves
ENGINE TOP END 5-49
Cylinders, Pistons
Cylinder Removal
NOTE
○The front and rear cylinder removal are same procedures.
• Remove:
Cylinder Head (see Cylinder Head Removal)
Upper Oil Pipe [A]
Cylinder [B]
Cylinder Installation
NOTE
○If a new cylinder is used, use new piston ring.
○The front cylinder has a “F” mark [A] and the rear cylinder has a “R” mark [B]. Be careful not to mix up these
cylinders.
the dowel pins [A].
• Install
Apply
silicone
sealant to the are [B] where the mating sur• face of the crankcase
touches the cylinder gasket.
Sealant - Kawasaki Bond (Silicone Sealant) : 92104-0004
• Replace the cylinder gasket with a new one, and install it.
piston ring openings must be positioned as shown in
• The
the figure. The openings of the oil ring steel rails must be
about 30 ∼ 45° of angle from the opening of the top ring.
Top Ring [A]
Second Ring [B]
Oil Ring Steel Rails [C]
Oil Ring Expander [D]
Hollow [E]
30 ∼ 45° [F]
5-50 ENGINE TOP END
Cylinders, Pistons
molybdenum disulfide oil solution to the cylinder
• Apply
bore, piston rings and piston skirt.
the piston ring compressor assembly [A] with the
• Using
chamfered side [B] upward, install the cylinder block.
For Front Cylinder [C]
For Rear Cylinder [D]
Special Tools - Piston Ring Compressor Grip : 57001-1095
Piston Ring Compressor Belt, 95 ∼ 108 :
57001-1358
the O-rings [A] of the upper oil pipe [B] with new
• Replace
ones.
grease to the new O-rings, and insert the upper oil
• Apply
pipe to the hole of the cylinder securely.
Piston Removal
NOTE
○The front and rear piston removal are same procedures.
the cylinder (see Cylinder Removal).
• Remove
a clean cloth [A] under the piston and remove the
• Place
piston pin snap ring [B] from the outside.
• Using the piston pin puller [A], remove the piston pin.
Special Tool - Piston Pin Puller : 57001-1568
• Remove the piston [B] from the connecting rod.
ENGINE TOP END 5-51
Cylinders, Pistons
spread the ring opening with your thumbs and
• Carefully
then push up on the opposite side of the ring [A] to remove
•
it.
Remove the 3-piece oil ring with your thumbs in the same
manner.
Piston Installation
NOTE
○If a new piston is used, use new piston ring.
molybdenum disulfide oil solution to the oil ring ex• Apply
pander, install the oil ring expander [A] in the bottom piston ring groove so the ends [B] butt together.
Apply molybdenum disulfide oil solution to the oil ring steel
rails, and install the oil ring steel rails, one above the expander and one below it.
○Spread the rail with your thumbs, but only enough to fit
the rail over the piston.
○Release the rail into the bottom piston ring groove.
•
NOTE
○The oil ring rails have no “top” or “bottom”.
molybdenum disulfide oil solution to the top and
• Apply
second rings.
NOTE
○Do not mix up the top and second ring.
the top ring [A] so that the "R" mark [B] faces up.
• Install
Install
the
second ring [C] so that the "RN" mark [D] faces
• up.
the front piston [A], install the piston so that the hollow
• For
[B] faces the front side (exhaust side) [C].
the rear piston [D], install the piston so that the hollow
• For
[E] faces the rear side (exhaust side) [F].
NOTE
○The front and rear pistons are identical, but they should
be installed in their original positions.
CAUTION
Incorrect installation of the piston could cause piston seizure and result in severe engine damage.
5-52 ENGINE TOP END
Cylinders, Pistons
a new piston pin snap ring into the side of the piston
• Fit
so that the ring opening [A] does not coincide with the slit
[B] of the piston pin hole.
○Apply molybdenum disulfide oil solution to the piston pin
and piston skirt.
○When installing the piston pin snap ring, compress it only
enough to install it and no more.
CAUTION
Do not reuse snap rings, as removal weakens and
deforms them. They could fall out and score the
cylinder wall.
• Install the cylinder (see Cylinder Installation).
Cylinder Wear
there is a difference in cylinder wear in different di• Since
rections, take a side-to-side and a front-to-back measurement at each of the three locations (total of six measurements) shown in the figure.
If any of the cylinder inside diameter measurements exceeds the service limit, replace the cylinder.
10 mm (0.39 in.) [A]
60 mm (2.4 in.) [B]
20 mm (0.79 in.) [C]
Cylinder Inside Diameter
102.000 ∼ 102.012 mm
Standard:
(4.0157 ∼ 4.0162 in.)
Service Limit: 102.10 mm (4.020 in.)
Piston Wear
the outside diameter [A] of each piston 9 mm
• Measure
(0.35 in.) [B] up from the bottom of the piston at a right
angle to the direction of the piston pin.
If the measurement is under service limit, replace the piston.
Piston Diameter
101.942 ∼ 101.957 mm
Standard:
(4.0135 ∼ 4.0140 in.)
Service Limit: 101.79 mm (4.007 in.)
ENGINE TOP END 5-53
Cylinders, Pistons
Piston Ring, Piston Ring Groove Wear
for uneven groove wear by inspecting the ring seat• Check
ing.
•
The rings should fit perfectly parallel to groove surfaces.
If not, replace the piston and all the piston rings.
With the piston rings in their grooves, make several measurements with a thickness gauge [A] to determine piston
ring/groove clearance.
Piston Ring/Groove Clearance
Standard:
Top
0.04 ∼ 0.07 mm (0.015 ∼ 0.0027 in.)
Second
0.02 ∼ 0.06 mm (0.0007 ∼ 0.0023 in.)
Service Limit:
Top
0.17 mm (0.0067 in.)
Second
0.16 mm (0.0063 in.)
If the piston ring groove clearance is greater than the service limit, measure the ring thickness and groove width as
follows to decide whether to replace the rings, the piston
or both.
Piston Ring Groove Width
the piston ring groove width.
•○Measure
Use a vernier caliper at several points around the piston.
Piston Ring Groove Width
Standard:
Top [A]
1.23 ∼ 1.24 mm (0.0484 ∼ 0.0488 in.)
Second [B]
1.21 ∼ 1.23 mm (0.0476 ∼ 0.0484 in.)
Service Limit:
Top [A]
1.32 mm (0.0520 in.)
Second [B]
1.31 mm (0.0516 in.)
If the width of any of the two grooves is wider than the
service limit at any point, replace the piston.
Piston Ring Thickness
the piston ring thickness.
•○Measure
Use a micrometer to measure at several points around
the ring.
Piston Ring Thickness
Standard:
Top [A]
1.17 ∼ 1.19 mm (0.0461 ∼ 0.0469 in.)
Second [B]
1.17 ∼ 1.19 mm (0.0461 ∼ 0.0469 in.)
Service Limit:
Top [A]
1.10 mm (0.0433 in.)
Second [B]
1.10 mm (0.0433 in.)
If any of the measurements is less than the service limit
on either of the rings, replace all the rings.
NOTE
○When using new rings in a used piston, check for uneven groove wear. The rings should fit perfectly parallel
to the groove sides. If not, replace the piston.
5-54 ENGINE TOP END
Cylinders, Pistons
Piston Ring End Gap
the piston ring [A] inside the cylinder, using the pis• Place
ton to locate the ring squarely in place. Set it close to the
•
bottom of the cylinder, where cylinder wear is low.
Measure the gap [B] between the ends of the ring with a
thickness gauge.
Piston Ring End Gap
Standard:
Top
0.25 ∼ 0.35 mm (0.0098 ∼ 0.0138 in.)
Second
0.40 ∼ 0.55 mm (0.00157 ∼ 0.0217 in.)
Service Limit:
Top
0.7 mm (0.028 in.)
Second
0.9 mm (0.035 in.)
If the end gap of either ring is greater than the service
limit, replace all the rings.
ENGINE TOP END 5-55
Mufflers
WARNING
To avoid a serious burn, do not remove the muffler
when the engine is still hot. Wait until the muffler
cool down.
Muffler Body Removal
Left Muffler Body
Loosen the muffler body clamp bolt [A].
•
• Remove:
Left Saddlebag (see Saddlebag Removal in the Frame
•
chapter)
Muffler Body Mounting Bolts [A]
Pull out the left muffler body [B] to left side from the exhaust pipe.
Right Muffler Body
For equipped with the oxygen sensor, remove the following parts.
Right Side Cover (see Right Side Cover Removal in the
Frame chapter)
Oxygen Sensor Lead Connector [A]
•
CAUTION
Do not pull strongly, twist, or bend the oxygen sensor lead. This may cause the wiring open.
the muffler body clamp bolt [A].
• Loosen
• Remove the middle exhaust pipe cover holder bolt [B].
5-56 ENGINE TOP END
Mufflers
• Remove:
Right Saddlebag (see Saddlebag Removal in the Frame
•
chapter)
Muffler Body Mounting Bolts [A]
Pull out the right muffler body [B] backward from the exhaust pipe.
Muffler Body Installation
If the left muffler body cover [A] was removed, install it as
follows.
○Hang the left muffler body cover clamp [B] on the hook
portion [C] of the cover securely.
○Set the left muffler body cover so that the distance between the cover end and belt cover [D] is the 10 ∼ 15 mm
(0.39 in. ∼ 0.59 in.) [E].
Upside View [F]
○Set the clamp so that its bolt head and the cover end [G]
become parallel, and tighten the clamp bolt securely.
○Hang the hook portion of the holder [H] into the slot of the
cover, and tighten the holder bolt [I].
○Set the holder so that the distance between the holder
and the welding portion of the muffler body is about 2 mm
(0.08 in.) [J].
Replace the muffler body gasket [K] with a new one.
First, install the gasket to the exhaust pipe [L] until it is
bottomed so that chamfer side (inner) [M] faces muffler
body, and then insert the muffler body to the exhaust pipe.
Tighten:
•
•
•
Torque - Muffler Body Mounting Bolts [N] : 25 N·m (2.5
kgf·m, 18 ft·lb)
the muffler body clamp [O] as shown in the figure,
• Install
and tighten the clamp bolt [P] securely.
○Insert the projection [Q] into the slot [R].
○Before tightening the clamp bolt, check that the muffler
•
•
gasket is in place on the exhaust pipe.
For right muffler body, hang the hook portion of the holder
[S] into the slot of the middle exhaust pipe cover [T], and
tighten the holder bolt [U].
Set the holder so that the distance between the holder
and the welding portion of the muffler body is about 2 mm
(0.08 in.) [V].
Right Side View [W]
ENGINE TOP END 5-57
Mufflers
○For equipped with the oxygen sensor, run the oxygen sensor lead correctly (see Cable, Wire, and Hose Routing
section in the Appendix chapter).
CAUTION
Do not pull strongly, twist, or bend the oxygen sensor lead. This may cause the wiring open.
warm up the engine, wait until the engine
• Thoroughly
cools down, retighten all the bolts.
Exhaust Pipe Removal
the left and right muffler bodies (see Muffler Body
• Remove
Removal).
the rear exhaust pipe cover clamp bolts [A]
• Loosen
the clamps [B] upward [C], and remove the rear ex• Slide
haust pipe cover [D].
5-58 ENGINE TOP END
Mufflers
the middle exhaust pipe cover clamp bolts [A]
• Loosen
Slide
the
[B] of the rear side backward [C].
• Slide the clamp
clamp
of the front side forward [E], and re• move the middle[D]exhaust
pipe cover [F].
the front exhaust pipe cover clamp bolt [A].
• Loosen
Slide
the
clamp [B] forward [C].
•
the front exhaust pipe cover clamp bolts [A].
• Loosen
Slide
the
clamps [B] upward [C], and remove the front
• exhaust pipe
cover [D].
• Remove:
Exhaust Pipe Holder Nuts [A]
Exhaust Pipe [B]
ENGINE TOP END 5-59
Mufflers
Dummy Page
5-60 ENGINE TOP END
Mufflers
Exhaust Pipe Installation
the exhaust pipe gaskets [A] with new ones.
• Replace
Install
the
pipe holders [B] so that the “up” mark
• faces upperexhaust
side.
Tighten:
•
Torque - Exhaust Pipe Holder Nuts [C] : 17 N·m (1.7 kgf·m,
12 ft·lb)
the front exhaust pipe cover clamps [D] on the hook
• Hang
portions [E] of the cover securely.
the front exhaust pipe cover so that the distance be• Set
tween the cutout portion [F] and clutch cover [G] is the 10
•
•
•
•
•
•
•
∼ 15 mm (0.39 in. ∼ 0.59 in.) [H].
Align the two clamp bolt heads of the upper side and the
cutout portions [I] of the cover, and tighten the clamp bolts
securely.
Set the clamp of the lower side so that its bolt head and
the cover end [J] become parallel, and tighten the clamp
bolt securely.
Hang the middle exhaust pipe cover clamps [K] on the
hook portions [L] of the cover securely.
Set the clamps so that its bolt head and the cover end [M]
become parallel, and tighten the clamp bolts securely.
Hang the rear exhaust pipe cover clamps [N] on the hook
portions [O] of the cover securely.
Set the rear exhaust pipe cover so that the distance between the cutout portion [P] and clutch cover [G] is the 10
∼ 15 mm (0.39 in. ∼ 0.59 in.) [Q].
Set the clamps so that its bolt head and the cover end [R]
become parallel, and tighten the clamp bolts securely.
ENGINE TOP END 5-61
Mufflers
the left and right muffler bodies (see Muffler Body
• Install
Installation).
warm up the engine, wait until the engine
• Thoroughly
cools down, retighten all the bolts and nuts.
CLUTCH 6-1
Clutch
Table of Contents
Exploded View........................................................................................................................
Specifications .........................................................................................................................
Special Tools ..........................................................................................................................
Clutch Fluid.............................................................................................................................
Clutch Fluid Level Inspection ............................................................................................
Clutch Fluid Change .........................................................................................................
Clutch Line Bleeding .........................................................................................................
Clutch Hose Removal/Installation .....................................................................................
Clutch Hose Inspection .....................................................................................................
Clutch Master Cylinder ...........................................................................................................
Clutch Lever Adjustment...................................................................................................
Clutch Master Cylinder Removal ......................................................................................
Clutch Master Cylinder Installation ...................................................................................
Clutch Master Cylinder Disassembly/Assembly................................................................
Clutch Master Cylinder Inspection ....................................................................................
Clutch Slave Cylinder .............................................................................................................
Clutch Slave Cylinder Removal ........................................................................................
Clutch Slave Cylinder Installation .....................................................................................
Clutch Slave Cylinder Disassembly/Assembly..................................................................
Clutch .....................................................................................................................................
Clutch Cover Removal ......................................................................................................
Clutch Cover Installation ...................................................................................................
Clutch Outer Covers Removal ..........................................................................................
Clutch Outer Covers Installation .......................................................................................
Clutch Removal.................................................................................................................
Clutch Installation..............................................................................................................
Clutch .....................................................................................................................................
Clutch Plate, Wear, Damage Inspection ...........................................................................
Clutch Plate Warp .............................................................................................................
Clutch Spring Free Length Measurement .........................................................................
Clutch Housing Finger Inspection .....................................................................................
Clutch Hub Spline Inspection............................................................................................
Damper Cam Inspection ...................................................................................................
6-2
6-4
6-5
6-6
6-6
6-6
6-6
6-6
6-6
6-7
6-7
6-7
6-7
6-7
6-8
6-9
6-9
6-9
6-10
6-11
6-11
6-11
6-11
6-12
6-12
6-14
6-18
6-18
6-18
6-18
6-18
6-19
6-19
6
6-2 CLUTCH
Exploded View
CLUTCH 6-3
Exploded View
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Fastener
Cam Damper Bolt
Clutch Cover Bolts
Clutch Hose Banjo Bolt
Clutch Hub Nut
Clutch Lever Pivot Bolt
Clutch Lever Pivot Bolt Locknut
Clutch Master Cylinder Clamp Bolts
Clutch Reservoir Cap Screws
Clutch Slave Cylinder Bleed Valve
Clutch Slave Cylinder Bolts
Clutch Spring Bolts
Front Outer Clutch Cover Bolts
Primary Chain Guide Bolts
Rear Outer Clutch Cover Bolts
Starter Lockout Switch Screw
Cruise Control Cancel Switch (Clutch) Screw
Clutch Pipe Bracket Bolt
N·m
69
12
25
185
1.0
5.9
11
1.5
7.8
12
12
9.8
9.8
9.8
1.2
1.2
12
Torque
kgf·m
7.0
1.2
2.5
19.0
0.10
0.60
1.1
0.15
0.80
1.2
1.2
1.0
1.0
1.0
0.12
0.12
1.2
ft·lb
51
106 in·lb
18
136
8.8 in·lb
52 in·lb
97 in·lb
13 in·lb
69 in·lb
106 in·lb
106 in·lb
87 in·lb
87 in·lb
87 in·lb
11 in·lb
11 in·lb
106 in·lb
18. Clutch Slave Cylinder
19. Starter Lockout Switch
20. Cruise Control Cancel Switch (Clutch)
C: Apply clutch fluid.
EO: Apply engine oil.
L: Apply a non-permanent locking agent.
M: Apply Molybdenum disulfide grease.
MO: Apply Molybdenum disulfide oil solution.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1)
R: Replacement Parts
S: Follow the specific tightening sequence.
Si: Apply silicone grease.
Remarks
MO, R
Si
S
L
L
L
L
6-4 CLUTCH
Specifications
Item
Clutch Fluid
Grade
Clutch Lever
Clutch Lever Position
Clutch Lever Free Play
Clutch
Friction Plate Thickness
Friction Plate Warp
Steel Plate Warp
Clutch Spring Free Lengh
Standard
Service Limit
DOT4
– – –
8-way adjustable (to suit Rider)
Non-adjustable
– – –
– – –
3.30 ∼ 3.50 mm (0.130 ∼ 0.138 in.)
0.20 mm (0.0078 in.) or less
0.15 mm (0.0059 in.) or less
77.77 mm (3.06 in.)
3.0 mm (0.12 in.)
0.3 mm (0.01 in.)
0.3 mm (0.01 in.)
74.4 mm (2.93 in.)
CLUTCH 6-5
Special Tools
Bearing Driver Set:
57001-1129
Grip:
57001-1591
Clutch Holder:
57001-1243
Rotor Holder:
57001-1726
6-6 CLUTCH
Clutch Fluid
Clutch Fluid Level Inspection
to the Clutch Fluid Level Inspection in the Periodic
• Refer
Maintenance chapter.
Clutch Fluid Change
to the Clutch Fluid Change in the Periodic Mainte• Refer
nance chapter.
Clutch Line Bleeding
the engine pulley outer cover (see Engine Pulley
• Remove
Outer Cover Removal in the Final Drive chapter).
the reservoir cap off, slowly pump the clutch lever
• With
several times until no air bubbles can be seen rising up
through the fluid from the holes at the bottom of the reservoir. This bleeds the air from the master cylinder end of
the line.
NOTE
○Tap the clutch hose lightly going from the lower end to
the upper end and bleed the air off at the reservoir.
a clear plastic hose [A] to the bleed valve on the
• Attach
clutch slave cylinder, and run the other end of the hose
into a container.
the clutch line as follows.
•○Bleed
Repeat this operation until no more air can be seen coming out into the plastic hose.
1. Pump the clutch lever a few times until it becomes hard
and then hold it applied [B].
2. Quickly open and close [C] the bleed valve.
3. Release [D] the clutch lever.
NOTE
○The fluid level must be checked often during the changing operation and replenished with fresh fluid. If the
fluid in the reservoir runs completely out any time during bleeding, the bleeding operation must be done over
again from the beginning since air will have entered the
line.
WARNING
Do not mix different grades and brands of fluid.
Torque - Clutch Reservoir Cap Screws: 1.5 N·m (0.15
kgf·m, 13 in·lb)
Clutch Slave Cylinder Bleed Valve: 7.8 N·m (0.80
kgf·m, 69 in·lb)
Clutch Hose Removal/Installation
to the Clutch Hose and Pipe Replacement in the
• Refer
Periodic Maintenance chapter.
Clutch Hose Inspection
to the Clutch Hose and Pipe Damage and Instal• Refer
lation Condition Inspection in the Periodic Maintenance
chapter.
CLUTCH 6-7
Clutch Master Cylinder
Clutch Lever Adjustment
The adjuster has 8 positions so that the clutch lever position can be adjusted to suit the operator’s hand.
Push the lever forward and turn the adjuster [A].
•
Clutch Master Cylinder Removal
• Disconnect
Starter Lockout Switch Connectors [A]
•
Cruise Control Cancel Switch Connectors [B]
Remove the banjo bolt [C] to disconnect the clutch hose
from the master cylinder (see Clutch Hose and Pipe Replacement in the Periodic Maintenance chapter).
the clamp bolts [A], and take off the master cylin• Unscrew
der [B] as an assembly with the clutch lever, starter lockout switch, and cruise control cancel switch installed.
CAUTION
Immediately wash away any clutch fluid that spills.
Clutch Master Cylinder Installation
the clutch master cylinder [A] so that the mating
• Install
surface [B] of the master cylinder is aligned with the punch
•
mark [C] of the handlebar.
Tighten the upper clamp bolt first, then the lower clamp
bolt.
Torque - Clutch Master Cylinder Clamp Bolts: 11 N·m (1.1
kgf·m, 97 in·lb)
the washers on each side of the hose fitting with
• Replace
new ones.
• Tighten:
Torque - Clutch Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18
ft·lb)
the clutch fluid into the reservoir and bleed the
• Replenish
clutch line (see Clutch Line Bleeding).
that the clutch line has proper fluid pressure and
• Check
no fluid leakage.
Clutch Master Cylinder Disassembly/Assembly
to the Clutch Master Cylinder Rubber Parts Re• Refer
placement in the Periodic Maintenance chapter.
6-8 CLUTCH
Clutch Master Cylinder
Clutch Master Cylinder Inspection
the clutch master cylinder (see Clutch Mas• Disassemble
ter Cylinder Rubber Parts Replacement in the Periodic
Maintenance chapter).
CAUTION
Do not remove the secondary cup from the piston
since removal will damage it.
that there are no scratches, rust or pitting on the
• Check
inside of the master cylinder [A] and on the outside of the
•
•
•
•
•
•
piston [B].
If the master cylinder or piston shows any damage, replace them.
Inspect the primary cup [C] and secondary cup [D].
If a cup is worn, damaged, softened (rotted), or swollen,
the piston assembly should be replaced to renew the
cups.
If fluid leakage is noted at the clutch lever, the piston assembly should be replaced to renew the cups.
Check the dust cover [E] for damage.
If it is damaged, replace it.
Check that the relief and supply ports are not plugged.
If the small relief port becomes plugged, the clutch will
drag. Blow the ports clean with compressed air.
Check the piston return spring for any damage.
If the spring is damaged, replace it.
CLUTCH 6-9
Clutch Slave Cylinder
Clutch Slave Cylinder Removal
• Remove:
Engine Pulley Outer Cover (see Engine Pulley Outer
Cover Removal in the Final Drive chapter)
Banjo Bolt [A]
Clutch Slave Cylinder Bolts [B]
Slave Cylinder [C]
CAUTION
Immediately wash away any clutch fluid that spills.
the following if the clutch slave cylinder is to be
• Perform
removed but not disassembled.
CAUTION
If the clutch slave cylinder is removed and left
alone, the piston will be pushed out by spring force
and the clutch fluid will drain out.
○Remove the clutch slave cylinder with the pipe installed.
○Push [A] the piston into the cylinder as far as it will go.
○Apply the clutch lever [A] slowly and hold it with a band
[B].
NOTE
○Holding the clutch lever keeps the piston from coming
out.
Clutch Slave Cylinder Installation
If the push rod [A] was removed, apply molybdenum disulfide grease to the end [B] of the push rod, and install the
push rod so that the greased end faces in.
6-10 CLUTCH
Clutch Slave Cylinder
a non-permanent locking agent to the threads of
• Apply
the slave cylinder bolts [A].
all the clutch slave cylinder bolts evenly.
• Hand-tighten
the band from the clutch lever and release the
• Remove
clutch lever.
• Tighten the slave cylinder bolts.
Torque - Clutch Slave Cylinder Bolts: 12 N·m (1.2 kgf·m,
106 in·lb)
the washers on each side of the clutch hose fit• Replace
ting with new ones.
• Tighten the banjo bolt [B] to the specified torque.
Torque - Clutch Hose Banjo Bolt : 25 N·m (2.5 kgf·m, 18
ft·lb)
the fluid level in the master cylinder reservoir, and
• Check
bleed the clutch line (see Clutch Line Air Bleeding).
the clutch operation (see Clutch Operation Inspec• Check
tion in the Periodic Maintenance chapter).
Clutch Slave Cylinder Disassembly/Assembly
to the Clutch Slave Cylinder Piston Seal Replace• Refer
ment in the Periodic Maintenance chapter.
CLUTCH 6-11
Clutch
Clutch Cover Removal
the engine oil (see Engine Oil Change in the Peri• Drain
odic Maintenance chapter).
the exhaust pipe (see Exhaust Pipe Removal in
• Remove
the Engine Top End chapter)
• Unscrew the clutch cover bolts (19) [A]
Clutch Cover Installation
the new needle bearing [A] is installed in the clutch
• When
cover, press and insert the needle bearing so that the
bearing surface is flush with the end of the hole.
Special Tools - Bearing Driver Set: 57001-1129
NOTE
○Install the needle bearings so that the manufacture’s
make face out.
sure that the dowel pins [A] are in position.
• Be
Replace
the clutch cover gasket with a new one.
•
• Tighten:
Torque - Clutch Cover Bolts: 12 N·m (1.2 kgf·m, 106 in·lb)
•
L = 50 mm (2.0 in.) [A]
L = 65 mm (2.6 in.) [B]
L = 75 mm (3.0 in.) [C]
Install the removed parts (see appropriate chapter).
Clutch Outer Covers Removal
the clutch outer mark cover [A]
• Detach
• Remove:
Front Outer Clutch Cover Bolts [B]
Front Outer Clutch Cover [C]
Rear Outer Clutch Cover Bolts [D]
Rear Outer Clutch Cover [E]
6-12 CLUTCH
Clutch
Clutch Outer Covers Installation
the front and rear outer clutch covers.
• Install
When
installing the rear outer clutch cover [A], set the
• round mark
[B] downward.
Apply
a
non-permanent
locking agent to the threads of the
• front and rear outer clutch
cover bolts, and tighten them.
Torque - Front Outer Clutch Cover Bolts 9.8 N·m (1.0 kgf·m,
87 in·lb)
Rear Outer Clutch Cover Bolts 9.8 N·m (1.0 kgf·m,
87 in·lb)
the clutch outer mark cover [A] so that the mark [B]
• Install
of the clutch outer mark cover is aligned with the punch
mark [C] of the rear outer clutch cover.
Clutch Removal
the engine oil (see Engine Oil Change in the Peri• Drain
odic Maintenance chapter).
the clutch cover (see Clutch Cover Removal).
• Remove
Remove:
• Clutch Spring Bolts [A]
Clutch Springs (with Clutch Spring Holders)
Clutch Spring Plate [B]
• Remove:
Washer [A]
Thrust Bearing [B]
Push Rod [C]
• Remove:
Inner End Friction Plate (1) [A]
Friction Plates (8) [B]
Outer End Friction Plate (1) [C]
Steel Plates (9) [D]
Spring [E]
Spring Seat [F]
CLUTCH 6-13
Clutch
• Remove:
Primary Chain Guide Bolts [A]
Primary Chain Guides [B]
the clutch hub [A] steady with the clutch holder [B],
• Hold
and remove the clutch hub nut [C].
Special Tool - Clutch Holder: 57001-1243
• Remove:
Spring Washer
Washer
Clutch Hub
○Use the clutch holder with sharpened hook nose by grinding.
Special Tool - Clutch Holder: 57001-1243
○Grind the hook nose by 0.5 mm (0.02 in.) as shown in the
figure.
• Remove the spacer [A].
the cam damper bolt [A] while holding the al• Unscrew
ternator rotor steady with the rotor holder (see Alternator
Rotor Removal in the Electrical System chapter).
Special Tools - Grip: 57001-1591
Rotor Holder: 57001-1726
• Remove:
Spring Retainer [B]
Spring [C]
Cam Damper [D]
6-14 CLUTCH
Clutch
out the following parts as a set.
• Pull
Primary Chain [A]
Clutch Housing [B]
Starter Clutch Gear [C]
Damper Cam Sprocket [D]
Torque Limiter [E]
• Remove the collar [A] and spacer [B] from the input shaft.
the thrust bearing [A] and spacer [B] from the
• Remove
crankshaft.
the needle bearing [A].
• Remove
Separate
the following parts.
• Clutch Housing
[B]
Damper Cam Sprocket [C]
Primary Chain [D]
Starter Clutch Gear [E]
Clutch Installation
the spacer [A] to the crankshaft so that the stepped
• Install
side [B] faces inward.
the thrust bearing [C].
•○Install
Apply molybdenum disulfide oil to the both sides of the
thrust bearing.
CLUTCH 6-15
Clutch
the spacer [A] to the input shaft so that the stepped
• Install
side [B] faces inward.
the starter clutch gear [A] and collar [B].
•○Install
Apply molybdenum disulfide oil [C] to the starter clutch
gear and collar.
• Install the torque limiter [A] and spacer [B].
the primary chain [A] with the damper
• Engage
sprocket [B] and cutch housing [C] as shown.
cam
the clutch housing and sprocket together with the
• Insert
primary chain while turning counterclockwise [A] the
clutch housing and sprocket.
6-16 CLUTCH
Clutch
the needle bearing [A] to the input shaft while turn• Insert
ing counterclockwise [B] the clutch housing.
the cam damper [A] while fitting the alignment notch
• Install
[B] of the splines onto the alignment tooth [C].
• Install:
Spring [A]
•
Spring Retainer [B]
Tighten the cam damper bolt [C] while holding the alternator rotor steady with the rotor holder (see Alternator Rotor
Installation in the Electrical System chapter).
Special Tools - Grip: 57001-1591
Rotor Holder: 57001-1726
Torque - Cam Damper Bolt: 69 N·m (7.0 kgf·m, 51 ft·lb)
• Install:
Spacer [A]
Clutch Hub
the washer [A] and spring washer [B] so that the
• Install
“OUTSIDE” mark [C] faces outward.
the clutch hub nut with a new one.
• Replace
molybdenum disulfide oil to seating surface of the
• Apply
hub nut.
the clutch hub steady with the clutch holder, tighten
• Hold
the clutch hub nut.
Special Tool - Clutch Holder: 57001-1243
Torque - Clutch Hub Nut: 185 N·m (19.0 kgf·m, 136 ft·lb)
a non-permanent locking agent to the threads of
• Apply
the primary chain guide bolts, and tighten them.
• Install the primary chain guide.
Torque - Primary Chain Guide Bolts: 9.8 N·m (1.0 kgf·m, 87
in·lb)
CLUTCH 6-17
Clutch
• Install:
Inner End Friction Plate [A]
Friction Plates [B]
Outer End Friction Plate [C]
Steel Plates [D]
Spring [E]
Spring Seat [F]
CAUTION
If new dry friction plates and steel plates are installed, apply engine oil to the surfaces of each
plate to avoid clutch plate seizure.
the O-ring [A] with a new one.
• Replace
Applymolybdenum
disulfide grease [B] to the push rod
• [C].
the thrust bearing [A] and washer [B] to the push
• Install
rod [C].
the spring plate [D].
• Install
the clutch springs and spring holders, and tighten
• Install
the clutch spring bolts [E].
Torque - Clutch Spring Bolts: 12 N·m (1.2 kgf·m, 106 in·lb)
6-18 CLUTCH
Clutch
Clutch Plate, Wear, Damage Inspection
inspect the friction and steel plates for signs of
• Visually
seizure, overheating (discoloration), or uneven wear.
•
If any plates show signs of damage, replace the plates.
Measure the thickness of the friction plates [A] at several
points.
If they have worn past the service limit, replace the friction
plate and measure the spring plate gap and adjust it if
necessary.
Friction Plate Thickness
Standard:
3.30 ∼ 3.50 mm (0.130 ∼ 0.138 in.)
Service Limit:
3.0 mm (0.12 in.)
Clutch Plate Warp
each friction plate or steel plate on a surface plate,
• Place
and measure the gap between the surface plate [A] and
each friction plate or steel plate [B] with a thickness gauge
[C]. The gap is the amount of friction or steel plate warp.
If any friction plate is warped over the service limit, replace it and measure the spring plate gap, and adjust it if
necessary.
If any steel plate is warped over the service limit, replace
it with a new one of the same thickness.
Friction Plate Warp
Standard:
0.20 mm (0.0078 in.) or less
Service Limit:
Steel Plate Warp
Standard:
Service Limit:
0.3 mm (0.01 in.)
0.15 mm (0.0059 in.) or less
0.3 mm (0.01 in.)
Clutch Spring Free Length Measurement
the free length of the clutch springs [A].
• Measure
If any spring is shorter than the service limit, it must be
replaced.
Clutch Spring Free Length
Standard:
77.77 mm (3.06 in.)
Service Limit: 74.4 mm (2.93 in.)
Clutch Housing Finger Inspection
inspect the fingers [A] of the clutch housing where
• Visually
the tangs [B] of the friction plates hit them.
If they are badly worn or if there are groove cuts where the
tangs hit, replace the housing. Also, replace the friction
plates if their tangs are damaged and measure the spring
plate gap and adjust it if necessary.
CLUTCH 6-19
Clutch
Clutch Hub Spline Inspection
inspect where the teeth [B] on the steel plates
• Visually
wear against the splines [A] of the clutch hub.
If there are notches worn into the splines, replace the
outer clutch hub. Also, replace the steel plate with a new
one of the same thickness if their teeth are damaged.
Damper Cam Inspection
the damper cam (see Clutch Removal in this sec• Remove
tion).
inspect the damper cam [A], cam follower [B].
• Visually
Replace
the part if it appears damaged.
•
ENGINE LUBRICATION SYSTEM 7-1
Engine Lubrication System
Table of Contents
Exploded View........................................................................................................................
Engine Oil Flow Chart.............................................................................................................
Specifications .........................................................................................................................
Special Tools and Sealant ......................................................................................................
Engine Oil and Oil Filter..........................................................................................................
Oil Level Inspection...........................................................................................................
Engine Oil Change............................................................................................................
Oil Filter Replacement ......................................................................................................
Oil Screen...............................................................................................................................
Oil Screen Removal ..........................................................................................................
Oil Screen Installation .......................................................................................................
Oil Pressure Relief Valve........................................................................................................
Oil Pressure Relief Valve Removal ...................................................................................
Oil Pressure Relief Valve Installation ................................................................................
Oil Pressure Relief Valve Inspection.................................................................................
Oil Pump.................................................................................................................................
Oil Pump Gear Removal ...................................................................................................
Oil Pump Gear Installation ................................................................................................
Oil Pump Drive Gear Removal..........................................................................................
Oil Pump Drive Gear Installation.......................................................................................
Oil Pump Removal ............................................................................................................
Oil Pump Installation .........................................................................................................
Oil Pressure Measurement.....................................................................................................
Oil Pressure Measurement ...............................................................................................
Oil Pressure Switch ................................................................................................................
Oil Pressure Switch Removal ...........................................................................................
Oil Pressure Switch Installation ........................................................................................
Oil Pipes .................................................................................................................................
Oil Pipe Removal ..............................................................................................................
Oil Pipe Installation ...........................................................................................................
Blowby Gas System ...............................................................................................................
Blowby Gas System Inspection ........................................................................................
Breather Drain Cleaning ...................................................................................................
7-2
7-4
7-6
7-7
7-8
7-8
7-9
7-9
7-10
7-10
7-11
7-12
7-12
7-12
7-12
7-13
7-13
7-13
7-13
7-13
7-14
7-15
7-17
7-17
7-18
7-18
7-18
7-19
7-19
7-20
7-21
7-21
7-22
7
7-2 ENGINE LUBRICATION SYSTEM
Exploded View
ENGINE LUBRICATION SYSTEM 7-3
Exploded View
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Fastener
Breather Check Valve Cover Bolts
Engine Oil Drain Bolts
Inside Oil Pipe Retainer Bolt
Oil Filter
Oil Filter Pipe
Oil Passage Plug (PT1/8)
Oil Pressure Relief Valve
Oil Pressure Switch
Oil Pressure Switch Terminal Bolt
Oil Pump Cover Bolts
Oil Pump Drive Gear Bolt
Oil Screen Plugs
Out Side Oil Pipe Bolts
Torque Limiter Bearing Retainer Bolt
N·m
9.8
20
9.8
18
25
15
15
15
12
Torque
kgf·m
1.0
2.0
1.0
1.8
2.5
1.5
1.5
1.5
1.2
ft·lb
87 in·lb
14
87 in·lb
13
18
11
11
11
106 in·lb
42
20
9.8
9.8
4.3
2.0
1.0
1.0
31
15
87 in·lb
87 in·lb
Remarks
L
L
L
L
SS
Hand-tighten
15. Oil Screen for Feed Pump
16. Oil Screen for Scavenge Pump
17. Scavenge Pump
18. Feed Pump
G: Apply grease.
L: Apply a non-permanent locking agent.
M: Apply Molybdenum disulfide grease.
MO: Apply Molybdenum disulfide oil solution.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1)
R: Replacement Parts
SS: Apply silicone sealant.
MO
M
7-4 ENGINE LUBRICATION SYSTEM
Engine Oil Flow Chart
ENGINE LUBRICATION SYSTEM 7-5
Engine Oil Flow Chart
1. Camshaft Chain Tensioner
2. Balancer Chain Tensioner
3. Alternator Rotor Bolt (For Cooling Stator Coil)
4. Crankshaft
5. Piston Oil Jet
6. Drive Shaft
7. Output Shaft
8. Oil Screen for Scavenge Pump
9. Oil Screen for Feed Pump
10. Oil in Transmission Room
11. Scavenge Pump
12. Feed Pump
13. Outside Oil Pipe
14. To Transmission Room
15. Primary Chain
16. Damper Cam Sprocket
17. Upper Oil Pipe
18. Oil Pressure Relief Valve
19. Oil Pressure Switch
20. Inside Oil Pipe
21. Oil from Crank Room
22. Oil Filter
23. Rocker Case
24. Rocker Shaft
25. HLA (Hydraulic Lash Adjuster)
26. Breather Check Valve
27. To Left Air Cleaner Housing
28. Blowby Gass
7-6 ENGINE LUBRICATION SYSTEM
Specifications
Item
Engine Oil
Grade
Viscosity
Capacity
Level
Oil Pressure Measurement
Oil Pressure
Standard
API SE, SF or SG
API SH, SJ, SL or SM with JASO MA, MA1 or MA2
SAE 10W-40
4.1 L (4.3 US qt) (when filter is not removed)
4.3 L (4.5 US qt) (when filter is removed)
5.0 L (5.3 US qt) (when engine is completely disassembled and dry)
Between upper and lower level lines (wait 3 minutes or more after
idling or running)
80 ∼ 120 kPa (0.8 ∼ 1.2 kgf/cm², 12 ∼ 17 psi) at 2 000 r/min (rpm),
oil temperature 90°C (194°F)
ENGINE LUBRICATION SYSTEM 7-7
Special Tools and Sealant
Outside Circlip Pliers:
57001-144
Oil Pressure Gauge Adapter, PT1/8:
57001-1731
Oil Pressure Gauge, 10 kgf/cm²:
57001-164
Kawasaki Bond (Silicone Sealant):
56019-120
Gear Holder:
57001-1602
7-8 ENGINE LUBRICATION SYSTEM
Engine Oil and Oil Filter
Because of the semi-dry sump lubrication system, the engine oil level indicated on the dipstick will fluctuate depending on the motorcycle’s position and engine speed when the
engine is shut off. To ensure a proper reading of the engine
oil level, follow the Oil Level Inspection procedures closely.
WARNING
Motorcycle operation with insufficient, deteriorated, or contaminated engine oil will cause
accelerated wear and may result in engine or transmission seizure, accident, and injury.
Oil Level Inspection
the motorcycle so that it is vertical.
• Situate
the oil filler cap/dipstick [A], wipe it dry and thread
• Remove
in the oil filler cap/dipstick fully clockwise then remove
•
again to check the oil level.
Check that the engine oil level is between the H (High) [B]
and L (Low) [C] levels on the dip stick.
NOTE
○Situate the motorcycle so that it is perpendicular to the
ground.
○If the motorcycle has just been used, wait 3 minutes or
more for all the oil to drain down.
○If the oil has just been changed or the oil temperature is
low, start the engine and warm it up thoroughly until the
oil temperature in the transmission room goes up about
50°C (122°F). In addition, run the engine at idle speed
for about 30 seconds or more. Do not run the engine
at high engine speed. This fills the oil filter with oil.
Stop the engine, then wait 3 minutes or more until the
oil settles.
CAUTION
Racing the engine before the oil reaches every part
can cause engine seizure.
If the engine oil gets extremely low or if the oil pump
or oil passages clog up or otherwise do not function properly, the warning indicator light (LED) [A]
and oil pressure warning symbol [B] will light. If
this light stays on when the engine is running above
idle speed, stop the engine immediately and find the
cause.
If the oil level is too high, remove the excess oil, using a
syringe or some other suitable device.
If the oil level is too low, add the correct amount of oil
through the oil filler opening. Use the same type and
make of oil that is already in the engine.
NOTE
○If the engine oil type and make are unknown, use any
brand of the specified oil to top off the level in preference
to running the engine with the oil level low. Then at your
earliest convenience, change the oil completely.
ENGINE LUBRICATION SYSTEM 7-9
Engine Oil and Oil Filter
Engine Oil Change
to Engine Oil Change in the Periodic Maintenance
• Refer
Chapter.
Oil Filter Replacement
to Oil Filter Replacement in the Periodic Mainte• Refer
nance Chapter.
7-10 ENGINE LUBRICATION SYSTEM
Oil Screen
Oil Screen Removal
Oil Screen for Scavenge Pump
Remove:
Alternator Cover (see Alternator Cover Removal in the
Electrical System chapter)
Oil Screen Plug [A]
•
• Remove:
Oil Screen [A]
Spring [B]
Oil Screen for Feed Pump
Drain the engine oil (see Engine Oil Change in the Periodic Maintenance chapter).
Remove:
Downtube (see Downtube Removal in the Frame chapter)
Oil Screen Plug [A]
•
•
• Remove:
Oil Screen [A]
Spring [B]
ENGINE LUBRICATION SYSTEM 7-11
Oil Screen
Oil Screen Installation
NOTE
○Clean the oil screen thoroughly whenever it is removed
for any reason.
○While cleaning the screen, check for any metal particles
that might indicate internal engine damage.
the oil screen with a high-flash point solvent and
• Clean
remove any particles stuck to them.
WARNING
Clean the screen in a well-ventilated area, and take
care that there are no sparks or flame anywhere
near the working area. Because of the danger or
highly flammable liquids, do not use gasoline or
low-flash point solvent.
the screen [A] carefully for any damage, holes, and
• Check
broken wires.
If the screen is damaged, replace it.
the oil screen so that grommet side [A] faces in• Install
ward.
•
•
•
•
Washer [B]
Spring [C]
Replace the O-ring [D] with a new one.
Apply grease to the new O-ring.
Apply molybdenum disulfide grease [E] to the threads of
the oil screen plug [F].
Tighten:
Torque - Oil Screen Plugs: 20 N·m (2.0 kgf·m, 15 ft·lb)
7-12 ENGINE LUBRICATION SYSTEM
Oil Pressure Relief Valve
Oil Pressure Relief Valve Removal
the crankcase (see Crankcase Splitting in the Crank• Split
shaft/Transmission chapter).
the oil pressure relief valve [A] from the right
• Remove
crankcase half.
Oil Pressure Relief Valve Installation
a non-permanent locking agent to the threads of
• Apply
the oil pressure relief valve, and tighten it.
CAUTION
Do not apply too much non-permanent locking
agent to the threads. This may block the oil passage.
Torque - Oil Pressure Relief Valve: 15 N·m (1.5 kgf·m, 11
ft·lb)
Oil Pressure Relief Valve Inspection
the oil pressure relief valve (see Oil Pressure
• Remove
Relief Valve Removal).
to see if the valve [A] slides smoothly when push• Check
ing it in with a wooden or other soft rod, and see if it comes
back to its seat by spring [B] pressure.
NOTE
○Inspect the valve in its assembled state.
Disassembly
and assembly may change the valve performance.
If any rough spots are found during above inspection,
wash the valve clean with a high-flash point solvent and
blow out any foreign particles that may be in the valve with
compressed air.
WARNING
Clean the oil pressure relief valve in a well
-ventilated area, and take care that there is no
spark or flame anywhere near the working area.
Because of the danger of highly flammable liquids,
do not use gasoline or low-flash point solvent.
If cleaning does not solve the problem, replace the oil
pressure relief valve as an assembly. The oil pressure
relief valve is precision made with no allowance for replacement of individual parts.
ENGINE LUBRICATION SYSTEM 7-13
Oil Pump
Oil Pump Gear Removal
• Remove:
Clutch (see Clutch Removal in the Clutch chapter)
Circlip [A]
Oil Pump Gear [B]
Special Tool - Outside Circlip Pliers: 57001-144
Oil Pump Gear Installation
that the pin [A] is in place.
• Check
Fit
the
pin
into the slot [B] of the oil pump gear [C].
• Install a new
circlip.
•
Special Tool - Outside Circlip Pliers: 57001-144
Oil Pump Drive Gear Removal
the clutch (see Clutch Removal in the Clutch
• Remove
chapter).
the gear holder [A], secure the oil pump drive gear
• Using
[B].
Special Tool - Gear Holder : 57001-1602
○Engage the gear holder to the oil pump gear [C] and oil
•
pump drive gear.
Remove:
Oil Pump Drive Gear Bolt [D]
Oil Pump Drive Gear
Oil Pump Drive Gear Installation
that the pin [A] is in place.
• Check
• Fit the pin into the hole [B] of the oil pump drive gear [C].
7-14 ENGINE LUBRICATION SYSTEM
Oil Pump
molybdenum disulfide oil solution to the threads
• Apply
and seating surface of the oil pump drive gear bolt [A].
the gear holder [B], secure the oil pump drive gear
• Using
[C].
Special Tool - Gear Holder : 57001-1602
• Tighten:
Torque - Oil Pump Drive Gear Bolt : 42 N·m (4.3 kgf·m, 31
ft·lb)
Oil Pump Removal
• Remove:
Water Pump Impeller (see Water Pump Removal in the
Cooling System chapter)
Oil Pump Gear (see Oil Pump Gear Removal)
Pin [A]
Washer [B]
Oil Pump Cover Bolts [C]
NOTE
○The water pump impeller is installed in the end of the oil
pump shaft.
out the oil pump [A] as an assembly.
• Pull
Remove
the outer rotor [B] for scavenge pump.
•
• Remove the oil pump cover [A].
ENGINE LUBRICATION SYSTEM 7-15
Oil Pump
• Remove:
Pin [A]
Inner Rotor [B] for Feed Pump
Outer Rotor [C] for Feed Pump
• Remove:
Pin [A]
Inner Rotor [B] for Scavenge Pump
Oil Pump Shaft [C]
Oil Pump Installation
molybdenum disulfide oil solution to the portion [A]
• Apply
of the oil pump shaft as shown.
the following parts.
• Assemble
Oil Pump Shaft [B]
Pin [C]
Inner Rotor for Scavenge Pump [D]
Oil Pump Body [E]
Inner Rotor [F] for Feed Pump
Outer Rotor [G] for Feed Pump
○The
NOTE
scavenge pump rotors are wider than the feed
pump rotors.
the outer rotor [A] for scavenge pump.
•○Install
Turn the oil pump shaft so that the inner rotor [B] fits into
the outer rotor.
7-16 ENGINE LUBRICATION SYSTEM
Oil Pump
the dowel pin [A].
• Install
Fit
the
• [C]. dowel pin into the hole [B] on the oil pump cover
• Tighten:
Torque - Oil Pump Cover Bolts: 12 N·m (1.2 kgf·m, 106 in·lb)
sure to install the washer [A] and pin [B] on the oil
• Be
pump shaft.
• Install the removed parts (see appropriate chapters).
ENGINE LUBRICATION SYSTEM 7-17
Oil Pressure Measurement
Oil Pressure Measurement
the oil passage plug (1/8) [A] from the bottom of
• Remove
the right crankcase.
• 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, PT1/8: 57001
-1731
the engine and warm up the engine.
• Start
Run
the
at the specified speed, and read the oil
• pressureengine
gauge.
Oil Pressure
Standard:
80 ∼ 120 kPa (0.8 ∼ 1.2 kgf/cm², 12∼ 17 psi) at 2 000
r/min (rpm), oil temperature 90°C (194°F)
•
•
If the reading is much lower than the standard, check
the oil pump, relief valve, and/or crankshaft bearing insert wear immediately.
If the reading is much higher than the standard, check the
oil passages for clogging.
Stop the engine.
Remove the oil pressure gauge and adapter.
WARNING
Take care against burns form hot engine oil that
will drain through the oil passage when the gauge
adapter is removed.
a non-permanent locking agent to the oil passage
• Apply
plug, and install it.
Torque - Oil Passage Plug (PT1/8): 15 N·m (1.5 kgf·m, 11
ft·lb)
7-18 ENGINE LUBRICATION SYSTEM
Oil Pressure Switch
Oil Pressure Switch Removal
the engine oil (see Engine Oil Change in the Peri• Drain
odic Maintenance chapter).
• Remove:
Front Footboard Right (see Front Footboard Re-
•
•
•
moval/Installation in the Frame chapter)
Front Exhaust Pipe Cover (see Exhaust Pipe Removal
in the Engine Top End chapter)
Slide out the rubber boot [A].
Loosen the oil pressure switch terminal bolt [B], and remove the switch lead [C].
Remove the oil pressure switch [D].
Oil Pressure Switch Installation
silicone sealant to the threads of the oil pressure
• Apply
switch [A] and tighten it.
Sealant - Kawasaki Bond (Silicone Sealant): 56019-120
Torque - Oil Pressure Switch: 15 N·m (1.5 kgf·m, 11 ft·lb)
• Apply grease to the switch terminal [B].
NOTE
○Apply a small amount grease to the terminal so that
grease should not close two breather holes [C] for
switch diaphragm.
the switch lead direction upward.
• Install
Tighten:
•
Torque - Oil Pressure Switch Terminal Bolt: Hand-tighten
• Slide back the rubber boot to the original position.
ENGINE LUBRICATION SYSTEM 7-19
Oil Pipes
Oil Pipe Removal
Outside Oil Pipe
Remove:
Clutch (see Clutch Removal in the Clutch chapter)
Outside Oil Pipe Bolt [A]
Torque Limiter Bearing Retainer Bolt [B]
Torque Limiter Bearing Retainer [C]
Washer [D]
•
• Remove:
Outside Oil Pipe Bolts [A]
Outside Oil Pipe [B]
Inside Oil Pipe
Split the crankcase (see Crankcase Splitting in the Crankshaft/Transmission chapter).
Remove:
Inside Oil Pipe Retainer Bolt [A]
Retainer [B]
Inside Oil Pipe [C]
•
•
Upper Oil Pipe
Refer to the Cylinder Removal in the Engine Top End
chapter.
•
7-20 ENGINE LUBRICATION SYSTEM
Oil Pipes
Oil Pipe Installation
to the Cylinder Installation in the Crankshaft/Trans• Refer
mission chapter for upper oil pipe installation procedures.
the O-rings [A] with new ones.
• Replace
Apply
grease
to the O-rings.
• Outside Oil Pipe
[B]
Inside Oil Pipe [C]
Outside Oil Pipe
Install the washer and torque limiter bearing retainer.
○Note the position of the washer [A] so that the washer fits
onto the tangs [B].
Tighten:
•
•
Torque - Torque Limiter Bearing Retainer Bolt: 9.8 N·m (1.0
kgf·m, 87 in·lb)
Outside Oil Pipe Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
Inside Oil Pipe
Apply a non-permanent locking agent to the inside oil pipe
retainer bolt, and tighten it.
•
Torque - Inside Oil Pipe Retainer Bolt : 9.8 N·m (1.0 kgf·m,
87 in·lb)
ENGINE LUBRICATION SYSTEM 7-21
Blowby Gas System
Blowby Gas System Inspection
the fuel tank (see Fuel Tank Removal in the Fuel
• Remove
System (DFI) chapter).
certain that the breather hose [A] is routed without
• Be
being flattened or kinked, and is connected correctly to
left air cleaner housing.
If it is not, correct it.
the left air cleaner housing (see Air Cleaner
• Remove
Housing Removal in the Fuel System (DFI) chapter).
the breather hose and the air cleaner drain cap
• Inspect
[A] for damage or signs of deterioration.
○The hose and drain cap should not be hard and brittle,
nor should be soft or swollen.
Replace them if any cranks or swelling noticed.
• Remove:
Breather Check Valve Cover Bolts [A]
Breather Check Valve Cover [B]
the breather check valve [A].
•○Remove
Pinch the check valve with care so that it does not get
damage. Do not use tip of screwdriver, metal and the like.
inspect the breather check valve [A] for any dam• Visually
age.
Replace the valve, if it is damaged.
7-22 ENGINE LUBRICATION SYSTEM
Blowby Gas System
the O-ring [A] with a new one.
• Replace
Apply
grease
to the new O-ring, install it.
•
• Install:
Valve Seat [A]
•
•
Breather Check Valve [B]
Replace the breather check valve cover gasket with a new
one.
Tighten:
Torque - Breather Check Valve Cover Bolts : 9.8 N·m (1.0
kgf·m, 87 in·lb)
Breather Drain Cleaning
to the Air Cleaner Oil Draining in the Fuel System
• Refer
(DFI) chapter.
ENGINE REMOVAL/INSTALLATION 8-1
Engine Removal/Installation
Table of Contents
Exploded View........................................................................................................................
Special Tools ..........................................................................................................................
Engine Removal/Installation ...................................................................................................
Engine Removal................................................................................................................
Engine Installation.............................................................................................................
8-2
8-4
8-5
8-5
8-9
8
8-2 ENGINE REMOVAL/INSTALLATION
Exploded View
ENGINE REMOVAL/INSTALLATION 8-3
Exploded View
No.
Fastener
1
2
3
4
5
6
7
8
9
10
11
Cross Pipe Bolts
Downtube Bolts
Engine Mounting Adjusting Bolt
Engine Mounting Adjusting Bolt Locknut
Engine Mounting Bolt (M10)
Engine Mounting Bracket Bolts (M6)
Engine Mounting Bracket Bolts (M8)
Engine Mounting Bracket Bolts (M10)
Engine Mounting Bracket Nuts (M10)
Engine Mounting Nut (M10)
Engine Mounting Nut (M12)
N·m
34
59
9.8
49
44
9.8
25
44
59
44
59
R: Replacement Parts
S: Follow the specified tightening sequence.
WL: Apply a soap and water solution or rubber lubricant.
Torque
kgf·m
3.5
6.0
1.0
5.0
4.5
1.0
2.5
4.5
6.0
4.5
6.0
ft·lb
25
44
87 in·lb
36
32
87 in·lb
18
32
43
32
43
Remarks
S
S
S
S
R
R
R, S
8-4 ENGINE REMOVAL/INSTALLATION
Special Tools
Jack:
57001-1238
Socket Wrench:
57001-1347
ENGINE REMOVAL/INSTALLATION 8-5
Engine Removal/Installation
Engine Removal
• Raise the rear wheel off the ground using the jack.
Special Tool - Jack: 57001-1238
the brake lever slowly, and hold it with a band
• Squeeze
[A].
WARNING
Be sure to hold the front brake when removing the
engine, or the motorcycle may fall over. It could
cause an accident and injury.
CAUTION
Be sure to hold the front brake when removing the
engine, or the motorcycle may fall over. The engine
or the motorcycle could be damaged.
• Drain:
Coolant (see Coolant Change in the Periodic Mainte•
nance chapter)
Engine Oil (see Engine Oil Change in the Periodic Maintenance chapter)
Remove:
Battery Cables (see Battery Removal in the Electrical
System chapter)
Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)
Right Air Cleaner Housing (see Right Air Cleaner Housings Removal in the Fuel System (DFI) chapter)
Throttle Cable (see Throttle Body Assy Removal in the
Fuel System (DFI) chapter)
Exhaust Pipe (see Exhaust Pipe Removal in the Engine
Top End chapter)
Radiator (see Radiator Removal in the Cooling System
chapter)
Thermostat Housing (see Thermostat Removal in the
Cooling System chapter)
Ignition Coil #1 and #2 (see Ignition Coil Removal in the
Electrical System chapter)
Front Footboards (see Front Footboard Removal/Installation in the Frame chapter)
Engine Pulley (see Engine Pulley Removal in the Final
Drive chapter)
the connector bracket [A].
• Remove
Disconnect:
• Air Switching Valve Connector [B]
•
Inlet Air Pressure Sensor Connector [C]
Cruise Control Cancel Switch Connector [D]
Open the clamp [E] to free the lead.
8-6 ENGINE REMOVAL/INSTALLATION
Engine Removal/Installation
• Remove:
Vacuum Hose [A]
•
Vacuum Hoses [B] (CAL and SEA Models)
Disconnect the injector connectors [C].
• Disconnect the throttle body connectors [A].
• Disconnect:
Crankshaft Sensor Lead Connector [A]
Alternator Lead Connectors [B]
• Remove:
Engine Ground Cable Terminal Bolt [A]
Clamp [B] (CAL and SEA Models)
• Remove the brake hose bracket bolt [A].
ENGINE REMOVAL/INSTALLATION 8-7
Engine Removal/Installation
the side stand switch lead connector [A] from the
• Remove
brake hose clamp [B].
the starter motor cable [A].
• Remove
Open
the
• Disconnect:clamp [B], and free the leads.
• Speed Sensor Connector [C]
Gear Position Switch Lead Connector [D]
the engine with a commercially available stand
• Support
[A].
• Remove:
Engine Mounting Bracket Bolts and Nuts (M10) [A]
Engine Mounting Bolt (M10) [B]
Upper Engine Mounting Bracket [C]
• Remove:
Engine Mounting Bolt [A] and Nut
Engine Mounting Bracket Bolts (M10) [B] (Both Sides)
Front Engine Mounting Bracket [C]
8-8 ENGINE REMOVAL/INSTALLATION
Engine Removal/Installation
• Remove the engine mounting bolt and nut (M12) [A].
the socket wrench [A], loosen the engine mounting
• Using
adjusting bolt locknut [B].
Special Tool - Socket Wrench: 57001-1347
the Hexagon Wrench, turn the engine mounting ad• Using
justing bolt [A] counterclockwise to make the gap between
•
the engine and adjusting bolt.
Remove:
Engine Mounting Bracket Bolts (M8) [B]
Rear Engine Mounting Bracket (Upper) [C]
• Remove:
Engine Mounting Bracket Bolts (M6) [A]
Engine Mounting Bolt and Nut (M12) [B]
• Remove:
Engine Mounting Bracket Bolts (M8) [A] and Washers
Rear Engine Mounting Bracket (Lower)
ENGINE REMOVAL/INSTALLATION 8-9
Engine Removal/Installation
the downtube (see Downtube Removal in the
• Remove
Frame chapter).
• Remove the drive belt [A] from the output shaft [B].
• Remove the engine [A] from the motorcycle right side.
Engine Installation
the engine with a suitable stand.
• Support
Replace
the following nuts with new ones (see Exploded
• View section).
Engine Mounting Bracket Nuts (M10)
Engine Mounting Nuts (M10)
Engine Mounting Nuts (M20)
Install the engine mounting bolts and nuts, following the
specified installing sequence.
○First, Install the rear engine mounting bracket (lower) [A]
to the engine, and tighten the engine mounting bracket
bolts (M6) [B].
•
Torque - Engine Mounting Bracket Bolts (M6): 9.8 N·m (1.0
kgf·m, 87 in·lb)
○Second, tighten the engine mounting bracket bolts (M8)
[C] and washers temporarily.
○Third, install the rear engine mounting bracket (upper) [D],
and tighten the engine mounting bracket bolts (M8) [E].
Torque - Engine Mounting Bracket Bolts (M8): 25 N·m (2.5
kgf·m, 18 ft·lb)
○Forth, turn the engine adjusting bolt [F] until the clearance
between the bolt head and crankcase [G] come to zero
mm (zero in.).
Torque - Engine Mounting Adjusting Bolt: 9.8 N·m (1.0
kgf·m, 87 in·lb)
○Fifth,
tighten the adjusting bolt locknut [H], using the
socket wrench.
Special Tool - Socket Wrench: 57001-1347
Torque - Engine Mounting Adjusting Bolt Locknut: 49 N·m
(5.0 kgf·m, 36 ft·lb)
○Sixth, tighten the engine mounting nut (M12) (upper) [I].
Torque - Engine Mounting Nut (M12): 59 N·m (6.0 kgf·m, 43
ft·lb)
8-10 ENGINE REMOVAL/INSTALLATION
Engine Removal/Installation
○Seventh, tighten the engine mounting nut (M12) (lower)
[J].
Torque - Engine Mounting Nut (M12): 59 N·m (6.0 kgf·m, 43
ft·lb)
○Eighth,
tighten the engine mounting bracket bolts [C]
again to the specified torque.
Torque - Engine Mounting Bracket Bolts (M8): 25 N·m (2.5
kgf·m, 18 ft·lb)
○Lastly, remove the engine stand, and tighten the other
engine mounting bolts and nuts.
Torque - Downtube Bolts: 59 N·m (6.0 kgf·m, 44 ft·lb)
Engine Mounting Bracket Bolts (M10): 44 N·m (4.5
kgf·m, 32 ft·lb)
Engine Mounting Bracket Nuts (M10): 59 N·m (6.0
kgf·m, 43 ft·lb)
Engine Mounting Bolt (M10): 44 N·m (4.5 kgf·m, 32
ft·lb)
Engine Mounting Nut (M10): 44 N·m (4.5 kgf·m, 32
ft·lb)
Cross Pipe Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb)
installing the upper engine mounting bracket [A], fit
• When
the lower end [B] of the bracket to the cylinder block [C].
ENGINE REMOVAL/INSTALLATION 8-11
Engine Removal/Installation
the leads, cables and hoses correctly (see Cable,
• Run
Wire and Hose Routing section in the Appendix chapter).
the removed parts.
• Install
• Adjust:
Throttle Cables (see Throttle Control System Inspection
•
•
in the Periodic Maintenance chapter)
Drive Belt (see Belt Deflection inspection in the Periodic
Maintenance chapter)
Fill the engine with engine oil (see Engine Oil Change in
the Periodic Maintenance chapter).
Fill the engine with coolant and bleed the air from the cooling system (see Coolant Change in the Periodic Maintenance chapter).
CRANKSHAFT/TRANSMISSION 9-1
Crankshaft/Transmission
Table of Contents
Exploded View...................................
Specifications ....................................
Special Tools and Sealants ...............
Crankcase .........................................
Crankcase Splitting ......................
Crankcase Assembly ...................
Crankshaft and Connecting Rods......
Crankshaft Removal ....................
Crankshaft Installation .................
Connecting Rod Removal ............
Connecting Rod Installation .........
Crankshaft/Connecting Rod
Cleaning ....................................
Connecting Rod Bend..................
Connecting Rod Twist ..................
Connecting Rod Big End Side
Clearance..................................
Connecting Rod Big End Bearing
Insert/Crankpin Wear ...............
Crankshaft Side Clearance ..........
Crankshaft Runout .......................
Crankshaft Main Bearing/Main
Journal Wear.............................
Balancer ............................................
Balancer Mechanism Removal ....
Balancer Mechanism Installation .
Balancer Shaft Removal ..............
Balancer Shaft Installation ...........
Starter Clutch.....................................
Starter Clutch Removal................
Starter Clutch Installation.............
Starter Clutch Disassembly..........
Starter Clutch Assembly ..............
Starter Clutch Inspection..............
9-2
9-6
9-8
9-9
9-9
9-11
9-16
9-16
9-16
9-16
9-17
9-18
9-18
9-19
9-19
9-19
9-21
9-21
9-22
9-23
9-23
9-24
9-27
9-27
9-28
9-28
9-28
9-28
9-28
9-28
Torque Limiter....................................
Torque Limiter Removal ...............
Torque Limiter Installation ............
Torque Limiter Inspection.............
Transmission .....................................
Transmission Shaft and Shift Fork
Removal ....................................
Transmission Shaft and Shift Fork
Removal ....................................
Transmission Shaft Disassembly .
Transmission Shaft Assembly......
Shift Drum Removal.....................
Shift Drum Installation..................
Shift Drum Disassembly...............
Shift Drum Assembly ...................
Shift Fork Bending .......................
Shift Fork/Gear Groove Wear ......
Shift Fork Guide Pin/Drum
Groove Wear.............................
Gear Dog and Gear Dog Hole
Damage.....................................
External Shift Mechanism..................
Shift Pedal Removal ....................
Shift Pedal Installation .................
External Shift Mechanism
Removal ....................................
External Shift Mechanism
Installation .................................
Ball Bearing, Needle Bearing and Oil
Seal.................................................
Bearing and Oil Seal Installation..
Bearing Wear ...............................
Oil Seal Inspection .......................
9-30
9-30
9-30
9-30
9-31
9-31
9-31
9-31
9-32
9-34
9-34
9-34
9-35
9-36
9-36
9-36
9-36
9-37
9-37
9-37
9-39
9-40
9-44
9-44
9-45
9-46
9
9-2 CRANKSHAFT/TRANSMISSION
Exploded View
CRANKSHAFT/TRANSMISSION 9-3
Exploded View
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Fastener
Balancer Chain Tensioner Bolts
Balancer Sprocket Bolts
Ball Bearing Retainer Bolts
Ball Bearing Retainer Screws
Connecting Rod Big End Bolts
Crankcase Bolts (M10)
Crankcase Bolts (M6)
Engine Pulley Plate Bolts
Oil Nozzles
Oil Passage Plugs (PT1/2)
Oil Passage Plug (PT3/8)
Oil Passage Plugs (PT1/8)
Piston Oil Jet Bolts
Race Retainer Screw
Upper Balancer Chain Guide Bolts
Lower Balancer Chain Guide Bolts
N·m
12
83
9.8
9.8
60
39
12
12
3.9
20
20
15
6.9
9.8
12
12
Torque
kgf·m
1.2
7.0
1.0
1.0
6.1
4.0
1.2
1.2
0.40
2.0
2.0
1.5
0.70
1.0
1.2
1.2
ft·lb
106 in·lb
51
87 in·lb
87 in·lb
44
29
106 in·lb
106 in·lb
34 in·lb
15
15
11
61 in·lb
87 in·lb
106 in·lb
106 in·lb
17. Do not apply any grease or oil.
G: Apply grease.
L: Apply a non-permanent locking agent.
LG: Apply liquid gasket.
MO: Apply molybdenum disulfide oil solution.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1)
R: Replacement Parts
S: Follow the specified tightening sequence.
Remarks
L
L
MO
S
S
L
L
L
L
L
9-4 CRANKSHAFT/TRANSMISSION
Exploded View
CRANKSHAFT/TRANSMISSION 9-5
Exploded View
No.
Fastener
1
2
3
4
5
6
7
8
9
External Shift Mechanism Cover Bolts (L = 50 mm)
External Shift Mechanism Cover Bolts (L = 22 mm)
Gear Positioning Lever Nut
Shift Drum Bearing Retainer Bolts
Shift Drum Cam Bolt
Shift Lever Bolts
Shift Pedal Pad Screw
Shift Shaft Return Spring Pin
Tie-Rod Locknuts
EO: Apply engine oil.
G: Apply grease.
L: Apply a non-permanent locking agent.
Lh: Left-hand Threads
R: Replacement Parts
SS: Apply silicone sealant.
N·m
12
12
7.8
9.8
12
12
6.9
39
9.8
Torque
kgf·m
1.2
1.2
0.80
1.0
1.2
1.2
0.70
4.0
1.0
ft·lb
106 in·lb
106 in·lb
69 in·lb
87 in·lb
106 in·lb
106 in·lb
61 in·lb
29
87 in·lb
Remarks
L
L
L
Lh (1)
9-6 CRANKSHAFT/TRANSMISSION
Specifications
Item
Crankcase, Crankshaft and
Connecting Rods
Connecting Rod Bend
Connecting Rod Twist
Standard
–––
–––
Connecting Rod Big End Side
0.08 ∼ 0.30 mm (0.003 ∼ 0.012 in.)
Clearance
Connecting Rod Big End Bearing 0.026 ∼ 0.056 mm (0.0010 ∼ 0.0022 in.)
Insert/Crankpin Clearance
Crankpin Diameter:
51.981 ∼ 52.000 mm (2.0465 ∼ 2.0472 in.)
Marking:
None
○
Connecting Rod Big End Inside
Diameter:
Marking:
None
○
Service Limit
TIR 0.2/100 mm
(0.008/3.94 in.)
TIR 0.2/100 mm
(0.008/3.94 in.)
0.5 mm
(0.02 in.)
0.09 mm
(0.035 in.)
51.97 mm
(2.0461 in.)
51.981 ∼ 51.991 mm (2.0465 ∼ 2.0468 in.)
– – –
51.992 ∼ 52.000 mm (2.0469 ∼ 2.0472 in.)
– – –
55.000 ∼ 55.019 mm (2.1654 ∼ 2.1611 in.)
– – –
55.000 ∼ 55.010 mm (2.1654 ∼ 2.1657 in.)
– – –
55.011 ∼ 55.019 mm (2.1658 ∼ 2.1661 in.)
– – –
Connecting Rod Big End Bearing
Insert Thickness:
Brown
Black
Blue
Crankshaft Side Clearance
1.483 ∼ 1.487 mm (0.5838 ∼ 0.5854 in.)
1.487 ∼ 1.491 mm (0.5854 ∼ 0.5870 in.)
1.491 ∼ 1.495 mm (0.5870 ∼ 0.5886 in.)
0.05 ∼ 0.35 mm (0.002 ∼ 0.014 in.)
Crankshaft Web Length
106.85 ∼ 106.95 mm (4.2067 ∼ 4.2106 in.)
Crankshaft Runout
TIR 0.06 mm (0.0024 in.) or less
Crankshaft Main Journal
Diameter
52.986 ∼ 53.000 mm (2.0861 ∼ 2.0866 in.)
Crankcase Main Bearing
Inside Diameter
Transmission
Shift Fork Ear Thickness
53.030 ∼ 53.049 mm (2.0878 ∼ 2.0885 in.)
6.9 ∼ 7.0 mm (0.272 ∼ 0.276 in.)
Gear Groove Width
7.05 ∼ 7.15 mm (0.278 ∼ 0.281 in.)
Shift Fork Guide Pin Diameter
5.9 ∼ 6.0 mm (0.232 ∼ 0.236 in.)
Shift Drum Groove Width
6.05 ∼ 6.20 mm (0.238 ∼ 0.244 in.)
– – –
– – –
– – –
0.55 mm
(0.022 in.)
106.6 mm
(4.197 in.)
TIR 0.15 mm
(0.0059 in.)
52.96 mm
(2.085 in.)
53.08 mm
(2.090 in.)
6.8 mm
(0.268 in.)
7.25 mm
(0.285 in.)
5.8 mm
(0.228 in.)
6.3 mm
(0.248 in.)
CRANKSHAFT/TRANSMISSION 9-7
Specifications
Connecting Rod Big End Bearing Insert Selection
Con-rod Big End
Inside Diameter
Marking
Crankpin Diameter
Marking
Bearing Insert
Size Color
Part Number
None
○
Brown
92139-0227
None
None
○
○
○
Black
92139-0226
None
Blue
92139-0225
9-8 CRANKSHAFT/TRANSMISSION
Special Tools and Sealants
Outside Circlip Pliers:
57001-144
Rotor Holder:
57001-1726
Bearing Driver Set:
57001-1129
Kawasaki Bond (Silicone Sealant):
92104-0004
Grip:
57001-1591
Kawasaki Bond (Liquid Gasket - Black):
92104-1064
CRANKSHAFT/TRANSMISSION 9-9
Crankcase
Crankcase Splitting
the engine (see Engine Removal in the Engine
• Remove
Removal/Installation chapter).
the engine on a clean surface and hold the engine
• Set
steady while parts are being removed.
• Remove:
Clutch (see Clutch Removal in the Clutch chapter)
Balancer Mechanism (see Balancer Mechanism Removal)
Cylinders (see Cylinder Removal in the Engine Top End
chapter)
Pistons (see Piston Removal in the Engine Top End
chapter)
Camshaft Chains (see Camshaft Chain Removal in the
Engine Top End chapter)
Oil Pump Drive Gear (see Oil Pump Drive Gear Removal
in the Engine Lubrication System chapter)
Oil Pump (see Oil Pump Removal in the Engine Lubrication System chapter)
Oil Screens (see Oil Screen Removal in the Engine Lubrication System chapter)
Starter Motor (see Starter Motor Removal in the Electrical System chapter)
External Shift Mechanism (see External Shift Mechanism Removal)
the collar [A] on the output shaft.
• Remove
• Remove the O-ring [B].
9-10 CRANKSHAFT/TRANSMISSION
Crankcase
• Remove the left crankcase bolts (11) [A].
the right crankcase bolts, following the specified
• Remove
sequence.
○First, loosen the M6 bolts (9) [A].
○Next, loosen the M10 bolts (3) [B].
the engine so that the right crankcase half [A] faces
• Put
upside.
CRANKSHAFT/TRANSMISSION 9-11
Crankcase
the pry points, split the crankcase halves.
• Using
Pry Point (Front) [A]
Pry Points (Rear) [B]
If the crankcase does not split easily, tap the crankcase
mating surface lightly with a plastic mallet.
○Take care not to damage the crankcase.
Lift up the right crankcase half.
•
Crankcase Assembly
CAUTION
The left and right crankcase halves are machined at
the factory in the assembled state, so the crankcase
halves must be replaced as a set.
to the Bearing and Oil Seal Installation for the bear• Refer
ing, outer race and oil seal installation procedures.
a high-flash point solvent, clean off the mating sur• With
faces of the crankcase halves and wipe dry.
WARNING
Clean the crankcase in a well-ventilated area, and
take care that there is no spark or flame anywhere
near the working area. Because of the danger of
highly flammable liquids, do not use gasoline or low
-flash point solvent.
compressed air, blow out the oil passages in the
• Using
crankcase halves.
If the piston oil jet [A] was removed, install it as follows.
○Replace the O-ring [B] with a new one.
9-12 CRANKSHAFT/TRANSMISSION
Crankcase
○Insert the piston oil jet [A] into the hole on the crankcase
[B] as shown in the figure.
○Apply a non-permanent locking agent to the threads of
the piston oil jet bolt [C], and tighten it.
Torque - Piston Oil Jet Bolt : 6.9 N·m (0.70 kgf·m, 61 in·lb)
the following parts on the left crankcase half.
• Install
Crankshaft [A] (see Crankshaft Installation)
Front Balancer Shaft [B] (see Balancer Shaft Installation)
Rear Balancer Shaft [C] (see Balancer Shaft Installation)
Transmission Shafts [D] (see Transmission Shaft and
Shift Fork Installation)
Shift Forks [E] and Shift Rods (see Transmission Shaft
and Shift Fork Installation)
Shift Drum [F] (see Shift Drum Installation)
Dowel Pins [G]
New O-ring [H]
the following parts on the right crankcase half.
• Install
Inside Oil Pipe [A] (see Oil Pipe Installation in the Engine
Lubrication System chapter)
Oil Pressure Relief Valve [B] (see Oil Pressure Relief
Valve Installation in the Engine Lubrication System
chapter)
CRANKSHAFT/TRANSMISSION 9-13
Crankcase
liquid gasket [A] to the mating surface of the lower
• Apply
crankcase half.
Sealant - Kawasaki Bond (Liquid Gasket - Black): 92104
-1064
NOTE
○Especially, apply a sealant so that it shall be filled up on
the grooves [B].
CAUTION
Do not apply liquid gasket around the oil passage
hole [C]. This may block the oil passage.
• Fit the right crankcase half to the left crankcase half.
NOTE
○Make the application finish within 20 minutes when the
liquid gasket to the mating surface of the crankcase half
is applied.
○Moreover fit the case and tighten the bolts just after
application of the liquid gasket.
9-14 CRANKSHAFT/TRANSMISSION
Crankcase
NOTE
○Be sure to tighten the right crankcase bolts first.
• Tighten
steps.
the right crankcase bolts using the following
○First, tighten the M10 bolts (3) [A].
Torque - Crankcase Bolts (M10) : 39 N·m (4.0 kgf·m, 29 ft·lb)
○Next, tighten the M6 bolts (9) [B].
Torque - Crankcase Bolts (M6) : 12 N·m (1.2 kgf·m,
106 in·lb)
• Tighten the left crankcase bolts (11) [A].
Torque - Crankcase Bolts (M6) : 12 N·m (1.2 kgf·m,
106 in·lb)
tightening all crankcase bolts, check the following
• After
items.
○Wipe
up the liquid gasket that seeps out around the
crankcase mating surface.
○Crankshaft, transmission shafts and balancer shafts turn
freely.
○While spinning the output shaft, gears shift smoothly from
the 1st to 6th gear, and 6th to 1st.
○When the output shaft stays still, the gear can not be
shifted to 2nd gear or other higher gear positions.
CRANKSHAFT/TRANSMISSION 9-15
Crankcase
grease to the new O-ring [A] and install it on the
• Apply
output shaft as shown in the figure.
grease to oil seal lip.
• Apply
the collar [B] so that the stepped side [C] faces
• Install
inward.
• Install the removed parts (see appropriate chapters).
9-16 CRANKSHAFT/TRANSMISSION
Crankshaft and Connecting Rods
Crankshaft Removal
the crankcase (see Crankcase Splitting).
• Split
Turn
the
balancer shafts [A] to clear the balancers [B] from
• the crankshaft
web [C].
Remove
the
crankshaft.
•
Crankshaft Installation
molybdenum disulfide oil solution onto the crank• Apply
shaft main journal [A] on both sides.
the crankshaft so that the plug side [B] faces left
• Install
crankcase half.
the left connecting rod [A] into the rear cylinder open• Set
ing [B], and right connecting rod [C] into the front cylinder
opening [D].
Connecting Rod Removal
the crankshaft (see Crankshaft Removal).
• Remove
Remove
the
rod big end bolts [A] and take off
• the connectingconnecting
rod and big end cap [B].
NOTE
○Mark and record the locations of the connecting rods
and their big end caps so that they can be reassembled
in their original positions.
CRANKSHAFT/TRANSMISSION 9-17
Crankshaft and Connecting Rods
Connecting Rod Installation
CAUTION
To minimize vibration, the connecting rods should
have the same weight mark.
Big End Cap [A]
Connecting Rod [B]
“OUT” Mark [C]
Weight Mark, Alphabet [D]
Diameter Mark [E]: “O” or no mark
CAUTION
If the connecting rods, big end bearing inserts, or
crankshaft are replaced with new ones, select the
bearing insert and check clearance with a plastigage (press gauge) before assembling engine to be
sure the correct bearing inserts are installed.
molybdenum disulfide oil solution to the inner sur• Apply
face of upper and lower bearing inserts [A].
a small amount of molybdenum disulfide oil solution
• Apply
to the threads [B] and seating surface [C] of the connecting rod big end bolts.
If bearing inserts are replaced, install them as follows.
○Remove debris and clean the surface of inserts.
○Do not apply molybdenum disulfide oil solution to the outside [D] of the inserts or the inside [E] of the connecting
rod and big end cap.
CAUTION
Wrong application of oil and grease could cause
bearing damage.
○Install the inserts so that their nails [F] are on the same
side and fit into the recess of the connecting rod and big
end cap.
○When installing the inserts [A], be careful not to damage
the insert surface with the edge of the connecting rod [B]
or the big end cap [C]. One way to install inserts is as
follows.
Installation [D] to Big End Cap
Installation [E] to Connecting Rod
Push [F]
Spare Dowel Pin [G]
Connecting Rod Big End Bolts [H]
Suitable Block [J]
9-18 CRANKSHAFT/TRANSMISSION
Crankshaft and Connecting Rods
sure the dowel pins [A] on the big end cap [B] are in
• Be
position.
each connecting rod on its original position as fol• Install
lows.
○Left connecting rod [A] is for the rear cylinder and right
connecting rod [B] is for the front cylinder.
Engine Left Side [C]
Engine Right Side [D]
○Install the connecting rods so that their “OUT” marks [E]
face outward.
○Install the big end cap on the connecting rod, aligning the
diameter mark.
Tighten:
•
Torque - Connecting Rod Big End Bolts : 60 N·m (6.1 kgf·m,
44 ft·lb)
Crankshaft/Connecting Rod Cleaning
removing the connecting rods from the crankshaft,
• After
clean them with a high-flash point solvent.
the crankshaft oil passages with compressed air to
• Blow
remove any foreign particles or residue that may have
accumulated in the passages.
Connecting Rod Bend
the connecting rod big end bearing inserts, and
• Remove
reinstall the connecting rod big end cap.
an arbor [A] of the same diameter as the connect• Select
ing rod big end, and insert the arbor through the connect-
•
•
•
ing rod big end.
Select an arbor of the same diameter as the piston pin
and at least 100 mm (3.94 in.) long, and insert the arbor
[B] through the connecting rod small end.
On a surface plate, set the big-end arbor on V block [C].
With the connecting rod held vertically, use a height
gauge to measure the difference in the height of the
arbor above the surface plate over a 100 mm (3.94 in.)
length to determine the amount of connecting rod bend.
If connecting rod bend exceeds the service limit, the connecting rod must be replaced.
Connecting Rod Bend
Service Limit:
TIR 0.2/100 mm (0.008/3.94 in.)
CRANKSHAFT/TRANSMISSION 9-19
Crankshaft and Connecting Rods
Connecting Rod Twist
the big-end arbor [A] still on V block [B], hold the con• With
necting rod horizontally and measure the amount that the
arbor [C] varies from being parallel with the surface plate
over a 100 mm (3.94 in.) length of the arbor to determine
the amount of connecting rod twist.
If connecting rod twist exceeds the service limit, the connecting rod must be replaced.
Connecting Rod Twist
Service Limit:
TIR 0.2/100 mm (0.008/3.94 in.)
Connecting Rod Big End Side Clearance
connecting rod big end side clearance.
•○Measure
Insert a thickness gauge [A] between the big end and either crankshaft web to determine clearance.
Connecting Rod Big End Side Clearance
Standard:
0.08 ∼ 0.30 mm (0.003 ∼ 0.012 in.)
Service Limit: 0.5 mm (0.02 in.)
If the clearance exceeds the service limit, replace the connecting rod with new one and then check clearance again.
If clearance is too large after connecting rod replacement,
the crankshaft also must be replaced.
Connecting Rod Big End Bearing Insert/Crankpin
Wear
the connecting rod (see Connecting Rod Re• Remove
moval).
strips of plastigage to crankpin width. Place a strip
• Cut
on the crankpin parallel to the crankshaft installed in the
•
correct position.
Tighten the connecting rod big end bolts to the specified
torque (see Connecting Rod Installation).
NOTE
○Do not move the connecting rod and crankshaft during
clearance measurement.
the connecting rod again, measure each clear• Remove
ance between the bearing insert and crankpin [A] using
plastigage (press gauge) [B].
Connecting Rod Big End Bearing Insert/Crankpin
Clearance
Standard:
0.026 ∼ 0.056 mm (0.0010 ∼ 0.0022 in.)
Service Limit:
0.09 mm (0.035 in.)
9-20 CRANKSHAFT/TRANSMISSION
Crankshaft and Connecting Rods
If clearance is within the standard, no bearing replacement is required.
If clearance is between 0.057 mm (0.0022 in.) and the
service limit (0.09 mm, 0.035 in.), replace the bearing inserts [A] with inserts painted blue [B]. Check
insert/crankpin clearance with the plastigage. The clearance may exceed the standard slightly, but it must not be
less than the minimum in order to avoid bearing seizure.
If the clearance exceeds the service limit, measure the
diameter of the crankpin.
Crankpin Diameter
Standard:
51.981 ∼ 52.000 mm (2.0465 ∼ 2.0472 in.)
Service Limit: 51.97 mm (2.0461 in.)
If any crankpin has worn past the service limit, replace the
crankshaft with a new one.
If the measured crankpin diameter [A] is not less than the
service limit, but do not coincide with the original diameter
marking on the crankshaft, make new mark on it.
Crankpin Diameter Mark
None
51.981 ∼ 51.991 mm (2.0465 ∼ 2.0468 in.)
○
51.992 ∼ 52.000 mm (2.0469 ∼ 2.0472 in.)
Crankpin Diameter Mark, "○" mark or no mark [B].
the connecting rod big end inside diameter, and
• Measure
mark each connecting rod big end in accordance with the
•
bore diameter.
Tighten the connecting rod big end bolts to the specified
torque (see Connecting Rod Installation).
NOTE
○The mark already on the big end should almost coincide
with the measurement because of little wear.
Connecting Rod Big End Inside Diameter Marks
None
55.000 ∼ 55.010 mm (2.1654 ∼ 2.1657 in.)
○
55.011 ∼ 55.019 mm (2.1658 ∼ 2.1661 in.)
Big End Cap [A]
Connecting Rod [B]
Weight Mark, Alphabet [C]
Diameter Mark [D]: “○” or no mark
CRANKSHAFT/TRANSMISSION 9-21
Crankshaft and Connecting Rods
the proper bearing insert [A] in accordance with the
• Select
combination of the connecting rod and crankshaft coding.
Size Color [B]
Connecting Rod Big End Bearing Insert Selection
Bearing Insert
Con-rod Big End
Inside Diameter
Marking
Crankpin
Diameter
Marking
Size Color
Part Number
None
○
Brown
13034-0227
None
None
○
○
○
Black
13034-0226
None
Blue
13034-0225
the new inserts in the connecting rod and check
• Install
insert/crankpin clearance with the plastigage.
Crankshaft Side Clearance
the crankshaft side clearance.
• Measure
Crankshaft [A]
Crankcase [B]
Clearance [C]
Crankshaft Side Clearance
Standard:
0.05 ∼ 0.35 mm (0.002 ∼ 0.014 in.)
Service Limit:
0.55 mm (0.022 in.)
If the clearance exceeds the service limit, measure the
crankshaft web length [A] to see whether the crankshaft
or the crankcase is faulty.
Crankshaft Web Length
Standard:
106.85 ∼ 106.95 mm (4.2067 ∼ 4.2106 in.)
Service Limit: 106.6 mm (4.197 in.)
If the length measurement is smaller than the service limit,
replace the crankshaft. Otherwise, replace the crankcase
halves as a set.
NOTE
○The left and right crankcase halves are machined at
the factory in the assembled state, so they must be replaced as a set.
Crankshaft Runout
the crankshaft runout.
• Measure
If the measurement exceeds the service limit, replace the
crankshaft.
Crankshaft Runout
Standard:
TIR 0.02 mm (0.0008 in.) or less
Service Limit:
TIR 0.05 mm (0.002 in.)
9-22 CRANKSHAFT/TRANSMISSION
Crankshaft and Connecting Rods
Crankshaft Main Bearing/Main Journal Wear
the diameter [A] of the crankshaft main journal.
• Measure
If any journal has worn past the service limit, replace the
crankshaft with a new one.
Crankshaft Main Journal Diameter
Standard:
52.986 ∼ 53.000 mm (2.0861 ∼ 2.0866 in.)
Service Limit:
52.96 mm (2.085 in.)
the main bearing inside diameter [A] in the
• Measure
crankcase halves.
Crankcase Main Bearing Inside Diameter
Standard:
53.030 ∼ 53.049 mm (2.0878 ∼ 2.0885 in.)
Service Limit: 53.08 mm (2.090 in.)
If the diameter exceeds the service limit, replace the
crankcase halves as a set.
NOTE
○The left and right crankcase halves are machined at
the factory in the assembled state, so they must be replaced as a set.
CRANKSHAFT/TRANSMISSION 9-23
Balancer
Balancer Mechanism Removal
the alternator cover (see Alternator Cover Re• Remove
moval in the Electrical System chapter).
the front balancer sprocket bolt [A] and rear bal• Loosen
ancer sprocket bolt [B] while holding the alternator rotor
[C] steady with the rotor holder [D].
Special Tools - Grip [E] : 57001-1591
Rotor Holder : 57001-1726
the alternator rotor (see Alternator Rotor Re• Remove
moval in the Electrical System chapter).
down the balancer chain tensioner shoe [A] to align
• Push
the hole [B] of the link plate [C] and tensioner body [D].
the suitable pin [E] into the hole to hold the ten• Insert
sioner in place.
• Remove:
Balancer Chain Guide Bolts [A]
Upper Balancer Chain Guide [B]
Balancer Chain Tensioner Bolts [C]
Lower Balancer Chain Guide [D]
Balancer Chain Tensioner [E]
Front Balancer Sprocket Bolt [F] with Washer
Rear Balancer Sprocket Bolt [G] with Washer
the following parts as a set.
• Remove
Balancer Chain Sprocket [A]
Front Balancer Sprocket [B]
Rear Balancer Sprocket [C]
Balancer Chain [D]
9-24 CRANKSHAFT/TRANSMISSION
Balancer
Balancer Mechanism Installation
the line [A] on the following parts with the colored
• Align
chain links [B] as shown in the figure.
Balancer Chain Sprocket [C]
Front Balancer Sprocket [D]
Rear Balancer Sprocket [E]
The
○ front and rear balancer sprockets are identical.
Install the balancer chain sprocket and balancer sprockets by aligning [F] the alignment notch with the alignment
teeth on the following parts.
Crankshaft [G]
Front Balancer Shaft [H]
Rear Balancer Shaft [I]
Install the balancer sprocket bolts together with the washers, and tighten them temporarily.
•
•
down the balancer chain tensioer shoe [A] while
• Push
pushing the ratchet [B].
CAUTION
Be careful the oil remaining in the tensioner body
dashes out.
CRANKSHAFT/TRANSMISSION 9-25
Balancer
the first teeth [A] of the ratchet [B] with second
• Engage
groove [C] of the plunger [D].
the suitable pin [A] into the hole of the tensioner
• Insert
body [B] through the hole of the link plate [C].
9-26 CRANKSHAFT/TRANSMISSION
Balancer
• Install the upper balancer chain guide [A].
Torque - Upper Balancer Chain Guide Bolts [B] : 12 N·m
(1.2 kgf·m, 106 in·lb)
the balancer chain tensioner [C] and lower balancer
• Install
chain guide [D].
Torque - Balancer Chain Tensioner Bolts [E] : 12 N·m (1.2
kgf·m, 106 in·lb)
Lower Balancer Chain Guide Bolts [F] : 12 N·m (1.2
kgf·m, 106 in·lb)
out the suitable pin [G] from the balancer chain ten• Pull
sioner.
the alternator rotor (see Alternator Rotor Installa• Install
tion in the Electrical System chapter).
the front balancer sprocket bolt [H] and rear bal• Tighten
ancer sprocket bolt [I] while holding the alternator rotor
steady with the rotor holder.
Special Tools - Grip : 57001-1591
Rotor Holder : 57001-1726
Torque - Balancer Sprocket Bolts : 83 N·m (7.0 kgf·m, 51
ft·lb)
CRANKSHAFT/TRANSMISSION 9-27
Balancer
Balancer Shaft Removal
○The
NOTE
front and rear balancer shafts are same procedures.
the crankcase (see Crankcase Splitting).
• Split
Turn
the balancer shaft [A] to clear the balancer [B] from
• the crankshaft
web [C].
•
Front Balancer Shaft [D]
Rear Balancer Shaft [E]
Remove the balancer shaft.
Balancer Shaft Installation
the balancer shaft [A] so that the flanged side [B]
• Install
faces left crankcase.
Front Balancer Shaft [C]
Rear Balancer Shaft [D]
9-28 CRANKSHAFT/TRANSMISSION
Starter Clutch
Starter Clutch Removal
• Refer to the Clutch Removal in the Clutch chapter.
Starter Clutch Installation
• Refer to the Clutch Installation in the Clutch chapter.
Starter Clutch Disassembly
the clutch housing (see Clutch Removal in the
• Remove
Clutch chapter).
the hook portions [A] and remove the plate [B].
• Pry
Pull
the one-way clutch [C] out of the clutch housing.
• Remove
the washer [D].
•
Starter Clutch Assembly
the washer [A] on the clutch housing.
• Install
the one-way clutch [B] so that the circlip side [C]
• Install
faces inside.
the hook portions of the plate into the groove [D] of the
• Fit
clutch housing securely.
Starter Clutch Inspection
the starter motor (see Starter Motor Removal in
• Remove
the Electrical System chapter).
the torque limiter [A] by hand.
•○Turn
The torque limiter should turn clockwise freely [B], but
should not turn counterclockwise.
Left Side View [C]
If the torque limiter does not operate as it should or if it
makes noise, go to the next step.
the starter clutch (see Starter Clutch Disas• Disassemble
sembly), and visually inspect the clutch parts.
One-way Clutch [A]
Housing Part [B] of Clutch Housing
If there is any worm or damaged part, replace it.
CRANKSHAFT/TRANSMISSION 9-29
Starter Clutch
○Examine the starter clutch gear [A] as well.
clutch gear if it is worn or damaged.
Replace the
9-30 CRANKSHAFT/TRANSMISSION
Torque Limiter
Torque Limiter Removal
• Refer to the Clutch Removal in the Clutch chapter.
CAUTION
Do not disassemble the torque limiter [A]. The
torque limiter will not function if this is done.
Torque Limiter Installation
• Refer to the Clutch Installation in the Clutch chapter.
Torque Limiter Inspection
the torque limiter and visually inspect it.
• Remove
If the limiter has wear, discoloration, or other damage,
replace it as a set.
Gear [A]
Clutch Plates (4) [B]
Friction Plates (5) [C]
Springs (2) [D]
Pinion [E]
Shim [F]
CRANKSHAFT/TRANSMISSION 9-31
Transmission
Transmission Shaft and Shift Fork Removal
the crankcase (see Crankcase Splitting).
• Split
Remove:
• Speed Sensor (see Speed Sensor Removal in the Electrical System chapter)
Shift Rods [A]
Shift Forks [B]
• Take out the drive shaft [A] and output shaft [B] as a set.
Transmission Shaft and Shift Fork Removal
engine oil to the gear, and install the drive shaft and
• Apply
output shaft as a set.
engine oil to the shift forks and rods.
• Apply
Install
fork [A] of the shortest ears on the drive shaft
• so thatthe
the one digit (1 ∼ 8) mark side [B] faces upward.
the pin [C] in the center groove in the shift drum.
• Place
the two forks [D] of the shortest ears on the output
• Install
shaft so that the one digit (1 ∼ 8) mark side [E] faces
upward.
○The two forks on the output shaft are identical.
Place the pins [F] in the grooves on both sides in the shift
drum.
Install the shift rods [G].
○The shift rods are identical.
•
•
Transmission Shaft Disassembly
the transmission shafts (see Transmission Shaft
• Remove
and Shift Fork Removal).
the circlips, and then disassemble the transmis• Remove
sion shafts.
Special Tool - Outside Circlip Pliers: 57001-144
5th gear [A] on the output shaft has three steel balls
• The
for the positive neutral finder mechanism.
the 5th gear as follows.
•○Remove
Set the output shaft in a vertical position holding the 3rd
gear [B].
○Spin the 5th gear quickly [C] and pull it off upward.
9-32 CRANKSHAFT/TRANSMISSION
Transmission
Transmission Shaft Assembly
assembling the transmission shafts, refer to the
• When
transmission assembly illustration on ahead too.
• Apply engine oil to the bushings and shafts.
any circlips removed with new ones.
• Replace
Install
the
[A] so that opening [B] of it is aligned
• with a splinecirclips
groove [C].
Special Tool - Outside Circlip Pliers : 57001-144
drive shaft gears can be recognized by size: the gear
• The
with the smallest diameter is 1st gear, and the largest one
•
•
is 6th gear. Be sure that all parts are put back in the correct sequence and all circlips and washers are properly in
place.
Install the 3rd/4th gear onto the drive shaft with their oil
holes aligned.
Install the 6th gear bushing onto the drive shaft with their
oil holes aligned.
output shaft gears can be recognized by size: the
• The
gear with the largest diameter is 1st gear, and the small-
•
•
est one is 6th gear. Be sure that all parts are put back
in the correct sequence and all circlips and washers are
properly in place.
Install the 6th gear onto the output shaft with their oil holes
aligned.
Install the 3rd/4th gear bushing onto the output shaft with
their oil holes aligned.
the steel balls into the 5th gear holes in the output
• Fit
shaft, aligning three oil holes.
5th Gear [A]
Output Shaft [B]
Steel Balls [C]
Oil Holes [D]
CAUTION
Do not apply grease to the steel balls to hold them
in place. This will cause the positive neutral finder
mechanism to malfunction.
○After assembling the 5th gear with steel balls in place on
•
the output shaft, check the ball-locking effect that the 5th
gear does not come out of the output shaft when moving
it up and down by hand.
Check that each gear spins or slides freely on the transmission shafts without binding after assembly.
CRANKSHAFT/TRANSMISSION 9-33
Transmission
1. Drive Shaft
2. 1st Gear
3. 5th gear
4. Thrust Washer, Inside Diameter 30.3 mm
(1.19 in.)
5. Circlip, Outside Diameter 32.2 mm (1.27 in.)
6. 3rd/4th Gear
7. Toothed Washer, Outside Diameter 40 mm
(1.57 in.)
8. Bushing
9. 6th (Top) Gear
10. 2nd Gear
11. Thrust Washers, Inside Diameter 25.3 mm
(1.00 in.)
12. Needle Bearing
13. Circlip, Outside Diameter 27.9 mm (1.10 in.)
14. Output Shaft
15. Busing
16. 4th Gear
17. Bushing
18. 3rd Gear
19. Steel Ball
9-34 CRANKSHAFT/TRANSMISSION
Transmission
Shift Drum Removal
the crankcase (see Crankcase Splitting).
• Split
Remove:
• Shift Forks (see Transmission Shaft and Shift Fork Re-
•
moval)
Pin [A] and Spring [B]
Shift Drum Bearing Retainer Bolts [C]
Pull out the shift drum [D] while aligning the shift drum
cam with the left crankcase hole.
Shift Drum Installation
sure to install the spring and pin to hole of the shift
• Be
drum.
a non-permanent locking agent to the threads of
• Apply
the shift drum bearing retainer bolts, and tighten them.
Torque - Shift Drum Bearing Retainer Bolts : 9.8 N·m (1.0
kgf·m, 87 in·lb)
Shift Drum Disassembly
the shift drum (see Shift Drum Removal).
• Remove
Remove
the
drum cam bolt [A] while holding the shift
• drum with a shift
vise.
Remove:
• Shift Drum Holder [B]
Dowel Pin [C]
Shift Drum Cam [D]
CRANKSHAFT/TRANSMISSION 9-35
Transmission
Shift Drum Assembly
If the new pins [A] are installed on the shift drum cam [B],
note the following.
○Install the new pins so that the longest pin [C] is positioned
as shown in the figure.
Cutout Portion [D] of Shift Drum Cam
Install the following parts.
Ball Bearing [E]
Dowel Pin [F]
Shift Drum Cam
Shift Drum Holder [G]
Apply a non-permanent locking agent to the threads of
the shift drum cam bolt [H], and tighten it.
•
•
Torque - Shift Drum Cam Bolt : 12 N·m (1.2 kgf·m, 106 in·lb)
9-36 CRANKSHAFT/TRANSMISSION
Transmission
Shift Fork Bending
inspect the shift forks, and replace any fork that is
• Visually
bent. A bent fork could cause difficulty in shifting, or allow
the transmission to jump out of gear when under power.
90° [A]
Shift Fork/Gear Groove Wear
the thickness of the shift fork ears [A], and mea• Measure
sure the width [B] of the gear grooves.
If the thickness of a shift fork ear is less than the service
limit, the shift fork must be replaced.
Shift Fork Ear Thickness
Standard:
6.9 ∼ 7.0 mm (0.272 ∼ 0.276 in.)
Service Limit:
6.8 mm (0.268 in.)
If the gear groove is worn over the service limit, the gear
must be replaced.
Gear Groove Width
Standard:
7.05 ∼ 7.15 mm (0.278 ∼ 0.281 in.)
Service Limit:
7.25 mm (0.285 in.)
Shift Fork Guide Pin/Drum Groove Wear
the diameter of each shift fork guide pin [A], and
• Measure
measure the width [B] of each shift drum groove.
If the guide pin on any shift fork is less than the service
limit, the fork must be replaced.
Shift Fork Guide Pin Diameter
Standard:
5.9 ∼ 6.0 mm (0.232 ∼ 0.236 in.)
Service Limit:
5.8 mm (0.228 in.)
If any shift drum groove is worn over the service limit, the
drum must be replaced.
Shift Drum Groove Width
Standard:
6.05 ∼ 6.20 mm (0.238 ∼ 0.244 in.)
Service Limit:
6.3 mm (0.248 in.)
Gear Dog and Gear Dog Hole Damage
inspect the gear dogs [A] and gear dog holes [B].
• Visually
Replace any damaged gears or gears with excessively
worn dogs or dog holes.
CRANKSHAFT/TRANSMISSION 9-37
External Shift Mechanism
Shift Pedal Removal
the front footboard left (Front Footboard Re• Remove
moval/Installation in the Frame chapter).
• Remove:
Front Shift Lever Bolt [A]
Front Shift Lever [B]
Shift Pedal [C]
If the tie-rod is removed from the front and rear shift
levers, note the following.
○The following portions have left-hand threads.
Rear Shift Lever Side of Tie-Rod
Locknut [D] of Rear Shift Lever Side (This locknut is thinner than the front one.)
Ball Joint [E] of Rear Shift Lever
Shift Pedal Installation
the new oil seals [A] are installed in the front foot• When
board left bracket housing [B], press and insert the oil
seals until oil seal surface [C] is 0.4 ∼ 1.0 mm (0.016 in.
∼ 0.039 in.) [D] from the housing end [E].
NOTE
○Install the oil seals so that the oil seal rip faces the housing.
grease to the oil seal lips and sliding surface of shift
• Apply
pedal shaft.
the punch mark [A] on the shift pedal shaft with the
• Align
punch mark [B] on the front shift lever [C].
• Tighten:
Torque - Shift Lever Bolt : 12 N·m (1.2 kgf·m, 106 in·lb)
the front footboard left (Front Footboard
• Install
moval/Installation in the Frame chapter).
Re-
9-38 CRANKSHAFT/TRANSMISSION
External Shift Mechanism
installation, confirm that the shift pedal [A] is posi• After
tioned as shown in the figure.
30 ∼ 40 mm (1.18 ∼ 1.57 in.) [B]
About 1°[C]
About 240.0 mm (9.45 in.) [D]
About 7°[E]
If the pedal position is different, adjust it as follows.
○To adjust the pedal position, loosen the front locknut [F]
and rear locknut (left-hand threads) [G], and then turn the
tie-rod [H].
○Tighten:
Torque - Tie-Rod Locknuts : 9.8 N·m (1.0 kgf·m, 87 in·lb)
CRANKSHAFT/TRANSMISSION 9-39
External Shift Mechanism
sure the sealing lip of the rubber boot [A] fits into the
• Be
groove of the ball joint after installing the shift pedal.
Correctly Boot Fitting Position [B]
Incorrectly Boot Fitting Position [C]
External Shift Mechanism Removal
• Remove:
Alternator Cover (see Alternator Cover Removal in the
•
Electrical
Engine Pulley (see Engine Pulley Removal in the Final
Drive chapter)
Disconnect the gear position switch lead connector [A].
• Remove:
Engine Pulley Plate Bolts [A]
Engine Pulley Plate [B]
• Remove:
External Shift Mechanism Cover Bolts [A]
External Shift Mechanism Cover [B]
9-40 CRANKSHAFT/TRANSMISSION
External Shift Mechanism
• Remove the shift shaft assembly [A].
• Remove:
Gear Positioning Lever Nut [A]
Gear Positioning Lever [B]
Pin [C] and Spring
External Shift Mechanism Installation
If the shift shaft return spring pin [A] was removed, install
it as follows.
○Apply a non-permanent locking agent to the threads of
the shift shaft return spring pin, and tighten it.
Torque - Shift Shaft Return Spring Pin : 39 N·m (4.0 kgf·m,
29 ft·lb)
the gear positioning lever [B] as shown in the figure.
• Install
Collar [C]
Spring [D]
Washer [E]
○Install the spring so that the spring end [F] is touched to
the rib [G] of the crankcase.
Tighten:
•
Torque - Gear Positioning Lever Nut : 7.8 N·m ( 0.80 kgf·m,
69 in·lb)
sure to install the spring [H] and pin [I] to hole of the
• Be
shift drum holder [J].
CRANKSHAFT/TRANSMISSION 9-41
External Shift Mechanism
If the shift shaft assembly was disassembled, assemble
it as follows.
○Install the following parts on the shift shaft as a set.
Upper Lever [A]
Washer [B]
Spring [C]
Lower Lever [D]
○Push down [E] the above parts while opening [F] the upper lever.
○Fit the circlips [G] into the grooves of the shift shaft securely.
Special Tool - Outside Circlip Pliers : 57001-144
○Install the spring on the shift mechanism arm.
9-42 CRANKSHAFT/TRANSMISSION
External Shift Mechanism
• Be sure to install the spacer [A] on the shift shaft [B].
the shift shaft assembly [A].
• Install
Be
sure
install the spacer [B] on the shift shaft.
• Install thetodowel
pins [C].
•
the new needle bearing [A] is installed in the exter• When
nal shift mechanism cover [B], press and insert the new
needle bearing so that the bearing surface [C] is flush with
the housing end of the cover.
Special Tool - Bearing Driver Set : 57001-1129
NOTE
○Install the needle bearing so that manufacture’s make
face out.
the new oil seal [D] is installed in the external shift
• When
mechanism cover, press and insert the new oil seal so
that the oil seal surface [E] is flush with the end of the
hole.
Special Tool - Bearing Driver Set : 57001-1129
CRANKSHAFT/TRANSMISSION 9-43
External Shift Mechanism
silicone sealant to the gear position switch lead
• Apply
grommet [A].
Sealant - Kawasaki Bond (Silicone Sealant) : 92104-0004
the external shift mechanism cover gasket with
• Replace
a new one.
the external shift mechanism cover [A].
• Install
Tighten:
•
Torque - External Shift Mechanism Cover Bolts : 12 N·m
(1.2 kgf·m, 106 in·lb)
L = 22 mm (0.87 in.) [B]
L = 50 mm (1.97 in.) [C]
the gear position switch lead [A] as shown in the
• Run
figure.
that the damper [B] is in place on the engine pulley
• Check
plate [C].
• Tighten:
Torque - Engine Pulley Plate Bolts : 12 N·m (1.2 kgf·m, 106
in·lb)
9-44 CRANKSHAFT/TRANSMISSION
Ball Bearing, Needle Bearing and Oil Seal
Bearing and Oil Seal Installation
Left Crankcase
Refer to the Mechanical Seal Replacement in the Cooling
System chapter for mechanical seal, ball bearing and oil
seal of the water pump.
Before installing the bearing or race, apply small amount
of the engine oil to the outer surface of them.
When the following ball bearings or race are installed in
the left crankcase half, press and insert them until they
are bottomed.
•
•
•
Special Tool - Bearing Driver Set : 57001-1129
Ball Bearing [A] for Output Shaft
Race [B] for Drive Shaft
Ball Bearing [C] for Front Balancer Shaft
Ball Bearing [D] for Rear Balancer Shaft
the oil seal [A] for clutch push rod is installed in the
• When
left crankcase half, press and insert the oil seal so that
the oil seal surface [B] is flush with the end of the hole.
Special Tool - Bearing Driver Set : 57001-1129
NOTE
○Install the oil seal so that the spring side [C] faces inside.
the oil seal [D] for output shaft is installed in the left
• When
crankcase half, press and insert the oil seal so that the oil
seal surface [E] is flush with the end of the hole.
Special Tool - Bearing Driver Set : 57001-1129
NOTE
○Install the oil seal so that the spring side [F] faces inside.
CRANKSHAFT/TRANSMISSION 9-45
Ball Bearing, Needle Bearing and Oil Seal
Right Crankcase
Before installing the bearing or race, apply small amount
of the engine oil to the outer surface of them.
When the following ball bearings or race are installed in
the right crankcase half, press and insert them until they
are bottomed.
•
•
Special Tool - Bearing Driver Set : 57001-1129
Ball Bearing [A] for Drive Shaft
Race [B] for Output Shaft
Ball Bearing [C] for Front Balancer Shaft
Ball Bearing [D] for Rear Balancer Shaft
the needle bearing [A] for torque limiter is installed
• When
in the right crankcase half, press and insert the needle
bearing until it is bottomed.
Special Tool - Bearing Driver Set : 57001-1129
NOTE
○Install the needle bearing so that manufacture’s make
[B] face out.
Bearing Wear
CAUTION
Do not remove the ball bearings for inspection. Removal may damage them.
the ball bearings.
•○Check
Since the ball bearings are made to extremely close tolerances, the wear must be judged by feel rather than measurement. Clean each bearing in a high-flash point solvent, dry it (do not spin the bearing while it is dry), and oil
it with engine oil.
○Spin [A] the bearing by hand to check its condition.
If the bearing is noisy, does not spin smoothly, or has any
rough spots, replace it.
9-46 CRANKSHAFT/TRANSMISSION
Ball Bearing, Needle Bearing and Oil Seal
the needle bearings.
•○Check
The rollers in a needle bearing normally wear very little,
and wear is difficult to measure. Instead of measuring,
inspect the bearing for abrasion, color change, or other
damage.
If there is any doubt as to the condition of a needle bearing, replace it.
Oil Seal Inspection
the oil seal.
• Inspect
Replace it if the lips are misshapen, discolored (indicating
that the rubber has deteriorated), hardened or otherwise
damaged.
WHEELS/TIRES 10-1
Wheels/Tires
Table of Contents
Exploded View........................................................................................................................
Specifications .........................................................................................................................
Special Tools ..........................................................................................................................
Wheels (Rims) ........................................................................................................................
Front Wheel Removal .......................................................................................................
Front Wheel Installation ....................................................................................................
Rear Wheel Removal........................................................................................................
Rear Wheel Installation.....................................................................................................
Wheel Inspection ..............................................................................................................
Axle Inspection..................................................................................................................
Balance Inspection............................................................................................................
Balance Adjustment ..........................................................................................................
Balance Weight Removal..................................................................................................
Balance Weight Installation...............................................................................................
Tires........................................................................................................................................
Air Pressure Inspection/Adjustment..................................................................................
Tire Inspection ..................................................................................................................
Tire Removal ....................................................................................................................
Tire Installation..................................................................................................................
Tire Repair ........................................................................................................................
Hub Bearing............................................................................................................................
Hub Bearings Removal .....................................................................................................
Hub Bearings Installation ..................................................................................................
Hub Bearings Inspection...................................................................................................
Hub Bearings Lubrication..................................................................................................
10-2
10-4
10-5
10-6
10-6
10-7
10-8
10-9
10-11
10-11
10-12
10-12
10-12
10-12
10-14
10-14
10-14
10-14
10-14
10-16
10-17
10-17
10-17
10-18
10-18
10
10-2 WHEELS/TIRES
Exploded View
WHEELS/TIRES 10-3
Exploded View
No.
1
2
3
4
Fastener
Front Axle
Front Axle Clamp Bolts
Rear Axle Nut
Rear Air Valve Nuts
G: Apply grease.
HG: Apply high-temperature grease.
R: Replacement Parts
S: Follow the specified tightening sequence.
WL: Apply soap and water solution or rubber lubricant.
N·m
127
20
108
1.5
Torque
kgf·m
13.0
2.0
11.0
0.15
ft·lb
94
15
80
13 in·lb
Remarks
S
10-4 WHEELS/TIRES
Specifications
Item
Wheels (Rims)
Rim Runout:
Axial
Radial
Axle Runout/100 mm (3.94 in.)
Wheel Balance
Balance Weights
Rim Size:
Front
Rear
Tires
Air Pressure (when Cold):
Front
Rear
Tread Depth:
Front
Rear
Standard Tires:
Front
Rear
Standard
Service Limit
TIR 0.5 mm (0.02 in.) or less
TIR 0.8 mm (0.03 in.) or less
TIR 0.03 mm (0.001 in.) or less
10 g (0.35 oz.) or less
10 g (0.35 oz.), 20 g (0.71 oz.),
30 g (1.06 oz.)
TIR 1.0 mm (0.04 in.)
TIR 1.0 mm (0.04 in.)
TIR 0.2 mm (0.008 in.)
– – –
– – –
16 × 3.50
16 × 4.50
– – –
– – –
Up to 180 kg (397 lb) load:
200 kPa (2.00 kgf/cm², 28 psi)
– – –
Up to 97.5 kg (215 lb) load:
250 kPa (2.50 kgf/cm², 36 psi)
97.5 kg ∼ 180 kg (215 lb ∼ 397 lb)
load:
280 kPa (2.80 kgf/cm², 40 psi)
– – –
4.3 mm (0.17 in.)
7.2 mm (0.28 in.)
Make, Type
BRIDGESTONE,
EXEDRA G721 E
BRIDGESTONE,
EXEDRA G722 E
– – –
1 mm (0.04 in.)
(AT, CH, DE) 1.6 mm (0.06 in.)
Up to 130 km/h (80 mph):
2 mm (0.08 in.)
Over 130 km/h (80 mph):
3 mm (0.12 in.)
Size
130/90-B16 M/C 67H
170/70-B16 M/C 75H
WARNING
Use the same manufacturer’s tires on both front and rear wheels.
WHEELS/TIRES 10-5
Special Tools
Inside Circlip Pliers:
57001-143
Bearing Remover Head,
57001-1293
20 ×
22:
Bearing Driver Set:
57001-1129
Bearing Remover Head,
57001-1346
25 ×
28:
Jack:
57001-1238
Bearing Remover Shaft,
57001-1377
13:
10-6 WHEELS/TIRES
Wheels (Rims)
Front Wheel Removal
• Remove:
Front Caliper Mounting Bolts [A] (Both Sides)
Front Caliper (with the hose installed) [B] (Both Sides)
• Loosen:
Front Axle Clamp Bolts [A]
Front Axle [B]
the jack [A] under the frame pipe, and a commer• Using
cially available jack [B] under the engine, lift the front
wheel off the ground until the rear wheel touches the
ground.
Special Tool - Jack: 57001-1238
CAUTION
Be sure to put the rear wheel on the ground when
removing the front wheel, or the motorcycle may fall
over. The motorcycle could be damaged.
WARNING
Be sure to put the rear wheel on the ground when
removing the front wheel, or the motorcycle may fall
over. It could cause an accident and injury.
• Remove the axle, and take off the front wheel.
CAUTION
Do not lay the wheel directly on the ground with
the disc facing down. This can damage or warp the
disc. Place blocks to under the wheel so that the
disc does not touch the ground.
WHEELS/TIRES 10-7
Wheels (Rims)
Front Wheel Installation
high-temperature grease to the grease seal lips.
• Apply
Fit
the
collars [A] on both sides of the hub.
•○The collars
are identical.
the front wheel, and insert the front axle.
• Install
Remove
• Tighten: the commercially available jack.
•
Torque - Front Axle : 127 N·m (13.0 kgf·m, 94 ft·lb)
tightening the front axle clamp bolts, pump the
• Before
forks up and down [A] 4 or 5 times to allow the right fork
leg to find a neutral position on the front axle.
NOTE
○Put a block [B] in front of the wheel to stop moving.
○Do not apply the front brake.
• Tighten:
Torque - Front Axle Clamp Bolts: 20 N·m (2.0 kgf·m, 15 ft·lb)
○Tighten the inner bolt [A] first, tighten the outer bolt [B]
•
second, and then tighten the inner bolt again.
Check the clearance [C] between the right fork leg [D] and
collar [E]. There should be about 2.0 mm (0.08 in.) of
clearance.
If the clearance is out of this range, remove the front wheel
again and check the axle, wheel hub and other related
parts for damage.
the front calipers (see Caliper Installation in the
• Install
Brakes chapter).
• Check the front brake effectiveness.
WARNING
Do not attempt to ride the motorcycle until a full
brake lever is obtained by pumping the brake lever
until the pads are against the disc. The brakes will
not function on the first application of the lever if
this is not done.
10-8 WHEELS/TIRES
Wheels (Rims)
Rear Wheel Removal
• Remove:
Saddlebags
•
(see Saddlebag Removal in the Frame
chapter)
Saddlebag Stays (see Saddlebag Stay Removal in the
Frame chapter)
Right Muffler Body (see Muffler Body Removal in the
Engine Top End chapter)
Rear Fender (see Rear Fender Removal in the Frame
chapter)
Using the jack under the frame pipe, raise the rear wheel
off the ground.
Special Tool - Jack: 57001-1238
CAUTION
Be sure to put the front wheel on the ground when
removing the rear wheel, or the motorcycle may fall
over. The motorcycle could be damaged.
WARNING
Be sure to put the front wheel on the ground when
removing the rear wheel, or the motorcycle may fall
over. It could cause an accident and injury.
• Remove the bolts [A], and take off the belt cover [B].
the brake lever slowly and hold it with a band
• Squeeze
[A].
CAUTION
Be sure to hold the front brake when removing the
rear wheel, or the motorcycle may fall over. The
motorcycle could be damaged.
WARNING
Be sure to hold the front brake when removing the
rear wheel, or the motorcycle may fall over. It could
cause an accident and injury.
WHEELS/TIRES 10-9
Wheels (Rims)
• Remove:
Bolt [A] and Brake Hose Guide [B]
Rear Caliper Mounting Bolts [C]
Rear Caliper (with the hose installed) [D]
• Remove:
Cotter Pin [A]
•
Rear Axle Nut [B]
Washer [C]
Loosen:
Belt Adjuster Locknuts [D] (Both Sides)
Belt Adjuster Nuts [E] (Both Sides)
out the rear axle.
• Pull
Clear
the drive belt [A] from the rear pulley [B].
• Remove
the rear wheel.
•
CAUTION
Do not lay the wheel directly on the ground with
the disc facing down. This can damage or warp the
disc. Place blocks to under the wheel so that the
disc does not touch the ground.
Rear Wheel Installation
high-temperature grease to the grease seal lips on
• Apply
both sides of the hub.
the collars [A] on both sides of the hub.
•○Fit
Fit the flange collar onto the right side.
• Turn the stepped side [A] of the belt adjusters outward.
10-10 WHEELS/TIRES
Wheels (Rims)
• Install the caliper bracket [A] onto the swingarm stop [B].
the drive belt [A] with the rear pulley [B].
• Engage
Insert
the
from the left side.
• Adjust theaxle
belt
deflection before tightening the axle nut
• (see Belt Deflection
Adjustment in the Periodic Mainte-
•
nance chapter).
Tighten:
Torque - Rear Axle Nut: 108 N·m (11.0 kgf·m, 80 ft·lb)
• Insert a new cotter pin [A].
NOTE
○When inserting the cotter pin, if the slots in the nut do
not align with the cotter pin hole in the axle, tighten the
nut clockwise [B] up to next alignment.
○It should be within 30°.
○Loosen once and tighten again when the slot goes past
the nearest hole.
• Bend the cotter pin [A] over the nut .
WARNING
If the rear axle nut is not securely tightened or the
cotter pin is not installed, an unsafe riding condition may result.
the removed parts (see appropriate chapters).
• Install
Check
that the drive belt does not touch the belt cover
• and other
parts.
Check
the
brake effectiveness (see Brake Operation
• Inspection rear
in the Periodic Maintenance chapter).
WARNING
Do not attempt to drive the motorcycle until a full
brake pedal is obtained by pumping the brake pedal
until the pads are against the disc. The brake will
not function on the first application of the pedal if
this is not done.
WHEELS/TIRES 10-11
Wheels (Rims)
Wheel Inspection
• Raise the wheel off the ground with the jack.
Special Tool - Jack: 57001-1238
the wheel lightly, and check for roughness or binding.
• Spin
If roughness or binding is found, replace the hub bearings.
the wheel for small cracks, dents, bending, or
• Inspect
warp.
If there is any damage to the wheel, replace the wheel.
the wheel, and support it with the tire by the axle.
• Remove
the rim runout, axial [A] and radial [B], with a dial
• Measure
gauge.
If rim runout exceeds the service limit, check the hub bearings.
If the problem is not due to the bearings, replace the
wheel.
Rim Runout (with tire installed)
Standard:
Axial
TIR 0.5 mm (0.02 in.) or less
Radial
TIR 0.8 mm (0.03 in.) or less
Service Limit:
Axial
TIR 1.0 mm (0.04 in.)
Radial
TIR 1.0 mm (0.04 in.)
WARNING
Never attempt to repair a damaged wheel. If there
is any damage besides wheel bearings, the wheel
must be replaced to insure safe operational condition.
Axle Inspection
the front and rear axles (see Front/Rear Wheel
• Remove
Removal).
inspect the front and rear axles for damages.
• Visually
If the axle is damaged or bent, replace it.
the axle in V blocks that are 100 mm (3.94 in.) [A]
• Place
apart, and set a dial gauge [B] on the axle at a point
halfway between the blocks. Turn [C] the axle to measure the runout. The difference between the highest and
lowest dial readings is the amount of runout.
If axle runout exceeds the service limit, replace the axle.
Axle Runout/100 mm (3.94 in.)
Standard:
TIR 0.03 mm (0.001 in.) or less
Service Limit:
TIR 0.2 mm (0.008 in.)
10-12 WHEELS/TIRES
Wheels (Rims)
Balance Inspection
the front and rear wheels (see Front/Rear Wheel
• Remove
Removal).
the wheel so that it can be spun freely.
• Support
Spin
the
lightly, and mark [A] the wheel at the top
• when thewheel
wheel stops.
○Repeat this procedure several times.
If the wheel stops
of its own accord in various positions, it is well balanced.
If the wheel always stops in one position, adjust the wheel
balance (see Balance Adjustment).
Balance Adjustment
•
•
•
•
If the wheel always stops in one position, provisionally
attach a balance weight [A] on the rim at the marking using
adhesive tape.
Rotate the wheel 1/4 turn [B], and see whether or not the
wheel stops in this position. If it does, the correct balance
weight is being used.
If the wheel rotates and the weight goes up, replace the
weight with the next heavier size. If the wheel rotates and
the weight goes down, replace the weight with the next
lighter size. Repeat these steps until the wheel remains
at rest after being rotated 1/4 turn.
Rotate the wheel another 1/4 turn and then another 1/4
turn to see if the wheel is correctly balanced.
Repeat the entire procedure as many times as necessary
to achieve correct wheel balance.
Permanently install the balance weight.
Balance Weight Removal
screwdrivers [A] [B] between the rib [C] and weight
• Insert
[D] as shown in the figure.
the balance weight with two screwdrivers and remove
• Pry
the balance weight.
• Discard the used balance weight.
CAUTION
Do not tap the screwdrivers. The rim could be damaged.
Balance Weight Installation
if the weight portion has any play on the blade [A]
• Check
and clip [B].
Rear View [C]
Left Side [D]
If it does, discard it.
WARNING
If the balance weight has any play on the rib of the
rim, the blade and/or clip have been stretched. Replace the loose balance weight.
Do not reuse used balance weight.
Unbalanced wheels can create an unsafe riding
condition.
WHEELS/TIRES 10-13
Wheels (Rims)
Balance Weight
Part Number
Weight
41075-0007
10 g (0.35 oz.)
41075-0018
20 g (0.71 oz.)
41075-0017
30 g (1.06 oz.)
NOTE
○Balance weights are available from Kawasaki dealers
in 10, 20 and 30 g (0.35, 0.71 and 1.06 oz.) sizes. An
imbalance of less than 10 g (0.35 oz.) will not usually
affect running stability.
○Do not use five or more balance weights (more than 90
g, 3.17 oz.). If the wheel requires an excess balance
weight, disassemble the wheel to find the cause.
the balance weight [A] on to the rib [B], by pushing or
• Slip
tapping [C] the clip [D].
Rear View [E]
Left Side [F]
sure to install the balance weight.
•○Be
Check that the blade [A] and clip [B] are fully seated on
the rim [C] and that the clip is hooked over the rib [D].
Rear View [E]
Left Side [F]
10-14 WHEELS/TIRES
Tires
Air Pressure Inspection/Adjustment
to the Air Pressure Inspection in the Periodic Main• Refer
tenance chapter.
Tire Inspection
to the Wheel/Tire Damage Inspection in the Peri• Refer
odic Maintenance chapter.
Tire Removal
• Remove:
Wheel (see Front/Rear Wheel Removal)
•
Valve Core (Let out the air)
To maintain wheel balance, mark the air valve position on
the tire with chalk so that the tire can be reinstalled in the
same position.
Chalk Mark or Yellow Mark [A]
Air Valve [B]
Align [C]
the tire beads and rim flanges on both sides with
• Lubricate
a soap and water solution or rubber lubricant. This helps
the tire beads slip off the rim flanges.
CAUTION
Never lubricate with engine oil or petroleum distillates because they will deteriorate the tire.
the tire from the rim using a suitable commer• Remove
cially available tire changer.
NOTE
○The tires cannot be removed with hand tools because
they fit the rims too tightly.
Tire Installation
WARNING
Use the same manufacturer’s tires on both front and
rear wheels.
the rim and tire, and replace them if necessary.
• Inspect
Clean
the
surfaces of the rim and tire, and smooth
• the sealingsealing
surfaces of the rim with a fine emery cloth if
•
necessary.
Remove the air valve and discard it.
CAUTION
Replace the air valve whenever the tire is replaced.
Do not reuse the air valve.
WHEELS/TIRES 10-15
Tires
Install a new valve in the rim.
•Front
○Remove the valve cap, lubricate the stem seal [A] with a
soap and water solution or rubber lubricant, and pull [B]
the valve stem through the rim from the inside out until it
snaps into place.
CAUTION
Do not use engine oil or petroleum distillates to lubricate the stem because they will deteriorate the
rubber.
○The air valve is shown in the figure.
Valve Cap [A]
Valve Core [B]
Stem Seal [C]
Valve Stem [D]
Valve Seat [E]
Valve Opened [F]
Rear
○Insert the new air valve in the rear wheel rim.
Rear View [A]
Valve Body [B]
Valve Nuts [C]
Valve Washer [D]
Rim [E]
Right Side [F]
○Remove the valve cap, valve nuts, valve washer and insert the valve stem through the rim from the inside out.
Torque - Rear Air Valve Nuts: 1.5 N·m (0.15 kgf·m, 13 in·lb)
○Install the valve cap.
a soap and water solution or rubber lubricant to the
• Apply
rim flange and tire beads.
CAUTION
Never lubricate with engine oil or petroleum distillates because they will deteriorate the tire.
the tire rotation mark on the front and rear tires and
• Check
install them on the rim accordingly.
Tire Rotation Mark [A]
Rotating Direction [B]
10-16 WHEELS/TIRES
Tires
the tire on the rim so that the valve [A] align with
• Position
the tire balance mark [B] (the chalk mark made during
•
•
•
removal, or the yellow paint mark on a new tire).
Install the tire bead over the rim flange using a suitable
commercially available tire changer.
Lubricate the tire beads and rim flanges with a soap and
water solution or rubber lubricant to help seat the tire
beads in the sealing surfaces of the rim while inflating the
tire.
Center the rim in the tire beads, and inflate the tire with
compressed air until the tire beads seat in the sealing
surfaces.
WARNING
Be sure to install the valve core whenever inflating
the tire, and do not inflate the tire to more than 400
kPa (4.0 kgf/cm², 57 psi). Overinflation can explode
the tire with possibility of injury and loss of life.
to see that the bead lines [A] on both sides of the
• Check
tire sidewalls are parallel with the rim flanges.
If the rim flanges and tire sidewall bead lines are not parallel, remove the valve core.
Lubricate the rim flanges and tire beads.
Install the valve core and inflate the tire again.
After the tire beads seat in the rim flanges, check for air
leakage.
○Inflate the tire slightly above standard inflation.
○Use a soap and water solution or submerge the tire, and
check for bubbles that would indicate leakage.
Adjust the air pressure to the specified pressure (see Air
Pressure Inspection in the Periodic Maintenance chapter).
Adjust the wheel balance (see Balance Adjustment).
•
•
•
•
•
Tire Repair
Currently two types of repair for tubeless tires have come
into wide use. One type is called a temporary (external) repair which can be carried out without removing the tire from
the rim, and the other type is called permanent (internal)
repair which requires tire removal. It is generally understood that higher running durability is obtained by permanent (internal) repairs than by temporary (external) ones.
Also, permanent (internal) repairs have the advantage of
permitting a thorough examination for secondary damage
not visible from external inspection of the tire. For these
reasons, Kawasaki does not recommend temporary (external) repair. Only appropriate permanent (internal) repairs
are recommended. Repair methods may vary slightly from
make to make. Follow the repair methods indicated by the
manufacturer of the repair tools and materials so that safe
results can be obtained.
WHEELS/TIRES 10-17
Hub Bearing
Hub Bearings Removal
the wheel, and take out the following.
• Remove
Front Hub [A]
Rear Hub [B]
Collars
Coupling [C]
Grease Seals [D]
• Use the bearing remover to remove the hub bearings [A].
CAUTION
Do not lay the wheel directly on the ground with
the disc facing down. This can damage or warp the
disc. Place blocks to under the wheel so that the
disc does not touch the ground.
Special Tools - Bearing Remover Shaft, 13 [B]: 57001
-1377
Bearing Remover Head, 25 × 28 [C]:
57001-1346 (for Front Hub)
Bearing Remover Head, 20 × 22: 57001
-1293 (for Rear Hub)
Hub Bearings Installation
installing the wheel bearings, blow any dirt or for• Before
eign particles out of the hub with compressed air to pre-
•
vent contamination of the bearings.
Replace the bearings with new ones.
NOTE
○Install the bearings so that the marked side faces out.
the bearings by using a bearing driver.
• Install
• First, press each right bearing [A] in until it bottoms out.
Special Tool - Bearing Driver Set [B]: 57001-1129
install the following.
• Next,
New Circlip
Distance Collar
Left Bearing
10-18 WHEELS/TIRES
Hub Bearing
○Replace the circlips with new ones.
Special Tool - Inside Circlip Pliers: 57001-143
the grease seals with new ones.
• Replace
Press
in
the grease seals [A] so that the seal surface is
• flush [B] with
the end of the hole.
○Apply high-temperature grease to the grease seal lips.
Special Tool - Bearing Driver Set [C]: 57001-1129
Hub Bearings Inspection
○Since the hub bearings are made to extremely close tolerance, the clearance cannot normally be measured.
NOTE
○Do not remove any bearings for inspection. If any bearings are removed, they will need to be replaced with
new ones.
each bearing in the hub back and forth [A] while
• Turn
checking for plays, roughness, or binding.
•
If bearing play, roughness, or binding is found, replace
the bearing.
Examine the bearing seal [B] for tears or leakage.
If the seal is torn or is leaking, replace the bearing.
Hub Bearings Lubrication
NOTE
○Since the hub bearings are packed with grease
sealed, lubrication is not required.
and
FINAL DRIVE 11-1
Final Drive
Table of Contents
Exploded View........................................................................................................................
Specifications .........................................................................................................................
Special Tools ..........................................................................................................................
Drive Belt ................................................................................................................................
Belt Handling Precautions.................................................................................................
Drive Belt Wear Inspection ...............................................................................................
Drive Belt Deflection Inspection ........................................................................................
Drive Belt Deflection Adjustment ......................................................................................
Drive Belt Removal ...........................................................................................................
Drive Belt Installation ........................................................................................................
Pulley and Coupling................................................................................................................
Engine Pulley Outer Cover Removal ................................................................................
Engine Pulley Outer Cover Installation .............................................................................
Engine Pulley Inner Cover Removal .................................................................................
Engine Pulley Inner Cover Installation ..............................................................................
Engine Pulley Removal.....................................................................................................
Engine Pulley Installation..................................................................................................
Rear Pulley Removal ........................................................................................................
Rear Pulley Installation .....................................................................................................
Rear Pulley Coupling Installation ......................................................................................
Pulley Wear Inspection .....................................................................................................
Coupling Bearing Removal ...............................................................................................
Coupling Bearing Installation ............................................................................................
Coupling Bearing Inspection .............................................................................................
Coupling Bearing Lubrication............................................................................................
Rubber Damper Inspection ...............................................................................................
11-2
11-4
11-5
11-6
11-6
11-7
11-7
11-7
11-7
11-8
11-9
11-9
11-9
11-9
11-9
11-10
11-11
11-11
11-11
11-12
11-12
11-12
11-13
11-13
11-14
11-14
11
11-2 FINAL DRIVE
Exploded View
FINAL DRIVE 11-3
Exploded View
No.
1
2
3
4
5
6
7
Fastener
Engine Pulley Mounting Nut
Engine Pulley Inner Cover Bolts
Engine Pulley Outer Cover Bolts
Rear Axle Nut
Rear Coupling Stud Bolts
Rear Pulley Mounting Nuts
Rear Pulley Plate Bolts
G: Apply grease.
HG: Apply high-temperature grease.
L: Apply a non-permanent locking agent.
M: Apply molybdenum disulfide grease.
R: Replacement Parts
N·m
175
12
9.8
108
44
59
6.9
Torque
kgf·m
18.0
1.2
1.0
11.0
4.5
6.0
0.70
ft·lb
129
106 in·lb
87 in·lb
80
33
44
61 in·lb
Remarks
M
L
R
L
11-4 FINAL DRIVE
Specifications
Item
Drive Belt
Make
Belt Deflection (45 N, 4.6 kgf, 10 lb force)
(When installing new belt or engine is remounted)
Standard
GATES, 139T
3.0 ∼ 4.5 mm (0.12 ∼ 0.18 in.)
3.0 mm (0.12 in.)
FINAL DRIVE 11-5
Special Tools
Inside Circlip Pliers:
57001-143
Pulley Holder:
57001-1572
Oil Seal & Bearing Remover:
57001-1058
Grip:
57001-1591
Bearing Driver Set:
57001-1129
11-6 FINAL DRIVE
Drive Belt
The drive belt must be checked, and adjusted in accordance with the Periodic Maintenance Chart for safety and
to prevent excessive wear. If the belt becomes badly worn
or maladjusted-either too loose or too tight-the belt could
jump off the pulley or break.
Belt Handling Precautions
CAUTION
Do not adhere battery electrolyte, thinner or other
solvents to the belt. Immediately wash away any
solvent that spills on the belt.
○Drive belt is extremely durable and give long life in a properly designed drive. However, improper handling of the
belt before or during installation can result in dramatically
shortened service life.
○The belt’s tensile cords are designed to carry large loads
in tension but not compression.
○Compression causes damage to the tensile cords of the
belt and can also lead to adhesion problems.
○Handling situations that can cause compression in tensile
cord include aggressive bending and twisting.
assembly, handling and storage, the forward bend• When
ing [A] radius of the drive belt [B] shall not be smaller than
63.5 mm (2.50 in.) [C].
assembly, handling and storage, the back bending
• When
[A] radius of the drive belt [B] shall not be smaller than
127 mm (5.00 in.) [C].
FINAL DRIVE 11-7
Drive Belt
not twist [A] the drive belt [B] as shown in the figure.
•○Do
This includes coiling the belt to make it smaller for packaging.
not use tools [A] to pry [B] the drive belt [C] onto the
• Do
application.
○Bring the rear pulley [D] front side so that the belt can be
easily put on by hand.
Drive Belt Wear Inspection
to the Belt Wear and Damage Inspection in the Pe• Refer
riodic Maintenance chapter.
Drive Belt Deflection Inspection
to the Belt Deflection Inspection in the Periodic
• Refer
Maintenance chapter.
Drive Belt Deflection Adjustment
to the Belt Deflection Adjustment in the Periodic
• Refer
Maintenance chapter.
Drive Belt Removal
• Remove:
Rear Wheel
(see Rear Wheel Removal in the
Wheels/Tires chapter)
Engine Pulley (see Engine Pulley Removal)
Swingarm (see Swingarm Removal in the Suspension
chapter)
NOTE
○Before removing, observe the direction the belt’s printed
information [A] (such as manufacture’s name) is facing
so that it may be reinstalled on the pulleys to rotate in
the same direction as originally installed.
• Remove the drive belt [B].
11-8 FINAL DRIVE
Drive Belt
Drive Belt Installation
• Installation is the reverse of removal. Note the following.
NOTE
○Be sure the printed information faces the same direction
so the belt rotates in the same direction as originally instead. When installing a new belt, install it so the printed
information can be read from left side of the motorcycle.
the drive belt deflection (see Belt Deflection Ad• Adjust
justment in the Periodic Maintenance chapter).
FINAL DRIVE 11-9
Pulley and Coupling
Engine Pulley Outer Cover Removal
• Remove:
Bolts [A]
Engine Pulley Outer Cover [B]
Engine Pulley Outer Cover Installation
the trim [A] on the engine pulley outer cover [B].
•○Install
The higher side of the trim faces inside.
○Align the trim ends [C] with the notch [D] of the cover.
• Tighten:
Torque - Engine Pulley Outer Cover Bolts: 9.8 N·m (1.0
kgf·m, 87 in·lb)
Engine Pulley Inner Cover Removal
• Remove:
Engine Pulley Outer Cover (see Engine Pulley Outer
•
Cover Removal)
Clutch Slave Cylinder (see Clutch Slave Cylinder Removal in the Clutch chapter)
Remove the bolts [A], and take off the engine pulley inner
cover [B].
Engine Pulley Inner Cover Installation
• Install the drive belt guide [A].
11-10 FINAL DRIVE
Pulley and Coupling
the installation condition of the pad [A].
•○Check
Stick the pad securely.
• Install the dowel pins [B] as shown in the figure.
the engine pulley inner cover [A].
• Install
Tighten:
•
Torque - Engine Pulley Inner Cover Bolts [B] : 12 N·m (1.2
kgf·m, 106 in·lb)
• Install:
Clutch Slave Cylinder (see Clutch Slave Cylinder Installation in the Clutch chapter)
Engine Pulley Outer Cover (see Engine Pulley Outer
Cover Installation)
Engine Pulley Removal
• Remove:
Engine Pulley Outer Cover (see Engine Pulley Outer
Cover Removal)
Clutch Slave Cylinder (see Clutch Slave Cylinder Removal in the Clutch chapter)
Engine Pulley Inner Cover (see Engine Pulley Inner
Cover Removal)
Deflect the belt fully (see Drive Belt Deflection Adjustment
in the Periodic Maintenance chapter).
Flatten out the bent washer [A].
•
•
the engine pulley [A] steady with the pulley holder
• Hold
[B], and remove the pulley mounting nut [C].
Special Tools - Pulley Holder: 57001-1572
Grip: 57001-1591
• Pull out the engine pulley from the output shaft.
FINAL DRIVE 11-11
Pulley and Coupling
Engine Pulley Installation
the grooves inside the pulley onto the splines on the
• Fit
output shaft.
the washer with a new one.
• Replace
Apply
molybdenum
disulfide grease to the threads of
• the output shaft and seating
surface of the engine pulley
mounting nut.
NOTE
○If the grease stuck to the pulley or drive belt, wipe up it.
the engine pulley steady with the pulley holder, and
• Hold
tighten the pulley mounting nut.
Torque - Engine Pulley Mounting Nut: 175 N·m (18.0 kgf·m,
129 ft·lb)
Special Tools - Pulley Holder: 57001-1572
Grip: 57001-1591
the one side of the washer [A] over the nut.
• Bend
the drive belt deflection (see Belt Deflection Ad• Adjust
justment in the Periodic Maintenance chapter).
• Install the removed parts (see appropriate chapters).
Rear Pulley Removal
• Remove:
Rear Wheel
(see Rear Wheel Removal in the
Wheels/Tires chapter)
Rear Pulley Mounting Nuts [A] and Washers
Rear Pulley [B]
Rear Pulley Installation
the rear pulley plate [A].
•○Install
Turn the bent edge to outside.
a non-permanent locking agent to the rear pulley
• Apply
plate bolts [B].
• Tighten:
Torque - Rear Pulley Plate Bolts: 6.9 N·m (0.70 kgf·m, 61
in·lb)
the rear pulley mounting nuts with new ones.
• Replace
Install
the
• nuts. rear pulley, washers and rear pulley mounting
• Tighten:
Torque - Rear Pulley Mounting Nuts: 59 N·m (6.0 kgf·m, 44
ft·lb)
11-12 FINAL DRIVE
Pulley and Coupling
Rear Pulley Coupling Installation
grease to the coupling grease seal lips [A].
• Apply
Apply
• [B]. grease to the rear pulley coupling internal surface
• Install the sleeve [C].
the coupling dampers [A] so that the projections [B]
• Install
face to the outside.
• Install the coupling on the dampers.
Pulley Wear Inspection
inspect the engine and rear pulley teeth for wear
• Visually
and damage.
If the teeth are worn, damage, or loss of the chrome plating exists, replace the pulley, and inspect the drive belt
wear (see Drive Belt Wear and Damage Inspection in the
Periodic Maintenance chapter).
Engine Pulley [A]
Rear Pulley [B]
NOTE
○If the pulley requires replacement, the belt is probably
worn also. Whenever replacing the pulley, inspect the
belt.
Coupling Bearing Removal
the rear wheel (see Rear Wheel Removal in the
• Remove
Wheels/Tires chapter).
off the rear pulley coupling with the rear pulley from
• Take
the wheel.
• Remove the grease seal [A].
FINAL DRIVE 11-13
Pulley and Coupling
• Remove the circlip [A].
Special Tool - Inside Circlip Pliers: 57001-143
the sleeve [A].
• Remove
Remove
• side. the ball bearing [B] by tapping from the wheel
Special Tool - Oil Seal & Bearing Remover: 57001-1058
Coupling Bearing Installation
the bearing with a new one.
• Replace
Press
in
the
bearing [A] until it is bottomed.
•
Special Tool - Bearing Driver Set [B]: 57001-1129
• Replace the circlip with a new one.
Special Tool - Inside Circlip Pliers: 57001-143
the grease seal with a new one.
• Replace
Press
in
the grease seal [A] so that the seal surface is
• flush [B] with
the end of the hole.
○Apply grease to the grease seal lips.
Special Tool - Bearing Driver Set [C]: 57001-1129
Coupling Bearing Inspection
Since the coupling bearing [A] is made to extremely close
tolerances, the clearance can not normally be measured.
NOTE
○It is not necessary to remove the coupling bearing for
inspection. If the bearing is removed, it will need to be
replaced with a new one.
the bearing by hand to check its condition.
• Turn
If bearing play, roughness, or binding is found, replace
•
the bearing.
Examine the bearing seal for tears or leakage.
If the seal is torn or is leaking, replace the bearing.
11-14 FINAL DRIVE
Pulley and Coupling
Coupling Bearing Lubrication
NOTE
○Since the coupling bearing is packed with grease and
sealed, lubrication is not required.
Rubber Damper Inspection
the rear wheel (see Rear Wheel Removal in the
• Remove
Wheels/Tires chapter).
off the rear pulley with the coupling.
• Take
Visually
inspect the rubber dampers [A] for damage or
• deterioration.
Replace the damper if it appears damaged or deteriorated.
BRAKES 12-1
Brakes
Table of Contents
Exploded View........................................................................................................................
Specifications .........................................................................................................................
Special Tool ............................................................................................................................
Brake Lever, Brake Pedal.......................................................................................................
Brake Lever Position Adjustment......................................................................................
Brake Pedal Position Inspection .......................................................................................
Brake Pedal Position Adjustment......................................................................................
Brake Pedal Removal .......................................................................................................
Brake Pedal Installation ....................................................................................................
Calipers ..................................................................................................................................
Front Caliper Removal ......................................................................................................
Rear Caliper Removal.......................................................................................................
Caliper Installation ............................................................................................................
Front Caliper Disassembly................................................................................................
Front Caliper Assembly.....................................................................................................
Rear Caliper Disassembly ................................................................................................
Rear Caliper Assembly .....................................................................................................
Caliper Fluid Seal Damage Inspection..............................................................................
Caliper Dust Seal Damage Inspection ..............................................................................
Caliper Dust Boot and Friction Boot Damage Inspection..................................................
Caliper Piston and Cylinder Damage Inspection ..............................................................
Caliper Holder Shaft Wear Inspection...............................................................................
Brake Pads .............................................................................................................................
Front Brake Pad Removal.................................................................................................
Front Brake Pad Installation..............................................................................................
Rear Brake Pad Removal .................................................................................................
Rear Brake Pad Installation ..............................................................................................
Brake Pad Wear Inspection ..............................................................................................
Master Cylinder ......................................................................................................................
Front Master Cylinder Removal ........................................................................................
Front Master Cylinder Installation .....................................................................................
Rear Master Cylinder Removal.........................................................................................
Rear Master Cylinder Installation......................................................................................
Front Master Cylinder Disassembly ..................................................................................
Rear Master Cylinder Disassembly...................................................................................
Master Cylinder Assembly ................................................................................................
Master Cylinder Inspection (Visual Inspection).................................................................
Brake Discs ............................................................................................................................
Brake Disc Removal ........................................................................................................
Brake Disc Installation ......................................................................................................
Brake Disc Wear Inspection..............................................................................................
Brake Disc Warp Inspection..............................................................................................
Brake Fluid .............................................................................................................................
Brake Fluid Level Inspection.............................................................................................
Brake Fluid Change ..........................................................................................................
Brake Line Bleeding..........................................................................................................
Brake Hose.............................................................................................................................
Brake Hose and Pipe Removal/Installation.......................................................................
Brake Hose and Pipe Inspection.......................................................................................
12-2
12-6
12-7
12-8
12-8
12-8
12-8
12-8
12-9
12-10
12-10
12-10
12-11
12-11
12-11
12-11
12-11
12-12
12-12
12-13
12-13
12-14
12-15
12-15
12-15
12-15
12-15
12-15
12-16
12-16
12-16
12-17
12-17
12-17
12-17
12-18
12-18
12-19
12-19
12-19
12-19
12-19
12-20
12-20
12-20
12-20
12-23
12-23
12-23
12
12-2 BRAKES
Exploded View
BRAKES 12-3
Exploded View
No.
1
2
3
4
5
6
7
8
9
Fastener
Bleed Valves
Brake Hose Banjo Bolts
Brake Lever Pivot Bolt
Brake Lever Pivot Bolt Locknut
Front Brake Disc Mounting Bolts
Front Brake Light Switch Screw
Front Brake Reservoir Cap Screws
Front Caliper Mounting Bolts
Front Master Cylinder Clamp Bolts
B: Apply brake fluid.
L: Apply a non-permanent locking agent.
R: Replacement Parts
S: Follow the specified tightening sequence.
Si: Apply silicone grease (ex. PBC grease).
N·m
7.8
25
1.0
5.9
27
1.2
1.5
34
11
Torque
kgf·m
0.80
2.5
0.10
0.60
2.8
0.12
0.15
3.5
1.1
ft·lb
69 in·lb
18
8.9 in·lb
52 in·lb
20
11 in·lb
13 in·lb
25
97 in·lb
Remarks
Si
L
S
12-4 BRAKES
Exploded View
BRAKES 12-5
Exploded View
No.
1
2
3
4
5
6
7
Fastener
Bleed Valves
Brake Hose Banjo Bolts
Brake Pedal Bolt
Rear Brake Disc Mounting Bolts
Rear Caliper Mounting Bolts
Rear Master Cylinder Mounting Bolts
Rear Master Cylinder Push Rod Locknut
B: Apply brake fluid.
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
Si: Apply silicone grease (ex. PBC grease).
N·m
7.8
25
8.8
27
34
25
17.2
Torque
kgf·m
0.80
2.5
0.90
2.8
3.5
2.5
1.8
ft·lb
69 in·lb
18
78 in·lb
20
25
18
13
Remarks
L
12-6 BRAKES
Specifications
Item
Brake Lever, Brake Pedal
Brake Lever Position
Brake Lever Free Play
Pedal Free Play
Pedal Position
Standard
8-way adjustable (to suit rider)
Non-adjustable
Non-adjustable
About 100 mm (3.94 in.)
Service Limit
–
–
–
–
–
–
–
–
–
–
–
–
(height from pedal top to footboard top)
Brake Pads
Lining Thickness:
Front
Rear
Brake Discs
Thickness:
Front
Rear
Runout
Brake Fluid
Grade
4.5 mm (0.18 in.)
7.0 mm (0.28 in.)
4.8 ∼ 5.2 mm (0.19 ∼ 0.20 in.)
6.8 ∼ 7.2 mm (0.27 ∼ 0.28 in.)
TIR 0.15 mm (0.006 in.) or less
DOT4
1 mm (0.04 in.)
1 mm (0.04 in.)
4.5 mm (0.18 in.)
6.0 mm (0.24 in.)
TIR 0.3 mm (0.01 in.)
– – –
BRAKES 12-7
Special Tool
Jack:
57001-1238
12-8 BRAKES
Brake Lever, Brake Pedal
Brake Lever Position Adjustment
• Push the lever forward and turn the adjuster [A].
Brake Pedal Position Inspection
• Check that the brake pedal [A] is in the correct position.
Pedal Position
Standard: About 100 mm (3.94 in.) [B] (height from
pedal top to footboard top [C])
If it is incorrect, adjust the brake pedal position.
Brake Pedal Position Adjustment
NOTE
○Usually it is not necessary to adjust the pedal position,
but always adjust it when push rod locknut has been
loosened.
○If the push rod length cannot be adjusted by turning the
clevis, the brake pedal may be deformed or incorrectly
installed.
the locknut [A] and turn the push rod with the hex
• Loosen
head [B] to achieve the correct pedal position.
•
If the length [C] shown is 70 ±1 mm (2.76 ±0.04 in.), the
pedal position will be within the standard range.
Tighten:
Torque - Rear Master Cylinder Push Rod Locknut: 17.2 N·m
(1.8 kgf·m, 13 ft·lb)
the brake light switch operation (see Brake Light
• Check
Switch Operation Inspection in the Periodic Maintenance
chapter).
Brake Pedal Removal
• Remove:
Front Guard Mounting Bolt [A]
•
Front Footboard Bracket Bolts [B]
Slide the front guard forward.
BRAKES 12-9
Brake Lever, Brake Pedal
• Remove:
Brake Pedal Return Spring [A]
Rear Brake Light Switch Spring [B]
Bolt [C]
Washer [D]
Cotter Pin [E]
Washer [F]
Joint Pin [G]
Brake Pedal [H]
Brake Pedal Installation
grease to the pivot shaft [A].
• Apply
Install:
• Brake Pedal [B]
•
Joint Pin
Washer
Cotter Pin
Washer [C]
Tighten:
Torque - Brake Pedal Bolt [D]: 8.8 N·m (0.90 kgf·m, 78 in·lb)
the rear brake light switch spring [E] and brake
• Hook
pedal return spring [F].
the front footboard right (see Front Footboard Re• Install
moval/Installation in the Frame chapter).
the brake pedal position (see Brake Pedal Position
• Check
Inspection).
• Check the screw [A] position as shown in the figure.
5 mm (0.20 in.) [B]
If it is incorrect, loosen the locknut [C] and adjust the
screw.
12-10 BRAKES
Calipers
Front Caliper Removal
the banjo bolt [A] at the brake hose lower end,
• Loosen
and tighten it loosely.
the caliper mounting bolts [B], and detach the
• Unscrew
caliper [C] from the disc.
the banjo bolt and remove the brake hose [D]
• Unscrew
from the caliper (see Brake Hose and Pipe Replacement
in the Periodic Maintenance chapter).
CAUTION
Immediately wash away any brake fluid that spills.
NOTE
○If the caliper is to be disassembled after removal and if
compressed air is not available, disassemble the caliper
before the brake hose is removed (see Caliper Rubber
Parts Replacement in the Periodic Maintenance chapter).
Rear Caliper Removal
the right saddlebag (see Saddlebag Removal in
• Remove
the Frame chapter).
the banjo bolt [A] at the brake hose lower end,
• Loosen
and tighten it loosely.
the caliper mounting bolts [B], and detach the
• Unscrew
caliper [C] from the disc.
the banjo bolt and remove the brake hose [D]
• Unscrew
from the caliper (see Brake Hose and Pipe Replacement
in the Periodic Maintenance chapter).
CAUTION
Immediately wash away any brake fluid that spills.
NOTE
○If the caliper is to be disassembled after removal and if
compressed air is not available, disassemble the caliper
before the brake hose is removed (see Caliper Rubber
Parts Replacement in the Periodic Maintenance chapter).
BRAKES 12-11
Calipers
Caliper Installation
the caliper and brake hose lower end.
•○Install
Replace the washer on each side of hose fitting with new
•
ones.
Tighten:
Torque - Caliper Mounting Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb)
Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
the fluid level in the brake reservoirs (see Brake
• Check
Fluid Level Inspection in the Periodic Maintenance chap-
•
•
ter).
Bleed the brake line (see Brake Line Bleeding).
Check the brake for good braking power, no brake drag,
and no fluid leakage.
WARNING
Do not attempt to drive the motorcycle until a full
brake lever or pedal is obtained by pumping the
brake lever or pedal until the pads are against the
disc. The brakes will not function on the first application of the lever or pedal if this is not done.
Front Caliper Disassembly
to the Caliper Rubber Parts Replacement in the Pe• Refer
riodic Maintenance chapter.
Front Caliper Assembly
to the Caliper Rubber Parts Replacement in the Pe• Refer
riodic Maintenance chapter.
Rear Caliper Disassembly
to the Caliper Rubber Parts Replacement in the Pe• Refer
riodic Maintenance chapter.
Rear Caliper Assembly
to the Caliper Rubber Parts Replacement in the Pe• Refer
riodic Maintenance chapter.
12-12 BRAKES
Calipers
Caliper Fluid Seal Damage Inspection
The fluid seal (piston seal) [A] is placed around the piston to maintain clearance between the pad and the disc. If
the seal is in a poor condition, it could lead the pad to wear
excessively or the brake to drag, which may cause the temperature of the discs or the brake fluid to increase.
Replace the fluid seal if it exhibits any of the conditions
listed below.
○Brake fluid leakage around the pad.
○Brakes overheat.
○Considerable difference in inner and outer pad wear.
○Seal and piston are stuck together.
If the fluid seal is replaced, replace the dust seal [B] as
well. Also, replace all seals every other time the pads are
changed.
•
Caliper Dust Seal Damage Inspection
that the dust seals [A] are not cracked, worn,
• Check
swollen, or otherwise damaged.
If they show any damage, replace the dust seals with new
ones.
Pistons [B]
Fluid Seals [C]
BRAKES 12-13
Calipers
Caliper Dust Boot and Friction Boot Damage
Inspection
that the dust boot [A] and friction boot [B] are not
• Check
cracked, worn, swollen, or otherwise damaged.
If they show any damage, replace it.
Caliper Piston and Cylinder Damage Inspection
inspect the pistons [A] and cylinder surfaces [B].
• Visually
Replace the caliper if the cylinder and piston are badly
scores or rusty.
12-14 BRAKES
Calipers
Caliper Holder Shaft Wear Inspection
The caliper body must slide smoothly on the caliper holder
shafts [A]. If the body does not slide smoothly, one pad will
wear more than the other, pad wear will increase, and constant drag on the disc will raise brake and brake fluid temperature.
Check to see that the caliper holder shafts are not badly
worn or stepped, and that the friction boot [B] is not damaged.
If the friction boot is damaged, replace the friction boot. To
replace the friction boot, remove the pads and the caliper
holder.
If the caliper holder shafts are damaged, replace the
caliper holder.
•
BRAKES 12-15
Brake Pads
Front Brake Pad Removal
the front caliper with the hose installed (see Front
• Remove
Caliper Removal).
• Remove:
Snap Pin [A]
Pad Pin [B]
Brake Pads [C]
Front Brake Pad Installation
the caliper piston in by hand as far as it will go.
• Push
Install
the pad spring in place.
• Install the
piston side pad [A] first, and then another pad.
•○Fit the projections
[B] of the pad into the recess [C] of the
•
•
caliper holder.
Install the pad pin and snap pin.
Install the caliper (see Caliper Installation).
WARNING
Do not attempt to drive the motorcycle until a full
brake lever is obtained by pumping the brake lever
until the pads are against the disc. The brake will
not function on the first application of the lever if
this is not done.
Rear Brake Pad Removal
the rear caliper with the hose installed (see Rear
• Remove
Caliper Removal).
• Remove:
Snap Pin [A]
Pad Pin [B]
Brake Pads [C]
Rear Brake Pad Installation
the caliper piston in by hand as far as it will go.
• Push
the pad spring in place.
• Install
Install
the
piston side pad [A] first, and then another pad.
•○Fit the projections
[B] of the pad into the recess [C] of the
•
•
caliper holder.
Install the pad pin and snap pin.
Install the caliper (see Caliper Installation).
WARNING
Do not attempt to drive the motorcycle until a full
brake pedal is obtained by pumping the brake pedal
until the pads are against the disc. The brake will
not function on the first application of the pedal if
this is not done.
Brake Pad Wear Inspection
to the Brake Pad Wear Inspection in the Periodic
• Refer
Maintenance chapter.
12-16 BRAKES
Master Cylinder
Front Master Cylinder Removal
the banjo bolt [A] to disconnect the brake hose
• Remove
from the master cylinder (see Brake Hose Replacement
in the Periodic Maintenance chapter).
the front brake light switch connectors [A] and
• Disconnect
the cruise control cancel switch connectors [B].
the clamp bolts [C], and take off the master cylin• Unscrew
der as an assembly with the reservoir, brake lever, and
brake switch installed.
CAUTION
Immediately wash away any brake fluid that spills.
Front Master Cylinder Installation
the front master cylinder [A] to match its mating sur• Set
face [B] to the punch mark [C] of the handlebar.
the upper clamp bolt [A] first, and then the lower
• Tighten
clamp bolt [B].
Torque - Front Master Cylinder Clamp Bolts: 11 N·m (1.1
kgf·m, 97 in·lb)
the washers that are on each side of the hose
• Replace
fitting with new ones.
• Tighten:
Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
the fluid in the reservoir, and bleed the brake
• Replenish
line (see Brake Line Bleeding).
the brake for good braking power, no brake drag,
• Check
and no fluid leakage.
BRAKES 12-17
Master Cylinder
Rear Master Cylinder Removal
• Remove:
Bolt [A]
Cover [B]
Bolt [C]
• Unscrew:
Front Guard Mounting Bolt [A]
•
Brake Hose Banjo Bolt [B]
Front Footboard Bracket Bolts [C]
Slide the front guard forward.
• Remove:
Cotter Pin [A]
Joint Pin [B]
Rear Master Cylinder Mounting Bolts [C]
Rear Master Cylinder Installation
the cotter pin with a new one.
• Replace
Insert
the
cotter pin [A] to the hole of the joint pin [B] and
• separate the
cotter pin ends.
Replace
the
washers
• fitting with new ones. that are on each side of the hose
• Tighten:
Torque - Rear Master Cylinder Mounting Bolts: 25 N·m (2.5
kgf·m, 18 ft·lb)
Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
the front footboard (see Front Footboard Re• Install
moval/Installation in the Frame chapter).
the fluid in the reservoir, and bleed the brake
• Replenish
line (see Brake Line Bleeding).
the brake for good braking power, no brake drag,
• Check
and no fluid leakage.
Front Master Cylinder Disassembly
to the Master Cylinder Rubber Parts Replacement
• Refer
in the Periodic Maintenance chapter.
Rear Master Cylinder Disassembly
to the Master Cylinder Rubber Parts Replacement
• Refer
in the Periodic Maintenance chapter.
12-18 BRAKES
Master Cylinder
Master Cylinder Assembly
to the Master Cylinder Rubber Parts Replacement
• Refer
in the Periodic Maintenance chapter.
Master Cylinder Inspection (Visual Inspection)
the master cylinders (see Front/Rear Master
• Remove
Cylinder Removal).
the front and rear master cylinders (see
• Disassemble
Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter).
CAUTION
Do not remove the secondary cup from the piston
since removal will damage it.
that there are no scratches, rust or pitting on the
• Check
inner wall [A] of each master cylinder and on the outside
•
•
•
•
of each piston [B].
If a master cylinder or piston shows any damage, replace
them.
Inspect the primary cup [C] and secondary cup [D].
If a cup is worn, damaged softened (rotted), or swollen,
the piston assembly should be replaced to renew the
cups.
If fluid leakage is noted at the brake lever, the piston assembly should be replaced to renew the cups.
Check the dust covers [E] for damage.
If they are damaged, replace them.
Check the piston return springs [F] for any damage.
If the springs are damaged, replace them.
Check that relief port [G] and supply port [H] are not
plugged.
If the relief port becomes plugged, the brake pads will
drag on the disc. Blow the ports clean with compressed
air.
Front Master Cylinder [J]
Rear Master Cylinder [K]
BRAKES 12-19
Brake Discs
Brake Disc Removal
the wheels (see Front/Rear Wheel Removal in
• Remove
the Wheels/Tires chapter).
• Unscrew the mounting bolts [A], and take off the disc.
Brake Disc Installation
the brake disc [A] on the wheel so that the marked
• Install
side [B] faces out.
a non-permanent locking agent to the threads of
• Apply
the front and rear brake disc mounting bolts [C].
• Tighten:
Torque - Brake Disc Mounting Bolts: 27 N·m (2.8 kgf·m, 20
ft·lb)
Brake Disc Wear Inspection
the thickness of each disc [A] at the point where
• Measure
it has worn the most.
If the disc has worn past the service limit, replace it.
Measuring Area [B]
Brake Discs Thickness
Standard:
Front
4.8 ∼ 5.2 mm (0.19 ∼ 0.20 in.)
Rear
6.8 ∼ 7.2 mm (0.27 ∼ 0.28 in.)
Service Limit:
Front
4.5 mm (0.18 in.)
Rear
6.0 mm (0.24 in.)
Brake Disc Warp Inspection
• Raise the front/rear wheel off the ground.
Special Tool - Jack: 57001-1238
○For front disc inspection, turn the handlebar fully to one
•
side.
Set up a dial gauge against the disc [A] as shown in
the figure and measure disc runout, while turning [B] the
wheel by hand.
If the runout exceeds the service limit, replace the disc.
Disc Runout
Standard:
TIR 0.15 mm (0.006 in.) or less
Service Limit: TIR 0.3 mm (0.01 in.)
12-20 BRAKES
Brake Fluid
Brake Fluid Level Inspection
to the Brake Fluid Level Inspection in the Periodic
• Refer
Maintenance chapter.
Brake Fluid Change
to the Brake Fluid Change in the Periodic Mainte• Refer
nance chapter.
Brake Line Bleeding
The brake fluid has a very low compression coefficient so
that almost all the movement of the brake lever or pedal
is transmitted directly to the caliper for braking action. Air,
however, is easily compressed. When air enters the brake
lines, brake lever or pedal movement will be partially used
in compressing the air. This will make the lever or pedal feel
spongy, and there will be a loss in braking power.
WARNING
Be sure to bleed the air from the brake line whenever brake lever or pedal action feels soft or
spongy after the brake fluid is changed, or whenever a brake line fitting has been loosened for any
reason.
NOTE
○The procedure to bleed the front brake line is as follows.
Bleeding the rear brake line is the same as for the front
brake.
• Remove:
Screws [A]
Reservoir Cap [B]
Diaphragm Plate [C]
Diaphragm [D]
Protector [E]
the reservoir with fresh brake fluid to the upper level
• Fill
line in the reservoir.
pump the brake lever several times until no air
• Slowly
bubbles can be seen rising up through the fluid from the
holes [A] at the bottom of the reservoir.
BRAKES 12-21
Brake Fluid
the rubber cap from the bleed valve [A] on the
• Remove
caliper [B].
a clear plastic hose [C] to the bleed valve, and run
• Attach
the other end of the hose into a container.
the brake line and the caliper.
•○Bleed
Repeat this operation until no more air can be seen coming out into the plastic hose.
1. Pump the brake lever until it becomes hard, and apply
the brake lever and hold it [A].
2. Quickly open and close [B] the bleed valve while holding
the brake lever applied.
3. Release the brake lever [C].
NOTE
○The fluid level must be checked often during the bleeding operation and replenished with fresh brake fluid as
necessary. If the fluid in the reservoir runs completely
out any time during bleeding, the bleeding operation
must be done over again from the beginning since air
will have entered the line.
○Tap the brake hose lightly from the caliper to the reservoir for more complete bleeding.
○Front Brake: Repeat the above steps for the other
caliper.
the clear plastic hose.
• Remove
• Install:
Protector
•
Diaphragm
Diaphragm Plate
Reservoir Cap
Tighten:
Torque - Front Brake Reservoir Cap Screws: 1.5 N·m (0.15
kgf·m, 13 in·lb)
the procedure below to install the rear brake fluid
• Follow
reservoir cap correctly.
○First, tighten the rear brake fluid reservoir cap [B] clockwise [C] by hand until slight resistance is felt indicating
that the cap is seated on the reservoir body, then tighten
the cap an additional 1/6 turn [D] while holding the brake
fluid reservoir body [A].
12-22 BRAKES
Brake Fluid
NOTE
○For the rear brake caliper [A], bleed the brake line for
two bleed valves [B].
• Tighten the bleed valve, and install the rubber cap.
Torque - Bleed Valves: 7.8 N·m (0.80 kgf·m, 69 in·lb)
the fluid level (see Brake Fluid Level Inspection in
• Check
the Periodic Maintenance chapter).
bleeding is done, check the brake for good braking
• After
power, no brake drag, and no fluid leakage.
WARNING
When working with the disc brake, observe the precautions listed below.
1. Never reuse old brake fluid.
2. Do not use fluid from a container that has been left
unsealed or that has been open for a long time.
3. Do not mix two types and brands of fluid for use in
the brake. This lowers the brake fluid boiling point
and could cause the brake to be ineffective. It may
also cause the rubber brake parts to deteriorate.
4. Don’t leave the reservoir cap off for any length of
time to avoid moisture contamination of the fluid.
5. Don’t change the fluid in the rain or when a strong
wind is blowing.
6. Except for the disc pads and disc, use only disc
brake fluid, isopropyl alcohol, or ethyl alcohol for
cleaning of the brake parts. Do not use any other
fluid for cleaning these parts. Gasoline, engine oil,
or any other petroleum distillate will cause deterioration of the rubber parts. Oil spilled on any part will
be difficult to wash off completely and will eventually
deteriorate the rubber used in the disc brake.
7. When handling the disc pads or disc, be careful that
no disc brake fluid or any oil gets on them. Clean off
any fluid or oil that inadvertently gets on the pads or
disc with a high-flash point solvent. Do not use one
which will leave an oily residue. Replace the pads
with new ones if they cannot be cleaned satisfactorily.
8. Brake fluid quickly ruins painted surfaces; any
spilled fluid should be completely wiped up immediately.
9. If any of the brake line fittings or the bleed valve is
opened at any time, the AIR MUST BE BLED FROM
THE BRAKE LINE.
BRAKES 12-23
Brake Hose
Brake Hose and Pipe Removal/Installation
to the Brake Hose and Pipe Replacement in the
• Refer
Periodic Maintenance chapter.
Brake Hose and Pipe Inspection
to the Brake Hose and Pipe Damage and Instal• Refer
lation Condition Inspection in the Periodic Maintenance
chapter.
SUSPENSION 13-1
Suspension
Table of Contents
Exploded View........................................................................................................................
Specifications .........................................................................................................................
Special Tools ..........................................................................................................................
Front Fork ...............................................................................................................................
Fork Oil Change................................................................................................................
Front Fork Removal ..........................................................................................................
Front Fork Installation .......................................................................................................
Front Fork Disassembly ....................................................................................................
Front Fork Assembly.........................................................................................................
Inner Tube, Outer Tube Inspection ...................................................................................
Dust Seal Inspection .........................................................................................................
Spring Tension ..................................................................................................................
Rear Shock Absorber (Air Type).............................................................................................
Rebound Damping Adjustment .........................................................................................
Air Pressure Adjustment ...................................................................................................
Rear Shock Absorber Removal ........................................................................................
Rear Shock Absorber Installation .....................................................................................
Rear Shock Absorber Inspection ......................................................................................
Rear Shock Absorber Scrapping ......................................................................................
Swingarm................................................................................................................................
Swingarm Removal...........................................................................................................
Swingarm Installation........................................................................................................
Swingarm Bearing Removal .............................................................................................
Swingarm Bearing Installation ..........................................................................................
Swingarm Bearing, Sleeve Inspection ..............................................................................
Grease Seal and Needle Bearing Lubrication...................................................................
13-2
13-6
13-7
13-9
13-9
13-11
13-13
13-13
13-15
13-16
13-16
13-17
13-18
13-18
13-18
13-19
13-20
13-20
13-21
13-22
13-22
13-23
13-23
13-23
13-24
13-24
13
13-2 SUSPENSION
Exploded View
SUSPENSION 13-3
Exploded View
No.
1
2
3
4
5
Fastener
Upper Front Fork Clamp Bolts
Lower Front Fork Clamp Bolts
Fork Cover Clamp Bolts
Front Fork Bottom Allen Bolts
Front Axle Clamp Bolts
N·m
20
30
4.2
20
20
Torque
kgf·m
2.0
3.0
0.43
2.0
2.0
ft·lb
15
22
37 in·lb
15
15
AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.
L: Apply a non-permanent locking agent.
G: Apply grease.
R: Replacement Parts
S: Follow the specified tightening sequence.
Remarks
AL
L
S
13-4 SUSPENSION
Exploded View
SUSPENSION 13-5
Exploded View
No.
1
2
3
Fastener
Rear Shock Absorber Nuts
Rear Shock Absorber Air Valve
Swingarm Pivot Shaft Nut
N·m
34
5.5
108
G: Apply grease.
R: Replacement Parts
WL: Apply a soap and water solution or rubber lubricant.
Torque
kgf·m
3.5
0.56
11.0
ft·lb
25
49 in·lb
80
Remarks
13-6 SUSPENSION
Specifications
Item
Front Fork (per one unit)
Fork Inner Tube Diameter
Fork Spring Preload Setting
Air Pressure
Damper Setting
Fork Oil:
Viscosity
Amount (Per Side):
When changing oil
After disassembly
and completely dry
Fork Oil Level
Fork Spring Free Length
Rear Shock Absorber
Rebound Damper Setting
Spring Preload Setting
Air Pressure
Standard
43 mm (1.7 in.)
Non-adjustable
Atmospheric pressure (Non-adjustable)
Non-adjustable
SHOWA SS-8 or equivalent SAE 10W
Approx. 435mL (14.7 US oz.)
512 ±2.5mL (17.3 ±0.085 US oz.)
Fully compressed, without fork spring, below from inner tube top
133 ±2 mm (5.23 ±0.08 in.)
529.1 mm (20.83 in.) (Service limit: 519 mm (20.4 in.))
2nd (No. II) position (Adjustable Range : 1st ∼ 4th position)
Non-adjustable
Atmospheric Pressure (Usable Range : Atmospheric Pressure
∼ 290 kPa (3.0 kgf/cm2, 43 psi))
SUSPENSION 13-7
Special Tools
Inside Circlip Pliers:
57001-143
Front Fork Oil Seal Driver:
57001-1219
Fork Cylinder Holder Handle:
57001-183
Jack:
57001-1238
Fork Cylinder Holder Adapter:
57001-1057
Fork Oil Level Gauge:
57001-1290
Oil Seal & Bearing Remover:
57001-1058
Bearing Remover Head,
57001-1293
20 ×
Bearing Driver Set:
57001-1129
Bearing Remover Shaft,
57001-1377
13:
22:
13-8 SUSPENSION
Special Tools
Needle Bearing Driver,
57001-1610
28:
Spacer, 28:
57001-1637
SUSPENSION 13-9
Front Fork
Fork Oil Change
the front fork (see Front Fork Removal).
• Remove
Install
the
front fork temporary without the upper fork
• cover for removing
the top plug.
Remove
the
cap
[A].
•
• Push down the top plug [A] with a suitable tool [B].
• Remove:
Retaining Ring [A]
Top Plug [B]
Fork Spring
Front Fork
• Remove:
Lower Fork Cover [A]
Rubber Damper [B]
Washer [C]
the fork oil [A] into a suitable container.
•○Drain
Pump the inner tube up and down at least 10 times to
expel the oil from the fork.
13-10 SUSPENSION
Front Fork
• Fill the front fork with the specified oil.
Fork Oil:
Viscosity:
SHOWA SS-8 or equivalent SAE 10W
Amount (Per Side):
When changing oil:
Approx. 435mL (14.7 US oz.)
After disassembly and completely dry:
512 ±2.5 mL (17.3 ±0.085 US oz.)
for about 5 minutes so that any suspended air bub• Wait
bles can surface.
• Measure the oil level, using the fork oil level gauge [A].
Special Tool - Fork Oil Level Gauge: 57001-1290
○Set the gauge stopper [B] so that its lower side shows the
oil level distance specified [C].
○Insert the gauge hose into the inner tube [D] and position
the stopper across the top of the inner tube [E].
○Pull the handle slowly to draw out the excess oil until no
more oil comes up the hose.
If no oil is drawn out from the beginning, there is not
enough oil in the fork. Pour in some more oil, then draw
out the excess.
Fork Oil Level (Fully compressed, without fork spring)
Standard: 133 ±2 mm (5.23 ±0.08 in.)
• Install
Washer [A]
Rubber Damper [B]
Lower Fork Cover [C]
SUSPENSION 13-11
Front Fork
the fork spring with the smaller end [A] facing down• Install
ward [B].
Upward [C]
the front fork temporary without the upper fork
• Install
cover.
the O-ring [A] and retaining ring with new ones.
• Replace
the top plug [B] onto the spring, and push down it with
• Put
a suitable tool.
the retaining ring [A] into the groove of the inner
• Install
tube.
the cap, and reinstall the front fork correctly (see
• Install
Front Fork Installation).
• Install the removed parts (see appropriate chapters).
Front Fork Removal
• Remove:
Windshield
(see Windshield Removal in the Frame
chapter)
Headlight Unit (see Headlight Body Removal in the Electrical System chapter)
Front Fender (see Front Fender Removal in the Frame
chapter)
Front Wheel (see Front Wheel Removal in the
Wheels/Tires chapter)
NOTE
○If the front fork is to be disassembled, or if oil is to be
changed, remove the top plug previously (see Fork Oil
Change).
13-12 SUSPENSION
Front Fork
the connectors [A].
• Disconnect
Clear
the
harness
from the clamp [B].
•
• Remove:
Bolts [A] (Both Sides)
Headlight Body [B] with Bracket
• Remove:
Bolts [A]
Turn Signal Light Bracket [B]
Stem Cover [C]
• Remove:
Bolts [A]
Holder [B]
the upper front fork cover [A] to show the clamp bolts.
• Turn
Loosen:
• Upper Front Fork Clamp Bolt [B]
•
Lower Front Fork Clamp Bolts [C]
Hold the upper front fork cover by hand, and pull out the
front fork with a twisting motion.
SUSPENSION 13-13
Front Fork
Front Fork Installation
the rubber dampers onto the upper fork cover [A].
• Install
Thin Damper (Part No.: 92161-0604) [B]
Thick Damper (Part No.: 92161-0799) [C]
the fork together with the upper fork cover [A].
•○Install
The top end of the inner tube is flush [B] with the upper
•
surface of the steering stem head.
Tighten:
Torque - Upper Front Fork Clamp Bolts: 20 N·m (2.0 kgf·m,
15 ft·lb)
Lower Front Fork Clamp Bolts: 30 N·m (3.0 kgf·m,
22 ft·lb)
NOTE
○Tighten the two lower clamp bolts alternately two times
to ensure even tightening torque.
Front Fork Disassembly
• Drain the fork oil (see Fork Oil Change).
• Remove:
Rubber Damper [A]
Washer [B]
Fork Cover Clamp Bolt [C]
Fork Cover Clamp [D]
the front fork horizontally in a vise [A].
• Hold
the cylinder unit [B] from turning by using the special
• Stop
tools.
Special Tools - Fork Cylinder Holder Handle [C]:57001-183
Fork Cylinder Holder Adapter [D]:57001
-1057
the bottom Allen bolt [E], and take the gasket
• Unscrew
out of the bottom of the outer tube.
13-14 SUSPENSION
Front Fork
• Take the cylinder unit [A] out of the inner tube [B].
• Remove the dust seal [A].
• Remove the retaining ring [A] from the outer tube.
the inner tube [A] from the outer tube [B] as
• Separate
follows:
○Holding the outer tube by hand, pull the inner tube several
•
times to pull out the inner tube.
Take out the cylinder base out of the outer tube.
the inner [A] and outer [B] guide bushings,
• Remove
washer [C] and oil seal [D] from the inner tube.
SUSPENSION 13-15
Front Fork
Front Fork Assembly
the following parts with new ones.
• Replace
Dust Seal [A]
Retaining Ring [B]
Oil Seal [C]
Inner Guide Bushing [D]
Outer Guide Bushing [E]
Bottom Allen Bolt Gasket [F]
the cylinder unit [A] with the spring into the inner tube
• Put
[B], protruding from the inner tube, and install the cylinder
base [C] onto the bottom end of the cylinder unit.
○Install the cylinder base with the tapered end [D] up.
Install the inner tube, cylinder unit, and cylinder base as
a set into the outer tube.
•
the new guide bushing [A] with a used guide bush• Install
ing [B] on it by tapping the used guide bushing with fork
oil seal driver [C] until it stops.
Special Tool - Front Fork Oil Seal Driver: 57001-1219
grease to the oil seal lips.
• Apply
Install
• tube. the washer [A] and the oil seal [B] into the outer
○Turn the flat side [C] of the seal upward.
Special Tool - Front Fork Oil Seal Driver [D]: 57001-1219
• Install the retaining ring.
the front fork horizontally in a vise [A].
• Hold
Hold
the
cylinder unit [B] with the special tools.
•
Special Tools - Fork Cylinder Holder Handle [C]: 57001-183
Fork Cylinder Holder Adapter [D]: 57001
-1057
a non-permanent locking agent to the threads of
• Apply
the Allen bolt [E] and tighten it.
Torque - Front Fork Bottom Allen Bolt: 20 N·m (2.0 kgf·m,
15 ft·lb)
13-16 SUSPENSION
Front Fork
the front fork cover clamp [A] as shown.
• Install
Inner Tube [B]
•
About 248 mm (9.76 in.) [C]
Tighten:
Torque - Fork Cover Clamp Bolt: 4.2 N·m (0.43 kgf·m, 37
in·lb)
• Pour in the specified type of oil (see Fork Oil Change).
Inner Tube, Outer Tube Inspection
inspect the inner tube [A] and repair any damage.
•○Visually
Nick or rust damage can sometimes be repaired by using
a wet-stone to remove sharp edges or raised areas which
cause seal damage.
If the damage is not repairable, replace the inner tube.
Since damage to the inner tube damages the oil seal,
replace the oil seal whenever the inner tube is repaired
or replaced.
CAUTION
If the inner tube is badly bent or creased, replace
it. Excessive bending, followed by subsequent
straightening, can weaken the inner tube.
assemble the inner and outer tubes, and
• Temporarily
pump [A] them back and forth manually to check for
smooth operation.
If you feel binding or catching, the inner and outer tubes
must be replaced.
WARNING
A straightened inner or outer fork tube may fail in
use, possibly, causing an accident. Replace a badly
bent or damaged inner or outer tube, and inspect
the other tube carefully before reusing it.
Dust Seal Inspection
Inspect the dust seal [A] for any signs of deterioration or
damage.
Replace it if necessary.
SUSPENSION 13-17
Front Fork
Spring Tension
the spring becomes shorter as it weakens, check
• Since
its free length [A] to determine its condition.
If the spring of either fork leg is shorter than the service
limit, it must be replaced.
If the length of a replacement spring and that of the remaining spring vary greatly, the remaining spring should
also be replaced in order to keep the fork legs balanced
for motorcycle stability.
Fork Spring Free Length
Standard:
529.1 mm (20.83 in.)
Service Limit: 519 mm (20.4 in.)
13-18 SUSPENSION
Rear Shock Absorber (Air Type)
Rebound Damping Adjustment
The rebound damping force adjuster on each rear shock
absorber has 4 positions so that the rebound damping force
can be adjusted for different road and loading conditions.
The numbers on the adjuster show the setting position.
Turn the adjuster [A] until the desired number [B].
○The standard adjuster setting is No.II for an average-build
rider of 68 kg (150 lb) with no passenger and no accessories.
If the damper setting feels too soft or too stiff, adjust it in
accordance with the following table.
•
Rebound Damping Adjustment
Adjuster
Damping
Position
Force
I
Setting
Load
Road
Speed
Weak
Soft
Light
Good
Low
II
↑
↑
↑
↑
↑
III
↓
↓
↓
↓
↓
IIII
Strong
Hard
Heavy
Bad
High
WARNING
If both adjusters are not adjusted equally, handling
may be impaired and a hazardous condition may
result.
Air Pressure Adjustment
The air pressure in the rear shock absorbers can be adjusted for different road and loading conditions.
The following table shows an example of air pressure adjustment. To obtain stable handling and a suitable ride, adjust the air pressure as indicated. The standard air pressure
is atmospheric pressure for an average-build rider of 68
kg (150 lb) with no passenger and no accessories. Ordinarily, the heavier the total load becomes, the higher the air
pressure should be set.
Air Pressure Adjustment
Air Pressure
Setting
Load
Road
Soft
Light
Good
↑
↑
↑
↑
↓
↓
↓
↓
Hard
Heavy
Bad
Atmospheric Pressure
(0 kgf/cm², 0 psi)
290 kPa
(3.0 kgf/cm², 43 psi)
NOTE
○Check and adjust the air pressure when the rear shock
absorbers are cold (room temperature).
• Raise the rear wheel off the ground using the jack.
Special Tool - Jack: 57001-1238
SUSPENSION 13-19
Rear Shock Absorber (Air Type)
off the air valve cap [A] on both shock absorbers.
• Take
Check
the air pressure with the air pressure gauge.
•
NOTE
○Do not use tire gauges for checking air pressure. They
may not indicate the correct air pressure because of
air leakage that occur when the gauge is applied to the
valve.
the air pressure.
•○Adjust
To lower the air pressure, push the valve core in slightly.
To raise the pressure, inject air through the valve with a
tire pump. Change the air pressure within the range specified in the preceding table to suit various riding conditions.
CAUTION
Inject air little by little so that air pressure does not
rise rapidly. Air pressure exceeding 290 kPa (3.0
kgf/cm², 43 psi) may damage the oil seal.
Try to set the air pressure of the right and left shock
absorbers as equally as possible.
WARNING
Be sure to adjust the air pressure within the usable
range. Pressure too high can produce a hazardous
riding condition.
Only air or nitrogen gas can be used. Never inject
oxygen or any kind of explosive gas.
Rear Shock Absorber Removal
• Raise the rear wheel off the ground using the jack.
Special Tool - Jack: 57001-1238
the brake lever slowly and hold it with a band
• Squeeze
[A].
CAUTION
Be sure to hold the front brake when removing the
shock absorber, or the motorcycle may fall over.
The motorcycle could be damaged.
WARNING
Be sure to hold the front brake when removing the
shock absorber, or the motorcycle may fall over. It
could cause an accident and injury.
• Remove:
Saddlebags
chapter)
(see Saddlebag Removal in the Frame
13-20 SUSPENSION
Rear Shock Absorber (Air Type)
the nuts [A], spring washers, and flat washers
• Remove
from both ends of the rear shock absorber [B].
• Pull the rear shock absorber off the frame.
Rear Shock Absorber Installation
the sleeve [A] so the flange side faces inside.
• Install
Install
shock absorber.
•○Turn thetheairrear
valve and adjuster toward out.
•
Flat Washers [B]
Spring Washers [C]
Tighten:
Torque - Rear Shock Absorber Nuts [D]: 34 N·m (3.5 kgf·m,
25 ft·lb)
Rear Shock Absorber Inspection
the rear shock absorbers (see Rear Shock Ab• Remove
sorber Removal).
inspect the following items.
• Visually
Smooth Stroke
Oil Leakage (see Rear Shock Absorber Oil Leak Inspection in the Periodic Maintenance chapter)
Crack or Dent
If there is any damage to the rear shock absorber, one unit
feels weaker than the other, replace both shock absorbers
as a set.
inspect the rubber bushings [A].
• Visually
If they show any signs of damage, replace them.
inspect the shock absorber sleeves [A] and nee• Visually
dle bearings [B].
○The roller in a needle bearing normally wear very little,
and wear is difficult to measure. Instead of measuring,
inspect the bearing in the shock absorber for abrasion,
color change, or other damage.
If there is any doubt as to the condition of any of the needle bearings or sleeves, replace the sleeves, and needle
bearings as a set.
SUSPENSION 13-21
Rear Shock Absorber (Air Type)
Rear Shock Absorber Scrapping
the rear shock absorber (see Rear Shock Ab• Remove
sorber Removal).
WARNING
Since the rear shock absorber contains air, do not
incinerate the rear shock absorber without first releasing the air or it may explode.
Before a rear shock absorber is scrapped, remove
the air valve [A].
13-22 SUSPENSION
Swingarm
Swingarm Removal
• Remove:
Saddlebags
(see Saddlebag Removal in the Frame
chapter)
Saddlebag Stays (see Saddlebag Stay Removal in the
Frame chapter)
Rear Fender (see Rear Fender Removal in the Frame
chapter)
Rear Caliper (see Caliper Removal in the Brakes chapter)
Rear Wheel (see Rear Wheel Removal in the
Wheels/Tires chapter)
Mufflers (see Muffler Body Removal in the Engine Top
End chapter)
Exhaust Pipe (see Exhaust Pipe Removal in the Engine
Top End chapter)
the brake hose clamp [A].
• Remove
Clear
the
brake hose from the hose guide [B].
•
• Remove:
Rear Shock Absorbers (see Rear Shock Absorber Removal)
Swingarm Pivot Cap [A] (Left side only)
the swingarm pivot nut [A].
• Remove
Pull
out
• swingarm.the swingarm pivot shaft
and take off the
SUSPENSION 13-23
Swingarm
Swingarm Installation
• Apply grease to the grease seal lips [A].
the collar [A].
• Install
Insert
the
• Tighten: swingarm pivot shaft to install the swingarm.
•
Torque - Swingarm Pivot Shaft Nut: 108 N·m (11.0 kgf·m,
80 ft·lb)
the swingarm up and down [A] to check for abnor• Move
mal friction, and push and pull [B] it to check for bearing
•
play.
Install the removed parts (see appropriate chapters).
Swingarm Bearing Removal
the swingarm (see Swingarm Removal).
• Remove
Remove:
• Collar [A]
Grease Seals [B]
Sleeve [C]
Circlip [D]
Special Tool - Inside Circlip Pliers: 57001-143
• Remove:
Ball Bearing [A]
Needle Bearings [B]
Special Tools - Bearing Remover Head, 20 × 22: 57001
-1293
Bearing Remover Shaft, 13: 57001-1377
Oil Seal & Bearing Remover: 57001-1058
Swingarm Bearing Installation
the needle bearings, ball bearing, grease seals
• Replace
and circlip with new ones.
• Apply grease to the bearings and grease seal lips.
13-24 SUSPENSION
Swingarm
the needle bearings [A] as shown in the figure.
•○Install
Apply grease a little to the outer surface of the bearings.
○Turn the marked side of the bearings toward out.
Special Tools - Needle Bearing Driver, 28: 57001-1610
Spacer, 28: 57001-1637
Left Side [B]
24 ~ 27 mm (0.9 ~ 1.1 in.) [C]
5 ~ 7 mm (0.2 ~ 0.3 in.) [D]
Press in the ball bearing until it bottomed.
○Apply grease to the outer surface of the bearing.
○Turn the marked side of the bearing toward out.
•
Special Tool - Bearing Driver Set: 57001-1129
• Install the circlip.
Special Tool - Inside Circlip Pliers: 57001-143
the sleeve.
• Install
Install
the
grease seals.
•
Special Tool - Bearing Driver Set: 57001-1129
Swingarm Bearing, Sleeve Inspection
the swingarm (see Swingarm Removal).
• Remove
• Remove the grease seals on the swingarm.
CAUTION
Do not remove the bearings for inspection. Removal may damage them.
the needle bearings [A] and ball bearing installed
• Inspect
in the swingarm.
○The rollers and ball in a bearing normally wear very little,
and wear is difficult to measure. Instead of measuring,
visually inspect the bearing for abrasion, discoloration, or
other damage.
If the needle bearing and sleeve [B] show any sings of
abnormal wear, discoloration or damage, replace them
as a set.
the ball bearing in the swingarm back and forth [A]
• Turn
while checking for plays, roughness or binding.
If bearing play, roughness or binding is found, replace the
bearing.
Grease Seal and Needle Bearing Lubrication
to the Swingarm Pivot Lubrication in the Periodic
• Refer
Maintenance chapter.
STEERING 14-1
Steering
Table of Contents
Exploded View........................................................................................................................
Special Tools ..........................................................................................................................
Handlebar ...............................................................................................................................
Handlebar Removal ..........................................................................................................
Handlebar Installation .......................................................................................................
Steering ..................................................................................................................................
Handlebar Holder Installation............................................................................................
Steering Inspection ...........................................................................................................
Steering Adjustment..........................................................................................................
Steering Stem.........................................................................................................................
Steering Stem Removal ....................................................................................................
Steering Stem Installation .................................................................................................
Steering Stem Warp..........................................................................................................
Steering Stem Bearing ...........................................................................................................
Stem Bearing Removal .....................................................................................................
Stem Bearing Installation ..................................................................................................
Stem Bearing Lubrication..................................................................................................
Stem Cap Deterioration, Damage.....................................................................................
14-2
14-4
14-5
14-5
14-5
14-7
14-7
14-7
14-7
14-8
14-8
14-9
14-10
14-11
14-11
14-11
14-12
14-12
14
14-2 STEERING
Exploded View
STEERING 14-3
Exploded View
No.
1
2
3
4
5
6
Fastener
Handlebar Clamp Bolts
Upper Front Fork Clamp Bolts
Steering Stem Head Nut
Handlebar Holder Nuts
Steering Stem Nut
Lower Front Fork Clamp Bolts
N·m
34
20
88
59
29
30
Torque
kgf·m
3.5
2.0
9.0
6.0
3.0
3.0
ft·lb
25
15
65
44
22
22
Remarks
AD: Apply adhesive.
AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.
G: Apply grease.
Lh: Left-hand threads.
O: Apply 2-stroke oil.
R: Replacement Parts
S: Follow the specified tightening sequence.
WL: Apply a soap and water solution or rubber lubricant.
O, S
R
AL
14-4 STEERING
Special Tools
Head Pipe Outer Race Press Shaft:
57001-1075
Head Pipe Outer Race Remover ID > 37 mm:
57001-1107
Head Pipe Outer Race Driver,
57001-1077
Steering Stem Bearing Driver,
57001-1344
Steering Stem Nut Wrench:
57001-1100
54.5:
42.5:
Steering Stem Bearing Driver Adapter, 41.5:
57001-1345
STEERING 14-5
Handlebar
Handlebar Removal
• Remove:
Clamps [A]
Clutch Master Cylinder [B] (see Clutch Master Cylinder
Removal in the Clutch chapter)
Left Handlebar Switch Housing [C]
the left grip end cap [A] from the handlebar [B].
•○Remove
The left grip end cap has left-hand threads.
• Remove the left grip [C].
• Remove:
Clamps [A]
Front Brake Master Cylinder [B] (see Front Master Cylinder Removal in the Brakes chapter)
Right Handlebar Switch Housing [C]
Throttle Grip [D]
the handlebar clamp bolt caps [A].
• Remove
Unscrew
clamp bolts [B] and remove the
• handlebarthe[C]handlebar
from the holder.
Handlebar Installation
the punch mark [A] of the handlebar with the han• Align
dlebar holder upper surface [B].
14-6 STEERING
Handlebar
the handlebar clamps [A] so that the cut side [B] on
• Install
the clamp points at the rear.
2-stroke oil to the threads of the handlebar clamp
• Apply
bolts [C].
• Tighten:
Torque - Handlebar Clamp Bolts: 34 N·m (3.5 kgf·m, 25
ft·lb)
○Tighten the clamp bolts, front first and then the rear.
If
the handlebar clamp is correctly installed, there will be no
gap at the front and a gap at the rear after tightening.
the left handlber switch housing [A].
•○Install
Fit the projection [B] and the hole [C].
○Install the cap [A] temporary, then tighten the screw [B].
○Tighten the screws [C].
rubber adhesive to the inside of the left grip [A].
• Apply
the
left grip until punch mark [B] in the handlebar.
Insert
• Apply adhesive
of the left grip end cap [C].
• Tighten the end tocapthebythreads
turning
• Install the right handlebar switchcounterclockwise.
and throttle grip
• (see Cable Installation in the Fuelhousing
System (DFI) chapter).
STEERING 14-7
Steering
Handlebar Holder Installation
the rubber bushings [A] are installed in the steering
• When
stem head [B], apply soap and water solution or rubber
•
•
•
lubricant to the outer surface first, and then press and
insert them until rubber bush end is about 1.0 mm (0.039
in.) [C] from the steering stem head surface.
Install:
Washers [D]
Dampers [E]
Handlebar Holder Bolts [F]
New Handlebar Holder Nuts [G]
Before tightening the handlebar holder nuts, install the
handlebar on the handlebar holders temporarily (see
Handlebar Installation).
Tighten:
Torque - Handlebar Holder Nuts: 59 N·m (6.0 kgf·m, 44 ft·lb)
the circlips [H] with new ones.
• Replace
the circlips into the grooves of the handlebar holder
• Fit
bolts securely.
Steering Inspection
to the Steering Play Inspection in the Periodic Main• Refer
tenance chapter.
Steering Adjustment
to the Steering Play Adjustment in the Periodic
• Refer
Maintenance chapter.
14-8 STEERING
Steering Stem
Steering Stem Removal
• Remove:
Windshield
•
•
(see Windshield Removal in the Frame
chapter)
Headlight Unit (see Headlight Body Removal in the Electrical System chapter)
Disconnect the connectors [A].
Clear the harness from the clamp [B].
• Remove:
Bolt [A] (Both Sides)
Headlight Body [B] with Bracket
• Remove:
Bolt [A]
Turn Signal Light Bracket Bolts [B]
Turn Signal Light Bracket [C]
Stem Cover [D]
• Remove:
Bolts [A]
Holder [B]
• Remove the handlebar (see Handlebar Removal).
CAUTION
Take care not to bend the brake and clutch hoses
sharply.
STEERING 14-9
Steering Stem
• Remove:
Steering Stem Head Nut [A]
Washer [B]
Front Fork (see Front Fork Removal in the Suspension
chapter)
Steering Stem Head [C]
• Remove:
Lock Washer [A]
the steering stem base [A] by hand.
• Hold
Remove
steering stem nut [B] with the steering stem
• nut wrenchthe[C].
Special Tool - Steering Stem Nut Wrench: 57001-1100
• Take off the steering stem.
Steering Stem Installation
the stem bearings (see Stem Bearing Installation).
• Install
Install
• Tighten:the stem base [A], and hold it by hand.
•
Torque - Steering Stem Nut [B]: 29 N·m (3.0 kgf·m, 22 ft·lb)
Special Tool - Steering Stem Nut Wrench [C]: 57001-1100
the claw [A] of the lock washer to the groove of the
• Fit
stem nut [B].
• Install the steering stem head.
14-10 STEERING
Steering Stem
the front fork temporary.
• Install
Install
the
washer [A] and the steering stem head nut [B].
•
Torque - Steering Stem Head Nut: 88 N·m (9.0 kgf·m, 65
ft·lb)
the removed parts (see appropriate chapters).
• Install
Check
and adjust the following after installation.
• Steering
(see Steering Play Inspection in the Periodic
•
Maintenance chapter)
Throttle Cables (see Throttle Control System Inspection
in the Periodic Maintenance chapter)
Headlight Aim (see Headlight Aiming Inspection in the
Periodic Maintenance chapter)
Check the front brake effectiveness.
WARNING
Do not attempt to ride the motorcycle until a full
brake lever is obtained by pumping the brake lever
until the pads are against the disc. The brakes will
not function on the first application of the lever if
this is not done.
Steering Stem Warp
the steering stem is removed, or if the steer• Whenever
ing cannot be adjusted for smooth operation, check the
steering stem for straightness.
If the steering stem [A] is bent, replace the steering stem.
STEERING 14-11
Steering Stem Bearing
Stem Bearing Removal
the steering stem (see Steering Stem Removal
• Remove
in this chapter).
the upper stem bearing inner race [A] and bear• Remove
ing [B].
• Drive out the bearing outer races from the head pipe.
Special Tool - Head Pipe Outer Race Remover ID > 37 mm
[A]: 57001-1107
NOTE
○If either steering stem bearing is damaged, it is recommended that both the upper and lower bearings (including outer races) be replaced with new ones.
the lower bearing inner race [A] which is pressed
• Remove
onto the steering stem with a suitable commercially available chisel [B].
Stem Bearing Installation
the bearing outer races with new ones.
• Replace
grease to the outer races, and drive them into the
• Apply
head pipe at the same time.
Special Tools - Head Pipe Outer Race Press Shaft [A]:
57001-1075
Head Pipe Outer Race Driver, 54.5 [B]:
57001-1077
14-12 STEERING
Steering Stem Bearing
the bearing inner races and oil seal with new
• Replace
ones.
grease to the oil seal.
• Apply
the lower ball bearing inner race [A] applied the
• Drive
grease onto the stem.
Special Tools - Steering Stem Bearing Driver, 42.5 [B]:
57001-1344
Steering Stem Bearing Driver Adapter,
41.5 [C]: 57001-1345
grease to the ball bearings [A] and the inner race
• Apply
[B].
• Install the lower ball bearing to the stem.
the inner races in place as follows.
•○Settle
Tighten the steering stem nut with 55 N·m (5.6 kgf·m, 41
ft·lb) of torque first, and loosen it a fraction of a turn until
it turns lightly. Afterward tighten it again with specified
torque using a stem nut wrench [A] in the direction shown.
○Check that there is no play and the steering stem turns
smoothly without rattles. If not, the steering stem bearings
may be damaged.
Special Tool - Steering Stem Nut Wrench: 57001-1100
Torque - Steering Stem Nut: 29 N·m (3.0 kgf·m, 22 ft·lb)
• Install the removed parts (see appropriate chapters).
Stem Bearing Lubrication
with the Periodic Maintenance Chart, lubri• Incateaccordance
the steering stem bearings. Refer to the Stem Bearing Lubrication in the Periodic Maintenance chapter.
Stem Cap Deterioration, Damage
Replace the stem cap if its grease seal [A] shows damage.
FRAME 15-1
Frame
Table of Contents
Exploded View...................................
Special Tool .......................................
Seats .................................................
Rear Seat Removal......................
Rear Seat Installation...................
Front Seat Removal .....................
Front Seat Installation ..................
Side Covers .......................................
Left Side Cover Removal .............
Left Side Cover Installation ..........
Right Side Cover Removal...........
Right Side Cover Installation........
Fenders .............................................
Front Fender Removal .................
Rear Fender Removal..................
Rear Fender Installation...............
Battery Case......................................
Battery Case Removal .................
Battery Case Installation ..............
Footboard ..........................................
Front Footboard Removal/Installation..........................................
Front Footboard Disassembly......
Front Footboard Assembly...........
Rear Footboard Removal/Installation ............................................
Rear Footboard Disassembly ......
Rear Footboard Assembly ...........
Side Stand .........................................
Side Stand Removal ....................
Side Stand Installation .................
Windshield .........................................
Windshield Height Adjustment .....
Windshield and Deflector
Removal ....................................
15-2
15-8
15-9
15-9
15-9
15-9
15-9
15-10
15-10
15-10
15-11
15-11
15-12
15-12
15-12
15-13
15-14
15-14
15-14
15-15
15-15
15-16
15-16
15-17
15-17
15-18
15-19
15-19
15-19
15-20
15-20
15-20
Windshield and Deflector
Installation .................................
Windshield Assembly...................
Deflector Assembly ......................
Saddlebags........................................
Saddlebag Lid Unlocking .............
Saddlebag Lid Locking.................
Saddlebag Removal.....................
Saddlebag Installation..................
Saddlebag Stay Removal ............
Saddlebag Stay Installation .........
Guards...............................................
Front Guard Removal/Installation
Rear Guard Removal/Installation.
Rear View Mirrors..............................
Rear View Mirror Removal (Other
than EUR and SEA Models)......
Rear View Mirror Installation
(Other than EUR and SEA
Models) .....................................
Rear View Mirror Removal (EUR
and SEA Models) ......................
Rear View Mirror Installation
(EUR and SEA Models) ............
Downtube .........................................
Downtube Removal......................
Downtube Installation...................
Tandem Grip ......................................
Tandem Grip Removal .................
Tandem Grip Installation ..............
Frame ................................................
Frame Inspection .........................
15-20
15-20
15-21
15-22
15-22
15-22
15-22
15-22
15-23
15-24
15-25
15-25
15-25
15-26
15-26
15-26
15-26
15-27
15-28
15-28
15-28
15-29
15-29
15-29
15-30
15-30
15
15-2 FRAME
Exploded View
FRAME 15-3
Exploded View
No.
1
2
3
4
5
6
7
Fastener
Cross Pipe Bolts
Downtube Bolts
Front Footboard Bracket Bolts
Rear Footboard Bracket Bolts
Sidestand Mounting Bolt
Sidestand Mounting Nut
Sidestand Switch Mounting Bolt
8. Trim (EUR Models)
G: Apply grease.
L: Apply a non-permanent locking agent.
O: Apply 2-stroke oil.
R: Replacement Parts
N·m
34
59
34
25
44
44
8.8
Torque
kgf·m
3.5
6.0
3.5
2.5
4.5
4.5
0.90
ft·lb
25
44
25
18
32
32
78 in·lb
Remarks
L
R
L
15-4 FRAME
Exploded View
FRAME 15-5
Exploded View
No.
1
Fastener
Rear Fender Allen Bolts
2. Other than EUR and AU Models
N·m
25
Torque
kgf·m
2.5
ft·lb
18
Remarks
15-6 FRAME
Exploded View
FRAME 15-7
Exploded View
No.
1
2
3
4
Fastener
Cross Bar Mounting Bolts
Front Guard Mounting Bolts
Rear Guard Mounting Bolts
Saddlebag Stay Bolts
5. Other than EUR and AU Models
6. EUR and SEA Models
7. US, CA, CAL and AU Models
N·m
25
34
25
25
Torque
kgf·m
2.5
3.5
2.5
2.5
ft·lb
18
25
18
18
Remarks
15-8 FRAME
Special Tool
Jack:
57001-1238
FRAME 15-9
Seats
Rear Seat Removal
the ignition key into the seat lock [A], and turn it
• Insert
counterclockwise.
up the front part of the rear seat [B], and remove the
• Pull
rear seat forward.
Rear Seat Installation
the rear seat hook [A] into the brace [B] on the rear
• Slip
fender, and insert the latches [C] into the holes [D] on the
•
frame.
Push down the front part of the rear seat until the lock with
a click.
Front Seat Removal
the rear seat (see Rear Seat Removal).
• Remove
Detach
the
grommets [A] from the projections on the
• frame, and remove
the front seat [B] backward.
Front Seat Installation
the front seat hook [A] into the brace [B] on the fuel
• Slip
tank.
• Fit the grommets [C] to the projections [D] on the frame.
15-10 FRAME
Side Covers
CAUTION
Be careful not to scratch the painted surface during
removal or installation.
Left Side Cover Removal
• Remove:
Seats (see Front/Rear Seat Removal)
•
Screw [A]
Detach the projections [B], and remove the upper side
cover [C].
the bolt [A].
• Remove
Detach
the
• cover [C]. projections [B], and remove the lower side
• Remove:
Bolts [A]
Key Cylinder [B]
Left Side Cover Installation
the key cylinder, and tighten the bolts.
• Install
Insert
the
• mets [B]. projections [A] of lower side cover into the grom• Tighten the bolt.
FRAME 15-11
Side Covers
the projections [A] of upper side cover into the
• Insert
grommets [B].
• Tighten the screw.
Right Side Cover Removal
• Remove:
Seats (see Front/Rear Seat Removal)
•
Screw [A]
Detach the projections [B], and remove the upper side
cover [C].
• Remove:
Bolt [A]
•
Screw [B]
Detach the projections [C], and remove the lower side
cover [D].
Right Side Cover Installation
the projections [A] of lower side cover into the grom• Insert
mets [B].
• Tighten the bolt and screw.
the projections [A] of upper side cover into the
• Insert
grommets [B].
• Tighten the screw.
15-12 FRAME
Fenders
CAUTION
Be careful not to scratch the painted surface during
removal or installation.
Front Fender Removal
• Remove:
Front Wheel
(see Front Wheel Removal in the
Wheels/Tires chapter)
Front Fender Bolts [A]
Brake Hose Brackets [B]
Front Fender [C]
Rear Fender Removal
• Remove:
Seats (see Front/Rear Seat Removal)
•
Saddlebags (see Saddlebag Removal)
Saddlebag Stays (see Saddlebag Stay Removal)
Clear the connector [A] from the battery case cover, and
disconnect it.
• Clear the clamps [A] from the rear fender.
• Remove:
Bolts [A]
Rear Fender Allen Bolts [B] (Both Sides)
Rear Fender [C]
FRAME 15-13
Fenders
Rear Fender Installation
the grommet [A] so that its taper side faces inside.
• Install
Fit
the
grommet of the rear fender onto the stopper [B].
•
• Tighten:
Torque - Rear Fender Allen Bolts [A]: 25 N·m (2.5 kgf·m, 18
ft·lb)
• Tighten the bolts [B].
15-14 FRAME
Battery Case
Battery Case Removal
• Remove:
Seats (see Front/Rear Seat Removal)
Rear Fender (see Rear Fender Removal)
Battery (see Battery Removal in the Electrical System
chapter)
the following out from the battery case.
• Pull
ECU [A]
Turn Signal Control Relay [B]
Fuse Boxes [C]
ETV Actuator Relay [D]
Accessory Relay [E]
Starter Relay [F]
Vehicle-down Sensor (see Vehicle-down Sensor Removal in the Fuel System (DFI) chapter)
the clamp [A], and free the leads.
• Open
Remove
the bolt [B].
•
the battery case bolts [A].
• Remove
Front [B]
the battery case [A] upward as shown in the fig• Remove
ure.
Battery Case Installation
• Installation is the reverse of removal.
FRAME 15-15
Footboard
Front Footboard Removal/Installation
Left Side
Remove:
Rear Shift Lever Bolt [A]
Rear Shift Lever [B]
•
• Remove:
Front Footboard Bracket Bolt [A] (Tighten with Front
Guard)
Front Footboard Bracket Bolt [B]
Front Footboard Left [C]
is the reverse of removal; note the following.
•○Installation
Align the punch mark [A] on the shift shaft with the punch
mark [B] on the rear shift lever.
○Apply a non-permanent locking agent to the front footboard bracket bolts.
Tighten:
•
Torque - Front Footboard Bracket Bolt: 34 N·m (3.5 kgf·m,
25 ft·lb)
Shift Lever Bolt: 12 N·m (1.2 kgf·m, 106 in·lb)
Right Side
Remove:
Bolt [A] and Rear Brake Reservoir Cover [B]
Bolt [C] and Rear Brake Reservoir [D]
•
• Remove:
Front Guard Mounting Bolt [A]
Front Footboard Bracket Bolts [B]
Front Footboard Right [C]
15-16 FRAME
Footboard
the clamp [A], and free the lead.
• Open
Disconnect:
• Rear Brake Light Switch Lead Connector [B]
Cruise Control Cancel Switch Lead Connector [C]
If necessary, remove the rear brake master cylinder and
brake pedal (see Brake Pedal Removal in the Brakes
chapter).
is the reverse of removal; note the following.
• Installation
Tighten:
•
Torque - Front Footboard Bracket Bolt: 34 N·m (3.5 kgf·m,
25 ft·lb)
Front Guard Mounting Bolt: 25 N·m (2.5 kgf·m, 18
ft·lb)
Front Footboard Disassembly
Left Side
Remove:
Front Footboard Left (see Front Footboard Removal/Installation)
Spring [A]
Circlip [B]
Pin [C]
•
Right Side
Remove:
Front Footboard Right (see Front Footboard Removal/Installation)
Spring [A]
Circlip [B]
Pin [C]
•
Front Footboard Assembly
the circlips with new ones.
• Replace
Install
the
following onto the front footboards [A].
• Inner Dampers
[B]
Outer Dampers [C]
Bank Sensors [D] and Bolts [E]
FRAME 15-17
Footboard
the dampers [A] onto the front footboard brackets
• Install
[B].
the footboards [C] and the brackets together.
•○Put
Apply grease to the sliding surface of the front footboards.
○Insert the pins [D] from the front.
○Install the new circlips [E].
the springs [F].
•○Install
The direction of springs are as shown in the figure.
Rear Footboard Removal/Installation
• Remove:
Rear Exhaust Pipe Cover (see Exhaust Pipe Removal in
the Engine Top End chapter) (for Right Side)
Rear Footboard Bracket Bolts [A]
Rear Footboard [B]
• Tighten:
Torque - Rear Footboard Bracket Bolt: 25 N·m (2.5 kgf·m,
18 ft·lb)
Rear Footboard Disassembly
• Remove:
Rear Footboard (see Rear Footboard Removal/Installation)
Circlip [A]
Pin [B]
15-18 FRAME
Footboard
Rear Footboard Assembly
the circlips with new ones.
• Replace
Install
the
following onto the rear footboards [A].
• Inner Dampers
[B]
Outer Dampers [C]
Rear Footboard Covers [D] and Bolts [E]
the spring [A] and steel ball [B] into the hole [C] of
• Install
the footboard.
the stopper [D] onto the footboard.
•○Fit
Apply grease to the holes [E].
the dampers [A] onto the rear footboard brackets
• Install
[B].
the footboard assemblies [C] and the bracket to• Put
gether.
○Apply grease to the sliding surface of the rear footboards.
○Insert the pins [D] from the front.
○Install the new circlips [E].
FRAME 15-19
Side Stand
Side Stand Removal
• Raise the rear wheel off the ground using the jack.
Special Tool - Jack: 57001-1238
• Remove:
Side Stand Switch Bolt [A]
Side Stand Switch [B]
• Remove:
Spring [A]
Side Stand Nut [B]
Side Stand Bolt [C]
Side Stand [D]
Side Stand Installation
the sidestand mounting nut [A] with a new one.
• Replace
Apply
2-stroke
• side stand. oil to the contact surface of the frame and
• Install:
Side Stand [B]
•
Side Stand Mounting Bolt [C] and Nut
Tighten:
Torque - Side Stand Mounting Nut: 44 N·m (4.5 kgf·m, 32
ft·lb)
the spring [D] so that face the long spring end up• Hook
ward.
○Install the spring hook direction as shown in the figure.
a non-permanent locking agent to the side stand
• Apply
switch mounting bolt [E].
• Install the side stand switch [F].
Torque - Side Stand Switch Mounting Bolt: 8.8 N·m (0.90
kgf·m, 78 in·lb)
that the side stand switch mounting bolt is not loos• Check
ening.
15-20 FRAME
Windshield
Windshield Height Adjustment
○The windshield can be adjusted within 50 mm (2.0 in.) in
•
•
•
•
height to suit the rider’s preference.
Loosen the windshield bolts [A] on both sides.
Slide the windshield up or down [B].
Check to see that the position marks [C] are in the same
relative position on both sides.
Tighten the windshield bolts.
the subwindshield bolts [A] on both sides and
• Loosen
slide the subwindshield [B] up or down so the clearance
•
is 10 mm (0.4 in.) between the subwindshield lower edge
and the headlight body.
Tighten the subwindshield bolts.
Windshield and Deflector Removal
CAUTION
Be careful not to damage the surface of the windshield.
• Remove:
Bolt and Nut [A] (Both Sides)
Bolt and Collar [B] (Both Sides)
Deflector [C] (Both Sides)
Windshield [D]
○Take care not to drop the windshield and the deflectors.
Windshield and Deflector Installation
CAUTION
Be careful not to damage the surface of the windshield.
is the reverse of removal; note the following.
•○Installation
Adjust the windshield height after installation (see Windshield Height Adjustment).
Windshield Assembly
CAUTION
Be careful not to damage the surface of the windshield.
the following with the bolts and nuts to the wind• Install
shield [A].
Outer Center Plate [B] and Damper [C]
Inner Center Plate [D] and Damper [E]
FRAME 15-21
Windshield
the following with the bolts and nuts to the wind• Install
shield.
Outer Side Plates [A] and Dampers [B]
Dampers (D = 50 mm (2.0 in.)) [C]
Subwindshield [D]
Dampers (D = 35 mm (1.4 in.)) [E]
Windshield Stays [F]
○The outer side plates and windshield stays has an L or R
mark on its back.
○First, tighten all the bolts and nuts to a snug fit, and finally
tighten them evenly.
○Pull the subwindshield all the way up.
For EUR model, install the trim onto around the windshield.
•
Deflector Assembly
the following with the bolts [A] and nuts [B].
• Assemble
Left Deflector Stay [C]
Right Deflector Stay [D]
Left Deflector [E]
Right Deflector [F]
Dampers [G]
Left Deflector Bracket [H]
Right Deflector Bracket [I]
Washers [J]
15-22 FRAME
Saddlebags
Saddlebag Lid Unlocking
the ignition key into the lid lock [A], and turn it coun• Insert
terclockwise.
• Take hold of the knob [B], and open the lid.
Saddlebag Lid Locking
the lid until lock with a click.
• Close
Insert
the
• wise. ignition key into the lid lock [A], and turn it clock• Take hold of the knob [B] to check the locking condition.
Saddlebag Removal
the lid.
• Open
Remove
• Close thethelid.bolts [A].
•
the saddlebag from the saddlebag stay.
•○Remove
Clear the bottom stoppers [A] and the side hook [B].
Saddlebag Installation
• Install the rubber dampers [A].
FRAME 15-23
Saddlebags
the saddlebag onto the saddlebag stay.
•○Install
Fit the side hook [A] and the bottom stoppers [B] to the
saddlebag stay.
Saddlebag Stay Removal
• Remove:
Seats (see Front/Rear Seat Removal)
•
Saddlebag (see Saddlebag Removal)
Remove the bolts [A], and take off the cross bar [B].
• Remove:
Screw [A]
Bolts [B]
Rear Fender Cover Front [C]
• Remove:
Bolt [A]
Rear Fender Cover Rear [B]
• Remove:
Muffler Mounting Bolts [A]
Saddlebag Stay Bolts [B]
Saddlebag Stay [C]
15-24 FRAME
Saddlebags
Saddlebag Stay Installation
is the reverse of removal; note the following.
•○Installation
Tighten:
Torque - Saddlebag Stay Bolts [A]: 25 N·m (2.5 kgf·m, 18
ft·lb)
Muffler Mounting Bolts [B]: 25 N·m (2.5 kgf·m, 18
ft·lb)
Cross Bar Mounting Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
FRAME 15-25
Guards
Front Guard Removal/Installation
Left Side
Remove:
Front Guard Mounting Bolt [A]
Front Footboard Bracket Bolt [B]
Left Front Guard [C]
•
a non-permanent locking agent to the front foot• Apply
board bracket bolt.
• Tighten:
Torque - Front Footboard Bracket Bolt: 34 N·m (3.5 kgf·m,
25 ft·lb)
Front Guard Mounting Bolt: 34 N·m (3.5 kgf·m, 25
ft·lb)
Right Side
Remove:
Front Guard Mounting Bolts [A]
Right Front Guard [B]
•
• Tighten:
Torque - Front Guard Mounting Bolts: 34 N·m (3.5 kgf·m,
25 ft·lb)
Rear Guard Removal/Installation
• Remove:
Side Cover (see Side Cover Removal)
Saddlebag (see Saddlebag Removal)
Rear Guard Mounting Bolts [A]
Saddlebag Stay Bolts [B]
Rear Guard [C]
• Tighten:
Torque - Saddlebag Stay Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
Rear Guard Mounting Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
15-26 FRAME
Rear View Mirrors
Rear View Mirror Removal (Other than EUR and
SEA Models)
the bolt [A] and nut on both sides.
• Remove
• Tilt the windshield [B] forward.
the locknut [A].
• Loosen
Turn
the
view mirror stay [B] counterclockwise to re• move therear
rear view mirror from the holder [C].
Rear View Mirror Installation (Other than EUR and
SEA Models)
the locknut all the way up.
• Loosen
the mounting area of the rear view mirror [A] into
• Screw
the holder [B] all the way, then back it two turns out.
the stay to assure visibility to the rear with the rider
• Turn
sitting on the motorcycle, and tighten the locknut [C] securely.
Adjust the rear view mirror by slightly moving only the
mirror portion of the assembly.
○Installation and adjustment of the left side are common
with the those of right side. Follow the procedure specified at the right side.
•
Rear View Mirror Removal (EUR and SEA Models)
the bolt [A] and nut on both sides.
• Remove
• Tilt the windshield [B] forward.
FRAME 15-27
Rear View Mirrors
the lower hexagonal area [A].
• Loosen
Turn
the
view mirror stay [B] counterclockwise to re• move therear
rear view mirror from the holder [C].
CAUTION
Do not force to tighten and/or loosen the upper
hexagonal area (adapter) [A] with a pair of spanners or wrench. Disassembly of this area is not
possible. Non-permanent locking agent [B] is
already applied to the threads of this inner area.
Forcible loosening may damage the adapter and/or
the turning mechanism of the stay [C].
Rear View Mirror Installation (EUR and SEA
Models)
the mounting area of the rear view mirror [A] into
• Screw
the holder [B] all the way, and tighten the lower hexagonal
area [C] securely.
CAUTION
Do not force to tighten and/or loosen the upper
hexagonal area (adapter) [A] with a pair of spanners or wrench. Disassembly of this area is not
possible. Non-permanent locking agent [B] is
already applied to the threads of this inner area.
Forcible loosening may damage the adapter and/or
the turning mechanism of the stay [C].
the stay [A] to assure visibility to the rear with the
• Turn
rider sitting on the motorcycle.
the rear view mirror [B] by slightly moving only the
• Adjust
mirror portion of the assembly.
○Installation and adjustment of the left side are common
with the those of right side. Follow the procedure specified at the right side.
15-28 FRAME
Downtube
Downtube Removal
• Raise the rear wheel off the ground using the jack.
Special Tool - Jack: 57001-1238
• Remove:
Right Front Guard (see Front Guard Removal/Installation)
Front Footboard Right (see Front Footboard Removal/Installation)
Exhaust Pipes (see Exhaust Pipe Removal in the Engine
Top End chapter)
the engine with a commercially available stand
• Support
[A].
• Remove:
Engine Bracket Bolts [B]
Cross Pipe Bolt [C]
Downtube Bolts [D]
the clamps [A] to free the brake hose [B].
• Open
Remove
the downtube [C].
•
Downtube Installation
is the reverse of removal; note the following.
•○Installation
When installing the downtube, run the brake hose [A] on
•
the downtube [B].
Tighten:
Torque - Engine Bracket Bolts: 44 N·m (4.5 kgf·m, 32 ft·lb)
Cross Pipe Bolt: 34 N·m (3.5 kgf·m, 25 ft·lb)
Downtube Bolts: 59 N·m (6.0 kgf·m, 44 ft·lb)
FRAME 15-29
Tandem Grip
Tandem Grip Removal
• Remove:
Seats (see Front/Rear Seat Removal)
Saddlebags (see Saddlebag Removal)
the screw [A] and bolts [B], and take off the rear
• Remove
fender cover front [C] (Both Sides).
the bolts [A], and take off the tandem grip inner
• Remove
cover [B] (Both Sides).
• Remove:
Bolts and Nuts [A]
Backrest [B]
• Remove:
Bolts [A]
Tandem Grip [B]
Tandem Grip Installation
• Installation is the reverse of removal.
15-30 FRAME
Frame
Frame Inspection
inspect the frame [A] for cracks, dents, bending,
• Visually
or warp.
If there is any damage to the frame, replace it.
WARNING
A repaired frame may fail in use, possibly causing
an accident. If the frame is bent, dented, cracked,
or warped, replace it.
ELECTRICAL SYSTEM 16-1
Electrical System
Table of Contents
Exploded View...................................
Specifications ....................................
Special Tools and Sealant .................
Electrical Parts Location ....................
Wiring Diagram..................................
Servicing Precautions........................
Electrical Wiring.................................
Wiring Inspection .........................
Battery ...............................................
Battery Removal ..........................
Battery Installation .......................
Battery Activation .........................
Precautions ..................................
Interchange ..................................
Charging Condition Inspection.....
Refreshing Charge.......................
Charging System ...............................
Alternator Cover Removal............
Alternator Cover Installation.........
Alternator Stator Coil Removal ....
Alternator Stator Coil Installation .
Alternator Rotor Removal ............
Alternator Rotor Installation .........
Charging Voltage Inspection ........
Alternator Inspection ....................
Regulator/Rectifier Removal ........
Regulator/Rectifier Installation .....
Regulator/Rectifier Inspection......
Ignition System ..................................
Ignition Coil Removal ...................
Ignition Coil Installation ................
Ignition Coil Inspection.................
Spark Plug Removal ....................
Spark Plug Installation .................
Spark Plug Condition Inspection..
Ignition Coil Primary Peak
Voltage ......................................
Crankshaft Sensor Removal ........
Crankshaft Sensor Installation .....
Crankshaft Sensor Inspection......
Crankshaft Sensor Peak Voltage
Inspection..................................
Interlock Operation Inspection .....
IC Igniter Inspection .....................
Starter Motor......................................
Starter Motor Removal.................
Starter Motor Installation..............
Starter Motor Disassembly...........
Starter Motor Assembly ...............
Brush Inspection ..........................
16-4
16-10
16-11
16-12
16-14
16-18
16-19
16-19
16-20
16-20
16-20
16-21
16-23
16-24
16-24
16-24
16-26
16-26
16-27
16-28
16-29
16-29
16-29
16-30
16-30
16-32
16-32
16-33
16-35
16-35
16-36
16-36
16-37
16-37
16-37
16-38
16-39
16-39
16-39
16-40
16-40
16-41
16-44
16-44
16-44
16-45
16-45
16-47
Commutator Cleaning and
Inspection..................................
Armature Inspection.....................
Brush Lead Inspection .................
Right-hand End Cover Inspection
Starter Relay Inspection...............
Lighting System .................................
Headlight Beam Horizontal
Adjustment ................................
Headlight Beam Vertical
Adjustment ................................
Headlight Bulb Replacement .......
Headlight Body Removal .............
City Light Bulb Replacement
(EUR Models)............................
Tail/Brake Light (LED) Removal...
Tail/Brake Light (LED) Installation
Licence Plate Light Bulb
Replacemrnt..............................
Automatic Turn Signal Canceling
System............................................
Turn Signal Control Relay
Inspection..................................
Distance Sensor System
Inspection..................................
Turn Signal Light Bulb
Replacement .............................
Air Switching Valve ............................
Air Switching Valve Operation
Test............................................
Air Switching Valve Unit Test .......
Radiator Fan System.........................
Fan System Circuit Inspection .....
Fan Motor Inspection ...................
Meter, Gauge.....................................
Meter Unit Removal .....................
Meter Unit Installation ..................
Meter Unit Disassembly ...............
Meter Operation Inspection..........
Can Communication Item
Inspection..................................
Meter Unit Inspection ...................
Cruise Control System Switches .......
Cruise Control System Switch
Inspection..................................
Switch and Sensors...........................
Fuel Level Sensor Inspection.......
Water Temperature Sensor
Inspection..................................
Speed Sensor Removal ...............
16-47
16-47
16-48
16-48
16-48
16-50
16-50
16-50
16-50
16-51
16-52
16-52
16-52
16-53
16-55
16-55
16-56
16-56
16-60
16-60
16-60
16-62
16-62
16-62
16-64
16-64
16-64
16-64
16-65
16-69
16-72
16-79
16-79
16-84
16-84
16-84
16-85
16
16-2 ELECTRICAL SYSTEM
Speed Sensor Installation ............
Speed Sensor Inspection.............
Oxygen Sensor Removal
(Equipped Models) ....................
Oxygen Sensor Installation
(Equipped Models) ....................
Oxygen Sensor Inspection
(Equipped Models) ....................
Oxygen Sensor Heater Inspection
(Equipped Models) ....................
Gear Position Switch Removal ....
Gear Position Switch Installation .
Gear Position Switch Inspection ..
Front Brake Light Switch
Inspection..................................
16-85
16-85
16-85
16-85
16-85
16-86
16-86
16-86
16-86
16-87
Rear Brake Light Switch
Check/Adjustment .....................
Switch Inspection .........................
Relay Box ..........................................
Relay Box Removal .....................
Relay Box Installation ..................
Relay Circuit Inspection ...............
Diode Circuit Inspection ...............
Accessory Relay Inspection.........
Fuse...................................................
30 A Main Fuse Removal.............
Fuse Box Fuse Removal..............
Fuse Installation...........................
Fuse Inspection............................
16-87
16-88
16-89
16-89
16-89
16-89
16-90
16-91
16-92
16-92
16-92
16-92
16-93
ELECTRICAL SYSTEM 16-3
Dummy Page
16-4 ELECTRICAL SYSTEM
Exploded View
ELECTRICAL SYSTEM 16-5
Exploded View
No.
Fastener
1
2
3
Alternator Cover Bolts
Alternator Harness Clamp Bolt
Alternator Rotor Bolt
Alternator Stator Coil Lead Connector Stay
Bolt
4
5
6
Alternator Stator Coil Mounting Bolts
Crankshaft Sensor Bolts
7 Crankshaft Sensor Lead Holding Plate Bolt
Gear Position Switch Lead Holding Plate
8
Bolt
9 Gear Position Switch Bolts
10 Oil Pressure Switch
11 Oil Pressure Switch Terminal Bolt
12 Oxygen Sensor (Equipped Models)
13 Spark Plugs
14 Speed Sensor Mounting Bolt
15 Starter Motor Mounting Bolts
16 Starter Motor Terminal Locknut
17 Starter Motor Terminal Nut
18 Starter Motor Through Bolts
19 Stator Lead Holding Plate Bolts
N·m
12
9.8
150
Torque
kgf·m
1.2
1.0
15.3
ft·lb
106 in·lb
87 in·lb
111
9.8
1.0
87 in·lb
12
5.9
1.2
0.60
106 in·lb
52 in·lb
L
5.9
0.60
52 in·lb
L
4.9
0.50
43 in·lb
L
3.9
15.0
0.40
1.5
35 in·lb
11
-
-
-
L
SS
Hand
-tighten
25
18.0
2.5
1.8
18
13
9.8
9.8
11
5.9
5.0
5.9
1.0
1.0
1.1
0.60
0.51
0.60
87
87
97
52
44
52
in·lb
in·lb
in·lb
in·lb
in·lb
in·lb
G: Apply grease.
L: Apply a non-permanent locking agent.
MO: Apply Molybdenum disulfide oil solution.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1)
R: Replacement Parts
SS: Apply silicone sealant.
Remarks
MO
L
L
L
16-6 ELECTRICAL SYSTEM
Exploded View
ELECTRICAL SYSTEM 16-7
Exploded View
No.
1
2
3
4
5
6
7
Fastener
Engine Ground Mounting Bolt
Front Brake Light Switch Screw
Fuel Pump Bolts
Sidestand Switch Mounting Bolt
Starter Lockout Switch Screw
Cruise Control Cancel Switch (Clutch)
Screw
Water Temperature Sensor
8. Battery 12 V 18 Ah
9. Relay Box
10. ECU
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
S: Follow the specified tightening sequence.
N·m
9.8
1.2
9.8
8.8
1.2
Torque
kgf·m
1.0
0.12
1.0
0.90
0.12
ft·lb
87 in·lb
11 in·lb
87 in·lb
78 in·lb
11 in·lb
1.2
0.12
11 in·lb
12
1.2
106 in·lb
Remarks
L, S
L
16-8 ELECTRICAL SYSTEM
Exploded View
ELECTRICAL SYSTEM 16-9
Exploded View
No.
1
Fastener
Licence Plate Light Lens Screws
2. EUR Models
L: Apply a non-permanent locking agent.
N·m
0.9
Torque
kgf·m
0.09
ft·lb
8 in·lb
Remarks
16-10 ELECTRICAL SYSTEM
Specifications
Item
Battery
Type
Model Name
Capacity
Voltage
Charging System
Alternator Type
Battery Charging Voltage
Alternator Output Voltage (No Load)
Stator Coil Resistance
Regulator/Rectifier Resistance
Ignition System
Ignition Coil:
3 Needle Arcing Distance
Primary Winding Resistance
Secondary Winding Resistance
Primary Peak Voltage
Spark Plug:
Type
Gap
Crankshaft Sensor:
Peak Voltage
Crankshaft Sensor Resistance
Electric Starter System
Starter Motor:
Brush Length
Air Switching Valve
Resistance
Meter, Gauge
CAN Communication Line Resistance (at
Meter Unit)
Switch And Sensor
Fuel Level Sensor Resistance:
Full Position
Empty Position
Rear Brake Light Switch Timing
Engine Oil Pressure Switch Connections
Water Temperature Sensor Resistance
Gear Position Switch Resistance
Standard
Sealed Battery
FTZ16-BS
12 V 18 Ah
12.6 V or more
Three-phase AC
14.0 ∼ 15.0 V at 5 000 r/min (rpm)
76 V or more at 4 000 r/min (rpm)
0.23 ∼ 0.28 Ω at 20°C (68°F)
in the text
6 mm (0.24 in.) or more
1.8 ∼ 2.7 Ω
10.4 ∼ 15.6 kΩ
230 V or more
NGK ILZKAR7B11
1.0 ∼ 1.1 mm (0.039 ∼ 0.043 in.)
4 V or more
376 ∼ 564 Ω
12 mm (0.47 in.) (Service limit 6.5 mm, 0.26 in.)
18 ∼ 22 Ω at 20°C (68°F)
122 ∼ 126 Ω
9 ∼ 11 Ω
213 ∼ 219 Ω
ON after about 10 mm (0.4 in.) pedal travel
When engine is stopped: ON
When engine is running: OFF
in the text
in the text
ELECTRICAL SYSTEM 16-11
Special Tools and Sealant
Jack:
57001-1238
Grip:
57001-1591
Hand Tester:
57001-1394
Rotor Holder:
57001-1726
Peak Voltage Adapter:
57001-1415
Kawasaki Bond (Silicone Sealant):
92104-0004
Needle Adapter Set:
57001-1457
16-12 ELECTRICAL SYSTEM
Electrical Parts Location
Fuel Pump and Fuel Level Sensor [A]
Speed Sensor [B]
Crankshaft Sensor [C]
Alternator [D]
Gear Position Switch [E]
Sidestand Switch [F]
Meter Unit [A]
Ignition Switch [B]
Meter Unit Switch [C]
Cruise Control ON/OFF Button [D]
Cruise Control Switch [E]
Oil Pressure Switch [A]
Rear Brake Light Switch [B]
Cruise Control Cancel Switch (Rear Brake) [C]
Regulator/Rectifiers [D]
Engine Ground [A]
Water Temperature Sensor [B]
Ignition Coil #2 (Rear Cylinder) [C]
Spark Plug (Front Cylinder) [D]
Oxygen Sensor (Equipped Models) [E]
Frame Ground [A]
Air Switching Valve [B]
Spark Plug (Rear Cylinder) [C]
Starter Motor [D]
Ignition Coil #1 (Front Cylinder) [E]
Fan Motor [F]
ELECTRICAL SYSTEM 16-13
Electrical Parts Location
Front Brake Light Switch [A]
Cruise Control Cancel Switch (Front Brake) [B]
Starter Lockout Switch [A]
Cruise Control Cancel Switch (Clutch) [B]
Cruise Control Cancel Switch (Throttle) [A]
Frame Ground [A]
Accessory Relay [B]
ETV Actuator Relay [C]
Starter Relay [D]
Main Fuse 30 A [E]
Fuse Box 1 [F]
Battery 12 V, 18 Ah [G]
Vehicle-down Sensor [H]
Fuse Box 2 [I]
Turn Signal Control Relay [J]
Relay Box [K]
ECU [L]
16-14 ELECTRICAL SYSTEM
Wiring Diagram
ELECTRICAL SYSTEM 16-15
Wiring Diagram
16-16 ELECTRICAL SYSTEM
Wiring Diagram
ELECTRICAL SYSTEM 16-17
Wiring Diagram
16-18 ELECTRICAL SYSTEM
Servicing Precautions
There are a number of important precautions that are
musts when servicing electrical systems. Learn and observe all the rules below.
○Do not reverse the battery cable connections. This will
burn out the diodes on the electrical parts.
○Always check battery condition before condemning other
parts of an electrical system. A fully charged battery is a
must for conducting accurate electrical system tests.
○The electrical parts should never be struck sharply, as
with a hammer, or allowed to fall on a hard surface. Such
a shock to the parts can damage them.
○To prevent damage to electrical parts, do not disconnect
the battery leads or any other electrical connections when
the ignition switch is on, or while the engine is running.
○Because of the large amount of current, never keep the
starter button pushed when the starter motor will not turn
over, or the current may burn out the starter motor windings.
○Take care not to short the leads that are directly connected to the battery positive (+) terminal to the chassis
ground.
○Troubles may involve one or in some cases all items.
Never replace a defective part without determining what
CAUSED the failure. If the failure was caused by some
other item or items, they too must be repaired or replaced,
or the new replacement will soon fail again.
○Make sure all connectors in the circuit are clean and tight,
and examine wires for signs of burning, fraying, etc. Poor
wires and bad connections will affect electrical system operation.
○Measure coil and winding resistance when the part is cold
(at room temperature).
○Wire Color Codes:
BK: Black
BL: Blue
BR: Brown
CH: Chocolate
DG: Dark green
G: Green
GY: Gray
LB: Light blue
LG: Light green
O: Orange
P: Pink
PU: Purple
R: Red
V: Violet
W: White
Y: Yellow
ELECTRICAL SYSTEM 16-19
Electrical Wiring
Wiring Inspection
inspect the wiring for signs of burning, fraying,
• Visually
etc.
If any wiring is poor, replace the damaged wiring.
Pull each connector [A] apart and inspect it for corrosion,
dirt, and damage.
If the connector is corroded or dirty, clean it carefully. If it
is damaged, replace it.
Check that the connectors are not loose.
Check the wiring for continuity.
○Use the wiring diagram to find the ends of the lead which
is suspected of being a problem.
○Connect the hand tester between the ends of the leads.
•
•
•
Special Tool - Hand Tester: 57001-1394
○Set the tester to the × 1 Ω range, and read the tester.
If the tester does not read 0 Ω, the lead is defective. Replace the lead or the wiring harness [B] if necessary.
16-20 ELECTRICAL SYSTEM
Battery
Battery Removal
CAUTION
Do not remove the battery cables and fuses for 6
seconds after turning off the ignition switch.
the ignition switch OFF.
• Turn
Remove:
• Front Seat (see Front Seat Removal)
Connector [A]
Screws [B]
Battery Case Cover [C]
• Disconnect the battery negative (–) cable [A].
CAUTION
Be sure to disconnect the negative (–) cable first.
the red cap [B].
• Slide
Disconnect
the battery positive (+) cable [C].
• Pull the battery
[D] out of the case.
•
Battery Installation
that the damper [A] is properly on the battery case
• Check
[B].
the battery into the battery case so that the positive
• Put
(+) terminal faces to rear side [A] of the motorcycle.
the positive (+) cable [B] (red cap) to the positive
• Connect
(+) terminal first, and then the negative (–) cable [C] to the
•
•
negative (–) terminal.
Apply a light coat of grease on the terminals to prevent
corrosion.
Cover the positive (+) terminal with the red cap [D].
CAUTION
If each battery cable is not correctly disconnected
or connected, sparks can arise at electrical connections, causing damage to electrical and DFI parts.
ELECTRICAL SYSTEM 16-21
Battery
• Install the battery case cover [A].
NOTE
○Run each harness [B] under the battery case cover, and
do not run them over the frame pipe [C].
• Install the removed parts (see appropriate chapters).
Battery Activation
Electrolyte Filling
Make sure that the model name [A] of the electrolyte container matches the model name [B] of the battery. These
names must be the same.
•
Battery Model Name for VN1700C: FTZ16-BS
CAUTION
Be sure to use the electrolyte container with the
same model name as the battery since the electrolyte volume and specific gravity vary with the
battery type. This is to prevent overfilling of the
electrolyte, shorting the battery life, and deterioration of the battery performance.
CAUTION
Do not remove the aluminum sealing sheet [A] from
the filler ports [B] until just prior to use. Be sure to
use the dedicated electrolyte container for correct
electrolyte volume.
the battery on a level surface.
• Place
Check
• or holestoinseeit. that the sealing sheet has no peeling, tears,
• Remove the sealing sheet.
NOTE
○The battery is vacuum sealed. If the sealing sheet has
leaked air into the battery, it may require a longer initial
charge.
the electrolyte container from the vinyl bag.
• Remove
the strip of caps [A] from the container and set
• Detach
aside, these will be used later to seal the battery.
NOTE
○Do not pierce or otherwise open the sealed cells [B] of
the electrolyte container. Do not attempt to separate
individual cells.
16-22 ELECTRICAL SYSTEM
Battery
the electrolyte container upside down with the six
• Place
sealed cells into the filler ports of the battery. Hold the
container level, push down to break the seals of all six
cells. You will see air bubbles rising into each cell as the
ports fill.
NOTE
○Do not tilt the electrolyte container
the electrolyte flow.
• Check
If no air bubbles [A] are coming up from the filler ports, or
•
if the container cells have not emptied completely, tap the
container [B] a few times.
Keep the container in place for 20 minutes or more. Don’t
remove the container from the battery until it’s empty, the
battery requires all the electrolyte from the container for
proper operation.
CAUTION
Removal of the container before it is completely
empty can shorten the service life of the battery. Do
not remove the electrolyte container until it is completely empty and 20 minutes have elapsed.
remove the container from the battery.
• Gently
Let
the
battery sit for 60 minutes prior to charging to allow
• the electrolyte
to permeate into the plates for optimum
performance.
○Charging
NOTE
the battery immediately after filling can
shorten service life. Let the battery sit for at least 60
minutes after filling.
Initial Charge
Place the strip [A] of caps loosely over the filler ports.
Newly activated sealed batteries require an initial charge.
•
•
Standard Charge
1.8 A × 5 ∼ 10 hours
If using a recommended battery charger, follow the
charger’s instructions for newly activated sealed battery.
Kawasaki-recommended Chargers
Optimate III
Yuasa 1.5 Amp Automatic Charger
Battery Mate 150-9
If the above chargers are not available, use equivalent
one.
NOTE
○Charging rates will vary depending on how long the
battery has been stored, temperature, and the type of
charger used. Let battery sit 30 minutes after initial
charge, then check voltage using a voltmeter. If it is
not at least 12.6 volts, repeat charging cycle.
ELECTRICAL SYSTEM 16-23
Battery
charging is completed, press down firmly with both
• After
hands to seat the strip of caps [A] into the battery (don’t
pound or hammer). When properly installed, the strip of
the caps will be level with the top of the battery.
CAUTION
Once the strip of the caps [A] is installed onto the
battery, never remove the caps, nor add water or
electrolyte to the battery.
NOTE
○To ensure maximum battery life and customer satisfaction, it is recommended the battery be load tested at
three times its amp-hour rating for 15 seconds.
Re-check voltage and if less than 12.6 volts repeat the
charging cycle and load test. If still below 12.6 volts the
battery is defective.
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
seal cap to add water is very dangerous. Never do that.
2) Refreshing charge
If an engine will not start, a horn sounds weak, or lamps are dim, it indicates the battery has been
discharged. Give refresh charge for 5 to 10 hours with charge current shown in the specification
(see Refreshing Charge).
When a fast charge is inevitably required, do it following precisely the maximum charge current
and time conditions indicated on the battery.
CAUTION
This battery is designed to sustain no unusual deterioration if refresh-charged according
to the method specified above. However, the battery’s performance may be reduced noticeably if charged under conditions other than given above. Never remove the seal cap
during refresh charge.
If by chance an excessive amount of gas is generated due to overcharging, the relief valve
releases the gas to keep the battery normal.
3) When you do not use the motorcycle for months:
Give a refresh charge before you store the motorcycle and store it with the negative cable removed. Give a refresh charge once a month during storage.
4) Battery life:
If the battery will not start the engine even after several refresh charges, the battery has exceeded its useful life. Replace it (Provided, however, the vehicle’s starting system has no problem).
16-24 ELECTRICAL SYSTEM
Battery
WARNING
Keep the battery away from sparks and open flames during charging, since the battery
gives off an explosive gas mixture of hydrogen and oxygen. When using a battery charger,
connect the battery to the charger before turning on the charger.
This procedure prevents sparks at the battery terminals which could ignite any battery
gases.
No fire should be drawn near the battery, or no terminals should have the tightening loosened.
The electrolyte contains sulfuric acid. Be careful not to have it touch your skin or eyes. If
touched, wash it off with liberal amount of water. Get medial attention if severe.
Interchange
The sealed battery can fully display its performance only when combined with a proper vehicle electric system. Therefore, replace the sealed battery only on a motorcycle which was originally equipped
with the sealed battery.
Be careful, if the sealed battery is installed on a motorcycle which had an ordinary battery as original
equipment, the sealed battery’s life will be shortened.
Charging Condition Inspection
○Battery charging condition can be checked by measuring
•
•
battery terminal voltage with a digital meter [A].
Remove the front seat (see Front Seat Removal in the
Frame chapter).
Disconnect the battery terminals (see Battery Removal).
CAUTION
Be sure to disconnect the negative (–) cable first.
• Measure the battery terminal voltage.
NOTE
○Measure with a digital voltmeter which can be read one
decimal place voltage.
If the reading is 12.6 V or more, no refresh charge is required, however, if the read is below the specified, refresh
charge is required.
Battery Terminal Voltage
12.6 V or more
Standard:
Terminal Voltage (V) [A]
Battery Charge Rate (%) [B]
Refresh charge is required [C]
Good [D]
Refreshing Charge
the battery [A] (see Battery Removal).
• Remove
refresh charge by following method according to the
• Do
battery terminal voltage.
WARNING
This battery is sealed type. Never remove seal cap
[B] even at charging. Never add water. Charge with
current and time as stated below.
ELECTRICAL SYSTEM 16-25
Battery
Terminal Voltage: 11.5 ∼ less than 12.6 V
Standard Charge 1.8 A × 5 ∼ 10 h (see following
chart)
Quick Charge
9A×1h
CAUTION
If possible, do not quick charge. If quick charge is
done unavoidably, do standard charge later on.
Terminal Voltage: less than 11.5 V
1.8 A × 20 h
Charging Method:
NOTE
○Increase the charging voltage to a maximum voltage of
25 V if the battery will not accept current initially. Charge
for no more than 5 minutes at the increased voltage then
check if the battery is drawing current. If the battery
will accept current decrease the voltage and charge by
the standard charging method described on the battery
case. If the battery will not accept current after 5 minutes, replace the battery.
Battery [A]
Battery Charger [B]
Standard Value [C]
Current starts to flow [D]
the battery condition after refresh charge.
•○Determine
Determine the condition of the battery left for 30 minutes
after completion of the charge by measuring the terminal
voltage according to the table below.
Criteria
Judgement
12.6 V or higher
Good
12.0 ∼ lower than 12.6 V
Charge insufficient → Recharge
lower than 12.0 V
Unserviceable → Replace
16-26 ELECTRICAL SYSTEM
Charging System
Alternator Cover Removal
• Drain:
Engine Oil (see Engine Oil Change in the Periodic Maintenance chapter)
Coolant (see Coolant Change in the Periodic Maintenance chapter)
• Remove:
Front Footboard Right (see Front Footboard Removal in
the Frame chapter)
Front Exhaust Pipe Cover (see Exhaust Pipe Removal
in the Engine Top End chapter)
• Disconnect:
Oil Pressure Switch Lead [A]
Crankshaft Sensor Lead Connector [B]
Alternator Lead Connectors [C]
• Clear the leads [A] from the clamp [B].
• Remove:
Water Separator
•
Inner Cover (see Water Separator
Cover Removal in the Coolant System chapter)
Slave Cylinder (see Slave Cylinder Removal in the
Clutch chapter)
Remove the clutch pipe [A] and connector [B] from the
bracket [C].
ELECTRICAL SYSTEM 16-27
Charging System
• Remove:
Water Pipe Mounting Bolts [A]
• Remove:
Water Pipe Mounting Bolt [A]
Alternator Cover Bolts [B]
out the alternator cover [A] from the engine a little and
• Pull
remove the water pipe [B].
Alternator Cover Installation
silicone sealant to around grommets [A] of the al• Apply
ternator lead and crankshaft sensor lead.
Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004
that dowel pins [A] are in place on the crankcase.
• Check
Replace
the alternator cover gasket [B] with a new one.
•
16-28 ELECTRICAL SYSTEM
Charging System
the O-ring [A] of the water pipe [B] with a new
• Replace
one.
• Apply soap and water solution to the new O-ring.
the water pipe [A] into the alternator cover [B] and
• Insert
install the cover.
CAUTION
Do not pinch the alternator, crankshaft sensor
and sidestand switch leads between the alternator
cover and the crankcase.
• Install:
Clamp [A]
•
Alternator Cover Bolts [B] L=70 mm (2.8 in.)
Alternator Cover Bolts [C] L=50 mm (2.0 in.)
Tighten:
Torque - Alternator Cover Bolts: 12 N·m (1.2 kgf·m, 106
in·lb)
the leads correctly (see Cable, Wire and Hose Rout• Run
ing section in the Appendix chapter).
• Install the removed parts (see appropriate chapters).
Alternator Stator Coil Removal
• Remove:
Alternator Cover (see Alternator Cover Removal)
Holding Plate Bolt [A] and Plate
Alternator Lead Grommet [B]
• Remove:
Alternator Stator Coil Mounting Bolts [A]
Alternator Stator Coil [B]
ELECTRICAL SYSTEM 16-29
Charging System
Alternator Stator Coil Installation
a non-permanent locking agent to the thread of the
• Apply
alternator stator coil mounting bolts [A].
• Tighten:
Torque - Alternator Stator Coil Mounting Bolts: 12 N·m (1.2
kgf·m, 106 in·lb)
a non-permanent locking agent to the thread of the
• Apply
stator lead holding plate bolts [B].
• Install:
Stator Lead Holding Plate Bolts and Holding Plate
Tighten:
•
Torque - Stator Lead Holding Plate Bolts: 5.9 N·m (0.60
kgf·m, 52 in·lb)
silicone sealant to around grommet [C] of the alter• Apply
nator lead.
Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004
• Install:
Alternator Cover (see Alternator Cover Installation)
Alternator Rotor Removal
• Remove:
Alternator Cover (see Alternator Cover Removal)
the alternator rotor steady with the rotor holder [A],
• Hold
and remove the rotor bolt [B] and washer.
Special Tools - Grip [C]: 57001-1591
Rotor Holder: 57001-1726
Alternator Rotor Installation
the alternator rotor [A] while fitting the alignment
• Install
notch [B] of the splines onto the alignment tooth [C].
molybdenum disulfide oil solution to the threads of
• Apply
the alternator rotor bolt and seating surface of the bolt
•
head.
Hold the alternator rotor steady with the rotor holder, and
install the rotor bolt and washer.
Special Tools - Grip: 57001-1591
Rotor Holder: 57001- 1726
• Tighten:
Torque - Alternator Rotor Bolt: 150 N·m (15.3 kgf·m, 111
ft·lb)
• Install:
Alternator Cover (see Alternator Cover Installation)
16-30 ELECTRICAL SYSTEM
Charging System
Charging Voltage Inspection
the battery condition (see Charging Condition In• Check
spection).
up the engine to obtain actual alternator operating
• Warm
conditions.
the front seat (see Front Seat Removal in the
• Remove
Frame chapter).
that the ignition switch is turned off, and connect
• Check
the hand tester to the battery as shown in the table.
Special Tool - Hand Tester: 57001-1394
Battery Charging Voltage
Connections
Tester
Range
Tester (+) to
Tester (–) to
Reading
at 5 000 rpm
25 V DC
Battery (+)
Battery (–)
14.0 ∼ 15.0 V
the engine, and note the voltage readings at various
• Start
engine speeds. The readings should show nearly battery
•
voltage when the engine speed is low, and as the engine
speed rises, the readings should also rise. But they must
be kept under the specified voltage.
Turn off the ignition switch to stop the engine, and disconnect the hand tester.
If the charging voltage is kept between the values given in
the table, the charging system is considered to be working
normally.
If the output voltage is much higher than the values specified in the table, the regulator/rectifier is defective or the
regulator/rectifier leads are loose or open.
If the battery voltage does not rise as the engine speed
increases, then the regulator/rectifier is defective or the
alternator output is insufficient for the loads. Check the
alternator and regulator/rectifier to determine which part
is defective.
Alternator Inspection
There are three types of alternator failures: short, open
(lead burned out), or loss in rotor magnetism. A short or
open in one of the stator coil lead will result in either a low
output, or no output at all. A loss in rotor magnetism, which
may be caused by dropping or hitting the alternator, by leaving it near an electromagnetic field, or just by aging, will result in low output.
check the alternator output voltage, do the following
• To
procedures.
○Remove the front exhaust pipe cover (see Exhaust Pipe
Removal in the Engine Top End chapter).
○Disconnect the crankshaft sensor lead connector [A] temporarily.
○Remove the alternator lead connectors [B] to upper side
from the bracket.
ELECTRICAL SYSTEM 16-31
Charging System
○Disconnect the alternator lead connectors [A].
○Connect
the hand tester [A] to each connector [B] as
shown in the table 1.
Special Tool - Hand Tester: 57001-1394
○Connect the crankshaft sensor lead connector.
○Start the engine.
○Run it at the 4 000 rpm.
○Note the voltage readings (total 3 measurements at one
connector).
Table 1 Alternator Output Voltage
Tester
Range
Connections
Tester (+) to
Tester (–) to
Reading at
4 000 rpm
AC 250 V One black lead Another black lead 76 V or more
If the output voltage shows the value in the table, the alternator operates properly.
A much lower reading than the value in the table indicates
that the alternator is defective.
the stator coil resistance as follows:
•○Check
Stop the engine.
○Connect
the hand tester [A] to each connector [B] as
shown in the table2.
○Note the resistance readings.
Table 2 Stator Coil Resistance
Tester
Range
×1 Ω
Connections
Tester (+) to
Tester (–) to
at 20°C (68°F)
Reading
One black lead Another black lead 0.23 ∼ 0.28 Ω
If there is more resistance than shown in the table, or no
hand tester reading (infinity), the stator has an open lead
and must be replaced. Much less than this resistance
means the stator is shorted, and must be replaced.
Using the highest resistance range of the hand tester,
measure the resistance between each of the black leads
and chassis ground.
Any hand tester reading less than infinity (∞) indicates a
short, necessitating stator replacement.
If the stator coil has normal resistance, but the voltage
check showed the alternator to be defective, then the rotor
magnets have probably weakened, and the rotor must be
replaced.
○Repeat the test for another connector.
•
16-32 ELECTRICAL SYSTEM
Charging System
Regulator/Rectifier Removal
• Remove:
Connector Bracket Bolt [A]
•
Bolts [B] and Cross Pipe [C]
Pull out the cross pipe from the projections [D] of the radiator.
• Disconnect:
Regulator/Rectifier Lead Connectors [A]
Remove:
• Regulator/Rectifier Bolts [B] and Nuts
Regulator/Rectifiers [C]
Regulator/Rectifier Installation
the regulator/rectifier leads according to the Cable,
• Run
Wire, and Hose Routing section in the Appendix chapter.
• Tighten:
Torque - Cross Pipe Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb)
ELECTRICAL SYSTEM 16-33
Charging System
Regulator/Rectifier Inspection
• Remove:
Regulator/Rectifier (see Regulator/Rectifier Removal)
Set the hand tester to the × 1 kΩ range and make the
• measurements
shown in the table.
Special Tool - Hand Tester: 57001-1394
the hand tester to the regulator/rectifier.
• Connect
If the tester readings are not as specified, replace the
regulator/rectifier.
CAUTION
Use only Kawasaki Hand Tester 57001-1394 for this
test. A tester other than the Kawasaki Hand Tester
may show different readings. If a megger or a meter with a large capacity battery is used, the regulator/rectifier will be damaged.
Regulator/Rectifier Resistance
(Unit: kΩ)
Tester (+) Lead Connection
(−)*
Terminal
W
NC
BK/Y
AC1
AC2
AC3
W
−
∞
∞
∞
∞
∞
NC
∞
−
∞
∞
∞
∞
BK/Y
5~15
∞
−
3~11
3~11
3~11
AC1
3~11
∞
∞
−
∞
∞
AC2
3~11
∞
∞
∞
−
∞
AC3
3~11
∞
∞
∞
∞
−
(−)*: Tester (−) Lead Connection
16-34 ELECTRICAL SYSTEM
Charging System
Charging System Circuit
1. Ignition Switch
2. Load
3. Frame Ground 1
4. Frame Ground 2
5. Regulator/Rectifier #1
6. Regulator/Rectifier #2
7. Alternator
8. Starter Relay
9. Main Fuse 30 A
10. Battery
ELECTRICAL SYSTEM 16-35
Ignition System
WARNING
The ignition system produces extremely high voltage. Do not touch the spark plugs, ignition coils,
or spark plug high-tension cables while the engine
is running, or you could receive a severe electrical
shock.
CAUTION
Do not disconnect the battery cables or any other
electrical connections when the ignition switch is
on, or while the engine is running. This is to prevent
IC igniter damage in the ECU.
Do not install the battery backwards. The negative
side is grounded. This is to prevent damage to the
IC igniter in the ECU and the diodes.
Ignition Coil Removal
• Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)
Spark Plug Cap [A] (Rear Cylinder)
• Remove:
Ignition Coil Mounting Nuts [A]
Primary Leads [B]
Ignition Coil #1 [C] (Front Cylinder)
• Remove:
Spark Plug Cap [A] (Front Cylinder)
Ignition Coil Mounting Nuts [B]
Primary Leads [C]
Ignition Coil #2 [D] (Rear Cylinder)
16-36 ELECTRICAL SYSTEM
Ignition System
Ignition Coil Installation
the high-tension cables according to the Cable, Wire,
• Run
and Hose Routing section in the Appendix chapter.
the primary leads to the ignition coil [A].
• Connect
Ignition Coil #1 (Front Cylinder)
R/G Lead [B] to Green Terminal Cover [C]
BK/O Lead [D] to Black Terminal Cover [E]
Ignition Coil #2 (Rear Cylinder)
R/G Lead [B] to Green Terminal Cover [C]
BK Lead [F] to Black Terminal Cover [E]
• Install:
Ignition Coil
•
Frame Ground Lead Terminal [A] (at Ignition Coil #1
(Front Cylinder)
Tighten the ignition coil mounting nuts.
Ignition Coil Inspection
the ignition coils (see Ignition Coil Removal in
• Remove
this chapter).
the arcing distance with a commercially avail• Measure
able coil tester [A] to check the condition of the ignition
•
coil [B].
Connect the ignition coil (with the spark plug cap left attached at the end of the spark plug terminal) to the tester
in the manner prescribed by the manufacturer and measure the arcing distance.
3 Needle Arcing Distance
Standard:
6 mm (0.24 in.) or more
WARNING
To avoid extremely high voltage shocks, do not
touch the coil body or leads.
•
If the distance reading is less than the specified value, the
ignition coil or spark plug caps are defective.
To determine which part is defective, measure the arcing
distance again with the spark plug caps removed from the
ignition coil. Remove the caps by turning them counterclockwise.
If the arcing distance is subnormal as before, the trouble
is with the ignition coil itself. If the arcing distance is now
normal, the trouble is with the spark plug cap.
If the coil tester is not available, the coil can be checked
for a broken or badly shorted winding with the hand tester.
Special Tool - Hand Tester: 57001-1394
NOTE
○The hand tester cannot detect layer shorts and shorts
resulting from insulation breakdown under high voltage.
ELECTRICAL SYSTEM 16-37
Ignition System
the primary winding resistance [A] as follows.
•○Measure
Connect the hand tester between the coil terminals.
○Set the tester to the × 1 Ω range, and read the tester.
the secondary winding resistance [B] as follows.
•○Measure
Remove the plug caps by turning them counterclockwise.
○Connect the tester between the spark plug High-Tension
cables.
○Set the tester to the × 1 kΩ range and read the tester.
Ignition Coil Winding Resistance
Primary Windings:
1.8 ∼ 2.7 Ω
Secondary Windings:
10.4 ∼ 15.6 kΩ
If the tester does not read as specified, replace the coil.
○To install the plug cap, turn it clockwise.
Spark Plug Removal
to the Spark Plug Replacement in the Periodic
• Refer
Maintenance chapter.
Spark Plug Installation
to the Spark Plug Replacement in the Periodic
• Refer
Maintenance chapter.
Spark Plug Condition Inspection
to the Spark Plug Condition Inspection in the Peri• Refer
odic Maintenance chapter.
16-38 ELECTRICAL SYSTEM
Ignition System
Ignition Coil Primary Peak Voltage
NOTE
○Be sure the battery is fully charged.
the fuel tank (see Fuel Tank Removal in the Fuel
• Remove
System (DFI) chapter).
all the spark plug caps but do not remove the
• Remove
spark plugs.
• Install new spark plug into the spark plug cap.
the peak voltage adapter [A] to the hand tester
• Connect
[B].
Hand Tester Range: DC 1 000 V
Special Tools - Hand Tester: 57001-1394
Peak Voltage Adapter: 57001-1415
Type: KEK-54-9-B
the needle adapter [C] into the ignition coil primary
• Insert
lead terminal.
Front Ignition Coil [D]: BK/O Lead Terminal
Rear Ignition Coil: BK Lead Terminal
Special Tool - Needle Adapter Set: 57001-1457
the peak voltage adapter to the needle adapter
• Connect
and the ground [E].
Primary Lead Connections:
Adapter (R)
Adapter (BK)
Front Ignition Coil:
BK/O
←→
Ground
Rear Ignition Coil:
BK
←→
Ground
ECU [F]
Battery [G]
WARNING
To avoid extremely high voltage shocks, do not
touch the spark plugs or tester connections.
the engine stop switch to run position .
• Turn
Turn
the ignition switch to ON.
• Ground
new spark plug [H] onto the engine or frame.
• Pushingthe
the
starter button, turn the engine 4 ∼ 5 seconds
• with the transmission
in neutral to measure the primary
•
peak voltage.
Repeat the measurements 5 times for one ignition coil.
Ignition Coil Primary Peak Voltage
Standard:
230 V or more
the test for the other ignition coil.
• Repeat
If the reading is less than the specified value, check the
following:
Ignition Coils (see Ignition Coil Inspection )
Crankshaft Sensor (see Crankshaft Sensor Inspection )
If the ignition coils and crankshaft sensor are normal,
check the ECU (see ECU Power Supply Inspection in the
Fuel System (DFI) chapter).
ELECTRICAL SYSTEM 16-39
Ignition System
Crankshaft Sensor Removal
• Remove:
Alternator Cover (see Alternator Cover Removal)
Crankshaft Sensor Lead Holding Plate Bolt [A] and Holding Plate [B]
Crankshaft Sensor Bolts [C]
Crankshaft Sensor [D] and Grommet [E]
Crankshaft Sensor Installation
• Install:
Crankshaft Sensor [A]
•
Crankshaft Sensor Bolts [B]
Tighten:
Torque - Crankshaft Sensor Bolts: 5.9 N·m (0.60 kgf·m, 52
in·lb)
silicone sealant to the circumference of the crank• Apply
shaft sensor lead grommet [C], and fit the grommet into
the notch of the cover securely.
Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004
the crankshaft sensor lead with the holding plate
• Secure
[D], and apply a non-permanent locking agent to the
thread of the crankshaft sensor lead holding plate bolt
[E] and tighten it.
Torque - Crankshaft Sensor Lead Holding Plate Bolt: 5.9
N·m (0.60 kgf·m, 52 in·lb)
Crankshaft Sensor Inspection
• Remove:
Front Footboard Right (see Front Footboard Removal in
•
•
the Frame chapter)
Disconnect the crankshaft sensor lead connector [A] (see
Alternator Cover Removal).
Set the hand tester [B] to the × 10 Ω range and connect
it to the crankshaft sensor lead connector.
Special Tool - Hand Tester: 57001-1394
Crankshaft Sensor Resistance
Connections: BK Lead [C] ←→ Y Lead [D]
Standard: 376 ~ 564 Ω
•
If there is more resistance than the specified value, the
coil has an open lead and must be replaced. Much less
than this resistance means the coil is shorted, and must
be replaced.
Using the highest resistance range of the tester, measure
the resistance between the crankshaft sensor leads and
chassis ground.
Any tester reading less than infinity (∞) indicates a short,
necessitating replacement of the crankshaft sensor assembly.
16-40 ELECTRICAL SYSTEM
Ignition System
Crankshaft Sensor Peak Voltage Inspection
NOTE
○Be sure the battery is fully charged.
○Using the peak voltage adapter is more reliable way to
determine the condition of the crankshaft sensor than
crankshaft sensor internal resistance measurements.
the crankshaft sensor lead connector [A] (see
• Disconnect
Alternator Cover Removal).
the hand tester [B] to the DC 10 V range, and connect
• Set
it to the peak voltage adapter [C].
Special Tools - Hand Tester: 57001-1394
Peak Voltage Adapter: 57001-1415
Type: KEK-54-9-B
the adapter to the terminals of the crankshaft
• Connect
sensor lead connector.
Connections:
Crankshaft Sensor
Peak Voltage
Hand Tester
Adapter
Lead Connector
Y Lead [D]
←
R Lead
→
(+)
BK Lead [E]
←
BK Lead
→
(–)
the engine stop switch to run position.
• Turn
Turn
the ignition switch to ON.
• Pushing
the starter button, turn the engine 4 ~ 5 seconds
• with the transmission
in neutral to measure the peak volt-
•
age.
Repeat the measurements 5 times.
Crankshaft Sensor Peak Voltage
Standard: 4 V or more
If the reading is less than the standard, inspect the crankshaft sensor (see Crankshaft Sensor Inspection).
Interlock Operation Inspection
the rear wheel off the ground (see Rear Wheel Re• Raise
moval in the Wheels/Tires chapter).
1st Check
Start the engine to the following conditions.
•
Condition:
Transmission Gear → 1st Position
Clutch Lever → Release
Sidestand → Down or Up
○Turn the ignition switch to ON and push the starter button.
○Then the starter motor should not turn when the starter
system circuit is normality.
If the engine is start, inspect the starter lockout switch,
gear position switch, and relay box.
ELECTRICAL SYSTEM 16-41
Ignition System
2nd Check
Start the engine to the following conditions.
•
Condition:
Transmission Gear → 1st Position
Clutch Lever → Pulled in
Sidestand → Up
○Turn the ignition switch to ON and push the starter button.
○Then the starter motor should turn when the starter system circuit is normality.
If the starter motor is not turn, inspect the starter lockout
switch, gear position switch, sidestand switch, relay box
and starter relay.
3rd Check
Inspect the engine for its secure stop after the following
operations are completed.
Run the engine to the following conditions.
•
•
Condition:
Transmission Gear → 1st Position
Clutch Lever → Release
Sidestand → Up
the sidestand on the ground, then the engine will stop.
• Set
If whichever may not be stopped, inspect the gear position
switch, sidestand switch and relay box.
If their parts are normality, replace the ECU.
IC Igniter Inspection
○The IC igniter is built in the ECU [A].
to the following items.
• Refer
Interlock Operation Inspection (see Interlock Operation
Inspection)
Ignition System Troubleshooting (see Ignition System
Troubleshooting)
ECU Power Supply Inspection (see ECU Power Supply
Inspection in the Fuel System (DFI) chapter)
16-42 ELECTRICAL SYSTEM
Ignition System
Ignition System Troubleshooting
ELECTRICAL SYSTEM 16-43
Ignition System
Ignition System Circuit
1. Engine Stop Switch
2. Starter Button
3. Spark Plug #1 (Front
Cylinder)
4. Spark Plug #2 (Rear
Cylinder)
5. Ignition Coil #1 (Front
Cylinder)
6. Ignition Coil #2 (Rear
Cylinder)
7. Inlet Air Pressure Sensor
8. Water Temperature Sensor
9. Throttle Position Sensor/ETV Actuator
10. Throttle Position Sensor
1
11. Throttle Position Sensor
2
12. Gear Position Switch
13. Speed Sensor
14. ECU
15. Ignition Switch
16. Starter Lockout Switch
17. Crankshaft Sensor
18. Sidestand Switch
19. Vehicle-down Sensor
20. Starter Relay
21. Main Fuse 30A
22. Battery
23. Ignition Fuse 10 A
24. ECU Fuse 10 A
25. Engine Ground
26. Relay Box
27. Diodes
28. Frame Ground 3
16-44 ELECTRICAL SYSTEM
Starter Motor
Starter Motor Removal
• Remove:
Engine Pulley Inner Cover (see Engine Pulley Inner
•
Cover Removal in the Final Drive chapter)
Starter Motor Terminal Nut [A] and Cable [B]
Starter Motor Mounting Bolts [C]
Pull out the starter motor [D].
CAUTION
Never drop the starter motor, especially on a hard
surface. Such a shock to the motor can damage it.
Starter Motor Installation
CAUTION
Do not tap the starter motor body. Tapping the body
could damage the motor.
the O-ring [A] with a new one.
• Replace
Apply
grease
to the new O-ring.
•
the starter motor legs [A] and crankcase [B] where
• Clean
the starter motor is grounded.
a non-permanent locking agent to the threads of
• Apply
the starter motor mounting bolts, and tighten them.
Torque - Starter Motor Mounting Bolts: 9.8 N·m (1.0 kgf·m,
87 in·lb)
the starter motor cable [A] so that it is parallel to
• Install
the starter motor legs [B].
Torque - Starter Motor Terminal Nut: 5.9 N·m (0.60 kgf·m,
52 in·lb)
• Install the removed parts (see appropriate chapters).
ELECTRICAL SYSTEM 16-45
Starter Motor
Starter Motor Disassembly
the starter motor (see Starter Motor Removal).
• Remove
Take
off
the
motor through bolts [A] and remove
• the both end starter
covers [B].
• Pull out the armature [A] out of the yoke [B].
NOTE
○Do not remove the circlip [C] from the shaft.
• Remove the starter motor terminal locknut [A].
out the brushes [A] from the brush holder [B].
• Pull
Remove:
• Brush Springs [C]
Starter Motor Terminal [D] with Brush
Screw [E]
Brush Holder with Brushes
Starter Motor Assembly
sure that the stopper [A] is in position.
• Be
the hole [B] of the brush holder [C] with the hole [D]
• Align
of the end cover [E].
• Tighten the screw securely.
16-46 ELECTRICAL SYSTEM
Starter Motor
the O-ring [A] with a new one.
• Replace
Install
the
starter motor terminal [B] together with the fol• lowing parts.
New O-ring
Collar [C]
Washer [D]
Starter Motor Terminal Locknut [E]
○Install the collar so that stepped side faces outward.
Tighten:
•
Torque - Starter Motor Terminal Locknut:
kgf·m, 97 in·lb)
11 N·m (1.1
• Install the brush springs [A] and insert the brushes [B].
• Apply thin coat of grease to the oil seal [A].
the O-rings [A] with new ones.
• Replace
Insert
the
[B] so that commutator side [C] faces
• hollow sidearmature
[D] of the yoke [E].
the end cover [A] so that the stopper [B] is aligned
• Install
with the hollow [C] of the yoke.
ELECTRICAL SYSTEM 16-47
Starter Motor
the O-rings [A] with new ones.
• Replace
Install
the
end cover [B] and tighten the through bolts [C].
•
Torque - Starter Motor Through Bolts: 5.0 N·m (0.51 kgf·m,
44 in·lb)
Brush Inspection
the length of each brush [A].
• Measure
If any is worn down to the service limit, replace the brush
assy.
Starter Motor Brush Length
Standard:
12 mm (0.47 in.)
Service Limit: 6.5 mm (0.26 in.)
Commutator Cleaning and Inspection
the metallic debris off the between commutator
• Clean
segments [A].
NOTE
○Do not use emery or sand paper on the commutator.
the commutator for damage or abnormal wear.
• Check
Replace the starter motor with a new one if there is any
•
damage or wear.
Visually inspect the commutator segments for discoloration.
Replace the starter motor with a new one if discoloration
is noticed.
Armature Inspection
the × 1 Ω hand tester range, measure the resis• Using
tance between any two commutator segments [A].
Special Tool - Hand Tester: 57001-1394
•
If there is a high resistance or no reading (∞) between any
two segments, a winding is open and the starter motor
must be replaced.
Using the highest hand tester range, measure the resistance between the segments and the shaft [B].
If there is any reading at all, the armature has a short and
the starter motor must be replaced.
NOTE
○Even if the foregoing checks show the armature to be
good, it may be defective in some manner not readily
detectable with the hand tester. If all other starter motor
and starter motor circuit components check good, but
the starter motor still does not turn over or only turns
over weakly, replace the starter motor with a new one.
16-48 ELECTRICAL SYSTEM
Starter Motor
Brush Lead Inspection
the × 1 Ω hand tester range, measure the resis• Using
tance as shown.
Terminal Bolt and Positive Brushes [A]
End Cover and Negative Brushes [B]
Special Tool - Hand Tester: 57001-1394
If there is not close to zero ohms, the brush lead has an
open. Replace the brush plate assy.
Right-hand End Cover Inspection
the highest hand tester range, measure the resis• Using
tance as shown.
Terminal Bolt and End Cover [A]
Terminal Bolt and Negative Brushes [B]
Special Tool - Hand Tester: 57001-1394
If there is any reading, the brush assy and/or terminal bolt
assy have a short. Replace the starter motor.
Starter Relay Inspection
the battery negative (–) cable from the battery
• Remove
negative (–) terminal (see Battery Removal)
out the fuse box [A] and starter relay [B] from the
• Pull
battery case.
the starter motor cable [A] and battery positive
• Remove
(+) cable [B]
• Disconnect the connector [C]
the hand tester [A] and 12 V battery [B] to the
• Connect
starter relay [C] as shown.
If the relay does not work as specified, the relay is defective. Replace the relay.
Testing Relay
Tester Range: × 1 Ω range
Criteria:
When battery is connected → 0 Ω
When battery is disconnected → ∞ Ω
ELECTRICAL SYSTEM 16-49
Starter Motor
Electric Starter Circuit
1. Engine Stop Switch
2. Starter Button
3. Gear Position Switch
4. Ignition Switch
5. Starter Lockout Switch
6. Sidestand Switch
7. Starter Motor
8. Starter Relay
9. Main Fuse 30 A
10. Battery
11. Ignition Fuse 10 A
12. Engine Ground
13. Relay Box
14. Starter Circuit Relay
15. Frame Ground 3
16. Frame Ground 4
16-50 ELECTRICAL SYSTEM
Lighting System
This motorcycle adopts the daylight system and has a
headlight relay in the relay box. The headlight does not
go on when the ignition switch and the engine stop switch
are first turned on. The headlight comes on after the starter
button is released and stays on until the ignition switch is
turned off. The headlight will go out momentarily whenever
the starter button is pressed and come back on when the
button is released.
Headlight Beam Horizontal Adjustment
to the Headlight Aiming Inspection in the Periodic
• Refer
Maintenance chapter.
Headlight Beam Vertical Adjustment
to the Headlight Aiming Inspection in the Periodic
• Refer
Maintenance chapter.
Headlight Bulb Replacement
• Remove the headlight rim screws [A] on both sides.
the headlight unit [A] and disconnect the head• Remove
light connector [B].
• Remove the headlight dust cover [C].
• Remove:
Hook [A]
Headlight Bulb [B]
CAUTION
When handling the quartz-halogen bulb, never
touch the glass portion with bare hands. Always
use a clean cloth. Oil contamination from hands or
dirty rags can reduce bulb life or cause the bulb to
explode.
NOTE
○Clean off any contamination that inadvertently gets on
the bulb with alcohol or a soap and water solution.
ELECTRICAL SYSTEM 16-51
Lighting System
the headlight bulb.
• Replace
Fit
the
projections
[A] of the bulb in the hollows [B] of the
• headlight.
• Install the hook [A].
the dust cover [A] with the TOP mark [B] upward onto
• Fit
the bulb [C] firmly as shown.
Good [D]
Bad [E]
installation, adjust the headlight aim (see Headlight
• After
Aiming Inspection in the Periodic Maintenance chapter).
Headlight Body Removal
the headlight unit (see Headlight Bulb Replase• Remove
ment).
the rubber cover [A] and open the clamp [B].
• Remove
the headlight body bolts [C], then take off the
• Remove
body [D].
16-52 ELECTRICAL SYSTEM
Lighting System
City Light Bulb Replacement (EUR Models)
the headlight unit (see Headlight Bulb Replase• Remove
ment).
• Pull out the socket [A] together with the bulb.
the wedge-base type bulb [A], pull the bulb
• Remove
straight out of the socket [B].
CAUTION
Do not turn the bulb. Pull the bulb out to prevent
damage to the bulb. Do not use bulb rated for
greater wattage than the specified value.
• Replace the bulb with a new one.
Tail/Brake Light (LED) Removal
• Remove:
Rear Fender (see Rear Fender Removal in the Frame
chapter)
Bolts [A]
Cover [B]
out the tail/brake light lead connector [A] from the
• Take
cover [B] and disconnect it.
• Remove:
Screws [C] and Washers
• Remove:
Screws [A]
Tail/Brake Light Cover [B]
Tail/Brake Light [C]
Tail/Brake Light (LED) Installation
• Installation is basically the reverse of removal.
ELECTRICAL SYSTEM 16-53
Lighting System
Licence Plate Light Bulb Replacemrnt
• Remove:
Bolts [A]
Cover [B]
• Remove:
License Plate Light Lens Screws [A]
License Plate Light Lens [B]
and turn the bulb [A] counterclockwise [B] and re• Push
move it.
• Replace the bulb with a new one.
CAUTION
Do not use bulbs rated for greater wattage than the
specified value.
the new bulb [A] by aligning its pins [B] with the
• Insert
grooves [C] in the socket, and turn the bulb clockwise
about 15°.
• Install:
Licence Plate Light lens [A]
•
License Plate Light Lens Screws [B]
Tighten:
Torque - License Plate Light Lens Screws: 0.9 N·m (0.09
kgf·m, 8 in·lb)
• Install the removed parts.
16-54 ELECTRICAL SYSTEM
Lighting System
Headlight/Tail Light Circuit
1. Ignition Switch
2. Joint Connector 1
3. Frame Ground 1
4. Tail/Brake Lights (LED)
5. License Plate Light 12 V 5 W
6. Frame Ground 4
7. Frame Ground 5
8. Frame Ground 3
9. Headlight Relay
10. Relay Box
11. Taillight Fuse 10 A
12. Headlight Fuse 10 A
13. Engine Ground
14. Battery
15. Main Fuse 30 A
16. Alternator
17. Dimmer Switch
18. Meter Unit
19. High Beam Indicator Light (LED)
20. Running Position Lights 12 V 21/5 W (US, CA and CAL Models)
21. City Light 12 V 5 W (EUR Models)
22. Headlight
ELECTRICAL SYSTEM 16-55
Automatic Turn Signal Canceling System
Automobiles use a turn signal canceling system actuated by steering wheel turn. But, motorcycles
turn with a bank additionally, and so have a smaller steer angle. This makes difficult to adopt an
automobile type turn signal canceling system because of inaccurate operation in motorcycles. So,
motorcycles adopt time & distance counting system.
The canceling system consists of a battery, turn signal control relay, distance sensor, and turn signal
switch. When the turn signal switch is pushed onto the right or left, the turn signals start flashing
and the control relay starts counting off 8 seconds. At the end of this time, the control relay starts
calculating distance traveled using pulses from the distance sensor in the speedometer. The control
relay keeps working even after the turn signal switch was released and returned to the neutral position
by spring force. When the motorcycle has traveled an additional 65 meters (213 foots), the control
relay shuts off the current, turns off the turn signal lights, and resets itself.
If the turn signal canceling system does not function properly, first check on the turn signal light and switch in Second Step section in Lights and Switches Operation in the
Periodic Maintenance chapter.
inspect the following parts.
• Next,
Turn Signal Control Relay
Distance Sensor (in Meter Unit) System
Turn Signal Control Relay Inspection
CAUTION
Never drop the turn signal control relay, especially
on a hard surface. Such a shock to the unit can
damage it.
• Remove:
Battery Case Cover (see Battery Removal)
Turn Signal Control Relay [A]
one 12 V battery and turn signal lights as indi• Connect
cated in the figure, and count how many times the lights
flash for one minute.
Turn Signal Control Relay Connector [A]
Turn Signal Lights [B]
12 V Battery [C]
If the lights do not flash as specified, replace the turn signal control relay.
If the lights flash as specified, inspect the distance sensor
system (see Distance Sensor System Inspection).
Testing Turn Signal Control Relay Inspection
Load
Wattage (W)
Flashing Times
(c/m*)
1**
21 ~ 23
140 ~ 250
2
42 ~ 46
75 ~ 95
The Number of
Turn Signal Lights
(*): Cycle(s) per minute
(**): Corresponds to “one light burned out”
16-56 ELECTRICAL SYSTEM
Automatic Turn Signal Canceling System
Distance Sensor System Inspection
• Remove:
Battery Case Cover (see Battery Removal)
Turn Signal Control Relay
○Do not disconnect the connector.
the jack to lift the rear wheel (see Rear Wheel Re• Use
moval in the Wheel/Tires chapter).
Special Tool - Jack: 57001-1238
the hand tester [A] to the DC 25 V range and connect
• Set
it to the LB lead terminal [B] and battery (–) terminal [C]
as shown.
Connections
Hand Tester (+) → LB Lead Terminal
Hand Tester (–) → Battery (–) Terminal
the rear wheel slowly to see that the tester’s pointer
• Turn
fluctuates repeated by reading 0.5 V and 12 V.
If the tester’s pointer fluctuates, distance sensor is normal.
If the tester’s pointer does not fluctuate, inspect the following parts.
Speed Sensor (see Speed Sensor Output Voltage Inspection in the Fuel System (DFI) chapter)
Speed Signal Inspection (see Meter Unit Inspection)
Harness (see Wiring Inspection)
If the above parts are good, replace the turn signal control
relay.
Turn Signal Light Bulb Replacement
• Remove:
Turn Signal Light Lens Screw [A]
the lens [A] counterclockwise and remove the turn
• Turn
signal light assembly.
ELECTRICAL SYSTEM 16-57
Automatic Turn Signal Canceling System
• Remove:
Screw [A]
Socket Assembly [B]
and turn the bulb [A] counterclockwise [B] and re• Push
move it.
• Replace the bulb with a new one.
the new bulb [A] by aligning its upper and lower pins
• Insert
[B] with the upper and lower grooves [C] in the socket, and
turn the bulb clockwise about 15°.
the projection [A] of the socket into the groove in
• Insert
the lens assembly.
• Tighten the screw [B].
• Position the leads [A] inside the pins [B] as shown.
16-58 ELECTRICAL SYSTEM
Automatic Turn Signal Canceling System
the lens [A] by aligning projections [B] with the
• Insert
grooves [C] and turn the lens clockwise until it is stopped.
• Tighten the screw.
ELECTRICAL SYSTEM 16-59
Automatic Turn Signal Canceling System
Turn Signal Cancelling System Circuit
1. Ignition Switch
2. Joint Connector 1
3. Frame Ground 1
4. Hazard Button
5. Speed Sensor
6. Front Left Turn Signal Light 12 V 21 W
7. Front Right Turn Signal Light 12 V 21 W
8. Left Turn Signal Indicator Light (LED)
9. Right Turn Signal Indicator Light (LED)
10. Meter Unit
11. Turn Signal Switch
12. Starter Relay
13. Main Fuse 30 A
14. Turn Signal Control Relay Fuse 10 A
15. Battery
16. Engine Ground
17. Frame Ground 3
18. Turn Signal Control Relay
19. Frame Ground 5
20. Rear Left Turn Signal Light 12 V 21 W
21. Rear Right Turn Signal Light 12 V 21 W
16-60 ELECTRICAL SYSTEM
Air Switching Valve
Air Switching Valve Operation Test
to the Air Suction System Damage Inspection in the
• Refer
Periodic Maintenance chapter.
Air Switching Valve Unit Test
the air switching valve (see Air Switching Valve
• Remove
Removal in the Engine Top End chapter).
tester [A] to the × 1 Ω range and connect it
• toSetthetheairhand
switching valve terminals as shown in the figure.
Special Tool - Hand Tester: 57001-1394
Air Switching Valve Resistance
Standard: 18 ∼ 22 Ω at 20°C (68°F)
If the resistance reading is out of the specified value, replace it with a new one.
the 12 V battery [A] to the air switching valve
• Connect
terminals as shown.
the air to the inlet air duct [A], and make sure does
• Blow
not flow the blown air from the outlet air ducts [B].
the 12 V battery.
• Disconnect
the air to the inlet air duct [A] again, and make sure
• Blow
flow the blown air from the outlet air ducts [B].
If the air switching valve dose not operate as described,
replace it with a new one.
NOTE
○To check air flow through the air switching valve, just
blow through the air switching valve hose (inlet side)
[C].
ELECTRICAL SYSTEM 16-61
Air Switching Valve
Air Switching Valve Circuit
1. ECU
2. Air Switching Valve
3. Engine Stop Switch
4. Ignition Switch
5. Ignition Fuse 10 A
6. ECU Fuse 10 A
7. Main Fuse 30 A
8. Battery
9. Engine Ground
10. Relay Box
11. Fuel Pump Relay
12. Frame Ground 3
16-62 ELECTRICAL SYSTEM
Radiator Fan System
Fan System Circuit Inspection
• Remove:
Front Seat (see Front Seat Removal in the Frame chap•
•
ter)
Battery Case Cover (see Battery Removal)
Take out the relay box [A] from battery case.
Disconnect the 4-pin connector [B]
an auxiliary leads [A], connect G and BL/W termi• Using
nals in the relay box lead connector [B] of the harness
side.
NOTE
○The ignition switch need not be turned on.
If the fan does not rotate, inspect the following.
Main Fuse 30 A and Fan Fuse 10 A (see Fuse Inspection)
Fan Motor (see Fan Motor Inspection)
When the fan system is abnormal even if the above inspection is normal, check the following items.
Water Temperature Sensor (see Water Temperature
Sensor Inspection)
Fan Relay (see Relay Circuit Inspection)
Wiring (see Wiring Inspection)
If their parts are normality, replace the ECU (see ECU
Removal/Installation in the Fuel System (DFI) chapter).
Fan Motor Inspection
• Remove:
Right Footboard (see Footboard Removal in the Frame
•
chapter)
Disconnect:
Fan Motor Lead Connector [A]
an auxiliary lead, supply battery [A] power to the
• Using
fan motor.
Battery (+) → BK/BL Lead Terminal
Battery (–) → BK Lead Terminal
If the fan does not rotate, the fan motor is defective and
must be replaced.
ELECTRICAL SYSTEM 16-63
Radiator Fan System
Radiator Fan Circuit
1. Ignition Switch
2. Joint Connector 1
3. Frame Ground 1
4. Fan Motor
5. Water Temperature Sensor
6. ECU
7. Fan Relay
8. Relay Box
9. Ignition Fuse 10 A
10. Fan Fuse 10 A
11. Engine Ground
12. Battery
13. Main Fuse 30 A
14. Frame Ground 3
16-64 ELECTRICAL SYSTEM
Meter, Gauge
Meter Unit Removal
• Remove:
Key Cylinder Cover [A]
Bolts [B]
Meter Cover [C] with Meter Unit
the dust cover [A] and disconnect the meter unit con• Side
nector.
the screws [A] and separate the meter unit [B]
• Remove
and cover.
Meter Unit Installation
• Installation is basically the reverse of removal.
Meter Unit Disassembly
• Remove:
Meter Unit (see Meter Unit Removal)
Screws [A]
Meter Case [B]
ELECTRICAL SYSTEM 16-65
Meter, Gauge
• Separate the meter base assembly [A] and cover [B].
Meter Operation Inspection
NOTE
○Be sure the battery is fully charged.
○Be sure the ignition switch and meter unit switch are
normality (see Switch Inspection).
○Be sure the DFI/ETV system is normality.
○Be sure the wiring is normality (see Wiring Inspection).
the ignition switch to ON.
• Turn
the following items.
•○Check
The needle [A] of the speedometer momentarily points its
last reading and back to the minimum position.
○The all LCD segments appear for three seconds.
○The following indicator lights go on for three seconds.
Fuel Level Warning Indicator Light (LED) [B]
○The following indicator lights go on.
Cruise Control Indicator Light (LED) [C]
Cruise Control Set Indicator Light (LED) [D]
Neutral Indicator Light (LED) [E]
Warning Indicator Light (LED) [F]
The
○ neutral and oil pressure warning symbols appear.
If the meter function does not work, replace the meter
base. (see Meter Unit Disassembly).
16-66 ELECTRICAL SYSTEM
Meter, Gauge
pushing the meter unit switch [A] to MODE-A position
• By
[B] each time, check that the display [C] changes as follows.
○This display is ordinary indication.
pushing the meter unit switch [A] to MODE-B position
• By
[B] each time, check that the display [C] changes as follows.
If the display function does not work, replace the meter
base (see Meter Unit Disassembly).
the ordinary indication, push and hold the meter unit
• While
switch [A] more than two seconds.
ELECTRICAL SYSTEM 16-67
Meter, Gauge
that the display changes to the setting mode [A].
• Check
By
pushing
the meter unit switch each time, check that
• the display changes
as follows.
and hold the meter unit switch more than two sec• Push
onds.
○The display will change to the ordinary indication.
If the display function does not work, replace the meter
base (see Meter Unit Disassembly).
to the setting mode, and push the meter unit switch
• Set
[A] to MODE-A position [B].
hour display starts flashing.
•○The
The display changes to the setting mode of the clock.
pushing the meter unit switch to MODE-B position
• By
each time, check that the hour display changes.
the meter unit switch to MODE-A position, and
• Push
check that the hour display is decided and minute display
•
starts flashing.
By pushing the meter unit switch to MODE-B position
each time, check that the minute display changes.
16-68 ELECTRICAL SYSTEM
Meter, Gauge
the meter unit switch to MODE-A position,
• Push
check that the minute display is decided.
and
If the display function does not work, replace the meter
base (see Meter Unit Disassembly).
to the setting mode, and push the meter unit switch
• Set
[A].
that the display changes to the unit setting mode
• Check
[A].
pushing the meter unit switch [A] to MODE-B position
• By
[B] each time, check that the display changes as follows.
If the display function does not work, replace the meter
base (see Meter Unit Disassembly).
○To return to the ordinary indication, push and hold the
meter unit switch more than two seconds.
ELECTRICAL SYSTEM 16-69
Meter, Gauge
Can Communication Item Inspection
Cruise Control Indicator Light (LED) Inspection
Turn the ignition switch to ON.
Push the cruise control ON/OFF button [A].
•
•
that the cruise control indicator light (LED) [A] goes
• Check
on.
the cruise control ON/OFF button.
• Push
Check
• off. that the cruise control indicator light (LED) goes
If the cruise control indicator light (LED) does not function,
check the right handlebar switch housing (see Switch Inspection).
If the switch housing is good, replace the meter base
and/or ECU.
○The cruise control indicator light (LED) goes on at the
check of the cruise control cancel switches too (see
Cruise Control Cancel Switches Inspection).
Service Code Indication Inspection
○When the DFI/ETV system parts have trouble, the service
code appears (see Fuel System (DFI) chapter).
For example, disconnect the gear position switch lead
connector [A].
•
the ignition switch to ON.
• Turn
Check
that the “Error” [A], “25” and “FI” symbol [B] appear
• in the display.
16-70 ELECTRICAL SYSTEM
Meter, Gauge
and hold the meter unit switch [A] more than two
• Push
seconds.
that the display changes to the ordinary indication.
• Check
If the display function does not work, replace the meter
•
base and/or ECU.
Connect the gear position switch lead connector.
Water Temperature Warning Indication Inspection
Remove:
Front Seat (see Front Seat Removal in the Frame chapter)
Fuel Tank Mounting Bolts [A]
Bracket [B]
Lift up the rear end of the fuel tank, using a suitable wood
block.
•
•
the water temperature sensor connector [A].
• Disconnect
Connect
the
• harness. variable rheostat [B] to the connector of the
NOTE
○Note that the radiator fan rotates when connecting the
resistance of 120 Ω (115°C (239°F)).
the ignition switch to ON.
• Turn
Check
the warning indicator light (LED) [A] goes on,
• and thethat
water temperature warning symbol [B] appears
in the display when the variable rheostat is set the resistance of 90 Ω (120°C (248°F)).
If the display function does not work, replace the meter
base and/or ECU.
Idle Speed Indication Inspection
Refer to the Idle Speed Adjustment in the Periodic Maintenance chapter.
If the idle speed cannot adjust, check the following items.
Water Temperature Sensor (see Water Temperature
Sensor Inspection)
Right Handlebar Switch Housing (see Switch Inspection)
If the above items are good, replace the meter base
and/or ECU.
•
ELECTRICAL SYSTEM 16-71
Meter, Gauge
Gear Position Indication Inspection
Turn the ignition switch to ON in the neutral position.
The N mark [A] appears and the neutral indicator light [B]
(LED) goes on in the display.
Set the low gear position, check that the display changes
to 1 mark.
Using the center stand, raise the rear wheel off the
ground.
Start the engine, and change the gear position.
Check that the display corresponding to each gear position (1, 2, 3, 4, 5 or OD) appears.
If the display function does not work, check the gear position switch (see Gear Position Switch Inspection)
If the switch is good, replace the meter base and/or ECU.
•
•
•
•
•
•
Cruise Control Set Indicator Light (LED) Inspection
○The cruise control set indicator light (LED) [A] actually
goes on at the cruise control condition.
Cruise Control Main Conditions:
The cruise control ON/OFF button is ON position.
The vehicle speed is 48 ~ 137 km/h (30 ~ 85 mph).
The gear position is 3rd, 4th, 5th or OD (6th).
Any service code does not appear.
The cruise control switch (SET/–) pushed to ON.
If the cruise control set indicator light (LED) does not go on
at the cruise control condition, check the following items.
Right Handlebar Switch Housing (see Switch Inspection)
Speed Sensor (see Speed Sensor Inspection)
Gear Position Switch (see Gear Position Switch Inspection)
Cruise Control System Switches (see Cruise Control
System Switch Inspection)
If the above items are good, replace the meter base
and/or ECU.
Other Inspection
○The following items are displayed while running.
AVERAGE
RANGE
When the above item is faulty indication, check the following items.
Fuel Injectors (see Fuel Injectors section in the Fuel System (DFI) chapter)
Fuel Level Sensor (see Fuel Level Sensor Inspection)
If the above items are good, replace the meter base
and/or ECU.
•
16-72 ELECTRICAL SYSTEM
Meter, Gauge
Meter Unit Inspection
the meter unit (see Meter Unit Removal).
• Remove
[1] Right Turn Signal Indicator Light (LED) (+)
[2] High Beam Indicator Light (LED) (+)
[3] Unused
[4] Unused
[5] Unused
[6] CAN Communication Line (High)
[7] CAN Communication Line (Low)
[8] Unused
[9] Left Turn Signal Indicator Light (LED) (+)
[10] Fuel Level Sensor
[11] Battery (+)
[12] Ignition (+)
[13] Ground (–)
[14] Neutral Indicator Light (LED) (–)
[15] Meter Switch 1
[16] Meter Switch 2
[17] Meter Switch 3
[18] Oil Pressure Warning Indicator Light (LED) (–)
[19] Speed Sensor Signal
[20] Speed Sensor Supply Voltage (+)
CAUTION
Do not drop the meter unit. Place the meter unit so
that it faces upward. If the meter assembly is left upside down or sideways for a long time or dropped,
it will malfunction. Do not short each terminal.
Check 1: CAN Communication Line Resistance Inspection
Set the hand tester [A] to the ×1 Ω range and connect it
to the terminal [7] and [6] in the meter unit.
•
Special Tool - Hand Tester: 57001-1394
CAN Communication Line Resistance (at Meter Unit)
Standard: 122 ∼ 126 Ω
If the tester reading is not specified, replace the meter
base (see Meter Unit Disassembly).
Check 2: Meter Unit Power Supply Inspection
Using the auxiliary leads, the 12 V battery [A] to the meter
unit connector as follows.
○Connect the battery positive (+) terminal to the terminal
[11].
○Connect the battery negative (–) terminal to the terminal
[13].
Connect terminal [12] to the battery (+) terminal.
•
•
ELECTRICAL SYSTEM 16-73
Meter, Gauge
the following items.
•○Check
The needle [A] of the speedometer momentarily points its
last reading and back to the minimum position.
If the meter unit does not work, replace the meter base
(see Meter Unit Disassembly).
NOTE
○The flashings of the fuel level warning indicator light
(LED), fuel gauge, “FUEL” and “– – –” do not failure of
the meter unit.
○The lighting of the warning indicator light (LED) and
coolant temperature warning symbol do not failure of
the meter unit.
○Currently, for the meter is disconnected from the main
harness each flashing and lighting occur.
○The flashings of the fuel level warning indicator light
(LED), fuel gauge, “FUEL” and “– – –” are open of the
fuel level gauge.
○The lighting of the warning indicator light (LED) and
coolant temperature warning symbol are communication error to the ECU.
○Normally, each flashing and lighting disappears when
the meter unit is connected to main harness.
Check 3: Right Turn Signal Indicator Light (LED) Inspection
Connect the leads in the same circuit as Check 2.
Connect the terminal [1] to the battery (+) terminal.
•
•
that the right turn signal indicator light (LED) [A]
• Check
goes on.
If the indicator light does not go on, replace the meter
base (see Meter Unit Disassembly).
16-74 ELECTRICAL SYSTEM
Meter, Gauge
Check 4: High Beam Indicator Light (LED) Inspection
Connect the leads in the same circuit as Check 2.
Connect the terminal [2] to the battery (+) terminal.
•
•
that the high beam indicator light (LED) [A] goes
• Check
on.
If the indicator light does not go on, replace the meter
base (see Meter Unit Disassembly).
Check 5: Left Turn Signal Indicator Light (LED) Inspection
Connect the leads in the same circuit as Check 2.
Connect the terminal [9] to the battery (+) terminal.
•
•
that the left turn signal indicator light (LED) [A]
• Check
goes on.
If the indicator light does not go on, replace the meter
base (see Meter Unit Disassembly).
Check 6: Neutral Indicator Light (LED) Inspection
Connect the leads in the same circuit as Check 2.
Connect the terminal [14] to the battery (–) terminal.
•
•
ELECTRICAL SYSTEM 16-75
Meter, Gauge
that the neutral indicator light (LED) [A] goes on.
• Check
If the indicator light does not go on, replace the meter
base (see Meter Unit Disassembly).
Check 7: Oil Pressure Warning Symbol Inspection
Connect the leads in the same circuit as Check 2.
Connect the terminal [18] to the battery (–) terminal.
•
•
about 3 seconds, check that the oil pressure warning
• After
symbol [A] appears in the display.
If the oil pressure warning symbol does not appear, replace the meter base (see Meter Unit Disassembly).
Check 8: Fuel Gauge Inspection
Connect the leads in the same circuit as Check 2.
Connect the variable rheostat [A] to the terminal [10] and
the battery (–) terminal.
•
•
that the number of segments [A] matches the re• Check
sistance value of the variable rheostat.
○When the terminal [10] is connected, one segment in the
fuel level gauge should appear about every 5 seconds.
Variable Rheostat
Resistance (Ω)
Display Segments
50
5
100
3
160
1
If the display function does not work, replace the meter
base (see Meter Unit Disassembly).
16-76 ELECTRICAL SYSTEM
Meter, Gauge
Check 9: Fuel Level Warning Inspection
Connect the leads in the same circuit as Check 2.
Connect the variable rheostat [A] (about 213 Ω) to the
terminal [10] and the battery (–) terminal.
•
•
about 5 seconds, check that the fuel level warning
• After
indicator light (LED) [A] goes on, and the “FUEL” [B] and
one segment [C] flash in the display.
If the indicator light does not go on and/or the “FUEL” and
one segment do not flash, replace the meter base (see
Meter Unit Disassembly).
connecting the terminal [16] to the battery (+) terminal
• By
each time, check that the display changes as follows.
If the display function does not work, replace the meter
base (see Meter Unit Disassembly).
Check 10: Speedometer Inspection
Connect the leads in the same circuit as Check 2.
The speed equivalent to the input frequency is indicated in
the oscillator [A], if the square wave is input into terminal
[19].
○Indicates approximately 60 mph if the input frequency is
approximately 877 Hz.
○Indicates approximately 60 km/h if the input frequency is
approximately 548 Hz.
If the display function does not work, replace the meter
base (see Meter Unit Disassembly).
•
•
NOTE
○The input frequency of the oscillator adds the integrated
value of the odometer.
○The integrated value of the odometer cannot be reset.
ELECTRICAL SYSTEM 16-77
Meter, Gauge
Check 11: Odometer Inspection
Connect the leads in the same circuit as Check 10.
Set the odometer mode by connecting the terminal [16] to
the battery (+) terminal each time.
Raise the input frequency of the oscillator to see the result
of odometer inspection.
○Example: Indicates the increase of approximately 1 mile,
if the input frequency is approximately 877 Hz for one
minute.
○Example: Indicates the increase of approximately 1 km,
if the input frequency is approximately 548 Hz for one
minute.
If the value indicated by the odometer does not increase,
replace the meter base (see Meter Unit Disassembly).
•
•
•
NOTE
○The integrated value of the odometer cannot be reset.
Check 12: Trip A/B Meter Inspection
Connect the leads in the same circuit as Check 10.
Set the TRIP A or B meter mode by connecting the terminal [16] to the battery (+) terminal each time.
Raise the input frequency of the oscillator to see the result
of trip meter A/B inspection.
If the value indicated by the trip meter A/B do not increase,
replace the meter base (see Meter Unit Disassembly).
Connect the terminal [16] to the battery (+) terminal more
than two seconds and check that each TRIP meter resets
to 0.0.
If the display function does not change, replace the meter
base (see Meter Unit Disassembly).
•
•
•
•
NOTE
○The integrated value of the odometer cannot be reset.
16-78 ELECTRICAL SYSTEM
Meter, Gauge
Meter Unit Circuit
1. Ignition Switch
2. Meter Unit Switch
3. Water Temperature Sensor
4. Gear Position Switch
5. Speed Sensor
6. ECU
7. Turn Signal Control Relay
8. Frame Ground 3
9. Ignition Fuse 10 A
10. Cruise Control Fuse 5 A
11. ECU Fuse 10 A
12. Engine Ground
13. Battery
14. Main Fuse 30 A
15. Starter Relay
16. Crankshaft Sensor
17. Oil Pressure Switch
18. Fuel Level Sensor
19. to Turn Signal Switch
20. to Dimmer Switch
21. Meter Unit
22. Left Turn Signal Indicator Light (LED)
23. Right Turn Signal Indicator Light (LED)
24. Neutral Indicator Light (LED)
25. High Beam Indicator Light (LED)
26. Warning Indicator Light (LED)
27. Fuel Level Warning Indicator Light (LED)
28. Illumination Light (LED)
29. Cruise Control Indicator Light (LED)
30. Cruise Control Set Indicator Light (LED)
31. Speedometer
ELECTRICAL SYSTEM 16-79
Cruise Control System Switches
Cruise Control System Switch Inspection
NOTE
○Refer to the Fuel System (DFI) chapter for the information of the cruise control system parts.
○The inspection of cruise control system switches can
check by the following the cancel switch inspection
mode and the operating of each switch.
Cruise Control System Switches
Number
Name
1
Cruise Control Cancel
Switch (Throttle) [A]
2
Cruise Control Cancel
Switch (Front [B]/Rear
[C] Brake)
3
Place
Throttle Body
Right Handlebar
Switch Housing and
Front Brake Light Switch Brake Pedal
[D] or Rear Brake Light
Switch [E]
4
Cruise Control Cancel
Switch (Clutch) [F]
Left Handlebar Switch
Housing
5
Neutral Switch [G]
Gear Position Switch
6
Cruise Control Switch
(SET/-) [H]
Right Handlebar
Switch Housing
7
Cruise Control Switch
(RES/+) [I]
Right Handlebar
Switch Housing
NOTE
○The number that appears in the cancel switch diagnostic mode does not disappear until the diagnostic mode
is finished.
16-80 ELECTRICAL SYSTEM
Cruise Control System Switches
the transmission to 1st gear.
• Shift
While
pushing in meter switch [A], turn the ignition switch
• [B] to ON.
○The meter display will enter the cancel switch diagnostic
mode [A].
○“CHEC” [B] will appear on the display.
If a number [A] is flashed, inspect the switch that matches
the number according to the above table (see Switch Inspection).
• Close the throttle [A] to the stop.
number 1 [A] will appear and the “CRUISE” indicator
• The
light (LED) will come ON.
returning the throttle to the stop, the indicator light
• While
(LED) will go OFF.
If number 1 does not appear, inspect the cruise control
cancel switch (throttle) (see Switch Inspection).
If the switch is good, check the throttle cable condition
(see Cable Installation in the Fuel System (DFI) chapter).
ELECTRICAL SYSTEM 16-81
Cruise Control System Switches
in the front brake lever.
• Pull
The
number
[A] and 3 [B] will appear and the “CRUISE”
• indicator light2 (LED)
will come ON.
releasing the brake lever, the indicator light (LED)
• While
will go OFF.
If number 2 does not appear, inspect the cruise control
cancel switch (front brake) (see Switch Inspection).
If number 3 does not appear, inspect the front brake light
switch (see Switch Inspection).
the ignition switch to OFF and reset the meter to the
• Turn
cancel switch diagnostic mode.
the brake pedal.
• Depress
number 2 [A] and 3 [B] will appear and the “CRUISE”
• The
indicator light (LED) will come ON.
releasing the brake pedal, the indicator light (LED)
• While
will go OFF.
If number 2 does not appear, inspect the cruise control
cancel switch (rear brake) (see Switch Inspection).
If number 3 does not appear, inspect the rear brake light
switch (see Switch Inspection).
in the clutch lever.
• Pull
The
4 [A] will appear and the “CRUISE” indicator
• light number
(LED) will come ON.
releasing the clutch lever, the indicator light (LED)
• While
will go OFF.
If number 4 does not appear, inspect the cruise control
cancel switch (clutch) (see Switch Inspection).
the transmission to the neutral position.
• Shift
The
number
will appear and the “CRUISE” indicator
• light (LED) will5 [A]come
ON.
While
shifting
to
1st
gear,
the indicator light (LED) will go
• OFF.
•
If number 5 does not appear, inspect the gear position
switch (see Gear Position Switch Inspection).
Shift the transmission to 1st gear.
16-82 ELECTRICAL SYSTEM
Cruise Control System Switches
• Push the cruise control switch to the “SET/-” position [A].
number 6 [A] will appear and the “CRUISE” indicator
• The
light (LED) will come ON.
returning the switch to its original position, the indi• While
cator light (LED) will go OFF.
If number 6 does not appear, inspect the cruise control
switch (see Switch Inspection).
• Push the cruise control switch to the “RES/+” position [A].
number 7 [A] will appear and the “CRUISE” indicator
• The
light (LED) will come ON.
returning the switch to its original position, the indi• While
cator light (LED) will go OFF.
If number 7 does not appear, inspect the cruise control
switch (see Switch Inspection).
exit the cancel switch diagnostic mode:
•○To
Push the meter switch IN for more than 2 seconds.
○Operate the motorcycle above than 3.1 mph (5 km/h).
○Or when the ECU does not receive a signal from the cancel switches for 10 minutes while in the cancel switch diagnostic mode.
ELECTRICAL SYSTEM 16-83
Cruise Control System Switches
Cruise Control System Switch Circuit
1. Right Handlebar Switch Housing
2. Cruise Control Cancel Switch (Front Brake)
3. Front Brake Light Switch
4. Cruise Control Switch (RES/+)
5. Cruise Control Switch (SET/–)
6. Cruise Control ON/OFF Button
7. Meter Unit Switch
8. Cruise Control Cancel Switch (Rear Brake)
9. Rear Brake Light Switch
10. Cruise Control Cancel Switch (Throttle)
11. Gear Position Switch
12. ECU
13. Ignition Switch
14. Meter Unit
15. Cruise Control Indicator Light (LED)
16. Cruise Control Set Indicator Light (LED)
17. Left Handlebar Switch Housing
18. Cruise Control Cancel Switch (Clutch)
19. Main Fuse 30 A
20. Battery
21. Engine Ground
22. Taillight Fuse 10 A
23. Cruise Control Fuse 5 A
16-84 ELECTRICAL SYSTEM
Switch and Sensors
Fuel Level Sensor Inspection
• Remove:
Fuel Pump (see Fuel Pump Removal in the Fuel System
•
(DFI) chapter)
Check that the float moves up and down smoothly without
binding. It should go down under its own weight.
If the float does not move smoothly, replace the fuel pump.
Float in Full Position [A]
Float in Empty Position [B]
the hand tester [A], measure the resistance across
• Using
the terminals in the fuel level sensor lead connector [B].
Black/White [C]
Red/Black [D]
Special Tool - Hand Tester: 57001-1394
If the tester readings are not as specified, replace the fuel
pump.
Fuel Level Sensor Resistance
Standard: Full position [E]: 9 ∼ 11 Ω
Empty position: 213 ∼ 219 Ω
Water Temperature Sensor Inspection
• Remove:
Water Temperature
•
•
Sensor (see Water Temperature
Sensor Removal in the Fuel System (DFI) chapter)
Suspend the sensor [A] in a container of machine oil so
that the heat-sensitive portion and threaded portion are
submerged.
Suspend an accurate thermometer [B] with heat-sensitive
portions [C] located in almost the same depth.
NOTE
○The sensor and thermometer must not touch the container side or bottom.
the container over a source of heat and gradually
• Place
raise the temperature of the oil while stirring the oil gently
for even temperature.
Using the hand tester, measure the internal resistance of
the sensor across the terminal and the body at the temperatures shown in the table.
If the measurement is out of the range, replace the sensor.
Water Temperature Sensor Resistance
•
Temperature
Resistance (kΩ)
−20°C (−4°F)
*18.80 ±2.37
0°C (32°F)
*(about 6.544)
40°C (104°F)
1.136 ±0.095
100°C (212°F)
0.1553 ±0.0070
*: Reference Information
ELECTRICAL SYSTEM 16-85
Switch and Sensors
Speed Sensor Removal
• Remove:
Speed Sensor Lead Connector [A]
Speed Sensor Mounting Bolt [B]
Speed Sensor [C]
Speed Sensor Installation
grease to the O-ring [A] on the speed sensor.
• Apply
Fit
the
sensor into the crankcase surely.
• Apply aspeed
non-permanent
locking agent to the threads of
• the speed sensor mounting
bolt.
Tighten:
•
Torque - Speed Sensor Mounting Bolt: 9.8 N·m (1.0 kgf·m,
87 in·lb)
Speed Sensor Inspection
to the speed sensor Output Voltage Inspection in
• Refer
the Fuel System (DFI) chapter.
Oxygen Sensor Removal (Equipped Models)
• Remove:
Right Side Covers (see Side Covers Removal in the
Frame chapter)
Oxygen Sensor Lead Connector [A] (disconnect)
Oxygen Sensor [B]
CAUTION
Do not pull strongly, twist, or bend the oxygen sensor lead. This may cause the wiring open.
Oxygen Sensor Installation (Equipped Models)
CAUTION
Never drop the oxygen sensor [A], especially on a
hard surface. Such a shock to the unit can damage
it. Do not touch the sensing part [B] to prevent oil
contact. Oil contamination from hands can reduce
sensor performance.
Do not pull strongly, twist, or bend the oxygen sensor lead. This may cause the wiring open.
• Tighten:
Torque - Oxygen Sensor: 25 N·m (2.5 kgf·m, 18 ft·lb)
the oxygen sensor lead connector to the oxygen
• Connect
sensor.
Oxygen Sensor Inspection (Equipped Models)
to the Oxygen Sensor Inspection in the Fuel System
• Refer
(DFI) chapter.
16-86 ELECTRICAL SYSTEM
Switch and Sensors
Oxygen Sensor Heater Inspection (Equipped
Models)
to the Oxygen Sensor Heater Inspection in the Fuel
• Refer
System (DFI) chapter.
Gear Position Switch Removal
• Remove:
External
Shift Mechanism Cover (see External Shift
Mechanism Removal in the Crankshaft/Transmission
chapter)
Gear Position Switch Lead Holding Plate Bolt [A]
Gear Position Switch Lead Holding Plate [B]
Gear Position Switch Bolts [C]
Gear Position Switch [D]
Gear Position Switch Installation
the gear position switch [A].
• Install
a non-permanent locking agent to the threads of
• Apply
the gear position switch bolts [B].
• Tighten:
Torque - Gear Position Switch Bolts: 3.9 N·m (0.40 kgf·m,
35 in·lb)
silicone sealant to the circumference of the gear
• Apply
position switch lead grommet [C], and fit the grommet into
the notch of the cover securely.
Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004
the gear position switch lead with the holding
• Secure
plate [D], and apply a non-permanent locking agent to
the thread of the gear position switch lead holding plate
bolt [E] and tighten it.
Torque - Gear Position Switch Lead Holding Plate Bolt: 4.9
N·m (0.50 kgf·m, 43 in·lb)
• Install the removed parts (see appropriate chapters).
Gear Position Switch Inspection
NOTE
○Be sure the transmission and external shift mechanism
are good condition.
• Disconnect the gear position switch lead connector [A].
ELECTRICAL SYSTEM 16-87
Switch and Sensors
Set the hand tester [A] to the × 1 kΩ or × 100 Ω range and
• connect
it to the terminals in the gear position switch lead
connector [B] and ground.
Special Tool - Hand Tester: 57001-1394
changing the gear position from lower gear to
• When
higher gear, raise the rear wheel off the ground with the
stand and rotate the rear wheel by hand.
[C] Internal Circuit
[1] Green Lead
[2] Blue Lead
[3] Black Lead
Gear Position Switch Resistance
(Unit: kΩ)
Connections
Gear
[1] - Ground
[2] - Ground
[3] - Ground
Neutral
About 0
–
–
1st
–
3.00 ~ 3.32
11.64 ~ 12.87
2nd
–
1.71 ~ 1.89
10.35 ~ 11.44
3rd
–
1.07 ~ 1.19
9.71 ~ 10.74
4th
–
0.695 ~ 0.769 9.33 ~ 10.31
5th
–
0.430 ~ 0.476 9.07 ~ 10.02
6th
–
0.248 ~ 0.274
Position
8.88 ~ 9.82
If the tester reading is not as specified, replace the gear
position switch with a new one.
Front Brake Light Switch Inspection
to the Brake Light Switch Operation in the Periodic
• Refer
Maintenance chapter.
Rear Brake Light Switch Check/Adjustment
to the Brake Light Switch Operation in the Periodic
• Refer
Maintenance chapter.
16-88 ELECTRICAL SYSTEM
Switch and Sensors
Switch Inspection
a hand tester, check to see that only the con• Using
nections shown in the table have continuity (about zero
ohms).
Special Tool - Hand Tester: 57001-1394
○For the handlebar switches and the ignition switch, refer
to the tables in the Wiring Diagram.
If the switch has an open or short, repair it or replace it
with a new one.
Rear Brake Light Switch Connections
Sidestand Switch Connections
Cruise Control Cancel Switch (Rear Brake) Connections
Cruise Control Cancel Switch (Throttle) Connections
Oil Pressure Switch Connections*
*: Engine lubrication system is in good condition.
ELECTRICAL SYSTEM 16-89
Relay Box
Relay Box Removal
• Remove:
Front Seat (see Front Seat Removal in the Frame chapter)
Battery Case Cover (see Battery Removal)
ECU Assembly [A] (with Bracket)
the connectors [A].
• Disconnect
Remove:
• Relay Box [B]
NOTE
○The relay box has relays and diodes.
The relays and
diodes can not be removed.
Relay Box Installation
the connector and refer to the ECU Installation
• Connect
in the Fuel System (DFI) chapter.
Relay Circuit Inspection
the relay box (see Relay Box Removal).
• Remove
Check
conductivity
of the following numbered terminals
• by connecting the hand
tester and one 12 V battery to the
relay box as shown in the figure (see Relay Box Internal
Circuit).
Special Tool - Hand Tester: 57001-1394
If the tester does not read as specified, replace the relay
box.
16-90 ELECTRICAL SYSTEM
Relay Box
Relay Circuit Inspection (with the battery disconnected)
Tester Connection Tester Reading (Ω)
Headlight Circuit
Relay
ECU Main Relay**
Fuel Pump Relay
Starter Circuit Relay
Fan Relay
1-3
∞
6-7
∞
4-5
Not ∞*
7-8
∞
9-10
Not ∞*
11-16
∞
11-12
∞
17-20
∞
18-19
Not ∞*
*: The actual reading varies with the hand tester used.
**: In this motorcycle, the ECU main relay is not used.
Relay Circuit Inspection (with the battery connected)
Battery
Connection
(+) (–)
Tester
Connection
Tester
Reading (Ω)
2-11
1-3
0
4-5
7-6
0
Fuel Pump
Relay
9-10
7-8
0
Fan Relay
18-19
17-20
0
ECU Main
Relay
Battery
Connection
(+) (–)
Starter Circuit
Relay
Tester Connection
Tester
DC 25 V Range
Reading (V)
(+) (–)
16-12
11-12
Battery
Voltage
(+): Apply positive lead.
(–): Apply negative lead.
Diode Circuit Inspection
the relay box (see Relay Box Removal).
• Remove
conductivity of the following pairs of terminals (see
• Check
Relay Box Internal Circuit).
Diode Circuit Inspection
Tester Connection
1-11, 2-11, 12-13, 12-15, 12-16, 13-14,
13-15
The resistance should be low in one direction and more
than ten times as much in the other direction. If any diode
shows low or high in both directions, the diode is defective
and the relay box must be replaced.
NOTE
○The actual meter reading varies with the meter or tester
used and the individual diodes, but generally speaking,
the lower reading should be from zero to one half the
scale.
ELECTRICAL SYSTEM 16-91
Relay Box
Relay Box Internal Circuit
A. Headlight Circuit Relay
B. ECU Main Relay (Unused)
C. Fuel Pump Relay
D. Starter Circuit Relay
E. Fan Relay
Accessory Relay Inspection
• Remove:
Front Seat (see Front Seat Removal in the Frame chapter)
Accessory Relay [A]
○The acceory relay is identical to the ETV actuator relay
[B].
Refer to the ETV Actuator Relay Inspection in the Fuel
System (DFI) chapter for the accessory relay inspection.
•
16-92 ELECTRICAL SYSTEM
Fuse
30 A Main Fuse Removal
• Remove:
Front Seat (see Front Seat Removal in the Frame chap•
•
ter)
Battery Case Cover (see Battery Removal)
Disconnect:
Starter Relay Connector [A]
Pull out the 30 A main fuse [B] from the starter relay with
needle nose pliers.
Fuse Box Fuse Removal
the front seat (see Front Seat Removal in the
• Remove
Frame chapter)
Fuse Box 1 [A]
Fuse Box 2 [B]
• Push the hook [A] to lift up the lid [B].
the fuses [A] straight out of the fuse box with needle
• Pull
nose pliers.
Fuse Installation
•
If a fuse fails during operation, inspect the electrical system to determine the cause, and then replace it with a
new fuse of proper amperage.
Install the fuse box fuses on the original position as specified on the lid.
ELECTRICAL SYSTEM 16-93
Fuse
Fuse Inspection
the fuse.
• Remove
Inspect
the
element.
• If it is blownfuse
out, replace the fuse.
Before replacing a
blown fuse, always check the amperage in the affected
circuit. If the amperage is equal to or greater than the
fuse rating, check the wiring and related components for
a short circuit.
Housing [A]
Fuse Element [B]
Terminals [C]
Blown Element [D]
NOTE
○If the engine is operated under the condition which the
battery needs refreshing charge, a main fuse may blow
out due to a mass current flows to the battery.
CAUTION
When replacing a fuse, be sure the new fuse
matches the specified fuse rating for that circuit.
Installation of a fuse with a higher rating may cause
damage to wiring and components.
APPENDIX 17-1
Appendix
Table of Contents
Cable, Wire, and Hose Routing ..............................................................................................
Troubleshooting Guide ...........................................................................................................
17-2
17-38
17
17-2 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-3
Cable, Wire, and Hose Routing
1. Front Left Turn Signal Light Lead Connector (Black)
2. Front Right Turn Signal Light Lead Connector (Gray)
3. Right Switch Housing Lead Connector (White)
4. Left Switch Housing Lead Connector (Black)
5. Clamp (Clamp the front left and right turn signal light leads and left and right switch housing
leads.)
6. Headlight
7. Main Harness
8. Cover the front left and right turn signal light lead connectors and left and right switch housing
lead connectors with the cover of the main harness attachment after the lead connectors are
connected.
9. Run the front left and right turn signal light leads inside the headlight bracket and install them
into the headlight housing.
17-4 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-5
Cable, Wire, and Hose Routing
1. Clamps (Clamp the left or right switch housing leads.)
2. Clamp (Clamp the right switch housing lead and front brake hose.)
3. Clamp (Clamp the left switch housing lead and clutch hose.)
4. Install the clutch hose in the direction as shown.
5. Clutch Hose
6. Left Switch Housing Lead
7. Run the front brake hose, right switch housing lead, and throttle cables between the right side
of the bracket and steering stem head, and run the left switch housing lead and clutch hose
between the left side of the bracket and the steering stem.
8. Right Switch Housing Lead Connector
9. Brake Hose
10. Throttle Cables
11. Install the brake hose in the direction as shown.
12. Run the meter lead between the front dent of the fuel tank and the left side of the ignition switch
(Put in the slack mater lead between the ignition switch rearward and fuel tank.).
13. Run the throttle cables inside of the clutch hose and switch housing lead, and run the cables
forward of the head pipe and to the right side of the frame.
14. Insert the ignition switch lead connector (main harness side) to the welding clamp of the frame
from the rear side of the frame as shown.
15. Insert the clamp of the main harness to the welding clamp of the frame.
16. Connect the ignition coil lead connectors so that the red/green leads face outside of the frame
(front and rear).
17. Tighten the ignition coil mounting bolt together with the engine ground terminal.
18. Run the main harness for air switching valve between the front and rear ignition coils.
19. Harness to the downtube.
20. Clamp (Clamp the harness.)
21. Projection
22. Connect the horn connectors so that the projection of the connector faces rear side of the frame
as shown.
23. Clamp (Clamp the main harness, clutch hose, and throttle cables.)
24. Main Harness
17-6 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-7
Cable, Wire, and Hose Routing
1. Clamp the main harness with the thermostat housing bracket.
2. Run the main harness for the fuse box to the right side of the frame.
3. Clamp the left side and right side main harness, and reserve tank hose (at left side) with the
damper.
4. Run the main harness for ECU to the left side of the frame.
5. Connect the fuel pump lead connector, and put it under the fuel hose.
6. Fuel Hose
7. Main Harness
8. Reserve Tank Hose
9. Clamp (Clamp the ignition coil leads and throttle cables.)
17-8 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-9
Cable, Wire, and Hose Routing
1. Ignition Coil #1
2. Ignition Coil #2
3. Clamp (Clamp the ignition coil leads and throttle cables at the lines and tapes portions as
shown.)
4. Tapes
5. Ignition Coil #1 Lead
6. Ignition Coil #2 Lead
7. Throttle Cable (Accelerator)
8. Throttle Cable (Decelerator)
9. White Lines
17-10 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-11
Cable, Wire, and Hose Routing
1. Clamps (Clamp the clutch hose with the welding clamps of the frame. Cover the white paint
mark of the clutch hose with the upper clamp.)
2. Clamp (Clamp the main harness.)
3. Clamp (Align the separate portion of the main harness with the top of the engine bracket, and
clamp the main harness at the top of the engine bracket together with the frame pipe.)
4. Run the main harness inside of the engine mounting bracket, and run the clutch hose outside
of the engine mounting bracket.
5. Insert the sidestand switch lead connector to the clutch hose holding bracket.
6. Run the sidestand switch lead inside of the left front footboard bracket.
7. Clamp (Clamp the main harness in the direction as shown. Do not damage the main harness
when installing the radiator.)
8. Viewed from A-A
9. Radiator
10. Viewed from front
11. Run the regulator/rectifier leads under the water pipe. Regulator/rectifier leads do not enter
between the downtube and water hose.
12. Regulator/Rectifier
13. Front Cross Pipe
14. Insert the clamp of the harness to the hole of the front cross pipe bracket from upside.
15. Insert the fan motor lead connector (3-pin, black) , rear brake light switch lead connector (2-pin,
black) , and cruise control cancel switch (rear brake) lead connector (2-pin, green) to the bracket
in order from the top.
16. Clamps (Clamp the main harness.)
17. Alternator Lead Connectors (Each lead connector can be connected to both connectors.)
18. Fan Motor Lead Connector
19. Rear Brake Light Switch Lead Connector
20. Cruise Control Cancel Switch (Rear Brake) Lead Connector
21. Clamp (Clamp the rear brake light switch lead.)
22. Run the rear brake light switch lead and cruise control cancel switch (rear brake) lead over the
brake hose.
23. Crankshaft Sensor and Oil Pressure Switch Lead Connector
24. Clamp (Clamp the crankshaft sensor and alternator leads.)
25. Alternator Lead
26. Crankshaft Sensor Lead
17-12 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-13
Cable, Wire, and Hose Routing
1. Run the white hose (vacuum) inside of the inlet air pressure sensor vacuum hose, and over the
water hose, and rear side of the frame as shown (CAL and SEA models).
2. Clamp (Clamp the harness for throttle position sensors and accelerator position sensors, and
insert the clamp into the bracket hole.)
3. Inlet Air Pressure Sensor Connector
4. Insert the cruise control cancel switch (throttle) lead connector to the bracket.
5. Vacuum Hose of the Inlet Air Pressure Sensor
6. Water Temperature Sensor Lead Connector
7. Throttle Position Sensor Lead Connector
8. When installing the air cleaner housing, hold the throttle position sensor lead backward so as
not to pinch the lead with the air cleaner housing.
9. Run the accelerator position sensor lead to inside of the engine fins and throttle body after
connecting the connector, so as not to pinch the lead with the air cleaner housing and engine
fins.
10. Accelerator Position Sensor Lead Connector
11. Take care not to pinch the accelerator position sensor lead with the air cleaner connection ducts.
12. Fuel Injector Lead Connector (#1, Gray)
13. Inlet Air Temperature Sensor Lead Connector
14. Fuel Injector Lead Connector (#2, Brown)
15. White Hose (Vacuum, CAL and SEA Models)
16. Green Hose (Purge, CAL and SEA Models)
17. Reserve Tank Hose
18. Clamp the white hose (Vacuum) and green hose (Purge) together with the main harness with
the damper (CAL and SEA Models).
19. Run the harness for fuel injectors to inside of the water hose and reserve tank hose, and outside
of the green hose (purge) and white hose (vacuum). Run the reserve tank hose to inside of the
water hose and under the green hose (purge) and white hose (vacuum).
20. Run the harness to between the thermostat housing bracket and thermostat housing.
21. Run the throttle cables under the inlet manifold.
17-14 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-15
Cable, Wire, and Hose Routing
1. Turn Signal Control Relay
2. Assemble the damper of the ECU and Relay Box to the bracket, and insert the bracket hooks
to the grooves of the battery case.
3. Kawasaki Diagnostic System Connector
4. Clamp (Insert the clamp to the front left side hole of the battery case, and clamp the speed
sensor lead and gear position switch lead.)
5. Gear Position Switch Lead Connector
6. Vehicle-down Sensor
7. Connect the battery negative (–) lead connector (black), and put it into the right side of the starter
relay.
8. Starter Relay
9. Battery Negative (–) Cable
10. Insert the oxygen sensor lead connector to the welding bracket of the frame (Other than US and
CA models).
11. Battery Positive (+) Cable
12. Oxygen Sensor Lead Connector
17-16 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-17
Cable, Wire, and Hose Routing
1. Insert the accessory relay and ETV motor relay to the projections of the battery case so that the
connectors of the relays face downward. The positions of the two relays can be switched.
2. Starter Relay
3. Stick the damper on the battery case as shown.
4. Relay Box
5. ECU
6. Kawasaki Diagnostic System Connector
7. Install the turn signal control relay so that its connector faces downward.
8. Fuse Box 2
9. Vehicle-down Sensor
10. Fuse Box 1
11. Front
12. Battery
13. Tighten the frame ground terminals together from the left side and right side main harness.
14. Insert the rear sub harness connector to the projection of the tool case.
15. Run the reserve tank hose through into the left hole of the frame bracket.
16. Run the breather hose through into the right hole of the frame bracket.
17. Run the breather hose and reserve tank hose through from inside of the main harness to the
lower side, at the front of the front clamps.
18. Insert the clamps of the main harness to the holes of the frame pipe.
19. Run each harness under the battery cover, and do not run them over the frame pipe.
17-18 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-19
Cable, Wire, and Hose Routing
1. Clamp (Clamp the reserve tank overflow hose.)
2. Install the seat bracket so that the wire faces front side as shown.
3. Clamp (Clamp the red painted portion of the seat lock cable.)
4. Clamp (Clamp the seat lock cable.)
5. Assemble the seat lock cable so that the protector side faces side cover.
6. Reserve Tank Hose
7. Reserve Tank Overflow Hose
17-20 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-21
Cable, Wire, and Hose Routing
1. Rear Sub Harness (for Rear Left and Right Turn Signal Lights, License Plate Light, and
Tail/Brake Light)
2. Put the tail/brake light lead into the grommet, and insert the grommet to the rear fender hole.
3. Connect the tail/brake light lead connector, rear left and right turn signal light lead connector, and
license plate light lead connector, and then insert them into the cover of the rear sub harness.
4. Rear Left and Right Turn Signal Light Leads and License Plate Light Lead
5. Cover
6. Run the rear sub harness to the groove of the cover.
7. Clamp the rear sub harness with the welding clamps of the rear fender.
8. Put the 6-pin connector into the grommet, and insert the grommet to the rear fender hole.
9. 6-pin Connector
17-22 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-23
Cable, Wire, and Hose Routing
1. Purge Hose (Green)
2. Vacuum Hose (White)
3. Inlet Air Pressure Sensor Bracket
4. Damper (Right)
5. Run the breather hose (blue) into the right side hole of the frame, and inside of the front harness
clamp, injector lead, cylinder head mounting bracket and inlet air pressure sensor bracket, and
run it to the front of the damper (right) and connect it to the fuel tank breather pipe. Run the
breather hose (blue) inside of the purge hose (green) and the vacuum hose (white). (CAL and
SEA Models)
6. Check Valve
7. Run the breather hose (blue) to backward of the upper cross pipe as shown, and forward of the
swingarm pivot cross pipe and rear brake hose clamp bracket, and backward of the lower cross
pipe and out of the rear right lower engine mounting bracket.
8. Run the all of the evaporative emission control system hoses to rear side of the speed sensor
lead and starter motor cable.
9. Clamp (Run the three evaporative emission control system hoses (except blue hose) into the
clamp and to hole of the battery case.)
10. Viewed from upper right
11. Viewed from right
12. Viewed from front
13. CAL and SEA Models
17-24 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-25
Cable, Wire, and Hose Routing
1. Clamps (Install the clamps so that the screw heads face each direction as shown.)
2. White Paint Mark (Install the radiator hose to the thermostat housing so that the white paint
mark on the hose faces upside.)
3. White Paint Marks (Install the water hoses to the cylinder heads so that the white paint marks
on the hoses face upside.)
4. Thermostat Housing
5. Run the water hose inside of the bracket.
6. Clamp (Install the clamp so that the knob faces left side.)
7. White Paint Mark (Install the radiator hose so that the white paint mark on the hose faces left
side.)
8. Clamp (Install the clamp so that the screw head faces left side.)
17-26 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-27
Cable, Wire, and Hose Routing
1. Radiator
2. Radiator Hoses
3. Thermostat Housing
4. Reserve Tank Hose
5. Reserve Tank Overflow Hose
6. Reserve Tank
7. Run the reserve tank overflow hose to between the frame bracket and rear fender cover as
shown.
8. Run the reserve tank overflow hose under the frame pipe as shown.
9. Clamps
10. Run the radiator fan lead to this portion.
11. Radiator Fan Lead
12. Bracket for Radiator Screen
13. Run the reserve tank hose as shown.
14. Insert the reserve tank overflow hose in the direction as shown.
15. Install the clamp so that the clamp screw faces downward.
16. Viewed form A
17. Within 90°
18. Front
17-28 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-29
Cable, Wire, and Hose Routing
1. Main Harness
2. Thermostat Housing
3. Run the reserve tank hose between the water hose and frame pipe as shown.
4. Run the reserve tank hose under the air switching valve hose as shown.
5. Fix the reserve tank hose together with main harness with the damper.
6. Right Side
7. Left Side
17-30 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-31
Cable, Wire, and Hose Routing
1. Front Brake Master Cylinder
2. Brake Hoses
3. Three-way Joint of Hose Assembly
4. Clamps (Hold the brake hoses.)
5. Front Brake Caliper
17-32 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-33
Cable, Wire, and Hose Routing
1. Rear Brake Reservoir tank
2. Rear Brake Master Cylinder
3. Clamps (Hold the brake hose.)
4. Swingarm
5. Brake Hose
6. Rear Brake Caliper
17-34 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-35
Cable, Wire, and Hose Routing
1. White Paint Marks (Insert the air switching valve hoses to the air switching valve so that the
white paint marks of the hoses face upside.)
2. Air Switching Valve
3. Air Switching Valve Hoses
4. Thermostat Housing
5. Red Paint Marks (Align the red paint marks with the fitting pipe as shown.)
6. Fitting
7. Green Tape
8. To the green tape hose of the canister
9. CAL and SEA Models
10. Damper
17-36 APPENDIX
Cable, Wire, and Hose Routing
CAL and SEA Models
APPENDIX 17-37
Cable, Wire, and Hose Routing
1. Main Harness
2. Curve Side
3. Run the reserve tank hose through into the left hole of the frame bracket as shown.
4. Run the blue hose (breather) through into the right hole of the frame bracket as shown.
5. Clamp (Clamp the hoses and insert the clamp to the frame.)
6. To Fuel Tank
7. Canister
8. Separator
9. Blue Hose (Breather)
10. White Hose (Vacuum)
11. Red Hose (Return)
12. Green Hose (Purge)
13. Blue Hose (Breather)
14. Insert the green hose (Purge) so that the hose contacts the plug.
15. Put the dampers on the canister bracket as shown.
16. Breather Check Valve
17. To the green tape hose fitting of the air switching valve
18. To the fitting of the throttle body hose (white)
17-38 APPENDIX
Troubleshooting Guide
NOTE
○Refer to the Fuel System (DFI) chapter for
most of DFI trouble shooting guide.
○This is not an exhaustive list, giving every
possible cause for each problem listed. It
is meant simply as a rough guide to assist
the troubleshooting for some of the more
common difficulties.
Engine Doesn’t Start, Starting
Difficulty:
Starter motor not rotating:
Ignition and engine stop switch not ON
Starter lockout switch or gear position
switch trouble
Starter motor trouble
Battery voltage low
Starter relay not contacting or operating
Starter button not contacting
Starter system wiring open or shorted
Ignition switch trouble
Engine stop switch trouble
Main 30 A or ignition fuse blown
Starter motor rotating but engine doesn’t
turn over:
Vehicle-down sensor (DFI) coming off
Immobilizer system trouble
Starter clutch trouble
Engine won’t turn over:
Valve seizure
Rocker arm seizure
Cylinder, piston seizure
Crankshaft seizure
Connecting rod small end seizure
Connecting rod big end seizure
Transmission gear or bearing seizure
Camshaft seizure
Balancer bearing seizure
No fuel flow:
No fuel in tank
Fuel pump trouble
Fuel tank air vent obstructed
Fuel filter clogged
Fuel line clogged
No spark; spark weak:
Vehicle-down sensor (DFI) coming off
Ignition switch not ON
Engine stop switch turned OFF
Clutch lever not pulled in or gear not in neutral
Battery voltage low
Spark plug dirty, broken, or gap maladjusted
Spark plug cap or high tension wiring trouble
Spark plug cap shorted or not in good contact
Spark plug incorrect
Ignition coil shorted or not in good contact
Ignition coil trouble
ECU trouble
Gear position, starter lockout, or side stand
switch trouble
Crankshaft sensor trouble
Ignition switch or engine stop switch
shorted
Starter system wiring shorted or open
Main 30 A or ignition fuse blown
Fuel/air mixture incorrect:
Air cleaner clogged, poorly sealed, or missing
Leak from oil filler cap, breather hose or air
cleaner drain cap.
Compression Low:
Spark plug loose
Cylinder head not sufficiently tightened
down
Cylinder, piston worn
Piston ring bad (worn, weak, broken, or
sticking)
Piston ring/groove clearance excessive
Cylinder head gasket damaged
Cylinder head warped
Valve spring broken or weak
Valve not seating properly (valve bent,
worn, or carbon accumulation on the
seating surface)
KACR sticks open (engine stalls when moving off)
HLA damaged (worn, seizure, or spring broken)
HLA oil passage clogged
Poor Running at Low Speed:
Spark weak:
Battery voltage low
Ignition coil trouble
Ignition coil shorted or not in good contact
Spark plug dirty, broken, or maladjusted
Spark plug cap or high tension wiring trouble
Spark plug cap shorted or not in good contact
Spark plug incorrect
ECU trouble
Crankshaft sensor trouble
Fuel/air mixture incorrect:
Air cleaner clogged, poorly sealed, or missing
Fuel tank air vent obstructed
Fuel pump trouble
Throttle body assy loose
Air cleaner housing loose
APPENDIX 17-39
Troubleshooting Guide
Compression low:
Spark plug loose
Cylinder head not sufficiently tightened
down
Cylinder, piston worn
Piston ring bad (worn, weak, broken, or
sticking)
Piston ring/groove clearance excessive
Cylinder head gasket damaged
Cylinder head warped
Valve spring broken or weak
Valve not seating properly (valve bent,
worn, or carbon accumulation on the
seating surface)
Camshaft cam worm
KACR weights open (engine stalls when
moving off)
HLA seizure
Run-on (dieseling):
Ignition switch trouble
Engine stop switch trouble
Fuel injector trouble
Loosen terminal of battery (–) cable or ECU
ground lead
Carbon accumulating on valve seating surface
Engine overheating
Other:
ECU trouble
Engine vacuum not synchronizing
Engine oil viscosity too high
Drive train trouble
Brake dragging
Clutch slipping
Engine overheating
Air suction valve trouble
Air switching valve trouble
Blowby gas system trouble
Poor Running or No Power at High
Speed:
Firing incorrect:
Spark plug dirty, broken, or maladjusted
Spark plug cap or high tension wiring trouble
Spark plug cap shorted or not in good contact
Spark plug incorrect
Ignition coil shorted or not in good contact
trouble
Ignition coil trouble
ECU trouble
Fuel/air mixture incorrect:
Air cleaner clogged, poorly sealed, or missing
Air cleaner housing loose
Water or foreign matter in fuel
Throttle body assy loose
Fuel to injector insufficient
Fuel tank air vent obstructed
Fuel line clogged
Fuel pump trouble
Compression low:
Spark plug loose
Cylinder head not sufficiently tightened
down
Cylinder, piston worn
Piston ring bad (worn, weak, broken, or
sticking)
Piston ring/groove clearance excessive
Cylinder head gasket damaged
Cylinder head warped
Valve spring broken or weak
Valve not seating properly (valve bent,
worn, or carbon accumulation on the
seating surface.)
KACR weights open (engine stalls when
moving off)
HLA seizure
Knocking:
Carbon built up in combustion chamber
Fuel poor quality or incorrect
Spark plug incorrect
ECU trouble
Miscellaneous:
Throttle valve won’t fully open
Brake dragging
Clutch slipping
Engine overheating
Engine oil level too high
Engine oil viscosity too high
Drive train trouble
Camshaft cam worm
Air suction valve trouble
Air switching valve trouble
Catalytic converter melt down due to muffler
overheating (KLEEN)
Overheating:
Firing incorrect:
Spark plug dirty, broken, or maladjusted
Spark plug incorrect
ECU trouble
Muffler overheating:
For KLEEN, do not run the engine even if
with only one cylinder misfiring or poor
running (Request the nearest service facility to correct it)
For KLEEN, do not push-start with a dead
battery (Connect another full-charged
battery with jumper cables, and start the
engine using the electric starter)
17-40 APPENDIX
Troubleshooting Guide
For KLEEN, do not start the engine under
misfire due to spark plug fouling or poor
connection of the stick coil
For KLEEN, do not coast the motorcycle
with the ignition switch off (Turn the ignition switch ON and run the engine)
ECU trouble
Fuel/air mixture incorrect:
Throttle body assy loose
Air cleaner housing loose
Air cleaner poorly sealed, or missing
Air cleaner clogged
Compression high:
Carbon built up in combustion chamber
KACR weights close
Engine load faulty:
Clutch slipping
Engine oil level too high
Engine oil viscosity too high
Drive train trouble
Brake dragging
Lubrication inadequate:
Engine oil level too low
Engine oil poor quality or incorrect
Water temperature gauge incorrect:
Water temperature gauge broken
Water temperature sensor broken
Coolant incorrect:
Coolant level too low
Coolant deteriorated
Wrong coolant mixed ratio
Cooling system component incorrect:
Radiator fin damaged
Radiator clogged
Thermostat trouble
Radiator cap trouble
Radiator fan relay trouble
Fan motor broken
Fan blade damaged
Water pump not turning
Water pump impeller damaged
Over Cooling:
Water temperature meter incorrect:
Water temperature meter broken
Water temperature sensor broken
Cooling system component incorrect:
Thermostat trouble
Clutch Operation Faulty:
Clutch slipping:
Friction plate worn or warped
Steel plate worn or warped
Clutch spring broken or weak
Clutch slave cylinder trouble
Clutch hub or housing unevenly worn
Clutch master cylinder trouble
Clutch not disengaging properly:
Clutch plate warped or too rough
Clutch spring compression uneven
Engine oil deteriorated
Engine oil viscosity too high
Engine oil level too high
Clutch housing frozen on drive shaft
Clutch hub nut loose
Clutch hub spline damaged
Clutch friction plate installed wrong
Clutch fluid leakage
Clutch fluid deteriorated
Clutch master cylinder primary or secondary cup damaged
Clutch master cylinder scratched inside
Air in the clutch fluid line
Gear Shifting Faulty:
Doesn’t go into gear; shift pedal doesn’t
return:
Clutch not disengaging
Shift fork bent or seized
Gear stuck on the shaft
Gear positioning lever binding
Shift return spring weak or broken
Shift return spring pin loose
Shift mechanism arm spring broken
Shift mechanism arm broken
Jumps out of gear:
Shift fork ear worn, bent
Gear groove worn
Gear dogs and/or dog holes worn
Shift drum groove worn
Gear positioning lever spring weak or broken
Shift fork guide pin worn
Drive shaft, output shaft, and/or gear
splines worn
Overshifts:
Gear positioning lever spring weak or broken
Shift mechanism arm return spring weak or
broken
Abnormal Engine Noise:
Knocking:
ECU trouble
Carbon built up in combustion chamber
Fuel poor quality or incorrect
Spark plug incorrect
Overheating
Piston slap:
Cylinder/piston clearance excessive
Cylinder, piston worn
Connecting rod bent
Piston pin, piston pin hole worn
APPENDIX 17-41
Troubleshooting Guide
Valve noise:
Engine not sufficiently warmed up after HLA
installation
HLA damaged (worn, seizure, or spring broken)
HLA aeration due to low oil level
Air in HLA
Metal chips or dust jammed in HLA
Valve spring broken or weak
Camshaft bearing worn
Other noise:
Connecting rod small end clearance excessive
Connecting rod big end clearance excessive
Piston ring/groove clearance excessive
Piston ring worn, broken, or stuck
Piston ring groove worn
Piston seizure, damage
Cylinder head gasket leaking
Exhaust pipe leaking at cylinder head connection
Crankshaft runout excessive
Engine mounting portions loose
Crankshaft bearing worn
Primary gear worn or chipped
Camshaft chain tensioner trouble
Camshaft chain, sprocket, guide worn
Air suction valve damaged
Air switching valve damaged
Alternator rotor loose
Catalytic converter melt down due to muffler
overheating (KLEEN)
Balancer gear worn or chipped
Balancer shaft position maladjusted
Balancer bearing worn
Balancer shaft coupling rubber damper
damaged
Abnormal Drive Train Noise:
Clutch noise:
Clutch damper weak or damaged
Clutch housing/friction plate clearance excessive
Clutch housing gear worn
Wrong installation of outside friction plate
Transmission noise:
Bearings worn
Transmission gear worn or chipped
Metal chips jammed in gear teeth
Engine oil insufficient
Drive line noise:
Drive belt adjusted improperly
Drive belt worn
Rear and/or engine pulley worn
Rear wheel misaligned
Abnormal Frame Noise:
Front fork noise:
Oil insufficient or too thin
Spring weak or broken
Rear shock absorber noise:
Shock absorber damaged
Disc brake noise:
Pad installed incorrectly
Pad surface glazed
Disc warped
Caliper trouble
Other noise:
Bracket, nut, bolt, etc.
not properly
mounted or tightened
Warning Indicator Light (Oil Pressure
Warning) Doesn’t Go OFF:
Engine oil pump damaged
Engine oil screen clogged
Engine oil filter clogged
Engine oil level too low
Engine oil viscosity too low
Camshaft bearing worn
Crankshaft bearing worn
Oil pressure switch damaged
Wiring faulty
Relief valve stuck open
O-ring at the oil passage in the crankcase
damaged
Exhaust Smokes Excessively:
White smoke:
Piston oil ring worn
Cylinder worn
Valve oil seal damaged
Valve guide worn
Engine oil level too high
Blowby gas system trouble
Black smoke:
Air cleaner clogged
Brown smoke:
Air cleaner housing holder loose
Air cleaner poorly sealed or missing
Handling and/or Stability
Unsatisfactory:
Handlebar hard to turn:
Cable routing incorrect
Hose routing incorrect
Wiring routing incorrect
Steering stem nut too tight
Steering stem bearing damaged
Steering stem bearing lubrication inadequate
Steering stem bent
Tire air pressure too low
17-42 APPENDIX
Troubleshooting Guide
Handlebar shakes or excessively vibrates:
Tire worn
Swingarm pivot bearing worn
Rim warped, or not balanced
Wheel bearing worn
Handlebar holder bolt loose
Steering stem nut loose
Front, rear axle runout excessive
Engine mounting portions loose
Handlebar pulls to one side:
Frame bent
Wheel misalignment
Swingarm bent or twisted
Swingarm pivot shaft runout excessive
Steering maladjusted
Front fork bent
Right and left front fork oil level uneven
Shock absorption unsatisfactory:
(Too hard)
Front fork oil excessive
Front fork oil viscosity too high
Rear shock absorber adjustment too hard
Tire air pressure too high
Front fork bent
(Too soft)
Tire air pressure too low
Front fork oil insufficient and/or leaking
Front fork oil viscosity too low
Rear shock adjustment too soft
Front fork, rear shock absorber spring weak
Rear shock absorber oil leaking
Brake Doesn’t Hold:
Air in the brake line
Pad or disc worn
Brake fluid leakage
Disc warped
Contaminated pad
Brake fluid deteriorated
Primary or secondary cup damaged in master
cylinder
Master cylinder scratched inside
Battery Trouble:
Battery discharged:
Charge insufficient
Battery faulty (too low terminal voltage)
Battery cable making poor contact
Load excessive (e.g., bulb of excessive
wattage)
Ignition switch trouble
Alternator trouble
Wiring faulty
Regulator/rectifier trouble
Battery overcharged:
Alternator trouble
Regulator/rectifier trouble
Battery faulty
MODEL APPLICATION
Year
Model
2009
VN1700C9F
Beginning Frame No.
JKBVNRC1□9A000001 or
JKBVNT70CCA000001
□:This digit in the frame number changes from one machine to another.
Part No.99924-1414-01
Printed in Japan
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