Kawasaki VN900 CLASSIC Service Manual

VULCAN900 CLASSIC

VULCAN900 CLASSIC LT

VN900 CLASSIC

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

Periodic Maintenance

Fuel System (DFI)

Cooling System

Engine Top End

Clutch

Engine Lubrication System

Engine Removal/Installation

Crankshaft/Transmission

Wheels/Tires

Final Drive

Brakes

Suspension

Steering

Frame

Electrical System

Appendix

5 j

6 j

7 j

8 j

9 j

1 j

2 j

3 j

4 j

10 j

11 j

12 j

13 j

14 j

15 j

16 j

17 j

VULCAN900 CLASSIC

VULCAN900 CLASSIC LT

VN900 CLASSIC

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 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.

© 2006 Kawasaki Heavy Industries, Ltd.

First Edition (1): Feb. 7, 2006 (M)

g h

°F ft

L

A

ABDC

AC

ATDC

BBDC

BDC

BTDC

°C

DC

F

LIST OF ABBREVIATIONS ampere(s) after bottom dead center alternating current after top dead center before bottom dead center bottom dead center before top dead center degree(s) Celsius direct current farad(s) degree(s) Fahrenheit foot, feet gram(s) hour(s) liter(s)

TIR

V

W

Ω lb m min

N

Pa

PS r psi rpm

TDC pounds(s) meter(s) minute(s) newton(s) pascal(s) horsepower pound(s) per square inch revolution revolution(s) per minute top dead center total indicator reading volt(s) watt(s) ohm(s)

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 intake 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 preparing this manual, we divided the product into its major systems. These systems became the manual’s chapters. All information for a particular system from adjustment through disassembly and inspection is located in a single chapter.

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.

The Periodic Maintenance Chart is located in the Periodic Maintenance chapter. The chart gives a time schedule for required maintenance operations.

If you want spark plug information, for example, go to the Periodic Maintenance Chart first.

The chart tells you how frequently to clean and gap the plug. Next, use the Quick Reference

Guide to locate the Periodic Maintenance chapter. Then, use the Table of Contents on the first page of the chapter to find the Spark Plug 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.

•

Indicates a procedural step or work to be 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 .....................................................................................................................

1-2

Model Identification.................................................................................................................

General Specifications............................................................................................................

1-7

1-10

Unit Conversion Table ............................................................................................................

1-13

1

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-flush point solvent when cleaning parts. High

-flush 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.


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 or cotter pins 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.



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. Often, the tightening sequence is followed twice-initial tightening and final tightening with 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 new gaskets and replace 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.


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 circlips or cotter pins that were removed with new ones. Take care not to open the clip excessively when installing to prevent deformation.



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 Wires

A two-color wire is identified first by the primary color and then the stripe color. Unless instructed otherwise, electrical wires must be connected to those of the same color.

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.

Model Identification

VN900B6F (US and Canada) Left Side View:


VN900B6F (US and Canada) Right Side View:

Frame Number Engine Number

[A] Frame Number

[B] Front Fork (Right side)

[A] Engine Number

[B] Right Engine Cover



VN900B6F (Europe and Australia) Left Side View:

VN900B6F (Europe and Australia) Right Side View:


VN900D6F (US and Canada) Left Side View:


VN900D6F (US and Canada) Right Side View:


General Specifications

Items

Dimensions

Overall Length

Overall Width

Overall Height

(VN900B)

(VN900D)

Wheelbase

Road Clearance

Seat Height

Dry Mass

(VN900B)

(VN900D)

Curb Mass:

Front

(VN900B)

(VN900D)

Rear

(VN900B)

(VN900D)

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 Plugs

Cylinder Numbering Method

Firing Order

2 465 mm (97.05 in.)

1 005 mm (39.57 in.), (AU) 980 mm (38.6 in.)

1 065 mm (41.93 in.)

1 480 mm (58.27 in.)

1 645 mm (64.76 in.)

135 mm (5.31 in.)

680 mm (26.8 in.)

253 kg (558 lb), (EU) 254 kg (560 lb)

270 kg (595 lb)

130 kg (287 lb), (EU) 131 kg (289 lb)

134 kg (295 lb)

151 kg (333 lb)

164 kg (362 lb)

20 L (5.3 US gal)

2.9 m (9.5 ft)

VN900B6F/D6F

4-stroke, SOHC, V2-cylinder

Liquid-cooled

88.0 × 74.2 mm (3.46 × 2.92 in.)

903 mL (55.1 cu in.)

9.5 : 1

37 kW (50 PS) @5 700 r/min (rpm), (CA) (CAL) (US) –

78 N·m (8.0 kgf·m, 58 ft·lb) @3 700 r/min (rpm),

(CA) (CAL) (US) –

DFI (Digital Fuel Injection) System

Electric starter

Battery and coil (transistorized)

Electronically advanced (digital)

From 0° BTDC @1 000r/min (rpm) to 53° BTDC @5 800 r/min

(rpm)

(AU) From 3.5° BTDC @1 000r/min (rpm) to 53° BTDC

@5 800 r/min (rpm)

NGK CPR7EA-9

Front to Rear, 1-2

1-2



Items

Valve Timing:

Inlet open close duration

Exhaust

Open

Close

Duration

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

Final Drive System:

Type

Reduction Ratio

Overall Drive Ratio

Frame

Type

Caster (Rake Angel)

Trail

Front Tire:

Type

Size

Rim Size

Rear Tire:

Type

Size

Rim Size

VN900B6F/D6F

40° BTDC

40° ABDC

260°

55° BBDC

25° ATDC

260°

Forced lubrication (wet sump)

API SE, SF or SG class

API SH or SJ class with JASO MA

SAE10W-40

3.7 L (3.9 US qt)

Chain

2.184 (83/38)

Wet multi disc

5-speed, constant mesh, return shift

2.786 (39/14)

1.889 (34/18)

1.360 (34/25)

1.107 (31/28)

0.963 (26/27)

Belt

2.063 (66/32)

4.338 @ Top gear

Tubular, double cradle

32°

160 mm (6.30 in.)

Tubeless

130/90-16M/C 67H

16M/C × MT3.00

Tubeless

180/70-15M/C 76H

15M/C × MT4.50



Items

Front Suspension:

Type

Wheel Travel

Rear Suspension:

Type

Wheel Travel

Brake Type:

Front

Rear

Electrical Equipment

Battery:

Capacity

Telescopic fork

150 mm (5.90 in.)

Swingarm (uni-trak)

103 mm (4.06 in.)

Single disc

Single disc

12 V 10 Ah

VN900B6F/D6F

Headlight:

Type

Bulb

Tail/brake Light

Alternator:

Type

Rated Output

Semi-sealed beam

12 V 60/55W (quartz-halogen)

12 V 5/21 W

Three-phase AC

32 A × 14 V @5 000 r/min (rpm)

Specifications subject to change without notice, and may not apply to every country.

AU: Australia

CA: Canada

CAL: California

EU: Europe

US: United States of America

Unit Conversion Table

Prefixes for Units:

Prefix mega kilo centi milli micro

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

=

Units of Volume:

L × 0.2642

=

L mL mL mL

L

L

L

L

×

×

×

×

×

×

×

×

0.2200

=

1.057

=

0.8799

=

2.113

=

1.816

=

0.03381

=

0.02816

=

0.06102

=

Units of Force:

N × 0.1020

=

N kg kg

×

×

×

0.2248

=

9.807

=

2.205

= lb oz

N lb kg lb gal (US) gal (imp) qt (US) qt (imp) pint (US) pint (imp) oz (US) oz (imp) cu in


Units of Length: km × 0.6214

= m mm

×

×

3.281

=

0.03937 =

Units of Torque:

N·m × 0.1020

=

N·m

N·m kgf·m kgf·m kgf·m

×

×

×

×

×

0.7376

=

8.851

=

9.807

7.233

86.80

=

=

=

Units of Pressure: kPa × 0.01020 = kPa kPa kgf/cm² × kgf/cm² ×

×

× cm Hg ×

0.1450

=

0.7501

=

98.07

14.22

1.333

=

=

=

Units of Speed: km/h × 0.6214

=

Units of Power: kW kW

PS

×

×

×

1.360

1.341

0.7355

=

=

=

PS × 0.9863

= mile ft in mph

PS

HP kW

HP kgf·m ft·lb in·lb

N·m ft·lb in·lb kgf/cm² psi cm Hg kPa psi kPa

Units of Temperature:

PERIODIC MAINTENANCE 2-1

Periodic Maintenance


Periodic Maintenance Chart ...................................................................................................

Torque and Locking Agent......................................................................................................

2-3

2-6

Specifications .........................................................................................................................

Special Tools ..........................................................................................................................

2-11

2-13

Periodic Maintenance Procedures..........................................................................................

2-14

Fuel System (DFI)................................................................................................................

2-14

Fuel Hose Inspection (fuel leak, damage, installation condition) ......................................

Throttle Control System Inspection...................................................................................

Idle Speed Inspection .......................................................................................................

Idle Speed Adjustment......................................................................................................

Cooling System....................................................................................................................

Coolant Level Inspection...................................................................................................

Radiator Hose and Pipe Inspection (coolant leak, damage, installation condition) .........

2-14

2-14

2-15

2-15

2-16

2-16

2-16

Air Suction System ..............................................................................................................

Air Suction System Damage Inspection............................................................................

Engine Top End ...................................................................................................................

Valve Clearance Inspection ..............................................................................................

Valve Clearance Adjustment.............................................................................................

Clutch...................................................................................................................................

Clutch Operation Inspection..............................................................................................

Wheels and Tires.................................................................................................................

Tire Air Pressure Inspection..............................................................................................

Wheel/Tire Damage Inspection.........................................................................................

Tire Tread Wear Inspection...............................................................................................

Wheel Bearing Damage Inspection ..................................................................................

Spoke Tightness and Rim Runout Inspection...................................................................

Drive Train ...........................................................................................................................

2-22

2-22

2-22

2-22

2-23

2-24

2-25

2-17

2-17

2-17

2-17

2-17

2-21

2-21

Belt Deflection Inspection .................................................................................................

Belt Deflection Adjustment................................................................................................

Wheel Alignment Inspection/Adjustment ..........................................................................

Belt Wear and Damage Inspection ...................................................................................

Brake System ......................................................................................................................

Brake Fluid Leak Inspection..............................................................................................

Brake Hose Damage and Installation Condition Inspection..............................................

Brake Operation Inspection ..............................................................................................

Brake Fluid Level Inspection.............................................................................................

Brake Pad Wear Inspection ..............................................................................................

Brake Light Switch Operation Inspection ..........................................................................

Suspensions ........................................................................................................................

Front Forks/Rear Shock Absorber Operation Inspection ..................................................

Front Fork Oil Leak Inspection..........................................................................................

Rear Shock Absorber Oil Leak Inspection ........................................................................

Swingarm Pivot Lubrication ..............................................................................................

Rocker Arm Operation Inspection.....................................................................................

Tie-Rod Operation Inspection ...........................................................................................

Uni-trak Linkage Lubrication .............................................................................................

Steering System ..................................................................................................................

Steering Play Inspection ...................................................................................................

Steering Play Adjustment..................................................................................................

Steering Stem Bearing Lubrication ...................................................................................

2-32

2-32

2-33

2-33

2-34

2-34

2-35

2-35

2-25

2-27

2-28

2-28

2-31

2-31

2-32

2-35

2-35

2-35

2-36

2-36

2-36

2-36

2-38

2

2-2 PERIODIC MAINTENANCE

Electrical System .................................................................................................................

Lights and Switches Operation Inspection........................................................................

Headlight Aiming Inspection .............................................................................................

Sidestand Switch Operation Inspection ............................................................................

Engine Stop Switch Operation Inspection.........................................................................

Others ..................................................................................................................................

Chassis Parts Lubrication .................................................................................................

Bolts, Nuts and Fasteners Tightness Inspection...............................................................

Evaporative Emission Control SystemInspection (CAL)......................................................

Evaporative Emission Control System Inspection ............................................................

Replacement Parts ..............................................................................................................

Air Cleaner Element Replacement....................................................................................

Engine Oil Change............................................................................................................

Oil Filter Replacement ......................................................................................................

Fuel Hose Replacement ...................................................................................................

Coolant Change ................................................................................................................

Radiator Hose and O-ring Replacement...........................................................................

Brake Hose Replacement .................................................................................................

Brake Fluid Change ..........................................................................................................

Master Cylinder Rubber Parts Replacement ....................................................................

Caliper Rubber Parts Replacement ..................................................................................

Spark Plug Replacement ..................................................................................................

2-44

2-45

2-46

2-46

2-47

2-47

2-48

2-39

2-39

2-41

2-42

2-43

2-44

2-49

2-49

2-51

2-53

2-53

2-54

2-56

2-57

2-60


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

* ODOMETER READING

× 1 000 km

(× 1 000 mile)

1 6 12 18 24 30 36

See

Page

INSPECTION

Fuel System

Throttle control system (play, smooth return, no drag) - inspect

Idle speed - inspect

Every (0.6) (4) (7.5) (12) (15) (20) (24) year

Fuel leak (fuel hose and pipe) - inspect

Fuel hose - inspect year year year

•

•

•

•

• •

•

•

•

•

•

•

•

•

• •

•

•

•

•

2-14

2-15

2-14

2-14

2-14 Fuel hoses installation condition - inspect

Cooling System

Coolant level - inspect

Coolant leak (radiator hose and pipe) inspect

Radiator hose damage - inspect

Radiator hose installation condition inspect

Air Suction System

Air suction system damage - inspect

Evaporative Emission Control System

(CAL)

Evaporative emission control system function - inspect

Engine Top End

Valve clearance - inspect (US and CA)

Valve clearance - inspect (EU and AU)

Clutch

Clutch operation (play, disengagement, engagement) - inspect

Wheels and Tires

Tire air pressure - inspect

Wheel/tire damage - inspect

Tire tread wear, abnormal wear - inspect

Wheel bearings damage - inspect

Spoke tightness and rim runout-inspect

Drive Train

Belt deflection - inspect

Belt wear and damage - inspect

Brake System

Brake fluid leak - inspect year year year year year year

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

2-16

• •

2-16

• •

2-16

• •

2-16

•

• • • • • • •

Every 42 000 km (26 000 mile)

•

2-17

2-46

2-17

2-17

2-21

•

•

•

• • •

2-22

• •

2-22

• •

2-22

• •

2-23

• • • • • • •

2-24

• • • • • • •

• • • • • • •

• • • • • • •

2-25

2-28

2-31




* ODOMETER READING

× 1 000 km

(× 1 000 mile)

1 6 12 18 24 30 36

See

Page

INSPECTION

Brake hose damage - inspect

Brake hose installation condition - inspect

Brake operation (effectiveness, play, no drag) - inspect

Brake fluid level - inspect

Brake pad wear - inspect #

Brake light switch operation - inspect

Every (0.6) (4) (7.5) (12) (15) (20) (24) year year year

• • • • • • •

2-32

• • • • • • •

2-32

• • • • • • •

2-32

6 months

• • • • • • •

2-32

• • • • • •

2-33

• • • • • • •

2-33

Suspensions

Front forks/rear shock absorber operation

(damping and smooth stroke) - inspect

• • •

2-34

Front forks/rear shock absorber oil leak inspect

Swingarm pivot - lubricate

Uni - trak rocker arm operation - inspect

Uni - trak tie rod operation - inspect

Uni - trak rocker arm bearings - lubricate

Uni - trak tie rod bearings - lubricate year

•

•

• • •

2-35

•

•

2-35

• •

2-35

•

• •

2-35

2-36

2-36

Steering System

Steering play - inspect

Steering stem bearings - lubricate year

2 years

• •

•

• •

2-35

2-38


Lights and switches operation - inspect

Headlight aiming - inspect

Sidestand switch operation - inspect

Engine stop switch operation - inspect year year year year

•

•

•

• • •

2-39

• •

2-41

• •

2-42

• •

2-43

Others

Chassis parts - lubricate

Bolts and nuts tightness - inspect year

•

•

• •

• •

•

2-44

2-45

#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or frequent starting/stopping.

*: For higher odometer readings, repeat at the frequency interval established here.

(AU): Australia

(CA): Canada

(CAL):California

(EU): Europe

(US): United States



Periodic Replacement Parts


* ODOMETER READING

× 1 000 km

(× 1 000 mile)

12 24 36 48

See

Page

1

CHANGE/REPLACE ITEM Every (0.6) (7.5) (15) (24) (30)

Air cleaner element # Every 18 000 km (12 000 mile) 2-47

Engine oil #

Oil filter

Fuel hose

Coolant

Radiator hoses and O-rings year year

4 years

3 years

3 years

• • • • •

2-48

• • • • •

2-49

•

•

•

2-49

2-51

2-53

Brake hoses

Brake fluid (Front and Rear)

Rubber parts of master cylinder and caliper

Spark plug

4 years

2 years

4 years

•

•

2-53

•

2-54

•

2-57

• • • •

2-60

#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or frequent starting/stopping.

*: For higher odometer readings, repeat at the frequency interval established here.


Torque and Locking Agent

The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or liquid gasket.

Letters used in the “Remarks” column mean:

2T: Apply 2-stroke oil.

L: Apply a non-permanent locking agent to the threads.

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)

S: Tighten the fasteners following the specified sequence.

Si: Apply silicone grease (ex. PBC grease).

SS: Apply silicone sealant.

Fastener

N·m

Torque kgf·m ft·lb

Remarks

Fuel System

Water Temperature Sensor

Speed Sensor Mounting Bolt

Fuel Pump Bolts

Oxygen Sensor

Fuel Level Sensor Mounting Bolts

Air Cleaner Housing Bolts

Air Cleaner Cover Bolts

Air Cleaner Element Screw

Throttle Body Assy Holder Bolts

Inlet Manifold Bolts

Delivery Joint Bolts

Delivery Joint Bracket Bolts

Vehicle-down Sensor Bolts

Inlet Air Pressure Sensor Bolt

Inlet Air Temperature Sensor Screw

Cooling System

Radiator Hose Clamp Screws

Water Pump Impeller Bolt

Coolant Drain Bolt

Thermostat Housing Cover Bracket Bolts

Thermostat Housing Cover Bolts

Radiator Bolts

Radiator Screen Screws

Radiator Fan Bolts

Water Hose Fitting Bolts

Reserve Tank Bolts

Engine Top End

Cylinder Head nuts (M10) (First)

Cylinder Head nuts (M10) (Final)

Cylinder Head nuts (M8)

Camshaft Cap Bolts

12

9.8

9.8

25

6.9

9.8

4.9

4.9

9.8

9.8

9.8

9.8

4.9

6.9

1.2

2.0

9.8

9.8

6.9

4.9

6.9

6.9

8.3

9.8

6.9

20

49

25

25

1.2

1.0

1.0

2.5

0.70

1.0

0.50

0.50

1.0

1.0

1.0

1.0

0.50

0.70

0.12

0.20

1.0

1.0

0.70

0.50

0.70

0.70

0.85

1.0

0.70

2.0

5.0

2.5

2.5

106 in·lb

87 in·lb

87 in·lb

18

61 in·lb

87 in·lb

43 in·lb

43 in·lb

87 in·lb

87 in·lb

87 in·lb

87 in·lb

43 in·lb

61 in·lb

11 in·lb

18 in·lb

87 in·lb

87 in·lb

61 in·lb

43 in·lb

61 in·lb

61 in·lb

73 in·lb

87 in·lb

61 in·lb

15

36

18

18

L

L

L

L

L

L

MO, S

MO, S

S


Fastener

Cylinder Head Cover Bolts

Cylinder Head Outer Cover Bolts

Plug (PT1/4)

Plug (PT1/2)

Muffler Mounting Bolts

Muffler Mounting Nut

Muffler Joint Clamp Bolt

Exhaust Pipe Cover Clamp Bolts

Exhaust Pipe Cover Bolts

Exhaust Pipe Holder Nuts

Camshaft Sprocket Bolts

Camshaft Chain Tensioner Cap Bolts

Camshaft Chain Guide Bolts

Clutch

Right Engine Cover Mounting Bolts

Clutch Spring Bolts

Clutch Hub Nut

Clutch Lever Clamp Bolts

Engine Lubrication

Engine Oil Drain Plug

Oil Pump Cover Bolt

Oil Pump Drive Chain Guide Bolt

Oil Filter Plate Bolts

Oil Pressure Switch

Oil Pipe Bolts

Oil Return Pipe Bolts

Oil Pressure Switch Adapter

Oil Filter

Oil Screen Plug

Oil Pressure Relief Valve

Engine Removal/Installation

Engine Mounting Nuts

Engine Mounting Bracket Bolts (M10)

Engine Mounting Bracket Bolts (M8)

Downtube Bolts

Crankshaft/Transmission

Balancer Gear Bolt

Starter Motor Clutch Gear Bolt

Primary Gear Bolt

Connecting Rod Big End Bolts

Shift Drum Bearing Stopper Bolts

Shift Drum Cam Bolt

Neutral Switch


15

9.8

9.8

20

20

9.8

9.8

7.8

18

20

15

44

44

25

44

69

69

98

46

9.8

12

15

20

25

25

17

N·m

12

9.8

15

6.9

6.9

17

49

20

9.8

9.8

9.8

130

7.8

4.5

4.5

2.5

4.5

1.5

1.0

1.0

2.0

2.0

1.0

1.0

0.80

1.8

2.0

1.5

7.0

7.0

10

4.7

1.0

1.2

1.5

1.7

0.70

0.70

1.7

5.0

2.0

1.0

Torque kgf·m

1.2

1.0

1.5

2.0

2.5

2.5

ft·lb

106 in·lb

87 in·lb

11

15

18

18

12

61 in·lb

61 in·lb

12

36

15

87 in·lb

1.0

1.0

13.2

0.80

87 in·lb

87 in·lb

95.9

69 in·lb

15

87 in·lb

87 in·lb

69 in·lb

11

87 in·lb

87 in·lb

15

13

15

11

32

32

18

32

51

51

72

34

87 in·lb

106 in·lb

11

Remarks

L

L

L

L

L (1)

S

L

L

SS

L

L

MO

MO

L

L



Fastener

Rear Shift Lever Clamp Bolt

Shift Pedal Clamp Bolt

Shift Rod Locknut (Front)

Oil Nozzle

Shift Rod Locknut (Rear)

Rear Shift Pedal Pad Screw

Shift Drum Position Lever Bolt

Shift Shaft Return Spring Pin

Bearing Retainer Bolts

Balancer Shaft Bearing Stopper Plate Bolts

Crankcase Bolts (M10)

Crankcase Bolts (M6)

Engine Ground Lead Bolt

Clamp Mounting Bolts

External Shift Mechanism Cover Bolts

Wheels/Tires

Front Axle Nut

Front Axle Clamp Bolt

Rear Axle Nut

Spoke Nipples

Final Drive

Rear Pulley Mounting Nuts

Rear Pully Plate Bolts

Engine Pully Mounting Nut

Engine Pullly Plate Bolts

Engine Pulley Cover Bolts

Engine Pulley Cover Clamp Mounting Bolt

Drive Belt Guide Bolts

Brakes

Bleed Valves

Brake Hose Banjo Bolts

Brake Lever Pivot Bolt

Brake Lever Pivot Locknut

Brake Pedal Clamp Bolt

Front Brake Disc Mounting Bolts

Front Brake Light Switch Screw

Front Brake Reservoir Cap Screws

Front Caliper Mounting Bolts

Front Master Cylinder Clamp Bolts

Rear Brake Disc Mounting Bolts

Rear Caliper Mounting Bolts

Rear Master Cylinder Mounting Bolts

Rear Master Cylinder Push Rod Locknut

108

20

108

5.2

59

6.9

127

9.8

9.8

9.8

9.8

9.8

39

9.8

9.8

9.8

9.8

3.9

9.8

6.9

9.8

29

9.8

N·m

12

12

9.8

34

8.8

27

34

25

17

25

27

1.2

1.5

7.8

25

1.0

5.9

11.0

2.0

11.0

0.53

6.0

0.70

13.0

1.0

1.0

1.0

1.0

3.5

0.90

2.8

3.5

2.5

1.7

0.80

2.5

0.10

0.60

2.5

2.8

0.12

0.15

1.0

4.0

1.0

1.0

1.0

1.0

Torque kgf·m

1.2

1.2

1.0

0.40

1.0

0.70

1.0

3.0

1.0

ft·lb

106 in·lb

106 in·lb

87 in·lb

34 in·lb

87 in·lb

61 in·lb

87 in·lb

21

87 in·lb

87 in·lb

29

87 in·lb

87 in·lb

87 in·lb

87 in·lb

69 in·lb

18

88 in·lb

52 in·lb

18

20

11 in·lb

13 in·lb

25

78 in·lb

20

25

18

12

79.7

15

79.7

46 in·lb

44

61 in·lb

93.7

87 in·lb

87 in·lb

87 in·lb

87 in·lb

Remarks

Lh

L

L

S

S

L

M

Si

L

S

L


Fastener

Suspension

Swingarm Pivot Shaft Nut

Rear Shock Absorber Nuts

Lower Tie-Rod Nut

Upper Tie-Rod Nut

Rocker Arm Pivot Shaft Nut

Upper Front Fork Clamp Bolts

Lower Front Fork Clamp Bolts

Front Fork Bottom Allen Bolts

Front Fork Upper Cover Stopper Bolts

Steering

Handlebar Holder Nuts

Handlebar Clamp Bolts

Steering Stem Head Bolt

Steering Stem Nut

Frame

Sidestand Mounting Nut

Sidestand Mounting Bolt

Footboard Bracket Bolts

Left Footpeg Bracket Bolts

Right Footpeg Bracket Bolts

Lower Muffler Bracket Bolts

Upper Muffler Bracket Bolts


Alternator Outer Cover Bolts

Tail/Brake Light Unit Mounting Nuts

Alternator Cover Bolts

Timing Inspection Plate Bolts

Alternator Lead Holder Plate Bolts

Stator Coil Bolts

Alternator Rotor Bolt (First)

Alternator Rotor Bolt (Final)

Regulator/Rectifier Bolts

Starter Motor Mounting Bolts

Starer Relay Terminal Screws

Starter Motor Cable Terminal Nut

Starter Motor Terminal Locknut

Starter Motor Through Bolts

Headlight Rim Screws

Crankshaft Sensor Bolts

Ignition Coil Bracket Bolt

Ignition Coil Mounting Nuts

Fuel Level Sensor Mounting Bolts


25

34

34

44

44

34

25

34

34

49

4.9

11

4.9

2.9

5.9

6.9

9.8

3.9

5.9

5.9

12

69

160

9.8

5.9

9.8

9.8

9.8

6.9

6.9

N·m

98

59

59

108

59

20

34

20

4.2

4.5

4.5

3.5

2.5

2.5

3.5

3.5

3.5

3.5

5.0

0.50

0.70

1.0

0.40

0.60

1.1

0.50

0.30

0.60

1.0

0.60

1.0

1.0

0.60

1.2

7.0

16.3

1.0

0.70

0.70

Torque kgf·m

10

6.0

6.0

11.0

6.0

2.0

3.5

2.0

0.43

25

25

36

43 in·lb

18

25

25

32

32

25

18

87 in·lb

52 in·lb

87 in·lb

87 in·lb

52 in·lb

106 in·lb

51

118

61 in·lb

87 in·lb

34 in·lb

52 in·lb

97 in·lb

43 in·lb

26 in·lb

52 in·lb

87 in·lb

61 in·lb

61 in·lb ft·lb

72

44

44

80

44

15

25

15

37 in·lb

Remarks

L

S, 2T

L

S

S, MO

L



Fastener

Spark Plugs

Sidestand Switch Mounting Bolts

N·m

18

8.8

Torque kgf·m

1.8

0.90

ft·lb

13 in·lb

78 in·lb

Remarks

L

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 Diameter

(mm)

12

14

16

18

20

5

6

8

10

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

10.0

∼ 13.5

19.0

∼ 25

33 ∼ 45

54 ∼ 72

83 ∼ 115

125 ∼ 165

165 ∼ 240


Specifications

Item

Fuel System

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:

Exhaust

Inlet

Clutch

Clutch Lever Free Play


Engine Oil:

Type

Viscosity

Capacity

Level

Standard

2 ∼ 3 mm (0.08

∼ 0.12 in.)

1 000 ±50 r/min (rpm)

Polyurethane Foam

Permanent type of antifreeze

Green

Soft water 50%, Coolant 50%

–35°C (–31°F)

2.2 L (2.3 US qt)

0.20

∼ 0.25 mm (0.0079

∼ 0.0098 in.)

0.10

∼ 0.15 mm (0.0039

∼ 0.0059 in.)

2 ∼ 3 mm (0.08

∼ 0.12 in.)

API SE, SF or SG

API SH, SJ or SL with JASO MA

SAE 10W-40

3.0 L (3.2 US qt) (when filter is not removed)

3.2 L (3.4 US qt) (when filter is removed)

3.7 L (3.9 US qt) (when engine is completely dry)

Between upper and lower level lines

(after idling or running)

Wheels/Tires

Tread Depth:

Front 4.5 mm (0.18 in.)

Rear 7.4 mm (0.29 in.)

Service Limit

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

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.)

Air Pressure (when Cold):

Front – – –

Rear

Up to 180 kg (397 lb) load:

200 kPa (2.00 kgf/cm², 28 psi)

Up to 97.5 kg (215 lb) load:

200 kPa (2.00 kgf/cm², 28 psi)

97.5

∼ 180 kg (215 ∼ 397 lb) load:

225 kPa (2.25 kgf/cm², 32 psi)

– – –


Specifications

Item Standard

Final Drive

Drive Belt Deflection:

(45 N, 4.6 kgf, 10 lb fprce) 1.5

∼ 4.0 mm (0.059

∼ 0.16 in.)

When Installing New Belt or Engine Remounted

1.5 mm (0.059 in.)

Brakes

Brake Fluid:

Grade

Brake Pad Lining

Thickness:

Front

Rear

Brake Light Timing:

Front

Rear

DOT4

4.5 mm (0.18 in.)

7.0 mm (0.28 in.)

Pulled ON

ON after about 10 mm (0.39 in.) of pedal travel


Spark Plug Gap 0.8

∼ 0.9 mm (0.03

∼ 0.04 in.)

AT: Austria

CH: Switzerland

DE: Germany

Service Limit

– – –

– – –

– – –

– – –

1 mm (0.04 in.)

1 mm (0.04 in.)

– – –

– – –

– – –

Special Tools

Inside Circlip Pliers:

57001-143

Steering Stem Nut Wrench:

57001-1100

Jack:

57001-1238


Oil Filter Wrench:

57001-1249

Spark Plug Wrench, Hex 16:

57001-1262

Tension Gauge:

57001-1585


Periodic Maintenance Procedures


Fuel Hose Inspection (fuel leak, damage, installation condition)

○

The fuel hose is designed to be used throughout the motorcycle’s life without any maintenance. However, if the motorcycle is not properly handled, the high pressure inside the fuel line can cause fuel to leak [A] or the hose to burst. Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) and check the fuel hose.

Replace the fuel hose if any fraying, cracks [B] or bulges

[C] are noticed.

•

Check that the hoses are routed according to Cable, Wire and Hose Routing section in the Appendix chapter.

Replace the hose if it has been sharply bent or kinked.

Hose Joints [A]

Fuel Hose [B]

•

Check that the hose joints are securely connected.

○

Push and pull [A] the hose joint [B] back and forth more than two times, and make sure it is locked.

If it does not locked, reinstall the hose joint.

WARNING

Make sure the hose joint is installed correctly on the delivery pipe by sliding the joint, or the fuel could leak.

Throttle Control System Inspection

•

Check the throttle grip free play [A].

If the free play is incorrect, adjust the throttle cable.

Throttle Grip Free Play

Standard: 2 ∼ 3 mm (0.08

∼ 0.12 in.)

•

Check that the throttle grip moves smoothly from close to full open, and the throttle closes quickly and completely in all steering positions by the return spring.

If the throttle grip doesn’t return properly, check the throttle cable 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 doesn’t change.

If the idle speed increases, check the throttle grip free play and the cable routing.


•

If necessary, adjust the throttle cable as follows:

○

Loosen the locknuts [A] and screw the adjusters [B] all the way in so as to give the throttle grip plenty of play.

○

Turn out the adjuster of the decelerator cable [D] until there is no play.

○

Tighten the locknut against the adjuster.

Turn the adjuster of the accelerator cable [C] until the proper amount of throttle grip free play is obtained and tighten the locknut against the adjuster.


•

Idle Speed Inspection

Start the engine and warm it up thoroughly.

○

At first the engine will run fast to decrease warm up time

(fast idle).

○

Gradually the fast idle will lower to a certain RPM automatically. This is the idle speed.

•

Check the idle speed.

Idle Speed

Standard: 1 000 ±50 r/min (rpm)

•

With the engine idling, turn the handlebar to both sides.

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.

If the idle speed is out of the specified range, adjust it.

•

Idle Speed Adjustment


•

○

Wait until fast idle speed lowers to a certain value.

Turn the adjusting screw [A] until the idle speed is correct.

○

Open and close the throttle a few times to make sure that the idle speed is within the specified range. Readjust if necessary.

Front [B]



Cooling System

Coolant Level Inspection

NOTE

○

Check the level when the engine is cold (room or ambient temperature).

•

Check the coolant level in the reserve tank [A] with the motorcycle held upright.

If the coolant level is lower than the “L” level line [B], remove the reserve tank cover and unscrew the reserve tank cap, and add coolant to the “F” level line [C].

“L”: low

“F”: full

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 alone 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 reservoir 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.

Radiator Hose and Pipe Inspection (coolant leak, damage, installation condition)

○

The high pressure inside the radiator hose and pipe 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)


Air Suction System

•

Air Suction System Damage Inspection

•

Pull the air switching valve hose [A] out of the right air cleaner housing.

•

Start the engine and run it at idle speed.

Plug the air switching valve hose end 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).


Engine Top End

Valve Clearance Inspection

NOTE

○

Valve clearance must be checked and adjusted when the engine is cold (room temperature).

•

Remove:

Cylinder Head Cover (see Cylinder Head Cover Removal in the Engine Top End chapter)

Timing Inspection Plate (Engine Left Side)

•

Set the front piston at TDC (see Camshaft Installation in the Engine Top End chapter).

•

Using a thickness gauge [A], measure the valve clearance between the rocker arm [B] and the shim [C].

•

Set the rear piston at TDC by turning the crankshaft counterclockwise 305° (see Crankshaft Installation in the

Crankshaft/Transmission chapter).

•

Using a thickness gauge, measure the valve clearance between the rocker arm and the shim.

Valve Clearance

Standard:

Exhaust:

Inlet:

0.20

∼ 0.25 mm (0.079

∼ 0.0098 in.)

0.10

∼ 0.15 mm (0.0039

∼ 0.0059 in.)

If the valve clearance is not within the specified range and then adjust it.

Valve Clearance Adjustment

•

To change the valve clearance, slide [A] the rocker arm

[B] sideways and change the shim [C]. Replace the shim with one of a different thickness.

NOTE

○

Mark and record the shim locations so that the shims can be reinstalled in their original positions.

○

If there is no clearance, select a shim which is several sizes smaller and then measure the clearance.



•

To select a new shim which brings the valve clearance within the specified range, refer to the Valve Clearance

Adjustment Charts.

•

Remeasure any valve clearance that was adjusted.

Readjust if necessary.

CAUTION

Do not put shim stock under the shim. This may cause the shim to pop out at high rpm, causing extensive engine damage.

Do not grind the shim. This may cause it to fracture, causing extensive engine damage.



VALVE CLEARANCE ADJUSTMENT CHART INLET VALVE

1. Measure the clearance (when engine is cold).

2. Check present shim size.

3. Match clearance in vertical column with present shim size in horizontal column.

4. Install the shim specified where the lines intersect. This shim will give the proper clearance.

Example: Present shim is 2.60 mm (0.102 in.)

Measured clearance is 0.25 mm (0.010 in.)

Replace 2.60 mm (0.102 in.) shim with 2.70 mm (0.106 in.) shim.

5. Remeasure the valve clearance and readjust if necessary.

NOTE

○




VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE

1. Measure the clearance (when engine is cold).

2. Check present shim size.

3. Match clearance in vertical column with present shim size in horizontal column.

4. Install the shim specified where the lines intersect. This shim will give the proper clearance.

Example: Present shim is 2.55 mm (0.100 in.)

Measured clearance is 0.50 mm (0.020 in.)

Replace 2.55 mm (0.100 in.) shim with 2.75 mm (0.108 in.) shim.

5. Remeasure the valve clearance and readjust if necessary.

NOTE

○



Clutch

Clutch Operation Inspection

Clutch Lever Free Play Inspection

•

Pull the clutch lever just enough to take up the free play

[A].

•

Measure the gap between the lever and the lever holder.

If the gap is too wide, the clutch may not release fully. If the gap is too narrow, the clutch may not engage fully. In either case, adjust it.

Clutch Lever Free Play

Standard: 2 ∼ 3 mm (0.08

∼ 0.12 in.)


•

Clutch Lever Free Play Adjustment

Loosen the locknut [A] at the clutch lever.

•

Turn the adjuster [B] until the proper amount of clutch lever free play is obtained.

•

Tighten the locknut securely.

If it cannot be done, use the adjuster at the middle of the cable.

WARNING

To avoid a serious burn, never touch the engine or exhaust pipe during clutch adjustment.

•

Loosen the locknut [A] at the middle of the clutch cable.

•

Turn the adjuster nut [B] until the proper amount of clutch lever free play is obtained.

•

Tighten the locknut securely.

If it cannot be done, use the mounting nuts at the lower end of the cable.

•

Slide the dust cover [A] at the clutch cable lower end out of place.

•

Loosen both adjusting nuts [B] at the clutch cover as far as they will go.

•

Pull the clutch outer cable [C] tight and tighten the adjusting nuts against the bracket [D].

•

Slip the rubber dust cover back onto place.

•

Turn the adjuster at the clutch lever until the free play is correct.

•

Tighten the knurled locknut at the clutch lever.

WARNING

Be sure that the outer cable end at the clutch lever is fully seated in the adjuster at the clutch lever, or it could slip into place later, creating enough cable play to prevent clutch disengagement.

•

After the adjustment, start the engine and check that the clutch does not slip and that it releases properly.



Wheels and Tires

Tire Air Pressure Inspection

•

Measure the tire air pressure with an air pressure gauge

[A] when 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)

200 kPa (2.00 kgf/cm², 28 psi)

97.5

∼ 180 kg (215 ∼ 397 lb)

225 kPa (2.25 kgf/cm², 32 psi)

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 requiring 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/Tire Damage Inspection

•

Remove any imbedded stones [A] or other foreign particles [B] from tread.

•

Visually inspect the tire for cracks and cuts replacing the tire in case of damage. Swelling or high spots indicate internal 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.


•

Measure the tread depth at the center of the tread with a 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.


Tread Depth

Standard:

Front

Rear

Service Limit:

Front

4.5 mm (0.18 in.)

7.4 mm (0.29 in.)

Rear

1 mm (0.04 in.) (DE, AT, CH) 1.6 mm

(0.063 in.)

2 mm (0.08 in.): Up to 130 km/h (80 mph)

3 mm (0.1 in.): Over to 130 km/h (80 mph)

Wheel Bearing Damage Inspection

•

Using a jack raise the front wheel off the ground (see Front

Wheel Removal in the Wheels/Tires chapter).

•

Turn the handlebar all the way to the right or left.

•

Inspect the roughness of the front wheel bearing by pushing and pulling [A] the wheel.

•

Spin [B] the front wheel lightly, and check for smoothly turn, roughness, binding or noise.

If roughness, binding or noise is found, remove the front wheel (see Front Wheel Removal in the Wheel/Tires chapter) and inspect the wheel bearing (see Hub Bearing

Inspection in the Wheels/Tires chapter).

•

Using a jack raise the rear wheel off the ground (see Rear

Wheel Removal in the Wheels/Tires chapter).

•

Inspect the roughness of the rear wheel bearing by pushing and pulling [A] the wheel.

•

Spin [B] the rear wheel lightly, and check for smoothly turn, roughness, binding or noise.

If roughness, binding or noise is found, remove the rear wheel (see Rear Wheel Removal in the Wheel/Tires chapter) and inspect the wheel bearing (see Hub Bearing Inspection in the Wheels/Tires chapter) and coupling (see

Coupling Bearing Inspection in the Final Drive chapter).



Spoke Tightness and Rim Runout Inspection

•

Check that all the spokes are tightened evenly.

If spoke tightness is uneven or loose, tighten the spoke nipples evenly.

Torque - Spoke Nipples: 5.2 N·m (0.53 kgf·m, 46 in·lb)

•

Check the rim runout.

WARNING

If any spoke breaks, it should be replaced immediately. A missing spoke places an additional load on the other spokes, which will eventually cause other spokes to break

•

Raise the front/rear wheel off the ground.

Special Tool - Jack: 57001-1238

•

Spin the wheel lightly, and check for roughness or binding.

If roughness or binding is found, replace the hub bearings.

•

Inspect the rim for small cracks, dents, bending, or warping.

If there is any damage to the rim, it must be replaced.

NOTE

○

Avoid the curved part and the uneven part, and measure the rim runout on the side without the mark.

•

Measure the axial [A] and radial [B] rim runout with a dial gauge.

If rim runout exceeds the service limit, check the hub bearings first. Replace them if they are damaged. If the problem is not due to the bearings, correct the rim warp

(runout). A certain amount of rim warp can be corrected by recentering the rim. Loosen some spokes and tighten others within the standard torque to change the position of different parts of the rim. If the rim is badly bent, however, it must be replaced.

Rim Runout (with tire installed)

Standard:

Radial

Axial

1.0 mm (0.039 in.)

0.8 mm (0.03 in.)

Service Limit:

Radial

Axial

2.0 mm (0.079 in.)

2.0 mm (0.079 in.)


Drive Train

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 ride after belt replacement.

•

Check to see if wheel alignment is properly adjusted.

○

The left and right notches on the belt adjuster should point to the same marks or positions on the swingarm.

If they do not, adjust wheel alignment (see Wheel Alignment Inspection/Adjustment).

•

Remove:

Reserve Tank Cover (see Reserve Tank Removal in the

Cooling System chapter)

•

Using the jack under the frame, lift the rear wheel off the ground (see Rear Wheel Removal in the Wheels/Tires chapter).

•

Visually inspect the belt for damage (see Belt Wear and

Damage Inspection).

If the belt is damaged, replace it with a new one.

•

Mark the initial belt position [A] on the belt cover window.


•

Using the tension gauge [A], push up 45 N (4.5 kgf, 10 lb) of force from under and on the center of the belt at the front side of the swingarm cross pipe [B].

•

Measure the deflection (length between initial belt position [A] and position [B] after it measure it) of the belt (at the belt cover window).



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 center of the belt. 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.

•

Inspect the belt deflection at two positions by rotating the rear wheel.

Special Tool - Tension Gauge: 57001-1585

•

Inspect the drive belt deflection at arbitrary position, and record the value [A].

•

Turn the rear wheel 90 degrees.

•

Inspect the drive belt deflection, and record the value [B].


•

Decide the belt deflection at the position [C] of one where deflection is large.


Drive Belt Deflection (with 45 N, 4.6 kgf, 10 lb force)

Standard: 1.5

∼ 4.0 mm (0.059

∼ 0.16 in.)

Drive Belt Deflection (with 45 N, 4.6 kgf, 10 lb force, when installing new belt or engine remounted)

Standard: 1.5 mm (0.059 in.)

If the deflection is out of the specification, adjust it.

Belt Deflection Adjustment

•

Remove:

Muffler (see Muffler Removal in the Engine Top End

• chapter)

Remove the axle cotter pin, and loosen the axle nut.

•

Using the jack under the frame pipe ribs, lift the rear wheel off the ground (see Rear Wheel Removal in the

Wheels/Tires chapter).

•

Loosen the left and right belt adjuster locknuts [A].

If the belt is too tight, back out the left and right belt adjuster nuts [B], 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 left belt adjuster should align with the same swingarm mark

[C] that the right belt adjuster 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, 79.7 ft·lb)

•

Inspect the drive belt deflection (see Belt Deflection Inspection).

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 degree.

○

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.

•

Check the rear brake for weak braking power and brake drag.

Wheel Alignment Inspection/Adjustment

•

Check that the notch [A] on the left belt adjuster [B] aligns with the same swingarm mark [C] or position that the right belt adjuster notch aligns with.

If they do not, adjust the belt deflection (see Belt Deflection Adjustment) and align the wheel alignment.

NOTE

○

Wheel 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.

Belt Wear and Damage Inspection

•

Using the jack and jack attachment under the frame pipe ribs, lift the rear wheel off the ground (see Rear Wheel

Removal in the Wheels/Tires chapter).

•

Remove:

Bolts [A] and Washers

Upper Belt Cover [B]


•

Visually inspect the belt [A] for wear and damage.

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 Patterns and perform the according to the table of Drive Belt Wear

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.




Drive Belt Tooth Wear and Damage Patterns

A. Belt Cross Section

B. Edge Bevel Wear

C. Rub Wear

D. Stone



Drive Belt Wear and Damage Analysis

Pattern Condition

1 Internal tooth cracks (slight)

2

3

4

5

6

7

8

Scuffing to side of teeth

Fraying edge cord

Beveled wear

External tooth cracks (severe)

Severe fractured or missing teeth

Tooth hook wear

Stone damage

Brake System

Brake Fluid Leak Inspection

•

Apply the brake lever or pedal and inspect the brake fluid leak from the brake hoses [A] and fittings [B].

If the brake fluid leaked from any position, inspect or replace the problem part.

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.



Brake Hose Damage and Installation Condition

Inspection

•

Inspect the brake hoses and fittings for deterioration, 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)

•

Inspect the brake hose routing.

If any brake hose routing is incorrect, route the brake hose according to Cable, Wire and Hose Routing section in the

Appendix chapter.

Brake Operation Inspection

•

Inspect the operation of the front and rear brake by running 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

•

Check that the brake fluid level in the front brake reservoir

[A] is above the lower level line [B].

NOTE

○

Hold the reservoir horizontal by turning the handlebar when checking brake fluid level.

If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [C] in the reservoir.

•

Tighten:

Torque - Front Brake Reservoir Cap Screws: 1.5N·m (0.15

kg·fm, 13 in·lb)


•

Check that the brake fluid level in the rear brake reservoir

[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

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.


Recommended Disc Brake Fluid

Grade: DOT4

•

Follow the procedure below to install the rear brake fluid 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].

Brake Pad Wear Inspection

•

Check the lining thickness [A] of the pads in each caliper.

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

Rear

Service Limit:

4.5 mm (0.18 in.)

7.0 mm (0.28 in.)

1 mm (0.04 in.)

•

Brake Light Switch Operation Inspection

Turn on the ignition switch.

•

The brake light [A] should go on when the brake lever is applied or after the brake pedal is depressed about 10 mm (0.39 in.).



If it does not, adjust the brake light switch.

•

While holding the switch body, turn the adjusting nut [A] to adjust the switch.

CAUTION

To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment.

If it does not go on, inspect or replace the following items.

Battery (see Charging Condition Inspection in the Electrical System chapter)

Brake Light (see Tail/Brake Light Removal/Installation 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)

Suspensions

Front Forks/Rear Shock Absorber Operation

Inspection

•

Pump the forks down and up [A] 4 or 5 times, and inspect the smooth stroke.

If the forks do not smoothly or noise is found, inspect the fork oil level or fork clamps (see Front Fork Oil Change in the Suspension chapter).

•

Pump the seat down and up [A] 4 or 5 times, and inspect the smooth stroke.

If the shock absorber does not smoothly stroke or noise is found, inspect the oil leak (see Rear Shock Absorber

Oil Leak Inspection).


Front Fork Oil Leak Inspection

•

Visually inspect the front forks [A] for oil leakage.

Replace or repair any defective parts, if necessary.


Rear Shock Absorber Oil Leak Inspection

•

Remove the left side cover (see Left Side Cover Removal in the Frame chapter).

•

Visually inspect the shock absorber [A] for oil leakage.

If the oil leakage is found on it, replace the shock absorber with a new one.

Swingarm Pivot Lubrication

•

Remove the swingarm (see Swingarm Removal in the

Suspension chapter).

•

Clean the old grease out of the bearings.

•

Apply grease to the inner surface of the needle bearings

[A].

•

Apply a thin coat of grease to the lips of the grease seals.

•

Install the swingarm (see Swingarm Installation in the

Suspension chapter).

Rocker Arm Operation Inspection

•

Pump the seat down and up 4 or 5 times, and inspect the smooth stroke.

If the rocker arm [A] does not smoothly stroke or noise is found, inspect the fasteners and bearings.

Tie-Rod Operation Inspection

•

Pump the seat down and up 4 or 5 times, and inspect the smooth stroke.

If the tie-rod [A] do not smoothly stroke or noise is found, inspect the fasteners and tie-rod bearings.



Uni-trak Linkage Lubrication

•

Remove:

Tie-Rod (see Tie-Rod Removal in the Suspension chapter)

•

Apply grease to the inner surfaces of the needle bearings

[A]

•

For the rocker arm it has grease nipples [A] on the rocker arm for lubrication. Force grease into the nipple until it comes out both sides of the rocker arm, and wipe off any excess.

•

Apply a thin coat of grease to the lips of the grease seals.

Steering System

Steering Play Inspection

•

Raise the front wheel off the ground with jack.


•

With the front wheel pointing straight ahead, alternately 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 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 wires 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 (VN900D Models) (see Windshield Removal in the Frame chapter)

Handlebar Holder Nuts [A]

Handlebar Holders [B] together with the Handlebar

Upper Front Fork Clamp Bolt (Both Sides) [C]

Steering Stem Head Nut [D]

•

Remove the steering stem head [E].


•

Straighten the claws [A] of the claw washer.

•

Remove the steering stem locknut [B] and claw washer

[C].


•

Adjust the steering.

Special Tool - Steering Stem Nut Wrench [A]: 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.

•

Replace the claw washer with a new one.

•

Install the claw washer [A] so that its bent side [B] faces upward, and engage the bent claws with the grooves of stem locknut [C].

•

Hand tighten the stem locknut until it touches the claw washer.

•

Tighten the stem locknut clockwise until the claws are aligned with the grooves (ranging from 2nd to 4th) of stem

• nut [D], and bend the 2 claws downward [E].

Install the steering stem head.

•

Install the washer, and tighten the stem head nut.

•

Tighten:

Torque - Steering Stem Head Nut: 49 N·m (5.0 kgf·m, 36 ft·lb)

Upper Front Fork Clamp Bolts: 20 N·m (2.0 kgf·m,

15 ft·lb)

•

Check the steering again.

If the steering is still too tight or too loose, repeat the adjustment.

•

Install the removed parts.



Steering Stem Bearing Lubrication

•

Remove the steering stem (see Steering Stem Removal in the Steering chapter).

•

Using a high flash-point solvent, wash the upper and 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 Installation in the Steering chapter).

•

Adjust the steering (see Steering Play Adjustment).



Lights and Switches Operation Inspection

•

First Step


•

The following lights should go on according to below table.

Position Lights [A] ( US and Canada

Models) goes on

City Light [B] (Europe Models)

Taillight [C]

License Plate Light [D]

Neutral Indicator Light [E]

Oil Pressure Warning Indicator Light (LED)

[F]

Water Temperature Warning Indicator

Light (LED) [G]

FI Indicator Light (LED) [H] goes on goes on goes on goes on goes on goes on goes on

(about 2 seconds)

If the light does not go on, inspect or replace the following item.


Applicable Bulb (see Wiring Diagram section in the Electrical System chapter)

Meter Unit for Neutral Indicator Light (LED) (see Meter

Unit Inspection in the Electrical System chapter)

Meter Unit for Oil Pressure/Water Temperature Warning

Indicator Light (LED) (see Meter Unit Inspection in the


Meter Unit for FI Indicator Light (LED) (see Meter Unit

Inspection 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)

Neutral Switch (see Switch Inspection in the Electrical

System chapter)

Harness (see Wiring Inspection in the Electrical System

• chapter)

Turn off the ignition switch.

•

The all lights should go off.

If the light does not go off, replace the ignition switch.

•

Second Step

Turn the ignition switch to P (Park) position.

•

The city light, taillight and license plate light should go on.

If the light does not go on, inspect or replace the following item.


System chapter)




•

Third Step

Turn on the turn signal switch [A] (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 each light does not flash, inspect or replace the following item.

Turn Signal Light Bulb (see Turn Signal Light Bulb Replacement in the Electrical System chapter)

Meter Unit for Turn Signal Light Indicator Light (LED)

(see Meter Unit Inspection in the Electrical System chapter)

Turn Signal Relay Fuse 10 A (see Fuse Inspection in the


Turn Signal Switch (see Switch Inspection in the Electrical System chapter)

Turn Signal Relay (see Turn Signal 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 item.

Turn Signal Switch (see Switch Inspection in the Electrical System chapter)

Turn Signal Relay (see Turn Signal Relay Inspection in the Electrical System chapter)

•

Fourth Step

Set the dimmer switch [A] to low beam position.

•

Start the engine.

•

The low beam should go on.

If the low beam does not go on, inspect or replace the following item.

Headlight Low Beam 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 in Relay Box (see Relay Circuit Inspection in the Electrical System chapter)



•

•

Set the dimmer switch to high beam position.

The high beam should go on.

•

The high beam indicator light (LED) [A] should go on.

If the high beam headlight and/or high beam indicator light

(LED) does not go on, inspect or replace the following item.

Headlight Bulb (see Headlight Bulb Replacement in the


Dimmer Switch (see Switch Inspection in the Electrical

•

System chapter)

Turn off the engine stop switch.

•

The high beam should stay going on.

If the headlights and high beam indicator light (LED) does go off, inspect or replace the following item.

Headlight Relay in Relay Box (see Relay Circuit Inspec-

• tion in the Electrical System chapter)

Turn off the ignition switch.

•

The headlights and high beam indicator light (LED) should go off.


Headlight Aiming Inspection

•

Inspect the headlight beam for aiming.

If the headlight beam points to one side rather than straight ahead, adjust the horizontal beam.

Headlight Beam Horizontal Adjustment

•

Turn the horizontal adjuster [A] on the headlight with the screwdriver in or out until the beam points straight ahead.

If the headlight beam points too low or high, adjust the vertical beam.

Headlight Beam Vertical Adjustment

•

Turn the vertical adjuster [A] on the headlight with the screwdriver in or out to adjust the headlight vertically.

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 US model, the proper angle is 0.4 degrees below horizontal. This is 50 mm (2 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 in.) [A]

Center of Brightest Spot [B]

7.6 m (25 ft.) [C]

Sidestand Switch Operation Inspection

•

Inspect the sidestand switch [A] operation accordance to below table.

Sidestand Switch Operation

Sidestand

Gear

Position

Clutch

Lever

Engine

Start

Up

Up

Neutral

Neutral

Released

Pulled in

Starts

Starts

Engine

Run

Continue running

Continue running

Up In Gear Released

Doesn’t start

Stops

Up

Down

Down

In Gear

Neutral

Neutral

Pulled in

Released

Pulled in

Starts

Starts

Starts

Continue running

Continue running

Continue running

Down

Down

In Gear

In Gear

Released

Pulled in

Doesn’t start

Doesn’t start

Stops

Stops


If the sidestand switch operation does not work, inspect or replace the following item.


Main Fuse 30 A (see Fuse Inspection in the Electrical

System chapter)

Ignition Fuse 10 A (see Fuse Inspection in the Electrical

System chapter)


System chapter)

Sidestand 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)

Neutral Switch (see 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)

Starter Circuit Relay (see Relay Circuit Inspection in the



If the all parts are good condition, replace the ECU.

Engine Stop Switch Operation Inspection

•

First Step


•

Set the neutral position.

•

Turn 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 following item.


•

Second Step


•

Set the neutral position.

•

Turn the engine stop switch to run position [A].

•

•

Push the starter button and run the engine.

Turn the engine stop switch to stop position.

•

Immediately the engine should be stop.

If the engine does not stop, inspect or replace the following item.


If the engine stop switch is good condition, replace the

ECU.




Others

Chassis Parts Lubrication

•

Before lubricating each part, clean off any rusty spots with 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 Brake Joint Pin

Sidestand

Points: Lubricate with Grease.

Clutch Inner Cable Upper and Lower Ends [A]

Throttle Inner Cable Upper and Lower Ends

Cables: Lubricate with Rust Inhibitor.

Clutch Cable

Throttle Cables

•

Lubricate the cables by seeping the oil between the cable and housing.

○

The cable may be lubricated by using a commercially available pressure cable lubricator with an aerosol cable lubricant.

•

With the cable disconnected at both ends, the inner cable 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

•

Check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition.

NOTE

○

For the engine fasteners, check the tightness of them when the engine is cold (at room temperature).

If there are loose fasteners, retighten them to the specified torque following the specified tightening sequence.

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.

Bolt, Nut and Fastener to be checked

Engine:

Clutch Lever Pivot Nut

Engine Mounting Bolts and Nuts


Muffler Mounting Bolt and Nut

Wheels:

Front Axle Nut

Front Axle Clamp Bolt

Rear Axle Nut

Rear Axle Nut Cotter Pin

Brakes:

Brake Lever Pivot Nut

Brake Pedal Bolt

Brake 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 Bolt and Nut

Swingarm Pivot Shaft Nut

Steering:

Steering Stem Head Nut

Handlebar Clamp Bolts

Others:

Footboard Bracket Bolts

Footpeg Bracket Bolts

Front Fender Bolts

Sidestand Bolt

Downtube Bolts





Inspection (CAL)

•

Evaporative Emission Control System Inspection

Inspect the canister as follows:

○

Remove:

Muffler (see Muffler Removal in the Engine Top End

○ chapter)

Remove the bolts [A].

Remove the band [B] and take out the canister [C].

○

Disconnect the hoses [A] from the canister.

Visually inspect the canister for cracks and 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.

○

Install the canister and hoses.

○

Route the hoses according to Cable, Wire and Hose Routing section in the Appendix chapter. Refer to the diagram of the evaporative emission control system in the Fuel

System (DFI) chapter too.

•

Check the liquid/vapor separator as follows:

○

Remove the band [A] and take out the separator [B].

Disconnect the hoses [C] from 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. Refer to the diagram of the evaporative emission control system in the Fuel

System chapter too.

○

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.


Replacement Parts

Air Cleaner Element Replacement

WARNING

If dirt or dust is allowed to pass through into the throttle body assy, the throttle may become stuck, possibly causing accident.


CAUTION

If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur.

•

Remove:

Air Cleaner Cover Bolts [A] and Washer

Air Cleaner Cover [B]

•

Unscrew the air cleaner element screw [A] and remove the air cleaner element [B].

•

Discard:

Air Cleaner Element

•

Install a new element [A] with the mesh side facing up

-ward.

CAUTION

Use only the recommended air cleaner element

(Kawasaki part number 11013-0015). Using another air cleaner element will wear the engine prematurely or lower the engine performance.

Torque - Air Cleaner Element Screw: 4.9 N·m (0.50 kgf·m,

43in·lb)



Engine Oil Change

•

Situate the motorcycle so that it is vertical after warning up the engine.

•

Remove:

Oil Filler Cap [A]

Special Tool - Filler Cap Driver: 57001-1454

•

Remove the engine drain plug [A] to drain the oil.

○

The oil in the oil filter can be drained by removing the filter

(see Oil Filter Replacement).

Replace the drain plug gasket with a new one.

•

Tighten the drain plugs.

Torque - Engine Oil Drain Plug: 20 N·m (2.0 kgf·m, 15 ft·lb)

•

Pour in the specified type and amount of oil.

Recommended Engine Oil

Type: API SE, SF or SG class

API SH, SJ or SL class with JASO MA

Viscosity: SAE 10W-40

Amount:

2.7 L (2.8 US qt) (when filter is not removed)

2.9 L (3.1 US qt) (when filter is removed)

3.2 L (3.4 US qt) (when engine is completely disassembled and dry)

NOTE

○

Although 10W-40 engine oil is the recommended oil for most conditions, the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area.

•

Check the oil level (see Oil Level Inspection in the Engine

Lubrication System chapter).


•

Oil Filter Replacement

Drain the engine oil (see Engine Oil Change).

•

Remove:

Regulator/Rectifier (see Regulator/Rectifier Removal in the Electrical System chapter)

Bolts [A]

Bracket [B]


•

Remove the oil filter [A] with the oil filter wrench [B] and discard the oil filter.

Special Tool - Oil Filter Wrench: 57001-1249

•

Replace the oil filter with the new one.

•

Apply grease to the gasket [A] of the new filter before installation.

•

Tighten the filter with the oil filter wrench.

Torque - Oil Filter: 18 N·m (1.8 kgf·m, 13 ft·lb)

•

Pour in the specified type and amount of oil.

Fuel Hose Replacement

CAUTION

When removing and installing the fuel hose joint, do not apply strong force to the outlet pipe on the fuel pump and delivery pipe on the throttle body assy.

The pipes made from resin could be damaged.

•

Remove the fuel tank (see Fuel Tank Removal in the Fuel

System (DFI) chapter).

•

Insert a minus screw driver [A] into the slit [B] on the joint lock.



•

Twist the driver to disconnect the joint lock [A].

•

Pull [B] 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.

•

Pull [A] the joint lock [B] on the fuel hose fully as shown.

•

Insert the fuel hose joint [A] straight onto the delivery pipe.

•

Push [B] the joint lock [C] until the hose joint clicks.

•

Push and pull [A] the fuel hose joint [B] back and forth more than two times and make sure it is locked and doesn’t 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.

•

Run the fuel hose in accordance with the Cable, Wire and

•

Hose Routing section in the Appendix chapter.

•


Start the engine and check the fuel hose for leaks.


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.

•

Remove:

Left Side Cover (see Left Side Cover Removal in the

Frame chapter)

Bolt [A]

Reserve Tank Cover [B]

•

Remove:

Bolts [A]

Reserve Tank Cap [B]

•

Turn over the reserve tank, and pour the coolant into the suitable container.


•



•

Remove the radiator cap [A] 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.

○

Place a container under the coolant drain bolt [A], then remove the drain bolt.

○

The coolant will drain from the radiator and engine.

•

Install the reserve tank.

CAUTION

Soft or distilled water must be used with the antifreeze (see Specifications section) 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.



Water and Coolant Mixture Ratio (when recommended)

Soft Water : 50%

Coolant : 50%

Freezing Point : − 35°C ( − 31°F)

Total Amount : 2.2 L (2.3 US gt.)

•

Tighten:

Torque - Coolant Drain Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb)

•

Fill the radiator up to the filler neck [A] with coolant.

NOTE

○

Pour in the coolant slowly so that it can expel the air from the engine and radiator.

○

Choose a suitable mixture ratio by referring to the coolant manufacturer’s directions.

•

Check the cooling system for leaks.

•

Tap the radiator hoses to force any air bubbles caught inside.

•

Fill the radiator up to the filler neck with coolant.

•

Install the radiator cap.

•

Fill the reserve tank up to the “F” (full) level line [A] with coolant and install the cap.

•

Install the fuel tank (see Fuel Tank Installation in the Fuel


•

Start the engine and warm it up thoroughly until the radiator fan turns on and then stop the engine.

•

Check the coolant level in the reserve tank several times while the engine is cooling down, and replenish as necessary.

If the coolant level is lower than the “L” level line [B], add coolant to the “F” level line.

CAUTION

Do not add more coolant above the “F” level line.


•

Radiator Hose and O-ring Replacement

Drain the coolant (see Coolant Change).

•

Remove:

Thermostat Bracket [A] (see Thermostat Removal in the

Cooling System chapter)

•

Loosen the radiator hose clamps and remove the hoses

[B].

•

Unscrew the bolts and remove the water hose fittings [C] and O-rings [D].

•

Apply sorp and water solution to the new O-ring and install the water hose fittings.

•

Torque the water hose fitting bolts [E].

Torque - Water Hose Fitting Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

•

Install the new radiator hose and tighten the hose clamps.

Torque - Radiator Hose Clamp Screw: 2.0 N·m (2.0 kgf·m,

18 in·lb)

Thermostat Housing Cover Bracket Bolt: 6.9 N·m

•

(0.70 kgf·m, 61 in·lb)

•

Fill the coolant (see Coolant Change).

Check the cooling system for leaks.

Brake Hose Replacement

CAUTION

Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely washed away immediately.

•

When removing the brake hose [A], take care not to spill the brake fluid on the painted or plastic parts.

•

When removing the brake hoses, temporarily secure the end of the brake hose to some high place to keep fluid

• loss to a minimum.

Immediately wash away any brake fluid that spills.

•

Install new brake hoses.

•

There are washers [B] on each side of the brake hose fitting. Replace them with new ones when installing.

•

Tighten the banjo bolts [C] on the hose fittings.

Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)




•

When installing the hoses [A], avoid sharp bending, kinking, flattening or twisting, and route the hoses according to Cable, Wire and Hose Routing section in the Appendix chapter.

•

Fill the brake line after installing the brake hose (see

Brake Fluid Change).

Brake Fluid Change

NOTE

○

The procedure to change the front brake fluid is as follows. Changing the rear brake fluid is almost the same as for the front brake.

•

Level the brake fluid reservoir.

•

Remove:

Reservoir Cap [A]

Plate [B]

Diaphragm [C]

•

Remove the rubber cap from the bleed valve [A] on the front caliper [B].

•

Attach a clear plastic hose [C] to the bleed valve, and run the other end of the hose into a container.

•

Fill the reservoir with new brake fluid.

•

Temporarily install the reservoir cap.

•

Change the brake fluid as follows:

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.


○

Repeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes.

Open the bleed valve [A].

Pump the brake lever and hold it [B].

Close the bleed valve [C].

Release the brake lever [D].

Front Brake: Repeat the above steps for other caliper.


•

Remove the clear plastic hose.

•

Install the reservoir cap.

•

Follow the procedure below to install the rear brake fluid 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].

•

Tighten the bleed valves, and install the rubber caps.

Torque - Caliper Bleed Valves: 7.8 N·m (0.80 kgf·m, 69 in·lb)

Front Brake Reservoir Cap Screws: 1.5 N·m (0.15

kgf·m, 13 in·lb)

○

For the rear brake caliper [A], change the brake fluid for two bleed valves [B].

•

After changing the fluid, check the brake for good braking power, no brake drag, and no fluid leakage.

If necessary, bleed the air from the lines (see Brake Line

Bleeding in the Brakes chapter).



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], and return spring [I].

•

Replace:

Diaphragm

Dust Cover

Circlip

Piston Assy

Rear Master Cylinder Disassembly

NOTE

○

Do not remove the push rod clevis [A] for master cylinder disassembly since removal requires brake pedal position adjustment.

•

Remove the rear master cylinder (see Rear Master Cylinder Removal in the Brakes chapter).

•

Remove the reservoir cap [B] plate [C] and diaphragm [D].

•

Slide the dust cover [E] on the push rod out of place, and remove the circlip [F].

•

Special Tool - Inside Circlip Pliers: 57001-143

Pull out the push rod with the piston stop.

•

Take off the piston assy [G] (piston [H] primary cup [I], secondary cup [J]), and return spring [K].

•

Replace:

Piston Assy

Dust Cover

Brake Hose [L]

Diaphragm

O-ring [M]

Circlips


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.

•

Apply brake fluid to the removed parts and to the inner wall of the cylinder.

•

Take care not to scratch the piston or the inner wall of the cylinder.

CAUTION

Do not remove the secondary cup from the piston since removal will damage it.

•

Tighten the brake lever pivot bolt and the locknut.

Silicone Grease Brake Lever Pivot Bolt, Brake Lever

Pivot Contact, Push Rod Contact,

Dust Cover

Torque - Brake Lever Pivot Bolt: 1.0 N·m (0.10 kgf·m, 8.8

in·lb)

Brake Lever Pivot Locknut: 5.9 N·m (0.60 kgf·m,

52 in·lb)

Caliper Rubber Parts Replacement

Front Caliper Disassembly

•

Remove:

Front Caliper (see Front Caliper Removal in the Brakes chapter)

Cotter Pin [A]

Pin [B]

Pads [C] (see Front Brake Pad Removal in the Brakes chapter)

•

Push the piston in.

•

Remove:

Pad Springs [A]

Caliper Holder [B]




•

Using compressed air, remove the piston.

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.

○

Insert a wooden board [A] 5 mm (0.2 in.) thick inside the caliper opening.

○

Apply compressed air [B] to the banjo bolt hole to allow the pistons [C] to protrude and stop at the wooden board.

○

Remove the wooden board and pull out the piston by hand.

If compressed air is not available, with the brake hose still attached, apply the brake lever to remove the pistons.

The remaining process is as described above.

•

Remove:

Dust Seals [A]

Fluid Seals (Piston Seals) [B]

Friction Boot [C]

Bleed Valve

CAUTION

Immediately wash away any brake fluid that spills.

Front Caliper Assembly

•

Clean all parts other than the outer and inner pads.

CAUTION

For cleaning the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol.

•

Install the bleed valve [A] and the rubber cap [B].

Torque - Front Caliper Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb)

•

Replace the fluid seals [A] with new ones, apply brake fluid to them, and install them in the caliper body. Either side of the fluid seal may face outboard.

•

Check the dust seals [B] and replace them with new ones if they are damaged.


•

Apply brake fluid to the inside of the cylinders and to the outside of the pistons and push the pistons [A] into the cylinders.

•

Check the friction boot [B] and dust boot [C] and replace them with new ones if they are damaged.

•

Apply a thin coat of silicon grease to the holder shafts [D] and the holder holes.


•

Install the pad springs [A].

•

Install the pads (see Front Brake Pad Installation in the

Brakes chapter).

•

Wash the caliper with water to remove brake fluid and wipe it off.

Rear Caliper Disassembly

•

Remove:

Rear Caliper (see Rear Caliper Removal in the Brakes chapter)

Rear Brake Pad (see Rear Brake Pad Removal in the

Brakes chapter)

Antirattle Spring [A]

•

Pull out the caliper holder [B].

•

Insert a wooden board [A] 5 mm (0.2 in.) thick inside the caliper opening.

•

Remove the pistons using the compressed air.

WARNING

To avoid serious injury, never place your fingers or palm inside the caliper opening. If you apply compressed air into the caliper, the pistons may crush your hand or fingers.

•

Remove the board and pull out the pistons [A] by hand.

CAUTION

Immediately wash away any brake fluid that spills.



•

Remove:

Antirattle Spring [A]

Dust Seals [B] and Fluid Seals [C]

Rubber Friction Boots [D]

Bleed Valves [E] and Rubber Caps [F]

Rear Caliper Assembly

•

Tighten the bleed valve.

Torque - Rear Caliper Bleed Valves: 7.8 N·m (0.80 kgf·m, 69 in·lb)

○

It is recommended that the fluid seal (piston seal) which is removed, be replaced with a new one.

•

Replace the dust seals [A] if they are damaged.

•

Install the fluid seal [B]. Either side of the seal may face outboard.

•

Install the antirattle spring [A] in the caliper as shown.

•

Apply brake fluid to the cylinders, pistons, and fluid seals

(piston seals), and push the pistons into the cylinders by hand. Take care that neither the cylinder nor the piston skirt gets scratched.

•

Replace the caliper holder shaft rubber friction boot [A] and dust boot [B] if they are damaged.

•

Apply a thin coat of silicone or PBC grease to the caliper holder shafts [C] and holder holes (Silicone or PBC grease is a special high temperature, water-resistance grease).

•

Install the pads (see Rear Brake Pad Installation in the

Brakes chapter).

Spark Plug Replacement

•

Remove:

Fuel Tank (see Fuel Tank Removal in the Fuel System chapter)

Spark Plug Caps [A]

•

Remove the spark plug using the 16 mm (0.63 in.) plug wrench vertically.

Special Tool - Spark Plug Wrench, Hex16: 57001-1262


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 CPR7EA

•

Insert new spark plug in the plug hole, and finger-tighten it first.

•

Using the plug wrench [A] vertically, tighten the plug.

CAUTION

The insulator of the spark plug may break if when the wrench is inclined during tightening.

Special Tool - Spark Plug Wrench, Hex16: 57001-1262

•

Torque - Spark Plugs: 18 N·m (1.8 kgf·m, 13 ft·lb)

Install the spark plug caps securely.

○

Be sure the spark plug caps are installed by pulling up it lightly.

FUEL SYSTEM (DFI) 3-1



Exploded View........................................................................................................................

DFI Parts Location..................................................................................................................

Specifications .........................................................................................................................

Special Tools and Sealant ......................................................................................................

DFI System.............................................................................................................................

DFI Servicing Precautions ......................................................................................................

DFI Servicing Precautions ................................................................................................

Troubleshooting the DFI System ............................................................................................

Outline .................................................................................................................................

Outline...............................................................................................................................

Inquiries to Rider..................................................................................................................

Inquiries to Rider...............................................................................................................

DFI System Troubleshooting Guide .......................................................................................

Self-Diagnosis ........................................................................................................................

Self-diagnosis Outline..........................................................................................................

Self-diagnosis Outline .......................................................................................................

Self-diagnosis Procedures...................................................................................................

Self-diagnosis Procedures ................................................................................................

Service Code Clearing Procedures .....................................................................................

Service Code Clearing Procedures...................................................................................

How to Read Service Codes................................................................................................

How to Read Service Codes.............................................................................................

How to Erase Service Codes...............................................................................................

How to Erase Service Codes ............................................................................................

Service Code Table..............................................................................................................

Service Code Table...........................................................................................................

Backups ...............................................................................................................................

Backups ............................................................................................................................

Main Throttle Sensor (Service Code 11) ................................................................................

Main Throttle Sensor Removal/Adjustment ......................................................................

Input Voltage Inspection....................................................................................................

Output Voltage Inspection.................................................................................................

Resistance Inspection.......................................................................................................

Inlet Air Pressure Sensor (Service Code 12)..........................................................................

Inlet Air Pressure Sensor Removal...................................................................................

Inlet Air Pressure Sensor Installation................................................................................



Inlet Air Temperature Sensor (Service Code 13)....................................................................

Inlet Air Temperature Sensor Removal/Installation...........................................................


Sensor Resistance Inspection ..........................................................................................

Water Temperature Sensor (Service Code 14) ......................................................................

Removal/Installation..........................................................................................................


Water Temperature Sensor Resistance Inspection...........................................................

Crankshaft Sensor (Service Code 21)....................................................................................

Crankshaft Sensor Removal/Installation...........................................................................

Crankshaft Sensor Inspection...........................................................................................

Speed Sensor (Service Code 24, 25).....................................................................................

3-56

3-57

3-59

3-59

3-59

3-59

3-61

3-61

3-61

3-63

3-51

3-51

3-51

3-51

3-52

3-56

3-56

3-45

3-45

3-47

3-47

3-47

3-48

3-49

3-40

3-42

3-42

3-42

3-42

3-43

3-43

3-31

3-39

3-39

3-39

3-39

3-39

3-40

3-4

3-8

3-11

3-13

3-14

3-22

3-22

3-24

3-24

3-24

3-28

3-28

3

3-2 FUEL SYSTEM (DFI)

Speed Sensor Removal ....................................................................................................

Speed Sensor Installation .................................................................................................

Speed Sensor Inspection..................................................................................................



Vehicle-down Sensor (Service Code 31)................................................................................

Vehicle-down Sensor Removal .........................................................................................

Vehicle-down Sensor Installation ......................................................................................

Vehicle-down Sensor Inspection.......................................................................................

Subthrottle Sensor (Service Code 32)....................................................................................

Subthrottle Sensor Removal/Adjustment ..........................................................................




Oxygen Sensor-not activated (#1, #2: Service Code 33, 83)-Europe Models .......................

Oxygen Sensor Removal/Installation................................................................................

Oxygen Sensor Inspection................................................................................................

Ignition Coils (#1, #2: Service Code 51, 52)...........................................................................

Ignition Coil Removal/Installation......................................................................................


Radiator Fan Relay (Service Code 56)...................................................................................

Radiator Fan Relay Removal/Installation..........................................................................

Radiator Fan Relay Inspection..........................................................................................

Subthrottle Valve Actuator (Service Code 62) ........................................................................

Subthrottle Valve Actuator Removal .................................................................................

Subthrottle Valve Actuator Inspection ...............................................................................



Air Switching Valve (Service Code 64) ...................................................................................

Air Switching Valve Removal/Installation ..........................................................................

Air Switching Valve Inspection ..........................................................................................

Oxygen Sensor Heaters (#1, #2: Service Code 67)-Europe Models .....................................

Oxygen Sensor Heater Removal/Installation ....................................................................

Oxygen Sensor Heater Inspection ...................................................................................

Oxygen Sensors-Incorrect Output Voltage (#1, #2: Service Code 94, 95)-Europe Models ...

Oxygen Sensor Removal/Installation................................................................................

Oxygen Sensor Inspection................................................................................................

FI Indicator LED Light.............................................................................................................

LED Light Inspection.........................................................................................................

ECU ........................................................................................................................................

ECU Removal ...................................................................................................................

ECU Installation ................................................................................................................

ECU Power Supply Inspection..........................................................................................

Fuel Line.................................................................................................................................

Fuel Pressure Inspection ..................................................................................................

Fuel Flow Rate Inspection ................................................................................................

Fuel Pump ..............................................................................................................................

Fuel Pump Removal .........................................................................................................

Fuel Pump Installation ......................................................................................................

Pump Screen, Fuel Filter Cleaning ...................................................................................

Operation Inspection.........................................................................................................

Operating Voltage Inspection............................................................................................

3-98

3-98

3-99

Power Source Voltage Inspection .....................................................................................

3-100

Fuel Injectors ..........................................................................................................................

3-103

Injector Removal ...............................................................................................................

3-103

Injector Installation ............................................................................................................

3-104

Injector Fuel Line Inspection .............................................................................................

3-105

3-91

3-91

3-93

3-93

3-95

3-97

3-97

3-97

3-86

3-86

3-86

3-88

3-89

3-91

3-91

3-80

3-82

3-82

3-82

3-84

3-84

3-84

3-77

3-77

3-77

3-79

3-79

3-79

3-79

3-71

3-73

3-73

3-73

3-75

3-75

3-75

3-66

3-66

3-66

3-69

3-69

3-69

3-70

3-63

3-63

3-63

3-63

3-64

3-66


Audible Inspection.............................................................................................................

3-106

Fuel Injector Power Source Voltage Inspection ................................................................

3-106


3-107

Injector Signal Test............................................................................................................

3-108

Injector Resistance Inspection ..........................................................................................

3-108

Injector Unit Test ...............................................................................................................

3-109

Throttle Grip and Cables ........................................................................................................

3-112

Throttle Grip Free Play Inspection ....................................................................................

3-112

Throttle Grip Free Play Adjustment...................................................................................

3-112

Cable Removal/Installation ...............................................................................................

3-112

Cable Lubrication and Inspection......................................................................................

3-112

Throttle Body Assy .................................................................................................................

3-113

Idle Speed Inspection .......................................................................................................

3-113

Idle Speed Adjustment......................................................................................................

3-113

Throttle Bore Cleaning ......................................................................................................

3-113

High Altitude Performance Adjustment .............................................................................

3-113

Throttle Body Assy and Intake Manifold Removal ............................................................

3-113

Throttle Body Assy and Intake manifold Installation .........................................................

3-115

Air Cleaner..............................................................................................................................

3-118

Air Cleaner Element Removal/Installation ........................................................................

3-118

Air Cleaner Housing Removal...........................................................................................

3-118

Air Cleaner Housing Installation........................................................................................

3-118

Fuel Tank ................................................................................................................................

3-120

Fuel Tank Removal ...........................................................................................................

3-120

Fuel Tank Installation ........................................................................................................

3-123

Fuel Tank and Cap Inspection ..........................................................................................

3-124

Fuel Tank Cleaning ...........................................................................................................

3-124

Breather Check Valve Inspection......................................................................................

3-124

Evaporative Emission Control System ...................................................................................

3-126

Parts Removal/Installation ................................................................................................

3-126

Canister Installation ..........................................................................................................

3-126

Canister Inspection (Periodic Inspection) .........................................................................

3-126

Separator Inspection (Periodic Inspection) .......................................................................

3-126

Hose Inspection (Periodic Inspection) ..............................................................................

3-126

Separator Operation Test..................................................................................................

3-127


Exploded View

Exploded View

No.

Fastener

1 Fuel Pump Bolts

2 Air Cleaner Housing Bolts

3 Air Cleaner Cover Bolts

4 Throttle Body Assy Holder Bolts

5 Inlet Manifold Bolts

6 Delivery Joint Bolts

7 Delivery Joint Bracket Bolts

8 Vehicle-down Sensor Bolts

9 Speed Sensor Mounting Bolt

10 Inlet Air Pressure Sensor Bolt

11 Inlet Air Temperature Sensor Screw

12 Air Cleaner Element Screw

13 Water Temperature Sensor

CL: Apply cable lubricant.

G: Apply grease.

L: Apply a non-permanent locking agent.


4.9

9.8

6.9

1.2

4.9

12

9.8

9.8

9.8

9.8

N·m

9.8

9.8

4.9

Torque kgf·m

1.0

1.0

0.50

1.0

1.0

1.0

1.0

0.50

1.0

0.70

0.12

0.50

1.2

ft·lb

87 in·lb

87 in·lb

43 in·lb

87 in·lb

87 in·lb

87 in·lb

87 in·lb

43 in·lb

87 in·lb

61 in·lb

11 in·lb

43 in·lb

106 in·lb

Remarks

L

L

L


Exploded View


Exploded View

No.

Fastener

1 Fuel Level Sensor Mounting Bolts

2. California Model

3. Breather Hose (Other than California Models)


R: Replacement Parts

N·m

6.9

Torque kgf·m

0.70

ft·lb

61 in·lb

Remarks

L


DFI Parts Location

1. Ignition Coil #1

2. Fuel Pump

3. Ignition Coil #2

4. Main Fuse 30 A

5. Relay Box

6. Fuse Box

7. Vehicle Down Sensor

8. ECU

9. Battery

10. Crankshaft Sensor

11. Injector #2

12. Injector #1

13. Water Temperature Sensor

14. Main Throttle Sensor

15. Subthrottle Sensor

16. Subthrottle Valve Actuator

17. Air Switching Valve

18. Inlet Air Pressure Sensor

19. Inlet Air Temperature Sensor

20. Oxygen Sensors (Europe Models)

21. Speed Sensor






Specifications

Item

Throttle Grip Free Play

Air Cleaner Element

DFI System

Make

Idle Speed

Throttle Body Assy:

Type × Bore

2 ∼ 3 mm (0.08

Denso

∼

1 000 ±50 r/min (rpm)

Standard

0.12 in.)

Viscous paper element

With Engine Idling

Throttle Sensor:

Input Voltage

Output Voltage

Two barrel type × 34 mm (1.34 in.)

ECU (Electronic Control Unit):

Type Digital memory type, with built in IC igniter, sealed with resin

Fuel Pressure (High Pressure Line):

Right After Ignition Switch ON 304 kPa (3.1 kgf/cm², 44 psi) with fuel pump running

After Pump Runs 3 seconds and Stops. 280 kPa (2.9 kgf/cm², 41 psi) with fuel pump stopped

304 kPa (3.1 kgf/cm², 44 psi) with fuel pump running

Non-adjustable and non-removable

4.75

∼ 5.25 V DC between BL and BR/BK leads

1.05

∼ 4.26 V DC between Y/W and BR/BK leads

(at idle throttle opening to full throttle opening)

4 ∼ 6 k Ω Resistance

Inlet Air Pressure Sensor:

Input Voltage

Output Voltage

4.75


3.80

∼ 4.20 V DC between Y/BL and BR/BK leads

(at standard atmospheric pressure)

Inlet Air Temperature Sensor:

Resistance 5.4

∼ 6.6 k Ω at 0°C (32°F)

0.29

∼ 0.39 k Ω at 80°C (176°F) about 2.25

∼ 2.50 V at 20°C (68°F) Output Voltage

Water Temperature Sensor:

Resistance

Output Voltage

Vehicle-Down Sensor:

Detection Method

Detection Angle

Fuel Injectors:

Type see Electrical System chapter about 2.80

∼ 2.97 V at 20° C (68° F)

Magnetic flux detection method

More than 45° ±5° for each bank

INP-287

One spray type with 12 holes

11.7

∼ 12.3

Ω at 20° C (68° F)

Nozzle Type × Diameter

Resistance

Fuel Pump:

Type

Discharge

Speed Sensor:

Input Voltage at Sensor

Output Voltage at Sensor

Friction pump

50 mL (1.7 US oz.) or more for 3 seconds

4.75

∼ 5.25 V DC at Ignition Switch ON about 0.05

∼ 0.09 V DC or 4.5

∼ 4.9 V at Ignition

Switch ON and 0 km/h


Specifications

Item

Subthrottle Sensor:

Input Voltage

Output Voltage

Resistance

Subthrottle Valve Actuator:

Resistance

Input Voltage

Oxygen Sensor:

Output Voltage (Rich)

Output Voltage (Lean)

Heater Resistance

Standard

Non-adjustable and non-removable

4.75


0.93

∼ 4.59 V DC between BL/W and BR/BK leads

(at idle throttle opening to full throttle opening)

4 ∼ 6 k Ω about 5.2

∼ 7.8

Ω about 8.9

∼ 10.9 V DC

0.45

∼ 2.5 V

0.05

∼ 0.45 V about 8 Ω at 20°C (68°F)

Special Tools and Sealant

Oil Pressure Gauge, 5 kgf/cm²:

57001-125


Needle Adapter Set:

57001-1457

Fork Oil Level Gauge:

57001-1290

Hand Tester:

57001-1394

Fuel Pressure Gauge Adapter:

57001-1593

Fuel Hose:

57001-1607

Peak Voltage Adapter:

57001-1415

Filler Cap Driver:

57001-1454

Speed Sensor Measuring Adapter:

57001-1667

Kawasaki Bond (Silicone Sealant):

56019-120


DFI System

DFI System

DFI System

1. Battery

2. ECU

3. Injector

4. Fuel Pump

5. Fuel Tank


7. Air Cleaner






13. Vehicle-down Sensor

14. Speed Sensor

15. Oxygen Sensor (Europe Models)



18. FI Indicator Light (LED)

19. Air Flow

20. Fuel Flow



DFI System

DFI System Wiring Diagram (Other than Europe Models)

DFI System

Part Name

1. ECU

2. Diagnosis Connector

3. Self-diagnosis Terminal

4. Fuel Pump


6. Frame Ground

7. Battery

8. Main Fuse 30 A

9. Relay Box

10. Fuel Pump Relay

11. ECU Main Relay

12. Radiator Fan Relay

13. Radiator Fan Fuse 15 A

14. ECU Fuse 15 A

15. Ignition Fuse 10 A


17. Water Temperature Warning Indicator Light (LED)

18. Speedometer

19. Meter Unit

20. Joint Connector A

21. Joint Connector C

22. Ignition Switch

23. Engine Stop Switch

24. Starter Button

25. Fan Motor

26. Ignition Coil #1


28. Spark Plugs


30. Speed Sensor





35. Joint Connector B

36. Injector #1

37. Injector #2






DFI System

DFI System Wiring Diagram (Europe Models)

DFI System

Part Name

1. ECU

2. Diagnosis Connector


4. Fuel Pump


6. Frame Ground

7. Battery

8. Main Fuse 30 A

9. Relay Box

10. Fuel Pump Relay

11. ECU Main Relay


13. Oxygen Sensor Heater Fuse 10 A

14. Radiator Fan Fuse 15 A

15. ECU Fuse 15 A


17. Meter Unit


19. Water Temperature Warning Indicator Light (LED)

20. Speedometer



23. Ignition Switch


25. Starter Button

26. Fan Motor



29. Spark Plugs


31. Speed Sensor






37. Injector #1

38. Injector #2




42. Oxygen Sensor #1

43. Oxygen Sensor #2



DFI System

Other than Europe Models

Terminal Names

1. Subthrottle Valve Actuator Drive Signal 2


3. Water Temperature Warning Light Signal

4. Unused

5. Speed Sensor Signal

6. Main Throttle Sensor Signal

7. Inlet Air Pressure Sensor Signal

8. Power Supply to Sensors

9. Vehicle-down Sensor Signal

10. Neutral Switch Signal

11. Crankshaft Sensor (+) Signal

12. Power Supply to ECU (from ECU Main Relay)

13. External Diagnosis System Signal



16. Unused

17. Water Temperature Sensor Signal


19. Subthrottle Sensor Signal

20. Inlet Air Temperature Sensor Signal

21. Unused

22. Ground to Sensors

23. Unused

24. Crankshaft Sensor (–) Signal

25. Unused

26. Ground to ECU

27. Power Supply to ECU (from Battery)

28. Engine Stop Switch Signal

29. Starter Lockout Switch Signal

30. Starter Button Signal

31. Fuel Pump Relay Signal

32. Air Switching Valve Signal

33. Fuel Injector #2 Signal


35. Ignition Coil #1 Signal

36. Sidestand Switch Signal

37. Radiator Fan Relay Signal

38. Unused

39. Unused

40. FI Indicator LED Light

41. –

42. Ground for Fuel System

43. Ground for ignition System


DFI System

Europe Model


Terminal Names



3. Water Temperature Warning Light Signal

4. Oxygen Sensor Signal 2

5. Oxygen Sensor Signal 1

6. Speed Sensor Signal

7. Main Throttle Sensor Signal

8. Inlet Air Pressure Sensor Signal

9. Unused

10. Power Supply to Sensors

11. Vehicle-down Sensor Signal

12. Neutral Switch Signal

13. Crankshaft Sensor (+) Signal

14. Unused

15. Unused

16. Power Supply to ECU (from ECU Main Relay)

17. Power Supply to ECU (from Battery)



20. Water Temperature Sensor Signal

21. Unused


23. Unused

24. Subthrottle Sensor Signal

25. Unused

26. Inlet Air Temperature Sensor Signal

27. Unused

28. Ground to Sensors

29. Oxygen Sensor Heater Signal

30. Crankshaft Sensor (–) Signal

31. Unused

32. External Diagnosis System Signal

33. Unused

34. Ground to ECU

35. Engine Stop Switch Signal

36. Starter Lockout Switch Signal

37. Starter Button Signal

38. Unused

39. Fuel Pump Relay Signal

40. Air Switching Valve Signal




44. Sidestand Switch Signal

45. Radiator Fan Relay Signal

46. Unused

47. Unused


49. –

50. Ground for Fuel System

51. Ground for ignition System



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.

○

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.

○

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]

○

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, 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 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.

○

To prevent corrosion and deposits in the fuel system, do not add to fuel any fuel antifreeze chemicals.

DFI Servicing Precautions

○

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 plug [A] after filling the engine oil.

Alternator Cover [B]

Special Tool - Filler Cap Driver: 57001-1454



Troubleshooting the DFI System

Outline

Outline

When an abnormality in the system occurs, the FI indicator LED (Light Emitting Diode) light goes on to alert the rider on the meter panel. In addition, the condition of the problem is stored in the memory of the ECU (electronic control unit).

With the engine stopped and turned in the self-diagnosis mode, the service code [A] is indicated by the number of times the FI indicator LED light blinks.

When due to a malfunction, the FI indicator LED light remains lit, ask the rider about the conditions [B] under which the problem occurred and try to determine the cause [C].

•

First, conduct a self-diagnosis inspection and then a non

-self-diagnosis inspection. The non-self-diagnosis items are not indicated by the FI indicator LED light. Don’t rely solely on the DFI self-diagnosis function, use common sense.

Even when the DFI system is operating normally, the FI indicator LED light [A] may light up under strong electrical interference. No repair needed. Turn the ignition switch

OFF to stop the indicator light.

When the FI indicator LED light goes on and the motorcycle is brought in for repair, check the service codes.

When the repair has been done, the LED light doesn’t go on. But the service codes stored in memory are not erased to preserve the problem history, and the LED light can display the codes in the self-diagnosis mode. The problem history is referred when solving unstable problems.

When the motorcycle is down, the vehicle-down sensor is turned OFF and the ECU shuts off the fuel injectors and ignition system. The FI indicator LED light blinks but the service code cannot be displayed. The ignition switch is left

ON. If the starter button is pushed, the electric starter turns but the engine doesn’t start. To start the engine again, raise the motorcycle, turn the ignition switch OFF, and then ON.

The vehicle-down sensor is turned ON and the LED light goes OFF.


○

The DFI part connectors [A] have seals [B], including the

ECU.

•

Join the connector and insert the needle adapters [C] inside the seals [B] from behind the connector until the adapter reaches the terminal.

Special Tool - Needle Adapter Set: 57001-1457

CAUTION

Insert the needle adapter straight along the terminal in the connector to prevent short-circuit between terminals.

•

Make sure that measuring points are correct in the connector, noting the position of the lock [D] and the lead color before measurement. Do not reverse connections of the hand tester or 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.

Silicone Sealant (Kawasaki Bond: 56019-120)

- Seals of Vehicle-down Sensor Connector

•

Always check battery condition before replacing the DFI 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).

•

Make sure all connectors in the circuit are clean and tight, 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.




•

Pull each connector [A] apart and inspect it for corrosion, dirt, and damage.

If the connector is corroded or dirty, clean it carefully. If it

• is damaged, replace it. Connect the connectors securely.

Check the wiring for continuity.

○

Use the wiring diagram to find the ends of the lead which is suspected of being a problem.

○

Connect the hand tester between the ends of the leads.

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 sub harness.

○

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.

•

Narrow down suspicious locations by repeating the continuity 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.

○

Lead 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

W: White

Y: Yellow


○

There are two ways to inspect the DFI system. One is voltage Check Method and the other is Resistance Check

Method.

(Voltage Check Method)

○

This method is conducted by measuring the input voltage

[B] to a sensor [A] first, and then the output voltage [C] from the sensor.

○

Sometimes this method can detect a fault of the ECU.

•

Refer to each sensor inspection section for detail in this chapter.

•

Use a fully charged battery and a digital meter [D] which can be read two decimal places voltage or resistance.


(Resistance Check Method)

○

This method is simple. No need for a fully charged battery and the needle adapter. Just do the following especially when a sensor [A] is suspect.

•

Turn the ignition switch OFF and disconnect the connectors.

•

Inspect the sensor resistance, using a digital meter (see each sensor inspection in this chapter).

•

Inspect the wiring and connectors [B] for continuity, using the hand tester [C] (analog tester) rather than a digital meter.

Special Tool - Hand Tester: 57001-1394

If the sensor, the wiring and connections are good, inspect the ECU for its ground and power supply (see this chapter). If the ground and power supply are good, the

ECU is suspect. Replace the ECU.



DFI Diagnosis Flow Chart

Inquiries to Rider

Inquiries to Rider

○

Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered.

○

Try to find out exactly what problem occurred under exactly what conditions by asking the rider; knowing this information may help you reproduce the problem.

○

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.



Sample Diagnosis Sheet

Rider name Registration No. (license plate No.) Year of initial registration

Model Engine No.

Date problem occurred

Frame No.

Mileage

Weather

Temperature

Problem frequency

Road

Altitude

Environment when problem occurred.

□ fine,

□ cloudy,

□ rain,

□ snow,

□ always,

□ other:

□ hot,

□ warm,

□ cold,

□ very cold,

□ always

□ chronic,

□ often,

□ once

□ street,

□ highway,

□ mountain road (

□ uphill,

□ downhill),

□ bumpy,

□ pebble

FI indicator

LED light

Starting difficulty

Engine stops

Poor running at low speed

□ normal,

□ high (about 1000 m or more)

Motorcycle conditions when problem occurred.

□ light up immediately after ignition switch ON, and goes off after engine oil pressure is high enough (with engine running) (normal).

□ lights up immediately after ignition switch ON, and stays on after engine oil pressure is high enough (with engine running) (DFI problem)

□ lights up immediately after ignition switch ON, but goes off after about 10 seconds though engine oil pressure is high enough (with engine running) (DFI problem).

□ unlights (LED light, ECU or its wiring fault).

□ sometimes lights up (probably wiring fault).

□ starter motor not rotating.

□ starter motor rotating but engine doesn’t turn over.

□ starter motor and engine don’t turn over.

□ no fuel flow (

□ no fuel in tank,

□ no fuel pump sound).

□ engine flooded (do not crank engine with throttle opened, which promotes engine flooding).

□ no spark.

□ other:

□ right after starting.

□ when opening throttle grip.

□ when closing throttle grip.

□ when moving off.

□ when stopping the motorcycle.

□ when cruising.

□ other:

□ very low fast idle speed.

□ very low idle speed,

□ very high idle speed,

□ rough idle speed.

□ battery voltage is low (charge the battery).

□ spark plug loose (tighten it).

□ spark plug dirty, broken, or gap maladjusted (adjust it).

□ backfiring.

□ afterfiring.

□ hesitation when acceleration.

□ engine oil viscosity too high.

□ brake dragging.



Poor running or no power at high speed

□ engine overheating.

□ clutch slipping.

□ other:

□ 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:


DFI System Troubleshooting Guide

NOTE

○

This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties.

○

The ECU may be involved in the DFI electrical and ignition system troubles. If these parts and circuits checked out good, be sure to check the ECU for ground and power supply. If the ground and power supply are checked good, replace the ECU.

Engine Doesn’t Start, Starting Difficulty

Symptoms or Possible Causes

Starter motor not rotating

Actions (chapter)

Ignition and engine stop switches not ON Turn both switches ON.

Starter lockout switch or neutral switch trouble Inspect (see chapter 16).

Starter motor trouble

Battery voltage low

Starter relays not contacting or operating

Starter button not contacting

Inspect (see chapter 16).

Inspect and charge (see chapter 16).

Inspect the starter relay (see chapter 16).

Inspect and replace (see chapter 16).

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

Starter clutch trouble

Inspect the wiring (see chapter 16).


Inspect and repair or replace (see chapter 16).




Starter idle gear trouble

Engine won’t turn over

Valve seizure

Rocker arm seizure

Cylinder, piston seizure

Camshaft seizure

Connecting rod small end seizure

Connecting rod big end seizure

Crankshaft seizure

Transmission gear or bearing seizure

Balancer bearing seizure

No fuel flow

No or little fuel in tank

Fuel pump not rotating

Fuel injector trouble

Fuel tank air vent obstructed

Fuel filter or pump screen clogged

Fuel pressure regulator clogged

Fuel line clogged

Engine flooded

Spark plug dirty, broken or gap maladjusted










Supply fuel (see Owner’s Manual).



Inspect and repair (see chapter 3).

Inspect and replace fuel pump (see chapter 3)

Inspect and replace fuel pump (see chapter 3).


Starting technique faulty

Clean spark plugs and adjust plug gap (see chapter 2).

When flooded, don’t crank engine with throttle fully opened.




No spark or spark weak

Ignition and engine stop switches not ON

Clutch lever not pulled in and gear not in neutral whether sidestand up or not

Though clutch lever pulled in but sidestand up and gear not in neutral

Vehicle-down sensor coming off

Vehicle-down sensor trouble

ECU ground or power supply trouble

Battery voltage low


Spark plug cap or high tension wiring trouble Inspect the ignition coil (see chapter 16).

Spark plug cap shorted or not in good contact Reinstall or inspect the cap (see chapter 16).

Spark plug incorrect

IC igniter in ECU trouble

Neutral, starter lockout or sidestand switch trouble

Replace it with the correct plug (see chapter 16).


Inspect each switch (see chapter 16).

Crankshaft sensor trouble

Ignition coil trouble

Ignition switch shorted

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, crankcase breather hose or air cleaner drain hose

Water or foreign matter in fuel


Turn both switches ON.

Pull the lever in and shift the gear in neutral.

Sidestand down and clutch lever pulled inwhether gear in neutral, or not.

Reinstall (see chapter 3).




Clean spark plug and adjust plug gap (see chapter 2).



Clean or reinstall (see chapter 3).


Fuel pressure regulator trouble

Change fuel. Inspect and clean fuel system (see chapter 3).

Inspect fuel pressure and replace fuel pump (see chapter 3).





Throttle sensor trouble

Fuel pressure may be low

Fuel pump trouble


Inlet air pressure sensor trouble

Inlet air temperature sensor trouble

Water temperature sensor trouble

Throttle valves or actuator trouble


Compression low

Spark plug loose

Cylinder head not sufficiently tightened down

Cylinder, piston worn







Tighten (see chapter 5).




Symptoms or Possible Causes Actions (chapter)

Piston ring bad (worn, weak, broken or sticking) Inspect and replace (see chapter 5).

Piston ring/groove clearance excessive

Cylinder head gasket damaged


Replace (see chapter 5).

Cylinder head warped

Valve guide worn

Valve spring broken or weak

Valve not seating properly (valve bent, worn or carbon accumulating on seating surface)





Poor Running at Low Speed


Spark weak

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





Fuel/air mixture incorrect

Little fuel in tank

Air cleaner clogged, poorly sealed, or missing

Air cleaner duct loose

Air cleaner O-ring damaged


Throttle body assy loose

Throttle body assy O-ring damage


Fuel filter or pump screen clogged

Fuel pressure regulator clogged

Fuel line clogged

Thermostat trouble



Unstable (rough) idling






Fuel pressure too low or too high

Battery voltage low


Clean spark plugs and adjust plug gap (see chapter 2).

Inspect the ignition coil (see chapter 16).

Reinstall or inspect the cap (see chapter 16).

Replace it with the correct plug (see chapter 16).




Supply fuel (see Owner’s Manual).

Clean element or inspect sealing (see chapter 3).






Push in (see chapter 3).

Inspect and replace fuel pump (see chapter 3).

Inspect fuel pressure and replace fuel pump (see chapter 3).















Incorrect idle speed




Engine stalls easily

Fuel pump trouble


Throttle sensor trouble (engine stops when opening the throttle)




Fuel pressure regulator trouble





Loose injector connectors



Loose terminal of battery (–) lead or engine ground lead














Compression Low

Spark plug loose




Cylinder, piston worn Inspect and replace (see chapter 5).





Valve guide worn or stem seal damaged


Valve not seating properly (valve bent, worn or carbon accumulating on seating surface)







Camshaft cam worn

Hesitation

Too low fuel pressure

Clogged fuel line

Cracked or obstructed inlet air pressure sensor hose

Fuel pump trouble



Throttle sensor malfunction











Remedy (see chapter 3).







Delay of ignition timing

Poor acceleration



Clogged fuel filter

Fuel pump trouble





Engine oil level too high


Stumble






Surge

Unstable fuel pressure



Backfiring when deceleration




Fuel pump trouble





Air switching valve broken

Air suction valve trouble

After fire

Spark plug burned or gap maladjusted






Inspect crankshaft sensor and IC igniter in ECU

(see chapter 16).


Change fuel. Inspect and clean fuel system (see chapter 3)

Inspect (see chapter 3) and replace fuel pump.


Inspect (see chapter 3)




Repair (see chapter 7)

Clean spark plugs and adjust plug gap (see chapter 2)






Fuel pressure regulator trouble (Inspect and replace fuel pump) or kinked fuel line (Inspect and repair fuel line) (see chapter 3).



Clean spark plugs and adjust plug gap (see chapter 2)








Inspect and replace (see chapter 5 or 16).


Adjust plug gap or replace plug (see chapter 16).









Run-on (dieseling)

Ignition switch trouble

Engine switch trouble


Engine overheating






(see Overheating of Troubleshooting Guide, see chapter 17)

Other

Engine oil viscosity too high

Drive belt trouble

Brake dragging

Clutch slipping

Engine overheating

Air switching valve trouble


Intermittent any DFI fault and its recovery

Change (see chapter 2).


Inspect caliper fluid seal damage or clogging of master cylinder relief and supply ports (see chapter 12).

Inspect friction plates for wear (see chapter 6).

(see Overheating of Troubleshooting Guide in chapter 17



Check that DFI connectors are clean and tight, and examine wires for signs of burning or fraying

(see chapter 3).

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





Fuel/mixture incorrect

Air cleaner clogged, poorly sealed, or missing




Throttle body assy loose

Throttle body assy O-ring damaged


Fuel line clogged

Fuel pump operates intermittently and often DFI fuse blows.

Fuel pump trouble

Actions (detailed reference)

Clean spark plug and adjust plug gap (see chapter 2).

Inspect plug cap and ignition coil (see chapter

16).

Reinstall or inspect the cap (see chapter 16).

Replace it with the correct plug (see chapter 16)




Clean element or inspect sealing (see chapter 3).



Change fuel. Inspect and clean fuel system (see chapter 3).





Pump bearings may wear. Replace the pump

(see chapter 3).








Cracked or obstructed inlet air pressure sensor hose





Inspect and repair or replace (see chapter 3)

Injector clogged

Compression low

Spark plug loose


Visually inspect and replace (see chapter 3)



Cylinder, piston worn Inspect and replace (see chapter 5).






Valve not seating properly (valve bent , worn or carbon accumulating on the seating surface)

Knocking

Carbon buit up in combustion chamber

Fuel poor quality or incorrect (Use high-octone gasoline recommended in the Owner’s Manual)






Repair (see chapter 5).

Change fuel (see chapter 3).





Miscellaneous

Throttle valves won’t fulley open

Replace it with the correct plug (see chapter 16)




Brake dragging

Clutch slipping

Engine overheating


Engine oil viscosity too high

Drive belt trouble

Camshaft cam worn

Air switching valve trouble


Catalytic converters melt down due to muffler overheating

Inspect throttle cable and lever linkage (see chapter 3).

Inspect caliper fluid seal damage or clogging of master cylinder relief and supply ports (see chapter 12).

Inspect friction plates for wear (see chapter 6).

(see Overheating of Troubleshooting Guide in chapter 17)


Change (see chapter 3).



Inspect and replace (see chapter 5 or 16).


Replace muffler (see chapter 5).

Exhaust Smokes Excessively

White smokes

Piston oil ring worn Inspect and replace (see chapter 5).




Cylinder worn

Valve oil seal damaged

Valve guide worn


Black smoke

Air cleaner clogged

Too high fuel pressure

Injection stuck open



Brown smoke









Replace the guide (see chapter 5).


Clean (see chapter 3).










Self-Diagnosis

Self-diagnosis Outline

Self-diagnosis Outline

The self-diagnosis system has three modes and can be switched to another mode by grounding the self-diagnosis terminal.

User Mode

The ECU notifies the rider of troubles in DFI system and ignition system by lighting the FI indicator when DFI system and ignition system parts are faulty, and initiates fail-safe function. In case of serious troubles, the ECU stops the injection/ignition/starter motor operation.

Dealer Mode 1

The FI indicator light (LED) emits service code(s) to show the problem(s) which the DFI system, and ignition system has at the moment of diagnosis.

Dealer Mode 2

The FI indicator light (LED) emits service code(s) to show the problem(s) which the DFI system, and ignition system had in the past.

Self-diagnosis Procedures

Self-diagnosis Procedures

○

When a problem occurs with the DFI system and ignition system, the FI indicator light (LED) [A] goes on.

NOTE

○

Use a fully charged battery when conducting self-diagnosis.

Otherwise, the light (LED) blinks very slowly or doesn’t blink.

○

Keep the self-diagnosis terminal grounded during self

-diagnosis, with an auxiliary lead.

•

Remove the tool box (see Tool Box Removal in the Frame chapter).

•

Ground the self-diagnosis terminal [A] (Yellow lead) to the battery (–) terminal or battery (–) lead connector, using a wire.


•


•

Connect an auxiliary lead [E] to the self-diagnosis terminal

[G] for grounding.

•

To enter the self-diagnosis dealer mode 1, ground [A] the self-diagnosis indicator terminal to the battery (–) terminal for more than 2 seconds [C], and then keep it grounded continuously [D].

○

Count the blinks of the light (LED) to read the service code. Keep the auxiliary lead ground until you finish reading the service code.


Self-Diagnosis

•

To enter the self-diagnosis dealer mode 2, open [B] and ground [A] the lead more than five times [F] within 2 seconds [C] after the lead is first grounded, and then keep it grounded continuously [D] for more than 2 seconds.

○

Count the blinks of the light (LED) to read the service code. Keep the auxiliary lead ground until you finish reading the service code.

Auxiliary Lead [E]

Self-diagnosis Terminal [G]

NOTE

○

To enter the dealer mode 2 from the dealer mode 1, turn off the ignition switch once.

Service Code Clearing Procedures

Service Code Clearing Procedures

•

Enter the self-diagnosis dealer mode 2 (see Self

-diagnosis Procedures).

NOTE

○

Make sure to keep the grounding until the following opening and grounding starts.

•

Pull the clutch lever in more than 5 seconds, and then release it.

•

Repeat opening [B] and grounding [A] the lead

(self-diagnosis terminal) more than five times [F] within 2 seconds [C] after the lead is grounded, and then keep it grounded continuously [D] for more than 2 seconds.

Auxiliary Lead [E]

Self-diagnosis Terminal [G]

Self-Diagnosis



Self-Diagnosis

How to Read Service Codes

How to Read Service Codes

○

Service codes are shown by a series of long and short blinks of the FI indicator light (LED) as shown below.

○

Read 10th digit and unit digit as the FI indicator light (LED) blinks.

○

When there are a number of problems, all the service codes can be stored and the display will begin starting from the lowest number service code in the numerical order. Then after completing all codes, the display is repeated until the self-diagnosis indicator terminal is open.

○

If there is no problem, no code and unlight.

○

For example, if two problems occurred in the order of 21, 12, the service codes are displayed from the lowest number in the order listed.

(12 → 21) → (12 → 21) → · · · (repeated)

○

If the problem is with the following parts, the ECU cannot memorize these problems, the FI indicator light (LED) doesn’t go on, and no service codes can be displayed.

FI Indicator Light (LED)

Fuel Pump

Fuel Pump Relay

DFI Main Relay

ECU Power Source Wiring and Ground Wiring (see ECU Power Supply Inspection)

Fuel Injectors

How to Erase Service Codes

How to Erase Service Codes

○

Even if the ignition switch is turned OFF, the battery or the ECU are disconnected or the problem is solved, all service codes remain in the ECU.

○

Refer to the Service Code Clearing Procedure for the service code erasure.


24 and

25

33

51

52

31

32

56

62

64

Self-Diagnosis

Service Code Table

Service Code Table

Service

Code

FI Indicator Light (LED)

11

12

13

14

21

+

67

83

94

95

Problems

Main throttle sensor malfunction, wiring open or short

Inlet air pressure sensor malfunction, wiring open or short

Inlet air temperature sensor malfunction, wiring open or short

Water temperature sensor malfunction, wiring open or short

Crankshaft sensor malfunction, wiring open or short

Speed sensor malfunction, wiring open or short

First 24 is displayed and then 25, repeatedly

Vehicle-down sensor, malfunction, wiring open or short

Subthrottle sensor malfunction, wiring open or short

Oxygen sensor #1 inactivation, wiring open or short (Europe Models)

Ignition coil #1 malfunction, wiring open or short

Ignition coil #2 malfunction, wiring open or short

Radiator fan relay malfunction, wiring open or short

Subthrottle valve actuator malfunction, wiring open or short

Air switching valve malfunction, wiring open or short

Oxygen sensor heater malfunction, wiring open or short (Europe Models)

Oxygen sensor #2 inactivation, wiring open or short (Europe Models)

Oxygen sensor #1 malfunction, wiring open or short (Europe Models)

Oxygen sensor #2 malfunction, wiring open or short (Europe Models)


Self-Diagnosis

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 has no fault, and the mechanical parts of the DFI system and the engine are suspect.


Self-Diagnosis

Backups

Backups

○

The ECU takes the following measures to prevent engine damage when the DFI or the ignition system parts have troubles.

Service

Codes

Parts

11

12

13

14

21

24 and

25

31

32

33

Main Throttle

Sensor

Inlet Air

Pressure

Sensor

Inlet Air

Temperature

Sensor

Water

Temperature

Sensor

Crankshaft

Sensor

Speed Sensor

Vehicle-down

Sensor

Subthrottle

Sensor

Oxygen Sensor

#1 (Europe

Models)

Output Signal Usable

Range or Criteria

Backups by ECU

Main Throttle Sensor

Output Voltage

0.20

∼ 4.8 V

Inlet Air Pressure

(absolute)

Pv = 50 mmHg ∼ 890 mmHg

Inlet Air Temperature

Ta = –30°C ∼ +120°C

Water Temperature

Tw = –30°C ∼ +120°C

If the main throttle sensor system fails (the signal is out of the usable range, wiring short or open), the ECU locks ignition timing into the ignition timing at closed throttle position and sets the DFI in the D-J method.

Also, the main throttle sensor system and inlet air pressure fails, the ECU locks ignition timing into the ignition timing at closed throttle position and sets the DFI in the α -N method.

If the inlet air pressure sensor system fails (the signal Pv is out of the usable range, wiring short or open), the ECU sets the DFI in the α

- N method.

If the inlet air temperature sensor fails (the signal is out of the usable range, wiring short or open), the ECU sets Ta at 40°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.

Crankshaft sensor must send 17 signals (output signal) to the ECU at the one cranking.

Speed sensor must send 26 signals (output signal) to the ECU at the one rotation of the transmission gear.

The gear position is decided by the signal of the speed sensor.

If crankshaft sensor generates other than 17 signals, the engine stops by itself.

If the speed sensor system fails (no signal, wiring short or open), the speedometer shows

0, and the ECU sets the top (5) gear position.

Vehicle-down Sensor

Output Voltage (signal)

Vd = 0.65 V ∼ 4.45 V

Subthrottle Sensor

Output Voltage

0.15

∼ 4.85 V

If the vehicle-down sensor system has failures

(the output voltage Vd is more than usable range, wiring open), the ECU shuts off the fuel pump, the fuel injectors and the ignition system.

If the subthrottle sensor system fails (the signal is out of the usable range, wiring short or open), the actuator locks sub throttle valve at full open position.

The oxygen sensor is active and sensor must send signals (output voltage) continuously to the ECU.

If the oxygen sensor is not activated, the ECU stops oxygen sensor feedback mode.


Self-Diagnosis

Service

Codes

51

52

62

Parts

Ignition Coil #1*

Ignition Coil #2*

Subthrottle

Valve Actuator

Output Signal Usable

Range or Criteria

The stick coil primary winding must send signals (output voltage) continuously to the

ECU.

The stick coil primary winding must send signals (output voltage) continuously to the

ECU.

The actuator operates open and close of the subthrottle valve by the pulse signal from the

ECU.

If the subthrottle valve actuator fails (the signal is out of the usable range, wiring short or open), the ECU stops the current to the actuator.

Backups by ECU

If the ignition primary winding #1 has failures

(no signal, 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 primary winding #2 has failures

(no signal, wiring short or open), the ECU shuts off the injector #2 to stop fuel to the cylinder #2, though the engine keeps running.

64

Air Switching

Valve

The air switching valve solenoid opens and shuts the air switching valve according to the signal from the ECU.

(Europe Models)

When air switching valve solenoid does not operate, ECU ends the oxygen sensor feedback mode.

(Other than Europe Models)

ECU does not backup.

67

83

94

95

Oxygen Sensor

#1 (Europe

Models)

Oxygen Sensor

#2 (Europe

Models)

Oxygen Sensor

#1 (Europe

Models)

Oxygen Sensor

#2 (Europe

Models)

The oxygen sensor heater raise temperature of the sensor for its earlier activation. 12V-36 W,

1.5 A

The oxygen sensor is active and sensor must send signals (output voltage) continuously to the ECU.

The oxygen sensor must send signals

(output voltage) continuously to the

ECU

The oxygen sensor must send signals

(output voltage) continuously to the

ECU

If the oxygen sensor heater fails (wiring short or open), the ECU stops the current to the heater.

If the oxygen sensor is not activated, the ECU stops oxygen sensor feedback mode.

If the oxygen sensor output voltage is incorrect, the ECU stops oxygen sensor feedback mode.

If the oxygen sensor output voltage is incorrect, the ECU stops oxygen sensor feedback mode.

Note:

(1) D-J Method and α - N 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). This method is called D-J method (low-speed mode). 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 sensor output voltage) and the engine speed. This method is called α - N method (high-speed mode).

(*) This depends on the number of stopped cylinders.

Main Throttle Sensor (Service Code 11)

The main throttle sensor is a rotating variable resistor that change output voltage according to throttle operating. The

ECU senses this voltage change and determines fuel injection quantity, and ignition timing according to engine rpm, and throttle opening.

Input Terminal [A]

Output Terminal [B]

Ground Terminal [C]

Main Throttle Sensor Removal/Adjustment

CAUTION

Do not remove or adjust the main throttle sensor [A] since it has been adjusted and set with precision at the factory.

Never drop the sensor, especially on a hard surface.

Such a shock to the sensor can damage it.

Input Voltage Inspection

NOTE

○

Be sure the battery is fully charged.

•

Turn the ignition switch OFF.

•

Remove the ECU (see ECU Removal). Do not disconnect the ECU connectors.

•

Connect a digital voltmeter to the connector, using the needle adapter set.


Main Throttle Sensor Input Voltage

Connections to ECU Connector

(Other than Europe Models [A])

Meter (+) → BL lead (terminal 8)

Meter (–) → BR/BK lead (terminal 22)

(Europe Models [B])



•

Measure the input voltage with the engine stopped, and with the connectors joined.

•

Turn the ignition switch ON.

Input Voltage at ECU Connector

Standard: 4.75

∼ 5.25 V DC

•


If the reading of input voltage is less than the standard, check the ECU for its ground, power supply and wiring shorted (see ECU Power Supply Inspection).

If the input voltage is within the standard range remove the fuel tank, and check wiring from ECU to the throttle sensor for continuity.

If the wiring is good, check the output voltage of the throttle sensor.




Output Voltage Inspection

•

Measure the output voltage at the ECU in the same way as input voltage inspection.


Main Throttle Sensor Output Voltage

Connections to ECU


Meter (+) → Y/W lead (terminal 6)



Meter (+) → Y/W lead (terminal 7)

•


•


Check idle speed to ensure throttle opening is correct.

Idle Speed

Standard: 1 000 ±50 r/min (rpm)

If the idle speed is out of the specified range, adjust the idle speed (see Idle Speed Inspection in the Periodic

•

Maintenance chapter).


•

Measure the output voltage with the engine stopped, and with the connector joined.

•


•

Measure the output voltage when the throttle is fully opened or completely closed.

Output Voltage at ECU

Standard: 1.05

∼ 4.26 V DC (at idle throttle opening to full throttle opening)

NOTE

○

The throttle sensor is operating correctly if the following voltages are obtained:

• 1.05 VDC (or slightly higher) with the throttle at the idle position.

• 4.26 VDC (or slightly lower) with the throttle at the fully open position.

CAUTION

Do not remove or adjust the main throttle sensor.

It has been adjusted and set with precision at the factory.

Never drop the sensor can especially on a hard surface. A shock to the sensor can damage it.


NOTE

○

The standard voltage marked with an asterisk refers to the value when the voltage reading at the Input Voltage

Inspection shows 5 V exactly.

○

When the input voltage reading shows other than 5 V, derive a voltage range as follows.

Example:

In the case of a input voltage of 4.75 V.

1.05 × 4.75 ÷ 5.00 = 1.00 V

4.26 × 4.75 ÷ 5.00 = 4.05 V

Thus, the valid range is 1.00

∼

4.05 V

If the output voltage is within the standard range, check the wiring for continuity (see next diagram).

If the output voltage is far out of the standard range (e.g.

when the wiring is open, the reading is 0 V), check the throttle sensor resistance.

•

Resistance Inspection


•

Disconnect the main throttle sensor connector.

•

Connect a digital meter [A] to the main throttle sensor connector [B].

•

Measure the main throttle sensor resistance.

Main Throttle Sensor Resistance

Connections: BL lead [C] ←→ BR/BK lead [D]

Standard: 4 ∼ 6 k Ω

If the reading is out of the range, replace the throttle body assy.

If the reading is within the range, but the problem still exists, replace the ECU.




Main Throttle Sensor Circuit (Other than Europe Models)

Main Throttle Sensor Circuit (Europe Models)

1. ECU



Inlet Air Pressure Sensor (Service Code 12)

Inlet Air Pressure Sensor Removal

CAUTION


Such a shock to the part can damage it.

•

Remove:

Fuel Tank (see Fuel Tank Removal)

Bolt [A]

•

Disconnect the inlet air pressure sensor connector [B], and remove the sensor [C].

•

Disconnect the vacuum hose [D] from the sensor.

•

Inlet Air Pressure Sensor Installation

Connect the inlet air pressure sensor connector [A].

•

Route the vacuum hose correctly (see Cable, Wire and

Hose Routing section in the Appendix chapter). Make

• sure it doesn’t get pinched or kinked.

Install the inlet air pressure sensor [B].

○

The stopper [C] must not be on the sensor holder [D].

•

Tighten:

Torque - Inlet Air Pressure Sensor Bolt: 6.9 N·m (0.70


•

Install the fuel tank (see Fuel Tank Installation).


NOTE

○


○

The inspection is the same as “Input Voltage Inspection” of the throttle sensor and the atmospheric pressure sensor.

•


•


•

Connect a digital voltmeter to the connector, with the needle adapter set.


Inlet Air Pressure Sensor Input Voltage








•


•


Input Voltage at ECU

Standard: 4.75

∼ 5.25 V DC

If the reading is less than the standard range, check the

ECU for its ground, and power supply and wiring shorted

(see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU.




If the reading is within the standard range, remove the fuel tank, and check wiring from ECU to the inlet pressure sensor for continuity.

If wiring is good, check the output voltage of the inlet air pressure sensor.


•

Measure the output voltage at the ECU in the same way as input voltage inspection. Note the following.

Inlet Air Pressure Sensor Output Voltage



Meter (+) → Y/BL lead (terminal 7)



Meter (+) → Y/BL lead (terminal 8)



Usable Range: 3.80

∼ 4.20 V DC at the standard atmospheric pressure (101.32 kPa, 76 cmHg abs).

NOTE

○

The output voltage changes according to the local atmospheric pressure.

○

The sensor output voltage is based on a nearly perfect vacuum in the small chamber of the sensor. So, the sensor indicates absolute vacuum pressure.

If the output voltage is out of the usable range, replace the sensor

If the output voltage is normal, check the inlet air pressure sensor for vacuum other than 76 cmHg (abs), check the output voltage as follows:


•

Remove the inlet air pressure sensor [A] and disconnect the vacuum hose from the sensor.

○

Do not disconnect the sensor connector.

•

Connect an auxiliary hose [B] to the inlet air pressure sensor.

•

Temporarily install the inlet air pressure sensor.

○

Connect a commercially available digital meter [C], vacuum gauge [D], and the fork oil level gauge [E] to the inlet air pressure sensor.

Special Tool - Fork Oil Level Gauge: 57001-1290

Inlet Air Pressure Sensor Output Voltage Connection to

Sensor

Meter (+) → Y/BL lead

Meter (–) → BR/BK lead

○


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 Assy

Pl: Local Atmospheric Pressure (absolute) measured by a barometer

Pv: Vacuum Pressure (absolute) of Throttle Assy

Vv: Sensor Output Voltage (v) then

Pv = Pl – Pg

For example, suppose the following data is obtained:

Pg = 8 cmHg (vacuum gauge reading)

Pl = 70 cmHg (barometer reading)

Vv = 3.2 V (digital volt meter reading) then

Pv = 70 – 8 = 62 cmHg (abs)

Plot this Pv (62 cmHg) at a point [1] on the chart and draw a vertical line through the point. Then, you can get the usable range [2] of the sensor output voltage.

Usable range = 3.08

∼ 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.




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)



Inlet Air Pressure Sensor Circuit (Other than Europe Models)

Inlet Air Pressure Sensor Circuit (Europe Models)

1. ECU




Inlet Air Temperature Sensor (Service Code 13)

Inlet Air Temperature Sensor Removal/Installation

CAUTION



•

Remove the air cleaner housing (see Air Cleaner Housing

Removal).

•

Remove the screw [A].

•

Pull out the inlet air temperature sensor [B] out of the air cleaner housing.

•

Put the inlet air temperature sensor into the air cleaner housing.

•

Tighten:

Torque - Inlet Air Temperature Sensor Screw: 1.2 N·m (0.12



NOTE

○


•


•

Connect a digital voltmeter to the ECU connector, using needle adapter set.

Special Tool - Needle Adapter Set: 57001–1457

Inlet Air Temperature Sensor Output Voltage



Meter (+) → Y lead (terminal 20)



Meter (+) → Y lead (terminal 26)


•

Measure the sensor output voltage with the engine stopped and the connector joined.

•



Standard: about 2.25

∼ 2.50 V at inlet air temperature

20°C (68°F)

NOTE

○

The output voltage changes according to the inlet air temperature.

•


If the output voltage is out of the specified, check the ECU for its ground, and power supply (see ECU Power Supply

Inspection). If the ground and power supply are good, remove the air cleaner housing, check the wiring between the ECU and the inlet air temperature sensor.

If the wiring is good, check the sensor resistance.


Sensor Resistance Inspection

•

Remove the inlet air temperature sensor (see Inlet Air

Temperature Sensor Removal).

•

Suspend the sensor [A] in a container of machine oil so that the heat-sensitive portion is submerged.

•

Suspend a thermometer [B] with the heat-sensitive portion [C] located in almost the same depth with the sensor.

NOTE

○

The sensor and thermometer must not touch the container side or bottom.

•

Place the container over a source of heat and gradually 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 table.

Inlet Air Temperature Sensor Resistance

Standard: 5.4

∼ 6.6 k Ω at 0°C (32°F)

0.29

∼ 0.39 k Ω at 80°C (176°F)

If the measurement is out of the range, replace the sensor.

If the measurement is within the specified, replace the

ECU.




Inlet Air Temperature Sensor Circuit (Other than Europe Models)

Inlet Air Temperature Sensor Circuit (Europe Models)

1. ECU



Water Temperature Sensor (Service Code 14)

Removal/Installation

CAUTION



•

Remove the fuel tank (see Fuel Tank Removal).

•

Drain the coolant (see Coolant Change in the Periodic


•

Disconnect the sensor connector [A], and unscrew the water temperature sensor [B].

Torque - Water Temperature Sensor: 12 N·m (1.2 kgf·m, 106 in·lb)

•

Fill the engine with coolant and bleed the air from the cooling system (see Coolant Change in the Periodic Maintenance chapter).


NOTE

○


○

The output voltage changes according to the coolant temperature in the engine.

•

Remove the ECU (see ECU Removal). Do not disconnect the connectors.

•

Connect a digital voltmeter to the ECU connector, using two needle adapters.


•

Measure the output voltage of the sensor with the engine stopped and the connector joined.

•


Water Temperature Sensor Output Voltage



Meter (+) → O lead (terminal 17)



Meter (+) → O lead (terminal 20)



∼ 2.97 V at 20°C (68°F)

•


If the output voltage is out of the specified, check the ECU for its ground, and power supply (see ECU Power Supply

Inspection). If the ground and power supply are good, remove the fuel tank and check the wiring between the

ECU and the water temperature sensor for continuity.

If the wiring is good, check the water temperature sensor resistance.

Water Temperature Sensor Resistance Inspection

•

Refer to the Water Temperature Sensor Inspection in the

Electrical System chapter (see Water Temperature Sensor Inspection in the Electrical System chapter).



Water Temperature Sensor (Service Code 14)

Water Temperature Sensor Circuit (Other than Europe Models)

Water Temperature Sensor Circuit (Europe Models)

1. ECU



Crankshaft Sensor (Service Code 21)

Start the engine and switch the diagnosis mode to Dealer

1 mode to know all the problem that the DFI system has at the time of self-diagnosis. If the engine cannot be started, the self-diagnosis system does not detect dynamic condition of the crankshaft sensor. In this case turn off the ignition switch and turn it on again to enter the Dealer 2 mode.

In this mode the system tells all the troubles which the DFI system had in both static and dynamic conditions.

Crankshaft Sensor Removal/Installation

•

See the Ignition System section in Electrical System chapter.

Crankshaft Sensor Inspection

○

The crankshaft have no power source, and when the engine stops, the crankshaft generates no signals.

•

Crank the engine and measure the peak voltage of the crankshaft sensor (see Crankshaft Sensor Peak Voltage

Inspection in the Electrical System chapter) in order to check the sensor.

•

Check the wiring for continuity, using the following diagram.



Crankshaft Sensor (Service Code 21)

Crankshaft Sensor Circuit (Other than Europe Models)

Crankshaft Sensor Circuit (Europe Models)

1. ECU


Speed Sensor (Service Code 24, 25)

Speed Sensor Removal

•

Refer to the Speed Sensor Removal in the Electrical System chapter.

Speed Sensor Installation

•

Refer to the Speed Sensor Installation in the Electrical

System chapter.

Speed Sensor Inspection

•

Refer to the Speed Sensor Inspection in the Electrical

System chapter.


NOTE

○


•


•

Remove the speed sensor (see Speed Sensor Removal in the Electrical System chapter).

•

Connect the harness adapter [A] between the harness connector [B] and speed sensor connector [C].

Special Tool - Speed Sensor Measuring Adapter: 57001

-1667

•

Reinstall the speed sensor with the harness adapter connected.

•

Connect a digital meter [D] to the connector harness adapter leads.

Speed Sensor Input Voltage

Connections to Adapter

Meter (+) → BK/Y (sensor BL) lead

Meter ( − ) → BL (sensor BR/BK) lead

•


•


Input Voltage at Sensor

Standard: 4.75

∼ 5.25 V DC

If the reading is out of the range, check the wiring.

If the reading is good, check the output voltage.

•






•

Before this inspection, inspect the input voltage (see Input

Voltage Inspection in the Speed Sensor section).

NOTE

○


•


•

Using the jack, raise the rear wheel off the ground.


•

Remove the speed sensor (see Speed Sensor Removal in the Electrical System chapter).

•

Connect the harness adapter [A] between the harness connector [B] and speed sensor connector [C].

Special Tool - Speed Sensor Measuring Adapter: 57001

-1667

•

Reinstall the speed sensor with the harness adapter connected.

•

Connect a digital meter [D] to the connector harness adapter leads.

Speed Sensor Output Voltage

Connections to Adapter

Meter (+) → BL/Y (sensor LG/R) lead

Meter (–) → BL (sensor BR/BK) lead

•

Measure the output voltage with the engine stopped, and with the connectors joined.

•


Output Voltage at Sensor

Standard: DC 0.05

∼ 0.09 V or DC 4.5

∼ 4.9 V

•

Rotate the rear wheel by hand, confirm the output voltage will be raise or lower.

If the reading is out of the range, replace the speed sensor

(see Switch and Sensors section in the Electrical System chapter) and check the wiring to ECU (see next diagram).

If the reading, speed sensor and wiring are good, replace the ECU (see ECU section).

•



Speed Sensor Circuit (Other than Europe Models)


Speed Sensor Circuit (Europe Models)

1. ECU

2. Meter Unit


4. Speed Sensor


Vehicle-down Sensor (Service Code 31)

Vehicle-down Sensor Removal

•

Remove:

Tool Box (see Tool Box Removal in the Frame chapter)

Bolts [A]

Vehicle-down Sensor [B]

Connector [C] (disconnect)

Vehicle-down Sensor Installation

•

Install the vehicle-down sensor [A] in the original position.

The arrow mark [B] on the sensor must be on the rear and

• point upward.

Do not install the sensor upside down.

•

Tighten:

Torque - Vehicle-down Sensor Bolts [C]: 4.9 N·m (0.50

kgf·m, 43 ft·lb)

Front [D]

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 down sensor is held in place by its bolt as shown.

Vehicle-down Sensor Inspection

NOTE

○


•

Take out the vehicle-down sensor [A] (see Vehicle-down

Sensor Removal). Do not disconnect the connector [B].

•

Connect a digital volt meter [C] to the connector, using two needle adapters [D].


•

Turn the ignition switch ON, and measure the power source voltage with the connector joined.

Vehicle-down Sensor Power Source Voltage

Connections to Sensor

Meter (+) → BL lead [E]

Meter (–) → BR/BK lead [F]

Standard: 4.75

∼ 5.25 V DC

•


If the reading of input voltage is less than the standard, check the ECU for its ground, power supply and wiring shorted.


If the power source is normal, check the output voltage of the sensor.

•

Connect a digital volt meter [A] to the connector, using two needle adapters [B].

•

Turn the ignition switch ON, and measure the output voltage with the connector joined.

○

Tilt the sensor (40 ∼ 50°) or more [C] right or left, then hold the sensor almost vertical [D] with the arrow mark pointed up, and measure the output voltage.

Vehicle-down Sensor Output Voltage

Connections to Sensor

Meter (+) → Y/G lead [E]

Meter (–) → BR/BK lead [F]

Standard: with sensor tilted 40 ∼ 50° or more right or left: 0.65

∼ 1.35 V with sensor arrow mark pointed up: 3.55

∼

4.45 V

NOTE

○

If you need to test again, turn the ignition switch OFF, and then ON.

•


•

Remove the needle adapters, and apply silicone sealant to the seals of the connector for waterproofing.

Silicone Sealant (Kawasaki Bond: 56019-120)

- Seals of Vehicle-down Sensor Connector

If the output voltage is out of the specified, replace the vehicle-down sensor.

If the output voltage is normal, the wiring is suspect.

Check the wiring.




Vehicle-down Sensor Circuit (Other than Europe Models)

Vehicle-down Sensor Circuit (Europe Models)

1. ECU



Subthrottle Sensor (Service Code 32)

The subthrottle sensor is a rotating variable resistor that change output voltage according to throttle operating. The

ECU senses this voltage change and determines fuel injection quantity, and ignition timing according to engine rpm, and throttle opening.

Input Terminal [A]

Output Terminal [B]

Ground Terminal [C]

Subthrottle Sensor Removal/Adjustment

CAUTION

Do not remove or adjust the subthrottle sensor [A] since it has been adjusted and set with precision at the factory.




NOTE

○


○

The inspection is the same as “Input Voltage Inspection” of the inlet air pressure sensor and the atmospheric pressure sensor.

•


•


•



Subthrottle Sensor Input Voltage








•


•


Input Voltage at ECU Connector

Standard: 4.75

∼ 5.25 V DC




•


If the reading of input voltage is less than the standard, check the ECU for its ground, power supply and wiring shorted.

If the input voltage is within the standard range, remove the fuel tank, and check wiring from ECU to the subthrottle sensor for continuity.

If the wiring is good, check the output voltage of the subthrottle sensor.


•

Measure the output voltage at the ECU in the same way as input voltage inspection.


Subthrottle Sensor Output Voltage



Meter (+) → BL/W lead (terminal 19)



Meter (+) → BL/W lead (terminal 24)

•



•

Measure the output voltage when the subthrottle valve is fully opened or completely closed by hand.


Standard: 0.93

∼ 4.59 V DC (at subthrottle valve full opening to closing)

NOTE

○

The throttle sensor is operating correctly if the following voltages are obtained:

• 0.93 VDC (or slightly higher) with the subthrottle valve at the closed position.

• 4.59 VDC (or slightly lower) with the subthrottle valve at the fully open position.

CAUTION

Do not remove or adjust the subthrottle sensor. It has been adjusted and set with precision at the factory.

Never drop the sensor can especially on a hard surface. A shock to the sensor can damage it.


NOTE

○

The standard voltage marked with an asterisk refers to the value when the voltage reading at the Input Voltage

Inspection shows 5 V exactly.

○

When the input voltage reading shows other than 5 V, derive a voltage range as follows.

Example:

In the case of a input voltage of 4.75 V.

0.93 × 4.75 ÷ 5.00 = 0.88 V

4.59 × 4.75 ÷ 5.00 = 4.36 V

Thus, the valid range is 0.88

∼

4.36 V

If the output voltage is within the standard range, check the wiring for continuity (see next diagram).

If the output voltage is far out of the standard range (e.g.

when the wiring is open, the reading is 0 V), check the throttle sensor resistance.

•



•

Disconnect the subthrottle sensor connector.

•

Connect a digital meter [A] to the subthrottle sensor connector [B].

•

Measure the subthrottle sensor resistance.

Throttle Sensor Resistance

Connections: BL lead [C] ←→ BK lead [D]

Standard: 4 ∼ 6 k Ω


If the reading is within the range, but the problem still exists, replace the ECU.




Subthrottle Sensor Circuit (Other than Europe Models)

Subthrottle Sensor Circuit (Europe Models)

1. ECU




Oxygen Sensor-not activated (#1, #2: Service Code 33, 83)-Europe Models

Oxygen Sensor #1: Service Code 33


Oxygen Sensor Removal/Installation

•

Refer to Oxygen Sensor Removal and Installation in the

Electrical System chapter.

Oxygen Sensor Inspection

NOTE

○

The oxygen sensor itself is the same for #1 [A] and #2

[B], but wiring of the main harness side is different.

•

•

Warm up the engine thoroughly.


•

Remove the right side cover (see Right Side Cover Removal in the Frame chapter).

•

Connect a digital voltmeter [A] to the each oxygen sensor connector [B] (sensor side), using the needle adapter set.


Oxygen Sensor Output Voltage

Connections to Oxygen Sensor Connector

Meter (+) → BK lead

Meter ( − ) → GY lead

•

Remove the air switching valve hoses [A] (both sides) from the fittings.

•

•

Install the suitable plugs [A] (both sides) on the fittings and shut off the secondary air.

•


•

Start the engine, and let it idle.

Measure the output voltage of the sensor with the connector joined.

Oxygen Sensor Output Voltage (with Plugs)

Standard: 0.45

∼ 2.5 V


Oxygen Sensor-not activated (#1, #2: Service Code 33, 83)-Europe Models

•

Next, remove the plugs [A] (both sides) from the fittings with idling.

•


Oxygen Sensor Output Voltage (without Plugs)

Standard: 0.05

∼ 0.45 V

If the reading is within range (with plugs: 0.45

∼ 2.5 V, without plugs: 0.05

∼ 0.45 V), the oxygen sensor is good.

If the reading is without range, replace the oxygen sensor.

•

Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing.

Sealant - Kawasaki Bond (Silicone Sealant): 56019-120

Oxygen Sensor Circuit

1. ECU

2. Oxygen Sensor #1

3. Oxygen Sensor #2


5. Main Fuse 30 A

6. Starter Relay

7. Battery


9. Frame Ground


Ignition Coils (#1, #2: Service Code 51, 52)

Ignition Coil #1: Ignition Coil for Front Cylinder (Service

Code 51)

Ignition Coil #2: Ignition Coil for Rear Cylinder (Service

Code 52)

Ignition Coil Removal/Installation

CAUTION

Never drop the ignition coils, especially on a hard surface. Such a shock to the ignition coil can damage it.

•

Refer to the Ignition Coil Removal in the Electrical System chapter.


NOTE

○


•


•

Remove the ECU (see ECU Removal). Do not disconnect the ECU connector.

•

Connect a digital voltmeter as shown, using two needle adapters.


○

Measure the input voltage to each primary winding of the ignition coils with the engine stopped, and with the connectors joined.

•


Ignition Coil Input Voltage at ECU


Connections for Ignition Coil #1

Meter (+) → BK lead (terminal 35)

Meter (–) → Battery (–) Terminal


Meter (+) → BK/G lead (terminal 44)




Meter (+) → BK lead (terminal 43)



Meter (+) → BK/G lead (terminal 52)


Standard: Battery Voltage (12.8 V or more)



Ignition Coils (#1, #2: Service Code 51, 52)

If the reading is out of the standard, check the ECU for its ground and power supply (see ECU Power Supply Inspection).

If the reading is good remove the fuel tank and check the wiring between the ECU and the primary lead terminals at the ignition coils.

If the wiring is good, crank the engine, and check the peak voltage of the ignition coils (see Ignition Coil Primary Peak

Voltage Inspection in the Electrical System chapter) in order to check the primary coils.

Radiator Fan Relay (Service Code 56)

•

Radiator Fan Relay Removal/Installation

Radiator fan relay is bult in the relay box.

•

Remove the relay box (see Relay Box Removal in the

Electrical System chapter).

Radiator Fan Relay Inspection

•

Refer to the Relay Circuit Inspection in the Electrical System chapter.

•

Remove the relay box and ECU (see ECU Removal). Do not disconnect the relay box and ECU connectors. Check the wiring for continuity, using the following diagram.

If wiring and radiator fan relay are 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.



Radiator Fan Relay (Service Code 56)

Radiator Fan Relay Circuit

1. Ignition Switch

2. Radiator Fan



5. ECU

6. Frame Ground

7. Battery

8. Main Fuse 30 A

9. Relay Box

10. ECU Main Relay


12. ECU Fuse 15 A

13. Fan Fuse 15 A



A: Other than Europe Models

B: Europe Models

Subthrottle Valve Actuator (Service Code 62)

Subthrottle Valve Actuator Removal

CAUTION

Do not remove the subthrottle valve actuator [A] since it has been adjusted and set with precision at the factory.

Never drop the actuator , especially on a hard surface. Such a shock to the actuator can damage it.

•

Subthrottle Valve Actuator Inspection

•


Removal).

•


Check to see that all subthrottle valves [A] open and close smoothly.

If the subthrottle valves do not operate, check the actuator internal resistance (see Resistance Inspection in the

Subthrottle Valve Actuator section).

•



•


•

Disconnect the subthrottle valve actuator connector [A].


•

Connect a digital meter to the subthrottle valve actuator connector [A].

•

Measure the subthrottle valve actuator resistance.

Subthrottle Valve Actuator Resistance

Connections: BK lead [1] ←→ P lead [2]

Standard:

G lead [3] ←→ W/BL lead [4] about 5.2

∼ 7.8

Ω


If the reading is within the range, check the input voltage

(see Input Voltage Inspection in the Subthrottle Valve Actuator section).




•

NOTE

○


•


•


Connect the peak voltage adapter [A] and a digital meter

[B] to the connector (main harness side) [C], using the needle adapter set [D].

Special Tools - Peak Voltage Adapter: 57001-1415

Type: KEK-54-9-B

Needle Adapter Set: 57001-1457

Subthrottle Valve Actuator Input Voltage

Connections to Harness Connector

(I) Meter (+) → BK lead [1]

Meter (–) → P lead [2]

(II) Meter (+) → G lead [3]

Meter (–) → W/BL lead [4]

•

Measure the actuator input voltage with the engine stopped, and with the connector joined.

•


Input Voltage at Sensor


∼ 10.9 V DC

If the reading is out of the range, check the wiring to ECU

(see next diagram).

If the wiring is good, replace the ECU.

•




Subthrottle Valve Actuator Circuit (Other than Europe Models)

Subthrottle Valve Actuator Circuit (Europe Models)

1. ECU



Air Switching Valve (Service Code 64)

Air Switching Valve Removal/Installation

•

See Clean Air System section in the Engine Top End chapter.

Air Switching Valve Inspection

•

See Air Switching Valve Unit Test in the Electrical System chapter.

•

Check the wiring continuity, using the following diagram.

Air Switching Valve Circuit (Other than Europe Models)

1. ECU


3. Ignition Switch


5. ECU Fuse 15 A

6. Fuse Box

7. ECU Main Relay

8. Fuel Pump Relay

9. Relay Box

10. Main Fuse 30 A

11. Starter Relay

12. Battery



15. Frame Ground

16. Fuel Pump


Air Switching Valve (Service Code 64)

Air Switching Valve Circuit (Europe Models)


1. ECU


3. Ignition Switch


5. ECU Fuse 15 A

6. Fuse Box

7. ECU Main Relay

8. Fuel Pump Relay

9. Relay Box

10. Main Fuse 30 A

11. Starter Relay

12. Battery



15. Frame Ground

16. Fuel Pump



Oxygen Sensor Heaters (#1, #2: Service Code 67)-Europe Models

Oxygen Sensor Heater Removal/Installation

The oxygen sensor heater is bult in the oxygen sensor.

So, the heater itself can not be removed. Remove the oxygen sensor (see Switch and Sensors section in the Electrical System chapter).

Oxygen Sensor Heater Inspection

•

Remove:

Right Side Cover (see Right Side Cover Removal in the

Frame chapter)

•

Disconnect the each oxygen sensor lead connectors [A].

•

Set the hand tester [A] to the × 1 Ω range and connect it to the terminals in the oxygen sensor lead connector [B].

White Lead Terminal [C]

White Lead Terminal [D]


Oxygen Sensor Resistance

Standard: about 8 Ω at 20°C (68°F)

If the tester reading is not as specified, replace the oxygen sensor with a new one.

If he tester reading is specified, check the power source voltage Inspection.

NOTE

○


•

Connect a digital meter [A] to each oxygen sensor connector [B], using the needle adapter [C].


Oxygen Sensor Heaters Power Source Voltage


Tester (+) → W (main harness side P/BK) lead [D]

Tester ( − ) → Battery ( − ) Terminal [E]

Oxygen Sensor #1 [F]

Oxygen Sensor #2 [G]

•

Measure the power source voltage with the engine stopped, and with the oxygen sensor connector joined.

•


Power Source Voltage at Sensor Connector

Standard: Battery Voltage


Oxygen Sensor Heaters (#1, #2: Service Code 67)-Europe Models

If the reading is incorrect, check the following.



System chapter)

Oxygen Sensor Heater Fuse 10 A (see Fuse Inspection in the Electrical System chapter)

If the reading is good, the power source voltage is normal, Inspect the Red lead between the oxygen sensor connector and the ECU for continuity, using the following diagram.

If the wiring is good, inspect 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 section).

•

Remove the needle adapter set, and apply silicone sealant to the connector for water proofing.



1. ECU

2. Oxygen Sensor #1

3. Oxygen Sensor #2


5. Main Fuse 30 A

6. Starter Relay

7. Battery


9. Frame Ground



Oxygen Sensors-Incorrect Output Voltage (#1, #2: Service Code 94, 95)-Europe

Models



Oxygen Sensor Removal/Installation

•

Refer to Oxygen Sensor Removal and Installation in the


Oxygen Sensor Inspection

NOTE

○

The oxygen sensor itself is the same for #1 [A] and #2

[B], but wiring of the main harness side is different.

•

•



•

Remove the right side cover (see Right Side Cover Removal in the Frame chapter).

•

Connect a digital voltmeter [A] to the each oxygen sensor connector [B] (sensor side), using the needle adapter set.


Oxygen Sensor Output Voltage


Meter (+) → BK lead

Meter ( − ) → GY lead

•

Remove the air switching valve hoses [A] (both sides) from the fittings.

•

•

Install the suitable plugs [A] (both sides) on the fittings and shut off the secondary air.

•


•



Oxygen Sensor Output Voltage (with Plugs)

Standard: 0.45

∼ 2.5 V


Oxygen Sensors-Incorrect Output Voltage (#1, #2: Service Code 94, 95)-Europe

Models

•

Next, remove the plugs [A] (both sides) from the fittings with idling.

•


Oxygen Sensor Output Voltage (without Plugs)

Standard: 0.05

∼ 0.45 V

If the reading is within range (with plugs: 0.45

∼ 2.5 V, without plugs: 0.05

∼ 0.45 V), the oxygen sensor is good.

If the reading is without range, inspect the engine and fuel supply system.

If the engine and fuel supply system good, replace the oxygen sensor.

•

Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing.



1. ECU

2. Oxygen Sensor #1

3. Oxygen Sensor #2


5. Main Fuse 30 A

6. Starter Relay

7. Battery


9. Frame Ground



FI Indicator LED Light

Inspection Flow Chart


LED Light Inspection

○

The FI indicator LED light [A] goes ON when the ignition switch is turned ON and the LED light goes OFF when the engine oil pressure is high enough (the engine is running).

This is to ensure that the FI indicator LED light has not burned out and the DFI system and the ignition system function properly.

•

Refer to the Meter, Gauge section in the Electrical System chapter for LED Light Inspection.

WARNING

This inspection may produce sparks. Keep the battery and the meter unit away from the fuel tank.

If the LED light is abnormal, replace the meter unit.

If the FI indicator LED light is normal, the wiring or ECU has trouble. Check the wiring (see next diagram). If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection).




FI Indicator LED Light Circuit (Other than Europe Models)

FI Indicator LED Light Circuit (Europe Models)

1. ECU

2. Ignition Switch

3. Meter Unit


5. Main Fuse 30 A

6. Starter Relay



9. Battery

10. Frame Ground

11. Fuse Box


ECU

ECU Removal

CAUTION

Never drop the ECU, especially on a hard surface.

Such a shock to the ECU can damage it.

•

Remove:

Seat (see Seat Removal in the Frame chapter)

Tool Box (see Tool Box Removal in the Frame chapter)

•

Pull out the ECU [A] along with the harness.

If necessary, push the lock and disconnect the ECU connectors.

•

ECU Installation

•

Connect the ECU connectors [A].

Fit the ECU [A] in the battery case.


ECU Power Supply Inspection

•

Visually inspect the terminals of the ECU connector.

If the connector is clogged with mud or dust, blow it off with compressed air.

Replace the main harness if the terminals [A] of the main harness connectors are cracked, bent, or otherwise damaged.

Replace the ECU if the terminals of the ECU connector are cracked, bent, or otherwise damaged.

•

With the ECU connector joined, check the following ground leads for continuity with the ignition switch ON or

OFF, using a digital voltmeter.

ECU Grounding Inspection

Meter Connections:


26, 42, 43 (BK/Y) Terminal ←→ Battery (–) Terminal

22 (BR/BK) Terminal

Engine Ground

←→ Battery (–) Terminal



34, 50, 51 (BK/Y) Terminal ←→ Battery (–) Terminal

28 (BR/BK) Terminal

Engine Ground



Readings: 0 Ω (regardless of the ignition switch ON or OFF)

If no continuity, check the connector, the engine ground lead, or main harness, and repair or replace them if necessary.



ECU

•

Check the ECU power source voltage with a digital meter.

○

Position the terminal in accordance with terminal numbers of ECU connectors in this chapter figure.

ECU Power Source Inspection

Meter Connections:


Between Terminal 12 (BR/W) and Battery (–)

Terminal

Between Terminal 27 (W/BK) and Battery (–)

Terminal

Ignition Switch OFF:

Terminal 12 (BR/W): 0 V

Terminal 27 (W/BK): Battery Voltage (12.8 V or more)

Ignition Switch ON:

Both: Battery Voltage (12.8 V or more)


Between Terminal 16 (BR/W) and Battery (–)

Terminal

Between Terminal 17 (W/BK) and Battery (–)

Terminal

Ignition Switch OFF:

Terminal 16 (BR/W): 0 V

Terminal 17 (W/BK): Battery Voltage (12.8 V or more)

Ignition Switch ON:

Both: Battery Voltage (12.8 V or more)

Fuel Line

Fuel Pressure Inspection

NOTE

○

This inspection can determine which trouble the DFI system has, mechanical or electrical trouble.

○

It is preferable to measure the fuel pressure while running the motorcycle when the trouble has occurred in order to know symptom well.

○


•


•

Be sure to place a piece of cloth around the fuel hose joint and the delivery pipe.

•

Insert a minus screw driver [A] into the slit on the joint lock

[B].

•

Turn the driver to disconnect the joint lock.

•

Pull [C] the fuel hose joint [D] out of the delivery pipe.

WARNING


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.

•

Install the fuel pressure gauge adapter [A] between the fuel tank outlet pipe [B] and the inlet pipe [C] to the delivery joint [D].

○

Put the fuel pressure gauge adapter outside the frame.

•

Connect the pressure gauge [E] to the fuel pressure gauge adapter.

Fuel Tank [F]

Fuel Pump [G]

Front [H]

→ : Fuel Flow

Special Tools - Fuel Pressure Gauge Adapter: 57001-1593

Fuel Hose: 57001-1607

Oil Pressure Gauge: 57001-125

•

Temporarily, install the removed parts.

WARNING

Do not try to start the engine with the fuel hoses disconnected.



Fuel Line

•

Turn the ignition switch ON. The fuel pump will turn for 3 seconds, and then stop.

•

Measure the fuel pressure with the engine stopped.

Fuel Pressure right after Ignition Switch ON, with pump running:

Standard: 304 kPa (3.1 kgf/cm², 44 psi) after 3 seconds from Ignition Switch ON, with pump stopped:

Standard: 280 kPa (2.9 kgf/cm², 41 psi, residual fuel pressure)

The system should hold the residual pressure about 30 seconds.

•


•

Measure the fuel pressure with the engine idling.

Fuel Pressure (idling)

Standard: 304 kPa (3.1 kgf/cm², 44 psi)

NOTE

○

The gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum indications.

If the fuel pressure is normal, the fuel circulation system

(fuel pump, pressure regulator, and oil passage) is no faults. Check the DFI electronic control system (injectors, sensors, crankshaft sensors, and ECU).

If the fuel pressure is much higher than the specified, check the following:

Delivery Pipe Clogging

Injector Clogging

If the fuel pressure is much lower than specified, check the following:

Fuel Pump for Operation (check the sound of the pump)

Fuel Line Leakage or Clogging

Amount of Fuel Flow (see Fuel Flow Rate Inspection)

If the fuel pressure is much lower than specified, and if inspection above checks out good, replace the fuel pump assy (the fuel filter may be clogged) and measure the fuel pressure again.

•

Remove the fuel pressure gauge and adapter.

•

Pull [A] the joint lock [B] fully as shown.

Fuel Line

•

Insert the fuel hose joint [A] straight onto the delivery pipe.

•

Push [B] the joint lock [C] until the hose joint clicks.


•

Push and pull [A] the fuel hose joint [B] back and forth more than two times and make sure it is locked and doesn’t come off.

WARNING

Make sure the fuel hose joint is installed correctly on the delivery pipe or the fuel could leak.


•

Run the fuel hose correctly (see Cable, Wire and Hose

Routing section in the Appendix chapter).

•


Fuel Flow Rate Inspection

NOTE

○


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.


•

•

Turn both ignition switch, and engine stop switch OFF.

Wait until the engine cools down.

•

Open the fuel tank cap [A] to lower the pressure in the tank.


Fuel Line

•

Prepare a plastic hose of the inside diameter 7.5 mm × L

= about 400 mm and a measuring cylinder.

•

Remove:


•

Fuel Tank Bolts

Raise the fuel tank.

•

Stuff a clean shop towel around the fuel outlet hose joint.

○

While pinching the locks of the hose joint #1 with fingers, disconnect the joint (see Fuel Tank Removal) and insert

• the plastic hose [A] quickly onto the tank outlet pipe.

Secure the plastic hose with a clamp [B].

•

Run the other side of the plastic hose into the measuring cylinder [C].

•

Temporarily install the fuel tank and close the fuel tank cap.

WARNING

Wipe off spilled out fuel immediately.

Be sure to hold the measuring cylinder vertical.

•

With the engine stopped, turn the ignition switch ON. The fuel pump should operate for 3 seconds, and then should stop. Repeat this several times until the plastic hose is filled with fuel.

•

Measure the discharge for 3 seconds with the plastic hose filled with fuel.

Amount of Fuel Flow

Standard: 50 mL (1.7 US oz.) or more for 3 seconds

If the fuel flow is much less than the specified, check the battery condition (see Charging Condition Inspection in the Electrical System chapter). If the battery is good, replace the fuel pump.

•

After inspection, connect the fuel hoses, and install the fuel tank (see Fuel Tank Installation).

•

Start the engine and check for no fuel leakage.

Fuel Pump

Fuel Pump Removal

CAUTION

Never drop the fuel pump, especially on a hard surface. Such a shock to the pump can damage it.

WARNING


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.

•


○

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.

Turn the fuel tank upside down.

•

Remove the fuel pump inlet hose.

•

Unscrew the fuel pump bolts [A], and take out the fuel pump [B] and gasket.

•

Discard the fuel pump gasket.

CAUTION

Do not pull the leads (C) of the fuel pump. If they are pulled, the lead terminals may be damaged.

Fuel Pump Installation

•

Remove dirt or dust from the fuel pump [A] by lightly applying compressed air.


•

Replace the fuel pump gasket [A] with a new one.


Fuel Pump

•

•

Check that the terminals [A] and band [B] are in place.

•

Apply a non-permanent locking agent to the threads of the fuel pump bolts.

•

Tighten the fuel pump bolts [C] to a snug fit.

Tighten:

Torque - Fuel Pump Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

Pump Screen, Fuel Filter Cleaning

○

The pump screen [A] and fuel filter [B] are built into the pump and cannot be cleaned or checked.

If the pump screen or fuel filter is suspected of clogging or being damaged, replace it with the fuel pump as a set.

Operation Inspection

NOTE

○


○

Just listen to the pump sound in the fuel tank to confirm pump operation.

•

Turn the ignition switch ON and make sure that the fuel pump operates (make light sounds) for 3 seconds, and then stops.

•


If the pump does not work as described above, inspect the power source voltage.

Fuel Pump

Operating Voltage Inspection

NOTE

○


•


•

Remove the ignition coil cover (see Ignition Coil Removal in the Electrical System chapter).

•

Connect the hand tester (25 V DC) to the fuel pump connector [A] with needle adapter set.

Special Tools - Hand Tester: 57001-1394

Needle Adapter Set: 57001-1457

○

Measure the operating voltage with the engine stopped, and with the connector joined.

•


○

The tester needle should indicate battery voltage for 3 seconds, and then 0 V.

Pump Operating Voltage at Pump

Connections to Pump Connectors

Tester (+) → BK/Y Lead

Tester (–) → BK/W Lead

Operating Voltage at Pump Connector

Standard: Battery Voltage (12.8 V or more) for 3 seconds, and then 0 V.

If the reading stays on battery voltage, and never shows

0 V. Check the ECU and fuel pump relay.

If the voltage is in specification, but the pump doesn’t work, replace the pump.

If there is still no battery voltage, check the pump relay (see Relay Circuit Inspection in the Electrical System chapter).



Fuel Pump

Power Source Voltage Inspection

NOTE

○


•

Remove the ignition coil cover (see Ignition Coil Removal in the Electrical System chapter).

•

Connect a digital voltmeter [A] to the fuel pump connector

[B] (3P), using the needle adapter [C].


•

Measure the power source voltage with the engine stopped, and with the pump connector joined.

•


Pump Power Source Voltage

Connections to Pump Connector

Tester (+) → BK/Y lead [D]

Tester (–) → Battery (–) Terminal [E]


Fuel Pump [F]

If the reading is good, the power source voltage is normal.

Inspect operating source voltage (see Operating Voltage

Inspection).

If the reading is incorrect, check the following:

Battery

Main Fuse 30 A in Starter Relay (see Fuse Inspection in the Electrical System chapter)

Ignition Fuse 10 A in Fuse Box (see Fuse Inspection in the Electrical System chapter)

Fuel Pump Relay (see Electrical System chapter)

Wiring for Fuel Pump Power Source (see next diagram)

Vehicle-down Sensor (see Vehicle-down Sensor Inspection)

Fuel Pump

Fuel Pump Circuit (Other than Europe Models)


1. ECU


3. Ignition Switch


5. ECU Fuse 15 A

6. Fuse Box

7. ECU Main Relay

8. Fuel Pump Relay

9. Relay Box

10. Main Fuse 30 A

11. Starter Relay

12. Battery



15. Frame Ground

16. Fuel Pump


Fuel Pump

Fuel Pump Circuit (Europe Models)

1. ECU


3. Ignition Switch


5. ECU Fuse 15 A

6. Fuse Box

7. ECU Main Relay

8. Fuel Pump Relay

9. Relay Box

10. Main Fuse 30 A

11. Starter Relay

12. Battery



15. Frame Ground

16. Fuel Pump

Fuel Injectors

CAUTION

Never drop the injector, especially on a hard surface. Such a shock to the injector can damage it.

Injector Removal

WARNING

Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Disconnect the battery (–) lead terminal.

Do not smoke.

Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.


•

Check to see that the battery (–) lead terminal is disconnected.

•

Remove:


•

Disconnect the fuel hose joint connector (see Fuel Hose

Replacement in the Periodic Maintenance chapter).

•

Disconnect the injector connectors [A].


•

Remove:

Bolt [A]

Bracket [B]


Fuel Injectors

•

Unscrew the delivery joint bolts [A], and lift up the delivery joint [B] with the injectors [C].

•

Remove the injectors from the delivery joint.

Injector Installation

○

The front and rear injectors are the same.

•

Replace the seal [A] and O-ring [B] with new ones, and install them onto the injector [C].

•

Apply engine oil to the O-ring, and install them onto the injector.

CAUTION

To avoid air and fuel leak, be careful not to get dirt or dust on the O-ring. Be careful not to damage the

O-ring.

•

Apply grease to the O-ring [A], and install each injector

[B] into the delivery joint [C].

•

Check that there is no dirt or dust on the injector seating surface [A] of the inlet manifold [B].

•

Check that the two dowel pins [C] are in place in the inlet manifold.

•

Fit the end of the injector into the delivery joint, and install them into the inlet manifold.

•

Apply a non-permanent locking agent to the delivery joint bolts, and tighten them.

Torque - Delivery Joint Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

•

Install the delivery joint bracket [A] so that the bracket recesses fit the connections.

•

Tighten:

Torque - Delivery Joint Bracket Bolt [B]: 9.8 N·m (1.0 kgf·m,

87 in·lb)

•

Install:

Fuel Tank (see Fuel Tank Installation)

•

Connect the battery (–) lead.

Fuel Injectors

Injector Fuel Line Inspection

•

Remove:


Fuel Hose (see Fuel Hose Replacement in the Periodic

•

Maintenance chapter)

Check the injector fuel line for leakage as follows:

○

Connect a commercially available vacuum/pressure pump [A] to the nipple of the delivery pipe [B] with a high-pressure fuel hose [C] (both ends connected with clamps [D]) as shown.

Torque - Fuel Hose Clamp Screws: 1.5 N·m (0.15 kgf·m, 13 in·lb)

○

Apply a soap and water solution to the areas [E] shown.

○

Watching the pressure gauge, squeeze the pump lever

[F], and build up the pressure until the pressure reaches the maximum pressure.

Injector Fuel Line Maximum Pressure

Standard: 300 kPa (3.06 kgf/cm², 44 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 system is good.

If the pressure drops at once, or if bubbles are found in the area, the line is leaking. Perform the following as necessary.

○

Retighten the fuel hose clamps [D].

Torque - Fuel Hose Clamp Screws: 1.5 N·m (0.15 kgf·m, 13 in·lb)

○

Replace:

O-ring of Injectors [G]

○

Repeat the leak test, and check the fuel line for no leakage.

•

Install the fuel hose (see Fuel Hose Replacement in the

Periodic Maintenance chapter).

•

Run the hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).



Fuel Injectors

•

Audible Inspection

Start the engine.

•

Insert a screwdriver from the engine right side between the fuel tank bottom end and the engine top end.

•

Apply the tip of a screwdriver [A] to the injector [B]. Put the grip end onto your ear, and listen whether the injector is clicking or not.

○

A sound scope [C] can also be used.

•

Do the same for the other injector.

If all the injectors click at a regular intervals, the injectors are good. The trouble may be related to the fuel line, requiring fuel pressure inspection (see Fuel Line section).

○

The click interval becomes shorter as the engine speed rises.

If either injector doesn’t click, the DFI circuit or the injector is suspect. Perform “Power Source Voltage Inspection”, first.

Fuel Injector Power Source Voltage Inspection

•

Remove the ECU (see ECU Removal).

○

Do not disconnect the ECU connector.

•

Connect a digital meter to the ECU connector, using the needle adapter.


○

Measure the power source voltage with the engine stopped, and with the connector joined.

•


Injector Power Source Voltage at ECU


Connections: Meter (+) → BR/W (terminal 12)



Connections: Meter (+) → BR/W (terminal 16)


Service Limit: Battery Voltage (12.8 V or more)

If the meter doesn’t read as specified, check the following.


System chapter)

Fuel Pump Relay (see Relay Circuit Inspection in the


Power Source Wiring (see wiring diagram below)

○

To check the W/R leads between the injector connector and the fuel pump relay, remove the fuel tank (see Fuel

Tank Removal) and the right side cover (see Right Side

Cover Removal in the Frame chapter).

If the power source voltage is normal, check the output voltage of the injectors.

Fuel Injectors

•



•

Remove the ECU (see ECU Removal). Do not disconnect the ECU connector.

•



Injector Output Voltage at ECU


Connections for Injector #1

Meter (+) → BL/R lead (terminal 34)



Meter (+) → BL/G lead (terminal 33)




Meter (+) → BL/R lead (terminal 42)



Meter (+) → BL/G lead (terminal 41)

•



•

Start the engine.


•


If the output voltage is normal, perform “Injector Signal

Test”.

If the output voltage is out of the standard, turn the ignition switch OFF, remove the fuel tank, and check the injector wiring for continuity.

Injector Wiring Inspection

(Other than Europe Models)

ECU Connector Injector Connectors

Terminal 12 → Injector #1 Terminal (W/R)


Terminal 34 → Injector #1 Terminal (BL/R)

Terminal 33 → Injector #2 Terminal (BL/G)

(Europe Models)

ECU Connector Injector Connectors



Terminal 42 → Injector #1 Terminal (BL/R)

Terminal 41 → Injector #2 Terminal (BL/G)

If the wiring is good, inspect the resistance of the injectors

•

(see Injector Resistance Inspection).

Remove the needle adapter.

•

Apply silicone sealant to the seals of the ECU connector for waterproofing.



Fuel Injectors

Injector Signal Test

•

Prepare two test light sets with male terminals as shown.

Rating of Bulb [A]: 12 V × 3 ∼ 3.4 W

Terminal Width [B]: 1.8 mm

Terminal Thickness [C]: 0.8 mm

CAUTION

Do not use larger terminals than specified above. A larger terminal could damage the injector main harness connector (female), leading to harness repair or replacement.

Be sure to connect bulbs in series. The bulb works as a current limiter to protect the solenoid in the injector from excessive current.

•

Remove:


•

Remove connectors for injector [A].

•

Connect each test light set [B] to the injector main harness

• connector [C].

Connect the battery (–) lead terminal.

•

While cranking the engine with the starter motor, watch the test lights.

If the test lights flicker at regular intervals, the injector circuit in the ECU, and the wiring are good. Perform the

“Injector Resistance Inspection”.

○

Injector signals can be also confirmed by connecting the hand tester (× 10 V AC) instead of the test light set to the injector main harness (female) connector. Crank the engine with the starter motor, and check to see if the needle oscillates at regular intervals.


If the test light doesn’t flicker (or the tester needle doesn’t oscillates), check the wiring and connectors again. If the wiring is good, the ECU is suspect. Replace the ECU.

Injector Resistance Inspection

•

Remove:


•

Disconnect the connector from the injector (see Injector

Removal).

•

Measure the injector resistance with a digital voltmeter

[A].

Injector Resistance

Connections to Injector

Meter (+)

#1: W/R

#2: W/R

←→

←→

Meter (–)

BL/R Terminal

BL/G Terminal

Standard: 11.7

∼ 12.3

Ω at 20°C (68°F)

If the reading is out of the range, perform the “Injector Unit

Test”.

If the reading is normal, perform the “Injector Unit Test” for confirmation.

Fuel Injectors

Injector Unit Test

•

Use two wires [A] and the same test light set [B] as in

“Injector Signal Test”.

Rating of Bulb [C]: 12 V × (3 ∼ 3.4) W

12 V Battery [D]

CAUTION

Be sure to connect the bulb in series. The bulb works as a current limiter to protect the solenoid in the injector from excessive current.

•

Connect the test light set to the injector [E] as shown.

•

Open and connect [F] the end of the wire to the battery

(–) terminal repeatedly. The injector should click.

If the injector does not click, replace the injector.

If the injector clicks, check the wiring again. If the wiring is good, replace the injector (may be clogged) or ECU.



Fuel Injectors

Fuel Injector Circuit (Other than Europe Models)

1. ECU


3. Ignition Switch


5. ECU Fuse 15 A

6. Fuse Box

7. ECU Main Relay

8. Fuel Pump Relay

9. Relay Box

10. Main Fuse 30 A

11. Starter Relay

12. Battery


14. Frame Ground

15. Injector #2

16. Injector #1

Fuel Injectors

Fuel Injector Circuit (Other than Europe Models)


1. ECU


3. Ignition Switch


5. ECU Fuse 15 A

6. Fuse Box

7. ECU Main Relay

8. Fuel Pump Relay

9. Relay Box

10. Main Fuse 30 A

11. Starter Relay

12. Battery


14. Frame Ground

15. Injector #2

16. Injector #1


Throttle Grip and Cables

Throttle Grip Free Play Inspection

•

Refer to Throttle Control System Inspection in the Periodic Maintenance Chapter.

Throttle Grip Free Play Adjustment

•

Loosen the locknuts [A] and screw the adjusters [B] all the way in so as to give the throttle grip plenty of play.

•

Turn out the adjuster of the decelerator cable [D] until

• there is no play.

Tighten the locknut against the adjuster.

•

Turn the adjuster of the accelerator cable [C] until the proper amount of throttle grip free play is obtained and tighten the locknut against the adjuster.

WARNING

Operation with incorrectly routed or improperly adjusted cables could result in an unsafe riding condition.

Cable Removal/Installation

○

See Throttle Body Assy and Intake Manifold section in this chapter for removal/installation of the throttle cables.

Cable Lubrication and Inspection

•

Whenever the throttle cables are removed or in accordance with the Periodic Maintenance Chart, lubricate the these cables. Refer to the General Lubrication in the Periodic Maintenance Chapter.

○

Use a commercially available pressure cable lubricator to lubricate these cables.

○

With the cable disconnected at both ends, the cable should move freely in the cable housing.

Throttle Body Assy

Idle Speed Inspection

•

Refer to Idle Speed Inspection in the Periodic Maintenance Chapter.

Idle Speed Adjustment

•

Refer to Idle Speed Adjustment in the Periodic Maintenance Chapter.

•

Throttle Bore Cleaning

Check the throttle bore for cleanliness as follows:

○


Removal).

○

Check the throttle bores [A] at the throttle valves [B] and around them for carbon deposits by opening the valves.

If any carbon accumulates, wipe the carbon off the throttle bores around the throttle valves, using a lint-free cloth [C] penetrated with a high-flash point solvent.

High Altitude Performance Adjustment

○

Any modification is not necessary in this model since the atmospheric pressure sensor senses pressure change due to high altitude and the ECU compensates the change.

Throttle Body Assy and Intake Manifold Removal

•


WARNING




•

Remove:

Air Cleaner Housing (see Air Cleaner Housing Removal)

•

Disconnect:

Vacuum Hose [A] from Separator (California Model)

Vacuum Hose [B] from Inlet Air Pressure Sensor

Connectors [C]




•

Remove the screws and take off the right switch housing.

•

Remove the accelerator cable end [A] and decelerator cable end [B] at the throttle grip.

•

Disconnect the injector connectors [A].

•

Unscrew the bolts [B] and remove the throttle body assy

[C] with the throttle cables from the intake manifold.

•

Remove:

Clip [A]

Accelerator Cable End [B]

Decelerator Cable End [C]

•

Remove the injectors (see Injector Removal).

•

Unscrew the mounting bolts [A] and remove the intake manifold [B].


○

Be careful not to damage (dent, nick, flaw, and crack) the flange mating surface and the plastic parts.

○

Do not drop the throttle body assy, especially on a hard surface.

WARNING

The throttle body assy should never be allowed to fall. Throttle may become stuck, possibly causing an accident.

•

Stuff a piece of lint-free, clean cloth into the throttle body assy, and the inlet ports of the cylinder heads to keep dirt out of the engine.

WARNING

If dirt or dust is allowed to pass through into the throttle bore, the throttle may become stuck, possibly causing an accident.

CAUTION

If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur.

•

Do not remove or adjust the throttle sensors [A] and sub throttle valve actuator [B]. These parts are set at the factory and cannot be readjusted.

CAUTION

Adjustment of some parts could result in poor performance, requiring replacement of the throttle body.

Throttle Body Assy and Intake manifold

Installation

•

Turn the throttle pulley [A] to check that the throttle valves move smoothly and return by spring force.

If the throttle valves do not move smoothly, replace the throttle body.


•

Open the butterfly valves [A], and wipe any carbon off the throttle bores [B] around the valves, using a piece of

• lint-free cloth penetrated with a high-flash point solvent.

Clean the bores [C] of the inlet manifold [D] as well.

•

Blow away dirt or dust from the throttle body and the inlet manifold by applying compressed air.

CAUTION

Do not immerse the throttle body (or throttle assy) in a high-flash point solvent for cleaning. This could damage the throttle sensor on the throttle body.



•

Before Installation, visually inspect the mating surfaces

[A] for any damage, like dent, nick, rust, flaw, and crack.

•

Nick or rust damage can sometimes be repaired by using 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].

Fit the new gasket [C] into the groove. Be careful not to pinch the gasket between the mating surfaces.

•

Replace the flange seals [A] with a new one.

•

With a high-flash point solvent, clean off the flange surface of the cylinder head and wipe dry.

•

Install the flanges [B] and seal so that the larger diameter end face cylinder head.

○

The seal should be centered on the flange.

•

Apply a non-permanent locking agent to the inlet manifold bolts, and tighten them.

Torque - Inlet Manifold Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

•

Install the lower end of the throttle cables in the throttle pulley.

Accelerator Cable [A]

Decelerator Cable [B]

•

Install the throttle body assy.

•

Tighten:

Torque - Throttle Body Assy Holder Bolts: 9.8 N·m (1.0


•

Stake the cable clip [A] on the throttle cable holder [B].


•

Apply a thin coating of grease to the throttle cable upper ends.

•

Install the upper ends of the throttle cables in the grip.

•

Fit the projection [A] of the right switch housing into the hole [B] of the handlebar.

•

Turn the throttle grip and make sure that the throttle valves move smoothly and return by spring force.

•

Check the throttle grip free play (see Throttle Control System Inspection in the Periodic Maintenance chapter).

WARNING

Operation with an incorrectly routed cable could result in an unsafe riding condition.



Air Cleaner

Air Cleaner Element Removal/Installation

•

Refer to the Air Cleaner Element Replacement in the Periodic Maintenance chapter.

Air Cleaner Housing Removal

•

Remove the air cleaner housing bolts [A].

•

Clear the idle speed screw [A] from the recess on the air cleaner housing.

•

Pull the air cleaner housing [A] and disconnect the following.

Air Switching Valve Hose [B]

Inlet Air Temperature Sensor Connector [C]

Crankcase Breather Hose [D]

•

Remove the air cleaner housing.

Air Cleaner Housing Installation

•

Check that oil is in the breather drain cap [A].

If necessary, drain the oil in the cap.

Air Cleaner

•

Fit the idle speed screw [A] in the recess on the air cleaner housing.


•

Be sure the dampers [A] and collars [B] are in position.

○

Install the damper [A] into the air cleaner housing [C] as shown.

Smaller Diameter [D]

Larger Diameter [E]

Torque - Air Cleaner Housing Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

Air Cleaner Cover Bolts: 4.9 N·m (0.50 kgf·m, 43 in·lb)


Fuel Tank

Fuel Tank Removal

WARNING



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 with a pump as much as possible when the engine is cold.


•

•

Turn both ignition switch, and engine stop switch OFF.

Wait until the engine cools down.

•

Open the fuel tank cap [A] to lower the pressure in the tank, and draw the fuel out from the fuel tank with a commercially available pump.

WARNING

The fuel cannot be removed completely from the fuel tank. Be careful for remained fuel spillage.

•

Disconnect the battery (

•

Remove:

− ) terminal.

Bolt [A]

Meter Cover [B]

•

Disconnect:

Meter Connector [A]

Fuel Level Sensor Connector [B]

Breather Hose [C]

Fuel Tank

•

Remove:


Fuel Tank Bolts [A]


•

Disconnect (California Model):

Fuel Return Hose (Red) [A]

•

Unscrew the screw [A], and pull out the ignition coil cover

[B].

•

Disconnect:

Fuel Pump Connector [A]


Fuel Tank

•

Place a cloth around the fuel hose joint.

•

Insert a minus screw driver [A] into the slit on the joint lock

[B].

•

Turn the driver to disconnect the joint lock.

•

Pull [C] the fuel hose joint [D] out of the outlet pipe.

CAUTION

When removing the fuel hose joint, do not apply strong force to the outlet pipe on the fuel pump. The pipe made from resin could be damaged.

WARNING


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.

•

Close the fuel tank cap.

•

Remove the fuel tank from the vehicle, and place it on a flat surface.

CAUTION

For California model, 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.

•

For California model, note the following:

○


WARNING

For California model, 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 (California model).

○

Be careful of fuel spillage from the fuel tank since fuel still remains in the fuel tank and fuel pump.

WARNING

Store the fuel tank in an area which is well

-ventilated and free from any source of flame or sparks. Do not smoke in this area. Place the fuel tank on a flat surface and plug the fuel pipes to prevent fuel leakage.

Fuel Tank

•

Fuel Tank Installation

Read the above WARNING.

•

Route the hoses correctly (see Cable, Wire and Hose


•

For California model, note the following:

○


○

Connect the hoses according to the diagram of the system. Make sure they do not get pinched or kinked.

○

Route hoses with a minimum of bending so that the air or vapor will not be obstructed.

•

Check that the rubber dampers [A] are in place.

If the dampers are damaged or deteriorated, replace them.


•

Pull [A] the joint lock [B] fully as shown.

•

Insert the fuel hose joint [A] straight onto the tank outlet pipe [B].

•

Push the joint lock [C].

•

Push and pull [A] the hose joint [B] back and forth more than two times and make sure it is locked and doesn’t come off.

WARNING

Make sure the hose joint is installed correctly on the delivery pipe by sliding the joint, or the fuel could leak.


•

Connect the fuel pump, meter and the fuel level sensor connectors and the battery (–) lead terminal.


Fuel Tank

Fuel Tank and Cap Inspection

•

Visually inspect the gasket [A] on the tank cap for any damage.

Replace the gasket if it is damaged.

•

Check to see if the breather pipe [B] in the tank is not clogged.

If the breather pipe is clogged, 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 damage and clog 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 of highly flammable liquids, do not use gasoline or low-flash point solvent to clean the tank.

•


•

Remove the fuel pump from the fuel tank (see Fuel Pump

Removal).

•

Fill the fuel tank with some high-flash point solvent, and

• shake the tank to remove dirt and fuel deposits.

Draw the solvent out of the tank.

•

Dry the tank with compressed air.

•

Install the fuel pump on the fuel tank (see Fuel Pump Installation).

•


Breather Check Valve Inspection

•

Remove:

Cap [A] and Bolt

Ignition Switch [B]

Bolt [C]

Clamp [D]

Breather Hoses

Breather Check Valve [E]

Fuel Tank

•

Check to see if the valve [A] slides smoothly when pushing it in with a wooden or other soft rod, and see if it comes back to its seat by pressure of the spring [B].

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 in a well-ventilated area.

○

Take care that there is no spark or flame anywhere near the working area.

If cleaning does not solve the problem, replace the check valve.




The Evaporative Emission Control System for California

Model routes fuel vapors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Although no adjustments are required, a thorough visual inspection must be made at the intervals specified by the Periodic Maintenance Chart.

Parts Removal/Installation

WARNING


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.

•


•

Be sure to plug the return hose to prevent fuel spilling before fuel tank removal.

WARNING

When removing the fuel tank, 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.

•

Connect the hoses according to the diagram of the system (see Cable, Wire and Hose Routing section in the

Appendix chapter). Make sure they do not get pinched or kinked.

•

Route hoses with a minimum of bending so that the air or vapor will not be obstructed.

Canister Installation

•

Refer to the Evaporative Emission Control System Inspection in the Periodic Maintenance chapter.

Canister Inspection (Periodic Inspection)

•

Refer to the Evaporative Emission Control System Inspection in the Periodic Maintenance Chapter.

Separator Inspection (Periodic Inspection)

•


Hose Inspection (Periodic Inspection)

•



Separator Operation Test

WARNING


•

•

Remove the seat and left side cover (see Frame chapter).

Connect the hoses to the separator.

•

Disconnect the breather hose from the separator, and inject about 20 mL of gasoline [A] into the separator [B] through the hose fitting.

•

Disconnect the evaporative fuel return hose [C] from the fuel tank [D]

•

Run the open end of the return hose into the container level with the tank top [E].

•


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.




1. Fuel Tank

2. Throttle Body

3. Canister

4. Separator

5. Breather Check Valve

6. Breather Hose

7. Breather Hose (Blue)

8. Vacuum Hose (White)

9. Fuel Return Hose (Red)

10. Purge Hose (Green)

11. To Air Switching Valve

12. To Air Cleaner

COOLING SYSTEM 4-1

Cooling System


Exploded View........................................................................................................................

Specifications .........................................................................................................................


Coolant Flow Chart.................................................................................................................

Coolant ...................................................................................................................................

Coolant Deterioration Inspection.......................................................................................

Coolant Level Inspection...................................................................................................

Coolant Draining ...............................................................................................................

Coolant Filling ...................................................................................................................

Pressure Testing ...............................................................................................................

Reserve Tank Removal.....................................................................................................

Water Pump............................................................................................................................

Water Pump Impeller Removal .........................................................................................

Water Pump Impeller Installation ......................................................................................

Mechanical Seal Replacement .........................................................................................

Water Pump Inspection.....................................................................................................

Radiator, Radiator Fan ...........................................................................................................

Radiator and Radiator Fan Removal ................................................................................

Radiator Fan Installation ...................................................................................................

Radiator Inspection ...........................................................................................................

Radiator Cap Inspection ...................................................................................................

Radiator Filler Neck Inspection .........................................................................................

Thermostat .............................................................................................................................

Thermostat Removal.........................................................................................................

Thermostat Installation......................................................................................................

Thermostat Inspection ......................................................................................................

Hose and Pipes ......................................................................................................................

Hose Installation ...............................................................................................................

Hose Inspection ................................................................................................................

Water Temperature Sensor ....................................................................................................

Water Temperature Sensor Removal/Installation .............................................................

Water Temperature Sensor Inspection .............................................................................

4-14

4-15

4-15

4-16

4-16

4-16

4-16

4-10

4-10

4-10

4-12

4-13

4-13

4-14

4-18

4-18

4-18

4-19

4-19

4-19

4-2

4-4

4-5

4-6

4-8

4-8

4-8

4-8

4-8

4-8

4-9

4-10

4

4-2 COOLING SYSTEM

Exploded View

Exploded View

No.

Fastener

1 Water Pump Impeller Bolt

2 Water Hose Fitting Bolts

3 Water (Radiator) Hose Clamp Screws

4 Thermostat Housing Cover Bracket Bolts

5 Thermostat Housing Cover Bolts

6 Radiator Bolts

7 Radiator Screen Screws

8 Radiator Fan Bolts

9 Reserve Tank Bolts

10 Coolant Drain Bolt

11. Thermostat

G: Apply grease.


WL: Apply soap and water solution.


6.9

4.9

6.9

6.9

N·m

9.8

9.8

2.0

8.3

6.9

9.8

Torque kgf·m

1.0

1.0

0.20

0.70

0.50

0.70

0.70

0.85

0.70

1.0

ft·lb

87 in·lb

87 in·lb

18 in·lb

61 in·lb

43 in·lb

61 in·lb

61 in·lb

73 in·lb

61 in·lb

87 in·lb

Remarks

L


Specifications

Item

Coolant Provided When Shipping

Type

Color

Mixed Ratio

Freezing Point

Total Amount

Standard

Permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators)

Green

Soft water 50%, coolant 50%

–35°C (–31°F)

2.2 L (2.3 us qt) (reserve tank full level including radiator and engine)

Radiator Cap

Relief Pressure 93 psi)

∼ 123 kPa (0.95

∼ 1.25 kgf/cm², 13 ∼ 18

Thermostat

Valve Opening Temperature

Valve Full Opening Lift

58 ∼ 62°C (136 ∼ 144°F)

8 mm (0.31 in.) or more @75°C (167°F)

Service Limit

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –


Bearing Driver Set:

57001-1129


Bearing Remover Head, 10 × 12:

57001-1266

Bearing Remover Shaft, 9:

57001-1265


56019-120


Coolant Flow Chart


Coolant Flow Chart

1. Thermostat

2. Radiator Cap

3. Cylinder Head Jacket

4. Radiator Fan

5. Radiator

6. Cylinder Jacket

7. Water Pump

8. Reserve Tank

9. Hot Coolant

10. Cold Coolant

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 with 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 100°C (212°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 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, 14 ∼ 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, 14 ∼ 18 psi).

When the engine cools down, another small valve (vacuum valve) in the cap opens. As the coolant cools, the coolant contracts to form a vacuum in the system. The vacuum valve opens and allows the coolant from the reserve tank to enter the radiator.


Coolant

Coolant Deterioration Inspection

•

Visually inspect the coolant in the reserve tank.

If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting. In either case, flush the cooling system.

If the coolant gives off an abnormal smell, check for a cooling system leak. It may be caused by exhaust gas leaking into the cooling system.

Coolant Level Inspection

•

Refer to the Coolant Level Inspection in the Periodic Maintenance chapter.

Coolant Draining

•

Refer to the Coolant Change in the Periodic Maintenance chapter.

Coolant Filling

•

Refer to the Coolant Change in the Periodic Maintenance chapter.

Pressure Testing

•



•

Remove the radiator cap, and install a cooling system pressure tester [A] on the filler neck.

NOTE

○

Wet the cap sealing surfaces with water or coolant to prevent pressure leaks.

•

Build up pressure in the system carefully until the pressure reaches 123 kPa (1.25 kgf/cm², 18 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, 18 psi).

•

Watch the gauge for at least 6 seconds.

If the pressure holds steady, the system is all right.

If the pressure drops and no external source is found, check for internal leaks. Droplets in the engine oil indicate internal leakage. Check the cylinder head gasket and the water pump.

•

Remove the pressure tester, replenish the coolant, and install the radiator cap.

Coolant

Reserve Tank Removal

•

Remove:

Left Side Cover (see Left Side Cover Removal in the

Frame chapter)

Bolt [A]

Reserve Tank Cover [B]


•

Remove:

Bolts [A]

•

Cap [B]

Drain the coolant to the suitable container.

•

Remove:

Hose [C]


Water Pump

Water Pump Impeller Removal

•

Drain:

Engine Oil (see Engine Oil Change in the Periodic Maintenance chapter)

Coolant (see Coolant Change in the Periodic Maintenance chapter)

•

Remove:

Right Engine Cover (see Right Engine Cover Removal in the Clutch chapter)

Bolt [A] and Washer

Impeller [B]

Water Pump Impeller Installation

•

Be sure to install the rubber seal [A] and sealing seat [B] into the impeller [C] by hand until the seat bottoms out.

•

Apply a little coolant to the sealing seat to give the seal

• initial lubrication.

Put the washer on the water pump impeller bolt.

•

Tighten:

Torque - Water Pump Impeller Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb)

Mechanical Seal Replacement

•

Remove:

Water Pump Impeller (see Water Pump Impeller Removal)

•

Pry the mechanical seal flange [A] off with a small chisel

[B].

•

Pull the mechanical seal out of the right crankcase with needle nose pliers.

CAUTION

Be careful not to damage the water pump shaft and the inner sealing surface of the crankcase.

•

Discard the mechanical seal.

NOTE

○

Since the replacement mechanical seal has an adhesive coated body, do not apply liquid gasket to the exterior surface of the body.

•

Press the new mechanical seal [A] into the hole by using a suitable socket [B] and a bearing driver [C] until its flange touches the step [D].

Special Tool - Bearing Driver Set: 57001-1129

CAUTION

Be careful not to damage the water pump shaft and mechanical seal.

Water Pump

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).

•

Take the bearing [A] out of the right crankcase, using the bearing remover.

Special Tools - Bearing Remover Shaft, 9 [B]: 57001-1265

Bearing Remover Head, 10 × 12: 57001

-1266 [C]

•

Using a thin-bladed screwdriver, pry out the oil seal.

•

Press out the mechanical seal [A] from the inside of the right crankcase with the bearing driver set [B].



○

Be sure to replace the mechanical seal, oil seal, and ball bearing with new ones because these parts will be dam-

• aged by removal.

Apply plenty grease to the oil seal lips.

•

Press the oil seal [A] into the hole from the inside of the right crankcase with the bearing driver set so that the spring side of the seal lips is toward the inside of the crankcase.


○

Use the bearing driver which has a larger diameter than the oil seal.

•

Press in the ball bearing [B] with its manufacturer’s mark facing out until it bottoms out.

•

Press the mechanical seal [A] by using a suitable socket

[B] and a bearing driver [C] until its flange touches the step [D].



Water Pump

Water Pump Inspection

•

Check the drainage outlet passage [A] at the bottom of the right 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 with a new one.

•

Visually inspect the impeller [A].

If the surface is corroded, or if the blades are damaged, replace the impeller.

Radiator, Radiator Fan

Radiator and Radiator Fan Removal

WARNING

The radiator fan is connected directly to the battery. The radiator fan may start even if the ignition switch is off. NEVER TOUCH THE RADIATOR FAN

UNTIL THE RADIATOR FAN CONNECTOR IS DIS-

CONNECTED. TOUCHING THE FAN BEFORE THE

CONNECTOR IS DISCONNECTED COULD CAUSE

INJURY FROM THE FAN BLADES.

•

Drain:


•

Remove:


Fuel Tank (see Fuel Tank Removal in the Fuel System

(DFI) chapter)

Radiator Hose Clamp [A] (Loosen)

Radiator Hose [B]

•

Remove:

Radiator Hose Clamp [A] (Loosen)

Radiator Hose [B]

Radiator Mounting Bolt [C]


•

Remove:

Horn Lead Connectors [A]

Bolts [B]

Horn [C]

Radiator Mounting Bolt [D]

•

Pry open the clamps [A].



•

Remove:

Radiator Fan Connector [A]

Radiator

•

Remove:

Radiator Fan Mounting Bolts [A]

Radiator Fan [B]

CAUTION

Do not touch the radiator core. This could damage the radiator fins, resulting in loss of cooling efficiency.

Radiator Fan Installation

•

Torque the radiator fan bolts.

Torque - Radiator Fan Bolts: 8.3 N·m (0.85 kgf·m, 73 in·lb)

•

Fit the radiator stoppers [A] into the grommet [B].

•

Torque:

Torque - Radiator Hose Clamp Screws: 2.0 N·m (0.20 kgf·m,

18 in·lb)

Radiator Screen Bolts: 6.9 N·m (0.70 kgf·m, 61 in·lb)

Radiator Inspection

•

Check the radiator core.

If there are 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.

Keep the steam gun [A] away more than 0.5 m (1.6

ft) [B] from the radiator core.

Hold the steam gun perpendicular to the core surface.

Run the steam gun following the core fin direction.


Radiator Cap Inspection

•

Check the condition of the top [A] and bottom [B] valve seals and valve spring [C].

If any one of them shows visible damage, replace the cap with a new one.


•

Install the cap [A] on a cooling system pressure tester [B].

NOTE

○

Wet the cap sealing surfaces with water or coolant to prevent pressure leaks.

•

Watching the pressure gauge, pump the pressure tester to build up the pressure until the relief valve opens: the gauge hand 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 hand 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 ∼ 18 psi)

If the cap cannot hold the specified pressure, or if it holds too much pressure, replace it with a new one.

•

Radiator Filler Neck Inspection

Remove the radiator cap.

•

Check the radiator filler neck for signs of damage.

•

Check the condition of the top and bottom sealing seats

[A] in the filler neck. They must be smooth and clean for the radiator cap to function properly.


Thermostat

Thermostat Removal

•

Drain:

Coolant (about 200 mL)

•

Remove:



(DFI) chapter)

Reserve Tank Hose [A]

Radiator Hose Clamp [B] (Loosen)

Water Temperature Connector [C]

Bolt [D]

•

Remove:

Thermostat Housing Cover Bolts [A]

Thermostat Housing Cover

Thermostat

•

Thermostat Installation

Install a new O-ring [A] into the housing cover.

•

Install:

Thermostat

Thermostat Housing Cover

•

Tighten:

Torque - Thermostat Housing Cover Bolts: 4.9 N·m (0.50


•

Fill the radiator with coolant (see Coolant Change in the

Periodic Maintenance chapter).

Thermostat Inspection

•

Remove the thermostat, and inspect the thermostat valve

[A] at room temperature.

If the valve is open, replace the thermostat with a new one.

Thermostat

•

To check valve opening temperature, suspend the thermostat [A] in a container of water and raise the temperature of the water.

○

The thermostat must be completely submerged and must not touch the container sides or bottom. Suspend an accurate thermometer [B] in the water so that the heat sensitive portions [C] are located in almost the same depth.

It must not touch the container, either.

If the measurement is out of the specified range, replace the thermostat with a new one.

Thermostat Valve Opening Temperature

58 ∼ 62°C (136 ∼ 144°F)



Hose and Pipes

Hose Installation

•

Install the hoses and pipes being careful to follow bending direction or diameter. Avoid sharp bending, kinking, flattening, or twisting.

•

Install the clamps [A] as near as possible to the hose end to clear the raised rib or the fitting. This will prevent the hoses from working loose.

○

The clamp screws should be positioned correctly to prevent the clamps from contacting anything.

Torque - Water (Radiator) Hose Clamp Screws: 2.0 N·m

(0.20 kgf·m, 18 in·lb)

Hose Inspection

•

Refer to the Radiator Hose and Connection Inspection in the Periodic Maintenance chapter.

Water Temperature Sensor

Water Temperature Sensor Removal/Installation

CAUTION

The water temperature sensor should never be allowed to fall on a hard surface. Such a shock to water temperature sensor can damage it.

•

Refer to the Water Temperature Sensor Removal/Installation in the Fuel System (DFI) chapter.

Water Temperature Sensor Inspection

•

Refer to the Water Temperature Sensor Inspection in the



ENGINE TOP END 5-1

Engine Top End


Exploded View........................................................................................................................

Exploded Veiw ........................................................................................................................

Specifications .........................................................................................................................

Special Tools ..........................................................................................................................

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 Inspection ..........................................................................................

Clean Air System Hose Inspection ...................................................................................

Cylinder Head Cover ..............................................................................................................

Cylinder Head Cover Removal .........................................................................................

Cylinder Head Cover Installation ......................................................................................

Camshaft Chain Tensioner .....................................................................................................

Camshaft Chain Tensioner Removal ................................................................................

Camshaft Chain Tensioner Installation .............................................................................

Camshaft, Camshaft Chain ....................................................................................................

Camshaft Removal ...........................................................................................................

Camshaft Installation ........................................................................................................

Camshaft/Camshaft Cap Wear .........................................................................................

Camshaft Runout ..............................................................................................................

Cam Wear.........................................................................................................................

Camshaft Chain Removal .................................................................................................

Camshaft and Sprocket Assembly....................................................................................

Rocker Shaft, Rocker Arm......................................................................................................

Rocker Shaft, Rocker Arm Removal .................................................................................

Rocker Shaft, Rocker Arm Installation ..............................................................................

Cylinder Head.........................................................................................................................

Cylinder Compression Measurement................................................................................

Cylinder Head Removal ....................................................................................................

Cylinder Head Installation .................................................................................................

Cylinder Head Warp..........................................................................................................

Valves .....................................................................................................................................

Valve Clearance Inspection ..............................................................................................

Valve Clearance 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..............................................................................................................

Piston Removal.................................................................................................................

Cylinder, Piston Installation...............................................................................................

Cylinder Wear ...................................................................................................................

5-25

5-26

5-26

5-26

5-26

5-26

5-26

5-27

5-23

5-23

5-23

5-24

5-24

5-25

5-25

5-27

5-28

5-28

5-33

5-33

5-33

5-33

5-35

5-18

5-19

5-20

5-21

5-21

5-21

5-22

5-15

5-15

5-16

5-17

5-17

5-17

5-18

5-13

5-13

5-13

5-13

5-13

5-13

5-14

5-4

5-8

5-9

5-11

5-13

5-13

5

5-2 ENGINE TOP END

Piston Wear ......................................................................................................................

Piston/Cylinder Clearance ................................................................................................

Piston Ring, Piston Ring Groove Wear.............................................................................

Piston Ring Groove Width.................................................................................................

Piston Ring Thickness .....................................................................................................

Piston Ring End Gap ........................................................................................................

Muffler.....................................................................................................................................

Muffler Removal................................................................................................................

Muffler Installation.............................................................................................................

5-35

5-36

5-36

5-36

5-37

5-37

5-38

5-38

5-39

Dummy Page



Exploded View


Exploded View

No.

1

Cylinder Head nuts(M10)(First)

Cylinder Head nuts(M10)(Final)

2 Cylinder Head nuts(M8)

3 Camshaft Cap Bolts

4 Cylinder Head Cover Bolts

5 Cylinder Head Outer Cover Bolts

6 Plug(PT1/4)

7 Plug(PT1/2)

Fastener

N·m

20

49

25

25

12

9.8

15

20

Torque kgf·m

2.0

5.0

2.5

2.5

1.2

1.0

1.5

2.0

ft·lb

15

36

18

18

106 in·lb

87 in·lb

11

15

EO: Apply oil.

G: Apply grease.





R: Replace Parts

S: Follow specified tightening sequence.

Remarks

S, MO

S, MO

S

L

L


Exploded View


Exploded View

No.

1

2

3

4

5

6

7

Fastener

Muffler Mounting Bolts

Muffler Mounting Nut

Muffler Joint Clamp Bolt

Exhaust Pipe Cover Clamp Bolts

Exhaust Pipe Cover Bolts


Camshaft Sprocket Bolts

8 Camshaft Chain Tensioner Cap Bolts

9 Camshaft Chain Guide Bolts

N·m

25

25

17

6.9

6.9

17

49

20

9.8

Torque kgf·m

2.5

2.5

1.7

0.70

0.70

1.7

5.0

2.0

1.0

ft·lb

18

18

12

61 in·lb

61 in·lb

12

36

15

87 in·lb

EO: Apply engine oil.






Remarks

L

L


Exploded Veiw

Exhaust System

UK: U.K Model

FULL: Full Power

H: Honeycomb Type Catalyst

Silensor [A] without Boss [A] for Oxygen Sensor

Silensor with Boss [B] for Oxygen Sensor


Specifications

Cylinder Head Warp

Valves

Item

Camshafts

Cam Height:

Exhaust

Inlet

35.030

∼ 35.144 mm (1.3791

∼ 1.3836 in.) 34.93 mm (1.375 in.)

35.302

∼ 35.416 mm (1.3898

∼ 1.3943 in.) 35.20 mm (1.386 in.)

0.028

∼ 0.071 mm (0.0011

∼ 0.0028 in.) 0.16 mm (0.0063 in.) Camshaft Journal, Camshaft

Cap Clearance

Camshaft Journal Diameter 26.950

∼ 26.972 mm (1.0610

∼ 1.0619 in.) 26.92 mm (1.060 in.)

Camshaft Bearing Inside

Diameter

27.000

∼ 27.021 mm (1.0630

∼ 1.0638 in.) 27.08 mm (1.066 in.)

Camshaft Runout TIR 0.02 mm (0.0008 in.) or less

Rocker Arm Inside Diameter 16.000

Rocker Shaft Diameter

Cylinder Head

∼

(0.62992

16.018 mm

∼ 0.63063 in.)

15.965

∼ 15.984 mm

(0.62854

∼ 0.62929 in.)

TIR 0.1 mm

(0.004 in.)

16.05 mm

(0.6319 in.)

15.94 mm

(0.6276 in.)

Cylinder Compression

Standard

(usable range)

980 ∼ 1 570 kPa (10.0

∼ 16.0 kgf/cm², 142

∼ 228 psi) @470 r/min (rpm)

– – –

Service Limit

– – –

0.05 mm (0.002 in.)

Valve Clearance

Exhaust

Inlet

Valve Head Thickness:

Exhaust

Inlet

Valve Stem Bend

0.20

0.10

∼

∼

0.25 mm (0.0079

0.15 mm (0.0039

0.8 mm (0.03 in.)

0.5 mm (0.02 in.)

∼

∼

0.0098 in.)

0.0059 in.)

TIR 0.01 mm (0.0004 in.) or less

– – –

– – –

0.5 mm (0.02 in.)

0.3 mm (0.01 in.)

TIR 0.05 mm

(0.002 in.)

Valve Stem Diameter:

Exhaust

Inlet

4.955

∼ 4.970 mm (0.1951

∼ 0.1957 in.)

4.975

∼ 4.990 mm (0.1959

∼ 0.1964 in.)

Valve Guide Inside Diameter 5.000

∼ 5.012 mm (0.1968

∼ 0.1973 in.)

Valve/valve Guide Clearance

(wobble method):

Exhaust

Inlet

Valve Seat Cutting Angle

0.09

∼ 0.17 mm (0.0035

∼ 0.0067 in.)

0.03

∼ 0.11 mm (0.0012

∼ 0.0043 in.)

45°, 32°, 60°

Valve Seat Surface:

Width 0.5

∼ 1.0 mm (0.02

∼ 0.04 in.)

Outside Diameter:

Exhaust

Inlet

Valve Spring Free Length

26.9

∼ 27.1 mm (1.059

∼ 1.067 in.)

30.9

∼ 31.1 mm (1.216

∼ 1.224 in.)

40.5 mm (1.59 in.)

4.94 mm (0.194 in.)

4.96 mm (0.195 in.)

5.08 mm (0.200 in.)

0.38 mm (0.015 in.)

0.32 mm (0.013 in.)

– – –

– – –

– – –

– – –

38.6 mm (1.52 in.)


Specifications

Item

Cylinder, Piston

Cylinder Inside Diameter

Piston Diameter

Piston/Cylinder Clearance

Piston Ring/Groove

Clearance:

Top

Second

Piston Ring Groove Width:

Top

Second

Piston Ring Thickness:

Top and Second

Piston Ring End Gap:

Top

Second

Oil

Standard

0.05

∼ 0.09 mm (0.002

∼ 0.004 in.)

0.03

∼ 0.07 mm (0.001

∼ 0.003 in.)

1.04

∼ 1.06 mm (0.0409

∼ 0.0417 in.)

1.02

∼ 1.04 mm (0.0402

∼ 0.0409 in.)

0.97

∼ 0.99 mm (0.038

∼ 0.039 in.)

0.20

∼ 0.35 mm (0.0079

∼ 0.014 in.)

0.40

∼ 0.55 mm (0.016

∼ 0.022 in.)

0.20

∼ 0.70 mm (0.0079

∼ 0.028 in.)

Service Limit

88.000

∼ 88.012 mm (3.4646

∼ 3.4650 in.) 88.10 mm (3.468 in.)

87.955

∼ 87.970 mm (3.4628

∼ 3.4634 in.) 87.80 mm (3.457 in.)

0.030

∼ 0.057 mm (0.0012

∼ 0.0022 in.) – – –

0.19 mm (0.0075 in.)

0.17 mm (0.0067 in.)

1.14 mm (0.0449 in.)

1.12 mm (0.0441 in.)

0.90 mm (0.035 in.)

0.6 mm (0.02 in.)

0.8 mm (0.03 in.)

1.0 mm (0.039 in.)

Special Tools

Compression Gauge, 20 kgf/cm²:

57001-221


Valve Seat Cutter, 60° - 30:

57001-1123

Valve Spring Compressor Assembly:

57001-241

Valve Seat Cutter Holder Bar:

57001-1128

Piston Pin Puller Assembly:

57001-910


57001-1187


57001-1115


57001-1119


57001-1199

Valve Spring Compressor Adapter, 22:

57001-1202


Special Tools

Valve Guide Arbor, 5:

57001-1203

Spark Plug Wrench, Hex 16:

57001-1262

Valve Guide Reamer, 5:

57001-1204

Valve Seat Cutter Holder, 5:

57001-1208

Compression Gauge Adapter, M10 × 1.0:

57001-1317


57001-1334

NOTE

○

The following valve seat cutters can be used instead of the above tools.

Inlet Valve Seat:

Exhaust Valve Seat:

Valve Seat Cutter, 45° - 35: 57001-1116

(instead of Valve Seat Cutter: 45° - 32: 57001-1115)











Clean Air System

Air Suction Valve Removal

•

Remove:

Cylinder Head Covers (see Cylinder Head Cover Removal)

Air Suction Valves [A]


Air Suction Valve Installation

•

Install each air suction valve so that stopper side [A] of the reed faces downward.

Air Suction Valve Inspection

•

Remove the air suction valve (see Air Suction Valve Removal).

•

Visually inspect the reeds for cracks, folds, warps, heat damage or other damage.

If there is any doubt as to the condition of the reeds [A], replace the air suction valve as an assembly.

•

Check the reed contact areas [B] of the valve holder for grooves, scratches, any signs of separation from the holder or heat damage.

Air Switching Valve Removal

•

Remove:


(DFI) chapter)

•

Disconnect the air switching valve connector [A] and pull off the hoses [B].

•

Remove the air switching valve [C].

Air Switching Valve Installation

•

Route the hoses correctly (see Cable, Wire and Hose


Air Switching Valve Operation Test

•

Refer to the Air Switching Valve Operation Test in the Periodic Maintenance chapter.

Air Switching Valve Inspection

•

Refer to the Air Switching Valve Inspection in the Electrical System chapter.


Clean Air System

Clean Air System Hose Inspection

•

Be certain that all the hoses are routed without being flattened or kinked, and are connected correctly to the right air cleaner base, air switching valve, and fittings on the rocker case covers

If they are not, correct them. Replace them if they are damaged.

Cylinder Head Cover

Cylinder Head Cover Removal

•

Remove:



(DFI) chapter)

•

Slide [A] the air switching valve [B] forward to clear the clamp.


•

Remove:

Bolt [A]

Clamp [B]

•

Remove:

Cylinder Head Outer Cover Bolts [A]

•

Lift up the cylinder head outer cover [A], and while turn the it clockwise, remove it.


Cylinder Head Cover

•

Remove:

Dampers [A]

Cylinder Head Cover Bolts [B] and washers

Cylinder Head Cover [C]

Cylinder Head Cover Gasket

○

Just move everything that is between the cylinder head cover and the frame out of the may to make room. Then as a lift the cover up, make sure the spark plug pipe [A] stays all the way down in the cylinder head. If the pipe comes up with the cover.

Cylinder Head Cover Installation

•

If the plug pipe [A] was removed, install it, and apply grease to the O-ring [B].

•

Install:

Pin [C]

Air Suction Valve [D] (see Air Suction Valve Installation)

Head Cover Gasket [E]

•

Install the washer with the metal side [A] faces upward.

•

Tighten:

Torque - Cylinder Head Cover Bolts: 12 N·m (1.2 kgf·m, 106 in·lb)

•

Install:

Dampers

Cylinder Head Outer Cover

•

Tighten:

Torque - Cylinder Head Outer Cover Bolts: 9.8 N·m (1.0


•


Camshaft Chain Tensioner

Camshaft Chain Tensioner Removal

•

Remove:

Engine (see Engine Removal/Installation chapter)

Camshaft (see Camshaft Removal)

Cylinder Head (see Cylinder Head Removal)

•

Remove the camshaft chain tensioner body from the cylinder.

Camshaft Chain Tensioner Installation

•

Refer to the Cylinder Head Installation and Camshaft Installation.



Camshaft, Camshaft Chain

Camshaft Removal

•

Remove:

Cylinder Head Cover (see Cylinder Head Cover Removal)

Ignition Coil Cover (For Front Cylinder)(see Ignition Coil

Removal in the Electrical System chapter)

Tensioner Cap Bolt [A], Washer [B] and Spring

CAUTION

Do not turn over the crankshaft while the tensioner cap bolt is removed, The tensioner body is loose from the cylinder while the cap bolt is removed.

Turning the crankshaft could damage the tensioner body and/or cylinder, and also the valves because upsetting the camshaft chain timing.

•

Release the stopper [A] and push the push rod [B] into the tensioner body [C].

[D] Cylinder

[E] Camshaft Chain Guide

NOTE

○

Temporary, install the tensioner cap bolt [A] only to prevent the tensioner body from falling into the crankcase.

•

Remove:

Camshaft Cap Bolts [A]

Camshaft Cap [B]

•

Disengage the camshaft chain [C] from the camshaft sprocket [D], and remove the camshaft.

•

Stuff a clean cloth into the chain tunnel to keep any parts from dropping into 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.


Camshaft Installation

•

Apply engine oil to all cam parts and journals.

NOTE

○

The front and rear camshafts are different. The rear camshaft [A] has a groove [B].


•

Remove:

Alternator Outer Cover (see Alternator Outer Cover Removal in the Electrical System chapter)

Bolts [A]

Timing Inspection Plate [B]

•

Set the front piston at TDC.

○

Align the front piston TDC mark [A] and timing mark [B] by turning the alternator rotor bolt counterclockwise [C] (left side view).

•

Engage the camshaft chain [A] with the camshaft sprocket

[B].

○

Align the timing mark line [C] on the camshaft sprocket with the cylinder head upper surface [D].

•

Install the camshaft cap and tighten the cap bolts [E].

Torque - Camshaft Cap Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)

•

Install the front camshaft chain tensioner as follows:

○

Remove the cap bolt installed temporarily.

Hold the tensioner body and push the push rod [A] until the rod touches to the chain guide [B] lightly.

○

Install the spring, washer [C] and cap bolt [D].

Torque - Camshaft Chain Tensioner Cap Bolt: 20 N·m (2.0




NOTE

○

Installing the rear camshaft is the same as for the front camshaft. But noting the following.

•

Set the rear piston at TDC.

○

Align the rear piston TDC mark [A] and timing mark [B] by turning the crankshaft counterclockwise [C] 305° (left side view).

Camshaft/Camshaft Cap Wear

•

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 and the rocker case using plastigage.

NOTE

○

Do not turn the camshaft when the plastigage is between the journal and camshaft cap.

•

Tighten:

Torque - Camshaft Cap Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)

•

Remove the camshaft cap again, and measure the plastigage width [A] to determine the clearance between each journal and the camshaft cap. Measure the maximum plastigage width.

Camshaft Journal, Camshaft Cap Clearance

Standard: 0.028 ~ 0.071 mm

Service Limit:

(0.0011 ~ 0.0028 in.)

0.16 mm (0.0063 in.)

If any clearance exceeds the service limit, measure the diameter of each camshaft journal with a micrometer.

Camshaft Journal Diameter

Standard: 26.950 ~ 26.972 mm

Service Limit:

(1.0610 ~ 1.0619 in.)

26.92 mm (1.060 in.)

If the camshaft journal diameter is less than the service limit, replace the camshaft with a new one and measure the clearance again.

If the clearance still remains out of the limit, replace the cylinder head and camshaft cap.

CAUTION

The camshaft cap and cylinder head are machined in the assembled state, so they must be replaced as a set.


•

Camshaft Runout

Remove the camshaft (see Camshaft Removal).

•

Set the camshaft in a camshaft alignment jig or on V blocks.

•

Measure runout with a dial gauge at the specified place as shown.

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.)

•

Cam Wear

Remove the camshaft (see Camshaft Removal).

•

Measure the height [A] of each cam with a micrometer.

If the cams are worn down past the service limit, replace the camshaft.

Cam Height

Standard:

Exhaust

Inlet

35.030

∼ 35.144 mm (1.3791

∼ 1.3836 in.)

35.302

∼ 35.416 mm (1.3898

∼ 1.3943 in.)

Service Limit:

Exhaust 34.93 mm (1.375 in.)

Inlet 35.20 mm (1.386 in.)

Camshaft Chain Removal

Front Camshaft Chain

•

Remove:

Front Camshaft (see Camshaft Removal)

Alternator Rotor (see Alternator Rotor Removal in the


Bolts [A]

Rear Chain Guide [B]

Bolt [C] and Washer [D]

Front Chain Guide [E]

•

Disengage the camshaft chain [F] from the crankshaft sprocket and then remove the chain.

Rear Camshaft Chain

•

Remove:

Rear Camshaft (see Camshaft Removal)

Primary Gear (see Primary Gear Removal in the Crankshaft/Transmission chapter)

Clutch (see Clutch Removal in the Clutch chapter)

Bolts [A]

Rear Chain Guide [B]

Front Chain Guide [C]

•

Disengage the camshaft chain [D] from the crankshaft sprocket and then remove the chain.




•

Camshaft and Sprocket Assembly

Clean the sprocket bolt [A] and threads of the camshaft.

•

Be sure to install the pin [B].

•

Apply a non-permanent locking agent to the threads of the camshaft sprocket bolt, and tighten it. The sprockets are identical.

Torque - Camshaft Sprocket Bolt: 49 N·m (5.0 kgf·m, 36 ft·lb)

Rocker Shaft, Rocker Arm

Rocker Shaft, Rocker Arm Removal

•

Remove:

Cylinder Head Cover (see Cylinder Head Cover Removal)

Camshaft Cap (see Camshaft Removal)

Rocker Shafts [A]

Rocker Arms [B] and Springs [C]

•

Rocker Shaft, Rocker Arm Installation

Apply molybdenum disulfide grease to the rocker shaft.

•

Insert the rocker shaft into the camshaft cap and rocker arm so that the notch side [A] faces to the spring end.

○

Mark the red paint on the inlet side spring for discriminate.

•

Align the bolt holes [B] of the camshaft cap and rocker shaft.



Cylinder Head

Cylinder Compression Measurement

•

NOTE

○

Use the battery which is fully charged.

•


•

Stop the engine.

Remove:



(DFI) chapter)

Spark Plugs

Special Tool - Spark Plug Wrench, Hex 16: 57001-1262

•

Attach the compression gauge [A] and adapter [B] firmly 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, M10 × 1.0:

57001-1317

Cylinder Compression

Usable Range: 980 ∼ 1570 kPa (10.0

∼ 16.0 kgf/cm²,

142 ∼ 228 psi) @470 r/min (rpm)

•

Repeat the measurement for the other cylinders.

•

Install the spark plugs.

Torque - Spark Plugs: 18 N·m (1.8 kgf·m, 13 ft·lb)

The following table should be consulted if the obtainable compression reading is not within the usable range.

Problem

Cylinder compression is higher than usable range

Cylinder compression is lower than usable range

Diagnosis

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).

Remedy (Action)

Remove the carbon deposits and replace damaged parts if necessary.

Incorrect cylinder head gasket thickness.

Replace the gasket with a standard part.

Gas leakage around cylinder head Replace damaged gasket and check cylinder head warp.

Bad condition of valve seating

Incorrect valve clearance.

Incorrect piston/cylinder clearance

Piston seizure.

Bad condition of piston ring and/or piston ring grooves

Repair if necessary.

Adjust the valve clearance.

Replace the piston and/or cylinder

Inspect the cylinder and replace/repair the cylinder and/or piston as necessary.

Replace the piston and/or the piston rings.

Cylinder Head

Cylinder Head Removal

•

Remove:

Engine (see Engine Removal in the Engine Removal/Installation chapter)

Camshaft (see Camshaft Removal)

•

Remove the cylinder head nuts following sequence [1 ∼

6].

•

Remove:

Cylinder Head

Cylinder Head Installation

NOTE

○

The camshaft cap is machined with the cylinder head, so if a new cylinder head is installed, use the cap that is supplied with the new head.

○

The front cylinder head has a breather pipe fitting. Be careful not to mix up the front and rear cylinder heads.

•

Release the stopper and push the push rod into the tensioner body [A], and tighten the cap bolt only temporarily.

•

Replace the cylinder head gasket with a new one.

•

Install:

Oil Pipe [B]

Chain Guide (White) [C]

Knock Pins

Cylinder Head Gasket [D]

•

Temporary tighten the cylinder head nuts (M10) following the tightening sequence [1 ∼ 4].

Torque - Cylinder Head Nuts (M10)(First): 20 N·m (2.0


•

Tighten the cylinder head nuts following the tightening sequence [1 ∼ 6].

Torque - Cylinder Head Nuts (M10)(Final): 49 N·m (5.0


Cylinder Head Nuts (M8): 25 N·m (2.5 kgf·m, 18 ft·lb)

Cylinder Head Warp

•

Lay a straightedge across the lower surface of the cylinder head at several positions.

•

Use a thickness gauge [A] to measure the space between 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).



Valves

Valve Clearance Inspection

•

Refer to the Valve Clearance Inspection in the Periodic

Maintenance chapter.

Valve Clearance Adjustment

•

Refer to the Valve Clearance Adjustment in the Periodic


•

Valve Removal

Remove the cylinder head (see Cylinder Head Removal).

•

Swing open the rocker arm, and then remove the shims.

○

Mark and record the shim locations so that the shims can be installed in their original positions.

•

Using the valve spring compressor assembly, remove the valve.

Special Tools - Valve Spring Compressor Assembly: 57001

-241 [A]

Valve Spring Compressor Adapter, 22:

57001-1202 [B]

•

Valve Installation

Replace the oil seal with a new one.

•

Apply a thin coat of molybdenum disulfide grease to the valve stem before valve installation.

•

Install the springs so that the closed coil end faces downwards or painted side upwards.

Valve Stem [A]

Stem Oil Seal [B]

Spring Seat [C]

Spring [D]

Retainer [E]

Split Keepers [F]

Valve Guide Removal

•

Remove:

Valve (see Valve Removal)

Stem 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: 57001-1203

Valves

Valve Guide Installation

•

Apply oil to the valve guide outer surface before installation.

•

Heat the area around the valve guide hole to about 120 ∼

150°C (248 ∼ 302°F) (see Valve Guide Removal).

•

Drive the valve guide in from the top of the head using the valve guide arbor [A]. The flange stops the guide from going in too far.

Special Tool - Valve Guide Arbor, 5: 57001-1203

•

Ream the valve guide with the valve guide reamer [A] even if the old guide is reused.

Special Tool - Valve Guide Reamer, 5: 57001-1204


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

Inlet

0.09

∼ 0.17 mm (0.0035

∼ 0.0067 in.)

0.03

∼ 0.11 mm (0.012

∼ 0.0043 in.)

Service Limit:

Exhaust

Inlet

0.38 mm (0.015 in.)

0.26 mm (0.010 in.)


Valves

•

Valve Seat Inspection

Remove the valve (see Valve Removal).

•

Check the valve seating surface [A] between the valve [B] and valve seat [C].

○

Measure the outside diameter [D] of the seating 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 26.9

∼ 27.1 mm (1.059

∼ 1.067 in.)

Inlet 30.9

∼ 31.1 mm (1.216

∼ 1.224 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:

Inlet, Exhaust 0.5

∼ 1.0 mm (0.02

∼ 0.04 in.)

Valve Seat Repair

•

Repair the valve seat with the valve seat cutters [A].

Special Tools -

Valve Seat Cutter Holder, 5: 57001-1208 [B]

Valve Seat Cutter Holder Bar: 57001-1128 [C]

[For Inlet Valve Seat]

Valve Seat Cutter, 45° - 32: 57001-1115 or Valve Seat Cutter, 45° - 35: 57001-1116



[For Exhaust Valve Seat]




If the manufacturer’s instructions are not available, use the following procedure.

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.

Widened Width [A] of engagement by machining with

45° cutter

Ground Volume [B] by 32° cutter

32° [C]

Correct Width [D]

Ground Volume [E] by 60° cutter

60° [F]


Valves

•

Measure the outside diameter (O.D.) of the seating surface with 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° 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 of the seating surface is too large, make the 32° grind described below.

If the outside diameter [A] 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 O.D. 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 O.D. 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

O.D. measurement step above.

If the seat width is too wide, make the 60° [A] grind described below.

If the seat width is within the specified range, lap the valve to the seat as described below.

•

Grind the seat at a 60° angle until the seat width is within the specified range.

○

To make the 60° grind, fit 60° cutter into the holder, and slide it into the valve guide.

○

Turn the holder, while pressing down lightly.

○

After making the 60° grind, return to the seat width measurement step above.

Correct Width [B]

Valves

•

Lap the valve to the seat, once the seat width and O.D.

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.

•

When the engine is assembled, be sure to adjust the valve clearance (see Valve Clearance Adjustment in the Periodic Maintenance chapter).



Valves

Cylinders, Pistons

Cylinder Removal

•

Drain the coolant (see Coolant Change in the Periodic


•

Remove the cylinder head (see Cylinder Head Removal).

•

Pull out the front camshaft chain guide [A] and oil pipe [B].

•

Tap lightly up the cylinder with a plastic mallet to separate from the crankcase.

•

Remove the cylinder base gasket.

•

Piston Removal

Remove the cylinder (see Cylinder Removal).

•

Place a piece of clean cloth under the piston and remove the piston pin snap rings [A] from the outside of each piston.

CAUTION

Do not reuse snap rings, as removal weakens and deforms them. They could fall out and score the cylinder wall.

•

Using the piston pin puller assembly, remove the piston pins.

Special Tool - Piston Pin Puller Assembly [A]: 57001-910

•

Remove the piston.


•

Carefully spread the ring opening with your thumbs and 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.

Cylinder, Piston Installation

NOTE

○

The oil ring rails have no “top” or “bottom”.

•

Install the oil ring expander [A] in the bottom piston ring groove so the ends [B] butt together.

•

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.



•

•

Do not mix up the top ring and second ring.

Install the top ring [A] so that the “ R ” mark [B] faces up.

•

Install the second ring [C] so that the “ RN ” mark [D] faces up.

•

The piston ring openings must be positioned as shown in the figure. The openings of the oil ring steel rails must be about 30 ~ 45° [F] of angle from the opening of the top ring.

Top Ring [A]

Second Ring [B]

Oil Ring Steel Rails [C]

Oil Ring Expander [D]

Hollow [E] must be faced toward the exhaust side.

Opening Positions [G]

•

Face the hollow [A] on the front piston [B] toward the front side [C] and the hollow [D] on the rear piston [E] toward the rear side [F] as shown.

○

The front and rear pistons are the same, 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.

•

Fit a new piston pin snap ring into the side of the piston 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 outer surface of the piston pin.

○

The molybdenum disulfide oil is a mixture of engine oil and molybdenum disulfide grease with a weight ratio (10

: 1).

○

When installing the piston pin snap ring, compress it only enough to install it and no more.

•

Apply molybdenum disulfide oil to the cylinder bore.

•

Apply molybdenum disulfide oil to the front and rear of the piston skirt.

•

Install the rear cylinder first, with the rear piston at TDC.


NOTE

○

If a new piston or cylinder is used, check piston to cylinder clearance (see Piston/Cylinder Clearance), and use new piston ring.

•

Replace the cylinder base gasket with a new one.

•

Be sure to install the dowel pins [A].

•

Using the piston ring compressor assembly [A] with the chamfered side [B] upward, install the cylinder block [C].

Special Tools - Piston Ring Compressor Grip: 57001-1095

Piston Ring Compressor Belt, 80 ~ 91:

57001-1320


•

Install the front cylinder in the same way.

○

Position the front piston at TDC.

Tighten the cylinder nuts temporarily (These nuts are tightened to the specified torque after rocker case installation).

Cylinder Wear

•

Since there is a difference in cylinder wear in different directions, take a side-to-side and a front-to-back measurement at each of the 3 locations (total of 6 measurements) shown in the figure.

If any of the cylinder inside diameter measurements exceeds the service limit, the cylinder will have to be bored to oversize and then honed.

[A] 10 mm (0.39 in.)

[B] 60 mm (2.4 in.)

[C] 20 mm (0.79 in.)

Cylinder Inside Diameter

Standard: 88.000

∼ 88.012 mm (3.4646

∼ 3.4650 in.)

Service Limit: 88.10 mm (3.468 in.)

Piston Wear

•

Measure the outside diameter [A] of each piston 5 mm

(0.2 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

Standard: 87.955

∼ 87.970 mm (3.4628

∼ 3.4634 in.)




Piston/Cylinder Clearance

•

Subtract the piston diameter from the cylinder inside diameter to get the piston/cylinder clearance.

Piston/Cylinder Clearance

Standard: 0.030

∼ 0.057 mm (0.0012

∼ 0.0022 in.)

If the piston/cylinder clearance is less than the specified range, use a smaller piston or increase the cylinder inside diameter by honing.

If the piston/cylinder clearance is greater than specified range, use a larger piston.

If only a piston is replaced, the clearance may exceed the standard slightly. But it must not to be less than the minimum in order to avoid piston seizure.

Piston Ring, Piston Ring Groove Wear

•

Check for uneven groove wear by inspecting the ring seating.

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

Second

Service Limit:

Top

Second

0.05

∼ 0.09 mm (0.002

∼ 0.004 in.)

0.03

∼ 0.07 mm (0.001

∼ 0.003 in.)

0.19 mm (0.0075 in.)

0.17 mm (0.0067 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

Measure the piston ring groove width.

○

Use a vernier caliper at several points around the piston.

Piston Ring Groove Width

Standard:

Top

Second

Service Limit:

Top

Second

1.04

∼ 1.06 mm (0.0409

∼ 0.0417 in.)

1.02

∼ 1.04 mm (0.0402

∼ 0.0409 in.)

1.14 mm (0.0449 in.)

1.12 mm (0.0441 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

Measure the piston ring thickness.

○

Use a micrometer to measure at several points around the ring.

Piston Ring Thickness

Standard:

Top and Second 0.97

∼ 0.99 mm (0.038

∼ 0.039 in.)

Service Limit:

Top and Second 0.90 mm (0.035 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.

Piston Ring End Gap

•

Place the piston ring [A] inside the cylinder, using the piston 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

Second

Oil

Service Limit:

Top

Second

Oil

0.20

∼ 0.35 mm (0.0079

∼ 0.014 in.)

0.40

∼ 0.55 mm (0.016

∼ 0.022 in.)

0.20

∼ 0.70 mm (0.0079

∼ 0.0028 in.)

0.6 mm (0.02 in.)

0.8 mm (0.03 in.)

1.0 mm (0.039 in.)

If the end gap of either ring is greater than the service limit, replace all the rings.



Muffler

Muffler Removal

•

Remove:

Clamp Screws (Loosen) [A]

Bolt [B]

Rear Muffler Cover [C]

•

Remove:

Clamp Screws (Loosen) [A]

Bolt [B]

Front Muffler Cover [C]

•

Remove:

Muffler Mounting Nut [A], Collar and Damper

Muffler Mounting Bolt [B]

•

Remove:

Muffler Mounting Bolts [A]

•

Remove:

Front Exhaust Pipe Holder Nuts [A]

Muffler

•

Remove:

Rear Exhaust Holder Nuts [A]

•

Remove the upper and lower muffler jointed.

•

Muffler Installation

•

Joint the upper and lower muffler.

Temporary tighten the muffler joint clamp bolt [A].

•

Install the muffler.

•

Tighten:

Torque - Muffler Mounting Nut: 25 N·m (2.5 kgf·m, 18 ft·lb)

Muffler Mounting Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)

Exhaust Pipe Holder Nuts: 17 N·m (1.7 kgf·m, 12 ft·lb)

Muffler Joint Clamp Bolts: 17 N·m (1.7 kgf·m, 12

• ft·lb)

Install the muffler covers.

•

Tighten:

Torque - Exhaust Pipe Cover Clamp Bolts: 6.9 N·m (0.70


Exhaust Pipe Cover Bolts: 6.9 N·m (0.70 kgf·m, 61 in·lb)


CLUTCH 6-1

Clutch


Exploded View........................................................................................................................

Specifications .........................................................................................................................

Special Tool ............................................................................................................................

Clutch Lever and Cable ..........................................................................................................

Clutch Lever Free Play Inspection ....................................................................................

Clutch Lever Free Play Adjustment ..................................................................................

Clutch Cable Removal ......................................................................................................

Clutch Cable Installation ...................................................................................................

Cable Lubrication ..............................................................................................................

Clutch Lever Installation....................................................................................................

Right Engine Cover ................................................................................................................

Right Engine Cover Removal............................................................................................

Right Engine Cover Installation.........................................................................................

Release Shaft Removal ....................................................................................................

Release Shaft Installation .................................................................................................

Clutch Cover Disassembly................................................................................................

Clutch Cover Assembly.....................................................................................................

Clutch .....................................................................................................................................

Clutch Removal.................................................................................................................

Clutch Installation..............................................................................................................

Clutch Plate, Wear, Damage Inspection ...........................................................................

Clutch Plate Warp Inspection............................................................................................

Clutch Spring Free Length Measurement .........................................................................

6-8

6-9

6-9

6-9

6-9

6-10

6-10

6-10

6-11

6-12

6-12

6-2

6-4

6-5

6-6

6-6

6-6

6-6

6-6

6-6

6-7

6-8

6-8

6

6-2 CLUTCH

Exploded View

CLUTCH 6-3

Exploded View

No.

Fastener

1 Right Engine Cover Bolts

2 Clutch Hub Nut

3 Clutch Spring Bolts

N·m

98

130

9.8

Torque kgf·m

1.0

13.2

1.0

ft·lb

87 in·lb

95.9

87 in·lb

Remarks

CL: Apply cable lubricate.

EO: Apply engine oil.

G: Apply grease.


MO: Apply molybdenum disulfide oil.



L (1)

MO

6-4 CLUTCH

Specifications

Item

Clutch Lever Free Play

Clutch

Friction Plate Thickness

Friction and Steel Plate Warp

Clutch Spring Free Length

Standard

2 ∼ 3 mm (0.08

∼ 0.12 in.)

2.9

∼ 3.1 mm (0.114

∼ 0.122 in.)

0.2 mm (0.008 in.) or less

33.6 mm (1.32 in.)

Service Limit

2.8 mm (0.110 in.)

0.3 mm (0.01 in.)

32.6 mm (1.28 in.)

Special Tool

Clutch Holder:

57001-1243

CLUTCH 6-5

6-6 CLUTCH

Clutch Lever and Cable

Clutch Lever Free Play Inspection

•

Refer to the Clutch Operation Inspection in the Periodic


Clutch Lever Free Play Adjustment

•

Refer to the Clutch Operation Inspection in the Periodic


Clutch Cable Removal

•

Remove the muffler (see Muffler Removal in the Engine

•

Top End chapter).

•

Loosen the locknut [A] at the middle of the clutch cable.

Turn the adjusting nut [B] to give the cable plenty of play.

•

Slide the dust cover [A] at the clutch cable lower end out of place.

•

Loosen the nuts [B], and slide the lower end of the clutch cable to give the cable plenty of play.

•

Loosen the locknut [A] bat the clutch lever, and screw in the adjuster [B].

•

Line up the slots [C] in the clutch lever, locknut, and adjuster, and then free the cable from the lever.

•

Free the clutch inner cable tip from the clutch release lever.

•

Push the release lever toward the front of the motorcycle and tape the release lever to the clutch cover to prevent the release shaft from falling out.

•

Pull the clutch cable out of the frame.

Clutch Cable Installation

•

Run the clutch cable correctly (see Cable, Wire and Hose


•

Adjust the clutch cable (see Clutch Lever Free Play Adjustment in the Periodic Maintenance chapter).

Cable Lubrication

•

Refer to the Chassis Parts Lubrication in the Periodic


Clutch Lever and Cable

Clutch Lever Installation

•

Install the clutch lever so that the mating surface [A] of the lever holder is aligned with the punch mark [B] of the handlebar.

CLUTCH 6-7

6-8 CLUTCH

Right Engine Cover

Right Engine Cover Removal

•

Drain:



•

Remove:

Brake Pedal (see Brake Pedal Removal in the Brakes chapter)

Right Footboard (see Footboard Removal/Installation in the Frame chapter)

Muffler (see Muffler Removal in the Engine Top End chapter)

Clutch Cable (see Clutch Cable Removal)

Down Tube (see Downtube Removal in the Frame chapter)

Bolt [A]

Coolant Pipe [B]

•

Remove:

Clutch Cover Bolts [A]

•

Turn the release lever [B] toward the rear as shown, and remove the right engine cover.

•

The water pipe [C] is removed along with the right engine cover.

•

Right Engine Cover Installation

•

Install the dowel pins [A], and replace the cover gasket with a new one.

•

Check to see that the washer [B] is in place.

Apply a non-permanent locking agent to the threads of the right engine cover bolt (L = 50) [C].

•

Install the seals [A] to the water pipe so that tapered side

[B] facing the engine inside.

•

Apply a soap and water solution to the seal. Do not apply a grease or oil to the seal.

•

Be sure the water pipe installed correctly.

[C] Right Engine Cover Side

[D] Crankcase Side

•

Tighten:

Torque - Right Engine Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

Right Engine Cover

Release Shaft Removal

CAUTION

Do not remove the clutch release lever and shaft assembly unless it is absolutely necessary. If removed, the oil seal replacement may be required.

•

Remove the right engine cover (see Right Engine Cover

Removal).

•

Remove the circlip [A] from the release shaft.

•

Pull the lever and shaft assembly [B] out of the right engine cover.

Release Shaft Installation

•

Apply grease to the oil seal lip [A] on the lower ridge of the clutch cover.

•

Apply oil to the bearings [B] in the hole of the right engine cover.

•

Insert the release shaft [C] straight into the lower hole of the right engine cover.

CAUTION

When inserting the release shaft, be careful not to remove the spring of the oil seal.

•

Install the new circlip.

Clutch Cover Disassembly

•

Remove:

Oil Seal [A]

Needle Bearings [B]

Clutch Cover Assembly

•

Replace the needle bearings and oil seal with new ones.

NOTE

○

Install the needle bearings so that the manufacture’s mark face out.

•

Install the needle bearings [A] and oil seal [B] position as shown.

•

Press [C] the outer needle bearing so that the bearing surface [D] is flush with the housing end [E] of clutch cover.

•

Press [F] the inner needle bearing so that the bearing both surface does not protrude from the both housing ends [G] of clutch cover.

CLUTCH 6-9

6-10 CLUTCH

Clutch

Clutch Removal

•

Remove:

Right Engine Cover (see Right Engine Cover Removal)

Clutch Spring Bolts [A]

Clutch Springs

Clutch Spring Plate [B] (with thrust bearing and pusher

[C])

•

Remove:

Friction Plates, Steel Plates

Clutch Hub Nut [A]

•

Holding the clutch hub [B], remove the nut.

Special Tool - Clutch Holder [C]: 57001-1243

•

Remove:

Clutch Hub

•

Remove:

Spacer [A]

Clutch Housing [B], Needle Bearing and Bushing

Thrust Spacer

Clutch Installation

•

Install the thrust spacer [A] to the drive shaft so that the

• tapered side [B] faces inward.

•

Apply molybdenum disulfide oil to the needle bearing.

Install the bushing and needle bearing to the drive shaft.

•

Install:

Clutch Housing [A]

Spacer [B]

Clutch Hub

Clutch

•

Install the washer so that the OUTSIDE mark [A] faces outward.

•

Replace the clutch hub nut with a new one.

•

Apply molybdenum disulfide oil to seating surface of the hub nut.

•

Holding the clutch hub, tighten the clutch hub nut.

Special Tool - Clutch Holder: 57001-1243

Torque - Clutch Hub Nut: 130 N·m (13.3 kgf·m, 95.9 ft·lb)

•

Install the friction plates and steel plates, starting with a friction plate and alternating them.

○

Install the friction plates so that the plates of having more lining blocks [A] than other plate [C] are placed at both end [B].

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.

○

Install the last friction plate [A] fitting the tangs in the grooves in the housing as shown.

•

Install the clutch spring plate and spring, and tighten the clutch spring bolts.

Torque - Clutch Spring Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

•

Install the right engine cover (see Right Engine Cover Installation).

Clutch Plate, Wear, Damage Inspection

•

Visually inspect the friction and steel plates for signs of seizure, overheating (discoloration), or uneven wear.

•

Measure the thickness of each friction plate [A] at several points.

If any plates show signs of damage, or if they have worn past the service limit, replace them with new ones.

Friction Plate Thickness

Standard: 2.9

∼ 3.1 mm (0.114

∼ 0.122 in.)


CLUTCH 6-11

6-12 CLUTCH

Clutch

Clutch Plate Warp Inspection

•

Place each friction plate or steel plate on a surface plate 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 plate is warped over the service limit, replace it with a new one.

Friction and Steel Plate Warp

Standard: 0.2 mm (0.008 in.) or less


Clutch Spring Free Length Measurement

•

Measure the free length of the clutch springs [A].

If any spring is shorter than the service limit, it must be replaced.

Clutch Spring Free Length

Standard: 33.6 mm (1.32 in.)


ENGINE LUBRICATION SYSTEM 7-1



Exploded View........................................................................................................................

Engine Oil Flow Chart.............................................................................................................

Specifications .........................................................................................................................


Engine Oil and Oil Filter..........................................................................................................

Oil Level Inspection...........................................................................................................

Engine Oil Change............................................................................................................

Oil Filter Change ...............................................................................................................

Oil Screen Cleaning ..........................................................................................................

Oil Pressure Relief Valve........................................................................................................

Oil Pressure Relief Valve Removal/Installation.................................................................

Oil Pressure Relief Valve Inspection.................................................................................

Oil Pump, Oil Pump Drive Chain ...........................................................................................

Oil Pump Removal ...........................................................................................................

Oil Pump Installation .........................................................................................................

Oil Pump Drive Chain Guide Installation ..........................................................................

Oil Pressure Measurement ....................................................................................................

Oil Pressure Measurement ...............................................................................................

Oil Pressure Switch ................................................................................................................

Oil Pressure Switch Removal ...........................................................................................

Oil Pressure Switch Installation ........................................................................................

Oil Pipe and Oil Hose .............................................................................................................

Oil Pipe (Crankcase Outside) Removal ............................................................................

Oil Pipe (Crankcase Outside) Installation .........................................................................

Oil Pipe (Crankcase Inside) Removal ..............................................................................

Oil Pipe (Crankcase Inside) Installation ............................................................................

Blowby Gas System Inspection ........................................................................................

Breather Drain Cleaning ...................................................................................................

7-13

7-13

7-14

7-14

7-14

7-14

7-14

7-15

7-15

7-10

7-10

7-10

7-11

7-12

7-12

7-13

7-2

7-4

7-5

7-6

7-7

7-7

7-7

7-7

7-7

7-9

7-9

7-9

7

7-2 ENGINE LUBRICATION SYSTEM

Exploded View

Exploded View

No.

Fastener

1 Engine Oil Drain Plug

2 Oil Pump Cover Bolts

3 Oil Pump Drive Chain Guide Bolt

4 Oil Filter

5 Oil Filter Plate Bolts

6 Oil Screen Plug

7 Oil Pressure Relief Valve

8 Oil Pressure Switch

9 Oil Pressure Switch Adapter

10 Oil Pipe Bolts (Crankcase Inside)

11 Oil Pipe Bolts (Crankcase Outside)

12 Oil Return Pipe Bolts

G: Apply grease.


SS: Apply silicone sealant.


18

7.8

20

15

N·m

20

9.8

9.8

15

20

9.8

9.8

9.8

Torque kgf·m

2.0

1.0

1.0

1.8

0.80

2.0

1.5

1.5

2.0

1.0

1.0

1.0

ft·lb

15

87 in·lb

87 in·lb

13

69 in·lb

15

11

11

15

87 in·lb

87 in·lb

87 in·lb

Remarks

L

L

L

SS

L

L


Engine Oil Flow Chart

1. Rocker Arm

2. Oil Pipe

3. Output Shaft

4. Drive Shaft

5. Oil Screen

6. Oil Pump

7. Crankshaft

8. Oil Pressure Switch

9. Oil Filter

10. Oil Pressure Relief Valve


Specifications

Engine Oil

Type

Viscosity

Capacity

Item

Level (After warm-up or driving)

Oil Pressure Measurement

Oil pressure @4 000 r/min (rpm), oil temperature 90°C (194°F)

Standard

API SE, SFor SG

API SH, SJ or SL with JASO MA

SAE 10W-40

3.0 L (3.2 us qt) (when filter is not removed)

3.2 L (3.4 us qt) (when filter is removed)

3.7 L (3.9 us qt) (when engine is completely dry)

Between upper and lower level lines

294 ∼ 392 kPa (3.0

∼ 4.0 kgf/cm², 42.6

∼ 56.8 psi)



Oil Pressure Gauge, 10 kgf/cm²:

57001-164


56019-120

Oil Pressure Gauge Adapter, M10 × 1.25:

57001-1182


Engine Oil and Oil Filter

WARNING

Motorcycle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine or transmission seizure, accident, and injury.

Oil Level Inspection

•

Check that the engine oil level is between the upper [A] and lower [B] level lines next to the gauge [C].

NOTE

○

Situate the motorcycle so that it is perpendicular to the ground.

○

If the motorcycle has just been used, wait several minutes for all the oil to drain down.

○

If the oil has just been changed, start the engine and run it for several minutes at idle speed. This fills the oil filter with oil. Stop the engine, then wait several minutes 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 oil pressure warning light will light. If this light stays on when the engine is running above the idle speed, stop the engine immediately and find the cause.

Engine Oil Change

•

Refer to the Engine Oil Change in the Periodic Maintenance chapter.

Oil Filter Change

•

Refer to the Oil Filter Replacement in the Periodic Maintenance chapter.

Oil Screen Cleaning

•

Drain the engine oil (see Engine Oil Change in the Periodic Maintenance chapter).

•

Remove the oil screen plug [A], spring and washer.


Engine Oil and Oil Filter

•

Pull out the oil screen [A].

•

Clean the screen with high flash-point solvent.

WARNING

Clean the screen in a well-ventilated area, and take care that there is no spark or frame anywhere near the working area.

Because of the danger of highly flammable liquids, do not use gasoline or low-flash point solvents.

•

Check the screen carefully for any damage.

If the screen is damaged, replace it with a new one.

•

Replace the O-ring [B] with a new one.

•

Install:

Oil Screen and Rubber Gasket [C]

Washer [D]

Spring [E]

•

Apply grease to the O-ring, and tighten the plug.

Torque - Oil Screen Plug: 20 N·m (2.0 kgf·m, 15 ft·lb)


Oil Pressure Relief Valve

•

Oil Pressure Relief Valve Removal/Installation

•


•

Remove the relief valve [A] from the right crankcase.

Apply a non-permanent locking agent to the threads of the relief valve, and tighten it.

Torque - Oil Pressure Relief Valve: 15 N·m (1.5 kgf·m, 11 ft·lb)

Oil Pressure Relief Valve Inspection

•

Check to see if the steel ball [A] inside the valve slides smoothly when pushing it in with a wooden or other soft rod, and see if it comes back to its seat by valve spring pressure [B].

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 parts in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or low-flash point solvents.

If cleaning does not solve the problem, replace the relief valve as an assembly. The relief valve is precision made with no allowance for replacement of individual parts.


Oil Pump, Oil Pump Drive Chain

Oil Pump Removal

•


•

Remove:

Water Pump Impeller (see Water Pump Impeller Removal in the Cooling System chapter)

Crankshaft (see Crankshaft Removal in the Crankshaft/Transmission chapter)

Oil Pipes (see Oil Pipe (Crankcase Inside) Removal)

Oil Pump Cover Bolts [A]

•

Remove the following parts as a set.

Sprocket [B]

Oil Pump Shaft [C]

Oil Pump Cover [D]

Rotors

Balancer Shaft [E]

•

Oil Pump Installation

Replace the circlip [A] with a new one.

•

Assemble:

Oil Pump Shaft [B]

Oil Pump Cover [C]

Washer [D]

Pins [E]

Rotors [F]

Sprocket [G]

Circlip

○

Install a new circlip on the shaft so that the sharp edge faces away from the sprocket.

•

•

Check that the dowel pin [A] is in place.

•

Replace the O-ring [B] with a new one.

Apply grease to the O-ring on the pump body.

•

Install the oil pump assembly [B] and balancer shaft [C] along with the oil pump chain.

•

Apply a non-permanent locking agent to the threads of the oil pump cover bolts [A], and tighten them.

Torque - Oil Pump Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)


Oil Pump, Oil Pump Drive Chain

•

Oil Pump Drive Chain Guide Installation

Install the chain guide [A] to the left crankcase.

•

Apply a non-permanent locking agent to the threads of the chain guide bolt [B], and tighten it.

Torque - Oil Pump Drive Chain Guide Bolt: 9.8 N·m (1.0



Oil Pressure Measurement

•

Oil Pressure Measurement

Remove:

•

Regulator/Rectifier (see Regulator/Rectifier Removal in the Electrical System chapter)

•

Remove the oil pressure switch together with the adapter

(see Oil Pressure Switch Removal) without draining the engine oil.

•

Install the oil pressure gauge and adapter.

Special Tools - Oil Pressure Gauge, 10 kgf/cm²: 57001-164

[A]

Oil Pressure Gauge Adapter, M10 × 1.25:

57001-1182

•

Run the engine at the specified speed, and read the oil pressure gauge.

If the oil pressure is significantly below the specification, inspect the oil pump and relief valve.

If the oil pump and relief valve are not at fault, inspect the rest of the lubrication system.

Oil Pressure

Standard: 294 ∼ 392 kPa (3.0

∼ 4.0 kgf/cm², 42.6

∼

56.8 psi) @4 000 r/min (rpm), oil temp.

•

Stop the engine.

90°C (194 °F)

•

Remove the oil pressure gauge and adapter.

WARNING

Take care against burns from hot engine oil that will drain through the oil passage when the gauge adapter is removed.

•

Install the oil pressure switch (see Oil Pressure Switch

Installation).


Oil Pressure Switch

Oil Pressure Switch Removal

•

Drain:


•

Remove:

Switch Cover [A]

Switch Lead Terminal [B]

Oil Pressure Switch [C]

Oil Pressure Switch Installation

•

Apply silicone sealant to the threads of the oil pressure switch, and tighten it.


•

Torque - Oil Pressure Switch: 15 N·m (1.5 kgf·m, 11 ft·lb)

•

Tighten the terminal bolt securely.

Apply grease to the terminal, and install the switch cover.


Oil Pipe and Oil Hose

Oil Pipe (Crankcase Outside) Removal

•

Remove:

Alternator Cover (see Alternator Cover Removal in the


Oil Pipe Mounting Bolts [A]

Oil Pipe [B]

Oil Pipe (Crankcase Outside) Installation

•

Apply grease to the O-rings [A].

•

Plug the oil passage hole [A] with a clean cloth for prevent the bolt from dropping.

•

Apply a non-permanent locking agent to the threads of the mounting bolts [B], and tighten them.

Torque - Oil Pipe Mounting Bolts (Crankcase Outside): 9.8

N·m ( 1.0 kgf·m, 87 in·lb)

Oil Pipe (Crankcase Inside) Removal

•


•

Remove:

Crankshaft (see Crankshaft Removal in the Crankshaft/Transmission chapter)

Oil Return Pipe Bolts [A]

Oil Return Pipe [B]

Oil Pipe Bolts [C]

Oil Pipes [D]

•

•

Oil Pipe (Crankcase Inside) Installation

Replace the O-rings [A] with new ones.

•

Apply grease to the O-rings.

•

Install the oil pipes [B].

Apply a non-permanent locking agent to the threads of the mounting bolts, and tighten them.

Torque - Oil Pipe Bolts (Crankcase Inside): 9.8 N·m (1.0


Kawasaki VN900 CLASSIC Service Manual

VULCAN900 CLASSIC

VULCAN900 CLASSIC LT

VN900 CLASSIC

Motorcycle

Service Manual

Quick Reference Guide

VULCAN900 CLASSIC

VULCAN900 CLASSIC LT

VN900 CLASSIC

Motorcycle

Service Manual

EMISSION CONTROL INFORMATION

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.

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED

Foreword

How to Use This Manual

This note symbol indicates points of particular interest for more efficient and convenient operation.

GENERAL INFORMATION 1-1

General Information

1-2 GENERAL INFORMATION

Battery Ground

Edges of Parts

Solvent

Cleaning Vehicle before Disassembly

Arrangement and Cleaning of Removed Parts

GENERAL INFORMATION 1-3

Storage of Removed Parts

Inspection

Replacement Parts

Assembly Order

1-4 GENERAL INFORMATION

Tightening Sequence

Tightening Torque

Force

Gasket, O-ring

Liquid Gasket, Non-permanent Locking Agent

Press

GENERAL INFORMATION 1-5

Ball Bearing and Needle Bearing

Oil Seal, Grease Seal

Circlips, Cotter Pins

1-6 GENERAL INFORMATION

Lubrication

Direction of Engine Rotation

Electrical Wires

Instrument

GENERAL INFORMATION 1-7

1-8 GENERAL INFORMATION

GENERAL INFORMATION 1-9

1-10 GENERAL INFORMATION

GENERAL INFORMATION 1-11

1-12 GENERAL INFORMATION

GENERAL INFORMATION 1-13

PERIODIC MAINTENANCE 2-1

Periodic Maintenance

2-2 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE 2-3

2-4 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE 2-5

2-6 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE 2-7

2-8 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE 2-9

2-10 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE 2-11

2-12 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE 2-13

2-14 PERIODIC MAINTENANCE

Fuel Hose Inspection (fuel leak, damage, installation condition)

Throttle Control System Inspection

PERIODIC MAINTENANCE 2-15

Idle Speed Inspection

Idle Speed Adjustment

2-16 PERIODIC MAINTENANCE