Home

- Rage Motorsport

1. 4 6 Gr p 4 7 Coolant Deterioration InisDectlOri piti e pc p eed el eal i d a edle te 4 7 Coolant Level Inspection eene ve du 4 7 Coolant sedes dead 4 7 Coolant Filling eM 4 7 cU EIS Er 4 7 Cooling System Flushing pp 4 8 Coolant Reserve Tank Removal lnstallation pp 4 8 Water 4 9 Water Pump Removal tio 4 9 Water Pump Installation uei oct 4 9 Water Pump Impeller Inspection ient teet tec enn Pete 4 10 PAM AU RU 4 11 Radiator and Radiator Fan Removal trie e Heb RESI AR 4 11 Radiator and Radiator Fan Installation sse 4 12 Radiator IPSPOCHOM DE 4 12 eo e tte Utd cs 4 13 Radiator Filler Neck Inspection 4 13 Thermostat AE E E 4 14 Thermostat Removal pe 4 14 i A a E A 4 14 Thermostat Inspection p 4 14 ode ended rien eue tasti ua aa ue OUR e ue 4 16 Hose Installatlfy ire Dette ibat eos eig Exec da e 4 16 H s
2. Ha 14 4 SOUS NG co acc 14 5 Steering INSPECHOM 14 5 Steering AdjustiWmobib 2e pere e RA Eea Ap EEEE edocti 14 5 Steering ceo edente a o e e deese bc 14 6 Stem Stem Bearing Hemoval eet m ak Aaa PORTU Reis neue 14 6 Stem Stem Bearing Installatigm eene nnn 14 7 Steering Stem Bearing Lubrication cies oa RE erae qu Riego a DE e hd ia gd 14 9 steering Stem Warp Inspection 2 2 14 9 Stem Cap Deterioration Damage Inspection pp 14 9 PIO A TE 14 10 ccm 14 10 Handlebar InstallatOri rtt oe eei E 14 10 14 2 STEERING Exploded View STEERING 14 3 Exploded View No Fastener pole Remarks N m kgf m ft Ib 1 Front Fork Clamp Bolts Lower 30 3 1 22 AL 2 Front Fork Clamp Bolts Upper 20 2 0 15 3 Handlebar Bolts 34 3 5 25 L 4 Handlebar Holder Bolts 25 2 5 18 AL 5 Left Switch Housing Screws 3 5 0 36 31 in lb 6 Right Switch Housing Screws 9 5 0 36 31 in lb 7 Steering Stem Head Nut 78 8 0 58 8 Steering Stem Nut 23 2 3 17 AD Apply adhesive AL Tighten the two clamp bolts alternately two times to ensure even tightening torque G Apply grease L Apply a non permanent locking agent R
3. nnn nnne nennen 2 33 Drive Chain Guide Wear Irispectlon Free br bre ness 2 34 amp MA 2 35 Brake Fluid Leak Brake Hose and Pipe Inspection 2 35 Brake Hose and Pipe Damage and Installation Condition Inspection 2 36 Brake Operation Inspection iioc Ee ett ED D a eere periti acted xke 2 36 Brake Fluid Level Inspection en codon oe Pe e t b Re godere t Gd 2 36 Brake Pad Wear Inspection rere rece ite inte te eir ade mee ate ma Send 2 37 Brake Light Switch Operation 2 38 STi io Wet RE no PR TEE 2 38 Front Forks Rear Shock Absorber Operation 2 38 Front Fork Oil Leak Erde nius ae pude e 2 39 Rear Shock Absorber Oil Leak Inspection pp 2 39 Rocker Arm Operation Inspection enne 2 39 Tie Rod Operation Inspection Nt 2 39 amveasias 2 40 2 2 PERIODIC MAINTENANCE Steering Play Inspection pp Steering Play ar eda ED ku up KE Steering Stem Bearing Lubrication Electrical Systemi dick Lights and Switch
4. 6C172370W2 C 1 Ignition Switch 10 Relay Box 2 Immobilizer Antenna 11 Joint Connector 2 3 Meter Unit 12 Main Fuse 30 A 4 Immobilizer Amplifier 13 Starter Relay 5 Joint Connector 1 14 Battery 12 V 14 Ah 6 Fuse Box 2 15 Frame Ground 1 7 Ignition Fuse 10 16 Frame Ground 2 8 ECU Fuse 15 A 17 Immobilizer Kawasaki Diagnostic System 9 Main Relay Connector 18 Water proof Joint 1 19 ECU FUEL SYSTEM 3 85 Fuel Pump Relay Service Code 46 Fuel Pump Relay Removal CAUTION Never drop the relay box especially on a hard sur face Such a shock to the relay can damage it OThe fuel pump relay is included in the relay box e Remove the seat see Seat Removal in the Frame chap ter e Remove the relay box A and disconnect the connectors Fuel Pump Relay Inspection e Remove the relay box see Fuel Pump Relay Removal e Connect the hand tester A and one 12 V battery to the relay connector as shown in the figure Special Tool Hand Tester 57001 1394 Relay Coil Terminals 1 and 2 Relay Switch Terminals 3 and 4 Testing Relay Tester range range CIDA Criteria When battery is connected 0 Q When battery is disconnected If the relay does not work as specified replace the relay box 3 86 FUEL SYSTEM Fuel Pump Relay Service Code 46 Fuel Pump Relay Circuit W
5. Engine Sprocket Removal PR Engine Sprocket Installation tret te e rna eH ERR EO te EA e eee Rear Sprocket Removal uote tb e he or peter ode Cito e Ged Pb bg deni Rear Sprocket Irisfallation ror roe Coupling ANTS HA UNO Coupling Bearing Removal iue th Coupling Bearing Installation Coupling Bearing Inspection sas aduer ete xe cau equi eR ag UR SUAM Coupling Bearing Lubrication Coupling Damper at tuto hee Sits datae te Sa tee uus Sprocket Wear TnspOotlOIt ER ct sme Rear Sprocket Warp Inspection eren irr notre tr Rete qu ee IRR 11 10 11 2 FINAL DRIVE Exploded View Exploded View FINAL DRIVE 11 3 G Apply grease HG Apply high temperature grease HO Apply heavy oil L Apply a non permanent locking agent MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts Torque No Fastener Nm korm itib Remarks 1 Chain Guide Bolt 12 1 2 106 in lb L 2 Chain Guide Bolts 9 8 1 0 87 in lb L 3 Sprocket Cover Bolts 9 8 1 0 87 in lb 4 Engine Sprocket Nut 125 12 7 92 2 MO 5 Rear Axle Nut 127 13 0 93 7 6 Rear Sprocket Nuts 69 7 0 51 7 Speed Sensor Bol
6. GP30516BS1 0 3second Hh LIU UU UU UU UU GP30517BS1 0 5second 0 5second yp pep GP30515BS1 C ELECTRICAL SYSTEM 16 89 Immobilizer System Equipped Models Olf there is any problem in the registration the warning indicator light LED A blinks to display the collation error Immobilizer Amplifier Failure 0 2second hnnnnnnnnnnnnnn 81 6230516851 C When Registered User Key is Inserted 0 5second 0 5second ae 6230515851 C User Key Collation Error 0 3second hnnnnnnnnnnu 8 30517851 C e The user key 1 is successfully registered in the ECU OThe warning indicator light LED A blinks 2 times and stops for 1 second and then repeats this cycle Ole pp pb e Turn the user key 1 OFF and remove the user key 1 OThe warning indicator light LED A blinks to display the registration mode NOTE OTurn OFF the ignition switch and wait for the period of 15 seconds or more The registration mode automatically finishes and the warning indicator light LED will switch 0 5second 0 5second gt gt off ON E OThis procedure registered the master key and one user 8730515851 key OContinue with the procedure to register the second and later keys before the 15 seconds period has elapsed e Insert th
7. 2a Cl 17 48 APPENDIX Cable Wire and Hose Routing ABS Equipped Models Sey Hei p e 37 Yi Telos D 08809626045 C APPENDIX 17 49 Cable Wire and Hose Routing 12 DRAWN ABS Hydraulic Unit Brake Pipe Two White Paint Marks Brake Hose Clamps Run only the brake hose through the clamps Rear Wheel Rotation Sensor Lead Clamps Hold the rear wheel rotation sensor lead and brake hose at the white tape position of the rear wheel rotation sensor lead Clamp Hold the brake hose and rear wheel rotation sensor lead Clamp Hold the brake hose and rear wheel rotation sensor lead Brake Pipe Two Blue Paint Marks 10 11 Bracket Rear Wheel Rotation Sensor View from Rear Side 13 14 15 16 Brake Hose Two Blue Paint Marks Brake Hose Joint Pipe Two Blue Paint Marks Brake Hose Two White Paint Marks Brake Hose Joint Pipe White Paint Mark 17 50 APPENDIX Cable Wire and Hose Routing ABS Equipped Models 1 APPENDIX 17 51 Cable Wire and Hose Routing nk 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Brake Hose Clamps Clamp the brake hose on both sides Clamps Hold the front wheel rotation sensor lead and brake hose at the
8. 12V14Ah Ground 2 Color Code 22 BK Black Starter LI Relay Box L 4 Relay BR Brown Relay a Tm sin ruse Honeycomb Catalytic Converter CU mela cenar 39A Restricted Model Gray 4 Fuel Pump Relay LB Light Blue 5 Starter Circuit Relay 5 Le Light Green 9 Orange Pink Pu Purple Rea w White W2R0342CW5 C IGNITION SWITCH CONNECTIONS Ignition Battery Tail2 Battery Tail3 RIGHT SWITCH HOUSING CONNECTIONS Front Brake Light Switch Engine Stop Switch Starter Button Color BL w BK W G roci Color Color R R Color BL Brake Lever OFF Free Pulled Inl RUN Push 98052 03420 03430 16 22 ELECTRICAL SYSTEM Wiring Diagram ABS Equipped Models MY Model Camshaft Horn eae Position Right Switch Housing 12V 2 5 M 1 Front Brake Light Switch ensor Air 2 Engine Stop Switch Switching 3 Starter Button Valve Ignition ABS Switch 5 Right A Self Pe Switch Housing 28 diagnosis Terminal Immobilizer bs ED pm Antenna 82 Ez Joint L Connector 1 Rear Wheel Spark Plugs Rotation Sensor 2444 Front nee Rotation Sensor a ABS Kawasaki Self diagnosis System Connector Amplifier Meter Unit 1 Right Turn Signal Indicator Light LED 2 Shift Up Indicator
9. Loy Dut y 100 50 8 17705852 AVERAGE 12 RIP A 123 4 a GP17094C 5 H KM L 23456 y 1 00 16 82 ELECTRICAL SYSTEM Meter Gauge Indicator Unit Check 17 Speed Sensor Supply Voltage Inspection e Connect the leads in the same circuit as Check 2 e Set the hand tester to the 25 V range and connect it in the meter unit as follows Special Tool Hand Tester 57001 1394 Connections Hand Tester Hand Tester Terminal 11 Terminal 12 Speed Sensor Supply Voltage Standard About 12 V xlf the tester reading is not specified replace the meter assembly Check 18 Water Temperature Gauge Inspection e Connect the leads in the same circuit as Check 2 e Connect the CAN communication lines from meter con nector A to main harness connector B as shown in the figure Connections Meter Terminal 17 Meter Terminal 18 Main Harness Terminal 17 Main Harness Terminal 18 e Turn the ignition switch ON e Check that the symbol A appears in the water tempera ture gauge e Turn the ignition switch OFF xIf the display function does not work go to the Check 1 and check the following items Wiring see Wiring Inspection CAN Communication Line Resistance
10. see chapter 3 Water temperature sensor trouble Inspect see chapter 3 DFI System Troubleshooting Guide FUEL SYSTEM 3 35 Symptoms or Possible Causes Actions chapter Inlet air temperature sensor trouble Inspect see chapter 3 Other Intermittent any DFI fault and its recovery Check that DFI connectors are clean and tight and examine leads for signs of burning or fraying see chapter 3 Poor Running or No Power at High Speed Symptoms or Possible Causes Firing incorrect Stick coil shorted or not in good contact Stick coil trouble Spark plug dirty broken or gap maladjusted Spark plug incorrect ECU trouble Fuel air mixture incorrect Air cleaner clogged poorly sealed or missing Air duct holder loose Throttle body assy holder loose Actions chapter Inspect or reinstall see chapter 16 Inspect see chapter 16 Inspect and replace see chapter 16 Replace it with the correct plug see chapter 2 Inspect see chapter 3 Clean element or inspect sealing see chapter 3 Reinstall see chapter 3 Reinstall see chapter 3 Throttle body assy dust seal damage Replace see chapter 3 Water or foreign matter in fuel Change fuel Inspect and clean fuel system see chapter 3 Fuel injector O ring damage Visually inspect and replace see chapter 3 Fuel injector clogged Inspect and repair see chapter 3 F
11. Atmospheric Pressure Sensor Output Voltage Connections to ECU Connector Meter G W lead terminal 11 Meter BR BK lead terminal 34 6617154651 C Output Voltage at ECU Usable Range DC 3 80 4 20 V at standard atmospheric pressure 101 32 kPa 76 cmHg NOTE OThe output voltage changes according to the local at mospheric pressure OThe atmospheric sensor output voltage is based on a nearly perfect vacuum in the small chamber of the sensor So the sensor indicates absolute atmospheric pressure If the output voltage is within the usable range check the ECU for its ground and power supply see ECU Power Supply Inspection x lf the ground and power supply are good replace the ECU see ECU Removal Installation 3 64 FUEL SYSTEM Atmospheric Pressure Sensor Service Code 15 If the output voltage is far out of the usable range check the output voltage at the sensor connector A when the wiring is open the output voltage is about 1 8 V e Connect a digital meter to the harness adapter leads Atmospheric Pressure Sensor B Special Tool Sensor Harness Adapter 57001 1561 Atmospheric Pressure Sensor Output Voltage Connections to Adapter Meter G W sensor G W lead C Meter BK sensor BR BK lead D Output Voltage at Sensor Usable Range DC 3 80 4 20 V at standard atmospheric pressure 101 32 kPa 76 cmHg e Turn the
12. 17 18 19 20 21 22 23 24 25 26 Band Hold the main harness with the band and insert the band to the rear fender Alternator Lead Connector Install the alternator lead connector to the bracket Connector Insert the connector into the bracket Alternator Lead Connector Put into the alternator lead connector between the rear fender and rear frame Alternator Lead Run the alternator lead through under the main harness Align the gray tape with the end of the battery case to fix main harness position Fuel Hose Main Harness 10 11 12 13 14 15 16 Alternator Lead Run the alternator lead through the inside of the leads and hose Sidestand Switch Lead Connector Band Hold the main harness and insert the band into the bracket Throttle Body Subharness Connector Install the connector to the bracket Speed Sensor Lead Connector Oil Pressure Switch Gear Position Switch Lead Connector Run the sidestand switch gear position switch and oil pressure switch leads from the notch of the engine sprocket cover through inside of the cover Clamp Hold the fan motor lead Run the engine harness through the outside of the clutch hose Engine Harness Connector Insert the engine harness connector to the bracket tightened down the subframe Band Hold the main harness and insert the band into the bracket Stick Coil Lead Connector Install the stick coil lead
13. 7771 water proof 478K W 8K W 8K 2 eo sr Boze EGG Frame 38 z zz 5555 gees PE P 3488 3553 1 Vehicle down Sensor as Kawasaki 7 1 2 1 LI Signal dyes Diagnostic Joint Relay e tor 3 Reserve System onnector Ea Switch Connector Bear Beate pan ear Brake FH Light Switch Pump 3 IL TIL 15 551 2 Engine viaa Frame Ground Ground 2 T Starter 1 Relay Relay 4 Relay Box Motor T Te Pane Relay Cis coy Nalin Fuse Honeycomb Catalytic Converter 2 Headlight Circuit Relay 30A Restricted Model 3 ECU Main Relay estrieted Node 4 Fuel Pump Relay 5 Starter Circuit Relay IGNITION SWITCH CONNECTIONS Ignition Battery Tail2 Battery Tail3 RIGHT SWITCH HOUSING CONNECTIONS Front Brake Light Switch Engine Stop Switch Starter Button Color T koch Color Color R W R Color BL W Brake Lever OFF Free Pulled Inl RUN Push 98052 03440 0345 License Plate Light 12v5W Rear Right Turn Signal Light 129218 Tail Brake Light LEB 12V0 5 4 9 Rear Left Turn Signal Light 12V21W Color Code BK Black Brown BR 8 Green Gray Light Blue Le Light Green 9 Orange Pink Pu Purple
14. e Remove Radiator Fan Mounting Bolts A Radiator Fan B 60078245 P 4 12 COOLING SYSTEM Radiator Radiator and Radiator Fan Installation e Run the radiator fan motor lead correctly see Cable Wire and Hose Routing section in the Appendix chapter e Be sure that the trim seals A are in position on the radi ator as shown in the figure e Install the dampers B radiator bracket collars C and bolts as shown in the figure Torque Radiator Mounting Bolts Upper 25 N m 2 5 kgf m 18 ft lb Radiator Mounting Bolt Lower 9 8 N m 1 0 kgf m 87 in Ib Radiator Water Hose Clamp Screws 2 0 N m 0 20 kgf m 18 in Ib Radiator Inspection e Check the radiator core there are obstructions to air flow remove them the corrugated fins A are deformed carefully straighten them the air passages of the radiator core are blocked more than 20 by unremovable obstructions or irreparably de formed 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 C not oblique D to the core surface Run the steam gun following the core fin direction GD07046BS3 C 6007010451 C 6007020151 C Radiator Radiator Cap Insp
15. GE16203BS1 GE16181BS1 C CRANKSHAFT TRANSMISSION 9 27 Pistons Piston Installation e Apply molybdenum disulfide oil solution to the oil ring ex pander and install the oil ring expander A in the bottom piston ring groove so the ends B not butt together e Apply molybdenum disulfide oil solution to the oil ring steel rails and install the oil ring steel rails one above the ex pander and one below it OSpread the rail with your thumbs but only enough to fit the rail over the piston ORelease the rail into the bottom piston ring groove NOTE OThe oil ring rails have no top or bottom e Do not mix up the top and second ring e Install the top ring A so that the R mark B faces up e Install the second ring C so that the RN mark D faces up OApply molybdenum disulfide oil solution to the piston rings NOTE Olf a new piston is used use new piston ring e 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 OApply molybdenum disulfide oil solution to the piston pins and piston journals OWhen installing the piston pin snap ring compress it only enough to install it and no more CAUTION Do not reuse snap rings as removal weakens and deforms them They could fall out and score the cylinder wall e The piston ring openings must be positioned as shown in th
16. Torque No Fastener Nm Remarks 1 Adjusting Collars 15 1 5 11 M 2 Engine Bracket Bolts M8 25 2 5 18 3 Mounting Nuts M12 59 6 0 44 S 4 Front Engine Mounting Bolts M10 59 6 0 44 R S 5 Subframe Bolts 23 2 3 17 R M Apply molybdenum disulfide grease R Replacement Parts S Follow the specified tightening sequence 8 4 ENGINE REMOVAL INSTALLATION Engine Removal Installation Engine Removal e Support the rear part of the swingarm with a stand e Squeeze the brake lever slowly and hold it with a band A A WARNING Be sure to hold the front brake when removing the engine or the motorcycle may fall over It could cause an accident and injury CAUTION Be sure to hold the front brake when removing the engine or the motorcycle may fall over The engine or the motorcycle could be damaged e Remove Engine Oil Drain see Engine Oil Change in the Periodic Maintenance chapter Coolant Drain see Coolant Change in the Periodic Maintenance chapter Lower Fairings see Lower Fairing Removal in the Frame chapter Middle Fairings see Middle Fairing Removal in the Frame chapter Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Ducts see Throttle Body Assy Removal in the Fuel Sys tem DFI chapter Coolant Reserve Tank see Coolant Change in the Peri odic Maintenance chapter Clutch Slave Cylinder see Clutch Slave Cylinder Re
17. Torque No Fastener Nm kgf m Remarks 1 Alternator Cover Bolts 9 8 1 0 87 in lb 2 Alternator Lead Holding Plate Bolts 8 3 0 85 73 L Alternator Rotor Bolt 155 15 8 114 S 4 Camshaft Position Sensor Bolt 9 8 1 0 87 in lb 5 Crankshaft Sensor Bolts 5 9 0 60 52 in lb L 6 Crankshaft Sensor Cover Bolts 9 8 1 0 87 in lb L 1 7 Engine Ground Terminal Bolt 9 8 1 0 87 in lb 8 Fuel Level Sensor Bolts 6 9 0 70 61 in Ib L 9 Gear Position Switch Lead Clamp Bolts 9 8 1 0 87 in lb 10 Gear Position Switch Screws 2 9 0 30 26 in lb L 11 Pressure Switch 15 1 5 11 SS 12 Oil Pressure Switch Terminal Bolt 1 5 0 15 13 in lb G 13 Oxygen Sensor Equipped Models 25 2 5 18 14 Regulator Rectifier Bolts 9 8 1 0 87 in lb 15 Spark Plugs 13 1 3 115 in Ib 16 Speed Sensor Bolt 3 9 0 40 35 in Ib L 17 Stator Coil Bolts 12 1 2 106 in lb 18 Timing Rotor Bolt 39 4 0 29 19 Water Temperature Sensor 25 2 5 18 20 Immobilizer Equipped Models 21 Oxygen Sensor Equipped Models G Apply grease L Apply a non permanent locking agent R Replacement Parts S Follow the specified tightening sequence SS Apply silicone sealant 16 8 ELECTRICAL SYSTEM Exploded View 7 m gt f y 2 26 qo GP023778W5 C Exploded View ELECTRICAL SYSTEM 16 9 Torque No Fastener Nm itib Remarks 1 Brake Light Switch Screw 1 2 0 12 11 in lb 2 Left Switch Hous
18. GE04031BS1 C lt 7 lt GE04032BS1 Air Switching Valve Air Switching Valve ELECTRICAL SYSTEM 16 67 w R Ww BK w BK 8K X 8K M BK BR Y R BL ECU Joint Connector 3 Frame Ground 1 Main Fuse 30 A Battery 12 V 14 Ah Frame Ground 2 Engine Ground Joint Connector 2 Fuel Pump Relay 10 11 12 GP18420BW3 C ECU Main Relay Relay Box lgnition Fuse 10 A 13 14 15 16 17 18 ECU Fuse 15 Fuse Box 2 Ignition Switch Engine Stop Switch Air Switching Valve Water proof Joint 1 16 68 ELECTRICAL SYSTEM Radiator Fan System Fan Motor Inspection e Remove the left fairing cover see Fairing Cover Removal in the Frame chapter e Disconnect the connector A e Using an auxiliary leads supply battery power to the fan motor lf the fan does not rotate the fan motor is defective and must be replaced Radiator Fan Circuit 9 GP15043BW3 C Ignition Switch Joint Connector 1 9 Battery 12 V 14 Ah Fuse Box 2 10 Frame Ground 2 Fan Fuse 15 11 Engine Ground 12 Fan Motor 5 13 Water Temperature Sensor Main Fuse 30 A 14 Water proof Joint 2 Starter Relay 15 ECU ELECTRICAL SYSTEM 16 69 Meter Gauge Indicator Unit Meter
19. 0 80000 3 71 Gear Position Switch Removal Installation pp 3 71 Gear Position Switch Inspection itte te eren b eee eh der eu dro ek 3 71 Gear Position Switch Input Voltage Inspection pp 3 71 Vehicle down Sensor Service Code 31 3 73 Vehicle down Sensor Removal pp 3 73 Vehicle down Sensor 42444 000000011 nennen 3 73 Vehicle down Sensor Inspection pp 3 74 Subthrottle Sensor Service Code 32 3 76 Subthrottle Sensor 3 76 Subthrottle Sensor Input Voltage Inspection pp 3 76 Subthrottle Sensor Output Voltage Inspection pp 3 78 Subthrottle Sensor Resistance Inspection pp 3 80 Oxygen Sensor not activated Service Code 33 Equipped 3 81 Oxygen Sensor Removal Installation esee enne 3 81 Oxygen Sensor Inspection etica een eta cte ud etna ko pe Pe Ru E 3 81 Immobilizer Amplifier Service Code 35 Equipped 3 83 Antenna Resistance Inspection 3 83 Amplifier Input Voltage Inspectiom tats ett elt 3 83 Blank Key Detection Service Code 36 Equipped Models 3 84 User edv in
20. 9513156851 C PERIODIC MAINTENANCE 2 67 Periodic Maintenance Procedures e Remove Dust Seals A Fluid Seals B Bleed Valves C Rubber Caps D 6513157852 NOTE Olf compressed air is not available do as follows with the brake hose connected to the caliper OPrepare a container for brake fluid and perform the work above it ORemove the pad spring and pads see Rear Brake Pad Removal in the Brakes chapter OPump the brake pedal to remove the caliper piston Rear Caliper Assembly e Clean the caliper parts except for the pads CAUTION For cleaning the parts use only disc brake fluid isopropyl alcohol or ethyl alcohol e Install the bleed valves and rubber caps Torque Bleed Valves 7 8 N m 0 80 kgf m 69 in Ib e Apply brake fluid to the cylinder bores e Replace the fluid seals A with new ones OApply silicone grease to the fluid seals and install them into each cylinder by hand e Replace the dust seals B with new ones 6L05040281 2 68 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Replace the O ring A e Apply brake fluid to the outside of the pistons and push them into each cylinder by hand e Be sure to install the O ring e Apply a non permanent locking agent to the threads of the rear caliper assembly bolts and tighten them Torque Rear Caliper Assembly Bolts 37 N m 3 8 kgf m 27 ft lb e Install the pads see Rear Brake
21. R D 84 0 BL O BK W BL BL BL ay BR BK BR BK BR BK p BR Barer BR 68017232042 C ECU Joint Connector 3 Frame Ground 2 Battery 12 V 14 Ah Main Fuse 30 A Fuse Box 1 Oxygen Sensor Heater Fuse 10 A lgnition Switch Oxygen Sensor Water proof Joint 2 FUEL SYSTEM DFI 3 83 Immobilizer Amplifier Service Code 35 Equipped Models Antenna Resistance Inspection e Turn the ignition switch OFF e Remove the left inner cover see Inner Cover Removal in the Frame chapter e Disconnect the antenna lead connector A e Measure the antenna resistance Antenna Resistance Connections BK lead BK lead Standard About 0 6 0 9 O xIf the reading is out of the standard replace the antenna see Immobilizer System Parts Replacement in the Elec trical System chapter the reading is within the standard check the wiring to the amplifier see wiring diagram in next section lf the wiring is good check the input voltage of the ampli fier see Amplifier Input Voltage Inspection Amplifier Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Remove the windshield see Windshield Removal in the Frame chapter e Connect a digital meter to the amplifier connector A us ing the needle adapter set Special To
22. o 9 GPili3s4BW3 C Sidestand Switch Engine Stop Switch Starter Button Fuse Box 2 Ignition Fuse 10 A lgnition Switch Joint Connector 1 Gear Position Switch Frame Ground 1 Starter Lockout Switch Starter Circuit Relay Relay Box Starter Motor Main Fuse 30 A Starter Relay Battery 12 V 14 Ah Frame Ground 2 Engine Ground na n cla 16 58 ELECTRICAL SYSTEM Lighting System This motorcycle adopt the daylight system and have a headlight relay in the relay box The headlight does not go on when the ignition switch and the engine stop switch are first turned on The headlight comes on after the starter button is released and stays on until the ignition switch is turned off The headlight will go out momentarily whenever the starter button is pressed and come back on when the button is released Headlight Beam Horizontal Adjustment e Refer to the Headlight Aiming Inspection in the Periodic Maintenance chapter Headlight Beam Vertical Adjustment e Refer to the Headlight Aiming Inspection in the Periodic Maintenance chapter Headlight Bulb Replacement e Remove the inner covers see Inner Cover Removal in the Frame chapter e Disconnect the headlight connector A e Turn the headlight bulb A counterclockwise and pull out the bulb from the headlight CAUTION When handling the quartz halogen bulb never
23. Piston Ring Thickness Inspection e Measure the piston ring thickness OUse the micrometer to measure at several points around the ring Piston Ring Thickness Standard 0 87 0 89 0 0343 0 0350 0 97 0 99 mm 0 0382 0 0390 6 16070851 6 Service Limit Top A 0 80 mm 0 031 in Second B 0 90 mm 0 035 in lf any of the measurements is less than the service limit on either of the rings replace all the rings NOTE OWhen using new rings in a used piston check for un even groove wear The rings should fit perfectly parallel to the groove sides If not replace the piston Piston Ring End Gap Inspection e Place the piston ring A inside the cylinder upper crankcase using the piston to locate the ring squarely in place Set it close to the bottom of the cylinder where cylinder wear is low e Measure the gap B between the ends of the ring with a thickness gauge Piston Ring End Gap Standard 6E16066BS1 0 Top 0 20 0 30 mm 0 0079 0 0118 in Second 0 40 0 55 mm 0 0157 0 0217 in Cil 0 20 0 70 mm 0 0079 0 0276 in Service Limit Top 0 6 mm 0 024 in Second 0 8 mm 0 031 in Cil 1 0 mm 0 039 in xIf the end gap of either ring is greater than the service limit replace all the rings 9 30 CRANKSHAFT TRANSMISSION Balancer Front Balancer Removal e Split the crankcase see Crankcase Sp
24. BL R lead terminal 46 Meter Frame Ground 2 C Connections for Fuel Injector 2 Meter BL G lead terminal 59 Meter Frame Ground 2 C Connections for Fuel Injector 3 Meter BL BK lead terminal 44 Meter Frame Ground 2 C Connections for Fuel Injector 4 Meter BL Y lead terminal 57 Meter Frame Ground 2 C e Turn the ignition switch ON 6617447651 C Output Voltage at ECU Standard Battery Voltage for 3 seconds and then 0 V the output voltage is normal check the ECU for its ground and power supply see ECU Power Supply In spection x If the ground and power supply are good replace the ECU see ECU Removal Installation 3 112 FUEL SYSTEM DFI Fuel Injectors x If the output voltage is out of the standard check the out put voltage at the throttle body subharness connector A using a digital meter B and needle adapter set C when the lead is open the output voltage is 0 V Special Tool Needle Adapter Set 57001 1457 Fuel Injector Output Voltage at Fuel Injector Connections to Fuel Injector 1 Meter BL R lead D Meter Ground E Connections to Fuel Injector 2 Meter BL G lead F Meter Ground E Connections to Fuel Injector 3 Meter BL BK lead G Meter Ground E Connections to Fuel Injector 4 Meter BL Y lead H Meter Ground E e Turn th
25. Cam Gamshatt Ghiain Removal ete ee bern e ger He pco ere P fe e Camshaft Chain Cylinder Head Cylinder Compression Measurement pp Cylinder Head Removal Cylinder Head Installation due eec tei m o PROBE educ eua Cylinder Head Warp Inspection 22 Valve Clearance Inspection it ERR Valve Clearance Adjustment dee te pel Er rope Dex bte eo cn Rana dg qe Valve Removal Valve Installation Valve Guide Removal Valve Guide Installation Valve to Guide Clearance Measurement Wobble Valve Seat Inspection Valve Seat Repair Muffler Body Removal lnstallation pp Exhaust Pipe Removal Exhaust Pipe Installation 5 2 5 6 5 8 5 9 5 11 5 11 5 11 5 12 5 12 5 12 5 12 5 12 5 13 5 14 5 14 5 14 5 16 5 16 5 16 5 17 5 17 5 17 5 20 5 21 5 21 5 21 5 22 5 23 5 23 5 24 5 24 5 25 5 26 5 26 5 26 5 26 5 26 5 26 5 27 5 28 5 29 5 29 5 34 5 34 5 35 5 35 5 36 5 36 5 2 ENGINE TOP END Exploded View Qe Ces GE023668W5 C ENGINE TOP END 5 3 Exploded View Torque No Fastener Nm kgf m Remarks 1 Air Suction Valve Co
26. Subthrottle Valve Actuator Inspection NOTE OBe sure the battery is fully charged e Remove Fuel Tank see Fuel Tank Removal Air Cleaner Caps see Throttle Body Assy Removal e Turn the ignition switch ON e 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 Subthrottle Valve Actuator Resis tance Inspection Subthrottle Valve Actuator Resistance Inspection e Turn the ignition switch OFF e Disconnect the subthrottle valve actuator connector A e Connect a digital meter to the connector A e Measure the subthrottle valve actuator resistance Subthrottle Valve Actuator Resistance Connections Y lead 1 P lead 2 BK lead 3 lead 4 Standard About 5 7 If the reading is out of the range replace the throttle body assy see Throttle Body Assy Removal Installation If the reading is within the range check the input voltage see Subthrottle Valve Actuator Input Voltage Inspection 6617170651 C 3 90 FUEL SYSTEM Subthrottle Valve Actuator Service Code 62 Subthrottle Valve Actuator Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Connect the peak voltage adapter A and a digital meter B to the connector C using the needle adapter set D Special Tools Peak Voltage Adapter 57001 1415 Type
27. 3 70 FUEL SYSTEM Speed Sensor Service Code 24 Speed Sensor Circuit 6C17433CW2 1 ECU 2 Meter Unit 3 Speed Sensor 4 Frame Ground 1 FUEL SYSTEM 3 71 Gear Position Switch Service Code 25 Gear Position Switch Removal Installation e Refer to the Gear Position Switch Removal Installation in the Electrical System chapter Gear Position Switch Inspection e Refer to the Gear Position Switch Inspection in the Elec trical System chapter Gear Position Switch Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Remove the ECU see ECU Removal ODo not disconnect the ECU connectors e Connect a digital meter A to the connector using the needle adapter set Special Tool Needle Adapter Set 57001 1457 6617161651 C Gear Position Switch Input Voltage at 1 6 Gear Positions Connections to ECU Meter G R lead terminal 4 Meter Engine Ground e Measure the switch input voltage with the engine stopped and with the connector joined e Turn the ignition switch ON Input Voltage at 1 6 Gear Positions Standard 1st About 3 0 V 2nd About 2 5 V 3rd About 2 0 V 4th About 1 5 V 5th About 1 1 V 6th About 0 7 V e Turn the ignition switch OFF If the reading is out of the range check the gear position switch see Gear Position Switch Inspection in the Elec trical Syst
28. 6114301851 C 6114302851 C 6114288851 C 12 56 BRAKES Anti Lock Brake System Equipped Models ECU Inspection Service Code 55 e Do the 1st step test ORecheck the service code indication erase the service code perform the pre diagnosis inspection 1 and 2 and retrieve the service code xIf the ABS indicator light LED A lit faulty ECU in the ABS hydraulic unit Replace the ABS hydraulic unit xIf the ABS indicator light LED unlit ABS system is nor mal service code is not stored temporary failure ABS Hydraulic Unit Removal CAUTION The ABS hydraulic unit A has been adjusted and set with precision at the factory Therefore it should be handled carefully never struck sharply with a hammer or allowed to fall on a hard surface Be careful not to get water or mud on the ABS hy draulic unit e Drain the brake fluid from the front and rear brake lines ODrain the brake fluid through the bleed valve by pumping the brake lever and pedal e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Battery see Battery Removal in the Electrical System chapter Bolts A Cover B e Clean the ABS hydraulic unit CAUTION Clean all fittings on the ABS hydraulic unit and the rear master cylinder because dirt around the banjo bolts could contaminate the brake fluid in the line during removal installation Spread out a shop towel around the ABS hydrau
29. Rea w White W2R0344DW5 C 16 26 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems Learn and ob serve all the rules below ODo not reverse the battery cable connections This will burn out the diodes on the electrical parts OAlways check battery condition before condemning other parts of an electrical system A fully charged battery is a must for conducting accurate electrical system tests OThe electrical parts should never be struck sharply as with a hammer or allowed to fall on a hard surface Such a shock to the parts can damage them OTo prevent damage to electrical parts do not disconnect the battery cables or any other electrical connections when the ignition switch is ON or while the engine is running OBecause of the large amount of current never keep the starter button pushed when the starter motor will not turn over or the current may burn out the starter motor wind ings OTake care not to short the cables that are directly con nected to the battery positive terminal to the chassis ground OTroubles may involve one or in some cases all items Never replace a defective part without determining what CAUSED the failure If the failure was caused by some other item or items they must be repaired or replaced or the new replacement will soon fail again OMake sure all connectors in the circuit are clean and ti
30. lt ZZR1400 ZZR1400 ABS Kawasaki Ninja ZX 14 Motorcycle Service Manual Quick Reference Guide 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 Electrical System mek oO e OO NI DO BY Oo NO Appendix This quick reference guide will assist you in locating a desired topic or pro cedure Bend the pages back to match the black tab of the desired chapter num ber 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 spe cific topic required ZZR1400 ZZR1400 ABS Ninja ZX 14 Kawasaki Motorcycle Service Manual All rights reserved No parts of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Quality Assurance Division Consumer Products amp 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
31. G GY BL BK Y Y BL 9 6617445612 C 1 Meter Unit 2 Warning Indicator Light LED 3 Frame Ground 1 4 ECU Fuel Line Fuel Pressure Inspection NOTE OBe sure the battery is fully charged e Remove the fuel tank see Fuel Tank Removal e Be sure to place a piece of cloth around the delivery pipe of the throttle body assy e Remove the fuel hose from the delivery pipe of the throttle body assy see Fuel Hose Replacement in the Periodic Maintenance chapter WARNING Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is disconnected fuel spills out from the hose and the pipe because of residual pressure Cover the hose connection with a piece of clean cloth to prevent fuel spillage e Install the fuel pressure gauge adapter A and fuel hoses Special Tool 57001 1607 B between the fuel supply pipes of the fuel pump and throttle body assy e Secure the fuel hoses with the clamps e Install the throttle body assy e Connect the following parts temporary Fuel Pump Lead Connector Fuel Level Sensor Lead Connector e Connect the pressure gauge C to the fuel pressure gauge adapter Special Tools Oil Pressure Gauge 5 kgf cm 57001 125 Fuel Pressure Gauge Adapter 57001 1593 Fuel Hose 57001 1607 A WARNING Do not try to start the engine with the fuel hoses disconnected e Turn the engine stop switch ru
32. e 1st set the BATTERY display A e Check that the display indicates the battery voltage e 2nd disconnect the terminal 10 e Check that the display changes 9 0 V within about 30 sec onds e 3rd connect the terminal 10 e Check that the display changes the current battery volt age within about 30 seconds OThe tolerance of the voltage is 0 4 V lf the display function does not work replace the meter assembly Check 5 Immobilizer Flashing Mode Inspection Immo bilizer Equipped Models e Connect the leads in the same circuit as Check 2 e Disconnect the terminal 9 e Check that the warning light LED A starts flashing Im mobilizer Warning Light Flashing Mode e Push the upper B and lower C buttons more than 2 seconds within 20 seconds after the terminal 9 discon nected e Check that the warning light LED goes on one second and then the light goes off Immobilizer Warning Light No Flashing Mode NOTE OFor this inspection be sure the battery is 12 4 V or more Immobilizer Warning Light Flashing Mode does not work when the battery voltage is less than 1240 4 V Z BATTERY Ji B 126v 1 1 00 Bom H a NN i 12D 220 x1000c m m 4 1 She x Sz 6 170876 5 ELECTRICAL SYSTEM 16 77 Meter Gauge Indicator Unit e Connect the terminal 9 to the battery terminal e And then disc
33. e Remove Air Suction Valve Cover Bolts A Air Suction Valve Covers B Air Suction Valves C Air Suction Valve Installation e Install the air suction valve so that opening A of the reed faces the rear and downward e Apply a non permanent locking agent to the threads of the air suction valve cover bolts and tighten them Torque Air Suction Valve Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib 6 04055851 C 5 12 ENGINE TOP END Clean Air System Air Suction Valve Inspection e Remove the air suction valve see Air Suction Valve Re moval e Visually inspect the reeds A for cracks folds warps heat damage or other damage If there is any doubt as to the condition of the reeds re place the air suction valve as an assembly e Check the reed contact areas B of the valve holder for grooves scratches any sings of separation from the holder or heat damage x lf there is any doubt as to the condition of the reed contact areas replace the air suction valve as an assembly e f any carbon or other foreign particles have accumulated between the reed and the reed contact area wash the valve assembly with a high flash point solvent CAUTION Do not scrape off the deposits with a scraper as this could damage the rubber requiring replacement of the suction valve assembly Air Switching Valve Removal e Remove Middle Fairings see Middle Fairing Removal in the Frame chapter Conne
34. Clutch Slave Cylinder Removal 2 204044 000 Clutch Slave Cylinder Installation eco oett aote edet atio Clutch Slave Cylinder Disassembly 20204040 000 6 9 Clutch Slave Cylinder Assembly pp 6 9 Sirena NG EE E MT M ca aa 6 10 Clutch El id Eevel Inspection 6 10 ATC Sears ected M T C C 6 10 Bleeding the Cl tch Ehe ERNE er 6 10 Clutch Hose Removal Installation 4 6 12 Clutehm Hose InspeGtlOr n otio ee et etes en reser maet tenue dede mas 6 12 ct ce 6 13 Clutch Gover Rerrioval ertet Rr cR Rex ERE Let ER 6 13 Cl t h Cover rotae toad etes cd reple pas tee de 6 13 CIN o hos M MAIL MM Mc RM E PM e EE 6 14 Gluten ROT OV al pe ds 6 14 Clutch ALOR a tease damus saath Sect 6 14 Clutch Plate Assembly IHSpOCHOT oo aed Saw ne eae 6 16 Clutch Plate Assembly 6 17 Clutch Plate Wear Damage Inspection 6 17 Clutch Plate Warp lriSpecllOfk cc tts repe eene Bret Neen 6 17 Clutch Spring Free Length Measurement pp 6 18 6 2 CLUTCH Exploded View G
35. PERIODIC MAINTENANCE 2 65 Periodic Maintenance Procedures WARNING To avoid serious injury never place your fingers or palm in front of the piston If you apply compressed air into the caliper the piston may crush your hand or fingers OPull out the pistons by hand e Remove the dust seals A and fluid seals B e Remove the bleed valve C and rubber cap D e Repeat the previous step to remove the pistons from the other side of the caliper body NOTE Olf compressed air is not available do as follows for both calipers coincidentally with the brake hose connected to the caliper OPrepare a container for brake fluid and perform the work above it ORemove the pad springs and pads see Front Brake Pad Removal in the Brakes chapter OPump the brake lever until the pistons come out of the cylinders and then disassemble the caliper Front Caliper Assembly e Clean the caliper parts except for the pads CAUTION For cleaning the parts use only disc brake fluid isopropyl alcohol or ethyl alcohol e Install the bleed valve and rubber cap Torque Bleed Valves 7 8 N m 0 80 kgf m 69 in Ib e Replace the fluid seals A with new ones OApply silicone grease to the fluid seals and install them into the cylinders by hand e Replace the dust seals B with new ones if they are dam aged OApply silicone grease to the dust seals and install them into the cylinders by hand e Replace the O ri
36. gt yo GS13024B 5 CLUTCH 6 13 Clutch Cover Clutch Cover Removal e Remove Engine Oil Drain see Engine Oil Change in the Periodic Maintenance chapter Right Lower Fairing see Lower Fairing Removal in the Frame chapter Clutch Cover Bolts A Clutch Cover B Clutch Cover Installation e Apply silicone sealant to the area A where the mating surface of the crankcase touches the clutch cover gasket Sealant Kawasaki Bond Silicone Sealant 92104 0004 e Replace the clutch cover gasket with a new one e Tighten the clutch cover bolts OApply a non permanent locking agent to only one clutch cover bolt A shown in figure Torque Clutch Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib Olf the oil gauge A is removed press the gauge so that its projection B faces the inside using lubricant 6 14 CLUTCH Clutch Clutch Removal e Remove Clutch Cover see Clutch Cover Removal Clutch Spring Bolts A Clutch Springs Clutch Spring Plate B with Thrust Bearing Pusher C and Washer e Remove Friction Plates and Steel Plates Spring and Spring Seat Clutch Hub Nut A OHolding the clutch hub B with the clutch holder C re move the nut and washers D Special Tool Clutch Holder 57001 1243 e Remove Clutch Hub Washer e Using the two 4 mm 0 16 in bolts A pull out the sleeve B needle bearing C and clutch housing D e Remove the thrust washer Clutch Installation e Install
37. 0 5second 0 5second ore 6230515851 C 0 5second 0 5second dm SP30515BS1 C 16 96 ELECTRICAL SYSTEM Immobilizer System Equipped Models Olf there is any problem in the registration the warning indicator light LED A blinks to display the collation error Immobilizer Amplifier Failure When Registered User Key is Inserted User Key Collation Error e The user key 2 is successfully registered in the ECU OThe warning indicator light LED A blinks 3 times and stops for 1 second and then repeat this cycle to indicate successful programming of user key 2 e Turn OFF the ignition switch and wait for period more than 15 seconds e The registration mode automatically ends e Warning indicator light LED A goes off 0 2second Get GP30516BS1 C 0 5second 0 5second E bara GP30515BS1 0 3second UU GP30517BS1 0 30 30 3 0 30 3 1second ON A 81 1 UUL_IUUL GP30519BS1 C ON On GP30520BS1 Immobilizer System Equipped Models e Remove the key registration unit and connect the immo bilizer Kawasaki diagnostic system connector NOTE O Turn the ignition switch ON with the registered user key OCheck that the engine can be started using all regis tered user keys e Install the new ignition switch and ant
38. 3 53 6617148651 C 6617143851 6 3 54 FUEL SYSTEM Inlet Air Pressure Sensor Service Code 12 Inlet Air Pressure Sensor Circuit BL 4 Y BL 7 Y BL R BK BL BL BL Y BL Y BL R BK BR BK 5 8 R BK R BK olf 1 ECU 2 Inlet Air Pressure Sensor 3 Water proof Joint 2 66174256 2 C lf you need to check the inlet air pressure sensor for vac uum other than 76 cmHg check the output voltage as fol lows Inlet Air Pressure Sensor Service Code 12 x If the wiring is good check the sensor for various vacuum e Remove the inlet air pressure sensor A and disconnect the vacuum hose from the sensor e Connect an auxiliary hose B to the inlet air pressure sen sor e Temporarily install the inlet air pressure sensor OConnect a digital meter C vacuum gauge D fork oil level gauge E and the harnes adapter to the inlet air pressure sensor Special Tools Fork Oil Level Gauge 57001 1290 Vacuum Gauge 57001 1369 Sensor Harness Adapter 57001 1561 Inlet Air Pressure Sensor Output Voltage Connection to Adapter Meter G W sensor Y BL lead Meter sensor BR BK lead OTurn the ignition switch ON OMeasure the inlet air pressure sensor output voltage from various vacuum readings while pulling the handle of the fork oil level gauge OCheck the inlet air pressure sensor output v
39. Fuel Pump Operation Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch ON and make sure that the fuel pump operates make light sounds for 3 seconds and then stops e Turn the ignition switch OFF x If the pump does not operate as described above inspect the operating voltage see Fuel Pump Operating Voltage Inspection Fuel Pump Operating Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Remove the seat see Seat Removal in the Frame chap ter e Connect the hand tester DC x 25 V to the 4 pins con nector A using the needle adapter set Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 Fuel Pump Operating Voltage at Pump Connections to Pump Connector Tester BK Y Lead Tester BK W Lead e Measure the operating voltage with the engine stopped and with the connector joined e Turn the ignition switch ON OThe tester needle should indicate battery voltage for 3 seconds and then 0 V Operating Voltage at Pump Connector Standard Battery Voltage 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 the voltage is in specification but the pump doesn t work replace the pump there is still no battery voltage check the pump relay see Fuel Pump Relay Inspection GC10080BS1 C Fue
40. 2 Sq eee T ee Oy Wear NEIN Oe RSSI 7 16 1 m Re a y aug T d 9 wd G 443 y 6B09614CW5 C APPENDIX 17 11 Cable Wire and Hose Routing O o 11 12 13 14 15 16 Clamp Install the clamp from the arrow mark side Run the reserve tank hose through on the air bleeder hose come from the thermostat housing Run the air switch valve lead which is connected to the water temperature sensor lead between the throttle body 3 and 4 Connect the alternator lead to the regulator rectifier through the subharness Run the alternator lead through the backside of air bleeder hose come from the water pump Run the reserve tank hose through between the air switching valve and the bracket Connect the oil pressure switch gear position switch lead and sidestand switch lead to the main harness Air Cleaner Drain Hose Run the air cleaner drain hose through between the engine sprocket cover and clutch hose Run the air cleaner drain hose through on the water pump and insert it into the gap between the lower fairing and water pump Run the reserve tank overflow hose through the fairing bracket and route it through the clamp Water Hose To Cylinder Fitting Reserve Tank Overflow Hose Water Hose To Radiator Run the reserve tank overflow hose through between the w
41. Engine Ground Rear Left Turn Signal Light Rear Right Turn Signal Light lgnition Fuse 10 A Fuse Box 2 NNN AH HH AH AH VS SS Sl 16 66 ELECTRICAL SYSTEM Air Switching Valve Air Switching Valve Operation Test e Refer to the Air Suction System Damage Inspection in the Periodic Maintenance chapter Air Switching Valve Unit Test e Remove the air switching valve see Air Switching Valve Removal in the Engine Top End chapter e Set the hand tester A to the x 1 O range and connect it to the air switching valve terminals as shown in the figure Special Tool Hand Tester 57001 1394 Air Switching Valve Resistance Standard 20 24 at 20 C 68 F If the resistance reading is except the specified value re place it with a new one e Connect the 12 V battery A to the air switching valve terminals as shown in the figure e Blow the air to the inlet air duct A and make sure does not flow the blown air from the outlet air ducts B e Disconnect the 12 V battery e Blow the air to the inlet air duct A again and make sure flow the blown air from the outlet air ducts B the air switching valve does not operate as described replace it with a new one NOTE O To check air flow through the air switching valve just blow through the air switching valve hose inlet side GE04030BS1 C GE04033BS1 C
42. FRAME 15 21 6020016851 C ELECTRICAL SYSTEM 16 1 Electrical System Table of Contents EXO e bo C def 16 4 END P E 16 10 Special Tools Sealant quaai o udi oto dau 16 11 NT 16 13 Wiring Diagram CA CAL and US Mogels nnn 16 16 Wiring Diagram AU and MY Models remet tr 16 18 Wiring Diagram Other than CA CAL US AU and MY Models 16 20 Wiring Diagram ABS Equipped Models MY Model pp 16 22 Wiring Diagram ABS Equipped Models Other than MY 16 24 PICCAUMONS cuba ma DIU aes 16 26 Ele trical Cm 16 27 Wiring YS DS CUO 16 27 fe d 16 28 Battery Removal mre pub lae o e turae ee 16 28 Battery Installation 16 29 EE 16 29 PRECAUTIONS 16 32 Interchange east Erat en 16 32 Charging Condition 16 32 Refreshing Slate
43. In this way this system controls the engine temperature within narrow limits where the engine op erates 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 cm 13 18 psi the pressure valve opens and releases the pressure to the reserve tank As soon as pressure escapes the valve closes and keeps the pressure at 93 123 kPa 0 95 1 25 kgf cm 13 18 psi When the engine cools down another small valve vacuum valve in the cap opens As the coolant cools the coolant contracts to form a vacuum in the system The vacuum valve opens and allows the coolant from the reserve tank to enter the radiator 4 6 COOLING SYSTEM Specifications Item Coolant Provided when Shipping Type Recommended Color Mixed Ratio Freezing Point Total Amount Radiator Cap Relief Pressure T
44. Install the shim of this thickness mm m gt GS07089BW3 C Measure the clearance when engine is cold 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 Measured clearance is 0 33 mm Replace 2 60 mm shim with 2 70 mm shim 5 Remeasure the valve clearance and readjust if neces sary PERIODIC MAINTENANCE 2 27 Periodic Maintenance Procedures INLET VALVE CLEARANCE ADJUSTMENT CHART SS Present Shim Example Part 92025 1870 1871 1872 1873 1874 1875 1876 1877 1878 1879 18801881 1882 1883 1884 1885 1886 1887 1888 188911890 ff m mp a o_o s of e es ro or e eof o_o 0 00 0 05 E 2 00 2 05 2 10 2 15 2 20 2 2512 30 2 352 40 2 45 2 502 55 2 60 2 65 2 70 2 75 2 80 2 85 0 06 0 10 2 00 2 05 2 192 15 2 20 2 252 30 2 352 4042 4512 502 55 2 6012 65 2 70 2 75 2 80 2 85 2 90 0 11 0 14 2 00 2 05 2 102 15 2 20 2 2512 30 2 35 2 402 4512 5012 55 2 6012 65 2 70 2 75 2 80 2 8512 90 2 95 0 15 0 20 Specified Clearance No Change Required ENT EE DES DES 08 DEED OO DES ER DES DES ERTERT DES DESERT DES DES DI DR DET E fetes ee
45. Lapper A Valve Seat B Valve C e 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 e Be sure to remove all grinding compound before assem bly e When the engine is assembled be sure to adjust the valve clearance see Valve Clearance Inspection in the Periodic Maintenance chapter GE15012381 C GE15012081 ENGINE TOP END 5 33 Valves Valve Seat Repair Machinist s dye on seat 45 Grind Tool 45 Cutter Purpose make seating area smooth and round Measure Seating Area Outside Diameter Tool Vernier Caliper Purpose check seat outside diameter against specification Results Machinist s dye on seat 32 Grind Tool 32 Cutter Purpose reduce outside 45 Grind Tool 45 Cutter Purpose increase outside diameter of seat area to specification Measure Seating Width diameter of seat Tool Vernier Caliper area to specification Purpose check seat width against specification Results 45 Grind Machinist s dye Tool 45 Cutter Purpose increase width of seat area beyond specification to increase outside diameter 60 Grind Tool 60 Cutter Purpose reduce seat Lap Valve Tools Valve Lapper Grinding Compound P
46. Light LED 3 High Beam Indicator Meter Unit Light LED 4 Neutral Indicator Light LED 5 Warning Indicator Light LED 6 Left Turn Signal Indicator Light LED li flunination Light LED Fuel Level Gauge Water Temperature Gauge 10 Tachometer 11 Speedometer 12 Oil Pressure Warning Indicator Light LED 13 ABS Indicator Light LED ean Front Right Turn Signal Light 12V21 Right City Light 12 58 Headlight HI 12V65W Headlight LO 12V55W Headlight LO 12V55W YY Headlight HI we H 2885 5585 25 12V65 Left City Light 12V5W SE 55 Headlight Headlight 4 Left Switch Housin Relay Lo Relay Hi Horn Button Front Left Turn Signal Fuel 2 Hazard Button Light 12V21W ay 3 Turn Signal Switch Level 4 Dimmer Switch Sensor 5 Starter Lockout Switch Box 1 Box 2 6 Passing Buttoni 1 Fuse Box 2 i Turn Signal Relay Fuse 10A 1 Fan Fuse 15 2 Headlight Relay Fuse 10A 2 ECU Fuse 15A 3 Taillight Fuse 10 3 ABS Motor Relay Fuse 304 4 Horn Fuse 10A 4 ABS Solenoid Valve Relay Fuse 20A 5 Headlight Fuse Hi 15A 5 ABS ECU Fuse 10 8 Headlight Fuse Lo 15A 6 Ignition Fuse 10A LEFT SWITCH HOUSING CONNECTIONS Turn Signal Switch Starter Lockout vitch Passing Button Color BK WBK Color GY Color GY R BK BL Y R Y Color IBK R BL Y R BK Clutch
47. 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 3 32 FUEL SYSTEM DFI DFI System Troubleshooting Guide NOTE OThis is not an exhaustive list giving every possible cause for each problem listed It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties in DFI system OThe ECU may be involved in the DFI electrical and ignition system troubles If these parts and circuits are checked out good be sure to check the ECU for ground and power supply If the ground and power supply are checked good replace the ECU Engine Won t Turn Over Symptoms or possible Causes Gear position starter lockout or sidestand switch trouble Actions chapter Inspect each switch see chapter 16 Immobilizer system trouble Inspect see chapter 3 Vehicle down sensor coming off Reinstall see chapter 3 Vehicle down sensor trouble Inspect see chapter 3 Crankshaft sensor trouble Inspect see chapter 16 Stick coil shorted or not in good contact Inspect or Reinstall see chapter 16 Stick coil trouble Inspect see chapter 16 Spark
48. 11 clicks 10th click from the 1st click of the fully clockwise position Usable Range 0 lt gt 13 clicks Adjuster protrusion is 15 mm 0 59 in Usable Range 4 19 mm 0 16 0 75 in KAYABA 01 KHL15 10 or equivalent SAE 5W Approx 480 mL 16 2 US oz when changing oil 563 4 mL 19 0 0 135 US oz after disassembly and completely dry 88 2 mm 3 46 0 08 in fully compressed without fork spring below from the top of the inner tube 257 mm 10 12 in Service Limit 252 mm 9 92 in Rear Shock Absorber Rebound Damper Setting Compression Damper Setting Spring Preload Setting Standard Usable Range Gas Pressure 1 2 4 turns out from the fully clockwise position Usable Range 0 2 2 4 turns out 2 1 4 turns out from the fully clockwise position Usable Range 0 4 turns out Spring length 175 5 mm 6 9 in Spring length 175 5 191 5 mm 6 909 7 539 in weaker to stronger 1 080 kPa 11 0 kgf cm 156 psi Non adjustable Special Tools SUSPENSION 13 7 Inside Circlip Pliers 57001 143 7570143ST C Cil Seal amp Bearing Remover 57001 1058 7571058ST C Bearing Driver Set 57001 1129 7571129ST C Jack 57001 1238 7571238ST C Fork Cylinder Holder 57001 1287 875712875 C Fork Piston Rod Puller M12 x 1 25 57001 1289 N 7571289ST C Fork Oil Leve
49. 16 12 ELECTRICAL SYSTEM Special Tools and Sealant Stopper 57001 1679 875716795 Kawasaki Bond Silicone Sealant 92104 0004 879200045 ELECTRICAL SYSTEM 16 13 Parts Location Dummy Page 16 14 ELECTRICAL SYSTEM Parts Location 62048114 P 62048115 P Parts Location On O Headlight Relay High Immobilizer Amplifier Immobilizer Equipped Models Ignition Switch ELECTRICAL SYSTEM 16 15 Immobilizer Equipped Models Including Immobilizer Antenna Starter Lockout Switch Radiator Fan Motor Oil Pressure Switch Starter Relay Alternator Speed Senor 10 Gear Position Switch 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Regulator Rectifier Sidestand Switch Frame Ground 1 Fuse Box 1 Turn Signal Relay Relay Box Fuse Box 2 ECU Headlight Relay Low Meter Unit Front Brake Light Switch Air Switching Valve Stick Coils Spark Plugs Camshaft Position Sensor Water Temperature Sensor Crankshaft Sensor Frame Ground 2 Oxygen Sensor Equipped Models Battery 12 V 14 Ah Engine Ground Starter Motor Rear Brake Light Switch 16 16 ELECTRICAL SYSTEM Wiring Diagram CA CAL and US Models Meter Unit 1 Right Turn Signal Indicator Light LED 2 Shift Up Indicator 9 Light LED 3 High Beam Indica
50. 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 throttle body assy especially on a hard surface Such a shock to the main throttle sen sor can damage it Main Throttle Sensor Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Remove the ECU see ECU Removal ODo not disconnect the ECU connectors e Connect a digital meter A to the connector B using the needle adapter set Special Tool Needle Adapter Set 57001 1457 Main Throttle Sensor Input Voltage Connections to ECU Connector Meter BL lead terminal 7 Meter BR BK lead terminal 34 e Measure the input voltage with the engine stopped and with the connectors joined e Turn the ignition switch ON Input Voltage at ECU Connector Standard DC 4 75 5 25 V e Turn the ignition switch OFF xIf the reading of input voltage is less than the standard check the ECU for its ground and power supply see ECU Power Supply Inspection and wiring shorted x lf the input voltage is within the standard range check the input voltage at the main throttle sensor connector c 6617145651 C 3 46 FUEL SYSTEM Main Throttle Sensor Service Code 11 e Remove the right fairing cover see Fairing Cover Re moval in the Frame chapter e Disconnect the
51. Meter Gauge Indicator Unit Can Communication Line Resistance at Meter Unit Speed Sensor Supply Voltage 376 564 2 4 V or more 400 460 at 20 C 68 F 2 8 V or more 12 160 8 5 11 5 72 V or more NGK CR9EIA 9 0 8 0 9 mm 0 031 0 035 in 10 mm 0 39 in Service Limit 5 0 mm 0 20 in 28 mm 1 10 in Service Limit 27 mm 1 06 in 20 24 Q at 20 C 68 122 126 Q About 12 V Switches and Sensors Rear Brake Light Switch Timing Engine Oil Pressure Switch Connections Water Temperature Sensor Resistance Fuel Level Sensor Resistance Full Position Empty Position ON after about 10 mm 0 39 in of pedal travel When engine is stopped ON When engine is running OFF In the text 9 110 213 2190 Special Tools and Sealant ELECTRICAL SYSTEM 16 11 Hand Tester 57001 1394 7571394ST C Flywheel Puller Assembly M38 x 1 5 M35 x 1 5 57001 1405 7571405ST C Peak Voltage Adapter 57001 1415 875714155 C Lead Wire Peak Voltage Adapter 57001 1449 7571449ST C Needle Adapter Set 57001 1457 T571457ST C Harness Adapter 57001 1562 2 0 7571562ST C Key Registration Unit 57001 1582 875715825 C Grip 57001 1591 875715915 C Flywheel amp Pulley Holder 57001 1605 875716055 C Rotor Holder 57001 1672 75716728T
52. Rear Caliper Mounting Bolts A Rear Caliper B e Remove the rear wheel rotation sensor from the caliper bracket see Rear Wheel Rotation Sensor Removal in the Brakes chapter ABS Equipped Models e Remove Cotter Pin A Axle Nut B Washer C Axle D from Left Side e Remove the drive chain A from the rear sprocket toward the left e Move the rear wheel back and remove it CAUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground Rear Wheel Installation e Apply high temperature grease to the grease seal lips e Fit the collars on the both sides of the hub Right Side Collar A Left Side Collar B e Engage the drive chain with the rear sprocket e Install the caliper bracket A onto the swingarm stop B e Insert the axle from the left side of the wheel and tighten the axle nut Torque Rear Axle Nut 127 N m 13 0 kgf m 93 7 ft lb WHEELS TIRES 10 9 Wheels Rims e Insert a new cotter pin A NOTE OWhen 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 Olt should be within 30 OLoosen once and tighten again when the slot goes past the nearest hole e Bend the cotter pin A over the nut A WARNING If the rear axle nut i
53. Throttle Body Assy Holder Clamp Bolts 18 in Ib Vehicle down Sensor Bolts 52 in lb Water Temperature Sensor 18 Cooling System Coolant Drain Bolt 89 in Ib Coolant Fitting Bolts 78 in lb L Cylinder Fitting Mounting Bolts 87 in lb Hot Windshield Mounting Bolts 87 in lb Oil Cooler Mounting Bolts 106 in lb S Radiator Bracket Mounting Bolt 87 in lb Radiator Mounting Bolt Lower 87 in lb Radiator Mounting Bolts Upper 18 Torque and Locking Agent PERIODIC MAINTENANCE 2 7 Fastener TOUS Remarks N m kgf m ft Ib Radiator Water Hose Clamp Screws 2 0 0 20 18 in lb Reserve Tank Bolts 9 8 1 0 87 L Thermostat Housing Cover Bolts 5 9 0 60 52 Thermostat Housing Mounting Bolts 9 8 1 0 87 Water Pump Cover Bolts 9 8 1 0 87 in lb Water Temperature Sensor 25 2 5 18 Air Suction Valve Cover Bolts 9 8 1 0 87 in lb L Cam Sprocket Mounting Bolts 15 1 5 11 L Camshaft Cap Bolts 12 1 2 106 in Ib S Camshaft Chain Guide Bolts 12 1 2 106 in Ib S Camshaft Chain Tensioner Mounting Bolts 9 8 1 0 87 in lb Camshaft Position Sensor Bolt 9 8 1 0 87 in lb Crankshaft Sensor Cover Bolts 9 8 1 0 87 in lb L 1 Cylinder Head Bolts M11 64 6 5 47 MO S Cylinder Head Bolts M6 12 1 2 106 in Ib S Cylinder Head Cover Bolts 9 8 1 0 87 in lb S Engine Bracket Bolts M8 25 2 5 18 R S Exhaust Pipe Manifold Holder Nuts 17 1 7 13 Front Camshaft Chain Guide Bolt Lowe
54. Valve Guide Removal e Remove Valve see Valve Removal Oil Seal Spring Seat e 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 GE15043BS1 C GE15028BS1 C GE15045BS1 C Valves Valve Guide Installation e Apply engine oil to the valve guide outer surface before installation e Heat the area around the valve guide hole to about 120 150 C 248 302 F CAUTION warp the cylinder head Soak the cylinder head and heat the oil Do not heat the cylinder head with a torch This Will e Assembly the valve guide driver parts holder and attach ment E e Insert the rod of the driver into the valve guide bore and hammer the end of the driver until it bottoms Valve Guide Driver Attachment E A Valve Guide Driver Holder B Valve Guide C Cylinder Head D Valve Guide Installed Height 13 mm 0 51 in E Special Tools Valve Guide Driver 57001 1564 Valve Guide Driver Attachment E 57001 1677 e Ream the valve guide with valve guide reamer A even if the old guide is reused Special Tool Valve Guide Reamer 5 57001 1204 ENGINE TOP END 5 27 512 6
55. e Install the master cylinder clamp with the triangular mark A upward e Tighten the upper clamp bolt B first and then the lower clamp bolt C There will be a gap at the lower part of the clamp after tightening Torque Clutch Master Cylinder Clamp Bolts 10 3 N m 1 1 kgf m 91 in Ib e Replace the washers that are on each side of the hose fitting with new ones e Tighten Torque Clutch Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft Ib e Replenish the clutch fluid into the reservoir and bleed the clutch line see Bleeding the Clutch Line e Check that the clutch line has proper fluid pressure and no fluid leakage Clutch Master Cylinder Disassembly e Refer to the Rubber Parts of Clutch Master Cylinder Slave Cylinder Replacement in the Periodic Maintenance chap ter Clutch Master Cylinder Assembly e Refer to the Rubber Parts of Clutch Master Cylinder Slave Cylinder Replacement in the Periodic Maintenance chap ter Clutch Master Cylinder Inspection e Disassemble the clutch master cylinder see Rubber Parts of Clutch Master Cylinder Slave Cylinder Replace ment in the Periodic Maintenance chapter Special Tool Inside Circlip Pliers 57001 143 e Check that there are no scratches rust or pitting on the inside of the master cylinder A and on the outside of the piston B the master cylinder or piston shows any damage re place them e Inspect the primary cup C and secondary cup D c
56. e Remove the key registration unit and connect the immo bilizer Kawasaki diagnostic system connector NOTE the ignition switch ON with the registered user key OCheck that the engine can be started using all regis tered user keys 16 92 ELECTRICAL SYSTEM Immobilizer System Equipped Models Spare User Key Registration Flow Chart 6 ECU confirms the Immobilizer Blinking Patterns and Number 0 2secon4 gt 0 4 Seecerd O Seecond gt 2 8 0 Seecend teecend 9222 0 2 leeeere gt 4 8h 19393 8 3 teecere gt ORL Seeceed 6 2029 2 0 2 020 2 2 2 lsscortd gt 7 00293919191 0202 8 3 3 teecesd 8 if 0202 22 2 59 2 9 1 0309103 0 3 9 3 isotone Connection of Amplifier Time of Transmitting and Receiving Signals 2 ECU confirms the following immobilizer Ampiifier Fadure Pattern 1 Master Key Collation Pattern 6 3 ECU confirms the following Master Key Code O Matching Unique Code 4 Key Registrabon Waiting Time Insert next key and tum ON within 15 seconds after previous key is turned OFF 5 ECU confirms the following O Matching Unique Code O Not Registered User Key O User key or not O Registered User Key is inserted Pattem 2 ELECTRICAL SYSTEM 16 93 Immobilizer System Equipped Models Case 2 When the ignition switch is faulty and to be replaced e Prepare a new ignition switch A and
57. e Tighten Torque Rear Master Cylinder Push Rod Locknut 17 2 N m 1 8 kgf m 13 ft Ib e Check the brake light switch operation see Brake Light Switch Operation Inspection in the Periodic Maintenance chapter Brake Pedal Removal e Remove Rear Master Cylinder Mounting Bolts A Right Front Footpeg Bracket Bolts B BRAKES 12 15 Brake Lever Brake Pedal e Remove Cotter Pin A Joint Pin B Rear Brake Light Switch Spring C Return Spring D e Remove the brake pedal bolt E and take out the brake pedal Brake Pedal Installation e Apply grease to the pivot shaft A and install the washer B e Install Brake Pedal C Washer D Brake Pedal Bolt E Torque Brake Pedal Bolt 8 8 N m 0 90 kgf m 78 in Ib e Hook the lower end of the rear brake light switch spring A on the pedal hook e Hook the upper end of the return spring B on the pedal hook e Replace the cotter pin with a new one e Insert the cotter pin A and bend the pin ends e Install the right front footpeg bracket Torque Front Footpeg Bracket Bolts 25 N m 2 5 kgf m 18 ft lb ODepress the brake pedal A and then align the bolts holes of the master cylinder B e Install the rear master cylinder mounting bolts Torque Rear Master Cylinder Mounting Bolts 25 N m 2 5 kgf m 18 16 e Check the brake pedal position see Brake Pedal Position Inspection 12 16 BRAKES Calipers Front Caliper Removal
58. entrer nennen 3 24 3 24 gia mte E EE rM 3 29 DFI System Troubleshooting Guide pp 3 32 Simus Me E 3 37 Selt chagnoasis 55 dendi E ate eS Satta 3 37 Selt diagnosis el o ates ee 3 38 Service Code Readirig ae e retten sete mt to te s etes pere deci raa 3 41 SSsrvies EASING sse 3 41 HN 3 43 Main Throttle Sensor Service Code 11 nennen 3 45 Main Throttle Sensor Removal Adjustment pp 3 45 Main Throttle Sensor Input Voltage Inspection pp 3 45 Main Throttle Sensor Output Voltage Inspection pp 3 47 Main Throttle Sensor Resistance Inspection pp 3 50 Inlet Air Pressure Sensor Service Code 12 sese 3 51 Inlet Air Pressure Sensor Removal pp 3 51 Inlet Air Pressure Sensor 3 51 Inlet Air Pressure Sensor Input Voltage Inspection 3 52 Inlet Air Pressure Sensor Output Voltage Inspection pp 3 53 Inlet Air Temperature Sensor Service Code 13 3 57 Inlet Air Temperature Sensor Removal lnstallation pp 3 57 Inlet Air Temperature Sensor Output Voltage 3 57 Inlet Air Temperature Sensor Resistance Insp
59. gt BK sensor BR BK lead Standard DC 0 63 0 65 V at idle throttle opening lf the output voltage is out of the range check the throttle input voltage of the main throttle sensor see Main Throttle Sensor Input Voltage Inspection in the Fuel System DFI chapter 2 20 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Remove the vacuum gauge hoses and install the rubber caps on the original position e For the California and Southeast Asia models install the vacuum hoses ORun the vacuum 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 Idle Speed Inspection e Start the engine and warm it up thoroughly e With the engine idling turn the handlebar to both sides A If handlebar movement changes the idle speed the throttle cables may be improperly adjusted or incorrectly routed or damaged Be sure to correct any of these conditions before riding see Throttle Control System Inspection and Cable Wire and Hose Routing section in the Appendix chapter A WARNING Operation with improperly adjusted incorrectly routed or damaged cables could result in an unsafe riding condition e Check the idle speed Idle Speed Standard 1 100 50 r min rpm If the idle speed is out of the specified range adjust it Idle Speed Adjustment e Start the engine and warm it
60. or warped replace it 6009025851 C Center Stand Sidestand Center Stand Removal Equipped Models e Remove Muffler Bodies see Muffler Body Removal in the Engine Top End chapter Spring A Bolts B Bolts C and Nuts Center Stand D Center Stand Installation Equipped Models e Apply grease to the sliding area A of the center stand B e Tighten the bolts C and lock them with the nuts Torque Center Stand Bolts 44 N m 4 5 kgf m 32 ft Ib e Hook the spring D so that the long spring end of it faces upward Olnstall the spring hook direction as shown in the figure Sidestand Removal e Raise the rear wheel off the ground with the stand e Remove Sidestand Switch Bolt A Spring B Sidestand Bolt C Sidestand D Sidestand Bracket Bolts E Sidestand Installation e Apply grease to the sliding area A of the sidestand B e Apply a non permanent locking agent to the threads of the sidestand bracket bolts C e Tighten the bolt and lock them with the nut Torque Sidestand Bracket Bolts 49 N m 5 0 kgf m 36 ft Ib Sidestand Bolt D 44 N m 4 5 kgf m 32 ft lb e Hook the spring E so that the long spring end of it faces upward Olnstall the spring hook direction as shown in the figure e Install the sidestand switch e Apply a non permanent locking agent to the threads of the switch bolt F and tighten it Torque Sidestand Switch Bolt 8 8 N m 0 90 kgf m 78 in Ib
61. 1 6145 in 41 009 41 016 mm 1 6145 1 6148 in 1 490 1 494 mm 0 0587 0 0588 in 1 494 1 498 mm 0 0588 0 0590 in 1 498 1 502 mm 0 0590 0 0591 in 83 994 84 006 mm 3 3068 3 3073 in 83 959 83 974 mm 3 3055 3 3061 in 0 020 0 047 mm 0 0008 0 0019 in 0 03 0 07 mm 0 0012 0 0028 in 0 02 0 06 mm 0 0008 0 0024 in 0 92 0 94 mm 0 0362 0 0370 in 1 01 1 03 mm 0 0398 0 0406 in 0 87 0 89 mm 0 0343 0 0350 in 0 97 0 99 mm 0 0382 0 0390 in 0 20 0 30 mm 0 0079 0 0118 in 0 40 0 55 mm 0 0157 0 0217 in 0 20 0 70 mm 0 0079 0 0276 in 5 74 6 00 mm 0 2260 0 2362 in 6 05 6 15 mm 0 238 0 242 in 84 10 mm 3 3110 in 83 81 mm 3 2996 in 0 17 mm 0 0067 in 0 16 mm 0 0063 in 1 02 mm 0 040 in 1 11 mm 0 044 in 0 80 mm 0 031 in 0 90 mm 0 035 in 0 6 mm 0 024 in 0 8 mm 0 031 in 1 0 mm 0 039 in 5 6 mm 0 220 in 6 25 mm 0 246 in 9 8 CRANKSHAFT TRANSMISSION Specifications Item Shift Fork Guide Pin Diameter Shift Drum Groove Width Standard Service Limit 6 9 7 0 mm 6 8 mm 0 272 0 276 in 0 268 in 7 05 7 20 mm 7 3 mm 0 278 0 283 in 0 287 in Connecting Rod Big End Bearing Insert Selection Con rod Big End Ctankpin Diameter Bearing Insert Inside Diameter MGE Marking g Size Color P
62. 2 6 PERIODIC MAINTENANCE Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non permanent locking agent or silicone sealant etc Letters used in the Remarks column mean AL Tighten the two clamp bolts alternately two times to ensure even tightening torque G Apply grease L Apply a non permanent locking agent M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts S Follow the specified tightening sequence Si Apply silicone grease SS Apply silicone sealant Fastener 90103 Remarks Nm fib Fuel System Air Cleaner Element Cover Bolts 61 in lb Air Cleaner Element Holder Screws 61 in lb Bypass Screws 1 8 in Ib Camshaft Position Sensor Bolt 87 in lb Crankshaft Sensor Bolts 52 in lb L Delivery Pipe Mounting Screws 44 Duct Clamp Bolts 18 in Ib Front Air Inlet Duct Mounting Bolts 87 Fuel Pump Bolts 87 in lb L S Gear Position Switch Lead Clamp Bolts 87 in lb Gear Position Switch Screws 26 in lb L Inlet Air Pressure Sensor Bracket Screws 31 in lb Middle Air Inlet Duct Clamp Bolts 26 in lb Middle Air Inlet Duct Mounting Bolts 87 in lb Oxygen Sensor Equipped Models 18 Rear Air Inlet Duct Mounting Bolts 87 in lb L Speed Sensor Bolt 35 in lb L Throttle Body Assy Holder Bolts 87 S
63. 6113158851 6 9 42 CRANKSHAFT TRANSMISSION Transmission e The drive shaft gears can be recognized by size the gear with the smallest diameter is 1st gear and the largest one is 6th gear Be sure that all parts are put back in the cor rect sequence and all circlips and washers are properly in place e Install the 3rd 4th gear onto the drive shaft with their oil holes aligned e Install the 6th gear bushing onto the drive shaft with their oil holes aligned e The output shaft gears can be recognized by size the gear with the largest diameter is 1st gear and the small est one is 6th gear Be sure that all parts are put back in the correct sequence and all circlips and washers are properly in place e Install the 5th and 6th gears onto the output shaft with their oil holes aligned e Install the 3rd 4th gear bushings onto the output shaft with their oil holes aligned e Fit the steel balls into the 5th gear holes in the output shaft aligning three oil holes A 5th Gear B Output Shaft C Steel Balls D CAUTION Do not apply grease to the balls to hold them in place This will cause the positive neutral finder mechanism to malfunction OAfter assembling the 5th gear with steel balls in place on the output shaft check the ball locking effect that the 5th gear doesn t come out of the output shaft when moving it up and down by hand e Check that each gear spins or slides freely on the trans mission
64. B Brake Discs Thickness Standard Front 4 8 5 2 mm 0 19 0 20 in Rear 5 8 6 2 mm 0 23 0 24 in Service Limit Front 4 5 mm 0 18 in Rear 5 5 mm 0 22 in Brake Disc Warp Inspection e Raise the front rear wheel off the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1608 OFor front disc inspection turn the handlebar fully to one side e Set up a dial gauge against the disc A as shown in the figure and measure disc runout while turning B the wheel by hand If runout exceeds the service limit replace the disc Disc Runout Standard TIR 0 15 mm 0 006 in or less Service Limit TIR 0 3 mm 0 01 in 6108017851 C 9108018851 C Brake Fluid Brake Fluid Level Inspection e Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter Brake Fluid Change e Refer to the Brake Fluid Change in the Periodic Mainte nance chapter Brake Line Bleeding The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action Air however is easily compressed When air enters the brake lines brake lever or pedal movement will be partially used in compressing the air This will make the lever or pedal feel spongy and there will be a loss in braking power A WARNING Be sure to bleed the air from the brake line when ever brake lever or
65. B ECU Connectors C e Insert the slits of the rubber protector to the projections A of the rear fender e Install Connector Holder A Relay Box B 3 98 FUEL SYSTEM DFI ECU e Install the plate A to the tool kit case B and tighten the bolts C e Insert the stopper D of the fuse box E into the groove of the tool kit case ECU Power Supply Inspection e Remove the ECU see ECU Removal e Visually inspect the ECU connectors If the connector is clogged with mud or dust blow it off with compressed air e Visually inspect the terminals A of the ECU connectors x lf the terminals of the main harness connectors are dam aged replace the main harness xIf the terminals of the ECU connectors are damaged re place the ECU e With the ECU connectors A connected check the fol lowing ground lead for continuity with the ignition switch OFF using a digital meter B and needle adapter set Special Tool Needle Adapter Set 57001 1457 ECU Grounding Inspection 17 39 or 52 Terminal lt Frame Ground 2 C 0 Q Engine Ground Frame Ground 2 C 0 Q If no continuity check the connectors the engine ground lead or main harness and repair or replace them if nec essary 9617234051 ECU e Check the ECU power source voltage with a digital meter A OPosition the terminal in accordance with terminal numbers of ECU connectors B in t
66. B e Tighten the bolts Middle Fairing Removal e Remove Lower Fairings see Lower Fairing Removal Fairing Covers see Fairing Cover Removal Inner Covers see Inner Cover Removal Fuel Tank Cover see Fuel Tank Removal in the Fuel System DFI chapter e Push the central pin and then remove the quick rivets A FRAME 15 11 15 12 FRAME Fairings e Remove Bolts A with Washer Turn Signal Lead Connector Disconnect e Remove each middle fairing OClear the hook B from the bracket e Remove Inner Fairing see Inner Fairing Removal Screws Bracket Turn Signal Light Middle Fairing Installation e Install the turn signal light to the middle fairing e Install the bracket and tighten the screws e Install the inner fairing see Inner Fairing Installation e Connect the turn signal lead connector e Hang the hook of the middle fairing to the bracket e Install Washers and Bolts Quick Rivets Removed Parts see appropriate chapters Windshield Removal e Remove Bolts A with Washer Windshield B FRAME 15 13 Fairings Windshield Installation e Put the front tongue A into the hollow B e Tighten Torque Windshield Mounting Bolts 0 42 N m 0 043 kgf m 3 7 in Ib Upper Fairing Removal e Remove Lower Fairings see Lower Fairing Removal Fairing Covers see Fairing Cover Removal Inner Covers see Inner Cover Removal Middle Fairings see Middle Fairing Removal Windshie
67. Brown LG Light Green V Violet CH Chocolate O Orange W White DG Dark Green P Pink Y Yellow G Green FUEL SYSTEM DFI 3 13 3 14 FUEL SYSTEM DFI System Terminal Numbers of ECU Connectors 4 7 4 6 4 5 4 4 4 3 4 2 4 114013 9 3 813 7 3 6135 60 59 5815 7 5 6I5 515 415 315 215 1150 4 9 48 17 16 15 14 13 12111 1019 8 7 6 5 413 2 1 3 413 3 3 2 3 1 30 2928 27 26252423 22 2 1201918 6GC17422CW2 Terminal Names CAN Communication Line Low Subthrottle Valve Actuator Subthrottle Valve Actuator Gear Position Switch Crankshaft Sensor Speed Sensor Power Supply to Sensors Inlet Air Temperature Sensor Vehicle down Sensor Unused Atmospheric Pressure Sensor Unused Fuel Pump Relay Battery Monitor Power Supply to ECU from Battery Unused Ground for Control System CAN Communication Line High Subthrottle Valve Actuator Subthrottle Valve Actuator External Communication Line Immobilizer KDS Crankshaft Sensor Unused Camshaft Position Sensor Water Temperature Sensor Main Throttle Sensor Subthrottle Sensor Inlet Air Pressure Sensor Oxygen Sensor Equipped Models Radiator Fan Relay Unused Power Supply to ECU from Battery Ignition Switch Ground for Sensors DFI System 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 E
68. C of the middle air inlet duct D e Apply a non permanent locking agent to the threads of the mounting bolts and tighten them Torque Rear Air Inlet Duct Mounting Bolts 9 8 N m 1 0 kgf m 87 in Ib FUEL SYSTEM DFI 3 127 3 128 FUEL SYSTEM DFI Air Line e Install the clamp bolts A so that bolt heads B faces direction as shown in the figure Left Clamp C Right Clamp D About 30 E Rear View F e Tighten Torque Middle Air Inlet Duct Clamp Bolts 2 9 N m 0 30 kgf m 26 in Ib Front and Middle Air Inlet Duct Removal e Remove the upper fairing see Upper Fairing Removal in the Frame chapter e Open the clamps A e Open the clamps A e Remove Bolts A Both Sides Front Air Inlet Duct B Rubber Seal C e Loosen the clamp bolts D on both sides Pull off the left and right middle air inlet ducts E to for ward Front and Middle Air Inlet Duct Installation NOTE OThe left middle air inlet duct has a L mark A and the right middle air inlet duct has a R mark Air Line e Insert the middle air inlet duct A into the rear air inlet duct until the line B align with the duct end C of rear air inlet duct D e Tighten Torque Middle Air Inlet Duct Mounting Bolts 9 8 N m 1 0 kgf m 87 in Ib e Install the clamp bolts A so that bolt heads B faces direction as shown in the figure Left Clamp C Right Clamp D About 30 E Rear Vi
69. Cover Removal e Pinching A the stopper B release it and push C the push rod D into the interior of tensioner body E e Pushing A the push rod slide the snap ring B into the groove C of smaller diameter from the groove D of larger diameter e Install the tensioner body so that the stopper A faces upward e Tighten the tensioner mounting bolts Torque Camshaft Chain Tensioner Mounting Bolts 9 8 N m 1 0 kgf m 87 in Ib e Turn the crankshaft 2 turns clockwise to allow the ten sioner to expand and recheck the camshaft chain timing ENGINE TOP END 5 17 Camshaft Camshaft Chain Camshaft Removal e Remove Cylinder Head Cover see Cylinder Head Cover Re moval Crankshaft Sensor Cover see Crankshaft Sensor Re moval in the Electrical System chapter e Position the crankshaft at 1 4 piston TDC TDC mark A for 1 4 Pistons Timing Mark Crankcase Halves Mating Surface B e Remove Camshaft Chain Tensioner see Camshaft Chain Ten sioner Removal Camshaft Cap Bolts A Upper Chain Guide B Camshaft Caps C Camshafts D e Stuff a clean cloth into the chain tunnel to keep any parts from dropping into the crankcase e Remove Cam Sprocket Mounting Bolts A Cam Sprocket CAUTION The crankshaft may be turned while the camshafts are removed Always pull the chain taut while turn ing the crankshaft This avoids kinking the chain on the lower crankshaft sprocket A kinked chain
70. Exploded View WHEELS TIRES 10 3 Exploded View No Fastener pone Remarks N m kgf m ft Ib 1 Front Axle Clamp Bolts 20 2 0 15 AL 2 Front Axle Nut 127 13 0 93 7 3 Rear Axle Nut 127 13 0 93 7 4 Caliper Bracket ABS Equipped Models AL Tighten the two clamp bolts alternately two times to ensure even tightening torque HG Apply high temperature grease R Replacement Parts WL Apply soap and water solution or rubber lubricant 10 4 WHEELS TIRES Specifications Item Wheels Rims Rim Runout Axial Radial Axle Runout 100 mm 3 94 in Wheel Balance Balance Weights Standard TIR 0 5 mm 0 02 in or less TIR 0 8 mm 0 03 in or less TIR 0 03 mm 0 0012 in or less 10 g 0 35 oz or less 10 g 0 35 oz 20 g 0 71 oz Service Limit TIR 1 0 mm 0 04 in TIR 1 0 mm 0 04 in TIR 0 2 mm 0 008 in Tread Depth Front Rear 290 kPa 2 9 kgf cm 42 psi 3 8 mm 0 15 in 4 8 mm 0 19 in 30 g 1 06 oz Rim Size Front 17 x 3 50 SS Rear 17 x 6 00 Tires Air Pressure when Cold Front Up to 180 kg 397 Ib load 290 kPa 2 9 kgf cm 42 psi Rear Up to 180 kg 397 Ib load 1 mm 0 04 in AT CH DE 1 6 mm 0 06 in Up to 130 km h 80 mph 2 mm 0 08 in Over 130 km h 80 mph 3 mm 0 12 in Standard Tires Front Rear Make Type Size BRIDGESTONE BATTLAX BT014 F
71. L 45 mm 20 2 0 S 15 Crankcase Bolt 6 L 65 mm 12 1 2 S 16 Crankcase Bolt M6 L 50 mm 12 1 2 S 17 Crankcase Bolts M6 L 40 mm 12 1 2 106 in lb S 18 Crankcase Bolts M6 L 25 mm 12 1 2 106 in lb S 19 Drive Shaft Cover Bolts 25 2 5 18 L 20 Gear Position Switch Lead Clamp Bolts 9 8 1 0 87 21 Oil Jet Nozzles 2 9 0 30 26 in lb L 22 Oil Passage Plugs 20 2 0 15 L 23 Shift Drum Bearing Holder Screws 4 9 0 50 43 16 L 24 Timing Rotor Bolt 39 4 0 29 25 Do not apply any grease or oil G Apply grease L Apply a non permanent locking agent LG Apply liquid gasket M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts S Follow the specified tightening sequence 9 4 CRANKSHAFT TRANSMISSION Exploded View 08102254845 C CRANKSHAFT TRANSMISSION 9 5 Exploded View No Fastener Remarks N m kgf m ft Ib 1 Balancer Shaft Clamp Bolts 9 8 1 0 87 in lb 2 Balancer Shaft Clamp Lever Bolts 25 2 5 18 3 Gear Position Switch Screws 2 9 0 30 26 in lb L 4 Gear Positioning Lever Bolt 12 1 2 106 in lb 5 Shift Drum Cam Holder Bolt 12 1 2 106 in lb L 6 Shift Pedal Bolt 6 9 0 70 61 in lb 7 Shift Shaft Return Spring Pin 29 3 0 21 L 8 Starter Clutch Shaft Bolt 9 8 1 0 87 in lb L 9 Starter Clutch Shaf
72. PERIODIC MAINTENANCE 2 49 Periodic Maintenance Procedures Bolt Nut and Fastener to be checked Engine Clutch Lever Pivot Bolt Locknut Engine Mounting Bolts and Nuts Exhaust Pipe Manifold Holder Nuts Muffler Body Clamp Bolts Muffler Body Mounting Bolts Wheels Front Axle Clamp Bolts Front Axle Nut Rear Axle Nut Rear Axle Nut Cotter Pin Brakes Brake Lever Pivot Bolt Locknut Brake Pedal Bolt Caliper Mounting Bolts Front Master Cylinder Clamp Bolts Rear Master Cylinder Joint Cotter Pin Rear Master Cylinder Mounting Bolts Suspension Front Fork Clamp Bolts Rear Shock Absorber Nuts Swingarm Pivot Shaft Locknut Swingarm Pivot Shaft Nut Tie Rod Nuts Uni Trak Rocker Arm Nut Steering Handlebar Holder Bolts Steering Stem Head Nut Others Center Stand Bolts Equipped Models Footpeg Bracket Bolts Sidestand Bolt Replacement Parts Air Cleaner Element Replacement NOTE Oln dusty areas the element should be replaced more frequently than the recommended interval OAfter riding through rain or on muddily roads the ele ment should be replaced immediately A WARNING If dirt or dust is allowed to pass through into the throttle body assy the throttle may become stuck possibly causing an accident CAUTION If dirt gets through into the engine excessive en gine wear and possibly engine damage will occur 2 50 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Remove the fuel tank cover see Fue
73. Relay Box Fuel Pump Relay 12 ECU Main Relay 13 Fuse Box 2 14 ECU Fuse 15A 15 Ignition Fuse 10 A 16 Ignition Switch 17 Engine Stop Switch 18 Fuel Injector 1 19 Fuel Injector 2 20 Fuel Injector 3 21 Fuel Injector 4 22 Water proof Joint 1 Throttle Grip and Cables Free Play Inspection e Refer to the Throttle Control System Inspection in the Pe riodic Maintenance chapter Free Play Adjustment e Refer to the Throttle Control System Inspection in the Pe riodic Maintenance chapter Cable Installation e Install the throttle cables in accordance with the Cable Wire and Hose Routing section in the Appendix chapter e Install the lower ends of the throttle cables in the cable bracket on the throttle body assy after installing the upper ends of the throttle cables in the grip e After installation adjust each cable properly see Throttle Control System Inspection in the Periodic Maintenance chapter A WARNING Operation with incorrectly routed or improperly ad justed cables could result in an unsafe riding con dition Cable Lubrication e Refer to the Chassis Parts Lubrication in the Periodic Maintenance chapter FUEL SYSTEM 3 117 3 118 FUEL SYSTEM DFI Throttle Body Assy Idle Speed Inspection Adjustment e Refer to the Idle Speed Inspection Adjustment in the Pe riodic Maintenance chapter Throttle Bore Cleaning e Check the throttle bore for cleanliness as follow
74. and fuel symbol C appear alternately in the display OThis display is the warning message indication If the display function does not work replace the meter assembly e Disconnect the battery to disappear the warning message indication Check 13 Fuel Gauge Inspection e Connect the leads in the same circuit as Check 2 e Connect the resistor A about 1 kO to the terminal 15 and the battery terminal e Connect the variable rheostat B to the terminal 16 and the battery terminal e Check that the number of segments matches the resis tance value of the variable rheostat OWhen the terminal 16 is connected one segment in the fuel level gauge should appear about every 15 seconds Variable Rheostat Resistance Q 10 6 200 1 If the display function does not work replace the meter assembly Display Segments A FUEL Low on 2 45 y 5 12 00 221 7 GP170960 y ne le34d5b5k 12 00 m GP17588B S LP 180 140 f 120 TOD 2 40 E 18 CERN ao n 18 AS E H 10345 12 34 H 3 23 m O i GP17095C Meter Gauge Indicator Unit Check 14 Speedometer Inspection e Connect the leads in the same circuit as Che
75. e Loosen the upper front fork clamp bolt and lower front fork clamp bolts C e With a twisting motion work the fork leg down and out GM04359BS1 C Front Fork Front Fork Installation e Install the fork so that the top end A of the outer tube as shown in the figure 21 5 mm 0 85 in B e Tighten Torque Front Fork Clamp Bolts Lower 30 N m 3 1 kgf m 22 ft lb Front Fork Top Plugs 22 N m 2 2 kgf m 16 ft Ib Front Fork Clamp Bolts Upper 20 N m 2 0 kgf m 15 16 NOTE OTighten the top plug before tightening the upper front fork clamp bolt O Tighten the two clamp bolts alternately two times to en sure even tightening torque e Install the removed parts see appropriate chapters e Adjust Spring Preload see Spring Preload Adjustment Rebound Damping Force see Rebound Damping Force Adjustment Compression Damping Force see Compression Damp ing Force Adjustment Front Fork Oil Change e Remove the front fork see Front Fork Removal e Hold the inner tube lower end in a vise e Unscrew the top plug A out of the outer tube SUSPENSION 13 11 8 04360851 C 13 12 SUSPENSION Front Fork e Install the clamps A as shown in the figure NOTE OSet the clamps so that the cutout B of the upper side does not touch the tongue shape of stopper pull up the outer tube C to hold it by the clamps and then tighten the two bolts D The outer tube is use
76. is tightest e Measure the vertical movement chain slack A midway between the sprockets lf the chain slack exceeds the standard adjust it Chain Slack Standard 32 38 mm 1 3 1 5 in Drive Chain Slack Adjustment e Remove the cotter pin A and loosen the axle nut B e Loosen the both chain adjuster locknuts C the chain is too loose turn out the right and left chain adjusters D evenly xlf the chain is too tight turn in the right and left chain adjusters evenly and kick the wheel forward e Turn both chain adjusters evenly until the drive chain has the correct amount of slack To keep the chain and wheel properly aligned the notch E on the right wheel align ment indicator F should align with the same swingarm mark or position G that the left indicator notch aligns with A WARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition e Tighten both chain adjuster locknuts securely e Tighten the axle nut Torque Rear Axle Nut 127 N m 13 0 kgf m 93 7 ft Ib e Turn the wheel measure the chain slack again atthe tight est position and readjust if necessary GK04060781 o 6512021851 o PERIODIC MAINTENANCE 2 33 Periodic Maintenance Procedures e Insert a new cotter pin A NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle tighten th
77. moval in the Clutch chapter Radiator see Radiator and Radiator Fan Removal in the Cooling System chapter Muffler Bodies see Muffler Body Removal Installation in the Engine Top End chapter Exhaust Pipe see Exhaust Pipe Removal in the Engine Top End chapter Shift Pedal see Shift Pedal Removal in the Crank shaft Transmission chapter e Disconnect Sidestand Switch Lead Connector A Oil Pressure Switch Gear Position Switch Leads Con nector B Alternator Lead Connector see Alternator Cover Re moval in the Electrical System chapter Starter Motor Cable Terminal Nut see Starter Motor Re moval in the Electrical System chapter ENGINE REMOVAL INSTALLATION 8 5 Engine Removal Installation e Remove Clamp A Bolt B Subframe Bracket Bolt C Subframe Bolts D e Remove the subframe E with the clutch pipe F e Disconnect the connector G e Remove Throttle Body Subharness Connector A Disconnect Breather Hose B Fuel Hose C on the Delivery Pipe Throttle Cable Lower Ends D e Remove the bracket bolt A e Disconnect Air Switching Valve Connector B Stick Coil Subharness Connector C e Remove Bolt A and Bracket B Air Switching Valve see Air Switching Valve Removal in the Engine Top End chapter Bracket see Air Suction Valve Removal in the Engine Top End chapter e Remove the engine sprocket A see Engine Sprocket Removal in the Final Drive chapter e Support the engin
78. see ECU Removal Installation 3 96 FUEL SYSTEM DFI ECU ECU Identification OMost countries have their own regulations so each ECU has different characteristic So do not confuse ECU with each other and use only the ECU for your model Other wise the motorcycle cannot clear the regulation ECU Identification Part Number A Specification 21175 0142 80174400651 US except CAL without Immobilizer CA without Immobilizer 21175 0152 US CAL without Immobilizer 21175 0153 21175 0156 MY with Immobilizer AU with Immobilizer 21175 0191 SEA with Immobilizer 21175 0154 WVTA FULL H with Immobilizer GB WVTA FULL H with Immobilizer 21175 0155 ECU Removal WVTA 78 2 H with Immobilizer CAUTION Never drop the ECU especially on a hard surface Such a shock to the ECU can damage it e Remove the seat see Seat Removal in the Frame chap ter e Pull the hook A to lift up the lid B of the tool kit case e Remove the tool kit A e Remove Fuse Box A Bolts B and Plate Tool Kit Case C FUEL SYSTEM DFI 3 97 ECU e Remove the relay box A e Lift up the ECU B with rubber protector C e Remove ECU Connectors A ECU B e Refertothe Immobilizer System Parts Replacement in the Electrical System chapter for the immobilizer models ECU Installation e Install ECU A In rubber protector
79. ter to find the Ignition Coil section Whenever you see these WARNING and CAUTION symbols heed their instructions Always follow safe operating and maintenance practices A WARNING This warning symbol identifies special instructions or procedures which if not correctly followed could result in per sonal injury or loss of life CAUTION This caution symbol identifies special instructions or procedures which if not strictly observed could result in dam age 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 informa tion NOTE OThis note symbol indicates points of par ticular interest for more efficient and con venient operation e Indicates a procedural step or work to be done Olndicates 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 inspec tion in the procedural step or sub step it fol lows 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 spec ified tightening torque oil grease or a locking agent during assembly GENERAL INFORMATION 1 1 General Information Table of Contents B
80. 0984 in 92200 0332 3 95 4 00 mm 0 1555 0 1575 in NOTE OFor the crankcase only crankcase set P No 14001 0120 be available as spare parts e Check the width of the crankshaft 3 main journal e Measure the crankshaft 3 main journal width A If the measurement exceeds the standard replace the crankshaft B Crankshaft 3 Main Journal Width Standard 27 45 27 50 mm 1 0807 1 0827 in Crankshaft Runout Inspection e Measure the crankshaft runout If the measurement exceeds the service limit replace the crankshaft Crankshaft Runout Standard TIR 0 03 mm 0 0012 in or less Service Limit TIR 0 08 mm 0 0031 in Crankshaft Main Bearing Insert Journal Wear Inspection e Using a plastigage press gauge A measure the bear ing insert journal B clearance NOTE O Tighten the crankcase bolts to the specified torque see Crankcase Assembly ODo not turn the crankshaft during clearance measure ment 61050304 OJournal clearance less than 0 025 mm 0 00098 in can not be measured by plastigage however using genuine parts maintains the minimum standard clearance 21 9 24 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods Crankshaft Main Bearing Insert Journal Clearance Standard 0 031 0 063 mm 0 0012 0 0025 in Service Limit 0 09 mm 0 0035 in x If the clearance is within the standard no bearing replace ment is required x If the cl
81. 154 0 N m 15 7 kgfm 114 ft lb 7 500 r min rpm WVTA 78 2 119 0 N m 12 1 kgf m 87 8 ft lb 94 500 r min rpm CA CAL US FI Fuel Injection MIKUNI 44EIDW x 4 Electric starter Battery and coil transistorized Electronically advanced digital igniter in ECU From 10 BTDC 91 100 r min rpm NGK CR9EIA 9 Left to right 1 2 3 4 1 2 4 3 General Specifications GENERAL INFORMATION 1 11 Items ZX1400C8F C9F ZX1400D8F D9F Valve Timing Inlet Open 41 BTDC Close 71 ABDC Duration 292 Exhaust Open 64 BBDC Close 34 ATDC Duration 278 Lubrication System Forced lubrication wet sump with cooler Engine Oil Type API SE SF or SG SH SJ or SL with JASO MA MA1 MA2 Viscosity SAE 10W 40 Capacity 4 5 L 4 8 US qt Drive Train Primary Reduction System Type Reduction Ratio Clutch Type Transmission Type Gear Ratios 1st 2nd 3rd 4th 5th 6th Final Drive System Type Reduction Ratio Overall Drive Ratio Gear 1 556 84 54 Wet multi disc 6 speed constant mesh return shift 2 625 42 16 1 947 37 19 1 545 34 22 1 333 32 24 1 154 30 26 1 036 29 28 Chain drive 2 412 41 17 3 886 Top gear Frame Type Caster Rake Angle Trail Front Tire Type Size Rim Size Press backbone 23 94 mm 3 70 in Tubeless 120 70 ZR17 M C 58W 17 x 3 50 1 12 GENERAL INFORMATION General Specifications Items ZX1
82. 20 in Commutator Cleaning and Inspection e Smooth the commutator surface A if necessary with fine emery cloth B and clean out the grooves e Measure the diameter A of the commutator B If the commutator diameter is less than the service limit replace the starter motor with a new one Commutator Diameter Standard 28 mm 1 10 in Service Limit 27 mm 1 06 in Armature Inspection e Using the x 1 O hand tester range measure the resis tance between any two commutator segments A Special Tool Hand Tester 57001 1394 lf there is a high resistance or no reading between any two segments a winding is open and the starter motor must be replaced e Using the highest hand tester range measure the resis tance between the segments and the shaft B xIf there is any reading at all the armature has a short and the starter motor must be replaced NOTE OEven if the foregoing checks show the armature to be good it may be defective in some manner not readily detectable with the hand tester If all other starter motor and starter motor circuit components check good but the starter motor still does not turn over or only turns over weakly replace the starter motor with a new one ELECTRICAL SYSTEM 16 55 62118411 6211061051 6 6211060851 6 16 56 ELECTRICAL SYSTEM Electric Starter System Brush Lead Inspection e Using the x 1 O hand tester range measure the
83. 25 N m 2 5 kgf m 18 ft lb 9 38 CRANKSHAFT TRANSMISSION Transmission Shift Pedal Removal e Remove Shift Lever Bolt A Shift Lever B Shift Pedal Installation e Install the shift pedal OAlign A the punch mark B on the shift shaft with the upper surface C of shift lever slit e Tighten the shift pedal bolt securely Torque Shift Pedal Bolt 6 9 N m 0 70 kgf m 61 in Ib External Shift Mechanism Removal e Remove Shift Pedal see Shift Pedal Removal Snap Ring A and Washer B Clutch see Clutch Removal in the Clutch chapter e Remove the shift shaft assembly A while pulling the shift mechanism arm e Remove Gear Positioning Lever Bolt A Gear Positioning Lever B Collar and Spring 9113286851 CRANKSHAFT TRANSMISSION 9 39 Transmission External Shift Mechanism Installation e Install the gear positioning lever A as shown in the figure Spring B Collar C Bolt D e Tighten Torque Gear Positioning Lever Bolt 12 N m 1 2 kgf m 106 in Ib 6113288851 C External Shift Mechanism Inspection e Examine the shift shaft A for any damage xlf the shaft is bent straighten or replace it xIf the serration B are damaged replace the shaft xIf the springs C are damaged in any way replace them xIf the shift mechanism arm D is damaged in any way replace the shaft e Check the return spring pin A is not loose
84. 3 Exploded View Torque No Fastener Nm kgfm Remarks 1 Front Axle Clamp Bolts 20 2 0 15 AL 2 Front Fork Bottom Allen Bolts 23 2 3 17 L 3 Front Fork Clamp Bolts Lower 30 3 1 22 AL 4 Front Fork Clamp Bolts Upper 20 2 0 15 5 Front Fork Top Plugs 22 2 2 16 6 Piston Rod Nuts 28 2 9 21 7 Inner Tube ABS Equipped Models L Tighten the two clamp bolts alternately two times to ensure even tightening torque G Apply grease L Apply a non permanent locking agent R Replacement Parts 13 4 SUSPENSION Exploded View Exploded View SUSPENSION 13 5 No Fastener 101906 Remarks N m kgf m ft Ib 1 Rear Shock Absorber Nut Lower 34 3 5 25 2 Rear Shock Absorber Nut Upper 34 3 5 25 Swingarm Pivot Shaft 20 2 0 15 4 Swingarm Pivot Shaft Locknut 98 10 0 72 3 5 Swingarm Pivot Shaft Nut 108 11 0 79 7 6 Tie Rod Nuts 59 6 0 44 7 Uni Trak Rocker Arm Nut 34 3 5 25 G Apply grease R Replacement Parts 13 6 SUSPENSION Specifications Front Fork Per One Unit Fork Inner Tube Diameter Item Air Pressure Rebound Damper Setting Compression Damper Setting Fork Spring Preload Setting Fork Oil Viscosity Amount Fork Oil Level Fork Spring Free Length Standard 43 mm 1 7 in Atmospheric pressure Non adjustable 5th click from the 1st click of the fully clockwise position Usable Range 0
85. 3 Taillight Fuse 10 3 Ignition Fuse 10 4 Horn Fuse 10A 5 Headlight Fuse Hi 15A 8 Headlight Fuse Lo 15 LEFT SWITCH HOUSING CONNECTIONS Turn Signal Switch GY Color Color BK WBK Y Color TE Released eee r EE W2L03418W5 C Wiring Diagram CA Gear Position Sidestand Speed Water Switch Sensor Temperature eil Sensor Pressure Switch 1 E 1 1 T DT Alternator rT vi Inlet m Air LT Temperature 7 3 NES dernier Rectifier xm em 5 Water proof Joint 2 555 g B 1 ELECTRICAL SYSTEM 16 17 CAL and US Models Subthrottle Valve Crankshaft Actuator Sub Main MEN Sensor throttle Throttle Pesia Sensor sensore Se Fuel Injectors 1 2 3 4 m we BL R We BL 8 wR BL 8K wR re Atmospheric Pressure Sensor wR BL R 81 6 BL BK BL Y BR BK 1 water proof 478K ue Hitt Bk R R amp BL BK 81 6 BL R BK Y L4 wer wy WR oy Relay Box Relay Box Fan Relay Headlight Circuit Relay ECU Main Relay Fuel Pump Relay Starter Circuit Relay anon IGNITION SWITCH CONNECTIONS R
86. 3 Turn Signal Switch a 4 Dimmer Switch Fuse Sensor 5 Starter Lockout Switch 6 Passing Button Fuse Box 1 Fan Fuse 15 ECU Fuse 15 Turn Signal Relay Fuse 10A Headlight Relay Fuse 10A Taillight and Horn Fuse 10 Oxygen Sensor Heater Fuse 10A Headlight Fuse Hi 15 Headlight Fuse Lo 15 ABS ECU Fuse 10A Panos LEFT SWITCH HOUSING CONNECTIONS Turn Signal Switch Dimmer Switch Starter Lockout Switch Passing Button Color BK WB GY Color R BKBL Y R Y Color BK R Color BL YR BK O Clutch Lever Push a o Push a a Lo a a O L Released PFF Push PFF Push ABS Motor Relay Fuse 30A ABS Solenoid Valve Relay Fuse 20A Ignition Fuse 10A W2L0344DW5 C ELECTRICAL Wiring Diagram ABS Equipped Models Other than MY Model Subthrottle SYSTEM 16 25 Inlet Sub Main Air throttle Throttle Pressure Sensor Sensor Sensor Oxygen Gear Position Valve Sidestand Speed Water Saitek Switoh Crankshaft actuator Switch Sensor Temperature oil ET Sensor EE on Sensor Pressure Switch SRD S 1 Fuel Injectors 96 1 1 1 2 3 84 D 9 7 See m mammi 5 25 a 2247 T 525 Air ove so odor Temperature 70204 Sensor pr MM 11 Pressure Page 6 zZ Z 53 Water proof Sensor 1 Joint 2 6 688 2 ga H ri
87. 51 Stick coil 1 malfunction wiring open or short 52 Stick coil 2 malfunction wiring open or short 53 Stick coil 3 malfunction wiring open or short 54 Stick coil 4 malfunction wiring open or short 62 Subthrottle valve actuator malfunction wiring open or short 67 Oxygen sensor heater malfunction wiring open or short Equipped Models 75 ECU main relay malfunction relay is stuck Notes OThe 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 OWhen 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 FUEL SYSTEM DFI 3 43 OThe ECU takes the following measures to prevent engine damage when the DFI ignition or immo bilizer system parts have troubles Service Output Signal Usable Codes EARS Range or Criteria Backups If the main throttle sensor system fails the signal is out of the usable range wiring short 11 Main Throttle voltage or open the ECU locks ignition timing into the Sensor 0 2 4 8V Meise dap 7 ignition timing at closed throttle position and sets the DFI in the D J method nectar neri pressit If the inlet air pressure sensor system fails the 12 Pressure Absolute signal Pv is out of the usabl
88. 8 kgf m 13 ft lb e Bleed the brake line see Brake Line Bleeding e Check the brake for good braking power no brake drag and no fluid leakage e Install the removed parts see appropriate chapters ABS Hydraulic Unit Inspection e Remove the ABS hydraulic unit see ABS Hydraulic Unit Removal e Visually inspect the ABS hydraulic unit x Replace the ABS hydraulic unit if any of them are cracked or otherwise damaged e Visually inspect the connector terminals A Replace the ABS hydraulic unit or main harness if either of the terminals are cracked bent or otherwise damaged lf the ABS hydraulic unit connector is clogged with mud or dust blow it off with compressed air Front Wheel Rotation Sensor Removal CAUTION The wheel rotation sensor should be handled care fully never struck sharply with a hammer or al lowed to fall on a hard surface since the wheel rota tion sensor is precision made Be careful not to get water or mud on the wheel rotation sensor Do not try to disassemble or repair the wheel rota tion sensor 9 exe GL14104BS2 C Anti Lock Brake System Equipped Models e Remove Right Middle Fairing see Middle Fairing Removal in the Frame chapter Connector A Disconnect Clamps B e Remove Bolts A Bracket Bolt B Clamps C Front Wheel Rotation Sensor D Front Wheel Rotation Sensor Installation e Installation is the reverse of
89. 875702215 875711235 Valve Spring Compressor Assembly Valve Seat Cutter Holder Bar 57001 241 57001 1128 875702415 875711285 Valve Seat Cutter 45 535 Valve Seat Cutter 45 530 57001 1116 57001 1187 8 5711165 875711875 Valve Seat Cutter 32 30 Valve Guide Arbor 5 57001 1120 57001 1203 T571120ST C Ua s Valve Seat Cutter 32 35 Valve Guide Reamer 5 57001 1121 57001 1204 ST5711218T C 7571204ST C 5 10 ENGINE TOP END Special Tools and Sealant Valve Seat Cutter Holder 5 57001 1208 7571208ST C Valve Seat Cutter 60 533 57001 1334 Valve Guide Driver 57001 1564 875713345 6 875715645 C Valve Spring Compressor Adapter 24 57001 1586 ST571586ST Compression Gauge Adapter M10 x 1 0 57001 1601 ST571601ST C L Shape Hose 57001 1606 zx Valve Guide Driver Attachment E 57001 1677 7571606ST C 75716778T 6 Kawasaki Bond Silicone Sealant 92104 0004 es 879200045 ENGINE TOP END 5 11 Clean Air System Air Suction Valve Removal e Remove Middle Fairings see Middle Fairing Removal in the Frame chapter Bolt A Pull out the hoses e Disconnect the connector B e Remove the air switching valve C with the hoses e Remove the following from the bracket A Rivets B Bolts C
90. Assy Removal in the Fuel System DFI chapter Thermostat Housing A see Thermostat Removal in the Cooling System chapter Oil Cooler B see Oil Cooler Removal in the Engine Lubrication System chapter Fitting C Hoses D O rings E Apply grease to the new O rings and install them e Install the new hoses and tighten the clamps securely Torque Radiator Water Hose Clamp Screws 2 0 N m 0 20 kgf m 18 in Ib e Fill the coolant see Coolant Change e Check the cooling system for leaks GSO6042BS3 PERIODIC MAINTENANCE 2 55 Periodic Maintenance Procedures Clutch Hose and Pipe Replacement CAUTION Clutch fluid quickly ruins painted plastic surfaces any spilled fluid should be completely washed away immediately e Remove the left middle fairing see Middle Fairing Re moval in the Frame chapter e Remove the clutch hose banjo bolts A e When removing the clutch hose take care not to spill the clutch fluid on the painted or plastic parts e When removing the clutch hose B temporarily secure the end of the clutch hose to some high place to keep fluid loss to a minimum e Immediately wash away any clutch fluid that spills e There are washers on each side of the clutch hose fittings Replace them with new ones when installing e Tighten Torque Clutch Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft Ib e When installing the hose avoid sharp bending kinking flatting or twistin
91. Bypass Screws 0 20 N m 0 020 kgf m 1 8 in Ib CAUTION Do not over tighten them They could be damaged requiring replacement e Remove Bypass Screw Spring B Washer C O ring D e Check the bypass screw and its hole for carbon deposits If any carbons accumulate wipe the carbons off from the bypass screw and the hole using a cotton pad penetrated with a high flash point solvent e Replace the O ring with a new one e Check the tapered portion E of the bypass screw for wear or damage xIf the bypass screw is worn or damaged replace it e Turn in the bypass screw until it seats fully but not tightly Torque Bypass Screws 0 20 N m 0 020 kgf m 1 8 in Ib A 6505015851 6 e Back out the same number of turns counted when first turned in This is to set the screw to its original position NOTE CA throttle body has different turns out of the bypass screw for each individual unit On setting the bypass screw use the turns out determined during disassem bly e Repeat the same procedure for other bypass screws e Repeat the synchronization the vacuums are correct check the output voltage of the main throttle sensor see Main Throttle Sensor Output Voltage Inspection in the Fuel System DFI chapter Special Tool Throttle Sensor Setting Adapter 57001 1538 Main Throttle Sensor Output Voltage Connections to Adapter Digital Meter R sensor Y W lead Digital Meter
92. CA ZX1400C8F Mark KHI M 117 Ed uin AU ZX1400C8F Mark KHI K 528 MY EPA Noise Emission ZX1400C8F D8F Control Information Honeycomb Type Honeycomb Type Catalyst Catalyst WVTA FULL H ZX1400C8F D8F P No 18091 0516 WVTA FULL H ZX1400C8F D8F n P No 18091 0518 WVTA 78 2 H ZX1400C8F D8F Mark KHI M 118 SEA Mark KHI K 528 ZX1400C8F TH ZX1400C9F EPA Noise Emission Control Information Manifold Mark Position A Muffler Body Mark Position B Manifold with Hole C for Oxygen Sensor D GE24213BN2 C ENGINE TOP END 5 7 Exhaust System Honeycomb Type Catalyst Positions A GE240188 6 GE24244882 C 5 8 ENGINE TOP END Specifications Item Camshafts Cam Height Exhaust Inlet Camshaft Journal Camshaft Cap Clearance Camshaft Journal Diameter Camshaft Bearing Inside Diameter Camshaft Runout Standard 34 442 34 556 mm 1 3560 1 3605 in 35 042 35 156 mm 1 3796 1 3841 in 0 038 0 081 mm 0 0015 0 0032 in 23 940 23 962 mm 0 9425 0 9434 in 24 000 24 021 mm 0 9449 0 9457 in TIR 0 02 mm 0 0008 in or less Service Limit 34 34 mm 1 352 in 34 94 mm 1 376 in 0 16 mm 0 0063 in 23 91 mm 0 941 in 24 08 mm 0 948 in TIR 0 1 mm 0 004 in Cylinder Head Cylinder Compression Valve Clearance Exhaust Inlet Valve Head Thickness Exhaust Inlet Valve Stem Bend Valve Stem
93. Coil Primary Peak Voltage 16 47 Spatk Plug Removal sitse ose tote aped ma ial dus beo oi 16 47 Spark Plug Installation att esa that Bone ut aeu lr 16 47 Spark Plug Condition Inspection s s sco toe eode a eae 16 48 Interlock Operation Inspection nennen etn rer ei erra ceeeimncenane 16 48 IC lgriter InspeGtloras eiie 16 49 16 2 ELECTRICAL SYSTEM Electric Starter System T wend es Sarthe Er 16 52 Starter Motor 16 52 Starter Motor InstallatiOTis to tto ee etd 16 52 Starter Motor DisassSermibly mme pet ien ee 16 53 Starter Motor Assembly sucio i 16 53 Brush Inspection sca eun er p Rede hieu 16 55 Commutator Cleaning and Inspectigm 16 55 Armature IS DOO Ren a en Deos eds 16 55 Br shbead eio educi tp fd ale ne Cone dade 16 56 Right hand End Cover Assembly Inspection 16 56 starter Relay InsSpectlofy usate 16 56 SS SUT eat ear std t cde uia ue ach Aes deen si d E 16 58 Headlight Beam Horizontal 0 011 16 58 Headlight Beam Vertical Adl slImiglit uisi ede gaben 16 58 Headlight Bulb
94. FUEL SYSTEM DFI Exploded view Jes SPR 802327885 e Kise were ae s on D o FUEL SYSTEM DFI 3 7 Exploded View No Fastener Remarks N m kgf m ft Ib 1 Bypass Screws 0 20 0 020 1 8 in lb 2 Camshaft Position Sensor Bolt 9 8 1 0 87 in lb 3 Crankshaft Sensor Bolts 5 9 0 60 52 in lb L 4 Delivery Pipe Mounting Screws 5 0 0 51 44 in lb 5 Gear Position Switch Lead Clamp Bolts 9 8 1 0 87 in lb 6 Gear Position Switch Screws 26 in lb L 7 Inlet Air Pressure Sensor Bracket Screws 31 in lb 8 Oxygen Sensor Equipped Models 25 2 5 18 9 Speed Sensor Bolt 35 L 10 Throttle Body Assy Holder Bolts 87 inb S 11 Body Assy Holder Clamp Bolts 18 inb 12 Vehicle down Sensor Bolts 52 in lb 13 Water Temperature Sensor 25 2 5 18 14 Oxygen Sensor Equipped Models 15 Throttle Cable Accelerator 16 Throttle Cable Decelerator CL Apply cable lubricant EO Apply engine oil G Apply grease L Apply a non permanent locking agent R Replacement Parts S Follow the specified tightening sequence SS Apply silicone sealant 3 8 FUEL SYSTEM DFI Exploded View RISA 7 Se M r gs 78 EE amp 7 ue ANS lt NP MRE iS nih 6602328885 C FUEL SYSTEM DFI 3 9 Exploded View N Fast astener kaim itib emarks 1 F
95. Inspection e Turn the ignition switch OFF e Disconnect the subthrottle sensor connector e Connect a digital meter A to the subthrottle sensor con nector B Measure the subthrottle sensor resistance Ce Subthrottle Sensor Resistance Connections BL lead BR BK lead D Standard 4 6 80174246081 If the reading is out of the range replace the throttle body assy see Throttle Body Assy Removal Installation the reading is within the range but the problem still exists replace the ECU see ECU Removal Installation Subthrottle Sensor Circuit Y w BL BL W BL YA P P 2 CF Y BK Y BK BL BL K BL K BL Y BK aL Y 8 4 BL W4 8 K BL pd BR 8K4 BR BK 8R BK R B8K R BK 4 olf 6617423612 C 1 ECU 2 Subthrottle Valve Actuator 3 Subthrottle Sensor 4 Main Throttle Sensor 5 Water proof Joint 2 FUEL SYSTEM 3 81 Oxygen Sensor not activated Service Code 33 Equipped Models Oxygen Sensor Removal Installation e Refer to the Oxygen Sensor Removal Installation in the Electrical System chapter Oxygen Sensor Inspection e Warm up the engine thoroughly until the radiator fan starts e Turn the ignition switch to OFF e Remove the right lower fairing see Lower Fairing Re moval in the Frame chapter e Connect a digital meter A to the oxygen sensor lead con nector B s
96. Installation x If the input voltage is within the standard range check the input voltage at the subthrottle sensor connector OBO 6C17127BS1 Cee 80171450651 Subthrottle Sensor Service Code 32 e Remove the right fairing cover see Fairing Cover Re moval in the Frame chapter e Disconnect the subthrottle sensor connector A e Connect the harness adapter A between the harness connector and subthrottle sensor connector Special Tool Throttle Sensor Setting Adapter 57001 1538 e Connect a digital meter to the harness adapter leads Subthrottle Sensor Input Voltage Connections to Adapter Meter BK sensor BL lead Meter W sensor BR BK lead eMeasure the sensor input voltage with the engine stopped and with the connector joined e Turn the ignition switch ON Input Voltage at Sensor Standard DC 4 75 5 25 V e Turn the ignition switch OFF If the reading is out of the range check the wiring see wiring diagram in this section the reading is good check the output voltage of the sensor FUEL SYSTEM DFI 3 77 3 78 FUEL SYSTEM Subthrottle Sensor Service Code 32 Subthrottle Sensor Output Voltage Inspection e Measure the output voltage at the ECU in the same way as input voltage inspection Note the following Digital Meter A Connector B Special Tool Needle Adapter Set 57001 1457 Subthrottl
97. KEK 54 9 B Needle Adapter Set 57001 1457 Subthrottle Valve Actuator Input Voltage Connections to Harness Connector I Meter gt BK BL lead 1 Meter Frame Ground 2 E I Meter G lead 2 Meter Frame Ground 2 E Meter gt Y BK lead 3 Meter Frame Ground 2 E IV Meter 4 P lead 4 Meter Frame Ground 2 E e Measure the input voltage with the engine stopped and with the connector joined e Turn the ignition switch ON Input Voltage Standard About DC 10 5 12 5 V x f the reading is out of the range check the wiring to ECU see wiring diagram in this section xIf the wiring is good replace the ECU see ECU Re moval Installation 9017439652 C FUEL SYSTEM DFI 3 91 Subthrottle Valve Actuator Service Code 62 Subthrottle Valve Actuator Circuit YW R BK BL BL W R BK BL Y w P BK 8K BL BL W BL W 6 6 6 6 Y Y BK BK Y BK BL K BL K BL Y BK aL Y 8 4 BL W4 K BL BRK BR BK 8R BK R BK R BK 4 e 6617423612 C 1 ECU 2 Subthrottle Valve Actuator 3 Subthrottle Sensor 4 Main Throttle Sensor 5 Water proof Joint 2 3 92 FUEL SYSTEM Oxygen Sensor Heater Service Code 67 Equipped Models Oxygen Sensor Heater Removal installation The oxygen sensor heater is built in the oxygen sensor So the heater itself can not be removed Remove t
98. Lever Push TE a o a Released W2L0348CW5 C ELECTRICAL SYSTEM 16 23 Wiring Diagram ABS Equipped Models MY Model Gear Position Valve Sidestand Speed Water i Crankshaft 4 Inlet Switch Sensor Temperature eil Sensor Actuators usib Hain Air ace ai Sensor theottle Throttle pressure 2 Switch E Sensor Sensor Sensor N 1 xo sak Fuel Injectors gt 1 1 1 2 3 4 1 I Alternator 33 ata 297 he SL 5 5 258 a dy i2 i2 3 Temperature 70204 1 Sensor Wes aa idi 275 2 3333 2 safe 55 Rectifier M Pressure Baga 92 a rA n ster pros s Water proof Sensor ere Set g 50 8 5525 i58 2 g 28 8 2 5 Subthrottle R BL P 18 Bk R R amp eU BL BK 81 6 BL R BK Y L4 wer BL R BK vow w a et v Y BL G W Y o 1B RAY Busy BR a R YR Y R a BK BL L6 BK GY BL P BR BR BK BK Y BR Y License Plate Light 12v5W Rear Right Turn Signal Light 12 21 1 Vehicle down Sensor 8 Engine Battery aie Frame 12 14 round 2 Relay Box Relay Box anon Starter Relay Main Fuse 30A Fan Relay Headl
99. Maintenance chapter e Tighten Torque Throttle Body Assy Holder Clamp Bolts 2 0 N m 0 20 kgf m 18 in Ib xIf the grommet A was removed install it Olnstall the grommet from the inside of the frame e Insert the duct B to the grommet OApply a soap and water solution or rubber lubricant to the oblique portion C on the duct for easy installation e Fit the projections D of the duct into the holes E in the clamp e Install the duct clamp bolts A in the direction as shown in the figure Front B Upside View C e Tighten Torque Duct Clamp Bolts 2 0 N m 0 20 kgf m 18 in Ib FUEL SYSTEM DFI 3 121 00170711 P 8617450652 6617451651 C 3 122 FUEL SYSTEM DFI Throttle Body Assy e Install the air cleaner caps OThe right air cleaner cap A has a R mark B 6510694 P e Install the removed parts see appropriate chapters e Run the leads and hoses correctly see Cable Wire and Hose Routing section in the Appendix chapter e Adjust Throttle Grip Free Play see Throttle Control System In spection in the Periodic Maintenance chapter Idle Speed see Idle Speed Adjustment in the Periodic Maintenance chapter FUEL SYSTEM 3 123 Throttle Body Assy Throttle Body Assy Disassembly 66172250 2 C 1 Subthrottle Valve Actuator 2 Subthrottle Sensor 3 Main Throttle Sensor 4 Throttle Body Assy 5 Injector 6 Delivery Pipe 7 Throttle Bo
100. Mounting Bolts 12 1 2 106 in lb S 3 Filter 17 1 7 13 G R 4 Filter Holder Mounting Bolt 35 3 6 26 L 5 Pan Bolts 9 8 1 0 87 in lb 6 Oil Pan Plate Bolts 9 8 1 0 87 in lb L 7 Oil Passage Plug 20 2 0 15 L 8 Pressure Relief Valve 15 1 5 11 L 9 Oil Pressure Switch 15 1 5 11 SS 10 Oil Pressure Switch Terminal Bolt 1 5 0 15 13 in lb G 11 Oil Pump Cover Bolts 9 8 1 0 87 12 Oxygen Sensor Equipped Models EO Apply engine oil G Apply grease L Apply a non permanent locking agent MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts S Follow the specified tightening sequence SS Apply silicone sealant 7 4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart Camshaft 011 Passage Inlet Camshaft Exhaust Camshaft Crankshaft Oil Passage 011 Pressure Switch Relief Valve 01 Screen Breather Hose 1 pi for Return Oil Pipe 66040828 G ENGINE LUBRICATION SYSTEM 7 5 Engine Oil Flow Chart Rear Balancer Oil Passage Front Balancer Oil Passage y Passage Drive Shaft OZ Output Shaft 011 Passage Oil Passage Breather Hose 06041268 6 7 6 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil Type API SE SF or SG SH SJ or SL with JASO MA MA1 MA2 Viscosity SAE 10W 40 Capa
101. Pad Installation in the Brakes chapter e Wipe up any spilled brake fluid on the caliper with wet cloth Spark Plug Replacement e Remove the stick coils see Stick Coil Removal in the Electrical System chapter e Remove the spark plugs using the 16 mm 0 63 in plug wrench A vertically e Replace the spark plug with a new one Standard Spark Plug Type CR9EIA 9 e Insert a new spark plug in the plug hole and finger tighten it first e 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 Torque Spark Plugs 13 N m 1 3 kgf m 115 in Ib e Install the stick coils securely OBe sure the stick coils are installed by pulling up it lightly 9513158851 C FUEL SYSTEM DFI 3 1 Fuel System DFI Table of Contents EXploded SA 3 4 BigEc a M HT 3 10 al M ARES EG CAO Em 3 16 SPOCIICATIONS 3 18 3 20 DFI Servicing toe ferae HAE a or Rd 3 22 DEI Serviemdq Precaltions 3 22 Troubleshooting the DFI 444 4 00400 1 00
102. Plug Condition Inspection e Remove the spark plugs see Spark Plug Removal e Visually inspect the spark plugs the spark plug center electrode A and or side elec trode B are corroded or damaged or if the insulator C is cracked replace the plug lf the spark plug is dirtied or the carbon is accumulated replace the spark plug e Measure the gap D with a wire type thickness gauge the gap is incorrect replace the spark plug Spark Plug Gap 0 8 0 9 mm 0 031 0 035 in Use the standard spark plug or its equivalent Spark Plug CR9EIA 9 Interlock Operation Inspection e Raise the rear wheel off the ground with stand e Turn the engine stop switch ON run position 1st Check e Start the engine to the following conditions Condition Transmission Gear 1st Position Clutch Lever Release Sidestand Down or Up OTurn the ignition switch ON and push the starter button OThen the starter motor should not turn when the starter system circuit is normality the engine is start inspect the starter lockout switch gear position switch and relay box xIf their parts are normality replace the ECU 2nd Check e Start the engine to the following conditions Condition Transmission Gear 1st Position Clutch Lever Pulled in Sidestand Up OTurn the ignition switch ON and push the starter button OThen the starter motor should turn when the starter sys tem circuit is normalit
103. Pressure Sensor Removal CAUTION Never drop the atmospheric pressure sensor espe cially on a hard surface Such a shock to the sensor can damage it e Remove Seat see Seat Removal in the Frame chapter Atmospheric Pressure Sensor Connector A Damper B Atmospheric Pressure Sensor C Atmospheric Pressure Sensor Installation NOTE OThe atmospheric pressure sensor is the same part as the inlet air pressure sensor except that the inlet air pressure sensor has a inlet air pressure hose and dif ferent wiring e Installation is the reverse of removal Atmospheric Pressure Sensor Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF poe e Remove the ECU see ECU Removal 1 ODo not disconnect the ECU connectors e Connect a digital meter A to the connector B using the needle adapter set TUAM Special Tool Needle Adapter Set 57001 1457 Atmospheric Pressure Sensor Input Voltage Connections to ECU Connector Meter BL lead terminal 7 Meter BR BK lead terminal 34 e Measure the input voltage with the engine stopped and with the connector joined e Turn the ignition switch ON Input Voltage at ECU Standard DC 4 75 5 25 V the reading of input voltage is less than the standard range check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good
104. RADIAL SL BRIDGESTONE BATTLAX BT014 R RADIAL L 120 70 ZR17 M C 58W 190 50 ZR17 M C 73W A WARNING Use the same manufacturer s tires on both front and rear wheels WHEELS TIRES 10 5 Special Tools Bearing Driver Set Bearing Remover Shaft 13 57001 1129 57001 1377 7571129ST C 875713775 Jack Jack Attachment 57001 1238 57001 1608 7571238ST C 7571608ST C Bearing Remover Head 25 x 28 57001 1346 8757134697 10 6 WHEELS TIRES Wheels Rims Front Wheel Removal e Remove Front Caliper Mounting Bolts A Both Sides Front Calipers B Both Sides e Loosen Axle Clamp Bolts A Left Side Axle Nut B Axle Clamp Bolts Right Side e Remove the lower fairings see Lower Fairing Removal in the Frame chapter e Raise the front wheel off the ground with the jack Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Remove the axle nut and pull out the axle to the right and drop the front wheel out of the forks CAUTION Do not lay the wheel down on one of the discs This can damage or warp the disc Place blocks un der the wheel so that the disc does not touch the ground Front Wheel Installation NOTE OThe direction of the wheel rotation A is shown by an arrow B on the wheel spoke e Check the wheel rotation mark on the front wheel and install it 6J04079BS1 Wheels
105. Replacement pp 16 58 City Light Bulb Replacements pete 16 59 Headlight Removal Installation true e irr ierit hi tera ern er ads 16 59 Headlight Relay IrspecllOlks ds eee treet eee aie 16 60 Tail Brake Light LED Removal ha 16 60 Tail Brake Light 25 ee 16 61 License Plate Light Bulb 4 4 4 16 61 Turn Signal Light Bulb Replacement s hid elects 16 62 Turn Signal Relay Inspection pp 16 64 sie ern in dare adobe ante pub 16 66 Air Switching Valve Operation TeSt nennen nnne ren 16 66 Air Switching Valve Unit Test pp 16 66 Radiator Ear den gnus 16 68 Fan Motor Inspection tests ee cde bte ee 16 68 Mester Gauges Indicator etr ea cene pat eed Ve cct tect d a and 16 69 Meter Unit HemoVval each en ete te m o eter bd ori vette i duds 16 69 Met r Unit iS CAMARO N sce o ee eei cas one oa o louer as Cate 16 69 Meier Unit Disassembly pp 16 70 Meter Unit INSPeCton TL 16 70 Immobilizer System Equipped
106. Replacement Parts 14 4 STEERING Special Tools Head Pipe Outer Race Press Shaft 57001 1075 N 875710755 C Steering Stem Nut Wrench 57001 1100 875711005 C Bearing Driver Set 57001 1129 7571129ST C Steering Stem Bearing Driver 542 5 57001 1344 7571344ST C Steering Stem Bearing Driver Adapter 641 5 57001 1345 875713455 C Head Pipe Outer Race Driver 55 57001 1446 7571446ST C Steering Steering Inspection e Refer to the Steering Play Inspection in the Periodic Main tenance chapter Steering Adjustment e Refer to the Steering Play Adjustment in the Periodic Maintenance chapter STEERING 14 5 14 6 STEERING Steering Stem Stem Stem Bearing Removal e Remove Upper Fairing Bracket see Upper Fairing Bracket Re moval in the Frame chapter Front Wheel see Front Wheel Removal in the Wheels Tires chapter Handlebars see Handlebar Removal Front Forks see Front Fork Removal in the Suspension chapter Cover Bolts A and Cover B Bracket Bolts C Clamps D e Remove Steering Stem Head Nut A and Washer B Steering Stem Head C e Bend the claws A of the claw washer straighten e Remove the steering stem locknut B Special Tool Steering Stem Nut Wrench 57001 1100 e Remove the claw washer e Pushing up the stem base and remove the steering stem nut A with stem cap B Special To
107. Signal Relay License Plate Light Lead Connector Atmospheric Pressure Sensor Lead Connector Run the license plate light lead through the inside of the atmospheric pressure sensor License Plate Light Lead Run the turn signal relay lead through between the rear frame and rear frame pipe Rear Left Turn Signal Light Lead Connector Tail Brake Light Lead Connector Rear Right Turn Signal Light Lead Connector ABS Kawasaki Self diagnosis System Connector Fix the ABS Kawasaki self diagnosis system connector to the sponge Immobilizer Kawasaki Diagnostic System Connector Fix the Immobilizer Kawasaki diagnostic system connector to the sponge Fuse Box 2 ECU Leads Relay Box Leads Alternator Subharness Alternator Lead Clamp Hold the alternator lead and alternator subharness Run the alternator lead and alternator subharness through the outside of the rear frame Run the alternator lead and alternator subharness through under the rear brake reservoir Fuse Box 1 Run the alternator lead and alternator subharness through under the bracket 17 26 APPENDIX Cable Wire and Hose Routing APPENDIX 17 27 Cable Wire and Hose Routing 10 11 12 13 14 15 16 17 18 19 ABS Equipped Models Run the main harness through the hole of the lower side Run the inlet air temperature sensor lead through the hole of the upper side AB
108. Switch B Immobilizer Antenna C Immobilizer Equipped Models Immobilizer Amplifier D Immobilizer Equipped Models Vehicle down Sensor E Inlet Air Pressure Sensor A Fuel Pump A 3 18 FUEL SYSTEM Specifications Item Digital Fuel Injection System Idle Speed Throttle Assy Type Bore Throttle Body Vacuum Bypass Screws ECU Make Type Usable Engine Speed Fuel Pump Type Discharge Fuel Injectors Type Nozzle Type Resistance Main Throttle Sensor Input Voltage Output Voltage Resistance Inlet Air Pressure Sensor Atmo spheric Pressure Sensor Input Voltage Output Voltage Inlet Air Temperature Sensor Output Voltage at ECU Resistance Water Temperature Sensor Output Voltage at ECU Speed Sensor Input Voltage Output Voltage Vehicle down Sensor Detection Method Detection Angle Output Voltage Fuel Pressure High Pressure Line Standard 1 100 50 r min rpm Four barrel type 44 mm 1 7 in 34 4 1 3 kPa 258 10 mmHg Mitsubishi Electric Digital memory type with built in IC igniter sealed with resin 100 11 200 r min rpm 294 kPa 3 0 kgf cm 43 psi with engine idling In tank pump in fuel tank or Wesco pump friction pump 67 mL 2 3 US oz or more for 3 seconds INP 287 Fine atomizing type with 12 holes About 11 7 12 3 at 20 C 68 F DC 4 75 5 25 V DC 0 63 3 91 V at idle throttle opening to full throttle open
109. UIDI voltage igral wiring short or open the ECU sets the top 6 Vg 0 2 4 8 V i Switch gear position If the vehicle down sensor system has failures Vehicle the output voltage Vd is more than usable 31 down 227 range wiring open the ECU shuts off the Sensor UNS fuel pump the fuel injectors and the ignition system If the subthrottle sensor system fails the 32 Subthrottle Output Voltage signal is out of the usable range wiring short Sensor 0 2 4 8V or open the actuator locks subthrottle valve at full closed position The oxygen sensor must ds 2 i If the oxygen sensor output voltage is incorrect 33 Equipped the Po y the ECU stops the feedback mode of the Models Output Voltage p DAE 0 05 0 25 V 3 44 FUEL SYSTEM DFI Self Diagnosis Service Output Signal Usable Codes FANS Range or Criteria Backups by ECU none If the immobilizer system fails no signal wiring Amplifier 35 short or open the vehicle does not start and Equipped ain Models Master or 36 User Key The user or master key If the blank key or broken key is used the Equipped must use register key vehicle does not start and run Models When the relay ON Fuel Pump m 46 Relay condition battery monitor If the relay fails battery monitor voltage 12 V voltage 5 V or more The stick coil primary winding must send signals 51 Stick Coil 1 output voltage 32 or more times continuously to the ECU
110. a soap and water solution or rubber lubricant and pull B the valve stem through the rim from the inside out until it snaps into place CAUTION Do not use engine oil or petroleum distillates to lu bricate the stem because they will deteriorate the rubber 6305041851 C OThe air valve is shown in the figure Valve Cap A Valve Core B Stem Seal C Valve Stem D Valve Seat E Valve Opened F 6J05030781 6 e Check the tire rotation mark on the front and rear tires and install them on the rim accordingly Tire Rotation Mark A Rotating Direction B e Position the tire on the rim so that the valve A align with the tire balance mark B the chalk mark made during removal or the yellow paint mark on a new tire e Install the tire bead over the rim flange using a suitable commercially available tire changer e Lubricate the tire beads and rim flanges with a soap and water solution or rubber lubricant to help seat the tire beads in the sealing surfaces of the rim while inflating the tire e Center the rim in the tire beads and inflate the tire with compressed air until the tire beads seat in the sealing surfaces 6405044851 6 A WARNING Be sure to install the valve core whenever inflating the tire and do not inflate the tire to more than 400 kPa 4 0 kgf cm 57 psi Overinflation can explode the tire with possibility of injury and loss of life 10 16 WHEELS TIRES T
111. and next fix it to the clutch hose Clutch Hose Idle Adjusting Screw Clamp Clamp the speed sensor lead Speed Sensor Lead Breather Hose Clamp Align the white paint mark with the end of the plate 17 4 APPENDIX Cable Wire and Hose Routing EEC 28 TSN WEAK Ill 585 4 Lum AD Sp Vu e AE Ti A gt gt V CH W NS 44 aaa aN V aK S NS IG Py O 1089 lt Nes ID IE os APPENDIX 17 5 Cable Wire and Hose Routing ROD ON Idle Adjusting Screw Run the air cleaner drain hose through the front of the clamp Main Harness Run the air cleaner drain hose and idle adjusting screw cable through the outside of the main harness Clamp Position the clamp so that its pinch heads do not touch the frame and air cleaner drain hose Clutch Hose Run the air cleaner drain hose through the inside of the clutch hose 17 6 APPENDIX Cable Wire and Hose Routing A 25 OA SEY A APPENDIX 17 7 Cable Wire and Hose Routing Reserve Tank Hose Reserve Tank Overflow Hose Reserve Tank Radiator Right Side View Air Bleeder Hose for Thermostat Housing Thermostat Housing Water Hose Air Ble
112. at ECU see CAN Communication Line Resistance Inspection in the Fuel System DFI chapter Water Temperature Sensor see Water Temperature Sensor Service Code 14 section in the Fuel System DFI chapter If the above items are good replace the meter assembly and or ECU GP17591BS1 C 8 17598 52 C T7 CKM L H AVERAGE c Lo 123456 xn 1 00 a GP17109C ELECTRICAL SYSTEM 16 83 Meter Gauge Indicator Unit Check 19 FI IMMOBILIZER Error Inspection e Connect the leads in the same circuit as Check 18 e For example disconnect the atmospheric pressure sen sor A e Install the key registration unit B see Key Registration Immobilizer equipped models Special Tool Key Registration Unit 57001 1582 e Turn the ignition switch ON by the current key e Check that the warning light LED A starts flashing and the display B changes as follows pt J Kamvasalst _ IMMOBILIZER IMMOBILIZER gt gt ERROR FI PN ERROR ERROR E 123456 N 12 00 8P17596BN3 C 180 200 Warning Message C do om Symbol D OThis display is the warning message indication the display function does not work go to the Check 1 and check the following items Wiring see Wiring Inspection CAN Communication Line Resistance at ECU see CAN Commu
113. button pushing If the display function does not work replace the meter assembly e Select the LAMP MODE A indication e Push the upper button for more than two seconds check that the lighting mode setting menu B flashes e By pushing the lower button C each time check that the display changes as follows and the indicator light LED D goes on according to message BRIGHT DIM BLINK GP17558BN3 C e Check that the lighting mode setting menu is decided by the upper button pushing the display function does not work replace the meter assembly N B Kawasaki MILEAGE ENGAGE LAMP OFF gt SHIFT LAMP OFF LAMP MODE CLOCK OO BRIGHT 12 34 x M E 9 3 a 3 o Kawasaki N MILEAGE KM L ENGAGE LAMP SHIFT LAMP _ LAMP MODE BRIGHT CLOCK 1234 OO 180 200 7 er GP17560B N MILEAGE Ru Z N i 180 7 g E f me HOS CO bs Q NE 281 f y j GP17085C 5 Meter Gauge Indicator Unit e Select the CLOCK A indication e Push the upper button for more than two seconds OThe clock setting menu hour and minute B should flash e Push the lower button for more than two seconds OThe hour display
114. clear the projections B on both sides e Remove the fuel tank cover to forward C e Remove the bolts A Fuel Tank e Remove Bolts A Drain Hose B e For the California and Southeast Asia models remove the following Fuel Tank Breather Hose C Blue Fuel Return Hose D Red e Disconnect Fuel Pump Lead Connector A Fuel Level Sensor Lead Connector B e Open the fuel tank cap A to lower the pressure in the tank ODuring tank removal keep the tank cap open to release pressure in the tank This makes fuel spillage less e Draw the fuel out from the fuel tank with a commercially available pump A OUse a soft plastic hose B as a pump inlet hose in order to insert the hose smoothly OPut the hose through the fill opening C into the tank and draw the fuel out Front D A WARNING The fuel could not be removed completely from the fuel tank Be careful for remained fuel spillage e Be sure to place a piece of cloth A around the fuel hose joint B e Push C the joint lock claws D FUEL SYSTEM 3 131 6609033851 6 3 132 FUEL SYSTEM DFI Fuel Tank e Pull A the fuel hose joint B out of the delivery pipe A WARNING Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is disconnected fuel spills out from the hose and the pipe because of residual pressure Cover the hose connection with
115. code can be erased by grounding and un grounding each time for at least one second the ABS self diagnosis terminal three times or more within about 12 5 seconds after starting the erase mode OThe ABS indicator light LED remains lit during the erase mode OAfter erasing the ABS indicator light LED blinks and lights OOnce erasing is finished enter the self diagnosis mode again to confirm that the service codes have been erased If the ABS has been reset and all codes have been erased the ABS indicator light LED lights BRAKES 12 41 12 42 BRAKES Anti Lock Brake System Equipped Models Erasing of Service Gode 1S or more Permit of Service End of Service Code Erase Code Erase O _ gt ABS ON 1 Indicator M 1 1 Light LED OFF i 1 i l iStart s 0 45 0 45 0 45 of IService The signal to inform of the Erase erase completion of service code ABS Self Open 1 diagnosis 1 2 3 Terminal Ground 1 1 LJ Within 12 5 GL141128W2 C BRAKES 12 43 Anti Lock Brake System Equipped Models Self diagnosis Flow Chart Turn the ignition switch OFF Connect the ABS self diagnosis terminal to the ground terminal Turn the ignition switch ON Self diagnosis mode starts The ABS indicator light LED blinks to display the service code in about 3 6 seco
116. connector into the bracket tightened with the cylinder head cover Run the stick coil lead through under the throttle cables Band Hold the engine harness with the subframe Clamp Hold the fan motor lead connector and insert the clamp into the subframe Run the oil pressure switch gear position switch lead through the inside and front of the water pump Run the sidestand switch lead through the inside and backside of the water pump 17 18 APPENDIX Cable Wire and Hose Routing APPENDIX 17 19 Cable Wire and Hose Routing 1 Run the headlight lead through the clamp on both sides NO of 10 11 12 13 14 15 16 17 18 19 20 Immobilizer Equipped Models After connecting the ignition switch lead connector and left switch housing lead connector put their connector into the water proof cover Clamp Hold the main harness and insert the clamp into the middle air inlet duct Clamp Hold the left turn signal lead and insert the clamp into the middle air inlet duct Left Turn Signal Light Lead Connector Headlight Lead Run the left switch housing lead and ignition switch lead through the clamp and insert it into the bracket Run the left switch housing lead through the clamp from the outside of the front fork Run the ignition switch lead through the front clamp after routing it from the inside to backside of the front fork Clamp Left Ci
117. crankcase of rear side B 0118279 GE11192BS1 GE11193BS1 C ENGINE TOP END 5 19 Camshaft Camshaft Chain OThe timing marks must be aligned with the cylinder head upper surface A EX Mark B IN Mark C No 30 Pin GE 11948W2 C 5 20 ENGINE TOP END Camshaft Camshaft Chain e Install the camshaft cap following the identification No A and upper chain guide B OFirst tighten the camshaft cap and all chain guide bolts evenly to seat the camshaft in place then tighten all bolts following the specified tightening sequence Torque Camshaft Cap Bolts 1 18 12 N m 1 2 kgf m 106 in Ib Camshaft Chain Guide Bolts 19 20 12 N m 1 2 kgf m 106 in Ib e Install the camshaft chain tensioner see Camshaft Chain Tensioner Installation f GE112668W2 C Camshaft Camshaft Cap Wear e Remove Upper Chain Guide see Camshaft Removal Camshaft Caps see Camshaft Removal e Cut strips of plastigage to journal width Place a strip on each journal parallel to the camshaft installed in the correct position e Measure each clearance between the camshaft journal and the camshaft cap using plastigage press gauge A e Tighten the camshaft cap bolts and chain guide bolts see Camshaft Installation NOTE ODo not turn the camshaft when the plastigage is be tween the journal and camshaft cap Camshaft J
118. dial gauge A against the rear sprocket B near the teeth as shown in the figure and rotate C the rear wheel to measure the sprocket runout warp The difference between the highest and lowest dial gauge readings is the amount of runout warp the runout exceeds the service limit replace the rear sprocket Rear Sprocket Warp Standard TIR 0 4 mm 0 016 in or less Service Limit TIR 0 5 mm 0 020 in 6114010151 GKO5017BS1 GK05000BS1 C BRAKES 12 1 Brakes Table of Contents Exploded VIEW Aem 12 4 Specification gn e 12 12 Special TG0 S 12 13 Brake Lever Brake Pedal ui ette P a ERR FD RERO DRE CA DOE EN 12 14 Brake Lever Position Adjustment 12 14 Brake Pedal Position Inspection ied oeste ie sore tb re te tb anda deti ode e 12 14 Brake Pedal Position Adjustment dede eter ec Dices indc dr 12 14 Brake Pedal Hernoval etos 12 14 Brake Pedal Installation siae ed trt meae ceni es n epu tnu na on 12 15 Calipers me ES 12 16 Front Caliper Removal eb Dernier m 12 16 Rear Caliper Removal e ati atid tola tabes du Mud dedicate ATO I oca 12 16 Caliper Installation ees atu cun eee md au 12 17 Fron
119. e DES EET EX FRT PEE ENT ENS DES DES 0 460 50 5 2 40 95 3 00 o 510 55 0 2 45 5 28 00 60 60 081 08 02 6 o o 6170 05 E MEE 0 66 0 70 5 2 60 95 3 00 S o 7170 75 0 2 65 0 160 v0 hores D DET OE D 0 86 0 90 5 2 80 95 3 00 T 0 91 0 95 0 2 85 2 05 2 10 2 15 2 20 2 25 2 30 2 35 2 40 2 45 2 50 2 5512 6042 65 2 70 2 75 2 80 2 85 2 90 2 95 3 00 Sis aed aste odz odaad lt gt 1 0141 0 2 85 2 9012 9513 00 S Install the shim of this thickness mm 1 06 1 10 2 9012 95 3 00 gt 1 11 15 2 95 3 00 gt 1 1671 20 3 00 Measure the clearance when engine is cold Check present shim size Match clearance in vertical column with present shim size in horizontal column Install the shim specified where the lines intersect This shim will give the proper clearance Example Present shim is 2 55 mm Measured clearance is 0 36 mm Replace 2 55 mm shim with 2 75 mm shim Remeasure the valve clearance and readjust if neces sary GS07090BW3 C 2 28 PERIODIC MAINTENANCE Periodic Maintenance Procedures CAUTION Be sure to remeasure the clearance after selecting a shim according to the table If the clearance is out of the specified range use the additional shim Olf there is no valve clearance use a shim that is a few sizes smaller and rem
120. e Insert the fuel hose into the measuring cylinder B 3 106 FUEL SYSTEM DFI Fuel Line A WARNING Wipe off spilled out fuel immediately Be sure to hold the measuring cylinder vertical e Close the fuel tank cap e Turn the engine stop switch run position e Turn the ignition switch ON OThe fuel pump should operate for 3 seconds and then should stop CAUTION Do not drive the fuel pump 3 seconds or more with outthe fuel in the fuel tank If the fuel pump is driven without the fuel it may be damaged e Measure the discharge for seconds ORepeat this operation several times Amount of Fuel Flow Standard 67 mL 2 3 US oz or more for 3 seconds e Turn the ignition switch OFF x If the fuel flow is much less than the specified replace the fuel pump see Fuel Pump Removal Installation e Install the fuel tank see Fuel Tank Installation e Start the engine and check for fuel leakage Fuel Pump Fuel Pump Removal A WARNING Gasoline is extremely flammable and can be explo sive under certain conditions Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Turn the ignition switch OFF Disconnect the battery terminal 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 imme
121. eine doa o 12 24 Brake Disc InstallaliQr iere D ke min quse pe Rte e 12 24 Brake Disc Wear Inspectionm cie pae ese te toe edente 12 24 Brake Disc Warp etr tele tee e RR 12 24 12 25 Brake Fluid Level Inspection t tete tees dei te eee ete 12 25 Brake Flug alite 12 25 Brake Line Bleeding utut Rufe 12 25 Brake T 12 29 Brake Hose and Pipe Removallnstallatig 12 29 Brake Hose and Pipe Inspectiom 12 29 Anti Lock Brake System Equipped Models pp 12 30 ABS Servicing Precautions 12 33 ABS Troubleshooting Outline pp 12 35 12 2 BRAKES to Rider NEU TH Dr 12 38 Self diagnosis Outline xx imer e et Hee tec rasa dec 12 40 Self diagriosis Procedures pp 12 40 Service Code Clearing Procedures pp 12 41 How to Read Service 12 44 How to Erase Service Codes tete rte pde e 12 44 ABS Indicator Light LED Inspection edt vase o eda en RE ner irl tate 12 46 ABS Indicator Light LED is Unlit When the Ignition Switch turn
122. for replacement in flated to the standard pressure NOTE OMost countries may have their own regulations a mini mum tire tread depth be sure to follow them OCheck and balance the wheel when a tire is replaced with a new one Wheel Bearing Damage Inspection e Raise the front wheel off the ground with the jack see Front Wheel Removal in the Wheels Tires chapter e Turn the handlebar all the way to the right or left e Inspect the roughness of the front wheel bearing by mov ing A the wheel with both hands to both side e Spin B the front wheel lightly and check for smoothly turn roughness binding or noise lf roughness binding or noise is found remove the front wheel and inspect the wheel bearing see Front Wheel Removal Hub Bearing Inspection in the Wheels Tires chapter e Raise the rear wheel off the ground with the stand see Rear Wheel Removal in the Wheels Tires chapter e Inspect the roughness of the rear wheel bearing by mov ing A the wheel with both hands to both side e Spin B the rear wheel lightly and check for smoothly turn roughness binding or noise lf roughness binding or noise is found remove the rear wheel and inspect the wheel bearing see Rear Wheel Re moval Hub Bearing Inspection in the Wheels Tires chap ter and coupling see Coupling Bearing Inspection in the Final Drive chapter 538077 P Final Drive Drive Chain Lubrication Condition Inspection e special l
123. hand tester A to the 1 kO or x 100 O range and connect it to the terminals in the oil pressure switch gear position switch lead connector B and ground C Internal Circuit 1 Light Green Lead 2 Green Red Lead 3 Black Lead Special Tool Hand Tester 57001 1394 Gear Position Switch Resistance kQ Connections Gear Position 1 Ground 2 Ground 3 Ground 1st 2 22 2 46 about 0 2nd 1 42 1 58 3rd 0 954 1 055 about 0 4th 0 643 0 711 5th 0 410 0 453 about 0 6th 0 241 0 266 about 0 xIf the tester reading is not as specified replace the gear position switch with a new one GPi8243BSi C 8 18407852 16 114 ELECTRICAL SYSTEM Relay Box The relay box A has relays and diodes The relays and diodes can not be removed Relay Box Removal CAUTION Never drop the relay box especially on a hard sur face Such a shock to the relay box can damage it e Remove the seat see Seat Removal in the Frame chap ter e Take out the relay box A and disconnect the connectors B Relay Circuit Inspection e Remove the relay box see Relay Box Removal e Check conductivity of the following numbered terminals by connecting the hand tester and one 12 V battery to the relay box as shown see Relay Box Internal Circuit in this section x If the tester does not read as specified replace the relay box Relay Circuit Inspection with th
124. ignition switch OFF If the output voltage is normal check the wiring for conti nuity See wiring diagram in this section If the output voltage is out of the usable range replace the sensor LI 6617143851 C Atmospheric Pressure Sensor Circuit BL G W 2 R BK BR BK R BK 3 BR BK 1 ECU 2 Atmospheric Pressure Sensor 3 Water proof Joint 2 If you need to check the atmospheric pressure sensor for various altitudes other than sea level check the output voltage as follows ODetermine the local altitude elevation FUEL SYSTEM 3 65 Atmospheric Pressure Sensor Service Code 15 you know the local atmospheric pressure using a barometer substitute the atmospheric pressure for throt tle vacuum pressure in the inlet air pressure sensor chart see Inlet Air Pressure Sensor Output Voltage Inspection And get the usable range of the atmospheric pressure sensor output voltage and check if output volt age is within the standard or not in the same way as Output Voltage Inspection of the inlet air pressure sensor If you know the local altitude use the following chart Atmospheric Pressure Altitude Relationship 750 P Atmospheric Pressure mmHg abs Z Altitude km BEEN P 760 1 7 4 19026 700 600 Atomospheric Pressure mmHg abs 550 000ft 0 0 2
125. in the adjusting nut to the desired position and tighten the locknut by using hook wrenches A with the rear shock absorber attached the frame Special Tool Hook Wrench T 3 2 R37 57001 1522 lf the spring action feels too soft or too stiff adjust it Spring Adjustment Adjuster Damping Position Force Setting Load Road Speed 191 5 mm Weak Soft Light Good Low 7 539 in T T T T T T 175 5 Strong Bad High 6 909 in Rear Shock Absorber Removal e Remove Rear Fairing see Rear Fairing Removal in the Frame chapter Equipped Models Bolts A Both Sides and Bracket B Equipped Mod els Lower Fairings see Lower Fairing Removal in the Frame chapter e Raise the rear wheel off the ground with the jack Special Tools Jack 57001 1238 Jack Attachment 57001 1608 SUSPENSION 13 21 Rear Shock Absorber e Squeeze the brake lever slowly and hold it with a band A WARNING Be sure to hold the front brake when removing the shock absorber or the motorcycle may fall over It could cause an accident and injury e Remove Lower Shock Absorber Nut and Bolt A Upper Tie Rod Nut and Bolt B e Remove the upper shock absorber nut and bolt A e Remove the shock absorber downward Rear Shock Absorber Installation e Tighten Torque Rear Shock Absorber Nuts 34 N m 3 5 kgf m 25 ft Ib Tie Rod Nuts 59 N
126. inspection DFI system inspection immobilizer system Conduct general fuel system inspection General fuel system throttle body assy air cleaner fuel tank etc 00174626 Inquiries to Rider OEach rider reacts to problems in different ways so it is important to confirm what kind of symptoms the rider has encountered OTry to find out exactly what problem occurred under exactly what conditions by asking the rider knowing this information may help you reproduce the problem OThe diagnosis sheet will help prevent you from overlooking any areas and will help you decide if it is a DFl system problem or a general engine problem 3 30 FUEL SYSTEM DFI Troubleshooting the DFI System Sample Diagnosis Sheet Rider name Registration No license plate No Year of initial registration Model Date problem occurred Frame No Mileage Engine No Environment when problem occurred indicator light LED Starting difficulty Engine stalls Weather fine O cloudy O rain snow O always O other Temperature O hot warm cold O very cold O always O other Problem O chronic O often once frequency Road O street highway O mountain road 0 uphill C1 downhill C1 bumpy O pebble Altitude normal O high about 1 000 m or more Motorcycle conditions when problem occurred Warning Goes on about 3 seconds after from ignition switc
127. is a rotation angle method Observe one of the following two but the bolt length measurement method is preferable because this is a more reliable way to tighten the big end nuts CAUTION The connecting rod bolts are designed to stretch when tightened Never reuse the connecting rod bolts See the table below for correct bolt and nut usage CAUTION Be careful not to overtighten the nuts The bolts must be positioned on the seating surface correctly to prevent the bolt heads from hitting the crankcase 1 Bolt Length Measurement Method e Be sure to clean the bolts nuts and connecting rods thoroughly with a high flash point solvent because the new connecting rods bolts and nuts are treated with an anti rust solution A WARNING Clean the bolts nuts and connecting rods in a well ventilated area and take care that there is no spark or flame anywhere near the working area This in cludes any appliance with a pilot light Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents to clean them CAUTION Immediately dry the bolts and nuts with com pressed air after cleaning Clean and dry the bolts and nuts completely 9 18 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods e Install new bolts in reused connecting rods e Dent both bolt head and bolt tip with a punch as shown in the figure e Before tightening use a point microme
128. is displayed on the LCD by the num ber of two digits OWhen pushing and holding the upper button while the warning massage and warning symbol are displayed al ternately on the LCD the display on the LCD is shifted to the previous display with the warning indicator light LED goes on OAfter switching to the previous display the service code can not be displayed even if pushing the upper button and lower button for more than two seconds ERROR cone 31 12 00 e Any of the following procedures ends self diagnosis OWhen the service code is displayed on the LCD push the upper button and lower button for more than two seconds OWhen the ignition switch is turned OFF 3 40 FUEL SYSTEM DFI Self Diagnosis Self Diagnosis Flow Chart Turn the ignition switch OFF Turn the ignition switch ON Push the upper button and lower button for more than two seconds Then self diagnosis mode starts The service code s is displayed on the LCD Liquid Crystal Display Turn the ignition switch OFF Locate the problem with the service code table and inspect and repair DFI ignition and immobilizer system immobilizer models according to inspection procedure on all the service codes Turn the ignition switch ON Make sure the warning indicator light goes off and warning message and NG warning symbol are not displayed on the LCD Run the engine for several minutes at idling and run the motorcycle at 30 km
129. loose Water or foreign matter in fuel Throttle body assy holder loose Fuel to injector insufficient Fuel tank air vent obstructed Fuel line clogged Fuel pump trouble Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Knocking Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect ECU trouble Miscellaneous Throttle valve won t fully open Brake dragging Clutch slipping Engine overheating Engine oil level too high Engine oil viscosity too high Drive train trouble Camshaft cam worn Air suction valve trouble Air switching valve trouble Catalytic converter melt down due to muffler overheating KLEEN Overheating Firing incorrect Spark plug dirty broken or maladjusted Spark plug incorrect ECU trouble Muffler overheating For KLEEN do not run the engine even if with only one cylinder misfiring or poor running Request the nearest service fa cility to correct it For KLEEN do not push start with a dead battery Connect another full charged battery with jumper cables and start the engine using the electric starter For KLEEN d
130. meter to the harness adapter leads Subthrottle Sensor Output Voltage Connections to Adapter Meter sensor BL W lead Meter W sensor BR BK lead e Measure the output voltage with the engine stopped and with the connector joined e Turn the ignition switch ON e Measure the output voltage when the subthrottle valve is fully opened or completely closed by hand Output Voltage at Sensor Standard DC 0 62 4 14 V at subthrottle valve full opening to closing NOTE OThe subthrottle sensor is operating correctly if the fol lowing voltages are obtained DC 0 62 V or slightly higher with the subthrottle valve at the closed position DC 4 14 V or slightly lower with the subthrottle valve at the fully open position NOTE OThe standard voltage refers to the value when the volt age reading at the Input Voltage Inspection shows 5 V exactly OWhen 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 62 x 4 75 5 00 0 59 V 4 14 x 4 75 5 00 3 93 V Thus the valid range is 0 59 3 93 V e Turn the ignition switch OFF the reading is out of the standard range inspect the subthrottle sensor resistance lf the output voltage is normal check the wiring for conti nuity see wiring diagram in this section 3 80 FUEL SYSTEM Subthrottle Sensor Service Code 32 Subthrottle Sensor Resistance
131. molybdenum disulfide oil solution to the journal por tions A on the oil pump drive gear shaft B 6609072851 e Insert the outer rotor and the dowel into the lower crankcase half e Insert the pump cover A washer B pin C and inner rotor D to the oil pump drive gear shaft E 6609071851 ENGINE LUBRICATION SYSTEM 7 13 Oil Pump e Install the oil pump drive gear shaft with inner rotor OTurn the oil pump drive gear shaft so that the projection in its shaft fits onto the slot of the water pump shaft OFit the hole of the oil pump cover onto the pin on the lower crankcase half e Tighten Torque Oil Pump Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib e Install the removed parts see appropriate chapters 7 14 ENGINE LUBRICATION SYSTEM Oil Cooler Oil Cooler Removal e Remove Lower Fairings see Lower Fairing Removal in the Frame chapter Coolant Drain see Coolant Change in the Periodic Maintenance chapter Engine Oil Drain see Engine Oil Change in the Periodic Maintenance chapter Clamp Screws Loosen e Remove the water hoses from the oil cooler e Unscrew the oil cooler mounting bolts A and remove the oil cooler B Oil Cooler Installation Apply grease to the new O ring A before installation e Install the oil cooler and tighten the bolts following the specified tightening sequence 1 4 Torque Oil Cooler Mounting Bolts B 12 N m 1 2 kgf m 1
132. 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 e Connect the hoses to the separator and install the sepa rator on the motorcycle e Disconnect the breather hose from the separator and in ject about 20 mL 0 68 US oz of gasoline A into the separator B through the hose fitting e Disconnect the fuel return hose C from the fuel tank D e Run the open end of the return hose into the container and hold it level with the tank top E e Start the engine and let it idle xIf the gasoline the separator comes out of the hose the separator works well If it does not replace the separator with a new one Canister Inspection e Refer to the Evaporative Emission Control System In spection in the Periodic Maintenance chapter 3 138 FUEL SYSTEM DFI Evaporative Emission Control System CAL SEA and TH Models 68013024844 C 2 White Hose Vacuum 3 Throttle Body Assy 4 Green Hose Purge 1 Fuel Tank 5 Canister 2 o c put o ptr Go on 8 Fitting 9 Bracket for Separator 10 Separator 11 Blue Hose Breather 12 Blue Hose Breather COOLING SYSTEM 4 1 Cooling System Table of Contents Exploded VIBW 4 2 Goolant Flow iei re tete tema tee eS 4 4 MOC TAU ONS
133. of the bracket to fix the brake pipes Brake Pipe with Two Blue Paint Marks Brake Pipe with Two White Paint Marks 17 54 APPENDIX Cable Wire and Hose Routing ABS Equipped Models 58090706 G APPENDIX 17 55 Cable Wire and Hose Routing 10 11 Clamp Brake Hose Bracket Install the bracket from backside of the rear frame Rear Wheel Rotation Sensor Lead Connector Hold the joint portion of the brake hose to the bracket Clamp Clamp Clamp Clamps Hold the rear wheel rotation sensor lead and brake hose at the white tape position of the rear wheel rotation sensor lead Rear Wheel Rotation Sensor Lead Clamps Run only the brake hose through the clamps 17 56 APPENDIX Cable Wire and Hose Routing Oxygen Sensor Equipped Models Neat Jm RS SEA ADO prts P Bd ALES S D Aa 8 2 08099168045 C APPENDIX 17 57 Cable Wire and Hose Routing 1 Run the oxygen sensor lead through over the thermostat housing and crankshaft sensor lead 2 Run the oxygen sensor lead which is connected to the air switching valve lead between the throttle body 3 and 4 Pad for Middle Fairing Run the oxygen sensor lead and water hose through the hole of the pad note the shape of the hole at this time Run the oxygen sensor lead through t
134. or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below e Replacement of the original exhaust system or muffler with a component not in compliance with Federal regulations e Removal of the muffler s or any internal portion of the muffler s e Removal of the air box or air box cover e Modifications to the muffler s or air inlet system by cutting drilling or other means if such modifications result in increased noise levels Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop However it contains enough detail and basic in formation to make it useful to the owner who de sires to perform his own basic maintenance and repair work A basic knowledge of mechanics the proper use of tools and workshop proce dures must be understood in order to carry out maintenance and repair satisfactorily When ever the owner has insufficient experience or doubts his ability to do the work all adjust ments maintenance and repair should be car ried out only by qualified mechanics In order to perform the work efficiently and to avoid costly mistakes read the text thor oughly familiarize yourself with the procedures before starting work and then do the work care fully 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 in
135. pedal action feels soft or spongy after the brake fluid is changed or when ever a brake line fitting has been loosened for any reason NOTE OThe procedure to bleed the front brake line is as follows Bleeding the rear brake line is the same as for the front brake e Remove Screw A Clamp B Front Brake Reservoir Cap C Diaphragm Plate Diaphragm e Fill the reservoir with fresh brake fluid to the upper level line in the reservoir e Slowly pump the brake lever several times until no air bubbles can be seen rising up through the fluid from the holes at the bottom of the reservoir OBleed the air completely from the master cylinder by this operation e Remove the rubber cap from the bleed valve on the front master cylinder e Attach a clear plastic hose A to the bleed valve and run the other end of the hose into a container BRAKES 12 25 12 26 BRAKES Brake Fluid e Bleed the brake line and the master cylinder ORepeat this operation until no more air can be seen com ing out into the plastic hose 1 Pump the brake lever until it becomes hard and apply the brake and hold it A 2 Quickly open and close B the bleed valve while hold ing the brake applied 3 Release the brake C NOTE OThe fluid level must be checked often during the bleed ing operation and replenished with fresh brake fluid as necessary If the fluid in the reservoir runs completely out any time during bleeding the blee
136. plug dirty broken or gap maladjusted Inspect and replace see chapter 16 Spark plug incorrect Replace it with the correct plug see chapter 2 ECU ground and power supply trouble Inspect see chapter 3 ECU trouble Inspect see chapter 3 No or little fuel in tank Fuel injector trouble Fuel pump not operating Fuel pump relay trouble Fuel filter or pump screen clogged Fuel pressure regulator trouble Fuel line clogged Poor Running at Low Speed Symptoms or Possible Causes Spark weak Stick coil shorted or not in good contact Stick coil trouble Spark plug dirty broken or gap maladjusted Spark plug incorrect ECU trouble Supply fuel see Owner s Manual Inspect and replace see chapter 3 Inspect see chapter 3 Inspect and replace see chapter 3 Inspect and replace fuel pump see chapter 3 Inspect fuel pressure and replace fuel pump see chapter 3 Inspect and repair see chapter 3 Actions chapter Inspect or Reinstall see chapter 16 Inspect see chapter 16 Inspect and replace see chapter 16 Replace it with the correct plug see chapter 2 Inspect see chapter 3 Fuel air mixture incorrect Little fuel in tank Supply fuel see Owner s Manual Air cleaner clogged poorly sealed or missing Clean element or inspect sealing see chapter 3 Air duct holder loose Reinstall see chapter 3 Throttle body assy holde
137. 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 2007 Kawasaki Heavy Industries Ltd Second Edition 1 Jul 28 2008 LIST OF ABBREVIATIONS ABDC AC ATDC BBDC BDC BTDC DC ft 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 Ib m min N Pa PS psi rpm TDC TIR pound s meter s minute s newton s pascal s horsepower pound s per square inch revolution revolution s per minute top dead center total indicator reading volt s watt s ohm s COUNTRY AND AREA CODES AT AU CA CAL CH DE EUR GB Austria Australia Canada California Switzerland Germany Europe United Kingdom SEA TH US WVTA FULL H GB WVTA FU
138. pressure sensor especially on a hard surface Such a shock to the sensor can damage it e Remove Left Middle Fairing see Middle Fairing Removal in the Frame chapter Bolt A e Remove Inlet Air Pressure Sensor Connector A Inlet Air Pressure Sensor B Vacuum Hose C Inlet Air Pressure Sensor Installation NOTE OThe inlet air pressure sensor is the same part as the at mospheric pressure sensor except that the sensor has a vacuum hose and different wiring e Install the vacuum hose e Put the inlet air pressure sensor in the stay plate A of throttle body assy 3 52 FUEL SYSTEM Inlet Air Pressure Sensor Service Code 12 Inlet Air Pressure Sensor Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Remove the ECU see ECU Removal ODo not disconnect the ECU connectors e Connect a digital meter A to the connector B using the needle adapter set Special Tool Needle Adapter Set 57001 1457 Inlet Air Pressure Sensor Input Voltage Connections to ECU Connector Meter BL lead terminal 7 Meter BR BK lead terminal 34 Measure the input voltage with the engine stopped and with the connectors joined e Turn the ignition switch ON Input Voltage at ECU Standard DC 4 75 5 25 V the reading is less than the standard range check the ECU for its ground and power supply see ECU Power Supply Ins
139. replace the ECU see ECU Removal Installation FUEL SYSTEM 3 63 Atmospheric Pressure Sensor Service Code 15 xIf the reading is within the standard range remove the seat see Seat Removal in the Frame chapter and check the input voltage at the atmospheric pressure sensor con nector e Disconnect the atmospheric pressure sensor connector and connect the harness adapter A between the harness connector and atmospheric pressure sensor connector Special Tool Sensor Harness Adapter 57001 1561 e Connect a digital meter to the harness adapter leads Atmospheric Pressure Sensor B Atmospheric Pressure Sensor Input Voltage Connections to Adapter Meter G sensor BL lead C Meter gt BK sensor BR BK lead D e Measure the input voltage with the engine stopped and with the connector joined LI e Turn the ignition switch ON Input Voltage at Sensor Connector Standard DC 4 75 5 25 V e Turn the ignition switch OFF the reading is out of the standard range check the wiring see wiring diagram in this section xIf the reading is good the input voltage is normal Check the output voltage 80617142851 6 Atmospheric Pressure Sensor Output Voltage Inspection e Measure the output voltage at the ECU in the same way as input voltage inspection Note the following Digital Meter A rcm Connector B Special Tool Needle Adapter Set 57001 1457
140. resis tance as shown in the figure Terminal Bolt and Positive Brush A Right hand End Cover and Negative Brush B Special Tool Hand Tester 57001 1394 x lf there is not close to zero ohms the brush lead has an open Replace the brush holder assembly Right hand End Cover Assembly Inspection e Using the highest hand tester range measure the resis tance as shown in the figure Terminal and Right hand End Cover A Special Tool Hand Tester 57001 1394 x lf there is any reading the right hand end cover assembly have a short Replace the right hand end cover assembly Starter Relay Inspection e Remove the battery see Battery Removal e Disconnectthe starter motor cable A and battery positive cable B from the starter relay e Disconnect the connector C Pull out the starter relay from the damper e Connect the hand tester A and 12 V battery B to the starter relay C as shown in the figure Special Tool Hand Tester 57001 1394 If the relay does not work as specified the relay is defec tive Replace the relay Testing Relay Tester Range 1 range Criteria When battery is connected 0 O When battery is disconnected gt e Tighten Torque Starter Relay Cable Terminal Bolts 3 9 N m 0 40 kgf m 35 in Ib e Install the removed parts see appropriate chapters GP11019BS1 C ELECTRICAL SYSTEM 16 57 Electric Starter System Electric Starter Circuit
141. seal is in a poor condition it could lead the pad to wear excessively or the brake to drag which may cause the tem perature of the discs or the brake fluid to increase e Replace the fluid seal if it exhibits any of the conditions listed below OBrake fluid leakage around the pad OBrakes overheat OConsiderable difference in inner and outer pad wear OSeal and piston are stuck together the fluid seal is replaced replace the dust seal B as well Also replace all seals every other time the pads are changed Caliper Dust Seal Damage Inspection e Check that the dust seals A are not cracked worn swollen or otherwise damaged x If they show any damage replace the dust seals with new ones Pistons B Fluid Seals C 9105153851 C 9105155851 C 9105156851 C Calipers Caliper Piston and Cylinder Damage Inspection e Visually inspect the pistons A and cylinder surfaces B Replace the caliper if the cylinder and piston are badly scores or rusty BRAKES 12 19 6105157851 C 6105158851 C 12 20 BRAKES Brake Pads Front Brake Pad Removal e Loosen the pad pins A e Remove Pad Pins A Pad Springs B Brake Pads C Front Brake Pad Installation e Push the caliper pistons in by hand as far as they will go e Install the outside pad A and insert the pad pin B as shown in the figure e Set Inside Pad A Pad Spring B OPushing the pin holder
142. sensor lead connector A e Loosen the duct clamp bolts A on both sides e Remove Fuel Tank see Fuel Tank Removal Inlet Air Temperature Sensor A Bolts B Air Cleaner Caps C ODo not disconnect the inlet air temperature sensor lead connector e Remove the duct clamps from the ducts A and pull out the ducts upward 3 120 FUEL SYSTEM DFI Throttle Body Assy ORemove the grommets A as necessary e Remove the throttle case A to make a throttle cable slack e Remove Clamp A Throttle Cable Lower Ends B e Remove the adjuster screw A from the clamps B e Loosen the throttle body assy holder clamp bolts A on both sides e Pull out the throttle body assy B from the holder e Disconnect the fuel hose joint from the delivery pipe of the throttle body assy see Fuel Hose Replacement in the Periodic Maintenance chapter Throttle Body Assy e Remove the throttle body assy A to the left side of mo torcycle e After removing the throttle body assy stuff pieces of lint free clean cloths into the throttle body assy holders CAUTION If dirt gets into the engine excessive engine wear and possible engine damage will occur Throttle Body Assy Installation e Install the holder clamp bolts A in the direction as shown in the figure Bolt Heads B e Connect the fuel hose joint to the delivery pipe of the throt tle body assy see Fuel Hose Replacement in the Periodic
143. shafts without binding after assembly 9113331851 C CRANKSHAFT TRANSMISSION 9 43 Transmission 636 869 62 69609 26063690068 8 um 14 6 d 409 Q CD 6062 69 D 1 Output Shaft 13 5th Gear 2 Collar 14 Thrust Washer 35 mm 1 38 in 3 Ball Bearing 15 1st Gear 4 Bushing 16 Needle Bearing 5 2nd Gear 17 Bearing Outer Race 6 Toothed Washer 40 mm 1 57 in 18 Needle Bearing 7 Circlip 19 Snap Ring 25 5 mm 1 00 in 8 6th Top Gear 20 Toothed Washer 35 5 mm 1 40 in 9 4th Gear 21 Snap Ring 33 mm 1 30 in 10 Toothed Washer 43 mm 1 69 in 22 Toothed Washer 40 5 mm 1 59 in 11 Toothed Washer 39 7 mm 1 56 in 23 Toothed Washer 37 0 mm 1 46 in 12 3rd Gear 24 Drive Shaft OWhen the tangs A of the toothed washer 11 shall be assembled they shall be installed into the notches B of the toothed washer 10 OWhen the tangs C of the toothed washer 23 shall be assembled they shall be installed into the notches D of the toothed washer 22 9 44 CRANKSHAFT TRANSMISSION Transmission Shift Drum and Fork Removal e Remove Lower Crankcase Half see Crankcase Splitting Gear Positioning Lever see External Shift Mechanism Removal Screws A Shift Drum Bearing Holder B Pull out the shift rods C and take off the shift forks Pull out the shift drum D Shift Dr
144. tester E which is set to the DC 10 V range e Connect the adapter to the harness adapter Camshaft Position Sensor F Special Tools Hand Tester 57001 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Harness Adapter 57001 1562 Connections Peak Voltage Harness Adapter Adapter Hand Tester Red Black White lt Black e Turn the ignition switch and engine stop switch ON e Pushing the starter button turn the engine 4 5 sec onds with the transmission gear in neutral to measure the camshaft position sensor peak voltage e Repeat the measurement 5 or more times Camshaft Position Sensor Peak Voltage Standard 2 8 V or more xIf the peak voltage is lower than the standard inspect the camshaft position sensor see Camshaft Position Sensor Inspection Stick Coil Removal e Remove Middle Fairings see Middle Fairing Removal in the Frame chapter Air Switching Valve see Air Switching Valve Removal in the Engine Top End chapter e Disconnect the stick coil connectors A e Pull the stick coils B off the spark plugs CAUTION Do not pry the connector part of the coil while re moving the coil ELECTRICAL SYSTEM 16 45 6210357851 C 16 46 ELECTRICAL SYSTEM Ignition System Stick Coil Installation e Apply grease to the stick coils e Insert the stick coils A as shown being careful of the coil heads directions OAlign the l
145. the oxygen sensor heater fails wiring short ensor 67 Heater raise temperature of or open the ECU stops the current to the Equipped the sensor for its earlier heater and it stops the feedback mode of the Models activation Oxygen sensor When the relay OFF 75 ECU Main condition the main relay is Relay open Note 1 a N Method the DFI control method from medium to heavy engine load 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 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 main throttle sensor output voltage and the engine speed This method is called a N method 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 injec tion 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 FUEL SYSTEM DFI 3 45 OBO 6617127851 6 CAUTION
146. the shape of the current user key e Remove the seat see Seat Removal in the Frame chap ter e Disconnect the immobilizer Kawasaki diagnostic system connector A e Connect the key registration unit A Special Tool Key Registration Unit 57001 1582 16 88 ELECTRICAL SYSTEM Immobilizer System Equipped Models e Insert the master key to the ignition switch and turn it ON Verified OThe warning indicator light LED A blinks to display the registration mode go to the next step Not Verified OThe warning indicator light LED A blinks to display the collation error refer to the following failure illustrations Immobilizer Amplifier Failure Master Key Collation Error e Turn the master key OFF and remove the master key OThe warning indicator light LED A blinks continuously to display that the ECU is in the registration mode for 15 seconds NOTE Olnsert next key and turn ON within 15 seconds after pre vious key is turned OFF and removed otherwise regis tration mode will be ended and the warning indicator light LED stops flashing OTo return to the registration mode start the master key verification procedure This applies to all user key reg istration e Insert the user key 1 to the ignition switch and turn it ON NOTE OKeep the other user key away from the immobilizer an tenna 0 5second 0 5second M iy 0 GP30515BS1 C 0 2second
147. the thrust washer A by facing its chamfered side B towards the crankcase e Install Clutch Housing Needle Bearing Sleeve Washer A OApply engine oil to the needle bearing and the sleeve be fore installation CLUTCH 6 15 Clutch e Install the clutch hub and two washers A OThe outside washer has the OUT SIDE mark B e Replace the clutch hub nut with a new one e Holding the clutch hub with the clutch holder tighten the clutch hub nut with the torque wrench Special Tool Clutch Holder 57001 1243 Torque Clutch Hub Nut 135 N m 13 8 kgf m 99 6 ft Ib e Install the spring seat A spring B friction plates C D E and steel plates F as shown in the figure NOTE OThe inside diameter of first friction plate is larger than the others because the spring seat and spring are equipped to decrease the judder noise as shown in the figure Clutch Hub G Gritoo3BSi C CAUTION If new dry friction plates and steel plates are in stalled apply engine oil to the surfaces of each plate to avoid clutch plate seizure Olnstall outer end friction plate that has the large lining blocks A among others SF11004BS1 C Olnstall the last friction plate A fitting the tangs in the grooves in the housing as shown in the figure 6 06040151 6 6 16 CLUTCH Clutch e Apply molybdenum disulfide grease to the outside surface of the pusher A then in
148. thor oughly so that no gasket material or other material remains Install the new gaskets and replace the used O rings when re assembling Liquid Gasket Non permanent Locking Agent For applications that require Liquid Gasket or a Non permanent Locking Agent clean the surfaces so that no oil residue remains before applying liquid gasket or non permanent locking agent Do not apply them exces sively Excessive application can clog oil passages and cause serious damage 68020128 68020148 68020168 Before Servicing Press For items such as bearings or oil seals that must be pressed into place apply small amount of oil to the con tact area Be sure to maintain proper alignment and 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 grea
149. thrust washers B e Slide C one thrust washer into the upper crankcase half e Move the crankshaft to the left or right and then slide the other washer into the upper crankcase half NOTE OSlide the thrust washers so that the oil grooves D face outward Make sure that the blue painted edges E are positioned as shown in the figure Front F 9 16 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Removal e Split the crankcase see Crankcase Splitting e Remove Connecting Rod Nuts A Crankshaft NOTE OMark and record the locations of the connecting rods and their big end caps so that they can be reassembled in their original positions e Remove the piston see Piston Removal CAUTION Discard the connecting rod bolts To prevent dam age to the crankpin surfaces do not allow the con necting rod bolts to bump against the crankpins Connecting Rod Installation CAUTION To minimize vibration the connecting rods should have the same weight mark Big End Cap A Connecting Rod B Weight Mark Alphabet C Diameter Mark D O or no mark CAUTION If the connecting rods big end bearing inserts or crankshaft are replaced with new ones select the bearing insert and check clearance with a plasti gage press gauge before assembling engine to be sure the correct bearing inserts are installed e Apply molybdenum disulfide oil solution to the inner s
150. touch the glass portion with bare hands Always use a clean cloth Oil contamination from hands or dirty rags can reduce bulb life or cause the bulb to explode NOTE OClean off any contamination that inadvertently gets on the bulb with alcohol or soap and water solution e Replace the headlight bulb e Fit the projections A of the bulb in the hollows B of the headlight e Turn the headlight bulb clockwise e Connect the headlight connector e After installation adjust the headlight aim see Headlight Aiming Inspection in the Periodic Maintenance chapter OOther Bulbs Repeat the above steps ELECTRICAL SYSTEM 16 59 Lighting System City Light Bulb Replacement e Remove the inner covers see Inner Cover Removal in the Frame chapter e Unscrew the screw A e Disconnect the city light connector B e Turn the city light bulb counterclockwise and pull out the socket A together with the bulb e Pull out the bulb A straight from the socket B CAUTION Do not turn the bulb Pull the bulb out to prevent damage to the bulb Do not use bulb rated for greater wattage than the specified value e Replace the bulb with a new one e Insert the socket to the headlight OAlign the projections A of the socket and the grooves B of the headlight e Turn the city light bulb clockwise e Connect the city light connector Headlight Removal Installation e Remove Upper Fairing see U
151. two new user keys B OThese parts are available as a set Prepare the current master key C e Remove Ignition Switch and Immobilizer Antenna see Immobi lizer System Parts Replacement Seat see Seat Removal in the Frame chapter e Disconnect the immobilizer Kawasaki diagnostic system connector e Connect the key registration unit A Special Tool Key Registration Unit 57001 1582 e Connect New Ignition Switch Lead Connector A Immobilizer Antenna Lead Connector B NOTE OKeep the antenna more than 15 cm 5 9 in from the ignition switch e Put the current master key C at the antenna D e Insert the new user key 1 E to the new ignition switch F and turn it ON Verified OThe warning indicator light LED A blinks to display the ECU is in the registration mode go to the next step 0 5second 0 5second 6230515851 C Not Verified OThe warning indicator light LED A blinks to display the collation error Immobilizer Amplifier Failure 0 2second QN On 6230516851 C 16 94 ELECTRICAL SYSTEM Immobilizer System Equipped Models Master Key Collation Error e Turn OFF and remove the new user key 1 e Temporarily place the antenna A on the new ignition switch B e Insert the user key 1 C again into the new ignition switch and turn it ON NOTE OPlace the antenna on the ignition switch insert the next key and turn ON wit
152. up thoroughly e Turn the adjusting screw A until the idle speed is correct OOpen and close the throttle a few times to make sure that the idle speed is within the specified range Readjust if necessary Fuel Hose Inspection fuel leak damage installation condition Olf the motorcycle is not properly handled the high pres sure inside the fuel line can cause fuel to leak A or the hose to burst Remove the fuel tank see Fuel Tank Re moval in the Fuel System DFI chapter and left middle fairing see Middle Fairing Removal in the Frame chap ter and check the fuel hose Replace the fuel hose if any fraying cracks B or bulges C are noticed aS a 9505096851 C PERIODIC MAINTENANCE 2 21 Periodic Maintenance Procedures e Check that the hoses are routed according to Cable Wire and Hose Routing section in the Appendix chapter x Replace the hose if it has been sharply bent or kinked Hose Joints A Fuel Hose B e Check that the hose joints are securely connected OPush and pull A the hose joint B back and forth more than two times and make sure it is locked 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 Evaporative Emission Control System Inspection CAL SEA and TH Models e Inspect the canister as follows ORemove the
153. use for drinking e Remove Right Middle Fairing see Middle Fairing Removal in the Frame chapter Radiator Cap A ORemove the radiator cap in two steps First turn the cap counterclockwise to the first stop Then push and turn it further in the same direction and remove the cap e Remove the left middle fairing see Middle Fairing Re moval in the Frame chapter e Place a container under the drain bolt A at the bottom of the water pump cover e Drain the coolant from the radiator and engine by remov ing the drain bolt e Remove Hoses A Bolts B Reserve Tank C e Remove the cap D and pour the coolant into a container e Install the reserve tank and reconnect the reserve tank hose and overflow hose correctly see Cable Wire and Hose Routing section in the Appendix chapter e Apply a non permanent locking agent to the threads of the reserve tank bolts and tighten them Torque Reserve Tank Bolts 9 8 N m 1 0 kgf m 87 in Ib e Tighten the drain bolt with the gasket OReplace the drain bolt gasket with a new one Torque Coolant Drain Bolt 10 Nm 1 0 kgf m 89 in Ib 9506041851 PERIODIC MAINTENANCE 2 53 Periodic Maintenance Procedures Fill the radiator up to the radiator filler neck A with coolant and install the radiator cap NOTE O Pour in the coolant slowly so that it can expel the air from the engine and radiator e Fill the reserve tank up to the full level line with
154. water temperature sensor lead A ORun B the water temperature sensor lead between the 3 and 4 cylinder and connect the water temperature sensor body qm pone rem 59 ami GHO4091BW2 C e Install the engine mounting bolts and nuts following the specified installing sequence OApply molybdenum disulfide grease A to the threads of the adjusting collars OFirst tighten the adjusting collars fully by hand Upper Adjusting Collar B Upper Crankcase C Lower Adjusting Collar D Lower Crankcase E GHO2078BS2 C ENGINE REMOVAL INSTALLATION 8 9 Engine Removal Installation OSecond insert the mounting bolts A until they fit B in the adjusting collars C OBe sure that the collar D is in position NOTE OReplace the following bolts with new bolts pre coated with locking agent Engine Bracket Bolts P No 92153 1770 Front Engine Mounting Bolts P No 92153 1769 Subframe Bolts P No 92153 1768 OThird install the left engine bracket A and temporally tighten the left engine bracket bolts B and left front en gine mounting bolt C OFourth remove the wrench lever and leave the socket head on the engine mounting bolt A Turn the adjust ing coller F counter clockwise with the socket head to grabbed hands until it becomes hard to turn eliminating a gap B Crankcase C Swingarm D Zero mm E Torque
155. which is set to the DC 250 V range OConnect the adapter to the lead wire peak voltage adapter E which is connected between the stick coil connector and stick coil ECU F Battery G Special Tools Hand Tester 57001 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Lead Wire Peak Voltage Adapter 57001 1449 Primary Lead Connection Adapter R to lead wire peak voltage adapter W Adapter BK to lead wire peak voltage adapter R WARNING To avoid extremely high voltage shocks do not touch the spark plugs or tester connections e Turn the ignition switch and engine stop switch ON e Pushing the starter button turn the engine 4 5 seconds with the transmission in neutral to measure the primary peak voltage e Repeat the measurements 5 times for one stick coil Stick Coil Primary Peak Voltage Standard 72 V or more e Repeat the test for the other stick coils the reading is less than the specified value check the following Stick Coils see Stick Coil Inspection Crankshaft Sensor see Crankshaft Sensor Inspection ECU see ECU Power Supply Inspection in the Fuel Sys tem DFI chapter Spark Plug Removal e Refer to the Spark Plug Replacement in the Periodic Maintenance chapter Spark Plug Installation e Refer to the Spark Plug Replacement in the Periodic Maintenance chapter ELECTRICAL SYSTEM 16 47 8 10283851 C 16 48 ELECTRICAL SYSTEM Ignition System Spark
156. white tape position of the front wheel rotation sensor lead Brake Hose Clamp Run only the brake hose through the clamp Clamp Front Wheel Rotation Sensor Install the brake hose so that the joint pipe faces rear of the motorcycle Brake Hose View from Bottom Clamp Hold the brake hose and align the clamp with white tape of the front wheel rotation sensor lead Clamp Front Wheel Rotation Sensor Lead Connector Right Middle Air Inlet Duct Brake Hose Brake Hose Clamp Bracket Bracket Clamp Bracket Brake Pipe Brake Pipe Brake Hose Brake Hose 17 52 APPENDIX Cable Wire and Hose Routing ABS Equipped Models 68090896 6 APPENDIX 17 53 Cable Wire and Hose Routing 10 11 Bracket Push the joint portions of the brake pipe and hold them Brake Pipe with Blue Paint Mark ABS Hydraulic Unit Side Install the brake pipe along with the groove of the frame Brake Pipe with White Paint Mark ABS Hydraulic Unit Side Brake Hose with Two White Paint Marks and Brake Hose Joint Pipe with White Paint Mark Brake Hose with White Paint Mark and Brake Hose Joint Pipe with White Paint Mark Brake Hose with Blue Paint Mark and Brake Hose Joint Pipe with Blue Paint Mark Brake Hose with Two Blue Paint Marks and Brake Hose Joint Pipe with Two Blue Paint Marks Insert the brake pipes into the holes of the damper and align the projection of the damper with the hole
157. 0 4 0 6 0 8 1 1 2 1 4 1 6 1 8 2 2 2 2 4 2 6 2 8 X1 000m Altitude GC17A43584 3 66 FUEL SYSTEM Crankshaft Sensor Service Code 21 Crankshaft Sensor Removal Installation e Refer to the Crankshaft Sensor Removal Installation in the Electrical System chapter Crankshaft Sensor Inspection OThe crankshaft sensor has no power source and when the engine stops the crankshaft generates no signals e 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 e Check the wiring for continuity see wiring diagram in this section Crankshaft Sensor Circuit R BK BK Y 1 R BK R BK BK BK BK 6GCc17429CW2 C 1 ECU 2 Crankshaft Sensor FUEL SYSTEM 3 67 Camshaft Position Sensor Service Code 23 Camshaft Position Sensor Removal Installation The camshaft position sensor detects the position of the camshaft and distinguishes the cylinder e Refer to the Camshaft Position Sensor Removal Installa tion in the Electrical System chapter Camshaft Position Sensor Inspection OThe camshaft position sensor has no power source and when the engine stops the camshaft position sensor gen erates no signals e Crank the engine and measure the peak voltage of the camshaft position sensor see Camshaft Position Sensor Peak Voltage Inspect
158. 06 in Ib e Install the water hoses as shown in the figure White Mark A e Tighten Torque Radiator Water Hose Clamp Screws 2 0 N m 0 20 kgf m 18 in Ib e Install the removed parts see appropriate chapters 6611005851 C GG11011BS1 C ENGINE LUBRICATION SYSTEM 7 15 Oil Pressure Measurement Oil Pressure Measurement e Remove the left lower fairing see Lower Fairing Removal in the Frame chapter e Remove the oil passage plug and attach the adapter A and gauge B to the plug hole Special Tools Oil Pressure Gauge 10 kgf cm 57001 164 Oil Pressure Gauge Adapter PT3 8 57001 1233 e Start the engine and warm up the engine e Run the engine at the specified speed and read the oil pressure gauge xIf the oil pressure is much lower than the standard check the oil pump relief valve and or crankshaft bearing insert wear immediately x lf the reading is much higher than the standard check the oil passages for clogging Oil Pressure Standard 245 343 kPa 2 5 3 5 kgf cm 36 50 psi at 4 000 r min rpm oil temperature 90 194 F e Stop the engine e Remove the oil pressure gauge and adapter A WARNING Take care against burns form hot engine oil that will drain through the oil passage when the gauge adapter is removed e Apply a non permanent locking agent to the threads of the oil passage plug and tighten it Torque Oil Passage Plug 20 N m 2 0 kgf m 15 f
159. 145 in None 41 009 41 016 mm 1 6145 1 6148 in e Select the proper bearing insert A in accordance with the combination of the crankcase and crankshaft coding Size Color B 6105041781 9105276851 9105196851 C 6105041751 CRANKSHAFT TRANSMISSION 9 25 Crankshaft and Connecting Rods Crankcase Main Bearing Crankshaft Main Journal Bearing Insert Inside Diameter Marking Diameter Marking Size Color Part Number Journal Nos 92139 0134 1 3 5 1 Brown 92139 0137 2 4 None 92139 0133 1 3 5 Black O 92139 0136 2 4 92139 0132 1 3 5 92139 0135 2 4 None None Blue The bearing inserts for Nos 2 and 4 journals have an oil groove respectively e Install the new inserts in the crankcase halves and check insert journal clearance with the plastigage 9 26 CRANKSHAFT TRANSMISSION Pistons Piston Removal e Split the crankcase see Crankcase Splitting e Remove Connecting Rod Nuts A Connecting Rod Big End Caps e Remove the crankshaft e Remove the piston to the cylinder head side e Remove the piston pin snap ring A e Remove the piston pins Special Tool Piston Pin Puller Assembly A 57001 910 e Remove the pistons e Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring A to remove it e Remove the 3 piece oil ring with your thumbs in the same manner
160. 18 ft Ib e Install the seat see Seat Installation 15 18 FRAME Fenders Front Fender Removal e Remove Brake Hose Clamps A Both Sides Bolts B with Washer Both Sides Bracket C ABS Equipped Models Front Fender Assy D e Remove the screws A e Separate the front fender covers B and front fender C G008016BS1 C Front Fender Installation e Install the front fender covers to the front fender Olnsert the hooks A of the front fender cover into the slots B of the front fender e Tighten Torque Front Fender Cover Screws 1 2 N m 0 12 kgf m 11 in Ib e Install the front fender assy to the front fork e Install the brake hose clamps to the front fender holes Flap and Rear Fender Removal e Remove Seat see Seat Removal Seat Covers see Seat Cover Removal Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Tool Kit Case A see ECU Removal in the Fuel System DFI chapter Relay Box B see Relay Box Removal in the Electrical System chapter ECU see ECU Removal in the Fuel System DFI chap ter Rear Wheel C see Rear Wheel Removal in the Wheels Tires chapter Separator Bracket Bolt California Model Fuse Boxes D Bolts E and Cover F Seat Lock License Plate Light Connector G Disconnect Clamps H Bolts I Screws J Fenders e Remove Nuts A Flap with License Plate Light Tail Brake Light LED see Tail Brake Light LED Re moval in t
161. 180 0212 2 175 mm 92180 0213 2 225 mm 92180 0214 2 275 mm 92180 0215 2 325 mm 92180 0216 2 825 mm 92180 0217 2 875 mm 92180 0218 2 925 mm 92180 0219 2 975 mm e Clean the shim to remove any dust or oil e Measure the thickness of the removed shim A 2 26 PERIODIC MAINTENANCE Periodic Maintenance Procedures EXHAUST VALVE CLEARANCE ADJUSTMENT CHART Present Shim Example Part No ba 1870 1871 1872 1873 1874 1875 1876 1877 1878 1879 1880 188111882 1883 1884 1885 1886 1887 1888 1889 1890 Mark 60 ae RIEN E X X CAT DIT OT fooson ose oa ula aa ala ae oa o sla se oa es a 792 er s oven ede oda po ala ae aol o s ee odo 10112 ndo ENT ERE DES DIES DIS E DI PES DIESES ENTE DES 99 mlo 2270 27 Specified cheer ance peepee Required ER 02 00 ees DEC ERES ERES DRE ERES DESEE see rere oe oso on 0 48 0 52 95 0 5350 57 2 302 ras dr 45 2 50 2 55 2 60 2 deus dra ras E zs dead 95 3 00 0 63 0 67 ET 60 2 65 2 3 0 68 0 72 Eds 50 2 65 2 70 2 75 2 80 2 85 2 90 2 95 3 00 9 0 73 0 77 eran E ON A NT ENT CWT PR DICERET OT OT a ae He oe c m o o o
162. 2 mm 1 4954 1 4957 in 37 993 38 000 mm ae 1 4958 1 4961 in 41 000 41 016 mm 1 6142 1 6148 in 41 000 41 008 mm 1 6142 1 6145 in 41 009 41 016 mm 1 6145 1 6148 in 1 475 1 480 mm 0 05807 0 05827 in 1 480 1 485 mm 0 05827 0 05846 in 1 485 1 490 mm 0 05846 0 05866 in Usable Range 0 25 0 34 mm 0 0098 0 0134 in 0 25 0 34 mm 0 0098 0 0134 in 0 05 0 24 mm 0 30 mm 0 0020 0 0094 in 0 0118 in TIR 0 03 mm 0 0012 in or less TIR 0 08 mm 0 0031 in 0 031 0 063 mm 0 09 mm 0 0012 0 0025 in 0 0035 in 37 984 38 000 mm 37 96 mm 1 4954 1 4961 in 1 4945 in 37 984 37 992 mm 1 4954 1 4957 in 37 993 38 000 1 4958 1 4961 in 41 000 41 016 1 6142 1 6148 in CRANKSHAFT TRANSMISSION 9 7 Specifications Item Standard Service Limit Marking Crankshaft Main Bearing Insert Thickness Brown Black Blue Pistons Cylinder Upper Crankcase Inside Diameter Piston Diameter Piston Cylinder Clearance Piston Ring Groove Clearance Top Second Piston Ring Groove Width Top Second Piston Ring Thickness Top Second Piston Ring End Gap Top Second Oil Transmission Shift Fork Ear Thickness Gear Groove Width 41 000 41 008 mm 1 6142
163. 20 16 87 Operational 16 87 Key Registrations Mm 16 87 Immobilizer System Parts Replacement pp 16 103 ECU Electronic Control Unit Replacement for Immobilizer Equipped Models 16 104 Immobilizer System Inspection ee i e ed 16 105 SWITCHES ANG E 16 107 Brake Light Timing Inspectig reete arri Pe aeta tre ert bx eek de Rate Rd E RES 16 107 Brake Light Timing Adjustment ose eo etr rto eoe res ate Pic e e dd 16 107 eile cl Specto Nisa naa 16 107 Water Temperature Sensor 16 108 Speed Sensor Remoyval 5 de einem RUN Re ccr Mc 16 108 Speed Sensor Tnstallallori so o EP eoe eee 16 108 Speed Sensor Inspectigm dert eter e Pla ett Genua a ens 16 109 Oxygen Sensor Removal Equipped ModelSs pp 16 109 Oxygen Sensor Installation Equipped Mogels ppp 16 109 Oxygen Sensor Inspection Equipped Mogels pp 16 109 Fuel Level Sensor Inspectigm mune e temi p oet e dE ees 16 110 Fuel Reserve Switch Inspeotion cer ter terrena ER ere uice pida 16 111 Gear Position Switch Removal pp 16 112 Gear Position Switch Installation 16 113 Gear Position Switch Inspection pp 16 113 PRIA Box ee b m
164. 20 Tachometer Inspection e Connect the leads in the same circuit as Check 18 e Start the engine e Check that the needle A in the tachometer moves lf the needle does not move go to the Check 1 and in spect the following items Wiring see Wiring Inspection CAN Communication Line Resistance at ECU see CAN Communication Line Resistance Inspection in the Fuel System DFI chapter Crankshaft Sensor see Crankshaft Sensor Inspection If the above items are good replace the meter assembly and or ECU Check 21 Gear Position Indication Inspection e Install the meter unit see Meter Unit Installation e Turn the ignition switch ON e Check that the N mark A appears in the display and neu tral indicator light LED B goes on e Set the low gear position check that the display changes to 1 mark e For the other gear position indication e Using the stand raise the rear wheel off the ground e Start the engine change the gear position e Check that the display corresponding to each gear posi tion appears e Turn the ignition switch OFF xIf the display function does not work go to the Check 1 and check the following items Wiring see Wiring Inspection CAN Communication Line Resistance at ECU see CAN Communication Line Resistance Inspection in the Fuel System DFI chapter Gear Position Switch see Gear Position Switch Service Code 25 section in the Fuel System DFI chapter Speed Sensor see Speed Sensor Service C
165. 22 Radiator Hose and Pipe Inspection usc oce oce Ere t b a s bo ndisse tad 2 23 Engine Top End e ou reo metere rom abes 2 23 Valve Clearance rh re E ER Qr 2 23 Valve 2 tete pnt tee RH SERE o Ep DRM n URS Hane RA 2 24 Air Suction System Damage Inspectiom pp 2 28 Cc ers 2 28 Clutch OperatiomInspeclOrss 2 28 Clutch Fluid Level Inspection 5 etat done orn np ra ate tats ep Re e End 2 29 Clutch Fluid Leak Inspecton ico dre boh roo bt EDS oases 2 29 Clutch Hose and Pipe Damage and Installation Condition Inspection 2 29 Wheels Tires os een i cU capo ebd 2 30 Air Press rte Inspection se o tete Dess alle Camel d 2 30 Wheel Tire Damage Inspectlon c atre tt ert ed tet HERR X 2 30 Tire Tread Wear Inspection poe 2 30 Wheel Bearing Damage Inspection ect tente tedesca dunt eaae 2 31 Firtal Deeds 2 31 Drive Chain Lubrication Condition Inspection 2 31 Drive Chain SlackeInspeclDm sooo Seen Seay AR boda 2 32 Drive Chain Slack Adjustment Ne 2 32 Wheel Alignment 2 33 Drive Chain Wear Inspection
166. 300 20 200 20 750 0 5 20 300 20 200 20 750 2 0 5 20 300 0 5 20 300 20 300 20 750 BK Y 5 20 5 20 5 20 5 20 E Tester Lead Connection e Install the regulator rectifier e Tighten Torque Regulator Rectifier Bolts 9 8 N m 1 0 kgf m 87 in Ib e Install the removed parts see appropriate chapters BK3 BK2 BK1 GP09184BS1 C Charging System Charging Voltage Inspection e Check the battery condition see Charging Condition In spection e Warm up the engine to obtain actual alternator operating conditions e Remove the right fairing cover see Fairing Cover Re moval in the Frame chapter e Check that the ignition switch is turned off and connect the hand tester A to the battery terminal and ground Special Tool Hand Tester 57001 1394 e Start the engine and note the voltage readings at var ious engine speeds with the headlight turned on and then turned off To turn off the headlight disconnect the headlight connector on the headlight unit The readings should show nearly battery voltage when the engine speed is low and as the engine speed rises the readings should also rise But they must be kept under the specified voltage Charging Voltage Connections Tester Range Reading Tester to Tester to 25 V DC Battery Ground 14 2 15 2 V e Turn off the ignition switch t
167. 3381 oz US mL x 0 02816 oz imp Units of Speed mL x 0 06102 cu in km h M 0 6214 mph Units of Force Units of Power N x 0 1020 kg kW x 1 360 E PS eT kW x 1341 HP kg x 9 807 PS x 0 7355 kw kg x 2 205 Ib PS x 0 9863 HP Units of Temperature 60 104 5 F 40 40 248 i 420 284 176 212 80 100 120 140 160 1180 200 1220 240 260 280 300 1140 138 F 320 160 C PERIODIC MAINTENANCE 2 1 Periodic Maintenance Table of Contents Periodic Maintenance Chart pp 2 3 Torque arid Locking 2 6 ee 2 13 lere 2 15 Periodic Maintenance Procedures rte ede bte rie Ra C a tet 2 16 Fuel System 2 16 Throttle Control System InspeoctiOn ne eet cette 2 16 Engine Vacuum Synchronization InspectiOn o octo dence 2 16 Idle Speed Inspection pp 2 20 Speed AdIDStTert uiros ote E 2 20 Fuel Hose Inspection fuel leak damage installation condition 2 20 Evaporative Emission Control System Inspection CAL SEA and TH Models 2 21 Cool ete ced 2 22 Coolant Level e terret asada adden 2
168. 34 ELECTRICAL SYSTEM Charging System Alternator Cover Removal e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Left Middle Fairing see Middle Fairing Removal in the Frame chapter Alternator Lead Connector A Bolts B and Bracket C e Place a suitable container under the alternator cover A e Remove Pads B Alternator Cover Bolts C Alternator Cover e Pull the alternator lead out of between the engine and frame Alternator Cover Installation e Apply silicone sealant to the alternator lead grommet and crankcase halves mating surface A on the front and rear sides of the cover mount Sealant Kawasaki Bond Silicone Sealant 92104 0004 e Check that dowel pins B are in place on the crankcase e Install a new gasket and the alternator cover e Tighten Torque Alternator Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib e Run the alternator lead correctly see Cable Wire and Hose Routing section in the Appendix chapter Stator Coil Removal e Remove Alternator Cover see Alternator Cover Removal Holding Plate Bolts A and Plate Alternator Lead Grommet B Stator Coil Bolts C Stator Coil D ELECTRICAL SYSTEM 16 35 Charging System Stator Coil Installation e Tighten the stator coil bolts to the specified torque Torque Stator Coil Bolts 12 1 2 kgf m 106 in Ib e Apply silicone sealant to the circumference of the alter nator lead grommet and fit the
169. 351 P GPi8405BSi C 16 112 ELECTRICAL SYSTEM Switches and Sensors Gear Position Switch Removal e Remove the left lower fairing see Lower Fairing Removal in the Frame chapter e Slide out the rubber boot A e Loosen the oil pressure switch terminal bolt B and re move the switch lead C e Open the clamps A e Remove Engine Sprocket Cover see Engine Sprocket Removal in the Final Drive chapter Bolt A Clamp B e Disconnect the oil pressure switch gear position switch lead connector C e Open the clamp A e Remove Screws B Gear Position Switch C e Remove the pin A and spring from the shift drum ELECTRICAL SYSTEM 16 113 Switches and Sensors Gear Position Switch Installation e Securely place the spring A and pin B into the hole C of the shift drum e Apply grease to the new O ring D e Apply a non permanent locking agent to the threads of the gear position switch screws e Tighten Torque Gear Position Switch Screws 2 9 N m 0 30 kgf m 26 in Ib Gear Position Switch Lead Clamp Bolts 9 8 N m 1 0 kgf m 87 in Ib e Run the gear position switch and oil pressure switch lead correctly see Cable Wire and Hose Routing section in the Appendix chapter e Install the removed parts see appropriate chapters Gear Position Switch Inspection NOTE OBe sure the transmission mechanism is good condition e Disconnect the connector A e Set the
170. 36551 C 6 15046851 6 5 28 ENGINE TOP END Valves 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 e 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 e Move the stem back and forth C to measure valve valve guide clearance e Repeat the measurement in a direction at a right angle to the first If the reading exceeds the service limit replace the guide GE15007BS2 C NOTE OThe reading is not actual valve valve guide clearance because the measuring point is above the guide Valve Valve Guide Clearance Wobble Method Standard Exhaust 0 08 0 16 mm 0 0031 0 0063 in Inlet 0 03 0 10 mm 0 0012 0 0039 in Service Limit Exhaust 0 40 mm 0 016 in Inlet 0 34 mm 0 013 in ENGINE TOP END 5 29 Valves Valve Seat Inspection e Remove the valve see Valve Removal e Check the valve seating surface A between the valve B and valve seat C OMeasure the outside diameter D of the seating pattern on the valve seat x If the outside diameter is too large or too small repair the seat see Seat Repair Valve Seating Surface Outside Diameter Standard Exhaust 27 6 27 8 mm 1 087 1 094 in Inle
171. 400C8F C9F ZX1400D8F D9F Rear Tire Type Tubeless Size 190 50 ZR17 M C 73W Rim Size 17 x 6 00 Front Suspension Type Telescopic fork upside down Wheel Travel 117 mm 4 61 in Rear Suspension Type Swingarm uni trak Wheel Travel 122 mm 4 80 in Brake Type Front Dual discs Rear Single disc Electrical Equipment Battery 12 V 14 Ah Headlight Type Semi sealed beam Bulb High 12 V 55 W 65 W quartz halogen x 2 Low 12 V 55 W quartz halogen x 2 Tail Brake Light 12 V 0 5 4 9 W LED Alternator Type Three phase AC Rated Output 35 A 14 V 95 000 r min rpm Specifications are subject to change without notice and may not apply to every country GENERAL INFORMATION 1 13 Unit Conversion Table Prefixes for Units Units of Length Prefix Symbol Power m Eo Eee cxx MS mega M x 1 000 000 hi kilo k x 1000 mm x 0 03937 in centi 0 01 milli a x 0 001 Units of Torque micro x 0 000001 Nm x 0 1020 kgfm N m x 0 7376 ft lb N m x 8 851 in lb Units of Mass 9 807 N m kg x 2 205 Ib x 7 233 ft lb g x 0 03527 07 kgf m x 86 80 in Ib Units of Volume Units of Pressure L x 0 2642 gal US kPa x 0 01020 kgf cm L x 0 2200 gal imp kPa x 0 1450 psi L x 1 057 qt US kPa x 0 7501 cmHg L x 0 8799 X qt imp kgficm2 x 9807 kPa L x 2 113 pint US kgf cm x 1422 psi L x 1 816 pint imp cmHg x 1 333 kPa mL x 0 0
172. 5 Special Tools and Sealant Inside Circlip Pliers Kawasaki Bond Silicone Sealant 57001 143 92104 0004 7570143ST C 879200045 Clutch Holder 57001 1243 gt 875712435 C 6 6 CLUTCH Clutch Master Cylinder Clutch Lever Position Adjustment The clutch lever adjuster has 5 positions so that the clutch lever position can be adjusted to suit the operator s hand e Push the lever forward and turn the adjuster A to align the number with the triangular mark B on the lever holder OThe distance from the grip to the lever is minimum at num ber 5 and maximum at number 1 Clutch Master Cylinder Removal e Disconnect the starter lockout switch connector A e Drain the clutch fluid from the reservoir see Clutch Fluid Change in the Periodic Maintenance chapter e Remove Clamp Screw A Clutch Reservoir Bolt B e Remove the banjo bolt C to disconnect the clutch hose from the master cylinder e Unscrew the clamp bolts D and take off the master cylin der as an assembly with the clutch reservoir clutch lever and starter lockout switch installed CAUTION Clutch fluid quickly ruins painted surface any spilled fluid should be completely washed away immediately Clutch Master Cylinder Installation e Align the punch mark A on the handlebar with the mating surface B of the master cylinder clamp Front C CLUTCH 6 7 Clutch Master Cylinder
173. 6 116 ELECTRICAL SYSTEM Relay Box Relay Box Internal Circuit GPi90108W2 C A Headlight Circuit Relay B ECU Main Relay C Fuel Pump Relay D Starter Circuit Relay E Fan Relay ELECTRICAL SYSTEM 16 117 Fuse 30 A Main Fuse Removal e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Bolts A Cover B e Disconnect the 30 A main fuse connector A e Pull out the main fuse A from the starter relay with needle nose pliers Fuse Box Fuse Removal e Remove the seat see Seat Removal in the Frame chap ter e Unlock the hook A to lift up the lid B 16 118 ELECTRICAL SYSTEM Fuse e Pull the fuses A straight out of the fuse box with needle nose pliers 15 A ECU Fuse Removal e Remove the seat see Seat Removal in the Frame chap ter e Unlock the hook A to lift up the lid B e Pull out the ECU fuse A from the fuse box Fuse Installation If a fuse fails during operation inspect the electrical sys tem to determine the cause and then replace it with a new fuse of proper amperage e Install the fuse box fuses on the original position as spec ified on the lid ELECTRICAL SYSTEM 16 119 Fuse Fuse Inspection e Remove the fuse see 30 A Main Fuse Box 15 A ECU Fuse Removal e Inspect the fuse element xIf it is blown out replace the fuse Before replacing a blown fuse always check the amperage in the affected c
174. 6 in Inlet 0 15 0 20 mm 0 0059 0 0079 in Clutch Clutch Fluid Grade DOT4 Clutch Lever Free Play Non adjustable Engine Lubrication System Engine Oil Type API SE SF or SG Put API SH SJ or SL with JASO MA Viscosity SAE 10W 40 Capacity 3 7 L 3 9 US qt when filter is not removed 4 1 L 4 3 US qt when filter is removed 4 5 L 4 8 US qt when engine is tuis completely dry Level Between upper and lower level lines Wait 2 3 minutes after idling or running Wheels Tires Tread Depth Front 3 8 mm 0 15 in 1 mm 0 04 in AT CH DE 1 6 mm 0 06 in Rear 4 8 mm 0 19 in Up to 130 km h 80 mph 2 mm 0 08 in Over 130 km h 80 mph 3 mm 0 12 in 2 14 PERIODIC MAINTENANCE Specifications Drive Chain Slack Drive Chain Wear 20 link Length Standard Chain 32 38 mm 1 3 1 5 in 317 5 318 2 mm 12 50 12 5 in Item Standard Service Limit Air Pressure when Cold Front Up to 180 kg 397 Ib load 290 kPa 2 9 kgf cm 42 psi Rear Up to 180 kg 397 Ib load 290 kPa 2 9 kgf cm 42 psi Final Drive Electrical System Spark Plug Type Gap travel CR9EIA 9 0 8 0 9 mm 0 031 0 035 in Make DAIDO Type DID50ZVZ GC amp B Link 116 links Brakes Brake Fluid Grade DOT4 B
175. 7001 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Connections Crankshaft Sensor Peak Voltage Connector C Adapter Hand Tester Yellow Red Black Black 5 e Turn the ignition switch and engine stop switch ON e Pushing the starter button turn the engine 4 5 sec onds with the transmission gear in neutral to measure the crankshaft sensor peak voltage e Repeat the measurement 5 or more times Crankshaft Sensor Peak Voltage Standard 2 4 V or more If the tester reading is not specified one inspect the crank shaft sensor see Crankshaft Sensor Inspection Timing Rotor Removal e Remove the crankshaft sensor see Crankshaft Sensor Removal e Remove the timing rotor A OHolding the timing rotor with the flywheel amp pulley holder B and remove the rotor bolt C Special Tool Flywheel amp Pulley Holder 57001 1605 Timing Rotor Installation e Fit the rotor to the crankshaft e Tighten the rotor bolt Torque Timing Rotor Bolt 39 N m 4 0 kgf m 29 ft lb e Install the removed parts see appropriate chapters Camshaft Position Sensor Removal e Remove Right Middle Fairing see Middle Fairing Removal in the Frame chapter Camshaft Position Sensor Lead Connector Disconnect A 16 44 ELECTRICAL SYSTEM Ignition System e Remove Camshaft Position Sensor Bolt A Camshaft Position Sensor B Camshaft Position Sensor Installation e Replace the O ring of the cam
176. 7406651 C 12 36 BRAKES Anti Lock Brake System Equipped Models e Visually inspect the wiring for signs of burning or fraying lf any wiring is poor replace the damaged wiring e Pull each connector A apart and inspect it for corrosion dirt and damage x lf the connector is corroded or dirty clean it carefully If it is damaged replace it e Check the wiring for continuity OUse the wiring diagram to find the ends of the lead which is suspected of being a problem OConnect the hand tester between the ends of the leads Special Tool Hand Tester 57001 1394 OSet the tester to the x 1 O range and read the tester If the tester does not read 0 the lead is defective Re place the main harness B if necessary e Narrow down suspicious parts and close in on the faulty ABS part by repeating the continuity tests no abnormality is found in the wiring or connectors the ABS parts are the next likely suspects Check each part one by one lf an abnormality is found replace the affected ABS part GL14300BS1 BRAKES 12 37 Anti Lock Brake System Equipped Models ABS Diagnosis Flow Chart Problem occurs Confirm problems Gather information from rider Conduct pre diagnosis inspection 1 2 Conduct self diagnosis Check by other than self diagnosis Check by self diagnosis If harness or connector is faulty If ABS part is faulty Repair or replace Check AB
177. A e t e X 25 gt WES SEG gt Y Exploded View FRAME 15 3 No Fastener Torque Remarks N m kgf m ft Ib 1 Center Stand Bolts Equipped Models 44 4 5 32 2 Front Footpeg Bracket Bolts 25 2 5 18 3 Sidestand Bolt 44 4 5 32 4 Sidestand Bracket Bolts 49 5 0 36 L 5 Sidestand Switch Bolt 8 8 0 90 78 in lb L 6 Center Stand Equipped Models G Apply grease L Apply a non permanent locking agent R Replacement Parts 15 4 FRAME Exploded View 6G0022948W5 C Exploded View FRAME 15 5 5 ABS Equipped Models 6 Center Stand Grip Equipped Models G Apply grease L Apply a non permanent locking agent R Replacement Parts Torque No Fastener Nm kgf m itib Remarks 1 Rear Footpeg Bracket Bolts 25 2 5 18 2 Rear Frame Bolts 44 4 5 32 L 3 Rear Frame Pipe Bolts 44 4 5 32 4 Rear Frame Pipe Nuts 44 4 5 32 15 6 FRAME Exploded View 08002295845 C FRAME 15 7 Exploded View No Fastener Remarks N m kgf m ft Ib 1 Front Fender Cover Screws 1 2 0 12 11 in lb 2 Grab Rail Mounting Bolts Equipped Models 25 2 5 18 3 Rear Fender Mounting Bolts 0 80 0 082 7 1 in lb 4 Rear Fender Mounting Screws 1 2 0 12 11 in lb 5 Seat Lock Bracket Screws 1 2 0 12 11 inb 6 Grab Rail Equipped Models 7 Seat Cover Equipped Models 8 Reflector
178. A starts flashing e By pushing the upper button each time check that the hour display changes e By pushing the lower button for more than two seconds check that the hour display decide and minute display A starts flashing e By pushing the upper button each time check that the minute display changes e By pushing the lower button check that the hour and minute display A starts flashing e By pushing the upper button check that the hour and minute display decide e When both hour and minute display flashing by pushing the lower button for more than two seconds check that the hour display start flashing This flashing returns the hour setting mode xIf the display function does not work replace the meter assembly Check 4 Battery Voltage Inspection e Connect the leads in the same circuit as Check 2 ELECTRICAL SYSTEM 16 75 MILEAGE ENGAGE LA SHIFT LAMP S LAMP MODE BRIGH 12 N e IN Mo 5 SS G9 MILEAGE KM L ENGAGE LAMP OFF SHIFT LAMP OFF LAMP MODE BRIGHT 1234 KM L or BRIGHT 12 34 MILEAGE Rear LAMP MODE MILEAGE ENGAGE LAMP SHIFT LAMP 8 17537851 C 16 76 ELECTRICAL SYSTEM Meter Gauge Indicator Unit
179. AU CA and US Models 15 8 FRAME Exploded View 80022968845 C FRAME 15 9 Exploded View No Fastener noraue Remarks N m kgf m ft lb 1 Windshield Mounting Bolts 0 42 0 043 3 7 15 10 FRAME Seat Seat Removal e Insert the ignition switch key A into the seat lock and re move the seat turning the key counterclockwise pulling up on the rear of the seat B and pulling the seat back ward e For seat cover equipped models note the following e Remove Screws A Seat Cover B Seat Installation e Insert the slots A of the seat into the brackets B of the fuel tank e Insert the projections A of the seat into the slots B of the seat lock and insert the seat hook C into the slot D of the frame e Push down the rear part of the seat until the lock clicks Fairings Lower Fairing Removal e Pull up the core by the thin blade driver e Remove the quick rivet A e Remove the bolts B with washer e Clear the hook portions from the slots e Separate the left lower fairing from the right lower fairing Lower Fairing Installation e Insert the hook portions A into the slots B e Tighten the bolts with washer e Set the quick rivet and push the core Fairing Cover Removal e Remove the bolts A e Pull out the fairing cover B and clear the stoppers Fairing Cover Installation e Insert the projections A into the holes
180. Adjusting Collars 15 N m 1 5 kgf m 11 ft Ib ODo not exceed the specified torque of adjusting collars NOTE Olf the socket cannot be turned by hand adjust the po sition of the engine with a engine lifter to line up the alignment 6H02079BS1 C 6H02076BS1 C GHO2ZO77BWi C 8 10 ENGINE REMOVAL INSTALLATION Engine Removal Installation Right gt Engine Bracket Upper Side GH04092BW3 C OFifth tighten the left engine bracket bolts A and left front engine mounting bolt B OSixth put alignment mark on upper and lower engine mounting bolt and frame OTighten Torque Engine Mounting Nuts M12 upper and lower 59 N m 6 0 kgf m 44 ft lb NOTE OHold the mounting bolt at the right side of the frame not to turn when tightening the upper and lower engine mounting nuts at the left side of the frame OMake sure the alignment marks are still matched NOTE Olf the alignment marks not match repeat to tightening process again ENGINE REMOVAL INSTALLATION 8 11 Engine Removal Installation OSeventh install the right engine bracket and tighten the right engine bracket bolts E and the right front engine mounting bolt F OTighten Torque Engine Mounting Nuts M12 59 N m 6 0 kgf m 44 ft lb OTighten Torque Engine Bracket Bolts M8 25 N m 2 5 kgf m 18 ft Ib Front Engine Mounting Bolts M10 59 N m 6 0 kgf m 44 16 Subfram
181. Approx 48 Front Install the brake hose joint pipes as shown in the figure 17 44 APPENDIX Cable Wire and Hose Routing ABS Equipped Models 6809624085 C APPENDIX 17 45 Cable Wire and Hose Routing NO oR Clamps Insert the clamps into the front fender Clamp Hold the front wheel rotation sensor lead and brake hose at the white tape position of the front wheel rotation sensor lead Brake Hose Brake Hose Front Master Cylinder Right Front Caliper Clamp Hold the front wheel rotation sensor lead Front Wheel Rotation Sensor Lead Front Wheel Rotation Sensor 17 46 APPENDIX Cable Wire and Hose Routing ABS Equipped Models a gt O Iesse OA 7 2 DM n Yn rw par gr OLN B 6809625015 C APPENDIX 17 47 Cable Wire and Hose Routing ABS Hydraulic Unit Front Bracket Brake Pipe Blue Paint Mark Brake Pipe White Paint Mark Damper Brake Hose Brake Hose Blue Paint Mark Brake Hose Joint Pipe Blue Paint Mark Brake Hose White Paint Mark Brake Hose Joint Pipe White Paint Mark Front Wheel Rotation Sensor Lead Clamps Hold the front wheel rotation sensor lead Clamps Hold the front wheel rotation sensor lead and brake hose at the white tape position of the front wheel rotation sensor lead Bracket View from Front Side
182. BR BK Y r E x 8L 0 BL O BK dB 9 48 E 65 omi _ Barteria 1 Y BK Y BK Y BK Y 6017205DW5 C DFI System Part Names 11 24 ECU Joint Connector 3 Fuel Pump Vehicle down Sensor Frame Ground 1 Engine Ground Frame Ground 2 Battery 12 V 14 Ah Starter Relay 10 Joint Connector 2 12 13 14 15 16 17 18 19 20 21 22 23 Joint Connector 1 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 Main Fuse 30 A Relay Box Fuel Pump Relay ECU Main Relay Fuse Box 2 ECU Fuse 15A Ignition Fuse 10 A Fuse Box 1 Oxygen Sensor Heater Fuse 10 A Equipped Models Speedometer Water Temperature Gauge Warning Indicator Light LED Meter Unit Ignition Switch Engine Stop Switch Starter Button Stick Coil 1 2 3 4 Speed Sensor Camshaft Position Sensor Water Temperature Sensor Oxygen Sensor Equipped Models Inlet Air Temperature Sensor Water proof Joint 2 Atmospheric Pressure Sensor Injector 1 Injector 2 Injector 3 Injector 4 Crankshaft Sensor Subthrottle Valve Actuator Subthrottle Sensor Main Throttle Sensor Inlet Air Pressure Sensor Water proof Joint 1 OColor Codes BK Black GY Gray PU Purple BL Blue LB Light Blue R Red BR
183. Bearing Inspection Since the hub bearings are made to extremely close tol erances the clearance can not normally be measured NOTE ODo not remove any bearings for inspection If any bear ings are removed they will need to be replaced with new ones e Turn each bearing in the hub back and forth A while checking for plays roughness or binding xIf bearing play roughness or binding is found replace the bearing e Examine the bearing seal B for tears or leakage xIf the seal is torn or is leaking replace the bearing 6406043851 C 6J06008BSi 6 6406008851 6 6J06002BSi 6 10 18 WHEELS TIRES Hub Bearing Hub Bearing Lubrication NOTE OSince the hub bearings are packed with grease and sealed lubrication is not required FINAL DRIVE 11 1 Final Drive Table of Contents Exploded VIEW Em 11 2 Specification ee a a eea a 11 4 Special TOS RE e Ea E 11 5 NEPTIS 11 6 Drive Chain Slack Inspection mtd 11 6 Drive Chain Slack Adjustment pp 11 6 Wheel Alignment Inspection Adjustment 44444282 11 6 Drive Chain Wear Inspection Drive Chain Lubricatigm oa tds dentem toe te Drive Chain Removal Set cedi en Drive Chain Spro ket COUP UNG sree chet eat teal poss ta
184. Bleed Valve 7 8 0 80 69 in lb 13 Front Master Cylinder Clamp Bolts 11 121 97 in lb S B Apply brake fluid L Apply a non permanent locking agent R Replacement Parts S Follow the specified tightening sequence Si Apply silicone grease 12 10 BRAKES Exploded View ABS Equipped Models GL023148W5 C Exploded View BRAKES 12 11 Torque No Fastener Nm kgf m Remarks 1 Bleed Valves 7 8 0 80 69 in lb 2 Brake Hose Banjo Bolts 25 2 5 18 3 Pedal Bolt 8 8 0 90 78 in lb 4 Brake Pipe Joint Nuts ABS Equipped Models 18 1 8 13 5 Rear Brake Disc Mounting Bolts 27 2 8 20 L 6 Rear prake Pad Pin 17 2 13 7 L 8 Rear Caliper Mounting Bolts 18 9 Rear Master Cylinder Mounting Bolts 25 2 5 18 10 Rear Master Cylinder Push Rod Locknut 17 2 1 8 13 Apply brake fluid Apply grease Replacement Parts Si Apply silicone grease Apply a non permanent locking agent 12 12 BRAKES Specifications Item Standard Service Limit Brake Lever Brake Pedal Brake Lever Position 6 way adjustable to suit rider Brake Lever Free Play Non adjustable Pedal Free Play Non adjustable Pedal Position About 45 mm 1 77 in below top of footpeg Brake Pads Lining Thickness Front 4 0 mm 0 16 in 1 mm 0 04 in Rear 5 0 mm 0 20 in 1 mm 0 04 in Brake Discs Thickness Fro
185. C to hole of the pad and insert the pad pin Torque Front Brake Pad Pins 17 2 N m 1 8 kgf m 13 ft Ib WARNING Do not attempt to drive the motorcycle until a full brake lever is obtained by pumping the brake lever and the pads are against the disc The brake will not function on the first application of the lever if this is not done Brake Pads Rear Brake Pad Removal e Loosen the pad pin A e Unscrew the caliper mounting bolts B e Remove the caliper with the hose installed e Remove Pad Pin A Pad Spring B Brake Pads C Rear Brake Pad Installation e Push the caliper pistons in by hand as far as they will go e Install the outside pad A and insert the pad pin B as shown in the figure e Set Inside Pad A Pad Spring B OPushing the pin holder C to hole of the pad and insert the pad pin e Install the caliper see Caliper Installation e Tighten the pad pin Torque Rear Brake Pad Pin 17 2 N m 1 8 kgf m 13 ft Ib A WARNING Do not attempt to drive the motorcycle until a full brake pedal is obtained by pumping the brake pedal until the pads are against the disc The brake will not function on the first application of the pedal if this is not done Brake Pad Wear Inspection e Refer to the Brake Pad Wear Inspection in the Periodic Maintenance chapter BRAKES 12 21 12 22 BRAKES Master Cylinder Front Master Cylinder Removal e Remove the reservo
186. Diameter Exhaust Inlet Valve Guide Inside Diameter Exhaust Inlet Valve Valve Guide Clearance Wobble Method Exhaust Inlet Valve Seat Cutting Angle Valve Seating Surface Width Exhaust Inlet Outside Diameter Exhaust Inlet Valve Spring Free Length Exhaust Inlet Usable Range 1 030 1 570 kPa 10 5 16 0 kgf cm 149 228 psi at 300 r min rpm 0 22 0 27 mm 0 0087 0 0106 in 0 15 0 20 mm 0 0059 0 0079 in 0 8 mm 0 031 in 0 5 mm 0 020 in TIR 0 01 mm 0 0004 in or less 4 955 4 970 mm 0 1951 0 1957 in 4 975 4 990 mm 0 1959 0 1965 in 5 000 5 012 mm 0 1969 0 1973 in 5 000 5 012 mm 0 1969 0 1973 in 0 08 0 16 mm 0 0031 0 0063 in 0 03 0 10 mm 0 0012 0 0039 in 32 45 60 0 8 1 2 mm 0 031 0 047 in 0 5 1 0 mm 0 020 0 039 in 27 6 27 8 mm 1 087 1 094 in 32 6 32 8 mm 1 283 1 291 in 39 10 mm 1 539 in 38 72 mm 1 524 in Cylinder Head Warp 0 05 mm 0 002 in Valves 0 7 mm 0 028 in 0 3 mm 0 012 in TIR 0 05 mm 0 002 in 4 94 mm 0 194 in 4 96 mm 0 195 in 5 08 mm 0 200 in 5 08 mm 0 200 in 0 40 mm 0 016 in 0 34 mm 0 013 in 37 4 mm 1 472 in 37 1 mm 1 461 in ENGINE TOP END 5 9 Special Tools and Sealant Compression Gauge 20 kgf cm Valve Seat Cutter 60 530 57001 221 57001 1123 9
187. E Released W2L0342CW5 C ELECTRICAL SYSTEM 16 21 Wiring Diagram Other than CA CAL US AU and MY Models Subthrottle Mee Temperature Oxygen Gear Position Valve Sidestand Speed Water Crankshaft Inlet Switch Sensor Temperature Sensor eil SeLECH Sensor Actuator Subs Main Air ete or Sensor pressis throttle Throttle ji 2 Switch S EM Lxx Fuel Injectors ERR 1 1 1 2 3 4 D I ELE Alternator 55 5 5 See E CES 455 255 Regulator Atmospheric Rectifier Pressure Water proof Sensor Joint 2 RM VE 7 FH pis BL BK BL Y BR BK Y G a R Le Y Y Y we BL R We BL 8 wR BL 8K wR re 1 wR BL R 81 6 1 water proof License Plate Light 12v5W BR BK W 8K 478K Rear Right Turn Signal Light 129218 Tail Brake Light LEB 12V0 5 4 9 Rear Left Turn Signal Light 12V21W Ground i Vehicle down Sensor as Kawasaki Signal Fuel Diagnostic Joint Relay System Gonnector 3 2 gt Frame Zr LG BK BR W BR Y BR Y ek Y ek Y 21 Nico ve Hil Switch Connector E P Oop Light Switch d 1111 Be
188. F021278W5 C Exploded View CLUTCH 6 3 Torque 13 Starter Lockout Switch Screw C Apply clutch fluid EO Apply engine oil L Apply a non permanent locking agent M Apply molybdenum disulfide grease R Replacement Parts S Follow the specified tightening sequence Si Apply silicone grease 11 Clutch Spring Bolts 9 12 Oil Filler Plug 0 70 0 92 80 in lb 0 071 6 2 in lb Hand tighten No Fastener TS Remarks 1 Clutch Cover Bolts 9 8 1 0 87 in lb L 1 2 Clutch Hose Banjo Bolts 25 2 5 18 3 Clutch Hub Nut 135 13 8 99 6 R 4 Clutch Lever Pivot Bolt 1 0 0 10 8 9 in lb Si 5 Clutch Lever Pivot Bolt Locknut 5 9 0 60 52 in Ib 6 7 5 8 9 10 L 0 in 6 4 CLUTCH Specifications Item Clutch Lever Clutch Lever Position Clutch Lever Free Play Clutch Fluid Grade Clutch Clutch Plate Assembly Friction Plate Thickness 13088 0030 13088 0031 13088 0032 Friction and Steel Plate Warp Friction Plate Warp 13088 0030 only Clutch Spring Free Length Standard 5 way adjustable to suit rider Non adjustable DOT4 53 52 54 52 mm 2 11 2 15 in 2 92 3 08 mm 0 115 0 121 in 3 72 3 88 mm 0 146 0 153 in 0 15 mm 0 0059 in or less 0 2 mm 0 008 in or less 65 0 mm 2 56 in Service Limit 2 7 mm 0 106 in 3 5 mm 0 138 in 0 3 mm 0 012 in 0 3 mm 0 012 in 62 0 mm 2 44 in CLUTCH 6
189. G USA MPG UK e Check that the unit setting menu is decided by the upper button pushing xlf the display function does not work replace the meter assembly GP17555BN3 C ELECTRICAL SYSTEM 16 73 ENGL 5H FRANLAIS MILEAGE KM L ENGAGE LAMP DFF SHIFT LAMP OFF LAMP MODE BRIGHT CLOCK 12 34 200 DDM G MILEAGE S ENGAGE LAMP OFF 2 SHIFT LAMP OFF m LAMP MODE BRIGHT S 1234 2 gt CLOCK 16 74 ELECTRICAL SYSTEM Meter Gauge Indicator Unit e Select the ENGAGE LAMP A indication e Push the upper button for more than two seconds check that the engine speed setting menu B flashes e By pushing the lower button each time check that the display changes as follows OFF 1200 1300 5900 6000 682220 GP17084CN3 C e Check that the engine speed setting menu is decided by the upper button pushing If the display function does not work replace the meter assembly e Select the SHIFT LAMP A indication e Push the upper button for more than two seconds check that the engine speed setting menu B flashes e By pushing the lower button each time check that the display changes as follows OFF 7500 7600 10900 11000 622 GPI7557BN3 C Check that the engine speed setting menu is decided by the upper
190. Holder Bolt 12 1 2 106 in lb L Shift Pedal Bolt 6 9 0 70 61 in lb Shift Shaft Return Spring Pin 29 3 0 21 L Starter Clutch Shaft Bolt 9 8 1 0 87 in lb L Starter Clutch Shaft Plate Bolt 9 8 1 0 87 in lb L Timing Rotor Bolt 39 4 0 29 Torque Limiter Bolt 25 2 5 18 L Wheels Tires Front Axle Clamp Bolts 20 2 0 15 AL Front Axle Nut 127 13 0 93 7 Rear Axle Nut 127 13 0 93 7 Final Drive Chain Guide Bolt 12 1 2 106 in Ib L Chain Guide Bolts 9 8 1 0 87 in lb L Engine Sprocket Cover Bolts 9 8 1 0 87 in lb Engine Sprocket Nut 125 12 7 92 2 MO Rear Axle Nut 127 13 0 93 7 Rear Sprocket Nuts 69 7 0 51 Speed Sensor Bolt 3 9 0 40 35 in lb L Stud Bolts 15 1 5 11 L Brakes Bleed Valves 7 8 0 80 69 in lb Brake Hose Banjo Bolts 25 2 5 18 Brake Lever Pivot Bolt 1 0 0 10 8 9 in lb Si Brake Lever Pivot Bolt Locknut 5 9 0 60 52 Brake Pedal Bolt 8 8 0 90 78 Brake Pipe Joint Nuts ABS Equipped Models 18 1 8 13 Front Brake Disc Mounting Bolts 27 2 8 20 L Front Brake Light Switch Screw 1 2 0 12 11 in lb Front Brake Pad Pins 17 2 1 8 13 Front Brake Reservoir Cap Stopper Screw 1 2 0 12 11 in lb Front Caliper Assembly Bolts 27 2 8 20 L Front Caliper Mounting Bolts 34 3 5 25 Front Master Cylinder Bleed Valve 7 8 0 80 69 in lb Front Master Cylinder Clamp Bolts 11 1 1 97 in lb Rear Brake Disc Mounting Bolts 27 2 8 20 L Rear Brake Pad Pin 17 2 1 8 13 Rear Caliper Assembly Bolts 37 3 8 27 L Rear Caliper Mounting Bolts 25 2 5 18 2 10 PERIODIC MAINTENANCE Torqu
191. IVE Sprocket Coupling Coupling Bearing Inspection Since the coupling bearing is made to extremely close tolerances the clearance can not normally be measured NOTE Olt is not necessary to remove the coupling bearing for inspection If the bearing is removed it will need to be replaced with a new one e Turn the bearing in the coupling back and forth A while checking for plays roughness or binding x If the bearing play roughness or binding is found replace the bearing Coupling Bearing Lubrication e Pack the bearing with good quality bearing grease Turn the bearing around by hand a few times to make sure the grease is distributed uniformly inside the bearing Coupling Damper Inspection e Remove the rear wheel coupling and inspect the rubber dampers A e Replace the damper if it appears damaged or deterio rated Sprocket Wear Inspection e Visually inspect the engine and rear sprocket teeth for wear and damage If the teeth are worn as illustrated replace the sprocket and inspect the drive chain wear see Drive Chain Wear Inspection in the Periodic Maintenance chapter Worn Tooth Engine Sprocket A Worn Tooth Rear Sprocket B Direction of Rotation C NOTE Olf a sprocket requires replacement the chain is proba bly worn also When replacing a sprocket inspect the chain Rear Sprocket Warp Inspection e Raise the rear wheel off the ground with the stand so that it will turn freely e Set a
192. Ib 290 kPa 2 9 kgf cm 42 psi Wheel Tire Damage Inspection e Remove any imbedded stones A or other foreign parti cles from tread e Visually inspect the tire for cracks B cuts C and nail D and replace the tire if necessary Swelling or high spots indicate internal damage requiring tire replacement e Visually inspect the wheel for cracks cuts and dents dam age If any damage is found replace the wheel if necessary Tire Tread Wear Inspection As the tire tread wears down the tire becomes more sus ceptible to puncture and failure An accepted estimate is that 9096 of all tire failures occur during the last 1096 of tread life 9096 worn So it is false economy and unsafe to use the tires until they are bald e 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 see Tire Removal Installation in the Wheels Tires chapter Tread Depth Standard Front 3 8 mm 0 15 in Rear 4 8 mm 0 19 in Service Limit Front 1 mm 0 04 in AT CH DE 1 6 mm 0 06 in Rear 2 mm 0 08 in Up to 130 km h 80 mph 3 mm 0 12 in Over 130 km h 80 mph 6J05007BS1 C 9511067851 PERIODIC MAINTENANCE 2 31 Periodic Maintenance Procedures WARNING To ensure safe handling and stability use only the recommended standard tires
193. If the indicator light lights remedy the problem and clear the service code A WARNING Use of non recommended tires may cause malfunc tioning of ABS and can lead to extended braking distance The rider could have an accident as a re sult Always use recommended standard tires for this motorcycle OThe ABS indicator light LED may come on if the engine is run with the motorcycle on its stand and the transmis sion in gear If the indicator light comes on just turn the ignition switch OFF then clear service code 42 which in dicates a Faulty front wheel rotation sensor OWhen the ABS operates the ABS makes noise and the rider feels the reaction force on the brake lever and brake pedal This is a normal condition It informs the rider that the ABS is operating normally OService codes detected once by the ABS hydraulic unit will be memorized in the ABS hydraulic unit Therefore after maintenance work is finished be sure to erase the service codes Do not erase the service codes during troubleshooting Wait until all the checks and repair work are finished to prevent duplication of previous service codes and unnecessary maintenance work OBefore delivering the motorcycle to the customer be sure to erase any service codes which might be stored in the ABS hydraulic unit Using the self diagnosis feature make sure that the ABS indicator light LED lights A fully charged battery is a must for conducting reliable self diagnosi
194. If the stick coil 1 primary winding 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 The stick coil primary winding must send signals 52 Stick Coil 2 output voltage 32 or more times continuously to the If the stick coil 22 primary winding has failures no signal wiring short or open the ECU shuts off the injector 2 to stop fuel to the ECU cylinder 2 though the engine keeps running The stick coil primary winding must send signals 53 Stick Coil 3 output voltage 32 or more times continuously to the ECU The stick coil primary winding must send signals 54 Stick Coil 4 output voltage 32 or more times continuously to the If the stick coil 3 primary winding has failures no signal wiring short or open the ECU shuts off the injector 3 to stop fuel to the cylinder 3 though the engine keeps running If the stick coil 4 primary winding has failures no signal wiring short or open the ECU shuts off the injector 4 to stop fuel to the cylinder 4 though the engine keeps running ECU Subthrottle The actuator operates If the subthrottle valve actuator fails the 62 Valva open and close of the signal is out to the usable range wiring short Acti subthrottle valve by the or open the ECU stops the current to the pulse signal from the ECU actuator Oxygen S The oxygen sensor heater If
195. Inspection e Measure connecting rod big end side clearance Olnsert a thickness gauge A between the big end and ei ther crank web to determine clearance Connecting Rod Big End Side Clearance Standard 0 13 0 38 mm 0 0051 0 0150 in Service Limit 0 58 mm 0 023 in If the clearance exceeds the service limit replace the con necting rod with new one and then check clearance again If clearance is too large after connecting rod replacement the crankshaft also must be replaced Connecting Rod Big End Bearing Insert Crankpin Wear Inspection e Measure the bearing insert crankpin A clearance with plastigage B e Tighten the big end nuts to the specified torque see Con necting Rod Installation NOTE ODo not move the connecting rod and crankshaft during clearance measurement CAUTION After measurement replace the connecting rod bolts Connecting Rod Big End Bearing Insert Crankpin Clearance Standard 0 048 0 086 mm 0 0019 0 0034 in Service Limit 0 12 mm 0 0047 in 6105040781 9105236851 CRANKSHAFT TRANSMISSION 9 21 Crankshaft and Connecting Rods x lf the clearance is within the standard no bearing replace ment is required xIf the clearance is between 0 087 mm 0 0034 in and the service limit 0 12 mm 0 0047 in replace the bear ing inserts A with inserts painted blue B Check in sert crankpin clearance with the plastigage The cle
196. LECTRICAL SYSTEM 16 61 Lighting System Tail Brake Light LED Installation e Connect the connector e Insert the projections A of the tail brake light into the holes B of the rear fender Torque Tail Brake Light Mounting Screws 1 2 N m 0 12 kgf m 11 in Ib e Install the removed parts see appropriate chapters License Plate Light Bulb Replacement e Remove Screws A License Plate Light Cover B e Push and turn the bulb A counterclockwise and remove it e Replace the bulb with a new one e Insert the new bulb A by aligning its upper and lower pins B with the upper and lower grooves C in the socket and turn the bulb clockwise OTurn the bulb about 15 e Tighten Torque License Plate Light Cover Mounting Screws 0 90 N m 0 092 kgf m 8 0 in Ib 16 62 ELECTRICAL SYSTEM Lighting System Headlight Tail Light Circuit 4 soles 19 olemi Bi LS iti Li 15 12 ore 009 OD 62 GP12381882 C 1 Ignition Switch 15 Headlight Fuse Low 15 A 2 Joint Connector 1 16 Fuse Box 1 3 High Beam Indicator Light LED 17 Relay Box 4 Right City Light 18 Headlight Circuit Relay 5 Headlight High Beam 19 Alternator 6 Headlight Low Beam 20 Main Fuse 30 A 7 Left City Light 21 Starter Relay 8 Headlight Relay Low 22 Battery 12 V 14 Ah 9 Headlight Relay High 23 Frame Ground 1 10 Dimmer Switch 24 Frame Ground 2 11 Passing Button Ot
197. LL H WVTA 78 2 H Malaysia Southeast Asia Thailand United States WVTA Model with Honeycomb Catalytic Converter Full Power WVTA Model with Honeycomb Catalytic Converter Left Side Traffic Full Power WVTA Model with Honeycomb Catalytic Converter Restricted Power EMISSION CONTROL INFORMATION To protect the environment in which we all live Kawasaki has incorporated crankcase emis sion 1 and exhaust emission 2 control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board Addi tionally 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 pollu
198. Master Cylin der Removal in the Brakes chapter e Remove the seal cover A circlip B connector C and O ring D Special Tool Inside Circlip Pliers 57001 143 e Unscrew the locknut E and pivot bolt F and remove the brake lever e Remove the circlip G e Pull out the piston assy H e Replace Seal Cover A Circlip B O ring D Circlip G Piston Assy H Diaphragm I Rear Master Cylinder Disassembly e Remove the rear master cylinder see Rear Master Cylin der Removal in the Brakes chapter e Remove the circlip A connector B and O ring C Special Tool Inside Circlip Pliers 57001 143 e Slide the dust cover D out of place and remove the cir clip E e Pull out the push rod assy F e Take off the piston assy G and return spring H CAUTION Do not remove the secondary cup from the piston since removal will damage it e Replace Circlip A O ring C Circlip E Push Rod Assy F Piston Assy G Diaphragm I 6513175852 2 64 PERIODIC MAINTENANCE Periodic Maintenance Procedures Master Cylinder Assembly e 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 wil
199. Meter W Y lead terminal 58 Meter BK Y lead terminal 52 e Measure the input voltage to each primary winding of the stick coils with the engine stopped and with the connector joined e Turn the ignition switch ON Input Voltage at ECU Standard Battery Voltage e Turn the ignition switch OFF lf the reading is out of the standard check the wiring see wiring diagram in this section xIf the reading is good the input voltage is normal Crank the engine and check the peak voltage of the stick coils see Stick Coil Primary Peak Voltage Inspection in the Electrical System chapter in order to check the primary coils 3 88 FUEL SYSTEM Stick Coils 1 2 3 4 Service Code 51 52 53 54 Stick Coil Circuit 6C17438CW2 1 ECU 9 Fuse Box 2 2 Stick Coil 4 10 Starter Relay 3 Stick Coil 3 11 Main Fuse 30 A 4 Stick Coil 2 12 Battery 12 V 14 Ah 5 Stick Coil 1 13 Frame Ground 2 6 Engine Stop Switch 14 Engine Ground 7 Ignition Switch 15 Joint Connector 3 8 Ignition Fuse 10 A FUEL SYSTEM 3 89 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 throttle body assy especially on a hard surface Such a shock to the actuator can damage it
200. NING This battery is sealed type Never remove sealing cap B even at charging Never add water Charge with current and time as stated below 8 09001251 6 Terminal Voltage 11 5 less than 12 6 V S Standard Charge 1 4 A x 5 10 h see following chart Quick Charge 7TAxth Y 6 CAUTION If possible do not quick charge If quick charge is E done unavoidably do standard charge later on e i 11 6 11 8 12 0 12 2 12 4 12 6 12 8 13 0 Terminal Voltage less than 11 5 V d ME as Charging Method 1 4 20 NOTE Olncrease the charging voltage to a maximum voltage of 25 V if the battery will not accept current initially Charge forno more than 5 minutes at the increased voltage then check if the battery is drawing current If the battery will accept current decrease the voltage and charge by the standard charging method described on the battery case If the battery will not accept current after 5 min utes replace the battery s d Battery A Battery Charger B Standard Value C Current starts to flow D e Determine the battery condition after refresh charge ODetermine the condition of the battery left for 30 minutes after completion of the charge by measuring the terminal voltage according to the table below Judgement 12 0 lower than 12 6 V Charge insufficient Recharge lower than 12 0 V Unserviceable Replace 16
201. OMS CE 10 4 f MN HC EE ER Pee 10 5 Wheels apium TUS 10 6 Front Wheel Removal cedet sega ota euadere etie used 10 6 Front Wheel Installation 10 6 Rear Wheel Helnovalsi d abt 10 7 Rear Wheel Installation dta e adel E pedem ess 10 8 Wheel DII 10 10 Axle INSP SCHON mc 10 10 Balance InispSollOft conis o pede tor Ee 10 11 Balance Adjustment s oes m doc du dud 10 11 Balance Weight Removal sisri mensen odes deu teda peste etui e vat 10 11 Balance dssdo rte 10 12 AIMS Ss c PH ES 10 14 Air Pressure Inspection Adjustment 10 14 Tire Inspection Val usos aeria eae Tire Installation Tire Repairs T Aub ah puc Edu ote Ec I ms H b Bearing ISRO Vel dp 10 17 Hub Bearing 1 10 17 Hub Bearing INSPCCHON Em 10 17 Hub Bearing LUDMCAION sce Sit uec eH ra e Dye pae iR Her NOn axe vH 10 18 10 2 WHEELS TIRES
202. ON 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 idle speed stop the engine immediately and find the cause x lf the oil level is too high remove the excess oil using a syringe or some other suitable device lf the oil level is too low add the correct amount of oil through the oil filler opening Use the same type and make of oil that is already in the engine NOTE Olf the engine oil type and make are unknown use any brand of the specified oil to top off the level in preference to running the engine with the oil level low Then at your earliest convenience change the oil completely Engine Oil Change e Refer to the Engine Oil Change in the Periodic Mainte nance chapter Oil Filter Replacement e Refer to the Oil Filter Replacement in the Periodic Main tenance chapter 6005010851 C ENGINE LUBRICATION SYSTEM 7 9 Oil Pan Oil Pan Removal e Remove Engine Oil Drain see Engine Oil Change in the Periodic Maintenance chapter Muffler Bodies see Muffler Body Removal Installation in the Engine Top End chapter Exhaust Pipe see Exhaust Pipe Removal in the Engine Top End chapter Oil Pressure Switch Terminal A Disconnect Oil Filter B see Oil Filter Rep
203. R BR W W BK BR 16 EN 1 ECU 10 Fuel Pump Relay 2 Joint Connector 3 11 ECU Main Relay 3 Fuel Pump 12 Relay Box 4 Frame Ground 1 13 Fuse Box 2 5 Frame Ground 2 14 ECU Fuse 15 A 6 Battery 12 V 14 Ah 15 Ignition Fuse 10 A 7 Joint Connector 2 16 Ignition Switch 8 Starter Relay 17 Engine Stop Switch 9 Main Fuse 30 A 18 Water proof Joint 1 FUEL SYSTEM 3 87 Stick Coils 1 2 3 4 Service Code 51 52 53 54 Stick Coil 1 Service Code 51 Stick Coil 2 Service Code 52 Stick Coil 3 Service Code 53 Stick Coil 4 Service Code 54 Stick Coil Removal Installation e Refer to the Stick Coil Removal Installation in the Electri cal System chapter Stick Coil Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Remove the ECU see ECU Removal ODo not disconnect the ECU connectors e Connect a digital meter A to the connector B with the needle adapter set Special Tool Needle Adapter Set 57001 1457 6617168651 C Stick Coil Input Voltage at ECU Connections for Stick Coil 1 Meter W R lead terminal 47 Meter BK Y lead terminal 52 Connections for Stick Coil 42 Meter W BL lead terminal 60 Meter BK Y lead terminal 52 Connections for Stick Coil 3 Meter W G lead terminal 45 Meter BK Y lead terminal 52 Connections for Stick Coil 4
204. RNING Gasoline is extremely flammable and can be explo sive under certain conditions Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Turn the ignition switch OFF Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately NOTE OBe sure the battery is fully charged e Turn the ignition switch and engine stop switch OFF e Wait until the engine cools down e Prepare a fuel hose Special Tool 57001 1607 and a measuring cylinder Special Tool Fuel Hose 57001 1607 FUEL SYSTEM DFI 3 105 Fuel Line e Remove Seat see Seat Removal in the Frame chapter Fuel Tank Cover see Fuel Tank Removal Fuel Tank Bolts A e Remove the fuel tank bolts A e Open the fuel tank cap A to lower the pressure in the tank e Be sure to place a piece of cloth around the fuel supply pipe of the fuel pump e Remove the fuel hose from the fuel pump see Fuel Tank Removal A WARNING Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is disconnected fuel spills out from the hose and the pipe because of residual pressure Cover the hose connection with a piece of clean cloth to prevent fuel spillage e Connect the prepared fuel hose A to the fuel supply pipe of the fuel pump e Secure the fuel hose with a clamp
205. Removal Installation Adjusting Collars 15 11 M Engine Bracket Bolts M8 25 18 5 Engine Mounting Nuts M12 59 44 S Front Engine Mounting Bolts M10 59 44 5 Subframe Bolts 23 17 R Crankshaft Transmission Balancer Shaft Clamp Bolts 9 8 87 Balancer Shaft Clamp Lever Bolts 25 18 Bearing Position Plate Screws 4 9 43 L Breather Cover Bolts 9 8 87 Breather Plate Screws 9 8 87 L Connecting Rod Big End Nuts pee le lt text Crankcase Bolts M10 L 120 mm 47 35 MO S Crankcase Bolts M10 L 90 mm 47 35 MO S Crankcase Bolts M8 L 80 mm 27 20 S Crankcase Bolts M8 L 70 mm 27 20 S Crankcase Bolt M7 L 2 110 mm 20 15 S Crankcase Bolt M7 L 85 mm 20 15 S Crankcase Bolts M7 L 65 mm 20 15 S Crankcase Bolts M7 L 60 mm 20 15 S Crankcase Bolt M7 L 2 50 mm 20 15 S Crankcase Bolts M7 L 45 mm 20 15 S Crankcase Bolt M6 L 65 mm 12 106 in lb S Crankcase Bolt M6 L 50 mm 12 106 in lb S Crankcase Bolts M6 L 40 mm 12 106 in lb S Crankcase Bolts M6 L 25 mm 12 106 in lb S Drive Shaft Cover Bolts 25 18 L Gear Position Switch Lead Clamp Bolts 9 8 87 in lb Gear Position Switch Screws 2 9 26 in lb L PERIODIC MAINTENANCE 2 9 Torque and Locking Agent Fastener Remarks N m kgf m ft Ib Gear Positioning Lever Bolt 12 1 2 106 in Ib Oil Jet Nozzles 2 9 0 30 26 in lb Oil Passage Plugs 20 2 0 15 L Shift Drum Bearing Holder Screws 4 9 0 50 43 in lb L Shift Drum Cam
206. Rims e Apply high temperature grease to the grease seal lips e Fit the collars A on the both sides of the hub OThe collars are identical e Insert the axle from the right side e Tighten the axle nut B Right Axle Clamp Bolts C Left Axle Clamp Bolts D Viewed from Rear E Torque Front Axle Nut 127 N m 13 0 kgf m 93 7 ft Ib e Before tightening the axle clamp bolts on the right front fork leg pump the front fork up and down 4 or 5 times to all on the right front fork leg to seat on the front axle NOTE OPut a block in front of the front wheel to stop moving e Tighten the axle clamp bolts on the right fork leg first Next tighten the left axle clamp bolts Torque Front Axle Clamp Bolts 20 N m 2 0 kgf m 15 ft Ib NOTE Tighten the two clamp bolts alternately two times to en sure even tightening torque e Install the removed parts see appropriate chapters e Check the front brake effectiveness see Brake Operation Inspection in the Periodic Maintenance chapter A WARNING Do not attempt to drive the motorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against the disc The brake will not function on the first application of the lever if this is not done Rear Wheel Removal e Raise the rear wheel off the ground with the stand A WHEELS TIRES 10 7 e c o o o a 3 o 10 8 WHEELS TIRES Wheels Rims e Remove
207. Rotor see Alternator Rotor Removal in the Electrical System chapter Oil Cooler see Oil Cooler Removal in the Engine Lubri cation System chapter Oil Pan see Oil Pan Removal in the Engine Lubrication System chapter External Shift Mechanism see External Shift Mecha nism Removal e Remove the upper crankcase bolts OFirst loosen the M6 bolts M6 Bolts A M7 Bolt B M7 Bolt with Clamp C M8 Bolts with Washer D e Remove the lower crankcase bolts OFirst loosen the M7 bolts A Le aval Ty Ce ec ssec tue Thc 6104230BS1 CRANKSHAFT TRANSMISSION 9 11 Crankcase Splitting ONext loosen the M10 bolts 1 10 Sequence numbers If the crankshaft is to be removed remove the pistons see Piston Removal e Tap lightly around the crankcase mating surface with a plastic mallet and split the crankcase Take care not to damage the crankcase e Remove the front balancer A on the lower crankcase half B see Front Balancer Removal Crankcase Assembly CAUTION The upper and lower crankcase halves are ma chined at the factory in the assembled state so the crankcase halves must be replaced as a set NOTE OWhen replacing the crankcase halves install the thrust washers t 2 5 mm 0 0984 in on the upper crankcase half e With a high flash point solvent clean off the mating sur faces of the crankcase halve
208. S Hydraulic Unit Lead Inlet Air Temperature Sensor Lead Battery Ground Lead Starter Relay Lead Battery Positive Lead Connector Install the battery positive lead connector to the battery case Starter Motor Cable Frame Ground Lead Install the frame ground lead to the bracket with bolt so that it faces inside Run the frame ground lead through over the brake hoses Clamp Hold the inlet air temperature sensor lead Inlet Air Temperature Sensor Bracket Battery Ground Lead Connector Install the battery negative lead connector to the bracket Battery Positive Cable Battery Ground Lead Battery Negative Cable Direction of Battery Negative Cable Terminal Installation Tighten the battery negative cable together with the battery ground lead with bolt Battery Ground Lead 17 28 APPENDIX Cable Wire and Hose Routing 58095780 6 APPENDIX 17 29 Cable Wire and Hose Routing sss NOOR WD 18 19 Fuel Tank Drain Hose Run the fuel tank drain hose and fuel tank breather hose through under the bracket Align the yellow tape with the end of the bracket to fix fuel tank drain hose Run the fuel tank drain hose through the backside of the clamps Run the fuel tank drain hose and fuel tank breather hose through under the fuel hose Run the fuel tank drain hose and fuel tank breather hose through under the starter mo
209. S parts NG Final inspection OK End GLI4011B F 12 38 BRAKES Anti Lock Brake System Equipped Models Inquiries to Rider OEach rider reacts to problems in different ways so it is important to confirm what kind of condition the rider is dissatisfied with OTry to find out exactly what problem occurs under exactly what conditions by asking the rider know ing this information may help you reproduce the problem in the shop OThe diagnosis sheet will help prevent you from overlooking any keys so always use it Sample Diagnosis Sheet Rider name Registration No license plate No Year of initial registration Model Engine No Frame No Date problem occurred Frequency Weather Mileage Brake Indicator O Braking ABS not 0 ABS L1 ABS op lever light distance working works erating vibration blinks too long but too fre or noise indicator quently light Phenome doesn t non Pedal 0 Indicator Abnor light up vibration light mal or noise remains pedal lit up move ment Engine conditions at start up After starting At 5 000 r min rpm problem or more Road conditions L1 Slippery road COgravel O other L1 Rough surface Other Driving conditions High speed cornering Driving 10 km h 6 mph or above Driving below 10 km h 6 mph When stopping When turning Brake application Gradual Abr
210. Table of Contents Explod d VIEW c mms 15 2 ccc M 15 10 Seat T 15 10 Seat InstallatioN zs icm o b et td d afa 15 10 crm 15 11 Lower Fairing AG MOV Al er get o ta teret Hte das t npe uccide tae 15 11 Lower Fairing Installatlort er Cr e Mia tees 15 11 Fairing Cover Removal do occ etel 15 11 Fairing Cover a et Ren Et oue Rota Atta eatis e edited Ud 15 11 Middle Fairing Retrrovals uices cope oo eso tore ete steer wees 15 11 Middle Fairing Installatlglts s treat tot cade wader dav 15 12 Windshield dodo 15 12 Windshield de qua RE 15 13 Upper Fairing Removal RE EM HI E Ita ae eL RS 15 13 Upper Fairing Disassembly esos e p preste 15 13 Upper Fairing Assembly te tert trn rio ode RE pete ete ten gen Dio diede dade rti cra 15 13 Upper Fairing SVAN AON 15 14 Inner Cover Removal aiite ne teta deter ERE 15 14 Inner Gover IristallallQlt cc ete Dern dae tree See FERRE Fed hee Delo iei teal opere ita 15 14 Upper Inner Fairing Removal edt era ai 15 14 Uppe
211. This is to prevent damage to the ECU Crankshaft Sensor Removal CAUTION Never drop the sensor especially on a hard surface Such a shock to the sensor can damage it e Remove Right Middle Fairing see Middle Fairing Removal in the Frame chapter Crankshaft Sensor Lead Connector A e Remove Crankshaft Sensor Cover Bolts A with Clamp Crankshaft Sensor Cover B e Remove Crankshaft Sensor Bolts A Crankshaft Sensor B Grommet C 16 42 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Installation e Apply a non permanent locking agent to the threads of the crankshaft sensor bolts A and tighten them Torque Crankshaft Sensor Bolts 5 9 N m 0 60 kgf m 52 in Ib e Apply silicone sealant to the circumference of the crank shaft sensor lead grommet B and fit the grommet into the notch of the crankcase securely e Apply silicone sealant to the mating surface C of the crankcase halves Sealant Kawasaki Bond Silicone Sealant 92104 0004 e Replace the O ring D with a new one e Install the crankshaft sensor cover e Apply a non permanent locking agent to only one crank shaft sensor cover bolt E shown in figure e Tighten the crankshaft sensor cover bolts Torque Crankshaft Sensor Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib e Run the crankshaft sensor lead correctly see Cable Wire and Hose Routing section in the Appendix chapter e Install the removed parts see appropri
212. Unit Removal e Remove Windshield see Windshield Removal in the Frame chapter Immobilizer Amplifier A Equipped Models e Remove Immobilizer Amplifier Bracket Bolt A and Bracket Equipped Models Vehicle down Sensor Bracket Bolt B and Bracket Connector C e Remove Meter Unit Mounting Nuts A and Washers Meter Unit B CAUTION Place the meter unit so that the face is up If a meter unit is left upside down or sideways for any length of time it will malfunction Meter Unit Installation e Install Meter Unit A Washers B and Meter Unit Mounting Nuts C e Install Connector Vehicle down Sensor Bracket and Bolt A Immobilizer Amplifier Bracket and Bolt Equipped Mod els Immobilizer Amplifier B Equipped Models Windshield see Windshield Installation in the Frame chapter 16 70 ELECTRICAL SYSTEM Meter Gauge Indicator Unit Meter Unit Disassembly e Remove Meter Unit see Meter Unit Removal Screws A Lower Meter Cover B e Separate Upper Meter Cover A Middle Meter Cover B Meter Assembly C Meter Unit Inspection e Remove the meter unit see Meter Unit Removal 1 High Beam Indicator Light LED 2 Oil Pressure Warning Indicator Light LED 3 Right Turn Signal Indicator Light LED 4 Neutral Indicator Light LED 5 Unused 6 ABS Indicator Light LED ABS Equipped Models 7 Unused 8 Unused 9 Ignition 10 Bat
213. Voltage Connections to ECU Meter Y BL lead terminal 28 Meter BR BK lead terminal 34 Output Voltage at ECU Usable Range DC 3 80 4 20 V at standard atmospheric pressure 101 32 kPa 76 cmHg NOTE OThe output voltage changes according to the local at mospheric pressure If the output voltage is within the usable range check the ECU for its ground and power supply see ECU Power Supply Inspection x lf the ground and power supply are good replace the ECU see ECU Removal Installation If the output voltage is far out of the usable range check the output voltage again at the sensor connector A when the lead is open the output voltage is about 1 8 V e Connect a digital meter to the harness adapter leads Inlet Air Pressure Sensor B Special Tool Sensor Harness Adapter 57001 1561 Inlet Air Pressure Sensor Output Voltage Connections to Adapter Meter G W sensor Y BL lead C Meter gt BK sensor BR BK lead D Measure the input voltage with the engine stopped and with the connector joined x Turn the ignition switch ON Output Voltage at Sensor Usable Range DC 3 80 4 20 V at standard atmospheric pressure 101 32 kPa 76 cmHg e Turn the ignition switch OFF If the output voltage is normal check the wiring for conti nuity see wiring diagram in this section lf the output voltage is out of the usable range replace the sensor FUEL SYSTEM
214. Y Color Fuse Box 2 e Box 2 Fan Fuse 15 ECU Fuse 15 Ignition Fuse 10A Color BK WBK Y Color TE Released GY R BK BL Y R Y Color Clutch Lever IBK R BL Y R BK a O a 9210346885 C Wiring Diagram AU and MY Models ELECTRICAL SYSTEM 16 19 Subthrottle Sidestand Speed Water Gear Position Rate Cee imine Switch Sensor Temperature eil Seek Sancor osub Ha Air oi Sensor 2 S RUN 555 Sensor Sensor greene S 1 ved Fuel Injectors SA 1 1 1 2 3 4 1 T HT I Alternator 25 P 225 p 525 LG 1 Ur 5 sz Bee Air eo da ae 2 8 2 Temperature 7 3 24 4 3 Regulator Set Atmospheric ese z 5 2225 Sx Rectifier 258 ca Ul Pressure g 28 5 558 EE Water proof E ater proof Seiler sek B Beg m d a Bes 2 3 H HH H g 053 License Plate Light 12 5 Rear Right Turn Signal Light 12V21W 2 Frame Ground 1 Vehicle down Sensor Eun Ae rli Engine Ground Battery Frame Ground 2 Relay Box Starter Relay Relay Box Fan Relay Headlight Circuit Relay ECU Main Relay Fuel Pump Relay Starter Circuit Rel
215. a container Master Cylinder Rear Master Cylinder Installation e Replace the cotter pin with a new one e Replace the washers that are on each side of hose fitting with new ones e Tighten Torque Rear Master Cylinder Mounting Bolts 25 N m 2 5 kgf m 18 16 Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft Ib e Bleed the brake line see Brake Line Bleeding e Check the brake for good braking power no brake drag and no fluid leakage Front Master Cylinder Disassembly e Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter Rear Master Cylinder Disassembly e Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter Master Cylinder Assembly e Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter Master Cylinder Inspection Visual Inspection e Remove the master cylinders see Front Rear Master Cylinder Removal e Disassemble the front and rear master cylinders see Master Cylinder Rubber Parts Replacement in the Peri odic Maintenance chapter e Check that there are no scratches rust or pitting on the inner wall A of each master cylinder and on the outside of each piston B If a master cylinder or piston shows any damage replace them e Inspect the primary cup C and secondary cup D cup is worn damaged softened rotted or swollen the piston assembly should be replaced to
216. a minimum of bending so that the emission flow will not be obstructed Cooling System Coolant Level Inspection NOTE OCheck the level when the engine is cold room or ambi ent temperature e Check the coolant level in the reserve tank A with the motorcycle held perpendicularly Do not use the side stand xIf the coolant level is lower than the L level line B un screw 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 en gine 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 reserve tank has run completely dry there is probably leakage in the cooling system Check the system for leaks Coolant ruins painted surfaces Immediately wash away any coolant that spills on the frame engine wheels or other painted parts PERIODIC MAINTENANCE 2 23 Periodic Maintenance Procedures Radiator Hose and Pipe Inspection coolant leak damage installation condition OThe high pressure inside of the water hose can cause coolant to leak A or the hose to burst if the line is not properly maintained e Visually inspect the ho
217. a piece of clean cloth to prevent fuel spillage e Close the fuel tank cap e Remove the fuel tank and place a it on a flat surface ODo not apply the load to the delivery pipe of the fuel pump e For the California and Southeast Asia models note the following CAUTION For the California and Southeast Asia models if gasoline solvent water or any other liquid enters the canister the canister s vapor absorbing capac ity is greatly reduced If the canister does become contaminated replace it with a new one OBe sure to plug the evaporative fuel return hose to prevent fuel spilling before fuel tank removal A WARNING For the California and Southeast Asia models be careful not to spill the gasoline through the return hose Spilled fuel is hazardous x If liquid or gasoline flows into the breather hose remove the hose and blow it clean with compressed air careful of fuel spillage from the fuel tank since fuel still remains in the fuel tank and fuel pump A 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 65098313 P FUEL SYSTEM 3 133 Fuel Tank Fuel Tank Installation e Note the above WARNING see Fuel Tank Removal e Run the hoses correctly see Cable Wire and Hose Rout ing section in th
218. absorber damaged Disc brake noise Pad installed incorrectly Pad surface glazed Disc warped Caliper trouble Other noise Bracket nut bolt etc mounted or tightened not properly Oil Pressure Warning Light Goes On Engine oil pump damaged Engine oil screen clogged Engine oil filter clogged Engine oil level too low Engine oil viscosity too low Camshaft bearing worn Crankshaft bearing worn Oil pressure switch damaged Wiring faulty Relief valve stuck open O ring at the oil passage in the crankcase damaged Exhaust Smokes Excessively White smoke Piston oil ring worn Cylinder worn Valve oil seal damaged Valve guide worn Engine oil level too high Black smoke Air cleaner clogged Brown smoke Air duct holder loose Air cleaner poorly sealed or missing Handling and or Stability Unsatisfactory Handlebar hard to turn Cable routing incorrect Hose routing incorrect Wiring routing incorrect Steering stem nut too tight Steering stem bearing damaged Steering stem bearing lubrication inade quate Steering stem bent Tire air pressure too low Handlebar shakes or excessively vibrates Tire worn Swingarm pivot bearing worn Rim warped or not balanced Wheel bearing worn Handlebar holder bolt loose Steering stem nut loose Front rear axle runout excessive Engine mounting bolt loose Handlebar pulls to one side Frame bent Wheel misalignment Swingarm bent or twisted Swingarm pivot shaft runout excessive Steering maladju
219. acement for Immobilizer Equipped Models e Remove Seat see Seat Removal in the Frame chapter Tool Kit A Fuse Box B e Using a small chisel or other suitable tool cut off the screws A e Remove Plate B Tool Kit Case C e Remove Relay Box A ECU Connectors B ECU C e Install ECU Connectors Relay Box e Insert the slits of the rubber protector to the projections A of the rear fender e Install the connector holder A Immobilizer System Equipped Models e Install Tool Kit Case A Plate B e Tighten the new Kawasaki genuine screws C of which threads are coated with locking agent e Insert the stopper D of the fuse box into the groove E of the tool kit case Immobilizer Relational Parts Replacement Chart Failed or Lost Part Master User Key Key Red Black Ignition An Ampli Switch tenna fier Master Key Red User Key Black Replacement Part e Main Replacement Part Additional Replacement Part Immobilizer System Inspection e Refer to the Immobilizer Amplifier and Blank Key Detec tion section in the Fuel System DFI chapter ELECTRICAL SYSTEM 16 105 16 106 ELECTRICAL SYSTEM Immobilizer System Equipped Models Immobilizer System Circuit 6C172370W2 C lgnition Switch Immobilizer Antenna Meter Unit Immobilizer Amplifier Joint C
220. aeuo toto ciet tele bibi a reas eo cea roto Ded s Charging System pp Alternator Cover Removal Alternator Cover Installatigm eeepc tini disk step Rue adenine Stator Coll edere tesa dn Stator Coil Installation sped est One fee md eau Alternator Rotor Removal Ne Alternator Rotor Installation tad t er p Alternator InSpeoUOr oec ce et int teer Het es tea ce m exu aie meee eee Regulator Rectifier Inspection Charging Voltage Inspection ertt ht ek PR e nace eK e ESRA AE OE aE EEE SEA AAEE ENa ENEE Crankshaft Sensor Removal c ak a atts es Crankshaft Sensor Installation Crankshaft Sensor Inspection Crankshaft Sensor Peak Voltage 16 42 Timing Rotor MEI EID 16 43 TIMING ROOF IiStall avon a 16 43 Camshaft Position Sensor Removal ibt 16 43 Camshaft Position Sensor Installation 16 44 Camshaft Position Sensor Inspectlohi uiuis eer tte cente tee n e pelle ie 16 44 Camshaft Position Sensor Peak Voltage Inspectigm pp 16 45 Stick Ca 16 45 stick Coll Installation keit 16 46 Stick Coil MASH CUO M e 16 46 Stick
221. al in the Electrical Sys tem chapter Air Suction Valve Covers see Air Suction Valve Re moval e Remove the cylinder head cover bolts A e Remove the cylinder head cover to backward floating it a little up Cylinder Head Cover Installation e Replace the head cover gasket with a new one e Apply silicone sealant A to the cylinder head as shown in the figure Sealant Kawasaki Bond Silicone Sealant 92104 0004 e Install the new head cover gasket e Install Dowel Pins A Plug Hole Gaskets B Cylinder Head Cover GE09046BS1 GE09047BS1 GE09048BS1 C ENGINE TOP END 5 15 Cylinder Head Cover e Install the washer A with the metal side faces upward e Tighten the cover bolts B following the specified tighten ing sequence Torque Cylinder Head Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib e Install the removed parts see appropriate chapters 6 09070851 C 5 16 ENGINE TOP END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION Do not turn over the crankshaft while the tensioner is removed This could upset the camshaft chain timing and damage the valves e Remove the right middle fairing see Middle Fairing Re moval in the Frame chapter e Remove the mounting bolts A and take off the camshaft chain tensioner B Camshaft Chain Tensioner Installation e Remove the cylinder head cover see Cylinder Head
222. al of ignition switch connector A and ground Special Tool Hand Tester 57001 1394 OTurn the ignition switch ON Battery Terminal Voltage Standard 10 V or more If the battery terminal voltage is not within the specifica tion proceed the 3rd step the battery terminal voltage correct proceed the 4th step e Do the 3rd step test Olnspect the following parts Battery see Charging Condition Inspection in the Elec trical System chapter Ignition Switch see Switch Inspection in the Electrical System chapter Main Harness see Wiring Inspection in the Electrical System chapter Main Fuse 30 A see Fuse Inspection in the Electrical System chapter e Do the 4th step test ORecheck the service code indication erase the service code perform the pre diagnosis inspection 1 and 2 and retrieve the service code xIf the ABS indicator light LED A lit faulty ECU in the ABS hydraulic unit Replace the ABS hydraulic unit xIf the ABS indicator light LED unlit ABS system is nor mal service code is not stored temporary failure GL14301BS1 GL14302BS1 GL14288BS1 Anti Lock Brake System Equipped Models Power Supply Voltage Abnormal Over Voltage Service Code 53 e Do the 1st step test ODisconnect the ignition switch connector and ABS hy draulic unit connector OCheck for continuity between the brown lead terminal
223. allation Oil Pressure Relief Valve Inspection e Check to see if the valve A slides smoothly when push ing itin with a wooden or other soft rod and see if it comes back to its seat by spring B pressure NOTE Olnspect the valve in its assembled state Disassembly and assembly may change the valve performance any rough spots are found during above inspection wash the valve clean with a high flash point solvent and blow out any foreign particles that may be in the valve with compressed air WARNING Clean the oil pressure relief valve in a well ventilated area and take care that there is no spark or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline or low flash point solvent cleaning does not solve the problem replace the oil pressure relief valve as an assembly The oil pressure relief valve is precision made with no allowance for re placement of individual parts 6808060281 6 7 12 ENGINE LUBRICATION SYSTEM Oil Pump Oil Pump Removal e Remove Coolant Drain see Coolant Change in the Periodic Maintenance chapter Engine Oil Drain see Engine Oil Change in the Periodic Maintenance chapter Clutch see Clutch Removal in the Clutch chapter e Remove the oil pump cover bolts A e Remove the oil pump cover B with oil pump drive gear shaft e Remove the outer rotor and inner rotor Oil Pump Installation e Apply
224. ance chapter Tire Inspection e Refer to the Wheel Tire Damage Inspection in the Peri odic Maintenance chapter Tire Removal e Remove Wheels see Front Rear Wheel Removal Valve Core Let out the air e To maintain wheel balance mark the valve stem position on the tire with chalk so that the tire can be reinstalled in the same position Chalk Mark or Yellow Mark A Air Valve B Align C e Lubricate the tire beads and rim flanges on both sides with a soap and water solution or rubber lubricant This helps the tire beads slip off the rim flanges CAUTION Never lubricate with engine oil or petroleum distil lates because they will deteriorate the tire e Remove the tire from the rim using a suitable commer cially available tire changer NOTE OThe tires cannot be removed with hand tools because they fit the rims too tightly Tire Installation A WARNING Use the same manufacturer s on both front and rear wheels e Inspect the rim and tire and replace them if necessary e Clean the sealing surfaces of the rim and tire and smooth the sealing surfaces of the rim with a fine emery cloth if necessary e Remove the air valve and discard it CAUTION Replace the air valve whenever the tire is replaced Do not reuse the air valve 6J05040BS1 C WHEELS TIRES 10 15 Tires e Install a new valve in the rim ORemove the valve cap lubricate the stem seal A with
225. and Ground Wiring see Stick Coil Inspection in the Electrical System chapter ECU Power Source Wiring and Ground Wiring see ECU Power Supply Inspection Service Code Erasing OWhen repair has been done warning indicator light LED goes off and warning message and warn ing symbol are not displayed and no service code is displayed x But the service codes stored in memory of the ECU are not erased to preserve the problem history In this model the problem history can not be erased 3 42 FUEL SYSTEM DFI Self Diagnosis Service Code Table Service Code Problems 11 Main throttle sensor malfunction wiring open or short 12 Inlet air pressure sensor malfunction wiring open or short 13 Inlet air temperature sensor malfunction wiring open or short 14 Water temperature sensor malfunction wiring open or short 15 Atmospheric pressure sensor malfunction wiring open or short 21 Crankshaft sensor malfunction wiring open or short 23 Camshaft position sensor malfunction wiring open or short 24 Speed sensor malfunction 25 Gear position switch malfunction wiring open or short 31 Vehicle down sensor malfunction wiring open or short 32 Subthrottle sensor malfunction wiring open or short 33 Oxygen sensor inactivation wiring open or short Equipped Models 35 Immobilizer amplifier malfunction Equipped Models 36 Blank key detection Equipped Models 46 Fuel pump relay malfunction relay is stuck
226. ar ance may exceed the standard slightly but it must not be less than the minimum in order to avoid bearing seizure xIf the clearance exceeds the service limit measure the diameter of the crankpins Crankpin Diameter Standard 37 984 38 000 mm 1 4954 1 4961 in Service Limit 37 97 mm 1 4949 in If any crankpin has worn past the service limit replace the crankshaft with a new one If the measured crankpin diameters not less than the service limit but do not coincide with the original diameter markings on the crankshaft make new marks on it Crankpin Diameter Marks None 37 984 37 992 mm 1 4954 1 4957 in 37 993 38 000 mm 1 4958 1 4961 in A Crankpin Diameter Marks O or no mark 6105274851 C e Measure the connecting rod big end inside diameter and mark each connecting rod big end in accordance with the inside diameter e Tighten the connecting rod big end nuts to the specified torque see Connecting Rod Installation NOTE OThe mark already on the big end should almost coincide with the measurement Connecting Rod Big End Inside Diameter Marks None 41 000 41 008 mm 1 6142 1 6145 in 41 009 41 016 mm 1 6145 1 6148 in Big End Cap A Connecting Rod B Weight Mark Alphabet C Diameter Mark Around Weight Mark D or no mark 6105060181 6 9 22 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods e S
227. ar assembly e Visually inspect the rubber dampers A If they appear damaged or deteriorated replace them 0106036852 C 61068076 P CRANKSHAFT TRANSMISSION 9 35 Starter Motor Clutch and Torque Limiter Starter Motor Clutch Removal e Remove Engine see Engine Removal in the Engine Removal In stallation chapter Rear Balancer see Rear Balancer Removal e Unscrew the starter clutch shaft plate bolt A e Pull the starter clutch shaft bolt A with the shaft plate B and starter clutch shaft holding the starter clutch C e Remove the starter clutch Starter Motor Clutch Installation e Install Washer Long A Starter Motor Clutch B Washer Short C Starter Motor Clutch Shaft D OApply molybdenum disulfide grease E to the starter mo tor clutch shaft e Align F the starter motor clutch gear with the torque lim iter gear e Apply a non permanent locking agent to the threads of the starter clutch shaft plate bolt and tighten it Torque Starter Clutch Shaft Plate Bolt G 9 8 N m 1 0 kgf m 87 in Ib xIf the shaft bolt removed tighten it OApply a non permanent locking agent to the threads of the shaft bolt Torque Starter Clutch Shaft Bolt H 9 8 N m 1 0 kgf m 87 in Ib 6109004851 C Starter Motor Clutch Disassembly e Remove the starter motor clutch see Starter Motor Clutch Removal e Pull the driven gear out off from the drive gear e Remove the flat wa
228. are not displayed on the LCD But the service codes stored in memory of the ECU are not erased to preserve the problem history The problem history can be referred using the KDS Kawasaki Diagnostic System when solving unstable problems Much of the DFI system troubleshooting work consists of confirming continuity of the wiring The DFI parts are assembled and adjusted with precision and it is impossible to disassemble or repair them e When checking the DFI parts use a digital meter which can be read two decimal place voltage or resistance OThe DFI part connectors A have seals B including the ECU When measuring the input or output voltage with the connector joined use the needle adapter set C Insert the needle adapter inside the seal until the needle 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 e Make sure that measuring points are correct in the con nector noting the position of the lock D and the lead color before measurement Do not reverse connections of a digital meter e Be careful not to short circuit the leads of the DFI or elec trical system parts by contact between adapters e Turn the ignition switch ON and measure the voltage with the connector joined CAUTION Incorrect reverse connection or short circuit by needle adapters co
229. art Number None Brown 92139 0131 None None Black 92139 0130 Blue 92139 0129 Crankshaft Main Bearing Insert Selection Crankcase Main Crankshaft Main Bearing Insert Bearing Inside Journal Diameter Diameter Marking Marking Size Color Part Number Journal Nos 92139 0134 1 3 5 1 Brown 92139 0137 2 4 None 1 92139 0133 1 3 5 Black O None 92139 0136 2 4 92139 0132 1 None None Blue MS EUN 92139 0135 2 4 The bearing inserts for Nos 2 and 4 journals have an oil groove respectively Special Tools and Sealants CRANKSHAFT TRANSMISSION 9 9 Bearing Puller 57001 135 875701355 C Bearing Puller Adapter 57001 317 7570317ST C Piston Pin Puller Assembly 57001 910 7570910ST C Piston Ring Compressor Grip 57001 1095 875710955 C Piston Ring Compressor Belt 80 91 57001 1320 8 5713205 Kawasaki Bond 92104 1064 879210645 9 10 CRANKSHAFT TRANSMISSION Crankcase Splitting Crankcase Splitting e Remove the engine see Engine Removal in the Engine Removal Installation chapter e Set the engine on a clean surface and hold the engine steady while parts are being removed e Remove Clutch see Clutch Removal in the Clutch chapter Starter Motor see Starter Motor Removal in the Electri cal System chapter Oil Pump see Cil Pump Removal in the Engine Lubri cation System chapter Alternator
230. asher A M7 Bolt with Clamp B M7 Bolt C M6 Bolts D Torque Crankcase Bolts M8 27 N m 2 8 kgf m 20 ft Ib Crankcase Bolts M7 20 2 0 kgf m 15 ft Ib Crankcase Bolts M6 12 N m 1 2 kgf m 106 in Ib 6104233852 C e After tightening all crankcase bolts check the following items OCrankshaft and transmission shafts turn freely OWhile spinning the output shaft gears shift smoothly from the 1st to neutral and neutral to 1st e Install the removed parts see appropriate chapters CRANKSHAFT TRANSMISSION 9 15 Crankshaft and Connecting Rods Crankshaft Removal e Split the crankcase see Crankcase Splitting e Remove the crankshaft see Connecting Rod Removal Crankshaft Installation CAUTION If the crankshaft bearing inserts or crankcase halves are replaced with new ones select the bear ing inserts and check clearance with a plastigage press gauge before assembling engine to be sure the correct bearing inserts are installed NOTE OWhen replacing the crankcase halves install the thrust washers t 2 5 mm 0 0984 in on the upper crankcase half e Apply molybdenum disulfide oil solution to the crankshaft main bearing inserts e Follow the next procedure to insert the thrust washers on the upper crankcase half after installing connecting rod on the crankshaft see Connecting Rod Installation e Apply molybdenum disulfide grease to the outside sur faces A of both
231. assem bly e Connect the terminal 9 to the battery terminal e Check that the following items OThe speedometer and tachometer needles momentarily point their last readings and back to the minimum position OThe ABS indicator light LED A ABS equipped models should go on OThe K Kawasaki mark B in the LCD appears for three seconds SP170770S1 C 16 72 ELECTRICAL SYSTEM Meter Gauge Indicator Unit OAfter the K Kawasaki mark appeared the ordinary indica tion A Example N AVERAGE KM L odometer B or trip meter clock C water temperature gauge D and b LF fuel level gauge E appear in the display ZA If the meter unit does not wo rk replace the meter assembly NOTE OThe flashings of the three segments for the water tem EN perature gauge and fuel level gauge do not failure of the xs JR meter unit OCurrently for the meter is disconnected from the main harness each flashing occur The flashing of the water temperature gauge is commu nication error to the ECU OThe flashing of the fuel level gauge is open or short of the fuel reserve switch ONormally each flashing disappears when the meter unit is connected to main harness CAVIS aka JAVERAGE 7 7KM L 123 456 4 2 34 o A 7 8 1000c GP17079G 47 Check 3 Upper and Lower Button Operation Check e Connect the leads in the same c
232. assembly Calipers Caliper Installation e Install the caliper and brake hose lower end OReplace the washers on each side of hose fitting with new ones e Tighten Torque Caliper Mounting Bolts Front 34 N m 3 5 kgf m 25 ft lb Rear 25 N m 2 5 kgf m 18 ft lb Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft lb e Check the fluid level in the brake reservoirs e Bleed the brake line see Brake Line Bleeding e Check the brake for good braking power no brake drag and no fluid leakage A WARNING Do not attempt to drive the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against the disc The brakes will not function on the first appli cation of the lever or pedal if this is not done Front Caliper Disassembly e Refer to the Caliper Rubber Parts Replacement in the Pe riodic Maintenance chapter Front Caliper Assembly e Refer to the Caliper Rubber Parts Replacement in the Pe riodic Maintenance chapter Rear Caliper Disassembly e Refer to the Caliper Rubber Parts Replacement in the Pe riodic Maintenance chapter Rear Caliper Assembly e Refer to the Caliper Rubber Parts Replacement in the Pe riodic Maintenance chapter BRAKES 12 17 12 18 BRAKES Calipers Caliper Fluid Seal Damage Inspection The fluid seal piston seal A is placed around the pis ton to maintain clearance between the pad and the disc If the
233. ate chapters Crankshaft Sensor Inspection e Remove the right fairing cover see Fairing Cover Re moval in the Frame chapter e Disconnect the crankshaft sensor lead connector B see Crankshaft Sensor Removal e Set the hand tester A to the x 100 O range and connect it to the crankshaft sensor lead connector Special Tool Hand Tester 57001 1394 Crankshaft Sensor Resistance 376 564 Q If there is more resistance than the specified value the coil has an open lead and must be replaced Much less than this resistance means the coil is shorted and must be replaced e Using the highest resistance range of the tester measure the resistance between the crankshaft sensor leads and chassis ground Any tester reading less than infinity lt indicates a short necessitating replacement of the crankshaft sensor Crankshaft Sensor Peak Voltage Inspection NOTE OBe sure the battery is fully charged OUsing the peak voltage adapter is a more reliable way to determine the condition of the crankshaft sensor than crankshaft sensor internal resistance measurements e Remove the right fairing cover see Fairing Cover Re moval in the Frame chapter e Disconnect the crankshaft sensor lead connector see Crankshaft Sensor Removal GP10492BS1 ELECTRICAL SYSTEM 16 43 Ignition System e Set the hand tester A to the DC 25 V range and connect the peak voltage adapter B Special Tools Hand Tester 5
234. ater hoses Run the oil pressure switch gear position switch lead through the backside of the air bleeder hose come from the water pump 17 12 APPENDIX Cable Wire and Hose Routing xem Os Uy INS v E SN E m W 8 08809615045 C APPENDIX 17 13 Cable Wire and Hose Routing 1 Oil Pressure Switch Gear Position Switch Lead 2 Band Hold the gear position switch lead lightly so that there is a gap between the gear position switch lead and the band and cut the end of the band Lower Fairing Bracket Clamp Install the clamp to the lower fairing bracket so that the band faces upside and set the position of the clamp as shown in the figure Do not touch the oil pan View from Bottom 17 14 APPENDIX Cable Wire and Hose Routing 580 670 6 APPENDIX 17 15 Cable Wire and Hose Routing Pad Pad Fit the position of the pad with the reserve tank and fix it by pushing the middle fairing at instal lation Fit the position of the pad with the water pump and reserve tank drain hose and fix it by pushing the lower fairing at installation Pad Fit the position of the pad with the water hose and fix it by pushing the middle fairing at instal lation 17 16 APPENDIX Cable Wire and Hose Routing 68098776 6 APPENDIX 17 17 Cable Wire and Hose Routing ROD
235. ation with insufficient deteriorated or contaminated engine oil will cause accelerated wear and may result in engine or transmission seizure accident and injury Engine Oil Change e Situate the motorcycle so that it is vertical after warming up the engine e Remove the engine oil drain bolt A to drain the oil OThe oil in the oil filter can be drained by removing the filter see Oil Filter Replacement e Replace the drain bolt gasket B with a new one e Tighten the drain bolt Torque Engine Oil Drain Bolt 30 N m 3 1 kgf m 22 ft Ib e Pour in the specified type and amount of oil PERIODIC MAINTENANCE 2 59 Periodic Maintenance Procedures Recommended Engine Oil Type API SE SF or SG SAE 20W 50 gt API SH SJ or SL with JASO MA MA1 or MA2 SAE 10W 50 Viscosity SAE 10W 40 Capacity 3 7 L 3 9 US qt when filter is not a SAE 10W 40 removed SAE TON SD 2 20 10 0 10 20 30 40 4 1 L 4 3 US qt when filter is removed NEC CT EN eT 4 5 L 4 8 US qt when engine is 6509010851 6 completely dry NOTE ODo not add any chemical additive to the oil Oils fulfilling the above requirements are fully formulated and provide adequate lubrication for both the engine and the clutch OAlthough 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 ridin
236. ature sensor trouble Miscellaneous Subthrottle sensor trouble Subthrottle valve actuator trouble Speed sensor trouble Throttle valves will not fully open Actions chapter Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect throttle cables and lever linkage see chapter 3 Engine overheating Water temperature sensor crankshaft sensor or speed sensor trouble see Overheating of Troubleshooting Guide in chapter 17 Air switching valve trouble Inspect and replace see chapter 16 Air suction valve trouble Inspect and replace see chapter 5 Exhaust Smokes Excessively White smokes Air cleaner clogged Fuel pressure too high Fuel injector trouble Water temperature sensor trouble Inlet air temperature sensor trouble Brown smoke Air duct holder loose Fuel pressure too low Water temperature sensor trouble Inlet air temperature sensor trouble Clean element see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Reinstall see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 FUEL SYSTEM DFI 3 37 Self Diagnosis Self diagnosis Outline The self diagnosis system has two modes and can be switched to another mode by operating the meter unit User Mode The ECU notifies the rider of troub
237. ay Main Fuse 30A mos IGNITION SWITCH CONNECTIONS Fuel Diagnostic Joint Reserve System Connector 3 Switch Connector Fuel Pum Rear Brake Light Switch Tail Brake Light LED 12V0 5 4 9W Rear Left Turn Signal Light 12v21W i Kawasaki OK R kz BRZY LG BK BKAY BRW BK Y BK Y BK Y BK Y iei Color Code BE ek Brack LI Pet Blue Lu 4 G Green LB Light Blue Malaysia Model LG Light Green 9 Orange Tail2 Battery Tail3 lgnition Battery 111 RIGHT SWITCH HOUSING CONNECTIONS Front Brake Light S witch Engine Stop Switch Starter Button Pink Pu Purple Rea Color BL w BK W G rech Color G Y Color Brake Lever OFF Free Pulled In RUN a Push a O 98052 0348B 0347B W White W2R0346BW5 C 16 20 ELECTRICAL SYSTEM Wiring Diagram Other than CA CAL US AU and MY Models Camshaft Horn Tut Position Right Switch Housing 12V 2 5 1 Front Brake Light Switch ensor Air 2 Engine Stop Switch Switching 3 Starter Button Valve Ignition a Switch siet ors Switch Housing 58 Immobilizer Antenna BK R Joint Connector 1 Spark Plugs 2444 555555 s TEE EEEF AAAA Y o R R ol Immobilizer Amplifier BK Y Meter Unit 1 Right Turn Sig
238. b bear ings see Hub Bearing Inspection the problem is not due to the bearings replace the wheel Rim Runout with tire installed Standard Axial TIR 0 5 mm 0 02 in or less Radial TIR 0 8 mm 0 03 in or less Service Limit Axial TIR 1 0 mm 0 04 in Radial TIR 1 0 mm 0 04 in WARNING Never attempt to repair a damaged wheel If there is any damage besides wheel bearings the wheel must be replaced to insure safe operational condi tion Axle Inspection e Remove the front and rear axles see Front Rear Wheel Removal e Visually inspect the front and rear axle for damages If the axle is damaged or bent replace it e Place the axle in V blocks that are 100 mm 3 94 in A apart and set a dial gauge B on the axle at a point halfway between the blocks Turn C the axle to mea sure the runout The difference between the highest and lowest dial readings is the amount of runout If axle runout exceeds the service limit replace the axle Axle Runout 100 mm 3 94 in Standard TIR 0 03 mm 0 0012 in or less Service Limit TIR 0 2 mm 0 008 in GJ04130BS1 6J04043BS1 C Wheels Rims Balance Inspection e Remove the front and rear wheels see Front Rear Wheel Removal e Support the wheel so that it can be spun freely e Spin the wheel lightly and mark A the wheel at the top when the wheel stops ORepeat this procedure several times If the wheel st
239. be ended and the warning indicator 0 5second 0 5second light LED goes off ae LI LI LPL To return to the registration mode start the master key 30515 51 verification procedure This applies to all user key reg istration e Insert the user key 1 to the ignition switch and turn it ON NOTE OKeep the other user keys away from the immobilizer antenna Olf there is any problem in the registration the warning indicator light LED A blinks to display the collation error Immobilizer Amplifier Failure 0 2second ON On GP30516BS1 C Immobilizer System Equipped Models When Registered User Key is Inserted User Key Collation Error e The user key 1 is registered in the ECU OThe warning indicator light LED A blinks 2 times and stops for 1 second and then repeats this cycle to indicate successful registration of user key e Turn OFF and remove the user key 1 OThe warning indicator light LED A blinks to display the registration mode codes NOTE Olnsert next key and turn ON within 15 seconds after pre vious key is turned OFF and removed otherwise regis tration mode will be ended and the warning indicator light LED goes off OTo return to the registration mode start the master key verification procedure This applies to all user key reg istration e Insert the user key 2 to the ignition switch and turn it ON ELECTRICAL SYSTEM 16 99 0 5second 0 5secon
240. ber A for oil leakage lf the oil leakage is found on it replace the shock absorber with a new one Rocker Arm Operation Inspection e Remove the rear fairing see Rear Fairing Removal in the Frame chapter equipped models e Pump the seat down and up 4 or 5 times and inspect the smooth stroke the rocker arm A does not smoothly stroke or noise is found inspect the fasteners and bearings see Rocker Arm Tie Rod Bearing Sleeve Inspection in the Suspen sion chapter 65148211 Tie Rod Operation Inspection e Remove the rear fairing see Rear Fairing Removal in the Frame chapter equipped models e Pump the seat down and up 4 or 5 times and inspect the smooth stroke x lf the tie rods A do not smoothly stroke or noise is found inspect the fasteners and tie rod bearings see Rocker Arm Tie Rod Bearing Sleeve Inspection in the Suspen sion chapter 2 40 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering Steering Play Inspection e Remove the lower fairings see Lower Fairing Removal in the Frame chapter e Raise the front wheel off the ground with the jack Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e 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 x If the wheel binds or catches before the stop the stee
241. bottom Suspend an ac curate thermometer B in the water so that the heat sen sitive 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 COOLING SYSTEM 4 15 6209020252 C 4 16 COOLING SYSTEM Hoses and Pipes Hose Installation e Install the hoses and pipes being careful to follow bend ing direction Avoid sharp bending kinking flattening or twisting e Run the hoses see Cable Wire and Hose Routing sec tion in the Appendix chapter e Install the clamp A as near as possible to the hose end to clear the raised rib of the fitting This will prevent the hoses from working loose OThe clamp screws should be positioned correctly to pre vent the clamps from contacting the other parts Torque Radiator Water Hose Clamp Screws 2 0 N m 0 20 kgf m 18 in Ib Hose Inspection e Refer to the Radiator Hose and Pipe Inspection in the Periodic Maintenance chapter DD Ww 6010020151 C Water Temperature Sensor CAUTION The water temperature sensor should never be al lowed to fall on a hard surface Such a shock to the water temperature sensor can damage it Water Temperature Sensor Removal e Refer to the Water Temperature Sensor Removal Instal lation in the Fuel S
242. ceed the 5th step the battery terminal voltage correct proceed the 6th step e Do the 5th step test OCheck for continuity between the positive cable A of the battery and red lead terminal of the main harness side connector B If there is the continuity in the lead proceed the 4th step there is not the continuity the lead replace or repair the main harness e Do the 6th step test ORecheck the service code indication erase the service code perform the pre diagnosis inspection 1 and 2 and retrieve the service code xIf the ABS indicator light LED A lit faulty ABS pump motor relay in the ABS hydraulic unit Replace the ABS hydraulic unit xIf the ABS indicator light LED unlit ABS system is nor mal service code is not stored temporary failure GL14132BS1 GL14133BS1 GL14288BS1 Anti Lock Brake System Equipped Models Front Wheel Rotation Sensor Signal Abnormal Service Code 42 e Do the 1st step test OMeasure the air gap between the front wheel rotation sen sor and sensor rotor Thickness Gauge A Air Gap Standard 0 7 0 9 mm 0 028 0 035 in the measurement is over standard check each part for deformation and looseness and correct accordingly Recheck the air gap x lf the measurement is correct proceed the 2nd step e Do the 2nd step test OCheck that there is
243. city 3 7 L 3 9 US qt when filter is not removed 4 1 L 4 3 US qt when filter is removed 4 5 L 4 8 US qt when engine is completely dry Level Between upper and lower level lines Wait 2 3 minutes after idling or running Oil Pressure Measurement Oil Pressure 245 343 kPa 2 5 3 5 kgf cm 36 50 psi at 4 000 r min rpm Oil Temperature 90 C 194 F ENGINE LUBRICATION SYSTEM 7 7 Special Tools and Sealant Oil Pressure Gauge 10 kgf cm Oil Filter Wrench 57001 164 57001 1249 7570164ST C 7571249ST C Oil Pressure Gauge Adapter PT3 8 Kawasaki Bond Silicone Sealant 57001 1233 56019 120 875712335 6 875601205 7 8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter A WARNING Motorcycle operation with insufficient deteri orated or contaminated engine oil will cause accelerated wear and may result in engine or trans mission seizure accident and injury Oil Level Inspection e Check that the engine oil level is between the upper A and lower B levels in the gauge NOTE OSituate the motorcycle so that it is perpendicular to the ground Olf the motorcycle has just been used wait several min utes for all the oil to drain down Olf 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 CAUTI
244. ck 2 e The speed equivalent to the input frequency is indicated in the oscillator A if the square wave is input into terminal 13 Olndicates approximately 60 mph if the input frequency is approximately 131 2 Hz Olndicates approximately 60 km h if the input frequency is approximately 82 Hz the meter function does not work replace the meter assembly Check 15 Trip A B Meter Inspection e Connect the leads in the same circuit as Check 14 e Set the TRIP A or B meter mode A in the display e Raise the input frequency of the oscillator to see the result of this inspection x lf the value indicated by the trip meter do not increase replace the meter assembly e Push the lower button for more than two seconds and check that each TRIP meter resets to 0 0 lf the display function does not change replace the meter assembly NOTE OThe integrated value of the odometer cannot be reset Check 16 Odometer Inspection e Connect the leads in the same circuit as Check 14 e Raise the input frequency of the oscillator to see the result of odometer A inspection OExample Indicates the increase of approximately 1 mile if the input frequency is approximately 131 2 Hz for one minute OExample Indicates the increase of approximately 1 km h if the input frequency is approximately 82 Hz for one minute If the value indicated by the odometer does not increase replace the meter assembly ELECTRICAL SYSTEM 16 81
245. cle down Sensor C Vehicle down Sensor Installation e The UP mark A of the sensor should face upward A WARNING Incorrect installation of the vehicle down sensor could cause sudden loss of engine power The rider could lose balance during certain riding situ ations like leaning over in a turn with the potential for an accident resulting in injury or death Ensure that the vehicle down sensor is held in place by the sensor bracket 6617356851 6 e Tighten Torque Vehicle down Sensor Bolts 5 9 N m 0 60 kgf m 52 in Ib 3 74 FUEL SYSTEM Vehicle down Sensor Service Code 31 Vehicle down Sensor Inspection NOTE OBe sure the battery is fully charged e Remove the windshield see Windshield Removal in the Frame chapter e Connect a digital meter A to the connector of the vehicle down sensor B using the needle adapter set C Special Tool Needle Adapter Set 57001 1457 Vehicle down Sensor Power Source Voltage Connections to Sensor Meter BL lead D Meter BR BK lead E e Turn the ignition switch ON and measure the power source voltage with the connector joined Power Source Voltage at Sensor Standard DC 4 75 5 25 V e Turn the ignition switch OFF there is no voltage check the following Battery see Charging Condition Inspection in the Elec trical System chapter ECU Fuse 15 A see Fuse Inspection in the Electrical System chapt
246. codes 14 codes can be stored and the display will begin starting from the small number code entered OFor the display pattern first the smallest number code is shown next up to all service codes 14 codes starting with the last one stored then the display is repeated from the smallest number code once again Service Service Service Service Service gt gt gt code 13 code 14 code 17 code 53 code 55 poe Olf there is no fault the ABS indicator light LED lights as shown in the figure Repeat Start Self diagnosis End Self diagnosis 1 ABS Self Open diagnosis Terminal Ground Ignition ON Switch OFF 10th digit a digit 10th digit a digit oy poe ABS on Docs 0 48 0 45 0 45 0 45 0 45 0 45 0 48 0 45 0 45 0 48 Indicator abnormal 3 68 1 6 3 68 1 68 Light LED OFF 0 48 0 48 0 48 0 48 0 45 0 48 Y 2 V Y 2 Service Code 13 Service Code 42 Repetition ABS ON ne Indicator normai Light LED 1 1 GLi41i158W2 C How to Erase Service Codes OEven if the ignition switch is turned OFF the battery or the ABS hydraulic unit are disconnected all service codes remain in the ABS hydraulic unit ORefer to the Service Code Clearing Procedure for the service code erasure BRAKES 12 45 Anti Lock Brake System Equipped Models Service Code Table ON Rear inlet so
247. commended Repair methods may vary slightly from make to make Follow the repair methods indicated by the manufacturer of the repair tools and materials so that safe results can be obtained 6J05042BS1 C Hub Bearing Hub Bearing Removal e Remove the wheels see Front Rear Wheel Removal and take out the following Collars Coupling Out of rear hub Grease Seals e Use the bearing remover to remove the hub bearings A WHEELS TIRES 10 17 CAUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground Special Tools Bearing Remover Head 25 x 28 B 57001 1346 Bearing Remover Shaft 13 C 57001 1377 Hub Bearing Installation e Before installing the hub bearings blow any dirt or foreign particles out of the hub with compressed air to prevent contamination of the bearings e Replace the bearings with new ones e Install the bearings by using the bearing driver set which does not contact the bearing inner race e Press in each right the bearing A until they are bottomed Special Tool Bearing Driver Set B 57001 1129 e Replace the grease seals with new ones e Press in the grease seals A so that the seal surface is flush B with the end of the hole OApply high temperature grease to the grease seal lips Special Tool Bearing Driver Set C 57001 1129 Hub
248. coolant and install the cap CAUTION Soft or distilled water must be used with the an tifreeze in the cooling system If hard water is used in the system it causes scales accumulation in the water passages and consider ably reduces the efficiency of the cooling system Water and Coolant Mixture Ratio Recommended Soft Water 5096 Coolant 50 Freezing Point 35 31 F Total Amount 3 4 L 3 6 US qt e Bleed the air from the cooling system as follows OStart the engine with the radiator cap removed and run it until no more air bubbles A can be seen in the coolant OTap the radiator hoses to force any air bubbles caught inside OStop the engine and add coolant up to the radiator filler neck e Install the radiator cap e Start the engine warm it up thoroughly until the radiator fan turns on and then stop the engine e Check the coolant level in the reserve tank after the en gine cools down xIf the coolant level is lower than the low level line add coolant to the full level line CAUTION 6005010951 6 Do not add more coolant above the full level line 2 54 PERIODIC MAINTENANCE Periodic Maintenance Procedures Radiator Hose and O ring Replacement e Drain the coolant see Coolant Change e Remove Lower Fairings see Lower Fairing Removal in the Frame chapter Middle Fairings see Middle Fairing Removal in the Frame chapter Throttle Body Assy see Throttle Body
249. could damage both the chain and the sprocket 6 11189851 C Camshatt Installation e Be sure to install the following parts Plug Hole Gaskets A 2 4 di desc Ie Lp rif EID Ee TES BI zesz TE STIL Tea f Bnrm rea Hrs Figo Dowel Pins B LO 9 e Install the cam sprockets as shown in the figure 4 Cam Positions A Inlet Cam Sprocket B Exhaust Cam Sprocket C e Apply a non permanent locking agent to the threads of the mounting bolts and tighten the bolts Torque Cam Sprocket Mounting Bolts 15 N m 1 5 kgf m 11 ft lb 6 11191851 C 5 18 ENGINE TOP END Camshaft Camshaft Chain e Apply molybdenum disulfide oil solution oil to all cam parts and journals e f anew camshaft is to be used apply a thin coat of molyb denum disulfide grease to the cam surfaces NOTE O The exhaust camshaft has a 1090 EX mark A and the inlet camshaft has a 1090 IN mark B Be careful not to mix up these shafts NOTE OThe exhaust camshaft has the projection A for camshaft position sensor e Position the crankshaft at 1 4 piston TDC e Pull the tension side exhaust side A of the chain taut to install the chain e Engage the camshaft chain with the camshaft sprockets so that the timing marks on the sprockets are positioned as shown in the figure OThe timing marks of 1 4T must be aligned with the lower surface of
250. ct Bypass screw maladjusted Air passage clogged Air bleed pipe bleed holes clogged Pilot passage clogged Air cleaner clogged poorly sealed or miss ing Fuel tank air vent obstructed Fuel pump trouble Throttle body assy holder loose Air duct holder loose Troubleshooting Guide APPENDIX 17 61 Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Camshaft cam worn Run on dieseling Ignition switch trouble Engine stop switch trouble Fuel injector trouble Loosen terminal of battery cable or ECU ground lead Carbon accumulating on valve seating sur face Engine overheating Other ECU trouble Throttle body assy not synchronizing Engine oil viscosity too high Drive train trouble Brake dragging Clutch slipping Engine overheating Air suction valve trouble Air switching valve trouble Poor Running or No Power at High Speed Firing incorrect Spark plug dirty broken or maladjusted Spark plug incorrect Stick coil shorted or not in good contact trouble Stick coil trouble ECU trouble Fuel air mixture incorrect Air cleaner clogged poorly sealed or miss ing Air duct holder
251. ct a digital meter A to the ECU connector B Measure the resistance of the CAN communication line resistor CAN Communication Line Resistance at ECU Connector Connections Terminal 1 Terminal 18 Standard 114 126 lf the reading is out of the range replace the ECU see ECU Removal Installation xIf the reading is within the range resistor of the ECU for CAN communication line is normal e Check the wiring for continuity of the CAN communication line see wiring diagram in this section the wiring is open replace the main harness e Refer to the Meter Unit Inspection in the Electrical System chapter for the resistor in the meter unit CAN Communication Line Circuit FUEL SYSTEM DFI 3 101 imam 6617466651 C 6C17467CW2 C 1 Meter Unit 2 ECU 3 Resistor In the Meter Unit 4 Resistor In the ECU 3 102 FUEL SYSTEM DFI Warning Indicator Light LED Light LED Inspection OThe warning indicator light LED is used for the FI indicator and immobilizer indicator immobilizer models Oln this model the warning indicator light LED goes on or blinks by the special signal sent from the ECU e Refer to the fuel level warning inspection procedure see Meter Unit Inspection in the Electrical System chapter for the warning indicator light LED inspection 9617223051 Warning Indicator Light LED Circuit 9
252. ct the speed sensor lead connector B e Remove Bolt C Speed Sensor D Speed Sensor Installation e Install the speed sensor e Apply a non permanent locking agent to the threads of the sensor bolt and tighten it Torque Speed Sensor Bolt 3 9 0 40 kgf m 35 in Ib GP18247BS2 C Switches and Sensors Speed Sensor Inspection e Remove the speed sensor see Speed Sensor Removal e Connect the speed sensor lead connector A with the bat tery B 10 resistor C and hand tester D as shown in the figure e Set the tester to the DC 25 V range Special Tool Hand Tester 57001 1394 e Trace A each side of the speed sensor surface with the screwdriver OThen the tester indicator should flick B lf the tester indicator does not flick replace the speed sensor Oxygen Sensor Removal Equipped Models CAUTION Never drop the oxygen sensor especially on a hard surface Such a shock to the sensor can damage it e Remove Right Lower Fairing see Lower Fairing Removal in the Frame chapter Oxygen Sensor Lead Connector A Disconnect Clamp B Open Oxygen Sensor C Oxygen Sensor Installation Equipped Models CAUTION Never drop the oxygen sensor A especially on a hard surface Such a shock to the unit can damage it Do not touch the sensing part B of the sensor to prevent oil contact Oil contamination from hands can reduc
253. ctor A Air Switching Valve B CAUTION Never drop the air switching valve especially on a hard surface Such a shock to the air switching valve can damage it Air Switching Valve Installation e Install the air switching valve so that the air duct A faces left side e Run the hoses correctly see Cable Wire and Hose Rout ing section in the Appendix chapter Air Switching Valve Operation Test e Refer to the Air Switching Valve Operation Test in the Electrical System chapter Air Switching Valve Unit Test e Refer to the Air Switching Valve Unit Test in the Electrical System chapter Clean Air System Clean Air System Hose Inspection e Be certain that all the hoses are routed without being flat tened or kinked and are connected correctly to the air cleaner housing air switching valve and air suction valve covers they are not correct them Replace them if they are damaged ENGINE TOP END 5 13 5 14 ENGINE TOP END Cylinder Head Cover Cylinder Head Cover Removal e Remove Middle Fairings see Middle Fairing Removal in the Frame chapter Throttle Body Assy see Throttle Body Assy Removal in the Fuel System DFI chapter Air Switching Valve see Air Switching Valve Removal Camshaft Position Sensor Lead Connector see Camshaft Position Sensor Removal in the Electrical System chapter e Free the heat insulation rubber plate e Remove Stick Coils see Stick Coil Remov
254. d ore 6230515851 C 0 5second 0 5second dm SP30515BS1 C 16 100 ELECTRICAL SYSTEM Immobilizer System Equipped Models Olf there is any problem in the registration the warning indicator light LED A blinks to display the collation error code Immobilizer Amplifier Failure When Registered User Key is Inserted User Key Collation Error e The user key 2 is registered in the ECU OThe warning indicator light LED A blinks 3 times and stops for 1 second and then repeats this cycle to indicate successful registration of user key 2 e Turn OFF the ignition switch and wait for period more than 15 seconds e The registration mode automatically ends e Warning indicator light LED A goes off NOTE O Turn the ignition switch ON with the registered user key OCheck that the engine can be started using all regis tered user keys 0 2second Get GP30516BS1 C 0 5second 0 5second E bara GP30515BS1 0 3second UU GP30517BS1 0 30 30 3 0 30 3 1second ON A 81 1 UUL_IUUL GP30519BS1 C QN 51 GP30520BS1 ELECTRICAL SYSTEM 16 101 Immobilizer System Equipped Models Case 4 When master key is faulty or lost The master key replacement is considered very rare case However if it is required the followin
255. d Middle Air Inlet Duct 3 128 Fuel Iani Sets 3 130 FRG MOV AN rea ea desc 3 130 Fuel Tank 3 133 ee C EE 3 134 Pusl Tank CIA eot de noe 3 135 Evaporative Emission Control System CAL SEA 3 136 Parts RemoOval InStalation cem 3 136 Hose RP H 3 136 Separator InsSpectlori en idee De eco 3 136 Separator Operation celal uni hee uu cine 3 137 Canister Inspection 3 137 3 4 FUEL SYSTEM DFI Exploded View 80023268845 C FUEL SYSTEM DFI 3 5 Exploded View Torque No Fastener Nm kgf m itib Remarks 1 Air Cleaner Element Cover Bolts 6 9 0 70 61 in lb 2 Air Cleaner Element Holder Screws 6 9 0 70 61 in lb 3 Duct Clamp Bolts 2 0 0 20 18 in Ib 4 Front Air Inlet Duct Mounting Bolts 9 8 1 0 87 in lb 5 Middle Air Inlet Duct Clamp Bolts 2 9 0 30 26 in lb 6 Middle Air Inlet Duct Mounting Bolts 9 8 1 0 87 in lb 7 Rear Air Inlet Duct Mounting Bolts 9 8 1 0 87 in lb L 8 Ducts WVTA 78 2 Model L Apply a non permanent locking agent WL Apply soap and water solution or rubber lubricant 3 6
256. d air cleaner housing hole e Connect a vacuum gauge special tool and hoses A to the fittings on the throttle body Special Tool Vacuum Gauge 57001 1369 e Connect a highly accurate tachometer B to one of the stick coil primary leads e Start the engine and warm it up thoroughly e Check the idle speed using a highly accurate tachometer A lf the idle speed is out of the specified range adjust it with the adjusting screw CAUTION Do not measure the idle speed by the tachometer of the meter unit e While idling the engine inspect the throttle body vacuum using the vacuum gauge B Throttle Body Vacuum Standard 34 4 1 3 kPa 258 10 mmHg at idle speed 2 18 PERIODIC MAINTENANCE Periodic Maintenance Procedures If any vacuum is not within specifications first synchro nize the balance of the left 1 2 throttle valves and right 3 4 throttle valves assemblies Example 1 260 mmHg 2 290 mmHg 3 250 mmHg 4 270 mmHg e With the engine at the correct idle speed equalize higher vacuum of 1 or 2 for example 290 mmHg to higher vacuum of 3 or 4 for example 270 mmHg by turning the center adjusting screw A Right Side View B Oln this photo C the throttle body has been removed for clarity Special Tools Pilot Screw Adjuster C 57001 1292 Pilot Screw Adjuster Adapter 5 57001 1372 NOTE OAfter adjustment the final vacuum measurement be tween the
257. d as a guide Special Tools Fork Spring Compressor 57001 1540 Fork Spring Compressor 57001 1587 e Insert the holder bar A into the axle hole of the front fork B e Insert the compression shaft and install the nut e Insert the lower end of the compression shaft A into the hole B of the holder bar e Screw the adjust nut A onto the compression shaft as shown in the figure e Screw the locknut B About 20 mm 0 79 in C e Set the other side compression shaft as same as above process SUSPENSION 13 13 Front Fork e Set the holder bar A and compression shafts B e Screw in the nuts A until the piston rod nut comes out e Holding the piston rod nut with a wrench A remove the top plug B from the piston rod e Remove Washer A Collar B Rebound Damping Adjuster Rod C Fork Spring D GM04361BSi C e Drain the fork oil into a suitable container OPump the piston rod A up and down least ten times to expel the oil from the fork Special Tool Fork Piston Rod Puller M12 x 1 25 B 57001 1289 8 04362851 C 13 14 SUSPENSION Front Fork e Hold the fork tube upright press the inner tube A and the piston rod all the way down e Pour in the type and amount of fork oil specified Fork Oil Viscosity KAYABA 01 KHL15 10 or equivalent SAE 5W Amount Per Side When changing oil Approx 480 mL 16 2 US oz After disassembly and completely dry 563 4
258. d bend the 2 claws downward E e Install the stem head e Install the washer and tighten the stem head nut e Tighten Torque Steering Stem Head Nut 78 N m 8 0 kgf m 58 ft lb Front Fork Clamp Bolts Upper 20 N m 2 0 kgf m 15 16 e Check the steering again lf the steering is still too tight or too loose repeat the ad justment e Install the handlebars see Handlebar Installation in the Steering chapter 6515034851 C Steering Stem Bearing Lubrication e Remove the steering stem see Stem Stem Bearing Re moval in the Steering chapter e 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 e Visually check the outer races and the ball bearings Replace the bearing assemblies if they show wear or damage e 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 e Install the steering stem see Stem Stem Bearing Instal lation in the Steering chapter e Adjust the steering see Steering Play Adjustment 2 42 PERIODIC MAINTENANCE Periodic Maintenance Procedures Electrical System Lights and Switches Operation Inspection First Step e Turn on the ignition switch e The following lights should go on according to below table City Light A go
259. d parts and inspect the clutch plate as sembly length Torque Clutch Spring Bolts 9 0 N m 0 92 kgf m 80 in Ib Clutch Plate Wear Damage Inspection e Visually inspect the friction and steel plates for signs of seizure overheating discoloration or uneven wear e Measure the thickness of each friction plate A at several points xlf any plates show signs of damage or if they have worn past the service limit replace them with new ones Friction Plate Thickness 13088 0030 13088 0031 Standard 2 92 3 08 mm 0 115 0 121 in Service Limit 2 7 mm 0 106 in Friction Plate Thickness 13088 0032 Standard 3 72 3 88 mm 0 146 0 153 in Service Limit 3 5 mm 0 138 in Clutch Plate Warp Inspection e 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 15 mm 0 0059 in or less Service Limit 0 3 mm 0 012 in Friction Plate Warp 13088 0030 only Standard 0 2 mm 0 008 in or less Service Limit 0 3 mm 0 012 in CLUTCH 6 17 GF06060281 6 995999 6213010751 6 6 18 CLUTCH Clutch Clutch Spring Free Length Measurement e Measure the free length of the clutch spri
260. der from the engine with the pipe installed Push A the piston into the cylinder as far as it will go OApply the clutch lever A slowly and hold it with a band B NOTE OHolding the clutch lever keeps the piston from coming out j us m Ae GF10010181 Clutch Slave Cylinder Clutch Slave Cylinder Installation e Apply molybdenum disulfide grease to either end A of the push rod and install the push rod so that the greased end faces in e Replace the spacer B of the clutch slave cylinder with a new one e Install the spacer so that the stepped side C faces out ward e Apply a non permanent locking agent to the threads of the slave cylinder bolts A e Finger tighten all the clutch slave cylinder bolts e Remove the band from the clutch lever and release the clutch lever e Tighten Torque Clutch Slave Cylinder Bolts 9 8 N m 1 0 kgf m 87 in Ib e Replace the washers that are on each side of the hose fitting with new ones e Tighten Torque Clutch Hose Banjo Bolts B 25 N m 2 5 kgf m 18 e Check the fluid level in the master cylinder reservoir and bleed the air in the clutch line e Check the clutch operation e Install the removed parts see appropriate chapters Clutch Slave Cylinder Disassembly e Refer to the Rubber Parts of Clutch Master Cylinder Slave Cylinder Replacement in the Periodic Maintenance chap ter Clutch Slave Cylinder Assembly e Refer to the Rubber Par
261. des ea ee ug dp eod ud 3 84 Fuel Pump Relay Service Code 46 Nt 3 85 Fuel Pump Relay Removal 3 85 Fuel Pump Relay Inspeollotrs o cucine 3 85 Stick Coils 1 2 3 4 Service Code 51 52 53 54 3 87 Stick Coil Fremoval ristallaliOrt 3 87 Stick Coil Input Voltage Inspectigom irren 3 87 Subthrottle Valve Actuator Service Code 62 Ne 3 89 Subthrottle Valve Actuator Removal sessssesseeeseeeeeeeeenenen eene nnns 3 89 Subthrottle Valve Actuator Inspection uide Ever nee ke cibus 3 89 Subthrottle Valve Actuator Resistance Inspection pp 3 89 Subthrottle Valve Actuator Input Voltage Inspection pp 3 90 Oxygen Sensor Heater Service Code 67 Equipped 3 92 Oxygen Sensor Heater Removal Installation pp 3 92 Oxygen Sensor Heater Inspection 4422444 1 4 10 nennen 3 92 ECU Main Relay Service Code 5 euer haee ene se tarts om orae res Fo ode ui 3 95 ECU Main Relay Inspection ues root rr mter eoe pda e tbe wine ze se pul Da erede td tess 3 95 3 96 EC petite ae PD debe M 3 96 ze 3 96 ECU InstallatrT
262. det ue a Alo E EE 16 114 Relay Box BemoVal ie tot iret uec tick vend Bote 16 114 ELECTRICAL SYSTEM 16 3 Relay Circuit Inspection eon 16 114 Diode Circuit Inspection oor rede na Oa der iie dr 16 115 FISE 16 117 30 te scott tte md mI unie 16 117 Fuse Box F se RemoVval edite eet lel dette eee eh dene 16 117 15 A ECU Fuse 2 ness snas e sessanta 16 118 16 118 Fuse IMS PS CUOM usto odi 16 119 16 4 ELECTRICAL SYSTEM Exploded View GP023758W5 C ELECTRICAL SYSTEM 16 5 Exploded View Torque No Fastener NIS kgf m ft Ib Remarks 1 Front Turn Signal Light Mounting Screws 1 2 0 12 11 in lb 2 Headlight Mounting Screws 1 2 0 12 11 in lb 3 License Plate Light Cover Mounting Screws 0 90 0 092 8 0 in lb 4 License Plate Light Mounting Plate Screws 1 2 0 12 11 in lb 5 Rear Turn Signal Light Mounting Screws 1 2 0 12 11 in Ib 6 Tail Brake Light Mounting Screws 1 2 0 12 11 in Ib 16 6 ELECTRICAL SYSTEM Exploded View GP023768W5 C Exploded View ELECTRICAL SYSTEM 16 7
263. diately CAUTION Never drop the fuel pump especially on a hard sur face Such a shock to the pump can damage it e Draw the fuel out from the fuel tank with a commercially available electric pump e Remove the fuel tank see Fuel Tank Removal OBe 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 e Turn the fuel tank upside down Open the clamps A e Unscrew the fuel pump bolts B and take out the fuel pump assembly C and gasket e Discard the fuel pump gasket CAUTION Do not pull the leads D of the fuel pump and fuel reserve switch If they are pulled the lead terminals may be damaged Fuel Pump Installation e Remove dirt or dust from the fuel pump A by lightly ap plying compressed air e Replace the fuel pump gasket with a new one FUEL SYSTEM DFI 3 107 3 108 FUEL SYSTEM DFI Fuel Pump e Check that the fuel pump terminals fuel reserve switch terminal and band are in place Left A e Apply a non permanent locking agent to the threads of the fuel pump bolts e Tighten the fuel pump bolts to a snug fit following the tight ening sequence shown e Following the tightening sequence tighten the pump bolts to the specified torque Torque Fuel Pump Bolts 9 8 1 0 kgf m 87 in Ib e Tighten the pump bolts again to check the tightness in the order shown
264. ding operation must be done over again from the beginning since air will have entered the line e Remove the clear plastic hose e Tighten the bleed valve and install the rubber cap Torque Front Master Cylinder Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib e Remove the rubber cap A from the bleed valve on the caliper e Attach a clear plastic hose B to the bleed valve and run the other end of the hose into a container e Bleed the brake line and the caliper ORepeat this operation until no more air can be seen com ing out into the plastic hose 1 Pump the brake lever until it becomes hard and apply the brake and hold it A 2 Quickly open and close B the bleed valve while hold ing the brake applied 3 Release the brake C NOTE OThe fluid level must be checked often during the bleed ing operation and replenished with fresh brake fluid as necessary If the fluid in the reservoir runs completely out any time during bleeding the bleeding operation must be done over again from the beginning since air will have entered the line OTap the brake hose lightly from the caliper to the reser voir for more complete bleeding OFront Brake First bleeding the right caliper then repeat the above steps for the left caliper e Remove the clear plastic hose e Install Diaphragm Diaphragm Plate Front Brake Reservoir Cap GL09041BS2 C Brake Fluid e Follow the procedure below to install the front rear b
265. disconnected fuel spills out from the hose and the pipe Cover the hose connec tion with a clean shop towel to prevent fuel spillage e Install the new fuel hose so that the white mark A side faces throttle body assy e Run the fuel hose correctly see Cable Wire and Hose Routing section in the Appendix chapter e Pull B the joint lock C fully as shown in the figure e Insert the fuel hose joint A straight onto the delivery pipe until the hose joint clicks e Push B the joint lock C until the hose joint clicks e Push and pull the fuel hose joint A back and forth more than two times and make sure it is locked and doesn t come off A WARNING Make sure the fuel hose joint is installed correctly on the delivery pipe or the fuel could leak lf it comes off reinstall the hose joint e Install the throttle body assy see Throttle Body Assy In stallation in the Fuel System DFI chapter e Start the engine and check the fuel hose for leaks 2 52 PERIODIC MAINTENANCE Periodic Maintenance Procedures Coolant Change A 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 Immediately wipe up or wash away any coolant that spills on the frame engine or other painted parts Since coolant is harmful to the human body do not
266. dy Subharness CAUTION Do not remove disassemble or adjust the main throttle sensor subthrottle sensor subthrottle valve actuator throttle link mechanism and throttle body assy because they are adjust or set surely at the manufacturer Adjustment of these parts could result in poor performance requiring replacement of the throttle body assy e Remove the throttle body assy see Throttle Body Assy Removal e Disconnect the fuel injector connectors A 3 124 FUEL SYSTEM DFI Throttle Body Assy e Disconnect the main throttle sensor A and subthrottle sensor B connectors e Disconnect Subthrottle Valve Actuator Lead Connector A Inlet Air Pressure Sensor Connector B e Remove the clamps A e Separete the hoses B from the throttle body fittings and inlet air pressure sensor e Remove the screws C to pull out the injector assies from the throttle body assy together with the delivery pipe D NOTE ODo not damage the insertion portions of the injectors when they are pulled out from the throttle body e Pull out the injectors A from the delivery pipe B NOTE ODo not damage the insertion portions of the injectors when they are pulled out from the delivery pipe Throttle Body Assy Assembly e Before assembling blow away dirt or dust from the throttle body and delivery pipe by applying compressed air e Apply daphne oil or engine oil to the new O rings A of each injector insert t
267. e nut clockwise B up to next alignment Olt should be within 30 OLoosen once and tighten again when the slot goes past the nearest hole e Bend the cotter pin A over the nut A WARNING If the rear axle nut is not securely tightened or the cotter pin is not installed an unsafe riding condi tion may result Wheel Alignment Inspection e Check that the notch A on the right alignment indicator B aligns with the same swingarm mark or position C that the left alignment indicator notch aligns with xIf they do not adjust the chain slack and align the wheel alignment see Drive Chain Slack Adjustment NOTE OWheel alignment can be also checked using the straightedge or string method A WARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition Drive Chain Wear Inspection e Remove the chain cover see Drive Chain Removal in the Final Drive chapter Rotate the rear wheel to inspect the drive chain for dam aged rollers and loose pins and links xIf there is any irregularity replace the drive chain x Lubricate the drive chain if it appears dry e Stretch the chain taut by hanging a 98 N 10 kg 20 Ib weight A on the chain e Measure the length of 20 links B on the straight part C of the chain from the pin center of the 1st pin to the pin center of the 21st pin Since the chain may wear unevenly take measurements at sev
268. e Appendix chapter e Check that the dampers A and pads B are in place on the fuel tank as well the dampers are damaged or deteriorated replace them 6609085852 For the California and Southeast Asia models note the following OTo prevent the gasoline from flowing into or out of the canister hold the separator perpendicular to the ground OConnect the hoses according to the diagram of the evap orative emission control system Make sure they do not get pinched or kinked ORun the hoses with a minimum of bending so that the air or vapor will not be obstructed e Pull A the joint lock B as shown in the figure e Insert the fuel hose joint A straight onto the delivery pipe until the hose joint clicks e Push B the joint lock C until the hose joint clicks 3 134 FUEL SYSTEM DFI Fuel Tank e 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 A WARNING Make sure the hose joint is installed correctly on the delivery pipe or the fuel could leak lf it comes off reinstall the hose joint e Connect the fuel pump fuel level sensor lead connectors and the battery terminal see Battery Installation in the Electrical System chapter e For models equipped with an ABS fit the grooves of the damper A on the brake pipes e Fit the dampers A of the fuel tank into the slots B of the fuel tank c
269. e Bolts 23 Nm 2 3 kgf m 17 16 e Run the leads cable and hoses correctly see Cable Wire and Hose Routing section in the Appendix chap ter e Install the removed parts see appropriate chapters e Adjust Throttle Cables see Throttle Control System Inspection in the Periodic Maintenance chapter Drive Chain see Drive Chain Slack Inspection in the Periodic Maintenance chapter e Fill the engine with engine oil see Engine Oil Change in the Periodic Maintenance chapter e Fill the engine with coolant and bleed the air from the cool ing system see Coolant Change in the Periodic Mainte nance chapter CRANKSHAFT TRANSMISSION 9 1 Crankshaft Transmission Table of Contents Exploded View 9 2 Front Balancer Installation 9 30 Specifications pp 9 6 Rear Balancer Removal 9 31 Special Tools and Sealants 9 9 Rear Balancer Installation 9 32 Crankcase Splitting 9 10 Balancer Adjustment 9 34 Crankcase Splitting 9 10 Balancer Damper Inspection 9 34 Crankcase Assembly 9 11 Starter Motor Clutch and Torque Crankshaft and Connecting Rods 9 15 9 35 Crankshaft Removal 9 15 Starter Motor Clutch Removal 9 35 Crankshaft Installation 9 15 Starter Motor Clutch Installation 9 35 Con
270. e Loosen the banjo bolt A at the brake hose lower end and tighten it loosely e Unscrew the caliper mounting bolts B and detach the caliper C from the disc CAUTION Do not loosen the caliper assembly bolts Take out only the caliper mounting bolts for caliper removal Loosening the caliper assembly bolts will cause brake fluid leakage e Unscrew the banjo bolt and remove the brake hoses D from the caliper see Brake Hose Removal Installation CAUTION Immediately wash away any brake fluid that spills NOTE Olf the caliper is to be disassembled after removal and if compressed air is not available disassemble the caliper before the brake hose is removed see Front Caliper Disassembly Rear Caliper Removal e Loosen the banjo bolt A at the brake hose lower end and tighten it loosely e Unscrew the caliper mounting bolts B and detach the caliper C from the disc CAUTION Do not loosen the caliper assembly bolts Take out only the caliper mounting bolts for caliper removal Loosening the caliper assembly bolts will cause brake fluid leakage e Unscrew the banjo bolt and remove the brake hose D from the caliper see Brake Hose Removal Installation CAUTION Immediately wash away any brake fluid that spills NOTE Olf the caliper is to be disassembled after removal and if compressed air is not available disassemble the caliper before the brake hose is removed see Rear Caliper Dis
271. e Measure the thickness of the shift fork ears A and mea sure the width B of the gear grooves If the thickness of a shift fork ear is less than the service limit the shift fork must be replaced Shift Fork Ear Thickness Standard 5 74 6 00 mm 0 2260 0 2362 in Service Limit 5 6 mm 0 220 in If the gear groove is worn over the service limit the gear must be replaced Gear Groove Width Standard 6 05 6 15 mm 0 238 0 242 in Service Limit 6 25 mm 0 246 in Shift Fork Guide Pin Drum Groove Wear Inspection e Measure the diameter of each shift fork guide pin A and measure the width B of each shift drum groove the guide pin on any shift fork is less than the service limit the fork must be replaced Shift Fork Guide Pin Diameter Standard 6 9 7 0 mm 0 272 0 276 in Service Limit 6 8 mm 0 268 in xIf any shift drum groove is worn over the service limit the drum must be replaced Shift Drum Groove Width Standard 7 05 7 20 mm 0 278 0 283 in Service Limit 7 3 mm 0 287 in Gear Dog and Gear Dog Hole Damage Inspection e Visually inspect the gear dogs A and gear dog holes B Replace any damaged gears or gears with excessively worn dogs or dog holes 6113014551 6 6113161851 C 6113162851 6 6113163851 6 WHEELS TIRES 10 1 Wheels Tires Table of Contents elele CO I PD TENES 10 2 SDC CIIC AU
272. e Sensor Output Voltage Connections to ECU Meter BL W lead terminal 27 Meter BR BK lead terminal 34 e Remove the air cleaner caps see Throttle Body Assy Re moval e Turn the ignition switch ON e Measure the output voltage when the subthrottle valve is fully opened or completely closed by hand Output Voltage at ECU Standard DC 0 62 4 14 V at subthrottle valve full opening to closing NOTE OThe subthrottle sensor is operating correctly if the fol lowing voltages are obtained DC 0 62 V or slightly higher with the subthrottle valve at the closed position DC 4 14 V or slightly lower with the subthrottle valve at the fully open position If the output voltage is within the standard range check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation x lf the output voltage is far out of the standard range e g when the wiring is open the reading is O V check the output voltage at the subthrottle sensor connector 80171840651 FUEL SYSTEM DFI 3 79 Subthrottle Sensor Service Code 32 e Disconnect the subthrottle sensor connector and connect the harness adapter A between the harness connector and subthrottle sensor connector Special Tool Throttle Sensor Setting Adapter 57001 1538 e Connect a digital
273. e Sprocket Removal Swingarm see Swingarm Removal in the Suspension chapter e Remove the drive chain A from the output shaft B and take it off the chassis Drive Chain Installation e Install the drive chain to the output shaft e Install Swingarm see Swingarm Installation in the Suspension chapter Engine Sprocket see Engine Sprocket Installation Rear Wheel see Rear Wheel Installation in the Wheels Tires chapter Chain Cover e Adjust the drive chain slack after installing the chain see Drive Chain Slack Adjustment in the Periodic Mainte nance chapter Sprocket Coupling Engine Sprocket Removal e Remove Left Lower Fairing see Lower Fairing Removal in the Frame chapter Speed Sensor A see Speed Sensor Removal in the Electrical System chapter Clutch Slave Cylinder B see Clutch Slave Cylinder Re moval in the Clutch chapter Engine Sprocket Cover Bolts C Engine Sprocket Cover D e Flatten out the bended washer A e Remove the engine sprocket nut B and washer NOTE OWhen loosening the engine sprocket nut hold the rear brake on e Remove Chain Guide Bolts A Chain Guide B e Raise the rear wheel off the ground with the stand e Loosen the drive chain see Drive Chain Slack Adjust ment in the Periodic Maintenance chapter e Remove the drive chain from the rear sprocket toward the right e Disengage the drive chain C from the engine sprocket D e Pull the engine sprocket off the outp
274. e and Locking Agent Fastener Torque Remarks ft Ib Rear Master Cylinder Mounting Bolts 18 Rear Master Cylinder Push Rod Locknut 13 Suspension Front Axle Clamp Bolts 15 AL Front Fork Bottom Allen Bolts 17 L Front Fork Clamp Bolts Lower 22 AL Front Fork Clamp Bolts Upper 15 Front Fork Top Plugs 16 Piston Rod Nuts 21 Rear Shock Absorber Nut Lower 25 Rear Shock Absorber Nut Upper 25 Swingarm Pivot Shaft 15 Swingarm Pivot Shaft Locknut 72 3 Swingarm Pivot Shaft Nut 79 7 Tie Rod Nuts 44 Uni Trak Rocker Arm Nut 25 Steering Front Fork Clamp Bolts Lower 22 AL Front Fork Clamp Bolts Upper 15 Handlebar Bolts 25 L Handlebar Holder Bolts 18 AL Left Switch Housing Screws 31 in Ib Right Switch Housing Screws 31 in Ib Steering Stem Head Nut 58 Steering Stem Nut 17 Frame Center Stand Bolts Equipped Models 32 Front Fender Cover Screws 11 inb Front Footpeg Bracket Bolts 18 Grab Rail Mounting Bolts Equipped Models 18 Rear Fender Mounting Bolts 7 1 in lb Rear Fender Mounting Screws 11 in lb Rear Footpeg Bracket Bolts 18 Rear Frame Bolts 32 L Rear Frame Pipe Bolts 32 Rear Frame Pipe Nuts 32 Seat Lock Bracket Screws 11 in Ib Sidestand Bolt 32 Sidestand Bracket Bolts 36 L Sidestand Switch Bolt 78 in lb L Windshield Mounting Bolts 3 7 Electrical System Alternator Cover Bolts 9 8 1 0 87 in lb PERIODIC MAINTENANCE 2 11 Torque and Locking Agent Fastener Remarks N m kgf m ft Ib Alterna
275. e battery disconnected Tester Connection Tester Reading Headlight Circuit Relay Es s 6 7 ECU Main Relay 4 5 Not Fuel Pump Rel das uel Pump Rela 4 9 10 11 16 Starter Circuit Relay 11 12 17 20 co Fan Relay 18 19 Not The actual reading varies with the hand tester used Relay Box Relay Circuit Inspection with the battery connected Battery Connection Tester Tester Connection Reading Q 2 11 1 3 0 ECU Main Relay 0 Fuel Pump Relay 0 Fan Relay 0 Battery Tester Connection Taster Connection DC 25 V Range Reading V Starter Circuit 16 12 11 12 Battery Relay Voltage Apply positive lead Apply negative lead Diode Circuit Inspection e Remove the relay box see Relay Box Removal e Check conductivity of the following pairs of terminals see Relay Box Internal Circuit in this section Diode Circuit Inspection 1 11 2 11 12 13 12 15 12 16 13 14 13 15 Tester Connection The resistance should be low in one direction and more than ten times as much in the other direction If any diode shows low or high in both directions the diode is defective and the relay box must be replaced NOTE OThe actual meter reading varies with the meter or tester used and the individual diodes but generally speaking the lower reading should be from zero to one half the scale ELECTRICAL SYSTEM 16 115 1
276. e figure The openings of the oil ring steel rails must be about 30 40 of angle from the opening of the top ring Top Ring A Second Ring B Upper Oil Ring Steel Rail C Oil Ring Expander D Lower Oil Ring Steel Rail E Hollow F 30 40 GE16060BSi 6 6 16061851 6 6105197851 C 6 1 6179851 C 9 28 CRANKSHAFT TRANSMISSION Pistons e Install the piston with its marking hollow facing exhaust side e Using the piston ring compressor assy A to install the piston from the cylinder head side Special Tools Piston Ring Compressor Grip 57001 1095 Piston Ring Compressor Belt 80 91 57001 1320 e Install Crankshaft see Crankshaft Installation Connecting Rod Big End Caps see Connecting Rod In stallation Cylinder Wear Upper Crankcase Inspection Since there is a difference in cylinder wear upper crankcase in different directions take a side to side and a front to back measurement at each of the two locations total of four measurements shown in the figure lf any of the cylinder inside diameter measurements ex ceeds the service limit replace the crankcase 10 mm 0 39 in A 60 mm 2 36 in B Cylinder Upper Crankcase Inside Diameter Standard 83 994 84 006 mm 3 3068 3 3073 in Service Limit 84 10 mm 3 3110 in Piston Wear Inspection e Measure the outside diameter A of each piston 10 mm 0 39 in B up from the bottom
277. e hose into a container Clutch Fluid e Bleed the clutch line and the master cylinder ORepeat this operation until no more air can be seen com ing out into the plastic hose 1 Pump the clutch lever until it becomes hard and apply the clutch lever and hold it A 2 Quickly open and close B the bleed valve while hold ing the clutch lever applied 3 Release the clutch lever C NOTE The fluid level must be checked often during the bleed ing operation and replenished with fresh clutch fluid as necessary If the fluid in the reservoir runs completely out any time during bleeding the bleeding operation must be done over again from the beginning since air will have entered the line e Remove the clear plastic hose e Tighten the bleed valve and install the rubber cap Torque Clutch Master Cylinder Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib e Remove the rubber cap from the bleed valve e Attach a clear plastic hose A to the bleed valve on the clutch slave cylinder and run the other end of the hose into a container e Bleed the clutch line as follows ORepeat this operation until no more air can be seen com ing out into the plastic hose 1 Pump the clutch lever until it becomes hard and apply the clutch lever and hold it B 2 Quickly open and close C the bleed valve while hold ing the clutch lever applied 3 Release the clutch lever D NOTE OCheck the fluid level in the reservoir often rep
278. e ignition switch ON Output Voltage at Fuel Injector Connector Standard Battery Voltage for 3 seconds and then 0 V If the output voltage is normal check the wiring for conti nuity see wiring diagram in this section If the wiring is good perform Fuel Injector Audible In spection for confirmation If the output voltage is out of the standard perform Fuel Injector Audible Inspection for confirmation Fuel Injector Audible Inspection NOTE OBe sure the battery is fully charged e Remove the fairing covers see Fairing Cover Removal in the Frame chapter e Start the engine e Apply the tip of a screwdriver A to the fuel injector B Put the grip end onto your ear and listen whether the fuel injector is clicking or not sound scope can also be used OThe click interval becomes shorter as the engine speed rises e Do the same for the other fuel injectors If all the fuel injectors click at a regular intervals the fuel injectors are good If either fuel injector doesn t click perform the Fuel Injec tor Signal Test for injector operation Fuel Injectors Fuel Injector Signal Test e Prepare two test light sets with terminals as shown in the figure Rating of Bulb A 12 V x 3 3 4 W Terminal Width x Thickness B 1 8 x 0 8 mm 0 07 x 0 03 in CAUTION Do not use larger terminals than specified above A larger terminal could damage the fuel injector main harness connect
279. e is the continuity in the lead replace the rear wheel rotation sensor If there is not the continuity in the lead proceed the 3rd step e Do the 3rd step test ORecheck the service code indication erase the service code perform the pre diagnosis inspection 1 and 2 and retrieve the service code xIf the ABS indicator light LED A lit faulty ECU in the ABS hydraulic unit Replace the ABS hydraulic unit xIf the ABS indicator light LED unlit ABS system is nor mal service code is not stored temporary failure BRAKES 12 53 2 6114137851 C 2 6114136851 C 6114288851 C 12 54 BRAKES Anti Lock Brake System Equipped Models Power Supply Voltage Abnormal Under Voltage Service Code 52 e Do the 1st step test ODisconnect the ignition switch connector and ABS hy draulic unit connector OCheck for continuity between the brown lead terminal of the main harness side connector A and yellow lead ter minal of the main harness side connector B x If there is the continuity in the lead proceed the 2nd step lf there is not the continuity in the lead inspect the ABS ECU fuse 10 A see Fuse Inspection in the Electrical System chapter and replace or repair the main harness e Do the 2nd step test OConnect the ignition switch connector and ABS hydraulic unit connector OCheck the battery terminal voltage connect the hand tester to the brown termin
280. e lnspectig oe pe ee er mee teer eedem um Mite nte EP n eade 4 16 Water Temperature Sensor uuu 4 17 Water Temperature Sensor 4 42044 0 0 eene nnn 4 17 Water Temperature Sensor Inspection Nt 4 17 4 2 COOLING SYSTEM Exploded View Exploded View COOLING SYSTEM 4 3 No Fastener 191908 Remarks N m kgf m ft Ib 1 Coolant Drain Bolt 10 1 0 89 in lb 2 Coolant Fitting Bolts 8 8 0 90 78 in lb L 3 Cylinder Fitting Mounting Bolts 9 8 1 0 87 4 Hot Windshield Mounting Bolts 9 8 1 0 87 in lb 5 Oil Cooler Mounting Bolts 12 1 2 106 in lb S 6 Radiator Bracket Mounting Bolt 9 8 1 0 87 7 Radiator Mounting Bolt Lower 9 8 1 0 87 8 Radiator Mounting Bolts Upper 25 2 5 18 9 Radiator Water Hose Clamp Screws 2 0 0 20 18 in lb 10 Reserve Tank Bolts 9 8 1 0 87 L 11 Thermostat Housing Cover Bolts 5 9 0 60 52 in lb 12 Thermostat Housing Mounting Bolts 9 8 1 0 87 13 Water Pump Cover Bolts 9 8 1 0 87 in lb 14 Water Temperature Sensor 25 2 5 18 G Apply grease L Apply a non permanent locking agent R Replacement Parts S Follow the specified tightening sequence 4 4 COOLING SYSTEM Coolant Flow Chart Reserve Tank Hose Air Bleeder Hose 7 1 Radiator Cap for Thermostat Ho
281. e mating line F e Tighten the balancer shaft clamp bolt G Torque Balancer Shaft Clamp Bolts 9 8 N m 1 0 kgf m 87 in Ib 6106B079W1 C Rear Balancer Removal e Remove Engine see Engine Removal in the Engine Removal In stallation chapter Breather Cover Bolts A Breather Cover B 9 32 CRANKSHAFT TRANSMISSION Balancer e Unscrew the balancer shaft clamp bolt A and balancer shaft clamp lever bolt B and pull off the clamp lever C e Pull the balancer shaft D out of the crankcase The bal ancer weight and gear assembly E come off with needle bearings and copper washers Rear Balancer Installation e Check that the rubber dampers A are in place as shown in the figure e Apply molybdenum disulfide oil solution to the damper contact portions of the balancer weight e Install the balancer weight A into the gear B OAlign the mark C of the balancer weight to the groove D of the gear e Apply molybdenum disulfide oil solution to the needle bearings Insert the needle bearings e Fit the copper washers A on both ends of the weight and gear assembly The projected sides B face inward 6106040551 CRANKSHAFT TRANSMISSION 9 33 Balancer e Position the crankshaft at 2 3 position TDC or at 1 4 position TDC e Align the mark A on the balancer gear B with the mating surface C of the upper crankcase half e Install the bala
282. e of proper amperage see Fuse Installation in the Electrical System chapter Fuse Inspection e Remove the fuses see ABS Solenoid Valve Relay Fuse 20 A ABS Motor Relay Fuse 30 A ABS ECU Fuse 10 A Removal e Refer to the Fuse Inspection in the Electrical System chapter C GL14110BS1 C SUSPENSION 13 1 Suspension Table of Contents Exploded P O 13 2 SBBCITIEAtIOTIS Tode ab eoa eae dc cL S e 13 6 serere rr 13 7 dme T T erm 13 9 Rebound Damping Force Adjustment pp 13 9 Compression Damping Force Adjustment pp 13 9 Spring Preload Adjustment sides dn quse 13 10 Front Fork Removal Each Fork Leg pp 13 10 Front Fork acc tee Dee eoe et 13 11 Front Fork Oil Giang 13 11 Erornit Eork Disassembly s esee peines eerie m BU ae crei te ef utu 13 16 Front Fork Assembly eret edo eto ait cte orae e ated netus 13 17 Inner Tube Outer Tube Inspection tne na trie Foe d pale 13 18 Dust Seal InSpectlori edet eee 13 18 Spring TENSIONMNSPECU ON aes ua esae e oet oi e 13 18 Rear Shock Absorber COND den as de cansharect neta ioe 13 19 Rebound Damping Force Adjustment pp 13 19 Compression Damping Force Adjustment pp 13 19 Spring Preload Adjust mbil oue
283. e range wiring Sensor Py 100 900 mmH short or open the ECU sets the DFI in the E 9 method 1 Inlet Air Aiet If the inlet air temperature sensor fails the 13 Temperature Ta 30 ko 00 C signal is out of the usable range wiring short Sensor i or open the ECU sets Ta at 30 C Water If the water temperature sensor system fails 14 Temperature 2 the signal is out of the usable range wiring Sensor short or open the ECU sets Tw at 80 C If the atmospheric pressure sensor system 15 2 NET Pressure fails the signal is out of the usable range wiring short or open the ECU sets Pa at 760 Sensor Pa 100 900 mmHg mmHg the standard atmospheric pressure Crankshaft If the crankshaft sensor generates less than a Sensor ene Ae Sna S to TUBE Gu 22 or more signals the engine stops by itself at the 1 cranking 9 9 peo a If the camshaft position sensor system fails camanan PANERAI posten A the signal is missing wiring short or open 23 Position must send 1 signal to the he ECU Tuer indere inih Sensor ECU at the 2 crankings the continues to ignite cylinders in t e i same sequence following the last good signal Sheed Muet send If the speed sensor system fails no signal Speed 4 signals output signal to 24 Sensor the ECU atthe one rotation winng short or open the speedometer shows of the drive shaft Gear If the speed sensor system fails no signal 25 Position
284. e sensor performance e Tighten Torque Oxygen Sensor 25 N m 2 5 kgf m 18 ft Ib e Run the oxygen sensor lead correctly see Cable Wire and Hose Routing section in the Appendix chapter Oxygen Sensor Inspection Equipped Models e Refer to the Oxygen Sensor Inspection in the Fuel System DFI chapter ELECTRICAL SYSTEM 16 109 8 18239851 C GPi8078BSi C 16 110 ELECTRICAL SYSTEM Switches and Sensors Fuel Level Sensor Inspection e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Clamps A Open e Remove Clamps A Open Bolts B Fuel Level Sensor C e Check that the float moves up and down smoothly without binding It should go down under its own weight x If the float does not move smoothly replace the sensor Float in Full Position A Float in Empty Position B Float Arm Stoppers GP18240BS1 e Using the hand tester A measure the resistance across the terminals in the fuel level sensor lead connector B Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 the tester readings are not as specified or do not change smoothly according as the float moves up and down replace the sensor Fuel Level Sensor Resistance Standard Full position C 9 11 O Empty position 213 219 O ELECTRICAL SYSTEM 16 111 Switches and Sensors e Install a new gasket A on the fuel le
285. e user key 2 to the ignition switch and turn it ON 16 90 ELECTRICAL SYSTEM Immobilizer System Equipped Models Olf there is any problem in the registration the warning indicator light LED A blinks to display the collation error Immobilizer Amplifier Failure When Registered User Key is Inserted User Key Collation Error e The user key 2 is registered in the ECU OThe warning indicator light LED A blinks 3 times and stops for 1 second and then repeats this cycle OThis procedure has registered the master key and 2 user keys e Continue with the procedure to register an additional 3 user keys NOTE OThe ECU can store up the six key codes master key x 7 and user key x 5 User Key Indicator Light Flashes Indicator Indicator Light Blinks Light Stop Remarks User Key 3 4 times 1 seconds Repeat User Key 4 5 times 1 seconds User Key 5 1 seconds e Turn OFF the ignition switch and wait for period of more than 15 seconds e The registration mode automatically ends 0 2second Get GP30516BS1 C 0 5second 0 5second E bara GP30515BS1 0 3second Hh UUUUUULUUUUUU GP30517BS1 0 30 30 3 0 30 3 1second A 81 UUL_IUUL GP30519BS1 C ELECTRICAL SYSTEM 16 91 Immobilizer System Equipped Models e Warning indicator light LED A goes off QN On 6230520851 C
286. e with a suitable stand B OPut a plank C onto the suitable stand for engine balance 8 6 ENGINE REMOVAL INSTALLATION Engine Removal Installation e Remove Engine Bracket Bolts A Front Engine Mounting Bolts B Engine Bracket C e Remove the engine mounting nuts A NOTE OHold the mounting bolt at the right side of the frame not to turn when loosening the upper and lower engine mounting nuts at the left side of the frame e Disconnect the engine ground terminal e Using a Hexagon Wrench turn the engine mounting bolts A clockwise to make the gap between the engine and adjusting collar e Remove the drive chain from the output shaft e Using the stand take out the engine Engine Installation e Support the engine with a suitable stand OPut a plank onto the suitable stand for engine balance e Install the heat insulation rubber plate ENGINE REMOVAL INSTALLATION 8 7 Engine Removal Installation GH040688W4 C After installation set the projection in the hole To Water Temperature Sensor To Breather Hose To Throttle Body Subharness Bracket To Throttle Body Holder To Throttle Pulley To Air Suction Valves and Stick Coils Only put the heat insulation rubber plate on the cylinder head cover Bracket on Air Suction Valve Cover c TO0Ommoou 8 8 ENGINE REMOVAL INSTALLATION Engine Removal Installation e Before installing the engine Confirm the routing of the
287. ealed lubrication is not required Chain Guide Inspection e Refer to the Chain Guide Wear Inspection in the Periodic Maintenance chapter 13 28 SUSPENSION Tie Rod Rocker Arm Tie Rod Removal e Squeeze the brake lever slowly and hold it with a band A e Remove Lower Fairings see Lower Fairing Removal in the Frame chapter Rear Fairing see Rear Fairing Removal in the Frame chapter Equipped Models Bracket see Rear Shock Absorber Removal e Raise the rear wheel off the ground with the jack Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Remove Upper Tie Rod Nut and Bolt A Lower Tie Rod Nut and Bolt B Tie Rods C Tie Rod Installation e Apply grease to the inside of the oil seals e Install each tie rod so that the arrow faces A forward e Tighten Torque Tie Rod Nuts 59 6 0 kgf m 44 ft Ib GM07058BS1 C Rocker Arm Removal e Squeeze the brake lever slowly and hold it with a band e Remove Lower Fairings see Lower Fairing Removal in the Frame chapter Rear Fairing see Rear Fairing Removal in the Frame chapter Equipped Models Bracket see Rear Shock Absorber Removal Muffler Bodies see Muffler Body Removal Installation in the Engine Top End chapter e Raise the rear wheel off the ground with the jack Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Remove Lower Rear Shock Absorber Nut and Bolt A Lower Tie Rod Nut and Bo
288. ear Brake Light Switch Engine Ground Battery Frame 12 14 round 2 Starter Relay Main Fuse 30A I gnition Battery 111 Color RIGHT SWITCH HOUSING CONNECTIONS Front Brake Light Switch Engine Stop Switch Starter Button Tail2 Battery Tail3 I gnition l gnition BL W BK w amp GY roch Color Color R R Color BL Brake Lever OFF Free Pulled In C O RUN a O Push a O 98052 03418 License 48 Plate Light 12vsw Rear Right Turn Signal Light i2V218 Tail Brake Light LED 12v0 5 4 9 Rear Left Turn Signal 404 Sa 5 55 5 55 555 i8 Light Ground 1111 Boas 12218 i Vehicle down Turn E x Sensor az Fuel Diagnostic en Reserve System Connector 3 Switch Fuel Connector Color Code BK Black Brown BR 8 Green Gray Light Blue Le Light Green 9 Orange Pink Pu Purple Rea w White W2RO34iBWS C 16 18 ELECTRICAL SYSTEM Wiring Diagram AU and MY Models T an een 10 12 ol Immobilizer Amplifier Meter Unit Right Turn Signal Indicator Light LED shift Up Indicator Light LED High Beam Indicator G Mrs Light LED Pena tet Neutral Indicator Light LED Q Le Warning Indicator Light LED Right Switch Housing 1 Front Brake Light Switch 2 Engine Stop Switch 3 Starter But
289. earance is between 0 064 mm 0 0025 in and the service limit 0 09 mm 0 0035 in replace the bearing in serts A with inserts painted blue B Check insert journal clearance with the plastigage The clearance may exceed the standard slightly but it must not be less than the min imum in order to avoid bearing seizure the clearance exceeds the service limit measure the diameter of the crankshaft main journal Crankshaft Main Journal Diameter Standard 37 984 38 000 mm 1 4954 1 4961 in Service Limit 37 96 mm 1 4945 in any journal has worn past the service limit replace the crankshaft with a new one the measured journal diameters are not less than the service limit but do not coincide with the original diameter markings on the crankshaft make new marks on it Crankshaft Main Journal Diameter Marks None 37 984 37 992 mm 1 4954 1 4957 in 1 37 993 38 000 mm 1 4958 1 4961 in D Crankshaft Main Journal Diameter Marks 1 or no mark e Measure the main bearing inside diameter and mark the upper crankcase half in accordance with the inside diam eter A Crankcase Main Bearing Inside Diameter Marks O or no mark e Tighten the crankcase bolts to the specified torque see Crankcase Assembly NOTE The mark already on the upper crankcase half should almost coincide with the measurement Crankcase Main Bearing Inside Diameter Marks O 41 000 41 008 mm 1 6142 1 6
290. easure the valve clearance e When installing the shim face the marked side toward the valve lifter At this time apply engine oil to the shim or the valve lifter to keep the shim in place during camshaft installation CAUTION Do not put shim stock under the shim This may cause the shim to pop out at high rpm causing ex tensive engine damage Do not grind the shim This may cause it to fracture causing extensive engine damage e Apply engine oil to the valve lifter surface and install the lifter e Install the camshaft see Camshaft Installation in the En gine Top End chapter e Recheck the valve clearance and readjust if necessary e Install the removed parts see appropriate chapters Air Suction System Damage Inspection e Remove the right middle fairing see Middle Fairing Re moval in the Frame chapter e Pull the air switching valve hose A out of the air cleaner housing e Start the engine and run it at idle speed e Plug B the air switching valve hose end with your finger and feel vaccum pulsing in the hose If there is no vaccum 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 Sys tem chapter or air suction valve see Air Suction Valve Inspection in the Engine Top End chapter Clutch Clutch Operation Inspection e Start the engine and check that the clutch does not slip and that it releases pr
291. ec trical System chapter Main Fuse 30 A see Fuse Inspection in the Electrical System chapter Oxygen Sensor Heater Fuse 10 A see Fuse Inspection in the Electrical System chapter xIf the reading is good the power source voltage is nor mal Inspect the Red lead between the oxygen sensor connector and the ECU for continuity using the follow ing diagram xIf 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 Removal Installation e Remove the needle adapter set and apply silicone sealant to the connector for waterproofing Sealant Kawasaki Bond Silicone Sealant 56019 120 6617162051 C 3 94 FUEL SYSTEM Oxygen Sensor Heater Service Code 67 Equipped Models Oxygen Sensor Circuit D BK Y w BL BK Y BK Y 8 0 BR 66172320 2 C ECU Joint Connector 3 Frame Ground Battery 12 V 14 Ah Main Fuse 30 A Fuse Box 1 Oxygen Sensor Heater Fuse 10 A lgnition Switch Oxygen Sensor Water proof Joint 2 FUEL SYSTEM DFI 3 95 ECU Main Relay Service Code 75 ECU Main Relay Inspection OThe ECU main relay function is included in the ECU A So the ECU main relay function cannot be inspected e When the service code 75 is displayed on the LCD re place the ECU
292. ection e Remove Right Middle Fairing see Middle Fairing Removal in the Frame chapter Radiator Cap e Check the condition of the bottom A and top B valve seals and valve spring C If any one of them shows visible damage replace the cap with a new one e Install the cap A on a cooling system pressure tester B NOTE O Wet the cap sealing surfaces with water or coolant to prevent pressure leaks e Watching the pressure gauge pump the pressure tester to build up the pressure until the relief valve opens the gauge needle flicks downward Stop pumping and mea sure 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 cm 13 18 psi If the cap can not hold the specified pressure or if it holds too much pressure replace it with a new one Radiator Filler Neck Inspection e Remove Right Middle Fairing see Middle Fairing Removal in the Frame chapter Radiator Cap e Check the radiator filler neck for signs of damage e 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 COOLING SYSTEM 4 13 6007013851 6 6007001851 C 4 14 COOLING SYSTEM Thermostat Thermostat Removal e Remove Coolant Drain see Coolant Cha
293. ection pp 3 58 Water Temperature Sensor Service Code 14 3 60 Water Temperature Sensor Removal Installation pp 3 60 Water Temperature Sensor Output Voltage 3 60 Water Temperature Sensor Resistance 3 61 Atmospheric Pressure Sensor Service Code 15 3 62 Atmospheric Pressure Sensor Removal nennen 3 62 Atmospheric Pressure Sensor Installation Nt 3 62 Atmospheric Pressure Sensor Input Voltage 3 62 Atmospheric Pressure Sensor Output Voltage Inspection pp 3 63 Crankshaft Sensor Service Code 21 entren nennen 3 66 Crankshaft Sensor Removal lnstallation 3 66 Crankshaft Sensor Inspeotion oriri Re Fee OH RR 3 66 Camshaft Position Sensor Service Code 23 pp 3 67 Camshaft Position Sensor 2 3 67 Camshaft Position Sensor Inspection pp 3 67 Speed Sensor Service Code 24 eene nennen nnne nnne ren 3 68 Speed Sensor RemovalVlnstallatigon esee enne 3 68 Speed Sensor Inspectigm eene nennen nennen nennt neni 3 68 Speed Sensor Input Voltage Inspection nen 3 68 3 2 FUEL SYSTEM Speed Sensor Output Voltage Inspection pp 3 69 Gear Position Switch Service Code 25
294. ector 1 ABS Kawasaki Self diagnosis System Connector Meter Unit 1 Right Turn Signal Indicator Light LED 2 Shift Up Indicator Light LED 3 High Beam Indicator Light LED 4 Neutral Indicator Light LED 5 Warning Indicator Lig 6 Left Turn Signal Indi Light LED 7 Illumination Light L 8 Fuel Level Gauge 9 Water Temperature Gau 10 Tachometer 1i Speedometer 12 Gil Pressure Warning Indicator Light LED 18 ABS Indicator Light Front Right Turn Signa Light 12V21W Right City Light 12V5W Headlight HI 12 65 Headlight 10 12V55W Headlight LO 12V55W Headlight HI 12V65W Left City Light 12V5W Front Left Turn Signal Light 12V21W 10111180811 Spark Plugs 750091 Anan we W BL wy wR BK Y 4 1 we wy 3 Immobilizer SE of gh me gt E o R M Meter Unit ht Leo E cator 14 ED LeyBK ER wY BR BR W LEB BK Y nr cu NU R BK Y 21 BK Y wy BK Y wy aK Y Box 2 Fuse Box 2 Box 1 2534 2225 aK Y Headlight Headlight e i Left Switch Housin Relay Lo Relay Hi T Here Button S a Fuel 2 Hazard Button Lael
295. ed Models Rear Brake Master Cylinder Joint Pin Sidestand Points Lubricate with Grease Throttle Inner Cable Upper End A 6904040381 2 48 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cables Lubricate with Rust Inhibitor Throttle Inner Cables e Lubricate the cables by seeping the oil between the cable and housing OThe cable may be lubricated by using a commercially available pressure cable lubricator with an aerosol cable lubricant e 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 e 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 OFor the engine fasteners check the tightness of them when the engine is cold at room temperature If there are loose fasteners retorque them to the spec ified 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 6604011451 C 80904020152 C
296. ed to ON 12 46 ABS Indicator Light LED Lights When the Motorcycle is Running No Service Code 12 47 Solenoid Valve Inspection Service Code 13 14 17 18 12 47 ABS Solenoid Valve Relay Inspection Service Code 19 12 47 Front Rear Wheel Rotation Difference Abnormal Service Code 25 12 49 ABS Pump Motor Relay Inspection Service Code 35 12 49 Front Wheel Rotation Sensor Signal Abnormal Service Code 42 12 51 Front Wheel Rotation Sensor Wiring Inspection Service Code 43 12 51 Rear Wheel Rotation Sensor Signal Abnormal Service Code 44 12 52 Rear Wheel Rotation Sensor Wiring Inspection Service Code 45 12 53 Power Supply Voltage Abnormal Under Voltage Service Code 52 12 54 Power Supply Voltage Abnormal Over Voltage Service Code 53 12 55 ECU Inspection Service Code ene 12 56 ABS Hydraulic Unit Removal Cr e adr ig etre bu e 12 56 ABS Hydraulic Unit E 12 57 ABS Hydraulic Unit Inspection so Aor nc tton teneo eme mes 12 58 Front Wheel Rotation Sensor Removal pp 12 58 Fr
297. eder Hose for Water Pump Outlet Hose Inlet Hose Oil Cooler Water Pump Water Hose Water Hose Clamp Left Side View Align the white paint mark on the hose with the mark on the thermostat housing cover Approx 45 Align the white paint mark on the hose with the mark on the water pump Install the hose so that white the paint mark on the hose faces the front side Insert the air bleeder hose into the water pump fitting so that it point to the center of the impeller shaft P PO AH AH HS SS SS Ss 17 8 APPENDIX Cable Wire and Hose Routing 22 pt te Oe FTS wa o o APPENDIX 17 9 Cable Wire and Hose Routing Clamp Install the clamp so that knob of the clamp faces right side of the frame as shown in the figure Reserve Tank Clamp Approx 20 mm 0 79 in Insert the hose until the hose end touches the projection of the cylinder fitting Inlet Hose Install the inlet hose so that white paint mark on the hose faces the front side Install the outlet hose so that white paint mark on the hose faces the front side Outlet Hose Clamp _ 17 10 APPENDIX Cable Wire and Hose Routing UY PIS CNRS 56 5 e 7 Os lt 7 aa e We Z Ls O hs
298. ee Idle Speed Adjustment in the Periodic Maintenance chapter e Turn the ignition switch OFF e Measure the output voltage with the engine stopped and with the connector joined e Turn the ignition switch ON e Measure the output voltage when the throttle is fully opened or completely closed Output Voltage at ECU Standard DC 0 63 3 91 V at idle throttle opening to full throttle opening NOTE OThe main throttle sensor is operating correctly if the fol lowing voltages are obtained DC 0 63 V or slightly higher with the throttle at the idle position DC 3 91 V or slightly lower with the throttle at the fully open position 3 48 FUEL SYSTEM Main Throttle Sensor Service Code 11 NOTE The standard voltage refers to the value when the volt age reading at the Input Voltage Inspection shows 5 V exactly OWhen 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 63 x 4 75 5 00 0 60 V 3 91 x 4 75 5 00 3 71 Thus the valid range is 0 60 3 71 V If the output voltage is within the standard range check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation x lf the output voltage is far out of the standard range e g when the wiring is open the reading is O V check the output voltage agai
299. efore Servicing esee aat edes te M testa een tained npe Model Identificati Ns General Specifications cates decile I TE CINE Conversion FAD 1 2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera tion on a motorcycle read the precautions given below To facilitate actual operations notes illustra tions photographs cautions and detailed descriptions 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 discon nect the battery cables from the battery to prevent the en 35 gine from accidentally turning over Disconnect the ground A Oe P cable first and then the positive When completed CFA CI with the service first connect the positive 4 cable to the positive terminal of the battery then the negative i ble to the negative terminal DISASSEMBLY ASSEMBLY 68020248 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 clea
300. elay Inspec tion wiring see wiring diagram in this section and the ECU for its ground and power supply see ECU Power Supply Inspection If the reading is normal check the power source voltage at the injector connector e Remove Left Middle Fairing see Middle Fairing Removal in the Frame chapter Bolts A FUEL SYSTEM DFI 3 111 Fuel Injectors e Connect a digital meter A to the throttle body subharness connector B using the needle adapter set C Special Tool Needle Adapter Set 57001 1457 Fuel Injector Power Source Voltage at Injector Connections to Injector 1 2 3 4 Meter W R lead D Meter Ground E e Measure the power source voltage with the engine stopped and with the connector joined e Turn the ignition switch ON Power Source Voltage at Injector Connector Standard Battery Voltage for 3 seconds and then 0 V e Turn the ignition switch OFF lf the reading is out of the standard check the wiring see wiring diagram in this section the reading is good and the power source voltage is normal check the output voltage Fuel Injector Output Voltage Inspection e Measure the output voltage at the ECU connector in the same way as power source voltage inspection Note the following Digital Meter A Connector B Special Tool Needle Adapter Set 57001 1457 Fuel Injector Output Voltage at ECU Connections for Fuel Injector 1 Meter
301. elect the proper bearing insert A in accordance with the combination of the connecting rod and crankshaft coding Size Color B 6105041751 Bi eee Crankpin Bearing Insert End Inside Diameter Diameter Marking Marking Size Color Part Number None O Brown 92139 0131 None None Black 92139 0130 O None Blue 92139 0129 e Install the new inserts in the connecting rod and check insert crankpin clearance with the plastigage Crankshaft Side Clearance Inspection e Move A the crankshaft to the side of the camshaft chain e Insert a thickness gauge B between the thrust washer C and the crank web D at the No 3 main journal to determine clearance Crankshaft Side Clearance Standard 0 05 0 24 mm 0 0020 0 0094 in Service Limit 0 30 mm 0 0118 in the clearance exceeds the service limit replace the thrust washer as a set e Measure the width A of the both thrust washers x If the thrust washers t 2 5 mm 0 0984 in are installed on the upper crankcase half replace them with new thrust washer t 2 5 mm 0 0984 in as a set CRANKSHAFT TRANSMISSION 9 23 Crankshaft and Connecting Rods x If the thrust washers t 4 0 mm 0 1575 are installed on the upper crankcase half replace them with new thrust washer t 4 0 mm 0 1575 in as a set Thrust Washer P No Thickness Edge Colar 2 45 2 50 mm 92200 0331 0065 0
302. em chapter the switch is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation 3 72 FUEL SYSTEM Gear Position Switch Service Code 25 Gear Position Switch Circuit 6C172310W2 C 1 ECU 2 Gear Position Switch 3 Frame Ground 1 FUEL SYSTEM 3 73 Vehicle down Sensor Service Code 31 This sensor has a weight A with two magnets inside and sends a signal to the ECU But when the motorcycle banks 60 70 or more to either side in fact falls down the weight turns and shuts off the signal The ECU senses this change and stops the fuel pump the fuel injectors and the ignition system Hall IC B When the motorcycle is down the ignition switch is left ON If the starter button is pushed the electric starter turns but the engine doesn t start To start the engine again raise the motorcycle turn the ignition switch OFF and then ON Vehicle down Sensor A Ground Terminal BR BK B Output Terminal Y G C Power Source Terminal BL D 6617355851 6 Vehicle down Sensor Removal CAUTION Never drop the vehicle down sensor especially on a hard surface Such a shock to the sensor can damage it e Remove Windshield see Windshield Removal in the Frame chapter Bolt A e Remove Connector A Bolts B Vehi
303. end bearing inserts and reinstall the connecting rod big end cap e Select an arbor A of the same diameter as the connect ing rod big end and insert the arbor through the connect ing rod big end e Select an arbor of the same diameter as the piston pin and at least 100 mm 3 94 in long and insert the arbor B through the connecting rod small end e On a surface plate set the big end arbor on V block C e With the connecting rod held vertically use a height gauge to measure the difference in the height of the arbor above the surface plate over a 100 mm 3 94 in length to determine the amount of connecting rod bend If connecting rod bend exceeds the service limit the con necting rod must be replaced Connecting Rod Bend Service Limit TIR 0 2 100 mm 0 008 3 94 in 6105040481 6105040581 6105040681 9 20 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Twist Inspection e With the big end arbor A still on V block C hold the connecting rod horizontally and measure the amount that the arbor B varies from being paralleled with the surface plate over a 100 mm 3 94 in length of the arbor to de termine the amount of connecting rod twist If connecting rod twist exceeds the service limit the con necting rod must be replaced Connecting Rod Twist Service Limit TIR 0 2 100 mm 0 008 3 94 in Connecting Rod Big End Side Clearance
304. enna Case 3 When the electronic control unit ECU is faulty and has to be replaced e Prepare a new ECU A current master key B and cur rent user keys C NOTE OThe key registration unit is not required OAfter replacing the ECU be sure to register the master key and 2 user keys If the 3 keys master key x 1 and user key x 2 are not registered the engine can be started e Replace the ECU A see Immobilizer System Parts Re placement e Insert the current master key into the ignition switch and turn it ON Olf there is any problem in the registration the warning indicator light LED A blinks to display the collation error Immobilizer Amplifier Failure ELECTRICAL SYSTEM 16 97 6230204851 C 0 2second hnnnnnnnnnnnnnni 81 6230516851 C 16 98 ELECTRICAL SYSTEM Immobilizer System Equipped Models Master Key Collation Error 0 3second oN SUL LLL GP30517BS1 e The master key is registered in the ECU OThe warning indicator light LED A blinks 1 time and stops for 1 second and the repeats this cycle to indicate successful registration of the master key On a _ e Turn OFF the master key and remove it OThe warning indicator light LED A blinks to display the registration mode NOTE Olnsert next key and turn ON within 15 seconds after pre vious key is turned OFF and removed otherwise regis tration mode will
305. ensor rotor tip for deformation or damage e g chipped sensor rotor teeth x If the sensor and sensor rotor bad condition remove the any deposits Install the properly or replace faulty part If the all correct proceed the 3rd step GL14136BS1 C Anti Lock Brake System Equipped Models e Do the 3rd step test ORecheck the service code indication erase the service code perform the pre diagnosis inspection 1 and 2 and retrieve the service code lf the ABS indicator light LED A lit faulty ECU in the ABS hydraulic unit Replace the ABS hydraulic unit xIf the ABS indicator light LED unlit ABS system is nor mal service code is not stored temporary failure Rear Wheel Rotation Sensor Wiring Inspection Service Code 45 e Do the 1st step test ODisconnect the ABS hydraulic unit connector and rear wheel rotation sensor connector OShort the black and white red lead terminals of the main harness side connector A with a jumper lead and check for continuity between the black and white red lead termi nals of the main harness side connector B If there is the continuity in the lead proceed the 2nd step xIf there is not the continuity the lead replace or repair the main harness e Do the 2nd step test OCheck for continuity between the black lead terminal of the sensor connector A and ground and white lead ter minal of the sensor connector and ground If ther
306. ensor side using the needle adapter set Special Tool Needle Adapter Set 57001 1457 Oxygen Sensor Output Voltage Connections to Oxygen Sensor Connector Meter BK lead Meter GY lead e Remove the right middle firing see Middle Fairing Re moval in the Frame chapter e Separate the hoses A from the air suction valve covers e Install the suitable plugs A on the fittings of the air suction valve covers B and shut off the secondary air e Turn the ignition switch to ON e Start the engine and let it idle e Measure the output voltage of the sensor with the con nector joined Output Voltage with Plugs Standard DC 0 8 V or more 3 82 FUEL SYSTEM Oxygen Sensor not activated Service Code 33 Equipped Models e Next remove the plugs from the fittings A with idling e Measure the output voltage of the sensor with the con nector joined Output Voltage without Plugs Standard DC 0 24 V or less the reading is within range with plugs 0 8 V or more without plugs 0 24 V or less the oxygen sensor is good If the reading is without range replace the oxygen sensor e 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 BR BK BK Y w BL BK Y BK Y R 9 BR BK BR BK LI R
307. ensor trouble Inspect see chapter 3 Atmospheric pressure sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inlet air temperature sensor trouble Inspect see chapter 3 Inspect see chapter 3 Engine stalls easily Spark plug dirty broken or gap maladjusted Inspect and replace see chapter 16 Stick coil trouble Inspect see chapter 16 Camshaft position sensor trouble Inspect see chapter 16 Main throttle sensor trouble Inspect see chapter 3 Subthrottle sensor trouble Subthrottle valve actuator trouble Inlet air pressure sensor trouble Atmospheric pressure sensor trouble Water temperature sensor trouble Inlet air temperature sensor trouble Fuel pump trouble Fuel injector trouble Fuel pressure too low or too high Fuel pressure regulator trouble Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect fuel pressure and replace fuel pump see chapter 3 Fuel line clogged Inspect and repair see chapter 3 Poor acceleration Fuel pressure too low Inspect see chapter 3 Water or foreign matter in fuel Change fuel Inspect and clean fuel system see chapter 3 Fuel filt
308. ep test OCheck the ABS solenoid valve relay fuse 20 A A If the fuse blown proceed the 2nd step If the fuse correct proceed the 4th step 148144 P 12 48 BRAKES Anti Lock Brake System Equipped Models e Do the 2nd step test ODisconnect the ABS hydraulic unit connector A OCheck for continuity between the light green and black yellow lead terminals of the ABS hydraulic unit connector x f there is the continuity in the lead replace the ABS hy draulic unit there is not the continuity in the lead proceed the 3rd step e Do the 3rd step test OCheck for continuity between the light green lead terminal of the main harness side connector A and light green lead terminal of the fuse box B If there is the continuity in the lead replace the fuse x lf there is not the continuity the lead replace or repair the main harness e Do the 4th step test OCheck the battery terminal voltage between the light green lead terminal of the fuse box A and ground Special Tool Hand Tester 57001 1394 Battery Terminal Voltage Standard Battery Voltage the battery terminal voltage is not within the specifica tion proceed the 5th step the battery terminal voltage correct proceed the 6th step e Do the 5th step test OCheck for continuity between the positive cable A of the battery and light green lead terminal of the main harness side connector B If there is the conti
309. er x If the power source is normal check the output voltage 6617357852 C FUEL SYSTEM DFI 3 75 Vehicle down Sensor Service Code 31 e Turn the ignition switch OFF e Remove the vehicle down sensor ODo not disconnect the sensor connector e Connect a digital meter A to the connector using the needle adapter set B Special Tool Needle Adapter Set 57001 1457 Vehicle down Sensor Output Voltage Connections to Sensor Meter Y G lead C Meter BR BK lead D e Hold the sensor vertically e Turn the ignition switch ON and measure the output volt age with the connector joined OTilt the sensor 60 70 or more E right or left then hold the sensor almost vertical with the arrow mark pointed up and measure the output voltage Output Voltage at Sensor Standard With sensor arrow mark pointed up 3 55 4 45 V With sensor tilted 60 70 or more right or left 0 65 1 35 V NOTE Olf you need to test again turn the ignition switch OFF and then ON e Turn the ignition switch OFF If the output voltage is out of the specified replace the sensor 6617358853 6 Vehicle down Sensor Circuit B Y 6 zm MM 2 Y G BL 6C17435CW2 C 1 ECU 3 Water proof Joint 2 2 Vehicle down Sensor 3 76 FUEL SYSTEM Subthrottle Sensor Service Code 32 The subthrottle
310. er Element Replace ment in the Periodic Maintenance chapter Screws A e Pull out the air cleaner element holder A from the hous ing Air Cleaner Element Holder Installation e Install the air cleaner element holder A so that the holder ends B shall be inserted along the ribs C in the housing e Tighten Torque Air Cleaner Element Holder Screws 6 9 N m 0 70 kgf m 61 in Ib Air Line Air Cleaner Oil Draining A drain hose is connected to the bottom of the air cleaner to drain water or oil accumulated in the cleaner part e Visually check the catch tank A of the drain hose if the water or oil accumulates in the tank any water or oil accumulates in the tank remove the plug B from the tank and drain it A WARNING Be sure to reinstall the plug in the tank after drain ing Oil on tires will make them slippery and can cause an accident and injury Rear Air Inlet Duct Removal e Remove Inner Covers see Inner Cover Removal in the Frame chapter Fuel Tank Cover see Fuel Tank Cover Removal e Loosen the clamp bolt A on both sides e Remove the mounting bolts B and pull off the right rear air inlet duct C to backward e Remove the left rear air inlet duct in the same way as right Rear Air Inlet Duct Installation e Insert the projections A of the holder B into the holes C of rear air inlet duct D e Insert the rear air inlet duct A until the duct end B align with the line
311. er Key 1 Collation Error Pattern 6 O Registered User Key is inserted Pattern 2 6 ECU confirms the following O User Key or Not O Match the Unique Code O Not Registered User Key 7 When the ECU registered is turned OFF ECU keeps the power for two seconds And in two seconds after the key is OFF ECU turns the power ELECTRICAL SYSTEM 16 103 Immobilizer System Equipped Models Immobilizer System Parts Replacement Immobilizer Antenna e Remove the left inner cover see Inner Cover Removal in the Frame chapter e Disconnect the lead connectors A e Remove the steering stem head see Stem Stem Bearing Removal in the Steering chapter e Using a small chisel or punch A turn out the Torx bolts e Cut the band A e Remove the screws B e Remove the antenna C with the cover D OPull the lower parts E of the cover outside to clear the projection F of the ignition switch e Tighten a new Torx bolt A until the bolt head B is broken Broken Head of Other Side C e Run the leads correctly see Cable Wire and Hose Rout ing section in the Appendix chapter Immobilizer Amplifier Replacement e Remove the windshield see Windshield Removal in the Frame chapter e Disconnect the connector A e Remove the amplifier B from the bracket C 16 104 ELECTRICAL SYSTEM Immobilizer System Equipped Models ECU Electronic Control Unit Repl
312. er Start Run Up Neutral Released Starts Continue running Up Neutral Pulled in Starts running Up In Gear Released Continue start running Up In Gear Pulled in Starts SONUS running Down Neutral Released Starts Continue running Down Neutral Pulled in Starts Continue running Down In Gear Released Most Stops start Down In Gear Pulled in If the sidestand switch operation does not work inspect or replace the following item Battery see Charging Condition Inspection in the Elec trical System chapter Main Fuse 30 A see Fuse Inspection in the Electrical System chapter ECU Fuse 30 A see Fuse Inspection in the Electrical System chapter Ignition Fuse 10 A see Fuse Inspection in the Electrical System chapter Ignition Switch see Switch Inspection in the Electrical System chapter Sidestand Switch see Switch Inspection in the Electrical System chapter Starter Lockout Switch see Switch Inspection in the Electrical System chapter Engine Stop Switch see Switch Inspection in the Elec trical System chapter Starter Button see Switch Inspection in the Electrical System chapter Gear Position Switch see Gear Position Switch Inspec tion in the Electrical System chapter Starter Relay see Starter Relay Inspection in the Elec trical System chapter Relay Box see Relay Circuit Inspection in the Electrical System chapter Starter Circuit Relay see Relay Circuit Inspection in the Electrical System cha
313. er or pump screen clogged Inspect and replace fuel pump see chapter 3 Fuel pump trouble Inspect see chapter 3 Fuel injector trouble Inspect see chapter 3 3 34 FUEL SYSTEM DFI System Troubleshooting Guide Symptoms or Possible Causes Main throttle sensor trouble Subthrottle sensor trouble Subthrottle valve actuator trouble Inlet air pressure sensor trouble Atmospheric pressure sensor trouble Actions chapter Inspect Inspect see chapter 3 see chapter 3 Inspect Inspect see chapter 3 Inspect see chapter 3 Water temperature sensor trouble see chapter 3 Inspect see chapter 3 Inlet air temperature sensor trouble Inspect see chapter 3 Spark plug dirty broken or gap maladjusted Inspect and replace see chapter 16 Stick coil trouble Inspect see chapter 16 Stumble Fuel pressure too low Inspect see chapter 3 Fuel Injector trouble Inspect see chapter 3 Main throttle sensor trouble Inspect see chapter 3 Subthrottle sensor trouble Inspect see chapter 3 Subthrottle valve actuator trouble Inlet air pressure sensor trouble Inspect see chapter 3 Atmospheric pressure sensor trouble Water temperature sensor trouble Inlet air temperature sensor trouble Surge Unstable fuel pressure Fuel pressure regulator trouble I
314. er tube to the outer tube e After installing the washer install the oil seal A by using the fork oil seal driver B Special Tool Fork Oil Seal Driver 643 57001 1530 e Install the retaining ring and dust seal into the outer tube e Pour in the specified type of oil see Front Fork Oil Change 6404042081 6 13 18 SUSPENSION Front Fork Inner Tube Outer Tube Inspection e Visually inspect the inner tube A and repair any dam age e Nicks or rust damage can sometimes be repaired by using a wet stone to remove sharp edges or raised areas which cause seal damage the damage is not repairable replace the inner tube Since damage to the inner tube damages the oil seal replace the oil seal whenever the inner tube is repaired or replaced CAUTION If the inner tube is badly bent or creased replace it Excessive bending followed by subsequent straightening can weaken the inner tube e Temporarily assemble the inner and outer tubes and pump them back and forth manually to check for smooth operation e f you feel binding or catching the inner and outer tubes must be replaced WARNING A straightened inner or outer fork tube may fall use possibly causing an accident Replace a badly bent or damaged inner or outer tube and inspect the other tube carefully before reusing it Dust Seal Inspection e Inspect the dust seal A for any signs of deterioration or damage Replace i
315. eral places lf any measurements exceed the service limit replace the chain Also replace the front and rear sprockets when the drive chain is replaced Drive Chain 20 link Length Standard 317 5 318 2 mm 12 50 12 53 in Service Limit 323 mm 12 7 in 6 04060651 6 2 34 PERIODIC MAINTENANCE Periodic Maintenance Procedures WARNING If the drive chain wear exceeds the service limit re place the chain or an unsafe riding condition may result A chain that breaks or jumps off the sprock ets could snag on the engine sprocket or lock the rear wheel severely damaging the motorcycle and causing it to go out of control For safety use only the standard chain It is an end less type and should not be cut for installation Standard Chain Make DAIDO Type DID50ZVZ GC amp B Link 116 links Drive Chain Guide Wear Inspection e Remove the swingarm see Swingarm Removal in the Suspension chapter e Visually inspect the chain guide A Replace the chain guide if it shows any signs of abnormal wear or damage PERIODIC MAINTENANCE 2 35 Periodic Maintenance Procedures Brakes Brake Fluid Leak Brake Hose and Pipe Inspection e For ABS equipped models note the following e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Battery see Battery Removal in the Electrical System chapter e Apply the brake lever or pedal and inspect the brake flu
316. es A of the cylinder head bolt washers B and the threads of the head bolts C GE14027BS1 C ENGINE TOP END 5 25 Cylinder Head e Tighten the M11 cylinder head bolts following the tighten ing sequence 1 10 4 ci dete tab NLT EnaA Torque Cylinder Head Bolts M11 f ee ts gt 99 E oe f First 39 N m 4 0 kgf m 29 ft Ib Final 64 N m 6 5 kgf m 47 ft lb e Tighten the M6 cylinder head bolts 11 12 Torque Cylinder Head Bolts M6 12 N m 1 2 kgf m 106 in Ib 8 14087851 C e Install Dowel Pin A Rear Camshaft Chain Guide B Front Camshaft Chain Guide C O ring D Collar E e Tighten Torque Front Camshaft Chain Guide Bolt Upper F 25 N m 2 5 kgf m 18 ft lb Front Camshaft Chain Guide Bolt Lower G 12 N m 1 2 kgf m 106 in Ib e Replace the following bolts with new bolts pre coated with locking agent and tighten them Engine Bracket Bolts M8 Front Engine Mounting Bolts M10 Subframe Bolts Torque Engine Bracket Bolts M8 25 N m 2 5 kgf m 18 ft lb Front Engine Mounting Bolts M10 59 N m 6 0 kgf m 44 ft lb Subframe Bolts 23 Nm 2 3 kgf m 17 ft Ib e Install the removed parts see appropriate chapters GE14088BS2 C Cylinder Head Warp Inspection e Clean the cylinder head e Lay astraightedge across the lower surface of the cylinder head at several pos
317. es Ope Headlight Aiming Inspect ration ooa ids o ates Sidestand Switch Operation Inspection pp Engine Stop Switch Operation Inspectigm men COSTS tudo Chassis Parts Lubrication dus Bolts Nuts and Fastener s Tightness InispectlOI in oc oo etre ineo uet Fera rede Replacement Paris iode ac dede Air Cleaner Element Rep Fuel Hose Replacement A E Goolant Changes Radiator Hose and O ring Replacement pp Clutch Hose and Pipe Replacement pp Clutch Fluid Change Rubber Parts of Clutch Master Cylinder Slave Cylinder Replacement Eine Ol CANIS c cd Oil Filter Replacement Brake Hose and Pipe Replacemient eerie etre ed ended Brake Fluid Change pp Master Cylinder Rubber Parts Replacement ppp Caliper Rubber Parts Replacement pp Spark Plug Replacement 2 40 2 40 2 41 2 42 2 42 2 45 2 46 2 47 2 47 2 47 2 48 2 49 2 49 2 51 2 52 2 54 2 55 2 56 2 57 2 58 2 59 2 60 2 62 2 63 2 64 2 68 PERIODIC MAINTENANCE 2 3 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 impo
318. es on Taillight B goes on License Plate Light C goes on Meter Panel Illumination Light LED D goes on Meter Panel LCD E goes on Neutral Indicator Light LED F goes on Oil Pressure Warning Indicator Light LED G goes on vo Light LED H ABS Equipped goes on x If the light does not go on inspect or replace the following item Battery see Charging Condition Inspection in the Elec trical System chapter Main Fuse 30 A and Taillight Fuse 10 A see Fuse In spection in the Electrical System chapter Applicable Bulb see Wiring Diagram in the Electrical System chapter Meter Unit for Meter Panel LCD see Meter Unit Inspec tion in the Electrical System chapter Meter Unit for Neutral Indicator Light LED see Meter Unit Inspection in the Electrical System chapter Meter Unit for Warning Indicator Light LED see Meter Unit Inspection in the Electrical System chapter Meter Unit for Oil Pressure Warning Indicator Light LED see Meter Unit Inspection in the Electrical Sys tem chapter Meter Unit for Illumination Light LED see Meter Unit Inspection in the Electrical System chapter ECU see ECU Power Supply Inspection in the Fuel Sys tem DFI chapter Ignition Switch see Switch Inspection in the Electrical System chapter Gear Position Switch see Gear Position Switch Inspec tion in the Electrical System chapter Harness see Wiring Inspection in the Electrical System chapter ABS Indicator Ligh
319. ession gauge stops rising the compression is the highest reading obtainable Special Tools Compression Gauge 20 kgf cm 57001 221 Compression Gauge Adapter M10 x 1 0 57001 1601 L Shape Hose C 57001 1606 Cylinder Compression Usable Range 1 030 1 570 kPa 10 5 16 0 kgf cm 149 228 psi at 300 r min rpm e Repeat the measurement for the other cylinders e Install the spark plugs Torque Spark Plugs 13 N m 1 3 kgf m 115 in Ib OThe following table should be consulted if the obtainable compression reading is not within the us able range Problem Diagnosis Remedy Action Cylinder Carbon accumulation on piston and in Remove the carbon deposits and compression combustion chamber possibly due to replace damaged parts if necessary is higher than damaged valve stem oil seal and or usable range damaged piston oil rings This may be indicated by white exhaust smoke Incorrect cylinder head gasket thickness Replace the gasket with a standard part Cylinder Gas leakage around cylinder head Replace damaged gasket and check compression cylinder head warp is lower than condition of valve seating Repair if necessary usable range Incorrect valve clearance Adjust the valve clearance Incorrect piston cylinder clearance Replace the piston and or cylinder Piston seizure Inspect the cylinder and replace repair the cylinder and or piston as necessary Bad condition of piston ring and or pis
320. ew F e Tighten Torque Middle Air Inlet Duct Clamp Bolts 2 9 N m 0 30 kgf m 26 in Ib e Install the rubber seal A so that the hollow side B faces forward e Insert the front air inlet duct into the rubber seal and tighten the bolts Torque Front Air Inlet Duct Mounting Bolts 9 8 N m 1 0 kgf m 87 in Ib e Run the leads correctly see Cable Wire and Hose Rout ing section in the Appendix chapter FUEL SYSTEM DFI 3 129 3 130 FUEL SYSTEM DFI Fuel Tank Fuel Tank Removal A WARNING Gasoline is extremely flammable and can be explo sive under certain conditions Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Turn the ignition switch OFF and disconnect the battery terminal To avoid fire do not remove the fuel tank when the engine is still hot Wait until it cools down To make fuel spillage minimum draw the fuel out from the fuel tank when the engine is cold Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately e Turn the ignition switch OFF e Remove the fairing covers see Fairing Cover Removal in the Frame chapter e Disconnect the battery terminal see Battery Removal in the Electrical System chapter e Remove Inner Covers see Inner Cover Removal in the Frame chapter Bolt A e Spread the fuel tank cover A evenly outward to
321. f the standard range inspect the main throttle sensor resistance lf the output voltage is normal check the wiring for conti nuity see wiring diagram in this section FUEL SYSTEM DFI 3 49 3 50 FUEL SYSTEM Main Throttle Sensor Service Code 11 Main Throttle Sensor Resistance Inspection e Turn the ignition switch OFF e Disconnect the main throttle sensor connector e Connect a digital meter A to the main throttle sensor connector B e Measure the main throttle sensor resistance Main Throttle Sensor Resistance Connections BL lead C BR BK lead D Standard 4 6 the reading is out of the standard replace the throttle body assy see Throttle Body Assy Removal Installation lf the reading is within the standard but the problem still exists replace the ECU see ECU Removal Installation Main Throttle Sensor Circuit 86617189651 C J Y BK BL Y W 4 BL MW G K BL YW R BK BL BL W R BK BL Y w P BK 8K BL BL W BL W 6 6 6 6 Y Y BK Y BK Y BK BL BL K BL K BL 38R 8K4 BR BK 8R BK R B8K R BK 4 olf 6617423612 C 1 ECU 2 Subthrottle Valve Actuator 3 Subthrottle Sensor 4 Main Throttle Sensor 5 Water proof Joint 2 FUEL SYSTEM DFI 3 51 Inlet Air Pressure Sensor Service Code 12 Inlet Air Pressure Sensor Removal CAUTION Never drop the inlet air
322. frame number changes from one machine to another Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Consumer Products amp Machinery Company Part No 99924 1389 02 Printed in Japan
323. fully clockwise position Rebound Damping Force Adjustment Adjuster Position Damping Force Setting Load Road Speed 4 Turns Out Weak Soft T 1 1 0 Spring Preload Adjustment e Remove the rear shock absorber from the frame see Rear Shock Absorber Removal e Loosen the locknut and turn out the adjusting nut to free the spring Special Tool Hook Wrench T 3 2 R37 57001 1522 SUSPENSION 13 19 Counterclockwise Clockwise Sof ter Harder STD Seated position adjuster turned fully clockwise 6905235851 C Counterclockwise Clockwise Softer Harder STD 4 3 2 1 Seated position adjuster turned fully clockwise 8 05236 51 C 13 20 SUSPENSION Rear Shock Absorber e To adjust the spring preload turn in the adjusting nut A to the desired position and tighten the locknut B Spring Length C Spring Preload Setting Standard Spring length 175 5 mm 6 9 in Usable Range Spring length 175 5 191 5 mm 6 909 7 539 in OThe standard adjusting nut setting for an average build rider of 68 kg 150 Ib with no passenger and no acces sories is 175 5 mm 6 9 in spring length e Remove the chain cover A see Drive Chain Removal in the Final Drive chapter e Remove the bolts B and left foot guard C for turning the hook wrench easily e To adjust the spring preload turn
324. g and Run the hoses according to Cable Wire and Hose Routing section in the Appendix chapter e Fill the clutch line after installing the clutch hose see Clutch Fluid Change 2 56 PERIODIC MAINTENANCE Periodic Maintenance Procedures Clutch Fluid Change e Level the clutch fluid reservoir and remove the reservoir cap e Remove the left lower fairing see Lower Fairing Removal in the Frame chapter e Remove the rubber cap from the bleed valve on the clutch slave cylinder e Attach a clear plastic hose A to the bleed valve and run the other end of the hose into a container e Fill the reservoir with fresh fluid e Change the clutch fluid as follows 1 Open B the bleed valve using a wrench 2 Pump the clutch lever and hold C it 3 Close D the bleed valve 4 Release E the clutch lever ORepeat this operation until fresh fluid comes out from the plastic hose or the color of the fluid changes OCheck the fluid level in the reservoir often replenishing it as necessary NOTE Olf the fluid in the reservoir runs completely out any time during fluid changing the bleeding operation must be done over again from the beginning since air will have entered the line WARNING Do not mix two brands of fluid e After changing the fluid check the clutch for good clutch power and no fluid leakage x If necessary bleed the air from the lines see Clutch Line Bleeding in the Clutch chapter e Remove the clear
325. g area e Check the oil level see Oil Level Inspection in the Engine Lubrication System chapter Oil Filter Replacement e Drain the engine oil see Engine Oil Change e Remove the left lower fairing see Lower Fairing Removal in the Frame chapter e Remove the oil filter A with the oil filter wrench B Special Tool Oil Filter Wrench 57001 1249 e Replace the filter with a new one e Apply grease to the gasket A before installation e Tighten the filter with the oil filter wrench Torque Oil Filter 17 N m 1 7 kgf m 13 ft Ib NOTE OHand tightening of the oil filter can not be allowed since it does not reach to this tightening torque e Pour in the specified type and amount of oil see Engine 2 Oil Change 2 60 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Hose and Pipe Replacement CAUTION Brake fluid quickly ruins painted plastic surfaces any spilled fluid should be completely washed away immediately e Remove the brake hose banjo bolts A e When removing the brake hose take care not to spill the brake fluid on the painted or plastic parts e When removing the brake hoses B temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum e Immediately wash away any brake fluid that spills PERIODIC MAINTENANCE 2 61 Periodic Maintenance Procedures e For ABS equipped models note the following e Remove Fuel Ta
326. g is necessary NOTE OThe ECU must be replaced with a new one because the master key code that is registered in the current ECU can not be rewritten e Prepare a new ECU A new master key B and current user keys C NOTE OThe key registration unit is not required OThe key registration process is same as the ECU re placement 6230204851 C Case 5 When replacing the antenna e Prepare a new antenna e Refer to the Immobilizer System Parts Replacement NOTE ONo key registration is required 16 102 ELECTRICAL SYSTEM Immobilizer System Equipped Models All Keys Initial Registration Flow Chart Blinking Patterns and Number 9 second gt 1 0 Seecend Seecend gt en 3second 1544424 gt 3 80 0303 ILI eg 0 22 2 0 32 3 0 3 teecand 5 87 Beecere 3 6 NOTE OK 1 Key Substitute Time Insert next key and tum ON within 15 seconds after ECU checks user previous key is turned OFF key 1 NOTES 2 ECU confirms the following Power Supply of OK O Connection of Amplifier O Time of Transmitting and Receiving Messages y 3 ECU confirms the following Immobilizer Pattern 1 Master Key Collation Error Pattern 6 O User Key is inserted 6 4 ECU confirms the following O Master Key or Not Match the Unique Code 5 ECU confirms the following Immobilizer Amp fier Fasure Pattern 1 Us
327. g it with specified torque e Install the washer and rotor bolt B and tighten it with 70 N m 7 0 kgf m 52 ft lb of torque Special Tools Grip 57001 1591 Rotor Holder 57001 1672 Stopper 57001 1679 e Remove the rotor bolt and washer e Check the tightening torque with flywheel puller Special Tool Flywheel Puller Assembly M38 x 1 5 M35 x 1 5 57001 1405 If the rotor is not pulled out with 20 N m 2 0 kgf m 15 ft lb of drawing torque it is installed correctly If the rotor is pulled out with under 20 N m 2 0 kgf m 15 ft lb of drawing torque clean off any oil dirt or flaw of the crankshaft and rotor tapered portion and washer and dry them with a clean cloth Then confirm that it is not pulled out with above torque e Install the washer and rotor bolt e Tighten the alternator rotor bolt A while holding the alter nator rotor steadily with the holder B Special Tools Grip C 57001 1591 Rotor Holder 57001 1672 Stopper D 57001 1679 Torque Alternator Rotor Bolt 155 N m 15 8 kgf m 114 ft Ib e Install the alternator cover see Alternator Cover Installa tion Alternator Inspection There are three types of alternator failures short open wire burned out or loss in rotor magnetism A short or open in one of the coil wires will result in either a low output or no output at all A loss in rotor magnetism which may be caused by dropping or hitting the alternator by leaving it near an elect
328. ght and examine wires for signs of burning fraying etc Poor wires and bad connections will affect electrical system op eration OMeasure coil and winding resistance when the part is cold at room temperature Electrical Wiring Wiring Inspection e Visually inspect the wiring for signs of burning fraying etc lf any wiring is poor replace the damaged wiring e Pull each connector A apart and inspect it for corrosion dirt and damage x If the connector is corroded or dirty clean it carefully If it is damaged replace it e Check the wiring for continuity OUse the wiring diagram to find the ends of the lead which is suspected of being a problem OConnect the hand tester between the ends of the leads Special Tool Hand Tester 57001 1394 OSet the tester to the x 1 O range and read the tester x If the tester does not read 0 the lead is defective Re place the lead or the wiring harness B if necessary ELECTRICAL SYSTEM 16 27 lt 6P070328S1 16 28 ELECTRICAL SYSTEM Battery Battery Removal e Turn off the ignition switch e Remove Right Fairing Cover see Fairing Cover Removal in the Frame chapter Bolt A with Washer Battery Compartment Cover B OClear the stoppers from the frame e Remove Bolt A Bracket Bolts B Bracket C Connector D Disconnect CAUTION Be sure to disconnect the negative cable first e Slightly pull out the battery tray A e Unhoo
329. grommet into the notch of the cover securely Sealant Kawasaki Bond Silicone Sealant 92104 0004 e Secure the alternator lead with a holding plate A and apply a non permanent locking agent to the threads of the plate bolts and tighten them Torque Alternator Lead Holding Plate Bolts 8 3 N m 0 85 kgf m 73 in Ib e Install the alternator cover see Alternator Cover Installa tion Alternator Rotor Removal e Remove the alternator cover see Alternator Cover Re moval e Hold the alternator rotor steady with the rotor holder A and remove the rotor bolt B and washer Special Tools Grip C 57001 1591 Rotor Holder 57001 1672 Stopper D 57001 1679 e Using the flywheel puller A remove the alternator rotor from the crankshaft Special Tool Flywheel Puller Assembly M38 x 1 5 M35 x 1 5 57001 1405 CAUTION Do not attempt to strike the alternator rotor itself Striking the rotor can cause the magnets to lose their magnetism Alternator Rotor Installation e Using a cleaning fluid clean off any oil or dirt on the fol lowing portions and dry them with a clean cloth Crankshaft Tapered Portion A Alternator Rotor Tapered Portion B e Install the alternator rotor 16 36 ELECTRICAL SYSTEM Charging System e Using a cleaning fluid clean off any oil or dirt on the washer A and dry if with a clean cloth NOTE OConfirm the alternator rotor fit or not to the crankshaft before tightenin
330. h 18 mph or above in order to confirm no problem OK END FUEL SYSTEM DFI 3 41 Self Diagnosis Service Code Reading OThe service code s is displayed on the LCD by the number of two digits OWhen 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 OThen after completing all codes the display is repeated until the ignition switch is turned OFF or upper button and lower button are pushed for more than two seconds OFor example if three problems occurred in the order of 46 15 35 the service codes are displayed each two seconds from the lowest number in the order listed as shown below 15 35 46 15 35 46 repeated ERROR CODE ERROR CODE 35 45 12 00 12 00 60172420 5 Oln the case more than two service codes are available you may push the upper button to shift into the other code too Olf the no problem or when the repair has done warning indicator light LED goes off and warning message and warning symbol are not displayed and no service code is displayed Olf the problem is with the following parts the ECU can not memorize these problem the warning indicator light LED do not lights up or blinks and warning message and warning symbol are not displayed and no service codes can be displayed Warning Indicator Light LED Meter Panel LCD Stick Coil Secondary Wiring
331. h ON and Fl warning message and FI warning symbol are displayed alternately on the LCD DFI system problem Starts blinking about 3 seconds after from ignition switch ON and immobilizer warning message and immobilizer warning symbol are displayed alternately on the LCD Immobilizer system problem Does not go on or blink about seconds after ignition switch ON O starter motor not rotating starter motor rotating but engine doesn t turn over starter motor and engine don t turn over fuel flow O no fuel in tank O no fuel pump sound L1 engine flooded do not crank engine with throttle opened which promotes engine flooding no spark O other O right after starting O when opening throttle grip O when closing throttle grip when moving off O when stopping the motorcycle when cruising other FUEL SYSTEM 3 31 Troubleshooting the DFI System Poor running at low speed Poor running or no power at high speed very low idle speed O very high idle speed O rough idle speed battery voltage is low charge the battery spark plug loose tighten it spark plug dirty broken or gap maladjusted remedy it backfiring afterfiring hesitation when acceleration engine oil viscosity too high brake dragging engine overheating clutch slipping other spark plug loose tighten it
332. h turned OFF Clutch lever not pulled in or gear not in neu tral Battery voltage low Immobilizer system trouble Spark plug dirty broken or gap malad justed Spark plug incorrect Stick coil shorted or not in good contact Stick coil trouble ECU trouble Camshaft position sensor trouble Gear position starter lockout or sidestand switch trouble Crankshaft sensor trouble Ignition switch or engine stop switch shorted Starter system wiring shorted or open Main 30 A or ignition fuse blown Fuel air mixture incorrect Bypass screw and or idle adjusting screw maladjusted Air passage clogged Air cleaner clogged poorly sealed or miss ing Leak from oil filler cap crankcase breather hose or air cleaner drain hose Compression Low Spark plug loose Cylinder head not sufficiently tightened down Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak No valve clearance Valve not seating properly valve bent worn or carbon accumulation on the seating surface Poor Running at Low Speed Spark weak Battery voltage low Immobilizer system trouble Stick coil trouble Stick coil shorted or not in good contact Spark plug dirty broken or maladjusted Spark plug incorrect ECU trouble Camshaft position sensor trouble Crankshaft sensor trouble Fuel air mixture incorre
333. haft Chain Removal e Remove Camshafts see Camshaft Removal Crankshaft Sensor A see Crankshaft Sensor Removal in the Electrical System chapter Timing Rotor B see Timing Rotor Removal in the Elec trical System chapter Front Camshaft Chain Guide Bolts C Front Camshaft Chain Guide D Dowel Pin E Rear Camshaft Chain Guide F 5 22 ENGINE TOP END Camshaft Camshaft Chain e Remove the crankshaft sprocket A e Pull out the camshaft chain B downward Camshaft Chain Installation e Install the camshaft chain from head side e Install the crankshaft sprocket A on the crankshaft B with their teeth C aligned e Install the front camshaft chain guide and tighten the bolts Torque Front Camshaft Chain Guide Bolt Upper 25 N m 2 5 kgf m 18 ft lb Front Camshaft Chain Guide Bolt Lower 12 N m 1 2 kgf m 106 in Ib e Install the removed parts see appropriate chapters GE11096BS1 C ENGINE TOP END 5 23 Cylinder Head Cylinder Compression Measurement NOTE OUse the battery which is fully charged e Warm up the engine thoroughly e Stop the engine e Remove Stick Coils see Stick Coil Removal in the Electrical Sys tem chapter Spark Plugs see Spark Plug Replacement in the Peri odic Maintenance chapter e Attach the compression gauge A and adapter B firmly into the spark plug hole OUsing the starter motor turn the engine over with the throt tle fully open until the compr
334. he same model name as the battery since the elec trolyte volume and specific gravity vary with the battery type This is to prevent overfilling of the electrolyte shorting the battery life and deteriora tion of the battery performance CAUTION Do not remove the aluminum sealing sheet A from the filler ports B until just prior to use Be sure to use the dedicated electrolyte container for correct electrolyte volume e Place the battery on a level surface e Check to see that the sealing sheet has no peeling tears or holes in it e Remove the sealing sheet NOTE OThe battery is vacuum sealed If the sealing sheet has leaked air into the battery it may require a longer initial charge ELECTRICAL SYSTEM 16 29 8 08020451 6 8 08003851 C 16 30 ELECTRICAL SYSTEM Battery e Remove the electrolyte container from the vinyl bag e Detach the strip of caps A from the container and set aside these will be used later to seal the battery NOTE ODo not pierce or otherwise open the sealed cells B of the electrolyte container Do not attempt to separate individual cells e Place the electrolyte container upside down with the six sealed cells into the filler ports of the battery Hold the container level push down to break the seals of all six cells You will see air bubbles rising into each cell as the ports fill NOTE ODo not tilt the electrolyte container e Check t
335. he Electrical System chapter e Pull out the rear fender B backward and downward Flap and Rear Fender Installation e Hang the hook A of the rear fender to the slot B of the rear frame e Tighten Torque Rear Fender Mounting Screws 1 2 N m 0 12 kgf m 11 in Ib Rear Fender Mounting Bolts 0 80 N m 0 082 kgf m 7 1 in Ib e Install the removed parts see appropriate chapters e Run the cables leads harness and hoses correctly see Cable Wire and Hose Routing section in the Appendix chapter FRAME 15 19 15 20 FRAME Frame Rear Frame Removal e Remove Rear Fender see Flap and Rear Fender Removal Regulator Rectifier A see Regulator Rectifier Inspec tion in the Electrical System chapter Bolt B and Brackets C Muffler Body Mounting Bolts D Both Sides Rear Footpeg Bracket Bolts E and Brackets Both Sides Rear Frame Bolts F and Rear Frame Rear Frame Installation e Apply a non permanent locking agent to the threads of the rear frame bolt and tighten them Torque Rear Frame Bolts 44 N m 4 5 kgf m 32 ft Ib Rear Footpeg Bracket Bolts 25 N m 2 5 kgf m 18 ft Ib e Install the removed parts see appropriate chapters Frame Inspection e Visually inspect the frame A for cracks dents bending or warp lf there is any damage to the frame replace it WARNING A repaired frame may fail in use possibly causing an accident If the frame is bent dented cracked
336. he electrolyte flow no air bubbles A are coming up from the filler ports or if the container cells have not emptied completely tap the container B a few times e Keep the container in place for 20 minutes or more Don t remove the container from the battery until it s empty the battery requires all the electrolyte from the container for proper operation CAUTION Removal of the container before it is completely empty can shorten the service life of the battery Do not remove the electrolyte container until it is com pletely empty and 20 minutes have elapsed e Gently remove the container from the battery e Let the battery sit for 60 minutes prior to charging to allow the electrolyte to permeate into the plates for optimum performance NOTE OCharging the battery immediately after filling can shorten service life Let the battery sit for at least 60 minutes after filling 8 09000851 C 8 09000851 C ELECTRICAL SYSTEM 16 31 Battery Initial Charge e Place the strip A of caps loosely over the filler ports e Newly activated sealed batteries require an initial charge Standard Charge 1 4 A 5 10 hours using a recommended battery charger follow the charger s instructions for newly activated sealed battery Kawasaki recommended chargers Optimate Yuasa 1 5 Amp Automatic Charger Battery Mate 150 9 the above chargers not available use eq
337. he figure ECU Power Source Inspection Meter Connections between 33 BR Terminal and Frame Ground 2 C between 15 W BK Terminal and Frame Ground 2 C between 32 W BK and Frame Ground 2 C Ignition Switch OFF 33 BR Terminal 0 V 15 W BK Terminal Battery Voltage 32 W BK Terminal Battery Voltage Ignition Switch ON 33 BR Terminal Battery Voltage 15 W BK Terminal Battery Voltage 32 W BK Terminal Battery Voltage lf the tester does not read as specified check the follow ing Powe Source Wiring see wiring diagram in this section Main Fuse 30 A see Fuse Inspection in the Electrical System chapter ECU Fuse 15 A see Fuse Inspection in the Electrical System chapter x lf the wiring and fuse are good replace the ECU see ECU Removal Installation FUEL SYSTEM 3 99 PE 6617442651 C 3 100 FUEL SYSTEM DFI ECU ECU Power Source Circuit w BK W BK 6617235042 C Water proof Joint 1 Ignition Switch ECU Fuse 15 Fuse Box 2 Starter Relay Main Fuse 30 A Battery 12 V 14 Ah Frame Ground 2 10 Joint Connector 3 CAN Communication Line Resistance Inspection Oln this model resistors for CAN communication line are built in the ECU and meter unit e Turn the ignition switch OFF e Disconnect the ECU connector A see ECU Removal OMDNDOARWOND ECU e Conne
338. he inside of the water hose Lower Fairing Bracket Clamp Install the clamp in a position that is the nearest to the motorcycle as shown in the figure Run the oxygen sensor lead through the clamp View from Bottom Crankshaft sensor lead clamp ZX1400C8F D8F Cable Wire and Hose Routing California Southeast Asia and Thailand Models 17 58 APPENDIX e C 6809629015 C 66 E 2 Lh Ty APPENDIX 17 59 Cable Wire and Hose Routing PO P NP PND Canister Clamps Hose Green Hose Blue Hose Red Separator Hose Blue Clamp Fuel Tank Fittings Hose White Hose Green Connect to the fitting of the throttle body 4 Hose White Connect to the fitting of the throttle body 3 Bracket Insert the bracket into the hole of the clamp Clamp Throttle Body Assy View from Front Side Band Connected position of the green hoses and fitting Connected position of the white hoses and fitting The paint mark on the hose faces to upward The paint mark on the hose faces to outside Run the green hose through between the subthrottle valve actuator lead and inlet air pressure sensor lead Run the white hose through between the subthrottle valve actuator lead connector and throt
339. he leads in the same circuit as Check 2 e Connect the terminal 2 to the battery terminal e Check that the oil pressure warning indicator light LED A goes on xlf the indicator light does not go on replace the meter assembly Check 10 Neutral Indicator Light LED Inspection e Connect the leads in the same circuit as Check 2 e Connect the terminal 4 to the battery terminal GP17578BS1 Meter Gauge Indicator Unit e Check that the neutral indicator light LED A goes on the indicator light does not go on replace the meter assembly Check 11 ABS Indicator Light LED Inspection ABS Equipped Models e Connect the leads in the same circuit as Check 2 e Check that the ABS indicator light LED A goes on e Connect the terminal 6 to the battery terminal e Check that the ABS indicator light LED goes off the indicator light does not go on replace the meter assembly Check 12 Fuel Level Warning Inspection e Connect the leads in the same circuit as Check 2 e Connect the variable rheostat A about 22 Q to the ter minal 15 and the battery terminal ELECTRICAL SYSTEM 16 79 GPI7584BSi C 16 80 ELECTRICAL SYSTEM Meter Gauge Indicator Unit e After about 5 seconds check that one segment A in the fuel gauge starts flashing e Check that the FUEL LOW B
340. he oxy gen sensor see Oxygen Sensor Removal in the Electrical System chapter Oxygen Sensor Heater Inspection e Turn the ignition switch to OFF e Remove the right lower fairing see Lower Fairing Re moval in the Frame chapter e Disconnect the oxygen sensor lead connector A e Set the hand tester A to the x 1 O range and connect it to the oxygen sensor lead connector B White C White D Special Tool Hand Tester 57001 1394 Oxygen Sensor Heater Resistance Standard 6 7 10 5 O at 20 C 68 F If the tester reading is far out of the specified replace the Oxygen sensor FUEL SYSTEM 3 93 Oxygen Sensor Heater Service Code 67 Equipped Models xIf the tester reading is specified check the power source voltage inspection NOTE OBe sure the battery is fully charged e Connect a digital meter A to the oxygen sensor connec tor B using the needle adapter set C Special Tool Needle Adapter Set 57001 1457 Oxygen Sensor Heater Power Source Voltage Connections to Oxygen Sensor Connector Meter W lead D Meter Battery Terminal E Oxygen Sensor F e Measure the power source voltage with the engine stopped and with the oxygen sensor connector joined e Turn the ignition switch to ON Power Source Voltage at Sensor Connector Standard Battery Voltage xIf the reading is incorrect check the following Battery see Charging Condition Inspection in the El
341. he specified tightening sequence Si Apply silicone grease 12 6 BRAKES Exploded View Exploded View BRAKES 12 7 No Fastener 191108 Remarks N m kgf m ft Ib 1 Bleed Valves 7 8 0 80 69 in lb 2 Hose Banjo Bolts 25 2 5 18 3 Pedal Bolt 8 8 0 90 78 in lb 4 Brake Disc Mounting Bolts L 5 Rear Brake Pad Pin 6 Rear Caliper Assembly Bolts L 7 Rear Caliper Mounting Bolts 8 Rear Master Cylinder Mounting Bolts 25 2 5 18 9 Rear Master Cylinder Push Rod Locknut 17 2 1 8 13 B Apply brake fluid G Apply grease L Apply a non permanent locking agent R Replacement Parts Si Apply silicone grease 12 8 BRAKES Exploded View ABS Equipped Models GL023138W5 C BRAKES 12 9 Exploded View No Fastener 191908 Remarks N m kgf m ft Ib 1 Bleed Valves 7 8 0 80 69 2 Brake Hose Banjo Bolts 25 2 5 18 3 Brake Lever Pivot Bolt 1 0 0 10 8 9 in lb Si 4 Brake Lever Pivot Bolt Locknut 5 9 0 60 52 inrlb 5 Brake Pipe Joint Nuts ABS Equipped Models 18 1 8 13 6 Front Brake Disc Mounting Bolts 27 2 8 20 L 7 Front Brake Light Switch Screw 1 2 0 12 11 in lb 8 Front Brake Pad Pins 17 2 1 8 13 9 Front Brake Reservoir Cap Stopper Screw 1 2 0 12 11 in Ib 10 Front Caliper Assembly Bolts 27 2 8 20 L 11 Front Caliper Mounting Bolts 34 3 5 25 12 Front Master Cylinder
342. heck the brakes for proper braking power and brake fluid level search for leaks etc Even when the ABS is operating normally the ABS indi cator light LED may light up under the conditions listed be low Turn the ignition switch OFF to stop the indicator light If the motorcycle runs without erasing the service code the light may light up again OAfter continuous riding on a rough road OWhen the engine is started with the stand raised and the transmission engaged and the rear wheel turns OWhen accelerating so abruptly that the front wheel leaves the ground OWhen the ABS has been subjected to strong electrical interference OWhen tire pressure is abnormal Adjust tire pressure OWhen tire different in size from the standard size is being used Replace with standard size OWhen the wheel is deformed Replace the wheel Much of the ABS troubleshooting work consists of con firming continuity of the wiring The ABS parts are assem bled and adjusted by the manufacturer so there is no need to disassemble or repair them Replace the ABS hydraulic unit The basic troubleshooting procedures are listed below e Carry out pre diagnosis inspections as a preliminary in spection e Determine the fault using the self diagnosis function e Check wiring and connections from the ABS hydraulic unit connector to the suspected faulty ABS part using the hand tester Special Tool Hand Tester 57001 1394 BRAKES 12 35 661
343. hem to the delivery pipe B and con firm whether the injectors turn smoothly or not NOTE OReplace the O rings of injectors to new ones Throttle Body Assy e Apply daphne oil or engine oil to the new dust seals A and insert the injectors into the throttle body which in stalled to the delivery pipe NOTE OReplace the dust seals of the throttle body to new ones e Install the delivery pipe to the throttle body e Tighten Torque Delivery Pipe Mounting Screws 5 0 N m 0 51 kgf m 44 in Ib e Connect the connectors e Insert the each hoses to the throttle body fittings and inlet air pressure sensor e Bind the harness and hoses with clamps e Install the throttle body assy see Throttle Body Assy In stallation FUEL SYSTEM DFI 3 125 3 126 FUEL SYSTEM DFI Air Line Air Cleaner Element Removal e Refer to the Air Cleaner Element Replacement in the Pe riodic Maintenance chapter Air Cleaner Element Installation e Refer to the Air Cleaner Element Replacement in the Pe riodic Maintenance chapter Air Cleaner Element Inspection e Remove the air cleaner element see Air Cleaner Element Replacement in the Periodic Maintenance chapter e Visually check the element A for tears or breaks If the element has any tears or breaks replace the ele ill ment I VN 2 II IN M illl 117 Mh Air Cleaner Element Holder Removal e Remove Air Cleaner Element see Air Clean
344. her than CA and US 25 Engine Ground Models 26 Tail Brake Light LED 12 Headlight Relay Fuse 10 A 27 License Plate Light 13 Taillight Fuse 10 A 28 Joint Connector 2 14 Headlight Fuse High 15 A 29 Fuse Box 2 30 Ignition Fuse 10 A Turn Signal Light Bulb Replacement Front Turn Signal Light e Remove Middle Fairings see Middle Fairing Removal in the Frame chapter Inner Fairings see Inner Fairing Removal in the Frame chapter e Turn the socket A counterclockwise and pull out the socket together with the bulb Lighting System e Push and turn the front turn signal light bulb A counter clockwise and remove it e Replace the bulb with new ones e Insert the new bulb A by aligning its upper and lower pins B with the upper and lower grooves C in the socket and turn the bulb clockwise OTurn the bulb about 15 e Pushing the socket and turn it clockwise OFit the projections A of the socket into the grooves B of the turn signal light e Install the removed parts see appropriate chapters Rear Turn Signal Light e Remove Screw A Rear Turn Signal Light Lens B e Push and turn the rear turn signal light bulb A counter clockwise and remove it ELECTRICAL SYSTEM 16 63 16 64 ELECTRICAL SYSTEM Lighting System e Insert the new bulb A by aligning its upper and lower pins B with the upper and lower grooves C in the socket and turn the bulb clockwise OTu
345. hermostat Valve Opening Temperature Valve Full Opening Lift Standard Permanent type of antifreeze soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators Green Soft water 5096 coolant 5096 35 31 F 3 4 L 3 6 US qt reserve tank full level including radiator and engine 93 123 kPa 0 95 1 25 kgf cm 13 18 psi 58 62 C 136 144 F 8 mm 0 31 in or more at 75 C 167 F Coolant Coolant Deterioration Inspection e Visually inspect the coolant in the reserve tank 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 e Refer to the Coolant Level Inspection in the Periodic Main tenance chapter Coolant Draining e Refer to the Coolant Change in the Periodic Maintenance chapter Coolant Filling e Refer to the Coolant Change in the Periodic Maintenance chapter Pressure Testing e Remove the right middle fairing see Middle Fairing Re moval in the Frame chapter e Remove the radiator cap and install the cooling system pressure tester A on the filler neck NOTE OWet the cap sealing surfaces with water or coolan
346. highest throttle valves may not be 290 mmHg for example The goal is to have the highest two vac uums between the left 1 and 2 and right 3 and 4 banks be the same and be within the service limits e Open and close the throttle after each measurement and adjust the idle speed as necessary e Once the throttle valves have been synchronized inspect output voltage of the main throttle sensor to ensure proper operation procedure is explained at the end of this sec tion If a value of measured vacuum pressure is out of the specified range after synchronization adjust the bypass screws A Special Tools Pilot Screw Adjuster C 57001 1292 Pilot Screw Adjuster Adapter 5 57001 1372 Rear View B e Adjust the lower vacuum between 1 and 2 to higher vacuum of 1 and 2 e Adjust the lower vacuum between 3 and 4 to higher vacuum of 3 and 4 e Open and close the throttle valves after each measure ment and adjust the idle speed as necessary e Check the vacuums as before If all vacuums are within the specification range finish the engine vacuum synchronization If any vacuum cannot be adjusted within the specification remove the bypass screws 1 4 and clean them 9505167851 PERIODIC MAINTENANCE 2 19 Periodic Maintenance Procedures e Turn in the bypass screw A with counting the number of turns until it seals fully but not tightly Record the number of turns Torque
347. hin 15 seconds after previous key is turned OFF and removed otherwise registration mode will be ended and the warning indicator light LED stops flashing OTo return to the registration mode start the master key verification procedure This applies to all user key reg istration OKeep other user keys away from the immobilizer an tenna Olf there is any problem in the registration the warning indicator light LED A blinks to display the collation error Immobilizer Amplifier Failure 0 3second oN LULL LLL LL GP30517BS1 0 2second Get d unnnnnnnnnnnrui GP30516BS1 C Immobilizer System Equipped Models When Registered User Key is Inserted User Key Collation Error e The user key 1 is successfully registered in the ECU OThe warning indicator light LED A blinks 2 times and stops for 1 second and then repeats this cycle to indicate successful registering of user key 1 e Turn OFF and remove user key 1 OThe warning indicator light LED A blinks to display the registration mode NOTE OTurn OFF the ignition switch and wait for the period more than 15 seconds The registration mode automat ically ends and warning indicator light LED goes off This procedure has registered the master key and one user key OContinue the procedure to program the second and later keys e Insert the user key 2 to the ignition switch and turn it ON ELECTRICAL SYSTEM 16 95
348. housing unevenly worn Clutch master cylinder trouble Clutch slave cylinder trouble Clutch not disengaging properly Clutch plate warped or too rough Clutch spring compression uneven Engine oil deteriorated Engine oil viscosity too high Engine oil level too high Clutch housing frozen on drive shaft Clutch hub nut loose Clutch hub spline damaged Clutch friction plate installed wrong Clutch slave cylinder trouble Clutch fluid deteriorated Air in clutch fluid line Clutch master cylinder primary or sec ondary cup damage Clutch master cylinder scratched inside Gear Shifting Faulty Doesn t go into gear shift pedal doesn t return Clutch not disengaging Shift fork bent or seized Gear stuck on the shaft Gear positioning lever binding Shift return spring weak or broken Shift return spring pin loose Shift mechanism arm spring broken Shift mechanism arm broken Shift pawl broken Jumps out of gear Shift fork ear worn bent Gear groove worn Gear dogs and or dog holes worn Shift drum groove worn Gear positioning lever spring weak or bro ken Shift fork guide pin worn Drive shaft output shaft and or gear splines worn Overshifts Gear positioning lever spring weak or bro ken Shift mechanism arm spring broken Abnormal Engine Noise Knocking ECU trouble Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Overheating Piston slap Cylinder piston clearance excessive Cylinder piston wor
349. i Lock Brake System Equipped Models e Do the 2nd step test O Check for continuity between the black lead terminal of the sensor connector A and ground and white lead ter minal of the sensor connector and ground x If there is the continuity in the lead replace the front wheel rotation sensor If there is not the continuity in the lead proceed the 3rd step e Do the 3rd step test ORecheck the service code indication erase the service code perform the pre diagnosis inspection 1 and 2 and retrieve the service code lf the ABS indicator light LED A lit faulty ECU in the ABS hydraulic unit Replace the ABS hydraulic unit xIf the ABS indicator light LED unlit ABS system is nor mal service code is not stored temporary failure Rear Wheel Rotation Sensor Signal Abnormal Service Code 44 e Do the 1st step test OMeasure the air gap between the rear wheel rotation sen sor and sensor rotor Thickness Gauge A Air Gap Standard 0 7 0 9 mm 0 028 0 035 in the measurement is over standard check each part for deformation and looseness and correct accordingly Recheck the air gap If the measurement is correct proceed the 2nd step e Do the 2nd step test OCheck that there is iron or other magnetic deposits be tween the sensor A and sensor rotor B and the sensor rotor slots for obstructions OCheck the installation condition of the sensor for loose ness OCheck the sensor and s
350. id leak from the brake hoses A pipes B ABS equipped models and fittings C lf the brake fluid leaked from any position inspect or re place the problem part 2 36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Hose and Pipe Damage and Installation Condition Inspection e For ABS equipped models note the following e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Battery see Battery Removal in the Electrical System chapter e Inspect the brake hoses pipes and fittings for deteriora tion cracks and signs of leakage OThe high pressure inside of the brake line can cause fluid to leak A or the hose pipes ABS equipped models to burst if the line is not properly maintained Bend and twist the rubber hose while examining it Replace the hose and pipe ABS equipped models 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 Ib Brake Pipe Joint Nuts 18 N m 1 8 kgf m 13 ft Ib ABS Equipped Models e Inspect the brake hose routing If any brake hose and pipe ABS equipped models rout ing is incorrect run the brake hose and pipe according to Cable Wire and Hose Routing section in the Appendix chapter Brake Operation Inspection e Inspect the operation of the front and rear brake by run ning the vehicle on the dry road If the brake operation is in
351. ide of the needle bearing driver according to its press ing depth GM07030BS1 Special Tools Bearing Driver Set 57001 1129 Needle Bearing Driver 417 018 57001 1609 Spacer 18 F 57001 1636 Needle Bearing Driver 020 amp Spacer 28 57001 1678 NOTE Olnstall the needle bearings so that the marked side faces out Needle Bearings A Oil Seals B Front C Right Side D Left Side E Rear Shock Absorber F Tie Rods G Rocker Arm H 7 5 mm 0 30 in I 10 mm 0 39 in J 5 5 mm 0 22 in K 5 0 mm 0 20 in L WO GM070608W2 C SUSPENSION 13 31 Tie Rod Rocker Arm Rocker Arm Tie Rod Bearing Sleeve Inspection CAUTION Do not remove the bearings for inspection Re 6 moval may damage them e Visually inspect the locker arm or tie rod sleeves A and needle bearings B e The rollers in a needle bearing normally wear very little and wear is difficult to measure Instead of measuring inspect the bearing for abrasion color change or other damage x lf there is any doubt as to the condition of any of the nee dle bearings or sleeve replace the sleeve and needle bearings as a set 6 07016851 Rocker Arm Tie Rod Bearing Lubrication NOTE OSince the bearings are packed with grease lubrication is not required STEERING 14 1 Steering Table of Contents Exploded aac stakes decade le dol a 14 2
352. ight Circuit Relay ECU Main Relay Fuel Pump Relay Starter Circuit Relay IGNITION SWITCH CONNECTIONS Rear Brake Light Switch Tail Brake Light LEB 12V0 5 4 9 Rear Left Turn Signal Light 12V21W BK Y BK Y Joint Connector 3 L Kawasaki Diagnostic System Connector Switch Color Code BK Black BL Brown BR amp Green Gray LB Light Blue Le flight Green 9 Orange Pink gnition Battery Taill Tail2 Battery Tail3 RIGHT SWITCH HOUSING CONNECTIONS Front Brake Light Switch Engine Stop Switch Starter Button Pu Purple Red v Violet Color BL W BK W G iE ON a O a a O Color Color R R Color BL Brake Lever OFF Free Pulled In C O RUN a O Push a o 98052 03480 w White Ly Yellow W2RO348CH5 C 16 24 ELECTRICAL SYSTEM Wiring Diagram ABS Equipped Models Other than MY Model Rear Wheel Rotation Sensor Front Wheel Rotation Sensor Camshaft Horn Bane Position Right Switch Housing 12V 2 5 5 4 1 Front Brake Light Switch ensor Air 2 Engine Stop Switch Switching 3 Starter Button Valve amare BR ition Y Ignition fani R ABS Switch franz Right 1 Eee x 55 5 Self Pate Switch Housing 55 i 52 diagnosis Terminal Immobilizer Antenna gn Joint Conn
353. ightening loos ened The electrolyte contains sulfuric acid Be careful not to have it touch your skin or eyes If touched wash it off with liberal amount of water Get medial attention if severe Interchange A sealed battery can fully display its performance only when combined with a proper vehicle electric system Therefore replace a sealed battery only on a motorcycle which was originally equipped with a sealed battery Be careful if a sealed battery is installed on a motorcycle which had an ordinary battery as original equipment the sealed battery s life will be shortened Charging Condition Inspection OBattery charging condition can be checked by measuring battery terminal voltage with a digital voltmeter A e Remove the battery see Battery Removal e Measure the battery terminal voltage NOTE OMeasure with a digital voltmeter which can be read one decimal place voltage 8 08010851 C ELECTRICAL SYSTEM 16 33 Battery xIf the reading is 12 6 V or more no refresh charge is re quired however if the read is below the specified refresh charge is required Battery Terminal Voltage Standard 12 6 V or more Terminal Voltage V A Battery Charge Rate 96 B Refresh charge is required C Note D Good E Refreshing Charge e Remove the battery A see Battery Removal e Do refresh charge by following method according to the battery terminal voltage A WAR
354. in side of the switch be sure that the switch body does not turn during adjustment x lf it does not go on inspect or replace the following items Battery see Charging Condition Inspection in the Elec trical System chapter Brake Light see Tail Brake Light Removal in the Electri cal System chapter Main Fuse 30 A and Taillight Fuse 10 A see Fuse In spection in the Electrical System chapter Front Brake Light Switch A see Switch Inspection in the Electrical System chapter Rear Brake Light Switch see Switch Inspection in the Electrical System chapter Harness see Wiring Inspection in the Electrical System chapter Suspension Front Forks Rear Shock Absorber Operation Inspection e 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 PERIODIC MAINTENANCE 2 39 Periodic Maintenance Procedures e 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 e Visually inspect the front forks A for oil leakage Replace or repair any defective parts if necessary Rear Shock Absorber Oil Leak Inspection e Visually inspect the shock absor
355. ines B of the cylinder head cover and coil heads CAUTION Do not tap the coil head while installing the coil e Connect the stick coil connectors e Run the hoses and harness correctly see Cable Wire and Hose Routing section in the Appendix chapter e Install the removed parts see appropriate chapters Stick Coil Inspection e Remove the stick coils see Stick Coil Removal e Measure the primary winding resistance A as follows OConnect the hand tester between the coil terminals OSet the tester to the x 1 O range and read the tester e Measure the secondary winding resistance B as follows OConnect the tester between the plug terminal and coil terminal OSet the tester to the x 1 range and read the tester Stick Coil Winding Resistance Primary Windings 1 2 1 60 Secondary Windings 8 5 11 5 kO lf the tester does not read as specified replace the coil Ei Q IN alse NE d Ba Se rat ON GP10353BS1 C 8 10011952 C Ignition System Stick Coil Primary Peak Voltage NOTE OBe sure the battery is fully charged e Remove the stick coils see Stick Coil Removal ODo not remove the spark plug e Measure the primary peak voltage as follows Olnstall the new spark plug A into each stick coil B and ground them onto the engine OConnect the peak voltage adapter C to the hand tester D
356. ing OAfter making the 32 grind return to the seat outside di ameter measurement step above e To measure the seat width use a vernier caliper to mea sure the width of the 45 angle portion of the seat at sev eral places around the seat xIf the seat width is too narrow repeat the 45 grind until the seat is slightly too wide and then return to the seat outside diameter measurement step above ENGINE TOP END 5 31 6 15011951 6 6 15012151 6 6 15012251 6 5 32 ENGINE TOP END Valves If the seat width is too wide make the 60 A grind de scribed below x If the seat width is within the specified range lap the valve to the seat as described below e Grind the seat at a 60 angle until the seat width is within the specified range OTo make the 60 grind fit 60 cutter into the holder and slide it into the valve guide OTurn the holder while pressing down lightly OAfter making the 60 grind return to the seat width mea surement step above Correct Width B e Lap the valve to the seat once the seat width and outside diameter are within the ranges specified above OPut a little coarse grinding compound on the face of the valve in a number of places around the valve head OSpin the valve against the seat until the grinding com pound produces a smooth matched surface on both the seat and the valve ORepeat the process with a fine grinding compound
357. ing 4 6 DC 4 75 5 25 V DC 3 80 4 20 V at standard atmospheric pressure see this text for details About 2 25 2 50 V at 20 C 68 2 21 2 69 at 20 68 F About 0 322 at 80 176 About 2 80 2 97 V at 20 C 68 4 75 5 25 V About DC 0 05 0 09 V or DC 4 5 4 9 V at ignition switch ON and 0 km h Magnetic flux detection method More than 60 70 for each bank With sensor arrow mark pointed up 3 55 4 45 V With sensor tilted 60 70 or more 0 65 1 35 V Specifications FUEL SYSTEM DFI 3 19 Item Standard Subthrottle Sensor Input Voltage Output Voltage Resistance Immobilizer Antenna Equipped Models Resistance Subthrottle Valve Actuator Resistance Input Voltage Oxygen Sensor Equipped Models Output Voltage Rich Output Voltage Lean Heather Resistance CAN Communication Line Resistance DC 4 75 5 25 V DC 0 62 4 14 V at subthrottle valve to full opening to closing 4 6kO About 0 6 090 About 5 70 About DC 10 5 12 5 V DC 0 8 V or more DC 0 24 V or less 6 7 10 5 at 20 C 68 F 114 126 at ECU Connector Throttle Grip and Cables Throttle Grip Free Play 2 3 mm 0 08 0 12 in Air Cleaner Element Viscous paper element 3 20 FUEL SYSTEM Special Tools and Sealant Oil Pressure Gauge 5 kgf cm 57001 125 7570125ST C Fork Oil Level Ga
358. ing Screws 3 5 0 36 31 in lb 3 Right Switch Housing Screws 3 5 0 36 31 in lb 4 Sidestand Switch Bolt 8 8 0 90 78 in lb L 5 Starter Lockout Switch Screw 0 70 0 071 6 2 in lb L 6 Starter Motor Cable Terminal Nut 5 9 0 60 52 in lb 7 Starter Motor Mounting Bolts 9 8 1 0 87 in lb 8 Starter Motor Terminal Locknut 6 9 0 70 61 in lb 9 Starter Motor Through Bolts 3 4 0 35 30 in lb 10 Starter Relay Cable Terminal Bolts 3 9 0 40 35 in lb 11 ABS Equipped Models 12 Immobilizer Equipped Models 13 MY and WVTA 78 2 H Models 14 Other than MY and WVTA 78 2 H Models G Apply grease L Apply a non permanent locking agent R Replacement Parts 16 10 ELECTRICAL SYSTEM Specifications Item Battery Type Model Name Capacity Voltage Charging System Type Alternator Output Voltage Stator Coil Resistance Charging Voltage Regulator Rectifier Output Voltage Standard Sealed battery FTZ14 BS 12 V 14 Ah 12 6 V or more Three phase AC 51 V or more at 4 000 r min rpm 0 05 0 5 O at 20 C 68 F 14 2 15 2 V Ignition System Crankshaft Sensor Resistance Crankshaft Sensor Peak Voltage Camshaft Position Sensor Resistance Camshaft Position Sensor Peak Voltage Stick Coil Primary Winding Resistance Secondary Winding Resistance Primary Peak Voltage Spark Plug Type Gap Electric Starter System Starter Motor Brush Length Commutator Diameter Air Switching Valve Resistance
359. ing compressor nuts e Remove the fork spring compressor e Raise the outer tube and screw the top plug into it e Install the front fork see Front Fork Installation Front Fork Disassembly e Remove the front fork see Front Fork Removal e Drain the fork oil see Front Fork Oil Change e Hold the front fork in a vise A e Stop the cylinder B from turning by using the fork cylinder holder C Special Tool Fork Cylinder Holder 57001 1287 e Unscrew the Allen bolt D then take the bolt and gasket out of the bottom of the inner tube e Take the cylinder unit A ODo not disassemble the cylinder unit e Separate the outer tube from the inner tube e Pull out the dust seal e Remove the retaining ring A from the outer tube e Remove the oil seal B and washer C GMO4081BS1 C SUSPENSION 13 17 Front Fork Front Fork Assembly e Replace the following parts with a new one Oil Seal Bottom Allen Bolt Gasket e Insert the cylinder unit A into the inner tube B e Stop the cylinder from turning by using the fork cylinder holder Special Tool Fork Cylinder Holder 57001 1287 e Apply a non permanent locking agent to the threads of the Allen bolt and tighten it Torque Front Fork Bottom Allen Bolts 23 N m 2 3 kgf m 17 ft lb e Install the following parts onto the inner tube A Dust Seal B Retaining Ring C Oil Seal D Washer E 6404041981 6 e Insert the inn
360. injector resistance with a digital meter Fuel Injector Resistance Connections to Fuel Injector Meter Meter 1 W R BL R Terminal 2 W R BL G Terminal 3 W R BL BK Terminal 4 W R BL Y Terminal Standard About 11 7 12 3 at 20 C 68 F If the reading is out of the range perform the Fuel Injector Unit Test the reading is normal perform the Fuel Injector Unit Test for confirmation Fuel Injector Unit Test Use two leads A and the same test light set B as in Fuel Injector Signal Test Rating of Bulb C 12 V x 3 3 4 W 12 V Sealed Battery D CAUTION Be sure to connect the bulb in series The bulb works as a current limiter to protect the solenoid in the fuel injector from excessive current 6017024481 e Connect the test light set to the fuel injector E as shown in the figure e Open and connect F the end of the lead to the battery terminal repeatedly The fuel injector should click x lf the fuel injector does not click replace the fuel injector Fuel Injectors Fuel Injector Fuel Line Inspection e Remove the throttle body assy see Throttle Body Assy Removal e Check the fuel injector fuel line for leakage as follows OConnect a commercially available vacuum pressure pump A to the nipple of the delivery pipe B with the fuel hose C both ends are connected with the clamps D as shown in the figure OAppl
361. inutes when the liquid gasket to the mating surface of the lower crankcase half is applied CAUTION Do not apply liquid gasket inside of the groove C near the crankshaft main bearing inserts and bal ancer bearing Do not plug the inside of breather hole D with liq uid gasket 2 2 2 D gt Bl 5 FH 6104309852 C CRANKSHAFT TRANSMISSION 9 13 Crankcase Splitting e Fit the lower crankcase half to the upper crankcase half e Be sure that the breather hole A on the upper crankcase E gt 9 6 mm m 4 B is not plugged with liquid gasket ate 2 38 t B 61042458 e The 10 bolts have washers replace them with new ones e Apply molybdenum disulfide oil solution to the seating sur faces A of the washers and the threads B of the M10 bolts e Tighten the lower crankcase bolts using the following steps OFollowing the sequence numbers on the lower crankcase half tighten the M10 bolts 1 10 with washers Torque Crankcase Bolts M10 47 N m 4 8 kgf m 35 ft Ib OTighten the M7 bolts A Torque Crankcase Bolts M7 20 N m 2 0 kgf m 15 ft Ib 6104230851 C 9 14 CRANKSHAFT TRANSMISSION Crankcase Splitting e Tighten the upper crankcase bolts in the order listed OThe M8 bolts have washers replace them with new ones OTighten M8 Bolts with W
362. ion see Refreshing Charge When a fast charge is inevitably required do it following precisely the maximum charge current and time conditions indicated on the battery CAUTION This battery is designed to sustain no unusual deterioration if refresh charged according to the method specified above However the battery s performance may be reduced no ticeably if charged under conditions other than given above Never remove the seal cap during refresh charge If by chance an excessive amount of gas is generated due to overcharging the relief valve releases the gas to keep the battery normal 3 When you do not use the motorcycle for months Give a refresh charge before you store the motorcycle and store it with the negative cable re moved Give a refresh charge once a month during storage 4 Battery life If the battery will not start the engine even after several refresh charges the battery has ex ceeded its useful life Replace it Provided however the vehicle s starting system has no prob lem A WARNING Keep the battery away from sparks and open flames during charging since the battery gives off an explosive gas mixture of hydrogen and oxygen When using a battery charger connect the battery to the charger before turning on the charger This procedure prevents sparks at the battery terminals which could ignite any battery gases No fire should be drawn near the battery or no terminals should have the t
363. ion in the Electrical System chapter in order to check the sensor e Check the wiring for continuity see wiring diagram in this section Camshaft Position Sensor Circuit Y R w Y Y R Y R Y R BK BK Y A lt 0 OF 2 6617430612 C 1 ECU 2 Camshaft Position Sensor 3 Frame Ground 1 3 68 FUEL SYSTEM Speed Sensor Service Code 24 Speed Sensor Removal Installation e Refer to the Speed Sensor Removal Installation in the Electrical System chapter Speed Sensor Inspection e Refer to the Speed Sensor Inspection in the Electrical System chapter Speed Sensor Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Disconnect the speed sensor connector A e Connect the harness adapter A between the harness connector and speed sensor connector Special Tool Throttle Sensor Setting Adapter 1 57001 1400 e Connect a digital meter to the harness adapter leads Speed Sensor Input Voltage Connections to Adapter Meter BL sensor P lead B Meter BK BL sensor BK lead C e Measure the input voltage with the engine stopped and with the connector joined e Turn the ignition switch ON Input Voltage Standard DC 4 75 5 25 V e Turn the ignition switch OFF If the reading is out of the standard check the wiring see wiring diagram in this section and meter unit see Meter Unit Inspection in the Elec
364. ions of the muffler bodies with the holes of the muffler body clamps e Tighten Torque Muffler Body Mounting Bolts 34 N m 3 5 kgf m 25 ft lb Muffler Body Clamp Bolts 17 N m 1 7 kgf m 13 ft Ib Exhaust Pipe Removal e Remove Oxygen Sensor Equipped Models see Oxygen Sen sor Removal Equipped Models in the Electrical System chapter Radiator see Radiator and Radiator Fan Removal in the Cooling System chapter Muffler Bodies see Muffler Body Removal Installation Exhaust Pipe Manifold Holder Nuts A Exhaust Pipe Manifold B Exhaust Pipe Installation e Replace the exhaust pipe gaskets A with new ones and install them e Tighten Torque Exhaust Pipe Manifold Holder Nuts 17 N m 1 7 kgf m 13 ft lb e Install the removed parts see appropriate chapters GE18051BS1 C GE18089BS1 C CLUTCH 6 1 Clutch Table of Contents elele CO VIG PD E tenn 6 2 SDC CIICAU ONG cite RM EE 6 4 Special Tools and Sealant iisdem 6 5 Gluten Master iode paren T RI 6 6 Clutch Lever Position Adjustment pp 6 6 Clutch Master Cylinder Removal pp 6 6 Clutch Master Cylinder Installation 2 6 6 Clutch Master Cylinder Disassembly esses 6 7 Clutch Master Cylinder Assembly pp 6 7 Clutch Master Cylinder Inspection nerit etn nte tee t Clutenslave eoo ee
365. ir bracket bolt A e Remove the banjo bolt B to disconnect the brake hose from the master cylinder see Brake Hose Removal In stallation e Unscrew the clamp bolts C and take off the master cylin der D as an assembly with the reservoir brake lever and brake switch installed e Disconnect the front brake light switch connector E CAUTION Immediately wash away any brake fluid that spills e Remove Brake Lever Pivot Bolt A and Locknut Brake Lever B Clamp C Slide Out Brake Hose D Front Brake Light Switch E Front Master Cylinder Installation e Set the front master cylinder to match its mating surface A to the punch mark B of the handlebar e The master cylinder clamp must be installed with the ar row mark C upward e Tighten the upper clamp bolt first and then the lower clamp bolt Torque Front Master Cylinder Clamp Bolts 11 N m 1 1 kgf m 97 in Ib e Replace the washers that are on each side of the hose fitting with new ones e Tighten Torque Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft lb e Bleed the brake line see Brake Line Bleeding e Check the brake for good braking power no brake drag and no fluid leakage Rear Master Cylinder Removal e Remove Brake Hose Banjo Bolt A Brake Hose B Cotter Pin C Joint Pin D Bolts E Foot Guard F Rear Master Cylinder e Slide out the clamp G e Pull off the reservoir hose lower end and drain the brake fluid into
366. ircuit If the amperage is equal to or greater than the fuse rating check the wiring and related components for a short circuit Housing A 8 20000151 6 Fuse Element B Terminals C Blown Element D NOTE OA mass current flows to the battery according to the state of the battery which needs refreshing charge when the engine is turned causing main fuse blown out CAUTION When replacing a fuse be sure the new fuse matches the specified fuse rating for that circuit Installation of a fuse with a higher rating may cause damage to wiring and components APPENDIX 17 1 Appendix Table of Contents Cable Wire and Hose ROUNO 17 2 Troubleshooting eed 17 60 17 2 APPENDIX Cable Wire and Hose Routing 4 3 bp AO 564 IP Ss APPENDIX 17 3 Cable Wire and Hose Routing 13 14 15 16 17 18 19 20 Air Cleaner Drain Hose Oil Pressure Switch Gear Position Switch Lead Air Bleeder Hose for Water Pump Sidestand Switch Lead Clamp Clamp the leads and hose as shown in the figure Air Switching Valve Hose Grommet Insert the air switching valve hose into the grommet until white paint mark on it is hidden a half Approx 41 mm 0 02 in Clamp First put the clamp on the idle adjusting screw as shown in the figure
367. ircuit as Check 2 e By pushing the upper button A each time check that the display B changes as follows OThis display is ordinary indication AVERAGE CURRENT RANGE gt BATTERY GP170800 5 GP17083CN3 C e By pushing the lower button A each time check that the display B changes as follows OThis display is ordinary indication also 000 gt TRIP A TRIP GP17015CN3 C the display function does not work replace the meter assembly Meter Gauge Indicator Unit e Push the upper button A and lower button B for more than two seconds e Check that the display changes to the language setting mode A OThis display is system menu indication e By pushing the lower button each time check that the display selects the ENGLISH or FRANCAIS xlf the display function does not work replace the meter assembly e By pushing the upper button each time at the language setting mode check that the display A selects as follows MILEAGE ENGAGE LAMP SHIFT LAMP ENGLISH FRANCAIS CLOCK LAMP MODE GP17554BN3 C xlf the display function does not work replace the meter assembly e Select the MILEAGE A indication e Push the upper button for more than two seconds check that the unit setting menu B flashes e By pushing the lower button each time check that the display changes as follows KM L L 100KM MP
368. ires e Check to see that the rim lines A on both sides of the tire sidewalls are parallel with the rim flanges If the rim flanges and tire sidewall rim lines are not parallel remove the valve core e Lubricate the rim flanges and tire beads e Install the valve core and inflate the tire again e After the tire beads seat in the rim flanges check for air leakage Olnflate the tire slightly above standard inflation OUse a soap and water solution or submerge the tire and check for bubbles that would indicate leakage e Adjust the air pressure to the specified pressure see Air Pressure Inspection in the Periodic Maintenance chap ter e Install the air valve cap e Adjust the wheel balance see Balance Adjustment Tire Repair Currently two types of repair for tubeless tires have come into wide use One type is called a temporary external re pair which can be carried out without removing the tire from the rim and the other type is called permanent internal repair which requires tire removal It is generally under stood that higher running durability is obtained by perma nent internal repairs than by temporary external ones Also permanent internal repairs have the advantage of permitting a thorough examination for secondary damage not visible from external inspection of the tire For these reasons Kawasaki does not recommend temporary exter nal repair Only appropriate permanent internal repairs are re
369. iron or other magnetic deposits be tween the sensor A and sensor rotor B and the sensor rotor slots for obstructions OCheck the installation condition of the sensor for loose ness OCheck the sensor and sensor rotor tip for deformation or damage e g chipped sensor rotor teeth x If the sensor and sensor rotor in bad condition remove the any deposits Install the properly or replace faulty part xlf the all correct proceed the 3rd step e Do the 3rd step test ORecheck the service code indication erase the service code perform the pre diagnosis inspection 1 and 2 and retrieve the service code xIf the ABS indicator light LED A lit faulty ECU in the ABS hydraulic unit Replace the ABS hydraulic unit xIf the ABS indicator light LED unlit ABS system is nor mal service code is not stored temporary failure Front Wheel Rotation Sensor Wiring Inspection Service Code 43 e Do the 1st step test ODisconnect the ABS hydraulic unit connector and front wheel rotation sensor connector OShort the brown and green lead terminals of the main har ness side connector A with a jumper lead and check for continuity between the brown and green lead terminals of the main harness side connector B If there is the continuity in the lead proceed the 2nd step xIf there is not the continuity the lead replace or repair the main harness BRAKES 12 51 6114135851 C 12 52 BRAKES Ant
370. is loose unscrew it apply a non permanent locking agent to the threads and tighten it Torque Shift Shaft Return Spring Pin 29 N m 3 0 kgf m 21 ft lb e Check the gear positioning lever B and its spring for breaks or distortion the lever or spring are damaged in way replace them e Visually inspect the shift drum cam C If they are badly worn or if they show any damage replace it Transmission Shaft Removal e Split the crankcase see Crankcase Splitting e Remove the output shaft A 9 40 CRANKSHAFT TRANSMISSION Transmission e Remove Cover Bolts A and Cover B Shift Forks see Shift Drum and Fork Removal Pull out the drive shaft Transmission Shaft Installation e Check to see that the set pin A and set ring B are in place e Install the output shaft into the upper crankcase half e Apply engine oil to the bearing OThe bearing set pin and ring must match properly with the hole or groove in the bearing outer races When they are properly matched there is no clearance between the crankcase and the bearing outer races e Install the drive shaft into the lower crankcase half e Apply grease to the O ring e Install the cover e Apply a non permanent locking agent to the threads of the drive shaft cover bolts A and tighten them Torque Drive Shaft Cover Bolts 25 N m 2 5 kgf m 18 ft Ib NOTE Olf the bearing for drive shaft pressed into the bearing cove
371. ise and unscrew the handlebar bolt A e Remove Handlebar Left Handlebar Grip Handlebar Installation e Apply adhesive cement to the inside of the left handlebar grip e Fit the pin A of the handlebar to the recess B of the handlebar holder e Apply a non permanent locking agent to the threads of the handlebar bolts e Tighten Torque Handlebar Bolts 34 N m 3 5 kgf m 25 ft Ib GNOGOBOBS1 C Handlebar e Install the handlebar holder with handlebar on the steering stem head e Tighten the handlebar holder bolts NOTE Tighten the handlebar holder bolt A first next the han dlebar holder bolt B OTighten the two handlebar holder bolts alternately two times to ensure even tightening torque Torque Handlebar Holder Bolts 25 N m 2 5 kgf m 18 ft Ib e Install the front master cylinder see Front Master Cylinder Installation in the Brakes chapter e Install Throttle Grip Throttle Cable Tips A Throttle Cases B OFit the projection into a hole in the handlebar e Apply a non permanent locking agent to the threads of the handlebar weight bolts and tighten them e Install the left and right switch housings OFit the projection A into a hole B in the handlebar Torque Switch Housing Screws 3 5 N m 0 36 kgf m 31 in Ib e Install the clutch lever see Clutch Lever Installation in the Clutch chapter STEERING 14 11 FRAME 15 1 Frame
372. itch operation inspect year e 2 47 Others Chassis parts lubricate year e 2 47 Bolts and nuts tightness inspect e 2 48 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 PERIODIC MAINTENANCE 2 5 Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY Whichever ODOMETER READING comes yy x 1 000 km first x 1 000 mile See 1 12 24 Page ITEM Every 0 6 7 5 12 15 24 30 Air cleaner element replace Every 18 000 km 12 000 mile 2 49 Fuel hose replace 4 years e 2 51 Coolant change 3 years 2 52 Radiator hose and O ring replace 3 years d 8 2 54 Clutch hose and pipe replace 4 years e 2 55 Clutch fluid change 2 years 2 56 2 oe master cylinder slave 4 years e 257 Engine oil change year e 2 58 Oil filter replace year e 2 59 Brake hose and pipe replace 4 years ERI e 2 60 Brake fluid change 2 years e 2 62 sed of brake master cylinder caliper 4 years M 1 Spark plug replace e e e e 2 68 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
373. ith new ones e Install the ball and needle bearings so that the manufac turer s marks face out Special Tools Bearing Driver Set 57001 1129 Needle Bearing Driver 528 B 57001 1610 28 57001 1663 8 06071851 C 13 26 SUSPENSION Swingarm e Install the needle bearings A ball bearing B and oil seals C position as shown in the figure Circlip D 32 mm 1 26 in E 17 mm 0 67 in F 27 5 mm 1 08 in G 9 5 mm 0 37 in H Swingarm Bearing Sleeve Inspection CAUTION Do not remove the bearings for inspection Re moval may damage them e Inspect the needle bearings A and ball bearing installed in the swingarm OThe rollers and ball in a bearing normally wear very little and wear is difficult to measure Instead of measuring visually inspect the bearing for abrasion discoloration or other damage If the needle bearing and sleeve B show any sings of abnormal wear discoloration or damage replace them as a set GMO61088W2 C SUSPENSION 13 27 Swingarm e Turn the bearing in the swingarm back and forth A while checking for plays roughness or binding lf bearing play roughness or binding is found replace the bearing e Examine the bearing seal B for tears or leakage xIf the seal is torn or is leaking replace the bearing Swingarm Bearing Lubrication NOTE OSince the bearings are packed with grease and s
374. ition inspect or re place the problem part Clutch Hose and Pipe Damage and Installation Condition Inspection e Inspect the clutch hoses and fittings for deterioration cracks corrosion and signs of leakage OThe high pressure inside of the clutch 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 exam ining it Replace it if any fraying cracks B or bulges C are no ticed e Check that the hoses are securely connected and banjo bolts are tightened correctly Torque Clutch Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft Ib e Inspect the clutch hose routing lf any clutch hose routing is incorrect run the hoses ac cording to Cable Wire and Hose Routing section in the Appendix chapter Replace the hose if the hose has been sharply bent or kinked M cy VES o Y er 6508004851 6 2 30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Wheels Tires Air Pressure Inspection e Remove the air valve cap e 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 e Install the air valve cap x Adjust the tire air pressure according to the specifications if necessary Air Pressure when Cold Front Up to 180 kg 397 Ib 290 kPa 2 9 kgf cm 42 psi Rear Up to 180 kg 397
375. itions e 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 the cylinder head is warped more than the service limit replace it xIf 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 GE14038BS1 C 5 26 ENGINE TOP END Valves Valve Clearance Inspection e Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter Valve Clearance Adjustment e Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter Valve Removal e Remove Cylinder Head see Cylinder Head Removal Valve Lifter And Shim OMark and record the valve lifter and shim locations so they can be installed in their original positions e Using the valve spring compressor assembly remove the valve Special Tools Valve Spring Compressor Assembly A 57001 241 Valve Spring Compressor Adapier 24 B 57001 1586 Valve Installation e Replace the oil seal with a new one e Apply a thin coat of molybdenum disulfide grease to the valve stem before valve installation e Install the springs so that the closed coil end faces down wards Valve Stem A Oil Seal B Spring Seat C Closed Coil End D Valve Spring E EX White Paint IN Red Paint Retainer F Split Keepers G
376. k or flame anywhere near the working area This in cludes any appliance with a pilot light Because of the danger or highly flammable liquids do not use gasoline or low flash point solvents to clean them CAUTION Immediately dry the bolts and nuts with com pressed air after cleaning Clean and dry the bolts and nuts completely CRANKSHAFT TRANSMISSION 9 19 Crankshaft and Connecting Rods e Install new bolts in reused connecting rods e Apply a small amount of molybdenum disulfide oil solution to the following Threads A of Nuts and Bolts Seating Surfaces B of Nuts and Connecting Rods e First tighten the nuts to the specified torque See the table below e Next tighten the nuts 120 5 OMark A the connecting rod big end caps and nuts so that nuts can be turned 120 B properly Connecting Torque Angle Bolt Nut Rod Assy N m 16 Attached to 21 6 2 2 16 Use the bolts new con rod 120 New attached to 21 6 2 2 16 new con rod 120 21 6 2 2 16 Replace the 120 Used bolts with new ones 21 6 2 2 16 120 Crankshaft Connecting Rod Cleaning e After removing the connecting rods from the crankshaft clean them with a high flash point solvent e Blow the crankshaft oil passages with compressed air to remove any foreign particles or residue that may have accumulated in the passages Connecting Rod Bend Inspection e Remove the connecting rod big
377. k the band B e Remove the battery cover C e Slide the red cap A out e Disconnect the positive cable B e Remove the battery tray with battery C e Disconnect the negative cable A e Remove the battery B from the battery tray Battery Battery Installation e Place the battery in the tray e Connect the negative cable to the battery e Apply a light coat of grease on the terminals to prevent corrosion e Insert the battery tray along with the battery into the bat tery compartment e Connect the positive cable to the battery e Cover the terminal with its red cap A e Install the battery cover on the battery and hook the band e Be sure insert the battery tray along with the battery into the battery compartment e Put the holes A of the bracket to the projections B of the battery tray e Tighten the bracket bolts e Connect the connector e Connect the negative cable to the frame e Put the projections of the battery compartment cover into the holes of the frame e Install Bolt with Washer Right Fairing Cover see Fairing Cover Installation in the Frame chapter Battery Activation Electrolyte Filling e Make sure that the model name A of the electrolyte con tainer matches the model name B of the battery These names must be the same Battery Model Name for ZX1400C D FTZ14 BS CAUTION Be sure to use the electrolyte container with t
378. l Gauge 57001 1290 7571290ST C Bearing Remover Head 20 x 22 57001 1293 7571293ST C Bearing Remover Shaft 13 57001 1377 ST5713778T Hook Wrench T 3 2 R37 57001 1522 2 75715228T 13 8 SUSPENSION Special Tools Fork Oil Seal Driver 43 57001 1530 7571530ST C Fork Spring Compressor 57001 1540 Fork Spring Compressor 57001 1587 7571540ST C 7571587ST C Swingarm Pivot Nut Wrench 57001 1597 875715975 C Jack Attachment E ul 7571608ST C Needle Bearing Driver 517 4918 57001 1609 875716095 C Needle Bearing Driver 28 57001 1610 GG 8 5716105 C Spacer 18 57001 1636 Nun T5716368T Spacer 28 57001 1663 ST571663ST C Needle Bearing Driver 620 amp Spacer 28 57001 1678 ST571678ST 6 SUSPENSION 13 9 Front Fork Rebound Damping Force Adjustment e To adjust the rebound damping force turn the rebound damping adjuster A until you feel a click OThe standard adjuster setting for the average build rider of 68 kg 150 Ib with no passenger and no accessories is the 5th click from the 1st click of the fully clockwise position WARNING If both adjusters are not adjusted equally handling may be impaired and a hazardous condition may result OThe damping force can be left s
379. l Pump Fuel Pump Circuit FUEL SYSTEM 3 109 m WR E 9818 1 ECU 10 Fuel Pump Relay 2 Joint Connector 3 11 ECU Main Relay 3 Fuel Pump 12 Relay Box 4 Frame Ground 1 13 Fuse Box 2 5 Frame Ground 2 14 ECU Fuse 15 A 6 Battery 12 V 14 Ah 15 Ignition Fuse 10 A 7 Joint Connector 2 16 Ignition Switch 8 Starter Relay 17 Engine Stop Switch 9 Main Fuse 30 A 18 Water proof Joint 1 3 110 FUEL SYSTEM DFI Fuel Injectors Fuel Injectors Removal Installation e Refer to the Throttle Body Assy Disassembly Assembly Fuel Injectors Power Source Voltage Inspection A NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Remove the ECU see ECU Removal ODo not disconnect the ECU connectors e Connect a digital meter A to the connector B using the needle adapter set Special Tool Needle Adapter Set 57001 1457 6617446651 Injector Power Source Voltage at ECU Connector Connections to ECU Connector Meter W R lead terminal 14 Meter Frame Ground 2 C e Measure the power source voltage with the engine stopped and with the connector joined e Turn the ignition switch ON Power Source Voltage at ECU Standard Battery Voltage for 3 seconds and then 0 V the power source voltage is less than the standard check the fuel pump relay see Fuel Pump R
380. l Removal in the Wheels Tires chapter e Measure the air gap between the sensor and sensor rotor at several points by turning the wheel slowly Thickness Gauge A Air Gap Standard Front 0 7 0 9 mm 0 028 0 035 in Rear 0 7 0 9 mm 0 028 0 035 in NOTE O The sensor air gap cannot be adjusted xIf the air gap is not within the specification inspect the hub bearing see Hub Bearing Inspection in the Wheels Tires chapter sensor installation condition and sensor see Wheel Rotation Sensor Inspection Wheel Rotation Sensor Rotor Inspection e Remove Wheels see Front Rear Wheel Removal in the Wheels Tires chapter Brake Disc Mounting Bolts A Sensor Rotor B 12 62 BRAKES Anti Lock Brake System Equipped Models e Visually inspect the wheel rotation sensor rotor the rotor is deformed or damaged chipped teeth A replace the sensor rotor with a new one If there is iron or other magnetic deposits B remove the deposits ABS Solenoid Valve Relay Fuse 20 A Removal e Refer to the Fuse Box Fuse Removal in the Electrical Sys tem chapter ABS Motor Relay Fuse 30 A Removal e Refer to the Fuse Box Fuse Removal in the Electrical Sys tem chapter ABS ECU Fuse 10 A Removal e Refer to the Fuse Box Fuse Removal in the Electrical Sys tem chapter Fuse Installation e f a fuse fails during operation inspect the electrical sys tem to determine the cause and then replace it with a new fus
381. l Tank Removal in the Fuel System DFI chapter e Unhook the insert portion A of the heat insulation rubber plate and turn up it e Remove Air Cleaner Element Cover Bolts A Air Cleaner Element Cover B e Discard the air cleaner element A e Install a new element A so that screen side B faces upward CAUTION Use only the recommended air cleaner element Kawasaki part number 11013 0014 Using another air cleaner element will wear the engine prema turely or lower the engine performance e Install the air cleaner element cover A so that arrow mark B faces forward e Tighten Torque Air Cleaner Element Cover Bolts 6 9 N m 0 70 kgf m 61 in Ib e Install the removed parts see appropriate chapters PERIODIC MAINTENANCE 2 51 Periodic Maintenance Procedures Fuel Hose Replacement e Pull out the throttle body assy A from the holder see Throttle Body Assy Removal in the Fuel System DFI chapter e Be sure to place a piece of cloth B around the fuel hose joint e Push the joint lock claws C e Pull A the joint lock B as shown in the figure e Pull the fuel hose joint C out of the delivery pipe e Remove the throttle body assy see Throttle Body Assy Removal in the Fuel System DFI chapter Pull out the fuel hose to forward A WARNING Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is
382. l cause deterioration of the rubber parts Oil spilled on any part will be diffi cult to wash off completely and will eventually de teriorate the rubber used in the disc brake e Apply brake fluid to the new parts and to the inner wall of the cylinder e Take care not to scratch the piston or the inner wall of the cylinder e Apply silicone grease to the brake lever pivot bolt e Tighten the brake lever pivot bolt and the locknut Torque Brake Lever Pivot Bolt 1 0 N m 0 10 kgf m 8 9 in Ib Brake Lever Pivot Bolt Locknut 5 9 N m 0 60 kgf m 52 in Ib Caliper Rubber Parts Replacement Front Caliper Disassembly e Loosen the front caliper pad pins A and banjo bolt B and tighten them loosely e Remove Front Caliper C see Front Caliper Removal in the Brakes chapter Brake Pads see Front Brake Pad Removal in the brakes chapter Front Caliper Assembly Bolts O ring e Using compressed air remove the pistons One way to remove the pistons is as follows Olnstall a rubber gasket A and a wooden board B more than 10 mm 0 4 in thick on the caliper half and fas ten them together with a suitable bolt and nut as shown Leave one of the oil passages C open OLightly apply compressed air D to the oil passage until the pistons hit the rubber gasket Block the hose joint opening E during this operation if the caliper half has the opening Bolt F and Nut Push down G 9513152851
383. l wear inspect Wheel bearing damage inspect year Final Drive Drive chain lubrication condition inspect Every 600 km 400 mile 2 31 2 4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY Whichever ODOMETER READING comes yy x 1 000 km first x 1 000 mile See 4 1 6 12 16 24 ao 36 age ITEM Every 0 6 4 7 5 12 15 20 24 Drive chain slack inspect Every 1 000 km 600 mile 2 32 Drive chain wear inspect e 2 33 Drive chain guide wear inspect e 2 34 Brakes ee leak brake hose and pipe year e 2 35 Brake hose and pipe damage inspect year e 2 36 Brake hose installation condition inspect year e 2 36 2 effectiveness play no drag year e 2 36 Brake fluid level inspect 6 months e 2 36 Brake pad wear inspect e 2 37 Brake light switch operation inspect e 2 38 Suspension Front forks rear shock absorber operation damping and smooth stroke inspect i dicus shock absorber leak year e 2 39 Rocker arm operation inspect e 2 39 Tie rods operation inspect e 2 39 Steering Steering play inspect year e 2 40 Steering stem bearings lubricate 2 years e 2 41 Electrical System Lights and switches operation inspect year e e e 2 42 Headlight aiming inspect year e 2 45 Sidestand switch operation inspect year e 2 46 Engine stop sw
384. lacement in the Periodic Maintenance chapter e Remove Oil Pan Bolts A Oil Pan B Gasket e Remove Oil Screen A Oil Pipe B Oil Pressure Relief Valve C If necessary CAUTION Do not remove the relief valve with the oil pipe in stalled on the lower crankcase half The oil pipe will be damaged Oil Pan Installation e Clean the oil screen A e Install the oil screen so that the crankcase rib B fits the notch C of the oil screen e Apply grease to the oil pipe O rings and install the oil pipe xIf the oil pressure relief valve was removed install it OApply a non permanent locking agent to the threads of the oil pressure relief valve and tighten it CAUTION Do not apply too much non permanent locking agent to the threads This may block the oil pas sage Torque Oil Pressure Relief Valve 15 N m 1 5 kgf m 11 ft Ib 7 10 ENGINE LUBRICATION SYSTEM Oil Pan e Install the brackets A as shown in the figure e Replace the oil pan gasket B with a new one e Tighten Torque Oil Pan Bolts 9 8 N m 1 0 kgf m 87 in Ib e Install the removed parts see appropriate chapters N SS Y LB Rati GG06025BS1 C ENGINE LUBRICATION SYSTEM 7 11 Oil Pressure Relief Valve Oil Pressure Relief Valve Removal e Refer to the Oil Pan Removal Oil Pressure Relief Valve Installation e Refer to the Oil Pan Inst
385. lack white lead termi nal of the main harness side connector A and black white lead terminal of the main harness side connector B there is the continuity in the lead replace the ABS hy draulic unit lf there is not the continuity in the lead replace or repair the main harness 6114126851 C ABS Indicator Light LED Lights When the Motorcycle is Running No Service Code e Do the 1st step test ODisconnect the ABS hydraulic unit connector and meter connector OCheck for continuity between the black white lead termi nal of the main harness side connector A and black white lead terminals of the main harness side connector A Special Tool Hand Tester 57001 1394 there is the continuity in the lead replace the ABS hy draulic unit xIf there is not the continuity the lead replace or repair the main harness 6114126851 C Solenoid Valve Inspection Service Code 13 14 17 18 e Do the 1st step test ORecheck the service code indication erase the service code perform the pre diagnosis inspection 1 and 2 and retrieve the service code x lf the ABS indicator light LED A lit faulty solenoid valve in the ABS hydraulic unit Replace the ABS hydraulic unit xIf the ABS indicator light LED unlit ABS system is nor mal service code is not stored temporary failure 6114288851 C ABS Solenoid Valve Relay Inspection Service Code 19 e Do the 1st st
386. ld see Windshield Removal Vehicle down Sensor Lead Connector Immobilizer Amplifier Lead Connector Equipped Mod els Bracket Screws A Both Sides e Disconnect Headlight Lead Connectors A Both Sides City Light Lead Connectors B Both Sides e Remove the bolts A Pull out the upper fairing forward Upper Fairing Disassembly e Remove Upper Fairing see Upper Fairing Removal Upper Inner Fairing see Upper Inner Fairing Removal Nuts A and Rear View Mirrors Both Sides Headlights B see Headlight Removal Installation in the Electrical System chapter Upper Fairing Assembly e Installation is the reverse of removal 15 14 FRAME Fairings Upper Fairing Installation e Installation is the reverse of removal Inner Cover Removal e Remove Bolts A Inner Cover B OPull the inner cover backward and clear the hooks Inner Cover Installation e Insert the hooks A into the slots B e Tighten the bolts Upper Inner Fairing Removal e Remove Upper Fairing see Upper Fairing Removal Bolt A Upper Inner Fairing B OSlide out the upper inner fairing backward FRAME 15 15 Fairings Upper Inner Fairing Installation e Insert the slots A of the upper inner fairing into the hooks B of the upper fairing e Tighten the bolt Upper Fairing Bracket Removal e Remove Upper Fairing see Upper Fairing Removal Front and Middle Inlet Ducts see Front and Middle Inle
387. lenishing it as necessary Olf the fluid in the reservoir runs completely out any time during bleeding the bleeding operation must be done over again from the beginning since air will have en tered the line A WARNING Do not mix different grades and brands of fluid e Remove the clear plastic hose e Tighten the bleed valve and install the rubber cap Torque Clutch Slave Cylinder Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib e Install Diaphragm Diaphragm Plate Clutch Reservoir Cap CLUTCH 6 11 6508804 P 6 12 CLUTCH Clutch Fluid e Follow the procedure below to install the clutch fluid reser voir cap correctly OFirst tighten the clutch 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 clutch fluid reservoir body A e Install the clamp and screw e Tighten Torque Clutch Reservoir Cap Stopper Screw 1 2 N m 0 12 kgf m 11 in Ib e After bleeding the clutch line check the clutch for good clutching effectiveness and no fluid leakage necessary bleed the air from the line again Clutch Hose Removal Installation e Refer to the Clutch Hose and Pipe Replacement in the Periodic Maintenance chapter Clutch Hose Inspection e Refer to the Clutch Hose and Pipe Damage and Instal lation Condition Inspection in the Periodic Maintenance chapter
388. lenoid valve trouble shorted or 1 JIUUL oFF open stuck valve ON ON 14 n Rear outlet solenoid valve trouble shorted ON or open stuck valve ON 17 Front inlet solenoid valve trouble shorted ON or open stuck valve ON 18 n RRRRRRRIL Front outlet solenoid valve trouble shorted ON or open stuck valve ON 19 fL RRRRRRRRUIL ABS solenoid valve relay trouble wiring ON shorted or open stuck relay ON or OFF Front rear tire abnormal substandard 25 tire deformation wheel sensor rotor teeth ON number wrong 35 nnn_nnnnn ABS motor relay trouble wiring shorted ON open or lock stuck relay ON or OFF Front wheel rotation sensor signal abnormal 42 sensor or rotor missing too large ON clearance rotor tooth worn or missing 43 nanan nnn Front wheel rotation sensor wiring abnormal ON wiring shorted or open Rear wheel rotation sensor signal abnormal 44 sensor or rotor missing too large ON clearance rotor tooth worn or missing 45 nmm nmmnmn Rear wheel rotation sensor wiring abnormal ON wiring shorted or open 52 nnnnn nn Power supply voltage abnormal ON under voltage 53 SU Power supply voltage abnormal ON over voltage 55 ECU trouble ECU operation abnormal ON 12 46 BRAKES Anti Lock Brake System Equipped Models ABS Indicator Light LED Inspection e Turn the ignition switch ON xIf the ABS indicator light LED A lights it is normal lf the ABS indica
389. les in DFI system igni tion system and immobilizer system by lighting up or blink ing the warning indicator light LED A and displaying the warning message B and warning symbol C alternately on the LCD Liquid Crystal Display when DFI ignition and immobilizer system parts are faulty and initiates fail safe function In case of serious troubles ECU stops the injec tion ignition starter motor operation Dealer Mode The LCD Liquid Crystal Display display the service code s A to show the problem s which the DFI system ignition system and immobilizer system has at the moment of diagnosis ERROR cour 31 oo 1109 _ 12 00 3 38 FUEL SYSTEM DFI Self Diagnosis Self diagnosis Procedures OWhen a problem occurs with DFI system and ignition sys tem the warning indicator light LED A goes on and FI warning message B and FI warning symbol C are dis played alternately on the LCD Liquid Crystal Display to alert the rider OFor models equipped with an immobilizer system the warning indicator light LED A blinks and immobilizer warning message and immobilizer warning symbol C are alternately displayed on the LCD when a problem occurs in the system I ms N 0 i x 1105 _ FUEL SYSTEM DFI 3 39 Self Diagnosis e Turn the ignition switch ON e Push the upper button A and lower button B for more than two seconds e The service code C
390. lic unit before removing the brake line so that brake fluid does not leak on the parts e Remove the brake pipe joint nuts A B C D e Tape the brake line opening to prevent brake fluid leakage or contamination by foreign matter CAUTION Brake fluid quickly ruins painted plastic surfaces any spilled fluid should be completely washed away immediately 148146 P Anti Lock Brake System Equipped Models e Disconnect the connector A OUnlock the joint lock B as shown in the figure e Remove the bolts A e Remove the ABS hydraulic unit with bracket e Remove the bolts A and bracket B CAUTION with precision at the factory Do not try to disas semble and repair the ABS hydraulic unit The ABS hydraulic unit has been adjusted and set ABS Hydraulic Unit Installation e Install the ABS hydraulic unit to the bracket CAUTION Brake fluid quickly ruins painted plastic surfaces any spilled fluid should be completely washed away immediately e Insert the bolts A into the grommets B e Run the lead correctly and fix the connector A securely OLock the joint lock B as shown in the figure BRAKES 12 57 P 12 58 BRAKES Anti Lock Brake System Equipped Models e Install the brake pipes correctly as shown in the figure 48 A 71 B 30 C 38 5 D e Tighten the joint nuts Torque Brake Pipe Joint Nuts 18 1
391. litting e Unscrew Balancer Shaft Clamp Bolt A Balancer Shaft Clamp Lever Bolt B e Remove the front balancer C from the lower crankcase half D Front Balancer Installation e Check that the rubber dampers A are in place as shown in the figure e Apply molybdenum disulfide oil solution to the damper contact portions of the balancer weight e Install the balancer weight A into the gear B OAlign the mark C of the balancer weight to the groove D of the gear e Apply molybdenum disulfide oil solution to the needle bearings Insert the needle bearings e Fit the copper washers A on both ends of the weight and gear assembly The projected sides B face inward 6106040551 CRANKSHAFT TRANSMISSION 9 31 Balancer e Position the crankshaft at 2 3 position TDC e Insert the pin A as shown in the figure e Set the front balancer on the upper crankcase half OAlign the punch mark B on the balancer gear C with the mark D on the balancer drive gear E of crankshaft 61068078 1 C e Assemble the crankcase see Crankcase Assembly e Install the new oil seal A so that its surface B is flush with the surface of the crankcase C the oil seal lips with grease e Tighten the balancer shaft clamp lever bolt D Torque Balancer Shaft Clamp Lever Bolts 25 N m 2 5 kgf m 18 16 e Turn the balancer shaft so that its mark E is aligned with the crankcas
392. lt B Rocker Arm Nut and Bolt C Rocker Arm D SUSPENSION 13 29 Tie Rod Rocker Arm Rocker Arm Installation e Apply grease to the inside of the oil seals e Tighten Torque Uni Trak Rocker Arm Nut 34 N m 3 5 kgf m 25 ft Ib Tie Rod Nuts 59 N m 6 0 kgf m 44 16 Rear Shock Absorber Nut Lower 34 N m 3 5 kgf m 25 ft lb e Install the removed parts see appropriate chapters Tie Rod and Rocker Arm Bearing Removal e Remove Tie Rods see Tie Rod Removal Rocker Arm see Rocker Arm Removal Sleeves A Oil Seals B Swingarm C see Swingarm Removal e Remove the needle bearings D using the bearing re mover head and bearing remover shaft Special Tools Bearing Remover Head 20 x 22 57001 1293 Bearing Remover Shaft 13 57001 1377 GM070598W2 C Tie Rod and Rocker Arm Bearing Installation e Replace the needle bearings and oil seals with new ones e Apply plenty of grease to the lips of the oil seals e Install the needle bearings and oil seals position as shown in the figure 13 30 SUSPENSION Tie Rod Rocker Arm OScrew the needle bearing driver A into the driver holder B Olnsert the needle bearing driver into the needle bearing C and press the needle bearing into the housing until the driver contacts the end surface of the housing Bearing Pressing Depth 5 5 mm 0 22 in D 5 0 mm 0 20 in E NOTE OFor a bearing of inner diameter 18 select the pressing s
393. lve Lifter Ahead G OWhen positioning 1 piston TDC at the end of the compression stroke Inlet Valve Clearance of 1 and 3 Cylinders Exhaust Valve Clearance of 1 and 2 Cylinders Measuring Valve A OWhen positioning 4 piston TDC at the end of the compression stroke Inlet Valve Clearance of 2 and 4 Cylinders Exhaust Valve Clearance of 3 and 4 Cylinders Measuring Valve A the valve clearance is not within the specified range first record the clearance and then adjust it Valve Clearance Adjustment e To change the valve clearance remove the camshaft chain tensioner camshafts and valve lifters Replace the shim with one of a different thickness NOTE OMark and record the locations of the valve lifters and shims so that they can be reinstalled in their original positions 6507024851 C OQ uec 6507016851 CH etm GSO7015BS1 C 7112170 6507022851 Periodic Maintenance Procedures PERIODIC MAINTENANCE 2 25 OBisides the standard shims in the valve clearance adjust ment charts the following additional shims maybe used Adjustment Shims Part Number Thickness 92025 1982 2 425 mm 92025 1983 2 475 mm 92025 1984 2 525 mm 92025 1985 2 575 mm 92180 1058 2 375 mm 92180 1059 2 625 mm 92180 1194 2 675 mm 92180 1195 2 725 mm 92180 1196 2 775 mm 92180 0209 2 025 mm 92180 0210 2 075 mm 92180 0211 2 125 mm 92
394. ly to ABS Motor Relay 10 ABS Kawasaki Self diagnosis System Terminal 11 Unused 12 Power Supply to Front Wheel Rotation Sensor 13 ABS Self diagnosis Terminal 14 Unused 15 Unused 16 Power Supply 17 Unused 18 Rear Wheel Rotation Sensor Signal 19 Unused 20 Unused 21 ABS Indicator Light LED 22 Unused 23 Unused 24 Ground 25 Ground to Motor Anti Lock Brake System Equipped Models ABS Servicing Precautions There are a number of important precautions that should be followed servicing the ABS system OThis ABS 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 ODo not reverse the battery cable connections This will damage the ABS hydraulic unit OTo prevent damage to the ABS parts do not disconnect the battery cables or any other electrical connections when the ignition switch is ON or while the engine is running OTake care not to short the leads that are directly con nected to the battery positive terminal to the chassis ground ODo not turn the ignition switch ON while any of the ABS electrical connectors are disconnected The ABS hy draulic unit memorizes service codes ODo not spray water on the electrical parts ABS parts con nectors leads and wiring Olf a transceiver is installed on the motorcycle make sure that the operation of the ABS system i
395. m 6 0 kgf m 44 ft Ib Rear Shock Absorber Inspection e Remove the rear shock absorber see Rear Shock Ab sorber Removal e Visually inspect the following items Smooth Stroke Oil Leakage Crack or Dent If there is any damage to the rear shock absorber replace it e Visually inspect the rubber bushing lf it show any signs of damage replace it 13 22 SUSPENSION Rear Shock Absorber Rear Shock Absorber Scrapping A WARNING Since the reservoir tank of the rear shock absorber contains nitrogen gas do not incinerate the reser voir tank without first releasing the gas or it may explode e Remove the reservoir shock absorber see Rear Shock Absorber Removal e Drill the hole of the reservoir tank using about 2 mm 0 08 in drillbit WARNING Since the high pressure gas is dangerous do not point the drill toward your face or body SUSPENSION 13 23 Swingarm Swingarm Removal e Remove Chain Cover see Drive Chain Removal in the Final Drive chapter Rear Wheel see Rear Wheel Removal in the Wheels Tires chapter Bolts A Brackets B e Remove Upper Tie Rod Nut and Bolt A Rear Shock Absorber B see Rear Shock Absorber Re moval e Unscrew the swingarm pivot shaft nut A e Unscrew the swingarm pivot shaft locknut A using the nut wrench B Special Tool Swingarm Pivot Nut Wrench 57001 1597 e Unscrew the swingarm pivot shaft A few times OTurn out
396. m B headlights should go on e The high beam indicator light LED C should go on x lf the high beam headlight and or high beam indicator light LED does not go on inspect or replace the following item Headlight High Beam Bulb see Headlight Bulb Replace ment in the Electrical System chapter Headlight Fuse High 15 A see Fuse Inspection in the Electrical System chapter Headlight Relay Fuse 10 A see Fuse Inspection in the Electrical System chapter Passing Button Equipped Models see Switch Inspec tion in the Electrical System chapter Dimmer Switch see Switch Inspection in the Electrical System chapter Headlight Circuit Relay in Relay Box see Relay Circuit Inspection in the Electrical System chapter Headlight Relay High see Headlight Relay Inspection in the Electrical System chapter Harness see Wiring Inspection in the Electrical System chapter e Turn off the engine stop switch e The low beam and high beam headlights should stay go ing on x If the headlights and high beam indicator light LED does go off inspect or replace the following item Headlight Circuit Relay in Relay Box see Relay Circuit Inspection in the Electrical System chapter e Turn off the ignition switch e The headlights and high beam indicator light LED should go off 9517111851 PERIODIC MAINTENANCE 2 45 Periodic Maintenance Procedures Headlight Aiming Inspection e Inspect the headlight beam fo
397. mL 19 0 40 135 US oz If necessary measure the oil level as follows the inner tube vertically in a vise OUsing the piston rod puller A move the piston rod B up and down more than ten times in order to expel all the air from the fork oil Special Tool Fork Piston Rod Puller M12 x 1 25 57001 1289 ORemove the piston rod puller OWait until the oil level settles OWith the fork fully compressed and the piston rod fully pushed in insert a tape measure or rod into the inner tube and measure the distance from the top of the inner tube to the oil Oil Level fully compressed without spring Standard 88 2 mm 3 46 0 08 in from the top of the inner tube NOTE OFork oil lever may also be measured using the fork oil level gauge Special Tool Fork Oil Level Gauge A 57001 1290 OWith the fork fully compressed and without fork spring insert the gauge tube into the inner tube B and position the stopper across the top end C of the inner tube OSet the gauge stopper D so that its lower side shows the oil level distance specified E OPull the handle slowly to pump out the excess oil until the oil no longer comes out If no oil is pumped out there is insufficient oil in the inner tube Pour in enough oil then pump out the excess oil as shown above v 6 04042851 C 8 04021351 C GM04363BS2 C Front Fork e Screw the fork piston rod pulle
398. main throttle sensor connector A e Connect the harness adapter A between the harness connector and main throttle sensor connector Special Tool Throttle Sensor Setting Adapter 57001 1538 e Connect a digital meter to the harness adapter leads Main Throttle Sensor Input Voltage Connections to Adapter Meter W sensor BL lead Meter gt BK sensor BR BK lead e Measure the input voltage with the engine stopped and with the connector joined e Turn the ignition switch ON Input Voltage at Sensor Standard DC 4 75 5 25 V e Turn the ignition switch OFF xlf the reading is out of the range check the wiring see wiring diagram in this section the reading is good check the output voltage of the sensor FUEL SYSTEM 3 47 Main Throttle Sensor Service Code 11 Main Throttle Sensor Output Voltage Inspection e Measure the output voltage at the ECU in the same way as input voltage inspection Note the following Digital Meter A Connector B Special Tool Needle Adapter Set 57001 1457 Main Throttle Sensor Output Voltage Connections to ECU Connector Meter Y W lead terminal 26 6617146081 Meter BR BK lead terminal 34 e Start the engine and warm it up thoroughly e Check idle speed to ensure throttle opening is correct Idle Speed Standard 1 100 r min rpm xIf the idle speed is out of the specified range adjust the idle speed s
399. mbly 9 44 Piston Wear Inspection 9 28 Shift Drum Assembly 9 44 Piston Ring Piston Ring Groove Shift Fork Bending Inspection 9 45 Wear Inspection 9 28 Shift Fork Gear Groove Wear Piston Ring Groove Width Inspection os oae hierba s 9 45 e E toits 9 29 Shift Fork Guide Pin Drum Piston Ring Thickness Inspection 9 29 Groove Wear Inspection 9 45 Piston Ring End Gap Inspection 9 29 Gear Dog and Gear Dog Hole Balancer i a denote dads 9 30 Damage Inspection 9 45 Front Balancer Removal 9 30 9 2 CRANKSHAFT TRANSMISSION Exploded View EB LI CRANKSHAFT TRANSMISSION 9 3 Exploded View No Fastener Remarks N m kgf m ft Ib 1 Bearing Position Plate Screws 4 9 0 50 43 in Ib L 2 Breather Cover Bolts 9 8 1 0 87 3 Breather Plate Screws 9 8 1 0 87 L 4 Connecting Rod Big End Nuts see the text lt lt 5 Bolts 10 L 120 mm 47 4 8 35 S 6 5 7 Bolts M8 L 80 mm 27 2 8 S 8 Crankcase Bolts M8 L 70 mm 27 2 8 S 9 Crankcase Bolt M7 L 110 mm 20 2 0 S 10 Crankcase Bolt M7 L 85 mm 20 2 0 S 5 12 Crankcase Bolts M7 L 60 mm 20 2 0 S 13 Crankcase Bolt M7 L 50 mm 20 2 0 S 14 Crankcase Bolts M7
400. mbly Order In most cases assembly order is the reverse of disassem eT die bly however if assembly order is provided in this Service ee i o Manual follow the procedures given E gt Sa GN 227 mi NS bw 2 21 f 68020118 S 1 4 GENERAL INFORMATION Before Servicing Tightening Sequence Generally when installing a part with several bolts nuts or screws start them all in their holes and tighten them to a snug fit Then tighten them according to the specified se quence 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 quar ter turn and then remove them If the specified tightening sequence is not indicated tighten the fasteners alternating diagonally Tightening Torque Incorrect torque applied to a bolt nut or screw may lead to serious damage Tighten fasteners to the specified torque using a good quality torque wrench Force Use common sense during disassembly and assembly excessive force can cause expensive or hard to repair dam age 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
401. n adjuster turned fully clockwise GMO4358BS1 C 13 10 SUSPENSION Front Fork Spring Preload Adjustment e Turn the spring preload adjuster A to change spring preload setting OThe standard adjuster setting for the average build rider of 68 kg 150 Ib with no passenger and no accessories is the 15 mm 0 59 in B from top as shown in the figure Adjuster Protrusion from top Standard 15 mm 0 59 in Usable Range 4 19 mm 0 16 0 75 in WARNING If both adjusters are not adjusted equally handling may be impaired and a hazardous condition may result OThe spring preload can be left soft for average riding But it should be adjusted harder for high speed riding or riding with a passenger If the spring action feels too soft or too stiff adjust it in accordance with the following table Spring Action Adjuster Damping Position Force Setting Load Road Speed ji T T 1 Strong Hard Heavy Bad High Front Fork Removal Each Fork Leg e Remove Middle Fairings see Middle Fairing Removal in the Frame chapter Front Wheel see Front Wheel Removal in the Wheels Tires chapter Front Fender see Front Fender Removal in the Frame chapter Loosen the upper front fork clamp bolt A and fork top plug B beforehand if the fork leg is to be disassembled NOTE OLoosen the top plug after loosening the upper front fork clamp bolt
402. n Connecting rod bent Piston pin piston pin hole worn Valve noise Valve clearance incorrect Valve spring broken or weak Camshaft bearing worn Valve lifter worn Other noise Connecting rod small end clearance exces sive Connecting rod big end clearance exces sive Piston ring groove clearance excessive Troubleshooting Guide APPENDIX 17 63 Piston ring worn broken or stuck Piston ring groove worn Piston seizure damage Cylinder head gasket leaking Exhaust pipe leaking at cylinder head con nection Crankshaft runout excessive Engine mount loose Crankshaft bearing worn Primary gear worn or chipped Camshaft chain tensioner trouble Camshaft chain sprocket guide worn Air suction valve damaged Air switching valve damaged Alternator rotor loose Catalytic converter melt down due to muffler overheating KLEEN Abnormal Drive Train Noise Clutch noise Clutch damper weak or damaged Clutch housing friction plate clearance ex cessive Clutch housing gear worn Wrong installation of outside friction plate Transmission noise Bearings worn Transmission gear worn or chipped Metal chips jammed in gear teeth Engine oil insufficient Drive line noise Drive chain adjusted improperly Drive chain worn Rear and or engine sprocket worn Chain lubrication insufficient Rear wheel misaligned Abnormal Frame Noise Front fork noise Oil insufficient or too thin Spring weak or broken Rear shock absorber noise Shock
403. n at the sensor connector Main Throttle Sensor Service Code 11 e Disconnect the main throttle sensor connector and con nect the harness adapter A between the harness con nector and main throttle sensor connector Special Tool Throttle Sensor Setting Adapter 57001 1538 e Connect a digital meter to the harness adapter leads Main Throttle Sensor Output Voltage Connections to Adapter Meter R sensor Y W lead Meter gt BK sensor BR BK lead e Measure the output voltage with the engine stopped and with the connector joined e Turn the ignition switch ON e Measure the output voltage when the throttle is fully opened or completely closed Output Voltage at Sensor Standard DC 0 63 3 91 V at idle throttle opening to full throttle opening NOTE OThe main throttle sensor is operating correctly if the fol lowing voltages are obtained DC 0 63 V or slightly higher with the throttle at the idle position DC 3 91 V or slightly lower with the throttle at the fully open position NOTE OThe standard voltage refers to the value when the volt age reading at the Input Voltage Inspection shows 5 V exactly OWhen 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 63 x 4 75 5 00 0 60 V 3 91 4 75 5 00 3 71 V Thus the valid range is 0 60 3 71 V e Turn the ignition switch OFF If the reading is out o
404. n position e Turn the ignition switch ON OThe fuel pump will turn for 3 seconds and then stop NOTE OAfter turning on the engine stop switch and ignition switch inspect the fuel leakage from the connected portion of the special tools CAUTION Do not drive the fuel pump 3 seconds or more with out the fuel in the fuel tank If the fuel pump is driven without the fuel it may be damaged FUEL SYSTEM 3 103 3 104 FUEL SYSTEM DFI Fuel Line e Start the engine and let it idle e Measure the fuel pressure with the engine idling Fuel Pressure with Engine Idling Standard 294 kPa 3 0 kgf cm 43 psi NOTE OThe gauge needle will fluctuate Read the pressure at the average of the maximum and minimum indications e Turn the ignition switch OFF x If the fuel pressure is much higher than specified replace the fuel pump because the fuel pressure regulator in the fuel pump have been clogged or stuck the fuel pressure is much lower than specified check the following Fuel Line Leakage see Fuel Injector Fuel Line Inspec tion Amount of Fuel Flow see Fuel Flow Rate Inspection e After above checks measure the fuel pressure again e Remove the fuel pressure gauge hoses and adapter e Install Fuel Hose see Fuel Hose Replacement in the Periodic Maintenance chapter Fuel Tank see Fuel Tank Installation e Start the engine and check for fuel leakage Fuel Flow Rate Inspection A WA
405. nal Indicator Light LED 2 Shift Up Indicator Light LED G 3 High Beam Indicator oo Light LED G 4 Neutral Indicator Light LED 16 LL 5 Warning Indicator Light LED 6 Left Turn Signal Indicator a Light LED 7 Illumination Light LED 8 Fuel Level Gauge 9 Water Temperature Gauge 10 Tachometer 11 Speedometer 12 Gil Pressure Warning Indicator Light LED Front Right Turn Signal Light 12V21W Right City Light 12 58 Headlight HI 2 12 654 BRAY wy Headlight LO 12V55W Headlight LO 12V55W wv BK Y Saar TY BLY BRZY Headlight HI H gs 285 25 12658 Left City Light 12V5W SE 55 Headlight Headlight 4 Left Switch Housin Relay Lo Relay Hi Horn Button Front Left Turn Signal a Fuel 2 Hazard Button Light 12V21W aky 15251 3 Turn Signal Switch ou 4 Dimmer Switch Fuse Sensor 5 Starter Lockout Switch Bort Box 2 6 Passing Buttoni 1 Fuse Box 2 i Turn Signal Relay Fuse 10A 1 Fan Fuse 15 2 Headlight Relay Fuse 10 2 ECU Fuse 15 3 Taillight Fuse 10A 3 Oxygen Sensor Heater Fuse 10A 4 Horn Fuse 10A 4 Ignition Fuse 5 Headlight Fuse Hi 15A 8 Headlight Fuse Lo 15 LEFT SWITCH HOUSING CONNECTIONS Turn Signal Switch Color BK WBK Color GY Color GY R BK BL Y R Y LEER T BL Y R BK Clutch Lever Push T
406. ncer shaft D and then align the balancer gear with the starter motor clutch gear e Install the new oil seal A so that its surface B is flush with the surface of crankcase C the oil seal lips with grease e Tighten the balancer shaft clamp lever bolt D Torque Balancer Shaft Clamp Lever Bolts 25 N m 2 5 kgf m 18 16 e Turn the balancer shaft so that its mark E is in position as shown in the figure e Tighten the balancer shaft clamp bolt F Torque Balancer Shaft Clamp Bolts 9 8 N m 1 0 kgf m 87 in Ib 6106025851 C 9 34 CRANKSHAFT TRANSMISSION Balancer Balancer Adjustment e First adjust the front balancer A next the rear balancer B OFor the front balancer adjustment remove the left middle fairing see Middle Fairing Removal in the Frame chap ter e Start the engine and warm it up thoroughly e Adjust the balancer gear backlash with the engine idling The amount of backlash can be changed by turning the balancer shaft which has eccentric journals OStart the engine and let it idle OLoosen the clamp bolt C and turn the balancer shaft D clockwise E until the balancer gear makes a whin ing sound OTurn the shaft counterclockwise F until the balancer gear whining sound disappears and tighten the clamp bolt Torque Balancer Shaft Clamp Bolts 9 8 N m 1 0 kgf m 87 in Ib Balancer Damper Inspection e Remove the balancer and disassemble the weight and ge
407. nd OWhen charging remove the battery from the motorcycle This is to prevent ECU damage by excessive voltage OWhenever the DFI electrical connections are to be dis connected first turn off the ignition switch and disconnect the battery terminal Do not pull the lead only the con nector Conversely make sure that all the DFI electrical connections are firmly reconnected before starting the en gine OConnect these connectors until they click A ODo not turn the ignition switch ON while any of the DFI electrical connectors are disconnected The ECU memo rizes service codes not spray water on the electrical parts DFI parts con nectors leads and wiring Olf 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 OWhen 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 ODo not operate the fuel pump if the pump is completely dry This is to prevent pump seizure OBefore removing the fuel system parts blow the outer sur faces of these parts clean with compressed air OWhen 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
408. nd Tester 57001 1394 e Make sure all connectors in the circuit are clean and tight and examine leads for signs of burning fraying etc Dete riorated leads and bad connections can cause reappear ance of problems and unstable operation of the DFI sys tem xIf any wiring is deteriorated replace the wiring FUEL SYSTEM DFI 3 27 6617037351 6 3 28 FUEL SYSTEM DFI Troubleshooting the DFI System e Pull each connector A apart and inspect it for corrosion dirt and damage x lf the connector is corroded or dirty clean it carefully If it is damaged replace it Connect the connectors securely e Check the wiring for continuity OUse the wiring diagram to find the ends of the lead which is suspected of being a problem OConnect the hand tester between the ends of the leads OSet the tester to the x 1 O range and read the tester lf the tester does not read 0 the lead is defective Re place the lead or the main harness or the subharness Olf both ends of a harness A are far apart ground B the one end C using a jumper lead D and check the con tinuity between the end E and the ground F This en ables to check a long harness for continuity If the harness is open repair or replace the harness OWhen 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 gro
409. nd until the diameter is within the spec ified range Widened Width A of engagement by machining with 45 cutter Ground Volume B by 32 cutter 32 C Correct Width D Ground Volume E by 60 cutter 60 F e Measure the outside diameter of the seating surface with a vernier caliper x 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 ORemove all pittings of flaws from 45 ground surface OAfter grinding with 45 cutter apply thin coat of machin ist s dye to seating surface This makes seating surface distinct and 32 and 60 grinding operation easier OWhen the valve guide is replaced be sure to grind with 45 cutter for centering and good contact lf the outside diameter A of the seating surface is too large make the 32 grind described below x lf the outside diameter of the seating surface is within the specified range measure the seat width as described be low e Grind the seat at a 32 angle B until the seat outside diameter is within the specified range OTo make the 32 grind fit a 32 cutter into the holder and slide it into the valve guide OTurn the holder 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 pre vent overgrind
410. nder this title follow ing its sale and delivery to the ultimate purchaser NOTE OThe 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 de vices or elements of design in order to perform maintenance 2 Tampering could include a Maladjustment of vehicle components such that the emission standards are ex ceeded 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 stan daras 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
411. nds after entering the self diagnosis mode 1 If no service code is shown drive at 20 km h 12 mph or more for one minute stop and try self diagnosis again Check the faulty point with the service code table and repair according to fault inspection 1 to 14 Erase the service code memorized in the ABS hydraulic unit Start the self diagnosis mode to confirm that erasing has been completed Disconnect the ABS self diagnosis terminal to the ground terminal ending the self diagnosis mode Activate the ABS by driving the motorcycle at 20 km h 12 mph or NG lit above in order to confirm that the ABS is normal Repeat self diagnosis OK Activate the ABS at a safe place in order to confirm that it operates normally 2 OK End 1 The self diagnosis mode ends following When the ignition switch is OFF When the motorcycle is driven while in the self diagnosis mode When the self diagnosis terminal disconnects 2 Apply brake suddenly at 30 km h 19 mph or more to confirm that the motorcycle stops smoothly and steady with pulsation on the brake lever and pedal GLI4113B 12 44 BRAKES Anti Lock Brake System Equipped Models How to Read Service Codes OService codes are shown by a series of long and short blinks of the ABS indicator light LED as shown below ORead 10th digit and unit digit as the ABS indicator light LED blinks OWhen there are a number of faults a maximum of all service
412. ne or stores the vapors in a canister when the engine is stopped Al though no adjustments are required a thorough visual in spection must be made at the intervals specified by the Pe riodic Maintenance Chart Parts Removal Installation A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF 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 CAUTION If gasoline solvent water or any other liquid enters the canister the canister s vapor absorbing capac ity is greatly reduced If the canister does become contaminated replace it with a new one e To prevent the gasoline from flowing into or out of the canister hold the separator perpendicular to the ground e Connect the hoses according to the diagram of the sys tem Make sure they do not get pinched or kinked Hose Inspection e Refer to the Evaporative Emission Control System In spection in the Periodic Maintenance chapter Separator Inspection e Refer to the Evaporative Emission Control System In spection in the Periodic Maintenance chapter FUEL SYSTEM 3 137 Evaporative Emission Control System CAL SEA and TH Models Separator Operation Test WARNING Gasoline is extremely flammable be ex plosive under certain conditions Turn the ignition switch OFF Do
413. necting Rod Removal 9 16 Starter Motor Clutch Disassembly 9 35 Connecting Rod Installation 9 16 Starter Motor Clutch Assembly 9 36 Crankshaft Connecting Rod Starter Clutch Inspection 9 36 Cleaning tits octets 9 19 Torque Limiter Removal 9 36 Connecting Rod Bend Inspection 9 19 Torque Limiter Installation 9 37 Connecting Rod Twist Inspection 9 20 TranNSM SS ON eerie rese 9 38 Connecting Rod Big End Side Shift Pedal Removal 9 38 Clearance Inspection 9 20 Shift Pedal Installation 9 38 Connecting Rod Big End External Shift Mechanism Bearing Insert Crankpin Wear s 9 38 INSpECtiOn 9 20 External Shift Mechanism Crankshaft Side Clearance Installation e 9 39 9 22 External Shift Mechanism Crankshaft Runout Inspection 9 23 InSpeCctlori 9 39 Crankshaft Main Bearing Transmission Shaft Removal 9 39 Insert Journal Wear Inspection 9 23 Transmission Shaft Installation 9 40 PISTONS ace 9 26 Transmission Shaft Disassembly 9 41 Piston Removal 9 26 Transmission Shaft Assembly 9 41 Piston Installation 9 27 Shift Drum and Fork Removal 9 44 Cylinder Wear Upper Crankcase Shift Drum and Fork Installation 9 44 Inspection 9 28 Shift Drum Disasse
414. ng A e Apply brake fluid to the outside of the pistons and push them into each cylinder by hand e Be sure to install the O ring e Apply a non permanent locking agent to the threads of the front caliper assembly bolts and tighten them Torque Front Caliper Assembly Bolts 27 N m 2 8 kgf m 20 ft lb 6513153851 C 8105040251 6 6513154851 C 2 66 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Install the pads see Front Brake Pad Installation in the Brakes chapter e Wipe up any spilled brake fluid on the caliper with wet cloth Rear Caliper Disassembly e Loosen the rear caliper pad pin A and banjo bolt B and tighten them loosely e Remove Rear Caliper C see Rear Caliper Removal in the Brakes chapter Brake Pads see Rear Brake Pad Removal in the Brakes chapter Rear Caliper Assembly Bolts O ring e Remove the left side piston as follows e Removal of the left side piston is the same as for the front caliper Left Side Caliper A Rubber Gasket B Wooden Board C Bolt D and Nut Apply compressed air E A WARNING To avoid serious injury never place your fingers or palm in rear of the piston If you apply compressed air into the caliper the piston may crush your hand or fingers e Remove the right side piston as follows e Using the rear caliper assembly bolt A remove the pis ton B as shown in the figure 9513155851
415. nge in the Periodic Maintenance chapter Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Throttle Body Assy see Throttle Body Assy Removal in the Fuel System DFI chapter Clamp Screw A Loosen Water Hose B Air Bleeder Hoses C Thermostat Housing Mounting Bolts D Thermostat Housing E e Remove Thermostat Housing Cover Bolts A Thermostat Housing Cover B Thermostat 00008057 P Thermostat Installation e Install the thermostat A in the housing so that the air bleeder hole B is on top e Install a new O ring into the housing e Tighten the thermostat housing cover bolts and the ther mostat housing mounting bolts Torque Thermostat Housing Cover Bolts 5 9 N m 0 60 kgf m 52 in Ib Thermostat Housing Mounting Bolts 9 8 N m 1 0 kgf m 87 in lb e Install the water hose and tighten the clamp screw Torque Radiator Water Hose Clamp Screws 2 0 N m 0 20 kgf m 18 in Ib e Fill the radiator with coolant see Coolant Change in the Periodic Maintenance chapter Thermostat Inspection e Remove the thermostat see Thermostat Removal and inspect the thermostat valve A at room temperature the valve is open replace the thermostat with a new one Thermostat e To check valve opening temperature suspend the ther mostat A in a container of water and raise the tempera ture of the water OThe thermostat must be completely submerged and must not touch the container sides or
416. ngine Ground Sidestand Switch Unused Ground Oxygen Sensor Heater Equipped Models Injector 4 Stick Coil 4 Injector 2 Stick Coil 2 KDS Kawasaki Diagnostic System External Communication Line Immobilizer KDS Immobilizer Amplifier Equipped Models Unused Air Switching Valve Engine Ground Starter Lockout Switch Unused Starter Button Unused Injector 3 Stick Coil 3 Injector 1 Stick Coil 1 Unused Immobilizer Amplifier Equipped Models Immobilizer Amplifier Equipped Models Unused FUEL SYSTEM DFI 3 15 KDS that runs on Windows personal computer PC is used as the diagnostic tool for motorcycle with Kawasaki DFI system 3 16 FUEL SYSTEM DFI Parts Location Main Throttle Sensor A Subthrottle Sensor B Subthrottle Valve Actuator C Water Temperature Sensor D Battery E Fuel Injectors 1 2 4 A Relay Box Fuel Pump Relay A Immobilizer Kawasaki Diagnostic System Connector B Atmospheric Pressure Sensor C ECU D Fuse Box ECU Fuse 15 A E Stick Coils 1 2 3 4 A Inlet Air Temperature Sensor A FUEL SYSTEM DFI 3 17 DFI Parts Location Camshaft Position Sensor A Crankshaft Sensor B Oxygen Sensor C Equipped Models y TP iy in s M 5 ET be Speed Sensor A Gear Position Switch B Ignition Key Transponder Immobilizer Equipped Mod els A Ignition
417. ngs A lf any spring is shorter than the service limit it must be replaced Clutch Spring Free Length Standard 65 0 mm 2 56 in Service Limit 62 0 mm 2 44 in GF06060381 C ENGINE LUBRICATION SYSTEM 7 1 Engine Lubrication System Exploded View Engine Oil Flow Chart Specifications eden tiet pene Special Tools and Sealant Engine Oil and Oil Filter Oil Level Inspection Engine Oil Change Oil Filter Replacement Oil Vp Oil Pan Removal Oil Pan Installation Oil Pressure Relief Valve Table of Contents Oil Pressure Relief Valve Removal mH rm nemen nenne rne nernn nenne Oil Cooler Remowval Oil Cooler Installation Oil Pressure Measurement Oil Pressure Measurement Oil Pressure Switch Oil Pressure Switch Removal Oil Pressure Switch Installation 7 2 7 6 7 7 7 8 7 8 7 8 7 8 7 9 7 9 7 11 7 11 7 11 7 11 7 12 7 12 7 12 7 14 7 14 7 14 7 15 7 15 7 16 7 16 7 16 7 2 ENGINE LUBRICATION SYSTEM Exploded View Exploded View ENGINE LUBRICATION SYSTEM 7 3 No Fastener conde Remarks N m kgf m ft Ib 1 Engine Oil Drain Bolt 30 3 1 22 2 Oil Cooler
418. nication Line Resistance Inspection in the Fuel System DFI chapter Example Immobilizer System see Immobilizer Amplifier and Blank Key Detection section in the Fuel System DFI chapter Atmospheric Pressure Sensor see Atmospheric Pres sure Sensor Service Code 15 section in the Fuel Sys tem DFI chapter ORefer to Troubleshooting the DFI System section in the Fuel System DFI chapter for other DFI parts xlf the above items are good replace the meter assembly and or ECU m 175938 5 e By pushing the upper button A each time check that the display changes the error messages B only ODuring this operating the symbols do not appear OThe warning indicator light LED keeps flashing LM vc i IMMOBILIZER 1 il ERROR Ri if m oa Pee 130 t amp T ian H MC 1 i Tom zanih b i ON 6 71106 16 84 ELECTRICAL SYSTEM Meter Gauge Indicator Unit e Push the upper and lower buttons for more than two sec onds check that each ERROR CODE A and numbers appears in the display OThe warning indicator light LED keeps flashing e Again push the upper and lower buttons for more than two seconds check that the display returns the warning message indication OThe warning indicator light LED keeps flashing If the display function does not work replace the meter assembly Check
419. ning 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 ve hicle disassembly can cause excessive wear and decrease performance of the vehicle GENERAL INFORMATION 1 3 Before Servicing Arrangement and Cleaning of Removed Parts Disassembled parts are easy to confuse Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly Storage of Removed Parts After all the parts including subassembly parts have been cleaned store the parts in a clean area Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re assembly Inspection Reuse of worn or damaged parts may lead to serious ac cident Visually inspect removed parts for corrosion discol oration 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 be yond its service limit Replacement Parts Replacement parts must be KAWASAKI genuine or 3 recommended by KAWASAKI Gaskets O rings oil seals Xs grease seals circlips or cotter pins must be replaced with new ones whenever disassembled 68020108 Asse
420. nk see Fuel Tank Removal in the Fuel System DFI chapter Battery see Battery Removal in the Electrical System chapter Upper Fairing see Upper Fairing Removal in the Frame chapter Brake Pipe Joint Nuts A Bolts B Brackets C e There are washers on each side of the brake hose fitting Replace them with new ones when installing e Tighten Torque Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft Ib Brake Pipe Joint Nuts 18 N m 1 8 kgf m 13 ft Ib ABS Equipped Models e When installing the hoses avoid sharp bending kinking flatting or twisting and run the hoses according to Cable Wire and Hose Routing section in the Appendix chapter e Fill the brake line after installing the brake hose see Brake Fluid Change 2 62 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Fluid Change NOTE OThe procedure to change the front brake fluid is as fol lows Changing the rear brake fluid is the same as for the front brake e Level the brake fluid reservoir e Remove the reservoir cap and diaphragm e Remove the rubber cap from the bleed valve A on the caliper e Attach a clear plastic hose B to the bleed valve and run the other end of the hose into a container e Fill the reservoir with fresh specified brake fluid e Change the brake fluid ORepeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes 1 Open the bleed valve A 2 Apply
421. nspect and Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 replace fuel pump or kinked fuel line Inspect and replace fuel pump see chapter 3 Fuel injector trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Backfiring when deceleration Spark plug dirty broken or gap maladjusted Inspect and replace see chapter 16 Fuel pressure too low Inspect see chapter 3 Fuel pump trouble Inspect see chapter 3 Main throttle sensor trouble Inspect see chapter 3 Subthrottle sensor trouble Inspect see chapter 3 Subthrottle valve actuator trouble Inlet air pressure sensor trouble Inspect see chapter 3 Atmospheric pressure sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inlet air temperature sensor trouble Inspect and replace see chapter 16 Air switching valve trouble Air suction valve trouble Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect and replace see chapter 5 After fire Replace see chapter 2 Spark plug burned or gap maladjusted Fuel injector trouble Inlet air pressure sensor trouble Atmospheric pressure sensor trouble Inspect see chapter 3 Inspect see chapter 3 Inspect
422. nt 4 8 5 2 mm 0 19 0 20 in 4 5 mm 0 18 in Rear 5 8 6 2 mm 0 23 0 24 in 5 5 mm 0 22 in Runout TIR 0 15 mm 0 006 in or less TIR 0 3 mm 0 01 in Brake Fluid Grade DOT4 BRAKES 12 13 Special Tools Inside Circlip Pliers Hand Tester 57001 143 57001 1394 7570143ST C 7571394ST C Jack Jack Attachment 57001 1238 57001 1608 7571238ST C 7571608ST C 12 14 BRAKES Brake Lever Brake Pedal Brake Lever Position Adjustment The brake lever adjuster has 6 positions so that the brake lever position can be adjusted to suit the operator s hand e Push the lever forward and turn the adjuster A to align the number with the arrow mark B on the lever holder OThe distance from the grip to the lever is minimum at num ber 6 and maximum at number 1 Brake Pedal Position Inspection e Check that the brake pedal A is in the correct position Footpeg B Pedal Position Standard About 45 mm 1 77 in C below top of footpeg xf it is incorrect adjust the brake pedal position Brake Pedal Position Adjustment NOTE OUsually it is not necessary to adjust the pedal position but always adjust it when push rod locknut has been loosened e Loosen the locknut A and turn the push rod with the hex head B to achieve the correct pedal position the length C shown is 80 1 mm 3 15 0 04 in the pedal position will be within the standard range
423. nuity in the lead proceed the 4th step x lf there is not the continuity in the lead replace or repair the main harness GL14127BS1 Lc GL14128BS1 GL14129BS1 GL14130BS1 BRAKES 12 49 Anti Lock Brake System Equipped Models e Do the 6th step test ORecheck the service code indication erase the service code perform the pre diagnosis inspection 1 and 2 and retrieve the service code xIf the ABS indicator light LED A lit faulty ABS solenoid valve relay in the ABS hydraulic unit Replace the ABS hydraulic unit lf the ABS indicator light LED unlit ABS system is nor mal service code is not stored temporary failure 6114288851 C Front Rear Wheel Rotation Difference Abnormal Service Code 25 e Do the 1st step test OCheck the following and correct the faulty part Incorrect the tire pressure Tires not recommended for the motorcycle were installed incorrect tire size Deformation of the wheel or tire Sensor rotor for missing teeth and clogging with foreign matter lf the all parts correct proceed the 2nd step e Do the 2nd step test O Recheck the service code indication erase the service code perform the pre diagnosis inspection 1 and 2 and retrieve the service code xIf the ABS indicator light LED A lit fa
424. ny two leads the stator has an open lead and must be replaced Much less than this resistance means the stator is shorted and must be replaced e Using the highest resistance range of the hand tester measure the resistance between each of the black leads and chassis ground Any hand tester reading less than infinity lt indicates a short necessitating stator replacement xIf the stator coils have normal resistance but the voltage check showed the alternator to be defective then the rotor magnets have probably weakened and the rotor must be replaced ELECTRICAL SYSTEM 16 37 16 38 ELECTRICAL SYSTEM Charging System Regulator Rectifier Inspection e Remove Right Seat Cover see Seat Cover Removal in the Frame chapter Connectors A Bolts B Regulator Rectifier C e Set the hand tester to the x 1 range and make the measurements shown in the table Special Tool Hand Tester 57001 1394 e Connect the hand tester to the regulator rectifier the tester readings are not as specified replace the regulator rectifier CAUTION Use only Kawasaki Hand Tester 57001 1394 for this test A tester other than the Kawasaki Hand Tester may show different readings If a megger or a meter with a large capacity battery is used the regulator rectifier will be damaged Regulator Rectifier Resistance Unit kQ Tester Lead Connection Terminal BK1 BK2 BK3 BK Y w 20 300 20
425. o not start the engine under misfire due to spark plug fouling or poor connection of the stick coil For KLEEN do not coast the motorcycle with the ignition switch off Turn the igni tion switch ON and run the engine ECU trouble Fuel air mixture incorrect Throttle body assy holder loose Air duct holder loose Air cleaner poorly sealed or missing 17 62 APPENDIX Troubleshooting Guide Air cleaner clogged Compression high Carbon built up in combustion chamber Engine load faulty Clutch slipping Engine oil level too high Engine oil viscosity too high Drive train trouble Brake dragging Lubrication inadequate Engine oil level too low Engine oil poor quality or incorrect Oil cooler incorrect Oil cooler clogged Gauge incorrect Water temperature gauge broken Water temperature sensor broken Coolant incorrect Coolant level too low Coolant deteriorated Wrong coolant mixed ratio Cooling system component incorrect Radiator fin damaged Radiator clogged Thermostat trouble Radiator cap trouble Radiator fan relay trouble Fan motor broken Fan blade damaged Water pump not turning Water pump impeller damaged Over Cooling Gauge incorrect Water temperature gauge broken Water temperature sensor broken Cooling system component incorrect Thermostat trouble Clutch Operation Faulty Clutch slipping Friction plate worn or warped Steel plate worn or warped Clutch spring broken or weak Clutch hub or
426. o stop the engine and discon nect the hand tester lf the charging voltage is kept between the values given in the table the charging system is considered to be working normally the charging voltage is much higher than the values specified in the table the regulator rectifier is defective or the regulator rectifier leads are loose or open If the charging voltage does not rise as the engine speed increases then the regulator rectifier is defective or the alternator output is insufficient for the loads Check the alternator and regulator rectifier to determine which part is defective ELECTRICAL SYSTEM 16 39 16 40 ELECTRICAL SYSTEM Charging System Charging System Circuit GPO91658W2 C Ignition Switch Regulator Rectifier Alternator Load Main Fuse 30 A Frame Ground 1 Battery 12 V 14 Ah Joint Connector 1 Frame Ground 2 Engine Ground ELECTRICAL SYSTEM 16 41 Ignition System WARNING The ignition system produces extremely high volt age Do not touch the spark plugs or stick coils while the engine is running or you could receive a severe electrical shock CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition switch is ON or while the engine is running This is to pre vent ECU damage Do not install the battery backwards The negative side is grounded
427. o the cutter with washing oil NOTE ODo 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 OPrior to grinding apply engine oil to the cutter and dur ing 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 Cutter angle SA DID poitea Outer diameter of cutter C Operating Procedures e Clean the seat area carefully e Coat the seat with machinist s dye e Fit a 45 cutter into the holder and slide it into the valve guide e 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 cylin der head must be replaced 8 15011851 C Valves e Measure the outside diameter of the seating surface with a vernier caliper x lf the outside diameter of the seating surface is too small repeat the 45 gri
428. ode 24 section in the Fuel System DFI chapter If the above items are good replace the meter assembly and or ECU d 2 12 00 RET ri AVERAGE L Z 1 es Ip IT 120 wx 220 diftus 241 3 AN f Ikeo Q EX s we O 6 71126 Kawasaki I filaverace B E mr 12 34 MS y Yi 6 71136 5 Meter Gauge Indicator Unit Check 22 Other Inspection OThe following items are displayed while running AVERAGE CURRENT RANGE Engage Lamp Shift Lamp Indication e When the above item is faulty indication check the follow ing items Wiring see Wiring Inspection CAN Communication Line Resistance see Check 1 and CAN Communication Line Resistance Inspection in the Fuel System DFI chapter Fuel Injectors see Fuel Injectors section in the Fuel Sys tem DFI chapter Speed Sensor see Speed Sensor Service Code 24 section in the Fuel System DFI chapter Crankshaft Sensor see Crankshaft Sensor Inspection Fuel Level Sensor see Fuel Level Sensor Inspection Fuel Reserve Switch see Fuel Reserve Switch Inspec tion lf the above items are good replace the meter assembly and or ECU ELECTRICAL SYSTEM 16 85 16 86 ELECTRICAL SYSTEM Meter Ga
429. oe eise eee toe eda 3 97 ECU Power Supply InspeGtiOn ouod cei erar SR bte SR e nb de tae e ce eda 3 98 CAN Communication Line Resistance Inspection pp 3 100 Warning Indicator Light 3 102 Light LED Inspeollon E A A eee 3 102 Fuer Dig soo aate OE a m 3 103 Fuel Pressure InspOCllOFt ated GOD iade haies cd en aed iux eed eee 3 103 Fuel Flow Rate Inspection tM 3 104 Fuel PUMP 3 107 Fuel Pump Remoyal Serre sae oos Ee tate tie deeded ait 3 107 Fuel Pump Installation 2 22 aera 3 107 Fuel Pump Operation Inspection rette E err det eter n Eu Lex eR 3 108 Fuel Pump Operating Voltage Inspection pp 3 108 Fuel Inject S 2 3 110 Fuel Injectors 3 110 Fuel Injectors Power Source Voltage Inspection 440 3 110 FUEL SYSTEM DFI 3 3 Fuel Injector Output Voltage Inspection 3 111 Fuel Injector Audible Inspection e erroe pe Len 3 112 Fuel Injector Signal Test ete peret tree tfe et rp pte 3 113 Fuel Injector Resistance Inspection eerte mand ete x 3 114 Eel TS ST 3 114 Fuel Injector F
430. of the main harness side connector A and yellow lead ter minal of the main harness side connector B lf there is the continuity in the lead proceed the 2nd step x lf there is not the continuity in the lead inspect the ABS ECU fuse 10 A see Fuse Inspection in the Electrical System chapter and replace or repair the main harness e Do the 2nd step test OConnect the ignition switch connector and ABS hydraulic unit connector OCheck the battery terminal voltage connect the hand tester to the brown terminal of ignition switch connector A and ground Special Tool Hand Tester 57001 1394 OTurn the ignition switch ON Battery Terminal Voltage Standard 16 V or less the battery terminal voltage is not within the specifica tion proceed the 3rd step the battery terminal voltage correct proceed the 4th step e Do the 3rd step test OCheck the battery condition and regulator rectifier see Charging Condition Inspection Regulator Rectifier In spection in the Electrical System chapter e Do the 4th step test ORecheck the service code indication erase the service code perform the pre diagnosis inspection 1 and 2 and retrieve the service code xIf the ABS indicator light LED A lit faulty ECU in the ABS hydraulic unit Replace the ABS hydraulic unit xIf the ABS indicator light LED unlit ABS system is nor mal service code is not stored temporary failure BRAKES 12 55
431. of Joint 2 Crankshaft Sensor Subthrottle Sensor Main Throttle Sensor Water proof Joint 1 16 52 ELECTRICAL SYSTEM Electric Starter System Starter Motor Removal CAUTION Do not tap the starter motor shaft or body Tapping the shaft or body could damage the motor e Remove Engine Sprocket Cover see Engine Sprocket Removal in the Final Drive chapter Left Middle Fairing see Middle Fairing Removal in the Frame chapter Bolts A Reserve Tank Bolts see Coolant Change in the Periodic Maintenance chapter e Take off the heat insulation rubber plate A e Slide out the rubber cap B e Remove the starter motor cable terminal nut C e Remove the starter motor mounting bolts A e Pull out the starter motor B from the left side Starter Motor Installation CAUTION Do not tap the starter motor shaft or body Tapping the shaft or body could damage the motor e Clean the starter motor legs A and crankcase B where the starter motor is grounded e Replace the O ring C with a new one e Apply grease to the new O ring e Tighten Torque Starter Motor Mounting Bolts 9 8 N m 1 0 kgf m 87 in Ib ELECTRICAL SYSTEM 16 53 Electric Starter System e Install the starter motor cable A side by side with starter motor B e Tighten Torque Starter Motor Cable Terminal Nut 5 9 N m 0 60 kgf m 52 in Ib e Slide back the rubber cap C to the original position e Install the removed parts
432. of the piston at a right angle to the direction of the piston pin If the measurement is under service limit replace the pis ton Piston Diameter Standard 83 959 83 974 mm 3 3055 3 3061 in Service Limit 83 81 mm 3 2996 in Piston Ring Piston Ring Groove Wear Inspection e Check for uneven groove wear by inspecting the ring seat ing The rings should fit perfectly parallel to groove surfaces If not replace the piston and all the piston rings e With the piston rings in their grooves make several mea surements with a thickness gauge A to determine piston ring groove clearance Piston Ring Groove Clearance Standard Top 0 03 0 07 mm 0 0012 0 0028 in Second 0 02 0 06 mm 0 0008 0 0024 in Service Limit Top 0 17 mm 0 0067 in Second 0 16 mm 0 0063 in 91058017 GE16063BS1 9105198851 C GE16182BS1 CRANKSHAFT TRANSMISSION 9 29 Pistons Piston Ring Groove Width Inspection e Measure the piston ring groove width OUse vernier caliper at several points around the piston Piston Ring Groove Width E Standard Top A 0 92 0 94 mm 0 0362 0 0370 in Second B 1 01 1 03 mm 0 0398 0 0406 in Service Limit Top A 1 02 mm 0 040 in Second B 1 11 mm 0 044 in xIf the width of any of the two grooves is wider than the service limit at any point replace the piston 6 16070751 6
433. oft for average riding But Counterclockwise Clockwise it should be adjusted harder for high speed riding or riding Softer t Harder with a passenger If the damping feels too soft or too stiff STD adjust it in accordance with the following table i 1110987654321 Rebound Damping Force Adjustment Ec 459 Adjuster Damping Position Force Seated position adjuster turned fully clockwise GMO4357BS1 C T T T T T T 4 i l 0 Strong Hard Heavy Bad High Compression Damping Force Adjustment e To adjust the compression damping force turn the com pression damping adjuster A until you feel a click OThe standard adjuster setting for the average build rider of 68 kg 150 Ib with no passenger and no accessories is the 10th click from the 1st click of the fully clockwise position A WARNING If both adjusters are not adjusted equally handling may be impaired and a hazardous condition may result OThe damping force can be left soft for average riding But Counterclockwise Clockwise it should be adjusted harder for high speed riding or riding Softer t Harder with a passenger If the damping feels too soft or too stiff STD adjust it in accordance with the following table 131211109 8 76 5 4 3 2 1 Compression Damping Force Adjustment DSL LEE E E 1 Damping Setting Load Road Speed Position Force Seated positio
434. ol Needle Adapter Set 57001 1457 Amplifier Input Voltage as ae Connections to Connector gt g N Meter BR W lead Meter BK Y lead e 2 Wy e Measure the input voltage with the engine stopped and with the connector joined e Turn the ignition switch ON Input Voltage Standard Battery Voltage e Turn the ignition switch OFF If the reading is out of the range check the wiring see wiring diagram in next section xIf the reading is within the standard check the wiring to ECU see wiring diagram in next section xIf the wiring is good replace the amplifier see Immobi lizer System Parts Replacement in the Electrical System chapter 3 84 FUEL SYSTEM Blank Key Detection Service Code 36 Equipped Models e This code appears in the following conditions OThe transponder A in the master and or user key is mal function OWhen the spare key of unregistration is used OWhen the master key is registered in the registered ECU e Therefore the service code 36 will disappear when the above issue is solved User Key Inspection e Register the user key correctly see Key Registration in the Electrical System chapter If the service code 36 appears again the transponder in the key is malfunction replace it Immobilizer System Circuit Par paN Tione battery ri IU JL i GY BL SSS O
435. ol Steering Stem Nut Wrench C 57001 1100 e Remove Steering Stem D Upper Ball Bearing Inner Race and Ball Bearing STEERING 14 7 Steering Stem e To remove the ball bearing outer races A pressed into the head pipe B insert a bar C into the recesses D of head pipe and applying it to both recess alternately hammer it to drive the race out NOTE Olf either steering stem bearing is damaged it is recom mended that both the upper and lower bearings includ ing outer races should be replaced with new ones e Remove the lower ball bearing inner race with its oil seal A which is pressed onto the steering stem with a suitable commercially available chisel B Stem Stem Bearing Installation e Replace the bearing outer races with new ones e Drive them into the head pipe at the same time Special Tools Head Pipe Outer Race Press Shaft A 57001 1075 Bearing Driver Set 57001 1129 Head Pipe Outer Race Driver 55 B 57001 1446 e Apply grease to the outer races e Replace the bearing inner races and oil seal with new ones e Apply grease to the oil seal e Install the oil seal A on the steering stem and drive the lower ball bearing inner race B applied the grease onto the stem Special Tools Steering Stem Bearing Driver 642 5 C 57001 1344 Steering Stem Bearing Driver Adapter 41 5 D 57001 1345 e Install the lower ball bearing A onto the stem e Grease the following Inner and O
436. oltage using the following formula and chart Suppose Pg Vacuum Pressure Gauge of Throttle Body Local Atmospheric Pressure absolute measured by a barometer Pv Vacuum Pressure absolute of Throttle Body Vv Sensor Output Voltage V then Pv PI Pg For example suppose the following data is obtained Pg 8 cmHg Vacuum Gauge Reading 70 cmHg Barometer Reading Vv 3 2 V Digital Meter Reading then Pv 70 8 62 cmHg absolute Plot this Pv 62 cmHg at a point 1 on the chart and draw a vertical line through the point Then you can get the usable range 2 of the sensor output voltage Usable range 3 08 3 48 V Plot Vv 3 2 V on the vertical line Point 3 Results In the chart Vv is within the usable range and the sensor is normal FUEL SYSTEM 3 55 6617119852 C 3 56 FUEL SYSTEM Inlet Air Pressure Sensor Service Code 12 V E Z fou 7 1 0 7 P4 7 P4 NET GPS 222 A V Gf 10 20 30 40 50 60 70 76 80 90 cmHg 2 1 1 1 1 20 40 60 80 101 32 120 kPa Ps lt gt 70 gt P abs 68017120844 C ID Idling Pv Throttle Vacuum Pressure Absolute Ps Standard Atmospheric Pressure Absolute ST Standard of Sensor Output Voltage V TO Throttle Full Open UR Usable Range of Sensor Output Voltage V Vv Inle
437. olts Upper 20 N m 2 0 kgf m 15 ft lb Steering Stem Head Nut 78 N m 8 0 kgf m 58 ft Ib Front Fork Clamp Bolts Lower 30 N m 3 1 kgf m 22 ft lb A WARNING Do not impede the handlebar turning by routing the cables harnesses and hoses improperly see Ca ble Wire and Hose Routing section in the Appen dix chapter e Install the removed parts see appropriate chapters 6 05060451 C 9515034851 STEERING 14 9 Steering Stem Steering Stem Bearing Lubrication e Refer to the Steering Stem Bearing Lubrication in the Pe riodic Maintenance chapter Steering Stem Warp Inspection e Whenever the steering stem is removed or if the steering can not be adjusted for smooth action check the steering stem for straightness If the steering stem A is bent replace the steering stem 8 05065851 C Stem Cap Deterioration Damage Inspection hHReplace the stem if its oil seal A shows damage 14 10 STEERING Handlebar Handlebar Removal e Remove Clutch Lever Clamp Bolts A Clutch Lever Assembly B Left Switch Housing C Handlebar Weight D e Remove Front Master Cylinder A see Front Master Cylinder Re moval in the Brakes chapter Right Switch Housing B Throttle Case C Handlebar Weight D Throttle Grip E e Unscrew the handlebar holder bolts A e Remove each handlebar holder B with handlebar C e Hold the handlebar in a v
438. on e Check if the weight portion has any play on the blade A and clip B lf it does discard it WARNING If the balance weight has any play on the rib of the rim the blade and or clip have been stretched Re place the loose balance weight Do not reuse used balance weight Unbalanced wheels can create an unsafe riding condition Balance Weight Part Number Weight 41075 0007 10 g 0 35 oz 41075 0008 20 g 0 71 oz 41075 0017 30 g 1 06 oz NOTE OBalance weights are available from Kawasaki dealers in 10 20 and 30 grams 0 35 0 71 and 1 06 oz sizes An imbalance of less than 10 grams 0 35 oz will not usually affect running stability ODo not use four or more balance weight more than 90 gram 3 2 oz If the wheel requires an excess balance weight disassemble the wheel to find the cause GJ04158BS2 C WHEELS TIRES 10 13 Wheels Rims e Slip the balance weight A on the rib B by pushing or lightly hammering C the clip D C Olnstall the balance weight at the left side of the motorcycle Left Side E A Right Side F A 215 0 B e Check that the blade A and clip B are fully seated on the rim C and that the clip is hooked over the rib D Left Side E Right Side F 6404160852 10 14 WHEELS TIRES Tires Air Pressure Inspection Adjustment e Refer to the Air Pressure Inspection in the Periodic Main ten
439. on or off as desired by holding the Mode and Reset buttons down for two seconds within twenty seconds of switching the ignition off e f all coded keys master key and user keys are lost the ECU and ignition switch will have to be replaced e The immobilizer system can not function until the master key code is registered in the ECU e A total of six keys can be registered in the ECU at any one time one master key and five user keys e f the master key is lost it is not possible to register new user keys Operational Cautions Do not put two keys of any immobilizer system on the same key ring Do not submerge any key in water Do not expose any key to excessively high temperature Do not place any key close to magnet Do not place a heavy item on any key Do not grind any key or alter its shape Do not disassemble the plastic part of any key Do not drop the key and or apply any shocks to the key When a user key is lost the user should go to his dealer to invalidate the lost key registration in the ECU 10 When the master key is lost the user should go to his dealer and have a new ECU installed and register a new master key and user keys 9 60 SIO MIU ORI s NOTE 9 and 10 are strongly recommended to the customer to ensure security of the motorcycle Key Registration Case 1 When the user key has been lost or additional spare user key is required e Prepare a new spare user key e Cut the key in accordance with
440. onnect the terminal 9 e Push the upper and lower buttons more than 2 seconds within 20 seconds after the terminal 9 disconnected e Check that the warning light LED goes on one second and then the light starts flashing Immobilizer Warning Light Flashing Mode the meter function does not work replace the meter assembly Check 6 High Beam Indicator Light LED Inspection e Connect the leads in the same circuit as Check 2 e Connect the terminal 1 to the battery terminal e Check that the high beam indicator light LED A goes on lf the indicator light does not go on replace the meter assembly Check 7 Right Turn Signal Indicator Light LED In spection e Connect the leads in the same circuit as Check 2 e Connect the terminal 3 to the battery terminal e Check that the right turn signal indicator light LED A goes on xIf the indicator light does not go on replace the meter Eme assembly GP170890 16 78 ELECTRICAL SYSTEM Meter Gauge Indicator Unit Check 8 Left Turn Signal Indicator Light LED Inspec tion e Connect the leads in the same circuit as Check 2 e Connect the terminal 19 to the battery terminal e Check that the left turn signal indicator light LED A goes on If the indicator light does not go on replace the meter assembly Check 9 Oil Pressure Warning Indicator Light LED Inspection e Connect t
441. onnector 1 Fuse Box 2 lgnition Fuse 10 A ECU Fuse 15 A Main Relay 10 Relay Box 11 Joint Connector 2 12 Main Fuse 30 A 13 Starter Relay 14 Battery 12 V 14 Ah 15 Frame Ground 1 16 Frame Ground 2 17 Immobilizer Kawasaki Diagnostic System Connector 18 Water proof Joint 1 19 ECU ELECTRICAL SYSTEM 16 107 Switches and Sensors Brake Light Timing Inspection e Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance chapter Brake Light Timing Adjustment e Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance chapter Switch Inspection e Using a hand tester check to see that only the connec tions shown in the table have continuity OFor the switch housings and the ignition switch refer to the tables in the Wiring Diagram If the switch has an open or short repair it or replace it with a new one Special Tool Hand Tester 57001 1394 Rear Brake Light Switch Connections Rear Brake Light Switch Connections When brake pedal is released Sidestand Switch Connections When sidestand is down When sidestand is up Oil Pressure Switch Connections Oil Pressure Switch Connections Color SW Terminal Ground When engine is stopped When engine is running Engine lubrication system is in good condition 16 108 ELECTRICAL SYSTEM Switches and Sensors Water Temperature Sensor Inspec
442. ont Wheel Rotation Sensor Installation pp 12 59 Rear Wheel Rotation Sensor Removal pp 12 59 Rear Wheel Rotation Sensor Installation pt 12 60 Wheel Rotation Sensor Inspectigm 12 60 Wheel Rotation Sensor Air Gap 12 61 Wheel Rotation Sensor Rotor Inspection pp 12 61 ABS Solenoid Valve Relay Fuse 20 A 12 62 ABS Motor Relay Fuse 30 A Removal pp 12 62 ABS ECU Fuse 10 AY 12 62 Gell AU OM one dte depart e o des e Dese 12 62 a sais 12 62 BRAKES 12 3 Dummy Page 12 4 BRAKES Exploded View Exploded View BRAKES 12 5 No Fastener rome Remarks N m kgf m ft Ib 1 Bleed Valves 7 8 0 80 69 2 Brake Hose Banjo Bolts 25 2 5 18 3 Brake Lever Pivot Bolt 1 0 0 10 8 9 in lb Si 4 Lever Pivot Bolt Locknut 5 9 0 60 52 in lb 5 Front Brake Disc Mounting Bolts 27 2 8 20 L 6 Front Brake Light Switch Screw 1 2 0 12 11 in lb 7 Front Brake Pad Pins 17 2 1 8 13 8 Front Brake Reservoir Stopper Screw 11 16 9 Front Caliper Assembly Bolts 20 L 10 Front Caliper Mounting Bolts 25 11 Front Master Cylinder Bleed Valve 69 in lb 12 Front Master Cylinder Clamp Bolts 97 in lb S B Apply brake fluid L Apply a non permanent locking agent R Replacement Parts S Follow t
443. ood No good Voltage is less than the specified value Inspect 1 Lower resistance in a hand tester Use KAWASAKI Hand Tester 2 Crankshaft sensor peak voltage 3 Camshaft position sensor peak voltage Stick coil primary peak voltage inspection Good Stick coil is defective Replace stick coil Voltage is zero No good or almost zero No good Inspect Replace bad parts or 1 Adapter connection is incorrect or inspect them with KAWASAKI Hand Tester adapter is defective Ignition switch and engine stop switch Crankshaft sensor peak voltage Camshaft position sensor peak voltage Replace bad parts ECU is defective Replace ECU GP10396B F Ignition System Ignition System Circuit ELECTRICAL SYSTEM 16 51 YR w 8K BR BK BK Y BK Y 1 wek BR BK Lu ll ECU Joint Connector 3 Vehicle down Sensor Engine Ground Frame Ground 2 Battery 12 V 14 Ah Frame Ground 1 Main Fuse 30 A Relay Box Ignition Fuse 10 ECU Fuse 15 A Fuse Box 2 Starter Lockout Switch gt 4 st 6210500844 C 14 15 16 17 18 19 20 21 22 23 24 25 Ignition Switch Engine Stop Switch Stick Coils Spark Plugs Sidestand Switch Camshaft Position Sensor Gear Position Switch Water pro
444. operly If the clutch operation is insufficiency inspect the clutch system A WARNING When inspecting by running the vehicle note a surrounding traffic situation enough in the place of safety PERIODIC MAINTENANCE 2 29 Periodic Maintenance Procedures Clutch Fluid Level Inspection e Hold the clutch fluid reservoir A horizontally e Check that the clutch fluid level of the clutch reservoir is between the lower B and the upper C level lines x If the fluid level is lower than the lower level line fill the reservoir to the upper level line in the reservoir OSince the clutch fluid is the same as the brake fluid refer to the Brake Fluid section in the Brakes chapter for further details e Follow the procedure below to install the clutch fluid reser voir cap correctly OFirst tighten the clutch fluid reservoir cap B clockwise C by hand until the resistance is felt fully then tighten the cap an additional 1 6 turn D while holding the clutch fluid reservoir body A A WARNING Change the fluid in the clutch line completely if the fluid must be refilled but the type and brand of the fluid that already is in the reservoir are unidentified After changing the fluid use only the same type and brand of fluid thereafter Clutch Fluid Leak Inspection e Apply the clutch lever and inspect the clutch fluid leak from the clutch hose pipe A and fittings lf the clutch fluid leaked from any pos
445. ops of its own accord in various positions it is well balanced If the wheel always stops one position adjust the wheel balance see Balance Adjustment Balance Adjustment e f the wheel always stops one position provisionally attach a balance weight A on the rim at the marking using adhesive tape e Rotate the wheel 1 4 turn B and see whether or not the wheel stops in this position If it does the correct balance weight is being used If the wheel rotates and the weight goes up replace the weight with the next heavier size If the wheel rotates and the weight goes down replace the weight with the next lighter size Repeat these steps until the wheel remains at rest after being rotated 1 4 turn e Rotate the wheel another 1 4 turn and then another 1 4 turn to see if the wheel is correctly balanced e Repeat the entire procedure as many times as necessary to achieve correct wheel balance e Permanently install the balance weight Balance Weight Removal e Insert a regular tip screwdrivers A B between the rib C and weight D as shown in the figure e Pry the balance weight with two screwdrivers and remove the balance weight e Discard the used balance weight CAUTION Do not tap the screwdrivers The rim could be dam aged WHEELS TIRES 10 11 6404098851 C 6404099851 C 6404073851 6 10 12 WHEELS TIRES Wheels Rims Balance Weight Installati
446. or Rear Wheel Rotation Sensor Rotor ABS Indicator Light LED ABS Hyaraulic Unit ABS Fuse Box ABS Kawasaki Self diagnosis System Connector 2 GL141058 BRAKES 12 31 Anti Lock Brake System Equipped Models ABS System Wiring Diagram ary 5 R BL BL R TuS pu ie 1 ABS Self diagnosis Terminal 13 Fuse Box 2 2 Ignition Switch 14 Ignition Fuse 10 A 3 Front Brake Switch 15 ABS ECU Fuse 10A 4 Water proof Joint 1 16 ABS Solenoid Valve Relay Fuse 20 A 5 Rear Brake Switch 17 ABS Motor Relay Fuse 30 A 6 Frame Ground 2 18 ECU Fuse 15A 7 Frame Ground 1 19 Meter Unit 8 Battery 12 V 14 Ah 20 ABS Hydraulic Unit 9 Main Fuse 30 A 21 ABS Kawasaki Self diagnosis System Con 10 Joint Connector 2 nector 11 Relay Box 22 Front Wheel Rotation Sensor 12 Main Relay 23 Rear Wheel Rotation Sensor OColor Codes BK Black GY Gray PU Purple BL Blue LB Light Blue R Red BR Brown LG Light Green V Violet CH Chocolate O Orange W White DG Dark Green P Pink Y Yellow G Green 12 32 BRAKES Anti Lock Brake System Equipped Models Terminal Names GL141078W2 C Unused Power Supply to Rear Wheel Rotation Sensor Front Wheel Rotation Sensor Signal Front and Rear Brake Light Switch Unused Unused Unused Power Supply to ABS Solenoid Valve Relay Power Supp
447. or Service Code 13 x If the output voltage is out of the specified check the ECU for its ground and power supply See ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation lf the output voltage is far out of the specified e g when the wiring is open the voltage is about 4 6 V check the wiring see wiring diagram in this section x If the wiring is good check the sensor resistance Inlet Air Temperature Sensor Resistance Inspection e Remove the inlet air temperature sensor see Inlet Air Temperature Sensor Removal Installation e Suspend the sensor A in a container of machine oil so that the heat sensitive portion is submerged e Suspend a thermometer B with the heat sensitive por tion C located in almost the same depth with the sensor NOTE OThe sensor and thermometer must not touch the con trainer side or bottom e Place the container over a source of heat and gradually raise the temperature of the oil while stirring the oil gently for even temperature e Using a digital meter measure the internal resistance of the sensor across the terminals at the temperatures shown in the following Inlet Air Temperature Sensor Resistance Standard 2 21 2 69 at 20 C 68 F About 0 322 at 80 C 176 F If the reading is out of the standard replace the sensor x lf the reading is within the standard replace the ECU see ECU Remo
448. or leading to harness repair or re placement Be sure to connect bulbs in series The bulb works as a current limiter to protect the solenoid in the fuel injector from excessive current e Disconnect the connectors for fuel injector A e Connect each test light set B to the fuel injector subhar ness connector C e Turn the ignition switch ON e While cranking the engine with the starter motor watch the test lights lf the test lights flicker at regular intervals the fuel injector circuit in the ECU and the wiring are good Perform the Fuel Injector Resistance Inspection O Fuel injector signals can be also confirmed by connecting the hand tester AC x 10 V instead of the test light set to the fuel injector main harness connector Crank the engine with the starter motor and check to see if the hand oscillates at regular intervals Special Tool Hand Tester 57001 1394 xIf the test light does not flicker or the test hand doesn t oscillates check the wiring and connectors again the wiring is good replace the ECU see ECU Re moval Installation FUEL SYSTEM 3 113 6617668651 o 6617024381 o 3 114 FUEL SYSTEM DFI Fuel Injectors Fuel Injector Resistance Inspection e Remove the throttle body assy see Throttle Body Assy Removal e Disconnect the connector from the fuel injector A see Throttle Body Disassembly Assembly e Measure the fuel
449. ournal Camshaft Cap Clearance Standard 0 038 0 081 mm 0 0015 0 0032 in Service Limit 0 16 mm 0 0063 in GE11089BS1 C ENGINE TOP END 5 21 Camshaft Camshaft Chain any clearance exceeds the service limit measure the diameter of each camshaft journal with a micrometer Camshaft Journal Diameter Standard 23 940 23 962 mm 0 9425 0 9434 in Service Limit 23 91 mm 0 941 in lf the camshaft journal diameter is less than the service limit replace the camshaft with a new one and measure the clearance again lf the clearance still remains out of the limit replace the cylinder head unit Camshaft Runout e Remove the camshafts see Camshaft Removal e Set the camshaft in a camshaft alignment jig or on V blocks e Measure runout with a dial gauge at the specified place as shown in the figure x lf the runout exceeds the service limit replace the shaft Camshaft Runout Standard TIR 0 02 mm 0 0008 in or less 8 11090851 Service Limit 0 1 mm 0 004 in Cam Wear e Remove the camshafts see Camshaft Removal e Measure the height A of each cam with a micrometer the cams are worn down past the service limit replace the camshaft A Cam Height Standard Exhaust 34 442 34 556 mm 1 3560 1 3605 in Inlet 35 042 35 156 mm 1 3796 1 3841 in SEDIS Service Limit Exhaust 34 34 mm 1 352 in Inlet 34 94 mm 1 376 in Cams
450. over C Fuel Tank Inspection e Visually inspect the gasket A on the tank cap for any damage Replace the gasket if it is damaged e Check to see if the water drain pipe B and fuel breather pipe C California and Southeast Asia models in the tank are not clogged Check the tank cap breather also x If they are clogged remove the tank and drain it and then blow the breather free with compressed air CAUTION Do not apply compressed air to the air vent holes D in the tank cap This could cause damage and clogging of the labyrinth in the cap FUEL SYSTEM 3 135 Fuel Tank Fuel Tank Cleaning A WARNING Clean the tank in a well ventilated area and take care that there are no sparks or flame anywhere near the working area Because of the danger or highly flammable liquids do not use gasoline or low flash point solvents to clean the tank e Remove Fuel Tank see Fuel Tank Removal Fuel Pump see Fuel Pump Removal e Pour some high flash point solvent into the fuel tank and shake the tank to remove dirt and fuel deposits e Draw the solvent out of the fuel tank e Dry the tank with compressed air e Install Fuel Pump see Fuel Pump Installation Fuel Tank see Fuel Tank Installation 3 136 FUEL SYSTEM DFI Evaporative Emission Control System CAL SEA and TH Models The Evaporative Emission Control System routes fuel va pors from the fuel system into the running engi
451. pe Left Side View 68038351 P GENERAL INFORMATION 1 9 Model Identification ZX1400D8F Europe Left Side View Frame Number lt y Se 1 10 GENERAL INFORMATION General Specifications ZX1400C8F C9F ZX1400D8F D9F Items Dimensions Overall Length Overall Width Overall Height Wheelbase Road Clearance Seat Height Dry Mass ZX1400C8F ZX1400D8F Curb Mass ZX1400C9F ZX1400D9F Front ZX1400C8F C9F ZX1400D8F D9F Rear ZX1400C8F C9F ZX1400D8F D9F Fuel Tank Capacity 2 170 mm 85 43 in 760 mm 29 92 in 1 170 mm 46 06 in 1 460 mm 57 48 in 125 mm 4 92 in 800 mm 31 50 in 220 kg 485 1 Ib 224 kg 493 9 Ib 257 kg 566 7 Ib 261 kg 575 5 Ib 128 kg 282 2 Ib 130 kg 286 6 Ib 129 kg 284 4 Ib 131 kg 288 8 Ib 22 L 5 8 US gal Performance 3 1 m 10 2 ft Minimum Turning Radius Engine Type Cooling System Bore and Stroke Displacement Compression Ratio Maximum Horsepower Maximum Torque Carburetion System Starting System Ignition System Timing Advance Ignition Timing Spark Plug Cylinder Numbering Method Firing Order 4 stroke DOHC 4 cylinder Liquid cooled 84 0 x 61 0 mm 3 31 x 2 40 in 1 352 cm 82 50 cu in 12 0 1 142 0 kW 193 PS 29 500 r min rpm WVTA 78 2 H 78 2 kW 106 PS 28 000 r min rpm MY SEA 140 0 kW 190 PS 29 000 r min rpm CAL US
452. pection x If the ground and power supply are good replace the ECU see ECU Removal Installation x lf the reading is within the standard range and check the input voltage at the inlet air pressure sensor connector e Disconnect the inlet air pressure sensor connector and connect the harness adapter A between the harness connector and inlet air pressure sensor connector Special Tool Sensor Harness Adapter 57001 1561 e Connect a digital meter to the harness adapter leads Inlet Air Pressure Sensor B Inlet Air Pressure Sensor Input Voltage Connections to Adapter Meter G sensor BL lead C Meter BK sensor BR BK lead D e Measure the input voltage with the engine stopped and with the connector joined e Turn the ignition switch ON Input Voltage at Sensor Connector Standard DC 4 75 5 25 V e Turn the ignition switch OFF the reading is out of the standard range check the wiring see wiring diagram in this section x lf the reading is good the input voltage is normal Check the output voltage 80171450651 LI 6617142851 C Inlet Air Pressure Sensor Service Code 12 Inlet Air Pressure Sensor Output Voltage Inspection e Measure the output voltage at the ECU in the same way as input voltage inspection Note the following Digital Meter A Connector B Special Tool Needle Adapter Set 57001 1457 Inlet Air Pressure Sensor Output
453. plastic hose e Install the reservoir cap e Tighten the bleed valve and install the rubber cap Torque Clutch Slave Cylinder Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib PERIODIC MAINTENANCE 2 57 Periodic Maintenance Procedures Rubber Parts of Clutch Master Cylinder Slave Cylinder Replacement Clutch Master Cylinder Cup and Dust Seal Replacement e Remove the clutch master cylinder see Clutch Master Cylinder Removal in the Clutch chapter e Remove the seal cover A circlip B connector C and O ring D Special Tool Inside Circlip Pliers 57001 143 e Unscrew the locknut E and pivot bolt F and remove the clutch lever e Pull the circlip G Pull out the piston assy H e Replace Seal Cover A Circlip B O ring D Circlip G Piston Assy H Diaphragm I 85808027852 e Before assembly clean parts including the master cylinder with clutch fluid or alcohol CAUTION Use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning parts Do not use any other fluid for cleaning these parts Gasoline motor oil or any other petroleum distillate will cause deterio ration of the rubber parts Oil spilled on any part will be difficult to wash off completely and will eventu ally deteriorate the rubber used in the cylinder e Apply clutch fluid to the parts removed and to the inner wall of the cylinder e Take care not to scratch the piston or the inne
454. pper Fairing Removal in the Frame chapter Upper Inner Fairing see Upper Inner Fairing Removal in the Frame chapter Nuts A and Rear View Mirrors Headlight Mounting Screws B Bracket C Headlights D e Tighten Torque Headlight Mounting Screws 1 2 N m 0 12 kgf m 11 in Ib 16 60 ELECTRICAL SYSTEM Lighting System Headlight Relay Inspection e Remove the inner covers see Inner Cover Removal in the Frame chapter e Take off the headlight relay A both sides e Set the hand tester to the x 1 O range and make the measurements shown in the figure Headlight Relay A 12 V Battery B Special Tool Hand Tester C 57001 1394 the tester readings are not as specified replace the headlight relay CAUTION Use only Kawasaki Hand Tester 57001 1394 for this test An ohmmeter other than the Kawasaki Hand Tester may show different readings If a megger or a meter with a large capacity battery is used the headlight relay will be damaged Testing Relay Criteria When battery is connected gt 0 Q When battery is disconnected gt Q Tail Brake Light LED Removal e Remove Tool Kit Case see ECU Removal in the Fuel System DFI chapter Relay Box see Relay Box Removal in the Electrical Sys tem chapter ECU see ECU Removal in the Fuel System DFI chap ter Screws A with Washer e Disconnect the connector A e Remove the tail brake light B GP12247BS1 E
455. prevent fuel spillage OWhen installing the fuel hoses avoid sharp bending kink ing flattening or twisting and run the fuel hoses with a minimum of bending so that the fuel flow will not be ob structed ORun the hoses according to Cable Wire and Hose Rout ing section in the Appendix chapter OTo prevent corrosion and deposits in the fuel system do not add to fuel any fuel antifreeze chemicals 6617036851 FUEL SYSTEM DFI 3 23 DFI Servicing Precautions Olf the motorcycle is not properly handled the high pres sure inside the fuel line can cause fuel to leak or the hose A to burst Bend and twist the fuel hose while examining it Replace the hose if any cracks or bulges are noticed OTo 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 Torque Oil Filler Plug Hand tighten 3 24 FUEL SYSTEM DFI Troubleshooting the DFI System Outline When a problem occurs with DFI system the warning in dicator light LED A goes on and Fl warning message B and Fl warning symbol C are displayed alternately on the LCD Liquid Crystal Display to alert the rider For models equipped with an immobilizer system the warning indicator light LED A blinks and immobilizer warning message B and immobilizer warning symbol C are alternately displayed on the LCD when a problem occ
456. pter Harness see Wiring Inspection in the Electrical System chapter xIf the all parts are in good condition replace the ECU PERIODIC MAINTENANCE 2 47 Periodic Maintenance Procedures Engine Stop Switch Operation Inspection First Step e Turn on the ignition switch e Set the neutral position e Turn the engine stop switch to stop position A e Push the starter button e The engine does not start xIf the engine starts inspect or replace the following item Engine Stop Switch see Switch Inspection in the Elec trical System chapter Second Step e Turn on the ignition switch e Set the neutral position e Turn the engine stop switch to run position A e Push the starter button and run the engine e Turn the engine stop switch to stop position e Immediately the engine should be stop lf the engine does not stop inspect or replace the follow ing item Engine Stop Switch see Switch Inspection in the Elec trical System chapter Others Chassis Parts Lubrication e Before lubricating each part clean off any rusty spots with rust remover and wipe off any grease oil dirt or grime e Lubricate the points listed below with indicated lubricant NOTE OWhenever the vehicle has been operated under wet or rainy conditions or especially after using a high pressure water spray perform the general lubri cation Pivots Lubricate with Grease Brake Lever Brake Pedal Clutch Lever Center Stand Equipp
457. r BR BK lead terminal 34 e Measure the sensor output voltage with the engine stopped and the connector joined e Turn the ignition switch ON Output Voltage at ECU Standard About 2 80 2 97 V at 20 C 68 F NOTE OThe output voltage changes according to the coolant temperature in the engine e Turn the ignition switch OFF x If the output voltage is out of the specified check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation x lf the output voltage is far out of the specified e g when the wiring is open the voltage is about 5 V check the wiring see wiring diagram in this section x lf the wiring is good check the water temperature sensor resistance 9617152051 FUEL SYSTEM DFI 3 61 Water Temperature Sensor Service Code 14 Water Temperature Sensor Resistance Inspection e Refer to the Water Temperature Sensor Inspection in the Electrical System chapter x f the reading is within the standard replace the ECU see ECU Removal Installation Water Temperature Sensor Circuit en Bi 4 R BK R BK Y BL R BK 6617427612 1 ECU 2 Meter Unit 3 Water Temperature Sensor 4 Water proof Joint 2 3 62 FUEL SYSTEM Atmospheric Pressure Sensor Service Code 15 Atmospheric
458. r 12 1 2 106 in Ib Front Camshaft Chain Guide Bolt Upper 25 2 5 18 Front Engine Mounting Bolts M10 59 6 0 44 Muffler Body Clamp Bolts 17 1 7 13 Muffler Body Mounting Bolts 34 3 5 25 Spark Plugs 13 1 3 115 in lb Throttle Body Assy Holder Bolts 9 8 1 0 87 in lb S Throttle Body Assy Holder Clamp Bolts 2 0 0 20 18 in lb Water Passage Plugs 20 2 0 15 L Clutch Clutch Cover Bolts 9 8 1 0 87 in lb L 1 Clutch Hose Banjo Bolt 25 2 5 18 Clutch Hub Nut 135 13 8 99 6 R Clutch Lever Pivot Bolt 1 0 0 10 8 9 in Ib Si Clutch Lever Pivot Bolt Locknut 5 9 0 60 52 in lb Clutch Master Cylinder Bleed Valve 7 8 0 80 69 in lb Clutch Master Cylinder Clamp Bolts 10 3 1 1 91 in lb S Clutch Reservoir Cap Stopper Screw 1 2 0 12 11 in lb Clutch Slave Cylinder Bleed Valve 7 8 0 80 69 in lb Clutch Slave Cylinder Bolts 9 8 1 0 87 in lb L Clutch Spring Bolts 9 0 0 92 80 in lb Oil Filler Plug 41 Starter Lockout Switch Screw 0 70 0 071 6 2 in lb L 2 8 PERIODIC MAINTENANCE Torque and Locking Agent Fastener fb Remarks Engine Lubrication System Engine Oil Drain Bolt 30 22 Oil Cooler Mounting Bolts 12 106 in lb S Oil Filter 17 13 G Oil Filter Holder Mounting Bolt 35 26 L Oil Pan Bolts 9 8 87 in lb Oil Pan Plate Bolts 9 8 87 L Oil Passage Plug 20 15 L Oil Pressure Relief Valve 15 11 L Oil Pressure Switch 15 11 SS Oil Pressure Switch Terminal Bolt 1 5 13 in lb G Oil Pump Cover Bolts 9 8 87 in lb Engine
459. r all the way to the right and left to ensure that the idle speed does not change the idle speed increases check the throttle cable free play and the cable routing If necessary adjust the throttle cable as follows e Loosen the locknuts A B e Screw both throttle cable adjusters C D to give the throttle grip plenty of play e Turn the decelerator cable adjuster C until 2 3 mm 0 08 0 12 in of throttle grip play is obtained e Tighten the locknut A e Turn the accelerator cable adjuster D until 2 3 mm 0 08 0 12 in of throttle grip play is obtained e Tighten the locknut B xIf the free play cannot be adjusted with the adjusters re place the cable Engine Vacuum Synchronization Inspection NOTE O These procedures are explained on the assumption that the inlet and exhaust systems of the engine are in good condition e Situate the motorcycle so that it is vertical e Remove Fuel Tank Cover see Fuel Tank Removal in the Fuel System DFI chapter Middle Fairings see Middle Fairing Removal in the Frame chapter e Pull off the rubber caps A from the fittings of each throttle body Front B 9505166851 C PERIODIC MAINTENANCE 2 17 Periodic Maintenance Procedures e For the California and Southeast Asia models pull off the vacuum hoses A e Pull off the air switching valve hose A from the air cleaner housing e Plug the air switching valve hose end an
460. r Inner Fairing Installatiom ss ise Sewers 15 15 Upper Fairing Bracket Removal pp 15 15 Upper Fairing Bracket Installation pp 15 15 Inner Eainngd3SroVal oet Ernesto Ce aud cater cae honte edi ur xm 15 15 Inner Fairing Installatlort a edu 15 15 Hear FEauning Hemoval enr tdi e eee 15 15 Rear Fairing 15 15 MT Seat Cover o e caves D e eibi ar Ee Seat Cover Installation Front Fender Removal Front Fender Installation pp 15 18 Flap Rear Fender Removal 15 18 Flap and Rear Fender Installatigo 4 15 19 le EE 15 20 Rear Frame rrr rare nnne rena 15 20 Rear Frame er 15 20 Erame Inspebliol Tes aeos Teo fict Puta te cen 15 20 Genter Stand Sid6stand sco Re DR RES 15 21 Center Stand Removal Equipped 15 21 Center Stand Installation Equipped Models pp 15 21 Sidestand Femowvalo 15 21 Sidestand Installatiot ot 15 21 15 2 FRAME Exploded View 7 AA 7 PET Mar NA N Wry C ay e Y
461. r aiming the headlight beam points to one side rather than straight ahead adjust the horizontal beam Headlight Beam Horizontal Adjustment e Remove the inner covers see Inner Cover Removal in the Frame chapter e Turn the horizontal adjuster A in both headlights in or out until the beam points straight ahead xIf the headlight beam points too low or high adjust the vertical beam Headlight Beam Vertical Adjustment e Remove the inner covers see Inner Cover Removal in the Frame chapter e Turn the vertical adjuster A in both headlights in or out to adjust the headlight vertically NOTE OON 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 an gle according to local regulations NOTE OFor 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 Height of Headlight Center D 6517113851 C 2 46 PERIODIC MAINTENANCE Periodic Maintenance Procedures Sidestand Switch Operation Inspection e Inspect the sidestand switch A operation accordance to the following table Sidestand Switch Operation Gear Clutch Engine Engine sidestand Position Lev
462. r and oil pressure switch gear position switch lead connectors Hold the clutch hose to the clamp of the subframe Run the clutch hose through inside of the radiator fan lead Run the clutch hose through inside of the subframe Run the ignition switch lead through over the clutch hose Run the clutch hose through the clamp 17 38 APPENDIX Cable Wire and Hose Routing APPENDIX 17 39 Cable Wire and Hose Routing 1 Install the clutch hose so that the joint pipe faces rear of the motorcycle 2 View from Bottom 3 Run the clutch reservoir hose through inside of the bracket 17 40 APPENDIX Cable Wire and Hose Routing APPENDIX 17 41 Cable Wire and Hose Routing 1 Brake Hose 2 Bracket 3 Clamps Insert the clamps into the front fender 4 Brake Hose 5 Clamps 6 Brake Hose 7 Face the white paint mark upward 17 42 APPENDIX Cable Wire and Hose Routing ABS Equipped Models Cable Wire and Hose Routing APPENDIX 17 43 Clamps Brake Hose Rear Wheel Rotation Sensor Rear Wheel Rotation Sensor Lead Rear Wheel Rotation Sensor Lead Connector Bracket ABS Hydraulic Unit Brake Pipes Damper Front Wheel Rotation Sensor Lead Connector Front Wheel Rotation Sensor Lead Front Wheel Rotation Sensor Brake Hose Approx 38 5 Approx 30 Approx 71
463. r loose Reinstall see chapter 3 Throttle body assy dust seal damage Replace see chapter 3 Fuel injector O ring damage Replace see chapter 3 Fuel filter or pump screen clogged Inspect and replace fuel pump see chapter 3 DFI System Troubleshooting Guide FUEL SYSTEM 3 33 Symptoms or Possible Causes Actions chapter Fuel pressure regulator trouble Fuel line clogged Inlet air pressure sensor trouble Atmospheric pressure sensor trouble Water temperature sensor trouble Inlet air temperature sensor trouble Main throttle sensor trouble Subthrottle sensor trouble Subthrottle valve actuator trouble Unstable rough idling Fuel pressure too low or too high Inspect fuel pressure and replace fuel pump see chapter 3 Inspect and repair see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 KS J J YJ SY Inspect see chapter 3 Fuel injector trouble Inspect see chapter 3 Main throttle sensor trouble Inspect see chapter 3 Subthrottle sensor trouble 2 Inspect see chapter 3 Subthrottle valve actuator trouble Inspect see chapter 3 Engine vacuum not synchronizing Inspect and adjust see chapter 2 Inlet air pressure s
464. r onto the end of the piston rod Special Tool Fork Piston Rod Puller M12 x 1 25 57001 1289 e Pull the puller up above the outer tube top e Install the fork spring A with the smaller end B facing upward e Install Collar Washer e Screw the rod nut A onto the piston rod B as shown in the figure 12 mm 0 47 in or more C e Check the distance between the bottom end A of the top plug and rebound damping adjuster B with a pair of vernier caliper 13 mm 0 51 in C e Set the fork spring compressor on the washer using the outer tube as a guide Special Tools Fork Spring Compressor 57001 1540 Fork Spring Compressor 57001 1587 NOTE OSet the clamps so that the cutout of the upper side does not fit the hole of washer pull up the outer tube to hold it by the clamps and then tighten the two bolts The outer tube is used as a guide e Hold the piston rod nut A e Remove the piston rod puller B e Install the rebound damping adjuster rod SUSPENSION 13 15 6514020851 6 GMO4364BS1 C 13 16 SUSPENSION Front Fork e Screw in the top plug A stopped onto the piston rod e Check the O ring B on the top plug and replace it with a new one if damaged e Holding the top plug with a wrench tighten the piston rod nut C against the top plug Torque Piston Rod Nuts 28 N m 2 9 kgf m 21 ft lb e While holding up the washer with the clamps loosen the fork spr
465. r shall be removed press it into the bearing cover until it is bottomed to the cover so that the shield side of it faces to outside of the cover e Assemble the crankcase e Press in the oil seal A onto collar B so that the surface of the oil seal is flush with the counterbore bottom surface C of the crankcase CRANKSHAFT TRANSMISSION 9 41 Transmission Transmission Shaft Disassembly e Remove the transmission shafts see Transmission Shaft Removal eRemove the circlips disassemble the transmission S shafts A ay e The 5th gear A on the output shaft has three steel balls assembled into it for the positive neutral finder mecha CC f DP nism Remove the 5th gear OSet the output shaft in a vertical position holding the 3rd gear B 61130828 5 OSpin the 5th gear quickly and pull it off upward e Remove the ball bearing A from each shafts Special Tools Bearing Puller B 57001 135 Bearing Puller Adapter C 57001 317 e Discard the bearing 6113048851 6 Transmission Shaft Assembly e Apply engine oil to the bushings ball bearings and shafts e Install the gear bushings A on the shaft with their holes B aligned 6113040881 e Replace any circlips removed with new ones e Install the circlips A so that the opening B of it is aligned with spline grooves C e Install the circlips so that the mark D on them faces to each gear side
466. r wall of the cylinder Torque Clutch Lever Pivot Bolt 1 0 N m 0 10 kgf m 8 9 in Ib Clutch Lever Pivot Bolt Locknut 5 9 N m 0 60 kgf m 52 in Ib e Install the clutch master cylinder see Clutch Master Cylin der Removal in the Clutch chapter 2 58 PERIODIC MAINTENANCE Periodic Maintenance Procedures Clutch Slave Cylinder Piston Seal Replacement e Remove Left Lower Fairing see Lower Fairing Removal in the Frame chapter Coolant Reserve Tank see Coolant Reserve Tank Re moval Installation in the Cooling System chapter e Loosen the banjo bolt A at the clutch pipe lower end and tighten it loosely e Unscrew the slave cylinder bolts B and detach the slave cylinder with the pipe installed from the engine e Pump the clutch lever until the piston comes out of the cylinder e Unscrew the banjo bolt and remove the slave cylinder C CAUTION Immediately wash away any clutch fluid that spills It may damage painted surfaces NOTE Olf the clutch slave cylinder is removed and left alone the piston will be pushed out by spring force e Remove the spring and piston seal CAUTION Replace the piston seal with a new one if it was re moved from the piston e Before assembly apply clutch fluid to the outside of the piston and the piston seal e Install the piston seal as shown in the figure Cylinder A Piston B Piston Seal C 6210001851 Spring D WARNING Motorcycle oper
467. rake fluid reservoir cap correctly OFirst tighten the 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 e Install the clamp and screw e Tighten Torque Front Brake Reservoir Cap Stopper Screw 1 2 N m 0 12 kgf m 11 in Ib e Tighten the bleed valve and install the rubber cap Torque Bleed Valves 7 8 N m 0 80 kgf m 69 in Ib e Check the fluid level see Brake Fluid Level Inspection in the Periodic Maintenance chapter e After bleeding is done check the brake for good braking power no brake drag and no fluid leakage BRAKES 12 27 12 28 BRAKES Brake Fluid A WARNING When working with the disc brake observe the pre cautions listed below 1 2 3 Never reuse old brake fluid Do not use fluid from a container that has been left unsealed or that has been open for a long time Do not mix two types and brands of fluid for use in the brake This lowers the brake fluid boiling point and could cause the brake to be ineffective It may also cause the rubber brake parts to deteriorate Don t leave the reservoir cap off for any length of time to avoid moisture contamination of the fluid Don t change the fluid in the rain or when a strong wind is blowing Except for the disc pads and disc use only disc brake fl
468. rake Pad Lining Thickness Front 4 0 mm 0 16 in 1 mm 0 04 in Rear 5 0 mm 0 20 in 1 mm 0 04 in Brake Light Timing Front Pulled ON Rear ON after about 10 mm 0 39 in of pedal Special Tools PERIODIC MAINTENANCE 2 15 Inside Circlip Pliers 57001 143 7570143ST C Steering Stem Nut Wrench 57001 1100 Jack 57001 1238 7571100ST C 7571238ST C Oil Filter Wrench 57001 1249 7571249ST C Pilot Screw Adjuster C 57001 1292 75712928T Vacuum Gauge 57001 1369 es 7571369ST C Pilot Screw Adjuster Adapter 5 57001 1372 75713728T 6 Throttle Sensor Setting Adapter 57001 1538 Jack Attachment 34 J L 7571608ST C 2 16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System DFI Throttle Control System Inspection e Check the throttle grip free play A Throttle Grip Free Play Standard 2 3 mm 0 08 0 12 in xIf the free play is incorrect adjust the throttle cables e Check that the throttle grip B moves smoothly from full open to close and the throttle closes quickly and com pletely by the return spring in all steering positions x If the throttle grip does not return properly check the throt tle cables routing grip free play and cable damage Then lubricate the throttle cable e Run the engine at the idle speed and turn the handleba
469. removal ORun the lead correctly see Cable Wire and Hose Rout ing section in the Appendix chapter Rear Wheel Rotation Sensor Removal CAUTION The wheel rotation sensor should be handled care fully never struck sharply with a hammer or al lowed to fall on a hard surface since the wheel rota tion sensor is precision made Be careful not to get water or mud on the wheel rotation sensor Do not try to disassemble or repair the wheel rota tion sensor e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Connector A Disconnect e Clear the connector from the bracket BRAKES 12 59 12 60 BRAKES Anti Lock Brake System Equipped Models e Remove Bracket Bolts A Clamps B Bolts C Rear Wheel Rotation Sensor D Rear Wheel Rotation Sensor Installation e Installation is the reverse of removal ORun the lead correctly see Cable Wire and Hose Rout ing section in the Appendix chapter Wheel Rotation Sensor Inspection e Remove the front wheel rotation sensor A from the front fork e Remove the rear wheel rotation sensor B from the caliper bracket e Visually inspect the wheel rotation sensors Replace the wheel rotation sensor if it is cracked bent or otherwise damaged BRAKES 12 61 Anti Lock Brake System Equipped Models Wheel Rotation Sensor Air Gap Inspection e Raise the front rear wheel off the ground see Front Rear Whee
470. renew the cups lf fluid leakage is noted at the brake lever the piston as sembly should be replaced to renew the cups e Check the dust covers E for damage lf they are damaged replace them e Check the piston return springs F for any damage lf the springs are damaged replace them e Check that relief port G and supply port H are not plugged the relief port becomes plugged the brake pads will drag on the disc Blow the ports clean with compressed air Front Master Cylinder J Rear Master Cylinder K BRAKES 12 23 6513050852 12 24 BRAKES Brake Disc Brake Disc Removal e Remove the wheels see Front Rear Wheel Removal in the Wheels Tires chapter e Unscrew the mounting bolts and take off the disc ORemove the sensor rotor ABS Equipped Models e Remove the gaskets Brake Disc Installation e Replace the gaskets with new ones e Install the brake disc on the wheel so that the marked side A faces out Olnstall the sensor rotor on the brake disc so that the marked side faces out ABS Equipped Models e Apply a non permanent locking agent to the threads of the front and rear brake disc mounting bolts B e Tighten Torque Brake Disc Mounting Bolts 27 N m 2 8 kgf m 20 ft Ib Brake Disc Wear Inspection e Measure the thickness of each disc A at the point where it has worn the most x lf the disc has worn past the service limit replace it Measuring Area
471. ring is too tight e Feel for steering looseness by pushing and pulling the forks If you feel looseness the steering is too loose NOTE OThe cables and wiring will have some effect on the mo tion of the fork which must be taken into account OBe sure the leads and cables are properly routed OThe bearings must be in good condition and properly lubricated in order for any test to be valid Steering Play Adjustment e Remove Handlebars see Handlebar Removal in the Steering chapter Stem Head Nut A and Washer B Upper Front Fork Clamp Bolts C Loosen Stem Head D e Bend the claws A of the claw washer straighten e Remove the steering stem locknut B Special Tool Steering Stem Nut Wrench 57001 1100 e Remove the claw washer C PERIODIC MAINTENANCE 2 41 Periodic Maintenance Procedures e Adjust the steering Special Tool Steering Stem Nut Wrench A 57001 1100 the steering is too tight loosen the stem nut a fraction of a turn xIf the steering is too loose tighten the stem nut a fraction of a turn NOTE OTurn the stem nut 1 8 turn at time maximum 85158144 e Install the claw washer so that its bent side faces upward and engage the bent claws with the grooves of stem locknut C e Hand tighten the stem locknut until it touches the claw washer e Tighten the stem locknut clockwise until the claws are aligned with the grooves ranging from 2nd to 4th of stem nut D an
472. rn the bulb about 15 e Fit the projections A of the lens into the grooves B of the turn signal light e A TEM ey Lao Tighten the screw gt a gt Ad emt 2 it Um mm ii M LP i a Turn Signal Relay Inspection e Remove Left Seat Cover see Seat Cover Removal in the Frame chapter Turn Signal Relay A e Disconnect the connector B e Connect one 12 V battery and turn signal lights as indi cated in the figure and count how may times the lights flash for one minute Turn Signal Relay A Turn Signal Lights B 12 V Battery C If the lights do not flash as specified replace the turn sig nal relay Testing Turn Signal Relay 8 12040251 C Load The Number of Turn Flashing Times Signal Lights Wattage W c m 1 21 23 140 250 2 42 or 46 75 95 Cycle s per minute Corrected to one light burned out ELECTRICAL SYSTEM 16 65 Lighting System Turn Signal Light Circuit GP123828W2 C lgnition Switch Joint Connector 1 Turn Signal Indicator Light LED Right Turn Signal Indicator Light LED Left Front Right Turn Signal Light Front Left Turn Signal Light Other than CA and US Models Hazard Button Turn Signal Switch Turn Signal Fuse 10 A Fuse Box 1 Turn Signal Relay Joint Connector 2 Frame Ground 1 Main Fuse 30 A Battery 12 V 14 Ah Frame Ground 2
473. romagnetic field or just by aging will result in low output Charging System e To check the alternator output voltage do the following procedures OTurn off the ignition switch ORemove the right seat cover see Seat Cover Removal in the Frame chapter ODisconnect the alternator lead connector A OConnect the hand tester as shown in the table 1 Special Tool Hand Tester 57001 1394 OStart the engine ORun it at the rpm given in the table 1 ONote the voltage readings total 3 measurements Table 1 Alternator Output Voltage Tester Connections Reading Range Tester 4 to Tester to at 4 000 rpm 250 V AC One Black Lead Another Black Lead 51 V or more If the output voltage shows the value in the table the al ternator operates properly If the output voltage shows a much higher than the value in the table the regulator rectifier is damaged A much lower reading than that given in the table indicates that the alternator is defective e Check the stator coil resistance as follows OStop the engine OConnect the hand tester as shown in the table 2 Special Tool Hand Tester 57001 1394 ONote the readings total 3 measurement Table 2 Stator Coil Resistance at 20 C 68 F Tester Range Reading Tester to Tester to One Black Lead Another Black Lead 0 05 0 5 Q there is more resistance than shown in the table or no tester reading infinity for a
474. rtant and must not be neglected Periodic Inspection Whichever ODOMETER READING comes x 1 000 km first x 1 000 mile 1 6 12 FREQUENCY See Page Fuel System Throttle control system play smooth return 2 16 no drag inspect y Engine vacuum synchronization inspect e Idle speed inspect e e 2 20 Fuel leak fuel hose and pipe inspect year e e 2 20 e Fuel hose and pipe damage inspect year e 2 20 Fuel hose and pipe installation condition year 2 20 inspect Evaporative emission control system function MINES 2 24 inspect CAL and SEA Models Cooling System 2 22 2 23 2 23 2 23 Coolant level inspect Coolant leak radiator hose and pipe inspect year Radiator hose damage inspect year Radiator hose installation condition inspect year Engine Top End US CA AU 2 Models Valve clearance inspect Other than US 2 23 CA AU Models Every 42 000 km 26 000 mile Air suction system damage inspect e e e 2 28 Clutch Clutch operation play disengagement e engagement inspect Clutch fluid level inspect 6months e e Clutch fluid leak clutch hose and pipe year ee inspect Clutch hose and pipe damage inspect year Clutch hose installation condition inspect year e Wheels and Tires Tire air pressure inspect year Wheel tire damage inspect Tire tread wear abnorma
475. s ORemove the throttle body assy see Throttle Body Assy Removal OCheck the main throttle valves and throttle bores A for carbon deposits by opening the main throttle valves If any carbon accumulates wipe the carbon off the throt tle bores around the throttle bores and the throttle valves using a cotton pad penetrated with a high flash point sol vent Synchronization Inspection Adjustment e Refer to the Engine Vacuum Synchronization Inspection in the Periodic Maintenance chapter Throttle Body Assy Removal A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Disconnect the battery cable ter minal 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 Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately e Remove Middle Fairings see Middle Fairing Removal in the Frame chapter Bolts A Subframe Bolts B and Washers e Disconnect the throttle body subharness connector A e Remove the connector from the connector bracket Olnsert the thin blade screwdriver into the connector stop per portion from the right side of motorcycle FUEL SYSTEM 3 119 Throttle Body Assy e For the California and Southeast Asia models pull off the vacuum hoses A e Disconnect the crankshaft
476. s Test run the motorcycle at a speed of more than 20 km h 12 mph to see that the ABS indicator light LED does not come on Finally test run the mo torcycle at a speed of more than 30 km h 20 mph and brake suddenly to see that the motorcycle stops without loss of steering control and the ABS operates normally The reaction force generated is felt in the brake lever and pedal This completes the final inspection GL14288BS1 Anti Lock Brake System Equipped Models ABS Troubleshooting Outline When an abnormality in the system occurs the ABS in dicator light LED lights up to alert the rider In addition the nature of the fault is stored in the memory of the ABS hydraulic unit and when in the self diagnosis mode the ser vice code A is indicated by the number of times the ABS indicator light LED blinks The service codes stored in memory are not erased until the mode has been changed to the fault erase mode after the fault has been corrected Therefore after correcting the problem always erase the service codes and then run the self diagnosis program to confirm normal signal output When due to a malfunction the ABS indicator light LED remains lit get a thorough understanding of the background before starting the repair work Ask the rider about the conditions B under which the problem occurred and try to determine the cause C Do not rely solely on the ABS self diagnosis function use common sense c
477. s 12 1 2 106 in Ib Tail Brake Light Mounting Screws 1 2 0 12 11 inb Timing Rotor Bolt 39 4 0 29 Water Temperature Sensor 25 2 5 18 2 12 PERIODIC MAINTENANCE Torque and Locking Agent The table below relating tightening torque to thread diameter lists the basic torque for the bolts and nuts Use this table for only the bolts and nuts which do not require a specific torque value All of the values are for use with dry solvent cleaned threads Basic Torque for General Fasteners Threads Torque Diameter mm N m kgf m ft Ib 5 3 4 4 9 0 35 0 50 30 43 in lb 6 5 9 7 8 0 60 0 80 52 69 in lb 8 14 19 1 4 1 9 10 0 13 5 10 25 34 2 6 3 5 19 0 25 12 44 61 4 5 6 2 33 45 14 73 98 7 4 10 0 54 72 16 115 155 11 5 16 0 83 115 18 165 225 17 0 23 0 125 165 20 225 325 23 0 33 0 165 240 Specifications PERIODIC MAINTENANCE 2 13 Item Standard Service Limit Fuel System DFI Throttle Grip Free Play Idle Speed Throttle Body Vacuum Air Cleaner Element Cooling System Coolant Type Recommended Color Mixed Ratio Freezing Point Total Amount 2 3 mm 0 08 0 12 in 1 100 50 r min rpm 34 4 11 3 kPa 258 10 mmHg at idle speed Viscous paper element Permanent type of antifreeze Green Soft water 5095 Coolant 5096 35 31 F 3 4 L 3 6 US qt Engine Top End Valve Clearance Exhaust 0 22 0 27 mm 0 0087 0 010
478. s and wipe dry e Using compressed air blow out the oil passages in the crankcase halves e Install the new drive shaft bearing A so that its stepped side B faces as shown using a press e Install the bearing position plate C with the screws D Olnstall the plate so that the stepped hole side faces out side Yellow Paint E OApply a non permanent locking agent to the threads of the bearing position plate screws and tighten them Torque Bearing Position Plate Screws 4 9 N m 0 50 kgf m 43 in Ib 6104308851 C 9 12 CRANKSHAFT TRANSMISSION Crankcase Splitting e Install the new needle bearing A for the shift shaft so that its marked side B faces as shown using a press e Install the new oil seal C so that its surface D is flush with the surface of the crankcase E e Install Crankshaft Pistons and Connecting Rods Transmission Shaft and Gears Dowel Pins A e Install the front balancer A on the upper crankcase half B see Front Balancer Installation e Before fitting the lower case on the upper case check the following OCheck to see that the shift drum and transmission gears are in the neutral position e Apply liquid gasket A to the mating surface of the lower crankcase half Sealant Kawasaki Bond 92104 1064 NOTE OAfter tightening the crankcase bolts wipe up the liquid gasket seeping out the output shaft bearing journal B OMake the application finish within 20 m
479. s not influenced by electric wave radiated from the antenna Locate the antenna as far as possible away from the ABS hydraulic unit OWhenever the ABS electrical connections are to be dis connected first turn off the ignition switch OThe ABS parts should never be struck sharply as with a hammer or allowed to fall on a hard surface Such a shock to the parts can damage them OThe ABS parts cannot be disassembled Even if a fault is found do not try to disassemble and repair the ABS parts replace it OThe ABS has many brake lines pipes and leads And the ABS cannot detect problems with the conventional braking system brake disc wear unevenly worn brake pad and other mechanical faults To prevent trouble check the brake lines and pipes for correct routing and connection the wiring for correct routing and the brakes for proper braking power Be sure to check for fluid leak age and bleed the brake line thoroughly A WARNING If any of the brake line fittings including the ABS hydraulic unit joint nuts or the bleed valve is opened at any time the air must be bled completely from the brake line CAUTION Do not ride the motorcycle with air in the brake line or the ABS could malfunction BRAKES 12 33 12 34 BRAKES Anti Lock Brake System Equipped Models OThe ABS indicator light LED A may light if the tire pres sure is incorrect a non recommended tire is installed or the wheel is deformed
480. s not securely tightened or the cotter pin is not installed an unsafe riding condi tion may result 6404082851 C e Adjust the drive chain slack after installation see Drive Chain Slack Inspection in the Periodic Maintenance chap ter e Install the rear caliper see Caliper Installation in the Brakes chapter e Install the rear wheel rotation sensor see Rear Wheel Rotation Sensor Installation in the Brakes chapter ABS Equipped Models e Check the rear brake effectiveness see Brake Operation Inspection in the Periodic Maintenance chapter A WARNING Do not attempt to drive the motorcycle until a full brake pedal is obtained by pumping the brake pedal until the pads are against the disc The brake will not function on the first application of the pedal if this is not done 10 10 WHEELS TIRES Wheels Rims Wheel Inspection e Raise the front rear wheel off the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Spin the wheel lightly and check for roughness or binding x If roughness or binding is found replace the hub bearings see Hub Bearing Removal Installation e Inspect the wheel for small cracks dents bending or warp If there is any damage to the wheel replace the wheel e Remove the wheel and support it with the tire by the axle e Measure the rim runout axial A and radial B with a dial gauge x If rim runout exceeds the service limit check the hu
481. se Fuel Tank Drain Hose Insert the seat lock cable in the hook portion of the rear frame and hold it Other than California and Southeast Asia Models 17 32 APPENDIX Cable Wire and Hose Routing ABS Equipped Models 5809220 6 APPENDIX 17 33 Cable Wire and Hose Routing Run the fuel tank drain hose through over the brake pipe Brake Pipe Fuel Tank Drain Hose Run the fuel tank drain hose through over the brake pipe Brake Pipe Fuel Tank Drain Hose 17 34 APPENDIX Cable Wire and Hose Routing APPENDIX 17 35 Cable Wire and Hose Routing 1 Run the throttle cables through inside of the brake hose 2 Run the throttle cables through the clamp of the front brake reservoir bracket 3 Run the throttle cables through inside of the brake hose 4 Run the throttle cables through the clamp 5 View from Bottom 17 36 APPENDIX Cable Wire and Hose Routing APPENDIX 17 37 Cable Wire and Hose Routing 1 Run the clutch hose through inside of the reserve tank 2 Run the clutch hose through outside of the sidestand switch speed sensor and oil pressure ON OD switch gear position switch leads Install the clutch hose so that the joint pipe faces the inside of the motorcycle Run the clutch hose through inside of the main harness Run the clutch hose through outside of the sidestand switch speed senso
482. se to the lip of seal before installing the seal Circlips Cotter Pins Replace the circlips or cotter pins that were removed with new ones Take care not to open the clip excessively when installing to prevent deformation GENERAL INFORMATION 1 5 6B02046BSi 68020268 1 6 GENERAL INFORMATION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation Lubri cation 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 Ro tate 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 thor oughly before using the meter Incorrect values may lead to improper adjustments 68020218 6802062851 GENERAL INFORMATION 1 7 Model Identification ZX1400C8F United States and Canada Left Side View 1 8 GENERAL INFORMATION Model Identification ZX1400C8F Euro
483. seat see Seat Removal in the Frame chap ter ORemove the canister A and disconnect the hoses from the canister OVisually inspect the canister for cracks or other damage If the canister has any cracks or bad damage replace it with a new one NOTE OThe canister is designed to work well through the motor cycle s life without any maintenance if it is used under normal conditions 2 22 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Check the liquid vapor separator as follows ORemove the fuel tank see Fuel Tank Removal in the Fuel System DFI chapter ODisconnect the hoses from the separator and remove the separator A from the motorcycle right side OVisually inspect the separator for cracks and other dam age x If the separator has any cracks or damage replace it with a new one OTo prevent the gasoline from flowing into or out of the canister hold the separator perpendicularly to the ground e Check the hoses of the evaporative emission control sys tem as follows OCheck that the hoses are securely connected and clips are in position OReplace any kinked deteriorated or damaged hoses ORun the hoses according to Cable Wire and Hose Rout ing section in the Appendix chapter Refer to the diagram of the evaporative emission control system in the Fuel System DFI chapter too OWhen installing the hoses avoid sharp bending kinking flattening or twisting and run the hoses with
484. see appropriate chapters o Starter Motor Disassembly e Remove the starter motor see Starter Motor Removal e Take off the starter motor through bolts A and remove the both end covers B e Pull the armature A out of the yoke B e Remove Brush Plate Terminal Nut Washer and Insulators A Brush Plate Assembly B Starter Motor Assembly e Pry the spring end A and insert the brush B 16 54 ELECTRICAL SYSTEM Electric Starter System e Install the brush plate assembly A into the right hand end cover B e Replace the O ring C with a new one e Install Insulators D Washer E e Tighten Torque Starter Motor Terminal Locknut F 6 9 N m 0 70 kgf m 61 in Ib e Install the armature A into the yoke B e Install the thrust washer C e Replace the O rings D with new ones e Put the armature among the brushes e Align the marks A to assembly the yoke and the end covers e Replace the O rings A with new ones e Tighten Torque Starter Motor Through Bolts B 3 4 N m 0 35 kgf m 30 in Ib e Replace the O ring A with a new one e Apply grease to the new O ring Geb P Electric Starter System Brush Inspection e Measure the length A of each brush B lf any is worn down to the service limit replace the brush holder assembly Starter Motor Brush Length Standard 10 mm 0 39 in Service Limit 5 0 mm 0
485. sensor is a rotating variable resistor that change output voltage according to throttle operating The ECU senses this voltage change and determines fuel injec tion 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 Never drop the throttle body assy especially on a hard surface Such a shock to the subthrottle sen sor can damage it Subthrottle Sensor Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Remove the ECU see ECU Removal ODo not disconnect the ECU connectors e Connect a digital meter A to the connector B using the needle adapter set Special Tool Needle Adapter Set 57001 1457 Subthrottle Sensor Input Voltage Connections to ECU Meter BL lead terminal 7 Meter BR BK lead terminal 34 e Measure the input voltage with the engine stopped and with the connector joined e Turn the ignition switch ON Input Voltage at ECU Standard DC 4 75 5 25 V e Turn the ignition switch OFF the reading of input voltage is less than the standard check the ECU for its ground power supply and wiring shorted x If the ground and power supply are good replace the ECU see ECU Removal
486. ses 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 6506005851 6 e Check that the hoses are securely connected and clamps are tightened correctly Torque Radiator Water Hose Clamp Screws 2 0 N m 0 20 kgf m 18 in Ib Engine Top End Valve Clearance Inspection NOTE O Valve clearance must be checked and adjusted when the engine is cold at room temperature e Remove Lower Fairings see Lower Fairing Removal in the Frame chapter Middle Fairings see Middle Fairing Removal in the Frame chapter Crankshaft Sensor Cover see Crankshaft Sensor Re moval in the Electrical System chapter Cylinder Head Cover see Cylinder Head Cover Re moval in the Engine Top End chapter e Position the crankshaft at 1 4 piston TDC TDC Mark A for 1 4 Pistons Timing Mark B Crankcase Halves Mating Surface e Using the thickness gauge A measure the valve clear ance between the cam and the valve lifter Valve Clearance Standard Exhaust 0 22 0 27 mm 0 0087 0 0106 in Inlet 0 15 0 20 mm 0 0059 0 0079 in 2 24 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTE OThickness gauge is horizontally inserted on the valve lifter Appropriateness A Inadequacy B Thickness Gauge C Horizontally Inserts D Cam E Valve Lifter F Hits the Va
487. shaft position sensor e Apply grease to the new O ring e Tighten Torque Camshaft Position Sensor Bolt 9 8 N m 1 0 kgf m 87 in Ib e Run the camshaft position sensor lead correctly see Cable Wire and Hose Routing section in the Appendix chapter Camshaft Position Sensor Inspection e Disconnect the camshaft position sensor lead connector see Camshaft Position Sensor Removal e Set the hand tester to the x 10 O range and connect it to the terminals Special Tool Hand Tester 57001 1394 Camshaft Position Sensor Resistance 400 460 at 20 C 68 F If there is more resistance than the specified value the sensor coil has an open lead and must be replaced Much less than this resistance means the sensor coil is shorted and must be replaced e Using the highest resistance range of the tester mea sure the resistance between the camshaft position sensor leads and chassis ground Any tester reading less than infinity lt indicates a short necessitating replacement of the camshaft position sen sor GP10155BS1 C Ignition System Camshaft Position Sensor Peak Voltage Inspection NOTE OBe sure the battery is fully charged e Disconnect the camshaft position sensor lead connector A see Camshaft Position Sensor Removal e Connect the harness adapter B between the camshaft position sensor lead connector and harness connector C e Connect the peak voltage adapter D to the hand
488. sher A 9 36 CRANKSHAFT TRANSMISSION Starter Motor Clutch and Torque Limiter e Holding the drive gear A with a hand take off the one way Clutch B from the gear by using the screwdriver C Starter Motor Clutch Assembly e Be sure to install the one way clutch A so that its arrow B faces the side of the flat washer e Turn in the driven gear A to the drive gear B Counterclockwise C Starter Clutch Inspection e Remove the rear balancer see Rear Balancer Removal e Turn the starter idle gear A by hand When viewed from the rear side of the engine the starter idle gear should turn forward B freely but should not turn backward C If the clutch does not operate as it should or if it makes noise disassemble the starter clutch examine each part visually and replace any worn or damaged parts Torque Limiter Removal e Remove Rear Balancer see Rear Balancer Removal Starter Motor Clutch see Starter Motor Clutch Removal Torque Limiter Bolt A CRANKSHAFT TRANSMISSION 9 37 Starter Motor Clutch and Torque Limiter e Holding the torque limiter A remove the torque limiter shaft B and the torque limiter Torque Limiter Installation e Replace the gasket with a new one e Apply molybdenum disulfide grease to the torque limiter shaft e Install the torque limiter bolt OApply a non permanent locking agent to the threads of the torque limiter bolt Torque Torque Limiter Bolt
489. spp 13 19 Rear Shock Absorber Removal Ne 13 20 Rear Shock Absorber Installation Set betas 13 21 Rear Shock Absorber Inspection ai 13 21 Rear Shock Absorber Scrapping pp 13 22 accola deco hottest ccce teda Madan Swingarm se Swingarm Installation Swingarm Bearing Removal sinu or bep dte e QU ere bci AR Rer rbd adt E ee reo n 13 25 Swingarm Bearing Installation d E ut 13 25 Swingarm Bearing Sleeve 13 26 Swingarm Bearing utes aca ra eive 13 27 Chain Guide Inspection sc eee tacet p Ste 13 27 iesRod Rocker Armi P c Peer dee d 13 28 0 13 28 Tie Bod Installation EL e te dO E Mb ceca 13 28 Rocker Arm Heltmbovalus eee duse iot etnies te its do ir bte p Ue o pee EE be deg Gc 13 28 Rocker Arm Installation rece rne tete a DO D RE mee EP mid pud 13 29 Tie Rod and Rocker Arm Bearing Removal pp 13 29 Tie Rod and Rocker Arm Bearing Installatiom 13 29 Rocker Arm Tie Rod Bearing Sleeve Inspection pp 13 31 Rocker Arm Tie Rod Bearing Lubrication pp 13 31 13 2 SUSPENSION Exploded View 6102218815 C SUSPENSION 13
490. stall the pusher into the drive shaft e Install Thrust Bearing Washer Clutch Spring Plate e Install the springs and tighten the clutch spring bolts evenly Torque Clutch Spring Bolts 9 0 N m 0 92 kgf m 80 in Ib e Install the clutch cover see Clutch Cover Installation Clutch Plate Assembly Inspection e Inspect the friction plate thickness see Clutch Plate Wear Damage Inspection e Measure the length A of the clutch plate assembly as shown in the figure OAssemble Clutch Hub B Spring Seat C Spring D Friction Plates E F G Steel Plates H Spring Plate J Springs K Spring Bolts L Torque Clutch Spring Bolts 9 0 N m 0 92 kgf m 80 in Ib Clutch Plate Assembly Length Standard 53 52 54 52 mm 2 11 2 15 in If the length is not within the specified range adjust the length see Clutch Plate Assembly Adjustment GF11008BS1 C GF11006BS2 C Clutch Clutch Plate Assembly Adjustment e Inspect the clutch plate assembly length and then re place the steel plate s which brings the length within the specified range e Remove Spring Bolts Springs Spring Plate e Replace the following steel plate s Part Number Thickness 13089 0019 2 3 mm 0 091 in 13089 0018 2 6 mm 0 102 in STD 13089 0020 2 9 mm 0 114 in NOTE ODo not use the steel plate of 2 3 mm 0 091 in and 2 9 mm 0 114 in thickness at the same time e Install the remove
491. sted Front fork bent Right and left front fork oil level uneven Shock absorption unsatisfactory Too hard Front fork oil excessive Front fork oil viscosity too high Rear shock absorber adjustment too hard 17 64 APPENDIX Troubleshooting Guide Tire air pressure too high Front fork bent Too soft Tire air pressure too low Front fork oil insufficient and or leaking Front fork oil viscosity too low Rear shock adjustment too soft Front fork rear shock absorber spring weak Rear shock absorber oil leaking Brake Doesn t Hold Air in the brake line Pad or disc worn Brake fluid leakage Disc warped Contaminated pad Brake fluid deteriorated Primary or secondary cup damaged in master cylinder Master cylinder scratched inside Battery Trouble Battery discharged Charge insufficient Battery faulty too low terminal voltage Battery cable making poor contact Load excessive e g bulb of excessive wattage Ignition switch trouble Alternator trouble Wiring faulty Regulator rectifier trouble Battery overcharged Alternator trouble Regulator rectifier trouble Battery faulty MODEL APPLICATION Year Model Beginning Frame No JKBZXNC108A000001 or 2008 ZX1400C8F JKBZXT40CCA000001 or ZXT40C 000001 JKBZXT40CDA000001 or ZXT40D 000001 JKBZXNC109A011001 or 2009 ZX1400C9F JKBZXT40CCA011001 or ZXT40C 011001 JKBZXT40CDA011001 or ZXT40D 011001 2008 ZX1400D8F 2009 ZX1400D9F O This digit in the
492. stores the service code for the service person to troubleshoot easily The service code memory is powered directly by the battery and cannot be canceled by the ignition switch The ABS hydraulic unit can memorize up to all service codes 14 codes Further service codes are memorized after erasing the preceding all service codes 14 codes If there is no fault the ABS indicator light LED lights indicating that The ABS is normal Self diagnosis Procedures OWhen a problem occurs with the ABS system the ABS indicator light LED A lights NOTE OUse a fully charged battery when conducting self diagnosis Otherwise the light blinks very slowly or doesn t blink OThe motorcycle is stopped OKeep the self diagnosis terminal grounded during self 8L14288B81 diagnosis with an auxiliary lead Anti Lock Brake System Equipped Models e Remove the seat see Seat Removal in the Frame chap ter e Ground the self diagnosis terminal A Gray to the ground terminal B Black Yellow using a lead e Turn on the ignition switch OCount the blinks of the light to read the service code Keep the auxiliary lead ground until you finish reading the service code Service Code Clearing Procedures e Start the service code erase mode with the following pro cedure OThe erase mode starts when the ABS self diagnosis ter minal is disconnected from the ground terminal after start ing the self diagnosis mode OThe service
493. struments are used and the use of substitute tools may ad versely 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 e Follow the Periodic Maintenance Chart in the Service Manual e Be alert for problems and non scheduled maintenance e Use proper tools and genuine Kawasaki Mo torcycle 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 e Follow the procedures in this manual care fully Don t take shortcuts e Remember to keep complete records of main tenance and repair with dates and any new parts installed How to Use This Manual In this manual the product is divided into its major systems and these systems make up the manual s chapters The Quick Reference Guide shows you all of the product s system and assists in locating their chapters Each chapter in turn has its own comprehensive Ta ble of Contents For example if you want ignition coil informa tion use the Quick Reference Guide to locate the Electrical System chapter Then use the Table of Contents on the first page of the chap
494. sufficiency inspect the brake system A WARNING When inspecting by running the vehicle note a surrounding traffic situation enough in the place of safety Brake Fluid Level Inspection e Check that the brake fluid level in the front brake reservoir A is above the lower level line B NOTE OHold the reservoir horizontally by turning the handlebar when checking brake fluid level x lf the fluid level is lower than the lower level line fill the reservoir to the upper level line C 6110020151 PERIODIC MAINTENANCE 2 37 Periodic Maintenance Procedures e Follow the procedure below to install the front brake fluid reservoir cap correctly OFirst tighten the front brake fluid reservoir cap B clock wise 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 e Remove the seat see Seat Removal in the Frame chap ter e Check that the brake fluid level in the rear brake reservoir A is above the lower level line B x If the fluid level is lower than the lower level line fill the reservoir to the upper level line C A 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 reser voir are unidentified After changing the fluid use onl
495. t Duct Removal in the Fuel System DFI chapter Meter Unit see Meter Unit Removal in the Electrical Sys tem chapter Bolts A Upper Fairing Bracket B Upper Fairing Bracket Installation e Installation is the reverse of removal Inner Fairing Removal e Remove Middle Fairings see Middle Fairing Removal Quick Rivet A Bolts B Inner Fairing C Inner Fairing Installation e Installation is the reverse of removal Rear Fairing Removal e Remove Bolts A Rear Fairing B Rear Fairing Installation e Installation is the reverse of removal 15 16 FRAME Seat Cover Seat Cover Removal e Remove Seat see Seat Removal Bolts A Screws B with Washer Grab Rail C Equipped Models Center Seat Cover D e Remove the quick rivets A e Remove the bolts A with washer e Clear the side seat covers B from the rear fender e Disconnect the turn signal light lead connectors and re move each side seat cover e Remove Screws A Turn Signal Light B Seat Cover Installation e Install the turn signal light and tighten the screws e Connect the turn signal light lead connector e Insert the hole A to the projection B e Install the bolts and quick rivets FRAME 15 17 Seat Cover e Insert the projection A into the hole B e Tighten the screws e Install the grab rail equipped models e Tighten Torque Grab Rail Mounting Bolts 25 N m 2 5 kgf m
496. t LED ABS Equipped Models see ABS Indicator Light LED Inspection in the Brakes chap ter e Turn off the ignition switch e The all lights should go off e For the immobilizer model warning indicator light LED will blinks see Immobilizer System Equipped Models section in the Electrical System chapter x lf the light does not go off replace the ignition switch 9517109851 C PERIODIC MAINTENANCE 2 43 Periodic Maintenance Procedures Second Step e Turn the ignition switch to P Park position e The city light taillight and license plate light should go on lf the light does not go on inspect or replace the following item Ignition Switch see Switch Inspection in the Electrical System chapter Third Step e Turn on the ignition switch e Turn on the turn signal switch A left or right position e The left or right turn signal lights B front and rear ac cording to the switch position should flash e The either of turn signal indicator lights LED C in the meter unit should flash the each light does not flash inspect or replace the following item Turn Signal Light Bulb see Turn Signal Light Bulb Re placement in the Electrical System chapter Meter Unit for Turn Signal Indicator Light LED see Me ter Unit Inspection in the Electrical System chapter Turn Signal Relay Fuse 10 A see Fuse Inspection in the Electrical System chapter Turn Signal Switch see Switch Inspection in
497. t 3 9 0 40 35 in lb L 8 Stud Bolts 15 1 5 11 L 11 4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain Drive Chain Slack 32 38 mm 1 3 1 5 in aS Drive Chain Wear 20 link 317 5 318 2 mm 12 50 12 53 in 323 mm 12 7 in Length Standard Chain Make DAIDO Type DID50ZVZ GC amp B Link 116 links Sprockets Rear Sprocket Warp TIR 0 4 mm 0 016 in or less TIR 0 5 mm 0 020 in FINAL DRIVE 11 5 Special Tools Inside Circlip Pliers Bearing Driver Set 57001 143 57001 1129 7570143ST C 7571129ST C 11 6 FINAL DRIVE Drive Chain Drive Chain Slack Inspection e Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter Drive Chain Slack Adjustment e Refer to the Drive Chain Slack Adjustment in the Periodic Maintenance chapter Wheel Alignment Inspection Adjustment e Refer to the Wheel Alignment Inspection in the Periodic Maintenance chapter Drive Chain Wear Inspection e Refer to the Drive Chain Wear Inspection in the Periodic Maintenance chapter Drive Chain Lubrication e Refer to the Drive Chain Lubrication Condition Inspection in the Periodic Maintenance chapter Drive Chain Removal e Remove the chain cover screws A and chain cover B OClear the chain cover from the swingarm e Remove Rear Wheel see Rear Wheel Removal in the Wheels Tires chapter Engine Sprocket see Engin
498. t 32 6 32 8 mm 1 283 1 291 in OMeasure 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 xIf the width is too wide G too narrow H or uneven J repair the seat see Valve Seat Repair Valve Seating Surface Width GE15011782 Standard Exhaust 0 8 1 2 mm 0 031 0 047 in Inlet 0 5 1 0 mm 0 020 0 039 in Valve Seat Repair e Repair the valve seat with the valve seat cutters A Special Tools Valve Seat Cutter Holder Bar B 57001 1128 Valve Seat Cutter Holder 5 C 57001 1208 For Exhaust Valve Seat Valve Seat Cutter 45 030 57001 1187 Valve Seat Cutter 32 p30 57001 1120 Valve Seat Cutter 60 p30 57001 1123 For Inlet Valve Seat Valve Seat Cutter 45 35 57001 1116 Valve Seat Cutter 32 535 57001 1121 Valve Seat Cutter 60 633 57001 1334 lf the manufacturer s instructions are not available use the following procedure 6 1 5133851 C 5 30 ENGINE TOP END Valves Seat Cutter Operation Care 1 This valve seat cutter is developed to grind the valve for repair Therefore the cutter must not be used for other purposes than seat repair 2 Do not drop or shock the valve seat cutter or the dia mond 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 t
499. t Air Pressure Sensor Output Voltage V Digital Meter Reading FUEL SYSTEM DFI 3 57 Inlet Air Temperature Sensor Service Code 13 Inlet Air Temperature Sensor Removal Installation CAUTION Never drop the inlet air temperature sensor espe cially on a hard surface Such a shock to the sensor can damage it e Remove the fuel tank see Fuel Tank Removal e Disconnect the connector A from the inlet air tempera ture sensor Pull out the inlet air temperature sensor B e Install the inlet air temperature sensor A in the grommet B Inlet Air Temperature Sensor Output Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Remove the ECU see ECU Removal ODo not disconnect the ECU connectors e Connect a digital meter to the ECU connector using the needle adapter set Special Tool Needle Adapter Set 57001 1457 Inlet Air Temperature Sensor Output Voltage Connections to ECU Connector Meter Y lead terminal 8 Meter BR BK lead terminal 34 e Measure the sensor output voltage with the engine stopped and the connector joined e Turn the ignition switch ON Output Voltage at ECU Standard About 2 25 2 50 V at 20 C 68 F NOTE OThe output voltage changes according to the inlet air temperature e Turn the ignition switch OFF 6617150651 C 3 58 FUEL SYSTEM DFI Inlet Air Temperature Sens
500. t Caliper Disassembly emeret rt ORE ARAS DOR Une ate ed exe 12 17 Front Caliper ASSOFIDDly bio tice shades dowel tie ti et secte ueni qa 12 17 Rear Galiper Disassembly pepe nite te cue ia Sr ers 12 17 Hear Galip r Assembly ten onn epi dt bati fece pec biu aeri ne pides unn 12 17 Caliper Fluid Seal Damage Inspectig 12 18 Caliper Dust Seal Damage Inspection pp 12 18 Caliper Piston and Cylinder Damage Inspection pp 12 19 Brake edel odo eeu a aca dad Front Brake Removal Front Brake Pad Installation Rear Brake Pad Removal der eb etes nr rex nba bed edv tute ene ER Hu Rear Brake Pad Installation Brake Pad Wear Inspection Master Cylind t ew Front Master Cylinder Removal pp 12 22 Front Master Cylinder Installation pe 12 22 Rear Master Cylinder 12 22 Rear Master Cylinder Installation eerte retener 12 23 Front Master Cylinder Disassembly pp 12 23 Rear Master Cylinder Disassembly pp 12 23 Master Cylinder ASSSIDIy uo ioo heed elites ce 12 23 Master Cylinder Inspection Visual Inspection 12 23 Brake ISG iori pe po Decet pre Seco b e cu ad ca oe dE Tea ad Berto peri Reap un wa Ras 12 24 Brake DISC Removal d taedio ntes us tio cada x s be e
501. t Plate Bolt 9 8 1 0 87 in lb L 10 Torque Limiter Bolt 25 2 5 18 L 11 Front Balancer 12 Rear Balancer 13 Install the bearing into the drive shaft cover so that the shield side faces out EO Apply engine oil G Apply grease L Apply a non permanent locking agent M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts 9 6 CRANKSHAFT TRANSMISSION Specifications Item Crankcase Crankshaft Connecting Rods Connecting Rod Bend Connecting Rod Twist Connecting Rod Big End Side Clearance Connecting Rod Big End Bearing Insert Crankpin Clearance Crankpin Diameter Marking None Connecting Rod Big End Inside Diameter Marking None Connecting Rod Big End Bearing Insert Thickness Brown Black Blue Connecting Rod Bolt Stretch New Connecting Rod Used Connecting Rod Crankshaft Side Clearance Crankshaft Runout Crankshaft Main Bearing Insert Journal Clearance Crankshaft Main Journal Diameter None Marking Crankcase Main Bearing Inside Diameter Standard Service Limit TIR 0 2 100 mm 0 008 3 94 in TIR 0 2 100 mm 0 008 3 94 in 0 13 0 38 mm 0 58 mm 0 0051 0 0150 in 0 023 in 0 048 0 086 mm 0 12 mm 0 0019 0 0034 in 0 0047 in 37 984 38 000 mm 37 97 mm 1 4954 1 4961 in 1 4949 in 37 984 37 99
502. t if necessary Spring Tension Inspection e Since a spring becomes shorter as it weakens check its free length A to determine its condition xlf the spring of either fork leg is shorter than the service limit it must be replaced If the length of a replacement spring and that of the remaining spring vary greatly the remaining spring should also be replaced in order to keep the fork legs balanced for motorcycle stability Spring Free Length Standard 257 mm 10 12 in Service Limit 252 mm 9 92 in GM04386BS1 C GM04128BS1 C 8 04011851 C Rear Shock Absorber Rebound Damping Force Adjustment e Remove the rear fairing see Rear Fairing Removal in the Frame chapter Equipped Models e To adjust the rebound damping force turn the lower damping adjuster A to the desired position until you feel a click OThe standard adjuster setting for an average build rider of 68 kg 150 Ib with no passenger and no accessories is the 1 2 4 turns out from the fully clockwise position Rebound Damping Force Adjustment Adjuster Damping Position Force 2 2 4 Turns Out Weak T 0 Compression Damping Force Adjustment e To adjust the compression damping force turn the upper damping adjuster A to the desired position until you feel a click OThe standard adjuster setting for the average build rider of 68 kg 150 Ib with no passenger and no accessories is the 2 1 4 turns out from the
503. t lb S hij 7 16 ENGINE LUBRICATION SYSTEM Oil Pressure Switch Oil Pressure Switch Removal e Remove Engine Oil Drain see Engine Oil Change in the Periodic Maintenance chapter Left Lower Fairing see Lower Fairing Removal in the Frame chapter Switch Cover A Switch Terminal B Oil Pressure Switch C Oil Pressure Switch Installation e Apply silicone sealant to the threads of the oil pressure switch and tighten it Sealant Kawasaki Bond Silicone Sealant 56019 120 Torque Oil Pressure Switch 15 N m 1 5 kgf m 11 ft lb e Install the switch lead direction A upward e Apply grease B to the terminal e Tighten the terminal bolt Torque Oil Pressure Switch Terminal Bolt 1 5 N m 0 15 kgf m 13 in Ib NOTE OApply a small amount grease to the terminal so that grease should not close two breather holes A for switch diaphragm GG13005BS1 C 6613004851 ENGINE REMOVAL INSTALLATION 8 1 Engine Removal Installation Table of Contents Exploded suo edet 8 2 Engine Hemoval InstallatiOr s ctor rt t ete e Beer eee 8 4 Engine RSNA hc 8 4 Engine Installations 8 6 8 2 ENGINE REMOVAL INSTALLATION Exploded View GH02115BW5 C ENGINE REMOVAL INSTALLATION 8 3 Exploded View
504. t to prevent pressure leaks e Build up pressure in the system carefully until the pres sure reaches 123 kPa 1 25 kgf cm 18 psi CAUTION During pressure testing do not exceed the pres sure for which the system is designed The maxi mum pressure is 123 kPa 1 25 kgf cm 18 psi e Watch the gauge for at least 6 seconds lf the pressure holds steady the system is all right 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 e Remove the pressure tester replenish the coolant and install the radiator cap e Install the right middle fairing see Middle Fairing Installa tion in the Frame chapter COOLING SYSTEM 4 7 6005011151 4 8 COOLING SYSTEM Coolant Cooling System Flushing Over a period of time the cooling system accumulates rust scale and lime in the water jacket and radiator When this accumulation is suspected or observed flush the cool ing system If this accumulation is not removed it will clog up the water passage and considerable reduce the effi ciency of the cooling system e Drain the cooling system see Coolant Change in the Pe riodic Maintenance chapter e Fill the cooling system with fresh water mixed with a flush ing compound CAUTION Do not use a flushing compound which is harmful to the aluminum engine and radiator Carefull
505. tant levels The exhaust system of this model motorcycle manufactured primarily for sale in California in cludes a catalytic converter system 3 Evaporative Emission Control System Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere In stead 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 know ingly 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 u
506. ter to measure the length of new connecting rod bolts and record the values to find the bolt stretch Connecting Rod A Dent here with a punch B Nuts C Fit micrometer pins into dents D e Apply a small amount of molybdenum disulfide oil solution to the following Threads of Nuts and Bolts Seating Surfaces of Nuts and Connecting Rods e Tighten the big end nuts until the bolt elongation reaches the length specified in the table e Check the length of the connecting rod bolts If the stretch is more than the usable range the bolt has stretched too much An overelongated bolt may break in use 6105040351 Bolt Length after _ Bolt Length before _ Bolt Stretch tightening tightening Connect Usable Range of ing Rod Bolt Nut Connecting Rod Assy Bolt Stretch Use the bolts Attached to 0 25 0 34 mm New attached to new con rod 0 0098 0 0134 new con rod in Replace the 0 25 0 34 mm Used bolts with new 0 0098 0 0134 ones New in 2 Rotation Angle Method If you don t have a point micrometer you may tighten the nuts using the Rotation Angle Method e Be sure to clean the bolts nuts and connecting rods thor oughly with a high flash point solvent because the new connecting rods bolts and nuts are treated with an anti rust solution A WARNING Clean the bolts nuts and connecting rods in a well ventilated area and take care that there is no spar
507. tery 11 Speed Sensor Supply Voltage 12 Ground 13 Speed Sensor Signal 14 Unused 15 Fuel Reserve Switch 16 Fuel Level Sensor 17 CAN Communication Line High 18 CAN Communication Line Low 19 Left Turn Signal Indicator Light LED 20 Unused CAUTION Do not drop the meter unit Place the meter unit so that itfaces upward If the meter assembly is left up side down or sideways for a long time or dropped it will malfunction Do not short each terminals 8 17427 52 C ELECTRICAL SYSTEM 16 71 Meter Gauge Indicator Unit Check 1 CAN Communication Line Resistance Inspec tion e Set the hand tester A to the x 1 O range and connect it to the terminal 17 and 18 in the meter unit Special Tool Hand Tester 57001 1394 ardi CAN Communication Line Resistance at Meter Unit Standard 122 126 Q the tester reading is not specified replace the meter assembly SP17544BS1 C Check 2 Meter Unit Primary Operation Check e Using the auxiliary leads the 12 V battery A to the meter unit connector as follows OConnect the battery positive terminal to the terminal 10 OConnect the battery negative terminal to the terminal 12 e Check that the speedometer and tachometer needles A momentarily point their last readings and back to the min imum position If the meter unit does not work replace the meter
508. the Electri cal System chapter Turn Signal Relay see Turn Signal Relay Inspection in the Electrical System chapter Harness see Wiring Inspection in the Electrical System chapter e Push the turn signal switch e 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 Electri cal System chapter Turn Signal Relay see Turn Signal Relay Inspection in the Electrical System chapter 6517110851 C 2 44 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fourth Step e Set the dimmer switch A to low beam position e Start the engine e The low beam headlights B should go on If the low beam headlight does not go on inspect or re place the following item Headlight Low Beam Bulb see Headlight Bulb Replace ment in the Electrical System chapter Headlight Fuse Low 15 A see Fuse Inspection in the Electrical System chapter Headlight Relay Fuse 10 A see Fuse Inspection in the Electrical System chapter Headlight Circuit Relay in Relay Box see Relay Circuit Inspection in the Electrical System chapter Headlight Relay Low see Headlight Relay Inspection in the Electrical System chapter Harness see Wiring Inspection in the Electrical System chapter e Push the passing button equipped models or set the dimmer switch to high beam position e The low beam A and high bea
509. the brake and hold it B 3 Close the bleed valve C 4 Release the brake D NOTE O The fluid level must be checked often during the chang ing 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 OFront Brake Repeat the above steps for the other caliper e Remove the clear plastic hose e Install the diaphragm and reservoir cap e Follow the procedure below to install the front brake fluid reservoir cap correctly OFirst tighten the front rear brake fluid reservoir cap B clockwise C by hand until slight resistance is felt indi cating 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 9513149852 C M C OT PERIODIC MAINTENANCE 2 63 Periodic Maintenance Procedures e Tighten Torque Front Brake Reservoir Cap Stopper Screw 1 2 N m 0 12 kgf m 11 in Ib e Tighten the bleed valve and install the rubber cap Torque Bleed Valves 7 8 N m 0 80 kgf m 69 in Ib e After changing the fluid check the brake for good braking power no brake drag and no fluid leakage necessary bleed the air from the lines Master Cylinder Rubber Parts Replacement Front Master Cylinder Disassembly e Remove the front master cylinder see Front
510. the clamp Run the rear wheel rotation sensor lead through the inside of the rear brake reservoir Rear Wheel Rotation Sensor Lead Connector Install the rear wheel rotation sensor lead con nector to the bracket Run the rear wheel rotation sensor lead through on the rear brake reservoir hose Run the alternator subharness through the outside of the fuse box 1 Fuse Box 1 Clamp Alternator Subharness Fuel Pump Lead Connector Fuel Level Sensor Lead Connector Clamp Hold the rear brake light switch lead and rear wheel rotation sensor lead Rear Brake Light Switch Lead Connector Run the rear brake light switch lead through the outside of the separator Rear Brake Light Switch Lead Connector Clamp Hold the rear brake light switch lead ABS Equipped Models California and Southeast Asia Models 17 22 APPENDIX Cable Wire and Hose Routing 68095176 6 APPENDIX 17 23 Cable Wire and Hose Routing 1 Horn Lead 2 Run the right switch housing horn headlight and front wheel rotation sensor leads through the clamp 3 Do not run the horn lead through the clamp on the steering stem 4 Horn 5 Run the horn lead through between the brake hose and front fork ABS Equipped Models 17 24 APPENDIX Cable Wire and Hose Routing APPENDIX 17 25 Cable Wire and Hose Routing 12 13 14 15 16 17 18 19 20 21 ABS Equipped Models Turn
511. the swingarm pivot adjusting collar B Pull out the pivot shaft right side of the motorcycle and remove the swingarm 13 24 SUSPENSION Swingarm Swingarm Installation e Apply plenty of grease to the lip of the oil seals A e Install the collar e Place the adjusting collar A into the frame B as shown in the figure 11 mm 0 43 in C GMO6105BS1 C e Insert the pivot shaft A into the frame from the right side e Tighten the pivot shaft so that the clearance between the adjusting collar B and the ball bearing C come to 0 mm 0 in Torque Swingarm Pivot Shaft 20 N m 2 0 kgf m 15 ft Ib e Tighten the shaft locknut A with the swingarm pivot nut wrench B Special Tool Swingarm Pivot Nut Wrench 57001 1597 Torque Swingarm Pivot Shaft Locknut 98 10 0 kgf m 72 3 ft lb e Tighten the pivot shaft nut A Torque Swingarm Pivot Shaft Nut 108 N m 11 0 kgf m 79 7 ft lb e Install the removed parts see appropriate chapters SUSPENSION 13 25 Swingarm Swingarm Bearing Removal e Remove Swingarm see Swingarm Removal Collar A Oil Seals B Sleeves C Circlip D Right Side Special Tool Inside Circlip Pliers 57001 143 e Remove the ball bearing and needle bearings Special Tool Oil Seal amp Bearing Remover A 57001 1058 8 06079851 C Swingarm Bearing Installation e Replace the ball and needle bearings A w
512. tion e Remove the water temperature sensor see Water Tem perature Sensor Removal Installation in the Fuel System DFI chapter e Suspend the sensor A in a container of coolant so that the threaded portion is submerged e Suspend an accurate thermometer B with temperature sensing portions C located in almost the same depth NOTE OThe sensor and thermometer must not touch the con trainer side or bottom e Place the container over a source of heat and gradu ally raise the temperature of the coolant while stirring the coolant gently e Using the hand tester measure the internal resistance of the sensor OThe sensor sends electric signals to the ECU and coolant temperature gauge in the meter unit OMeasure the resistance across the terminals and the body for the gauge at the temperatures shown in the table If the hand tester does not show the specified values re place the sensor Water Temperature Sensor Resistance for ECU D Resistance kQ Terminal 1 3 0 155 Temperature 20 C 68 2 46 80 C 176 F 0 32 0 011 110 C 230 F 0 1426 0 0041 Resistance for Water Temperature Gauge E 0 143 Resistance Q Temperature Terminal 2 Body 50 C 122 F 210 40 120 C 248 212 15 Speed Sensor Removal CAUTION Never drop the sensor especially on a hard surface Such a shock to the sensor can damage it e Loosen the bolt A e Disconne
513. tle body View from Upside 17 60 APPENDIX Troubleshooting Guide NOTE ORefer to the Fuel System chapter for most of DFI trouble shooting guide OThis is not an exhaustive list giving every possible cause for each problem listed It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties Engine Doesn t Start Starting Difficulty Starter motor not rotating Ignition and engine stop switch not ON Starter lockout switch or gear position switch trouble Starter motor trouble Battery voltage low Starter relay not contacting or operating Starter button not contacting Starter system wiring shorted or open Ignition switch trouble Engine stop switch trouble Main 30 A or ignition fuse blown Starter motor rotating but engine doesn t turn over Vehicle down sensor DFI coming off Immobilizer system trouble Starter clutch trouble Starter idle gear trouble Engine won t turn over Valve seizure Valve lifter seizure Cylinder piston seizure Crankshaft seizure Connecting rod small end seizure Connecting rod big end seizure Transmission gear or bearing seizure Camshaft seizure Starter idle gear seizure Balancer bearing seizure No fuel flow No fuel in tank Fuel pump trouble Fuel tank air vent obstructed Fuel filter clogged Fuel line clogged No spark spark weak Vehicle down sensor DFI coming off Ignition switch not ON Engine stop switc
514. ton Team BR EC Ignition S Switch R Right x p Switch Housing Immobilizer Es E Antenna k Joint Connector 1 BK Y BK Y BK Y BK Y BK Y BL BK Y Camshaft Horn Tui Position 12V 2 5 Sensor Air Switching Valve AR R BL Spark Plugs UE Left Turn Signal Indicator Light LED Illumination Light LED Fuel Level Gauge Water Temperature Gauge Tachometer Speedometer Oil Pressure Warning Indicator Light LED ts Front Right Turn Signal Light 12V21W ay aK Y Right City Light 12 58 Headlight HI 12V65W Headlight LO 12V55W wy Headlight LO 12V55W wv BK Y ee Headlight HI we 2885 5585 25 12V65 dorr on Left City Light 12V5W SE 55 Headlight Headlight HH Oa e is 2 2 Relay Lo Relay Hi 1 Horn Button Front Left Turn Signal Fuel 2 Hazard Button Light 12V21W ay 3 Turn Signal Switch Level 1 Dimmer Switch Sensor 5 Starter Lockout Switch Box 1 6 Passing Button puse Box 1 52 i Turn Signal Relay Fuse 10 1 2 Headlight Relay Fuse 2 3 Taillight Fuse 10 3 4 Horn Fuse 10A 5 Headlight Fuse Hi 15A 8 Headlight Fuse Lo 15 LEFT SWITCH HOUSING CONNECTIONS Turn Signal Switch Starter Lockout vitch Passing Button G
515. ton Replace the piston and or the piston ring grooves rings 5 24 ENGINE TOP END Cylinder Head Cylinder Head Removal e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Throttle Body Assy see Throttle Body Assy Removal in the Fuel System DFI chapter Thermostat Housing see Thermostat Removal in the Cooling System chapter Coolant Reserve Tank see Coolant Change in the Peri odic Maintenance chapter Exhaust Pipe see Exhaust Pipe Removal Cylinder Head Cover see Cylinder Head Cover Re moval Camshafts see Camshaft Removal Front Camshaft Chain Guide see Camshaft Chain Re moval Rear Camshaft Chain Guide see Camshaft Chain Re moval Water Temperature Sensor Connector see Water Tem perature Sensor Removal Installation in the Fuel System DFI chapter e Remove Front Engine Mounting Bolts M10 A Engine Bracket Bolts M8 B Engine Brackets C e Remove the M6 cylinder head bolts A and then the M11 cylinder head bolts B e Take off the cylinder head Cylinder Head Installation NOTE OThe 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 e Install a new cylinder head gasket and dowel pins e Replace the cylinder head bolt washers with new ones e Apply molybdenum disulfide oil solution to both sid
516. tor G Light LED 4 Neutral Indicator Light LED 5 Warning Indicator Light 6 Left Turn Signal Indicator Light LED 7 Illumination Light LED 8 Fuel Level Gauge 9 Water Temperature Gauge 10 Tachometer 11 Speedometer 12 611 Pressure Warning Indicator Light LED Front Right Turn Signal Canshaft Horn Tui Position Right Switch Housing 12V 2 5 M 1 Front Brake Light Switch ensor Air 2 Engine Stop Switch Switching 3 Starter Button Valve BR Y Ignition Switch R Right x x 7 z 3 8 Switch Housing Ze ey 1 IGNITION Meter Unit Joint Connector 1 555555 ARH R BL Spark Plugs 2444 stick we wy wy ay Light 12V21W BK Right City Light 12V5 SE Headlight HI 12V658 Headlight 10 12V55W Headlight LO w H 12V55W Headlight HI H 2885 5585 25 12V65 Left City Light 12V5W SE 55 Headlight Headlight Left Switch H Relay Lo Relay Hi BEEN ton Mode Front Left Turn Signal a Fuel 5 Hazard Button Light 12V21W Level 3 Turn Signal Switch A id 4 Dimmer Switch Fuse Sensor 5 Starter Lockout Switch Box 1 Box 2 Fuse Box 1 Fuse Box 2 i Turn Signal Relay Fuse 10 1 Fan Fuse 15 2 Headlight Relay Fuse 22 ECU Fuse 15
517. tor Lead Holding Plate Bolts 8 3 0 85 73 L Alternator Rotor Bolt 155 15 8 114 S Camshaft Position Sensor Bolt 9 8 1 0 87 in lb Crankshaft Sensor Bolts 5 9 0 60 52 in lb L Crankshaft Sensor Cover Bolts 9 8 1 0 87 in lb L 1 Engine Ground Terminal Bolt 9 8 1 0 87 Front Brake Light Switch Screw 1 2 0 12 11 in lb Front Turn Signal Light Mounting Screws 1 2 0 12 11 Fuel Level Sensor Bolts 6 9 0 70 61 in lb L Gear Position Switch Lead Clamp Bolts 9 8 1 0 87 in lb Gear Position Switch Screws 2 9 0 30 26 in lb L Headlight Mounting Screws 1 2 0 12 11 in lb Left Switch Housing Screws 3 5 0 36 31 in lb License Plate Light Cover Mounting Screws 0 90 0 092 8 0 in Ib License Plate Light Mounting Plate Screws 1 2 0 12 11 in lb Oil Pressure Switch 15 1 5 11 SS Oil Pressure Switch Terminal Bolt 1 5 0 15 13 in lb G Oxygen Sensor Equipped Models 25 2 5 18 Rear Turn Signal Light Mounting Screws 1 2 0 12 11 in lb Regulator Rectifier Bolts 9 8 1 0 87 Right Switch Housing Screws 3 5 0 36 31 in lb Sidestand Switch Bolt 8 8 0 90 78 in lb L Spark Plugs 13 1 3 115 in lb Speed Sensor Bolt 3 9 0 40 35 in lb L Starter Lockout Switch Screw 0 70 0 071 6 2 in lb L Starter Motor Cable Terminal Nut 5 9 0 60 52 in lb Starter Motor Mounting Bolts 9 8 1 0 87 in lb Starter Motor Terminal Locknut 6 9 0 70 61 in lb Starter Motor Through Bolts 3 4 0 35 30 in lb Starter Relay Cable Terminal Bolts 3 9 0 40 35 in lb Stator Coil Bolt
518. tor cable Fuel Tank Breather Hose Fuel Tank Drain Hose Run the fuel tank drain hose and fuel tank breather hose through under the clamp Align the yellow tape with the clamp Run the fuel tank drain hose and fuel tank breather hose through under the clamp Align the blue tape with the clamp to fix fuel tank breather hose Fuel Tank Drain Hose Fuel Tank Breather Hose Run the fuel tank breather hose through the inside of the fuel tank drain hose Blue Tape Run the fuel tank breather hose through the outside of the rear wheel rotation sensor lead and rear brake right switch lead Fuel Tank Drain Hose Fuel Tank Breather Hose Other than California and Southeast Asia Models ABS Equipped Models 17 30 APPENDIX Cable Wire and Hose Routing ZA qum VA CM V e 4 2 m 27 5809216 G APPENDIX 17 31 Cable Wire and Hose Routing Run the fuel tank drain hose through under the heat insulation rubber plate Clamp Hold the fuel tank breather hose and idle adjusting screw cable Run the fuel tank drain hose through over the speed sensor lead Run the fuel tank drain hose and fuel tank breather hose through the inside of the clutch hose Run the fuel tank drain hose and fuel tank breather hose through the inside of the lower fairing Align the yellow tape with the end of the lower fairing to fix the fuel tank drain hose Fuel Tank Breather Ho
519. tor light LED does not light go to step ABS Indicator Light LED is Unlit When the Ignition Switch turned to ON e Turn the ignition switch OFF xIf the ABS indicator light LED A does not light it is normal xIf the ABS indicator light LED lights go to step ABS In dicator Light LED Lights When the Motorcycle is Run ning No Service Code ABS Indicator Light LED is Unlit When the Ignition Switch turned to ON e Do the 1st step test OCheck the terminal voltage between the black white lead terminal of the meter connector A and ground Special Tool Hand Tester 57001 1394 OTurn the ignition switch ON Terminal Voltage Standard About 10 V If the terminal voltage is not within the specification pro ceed the 2nd step If the terminal voltage correct replace the meter assem bly e Do the 2nd step test ODisconnect the meter connector OCheck for continuity between the black white lead termi nal of the main harness side connector A and ground If there is the continuity in the lead replace or repair the main harness If there is not the continuity in the lead proceed the 3rd step GL14288BS1 goad GL14123BS1 GL14125BS1 BRAKES 12 47 Anti Lock Brake System Equipped Models e Do the 3rd step test ODisconnect the ABS hydraulic unit connector OCheck for continuity between the b
520. trical System chapter If the reading is good check the output voltage 80174310651 Speed Sensor Service Code 24 Speed Sensor Output Voltage Inspection e Before this inspection inspect the input voltage see Speed Sensor Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Using the stand raise the rear wheel off the ground e Disconnect the speed sensor connector and connect the harness adapter A between the harness connector and speed sensor connector e Connect a digital meter to the harness adapter leads Special Tool Throttle Sensor Setting Adapter 1 57001 1400 Speed Sensor Output Voltage Connections to Adapter Meter Y W sensor Y lead C Meter BK BL sensor BK lead D e Measure the output voltage with the engine stopped and with the connector joined e Turn the ignition switch ON Output Voltage at Sensor Standard About DC 0 05 0 09 V or 4 5 4 9 V e Rotate the rear wheel by hand confirm the output voltage will be raise or lower e Turn the ignition switch OFF the reading is out of the range check the speed sensor see Speed Sensor Inspection in the Electrical System chapter and the wiring to ECU see wiring diagram in this section If the reading speed sensor and wiring are good replace the ECU see ECU Removal Installation FUEL SYSTEM 3 69 6617432651 C
521. ts of Clutch Master Cylinder Slave Cylinder Replacement in the Periodic Maintenance chap ter CLUTCH 6 9 6 10 CLUTCH Clutch Fluid Clutch Fluid Level Inspection e Refer to the Clutch Fluid Level Inspection in the Periodic Maintenance chapter Clutch Fluid Change e Refer to the Clutch Fluid Change in the Periodic Mainte nance chapter Bleeding the Clutch Line A WARNING Be sure to bleed the air from the clutch line when ever clutch lever action feels soft or spongy after the clutch fluid is changed or whenever a clutch line fitting has been loosened for any reason CAUTION Clutch fluid quickly ruins painted or plastic sur faces any spilled fluid should be completely wiped up immediately with wet cloth e Remove Screw A Clamp B Clutch Reservoir Cap C Diaphragm Plate Diaphragm e Fill the reservoir with fresh clutch fluid to the upper level line in the reservoir NOTE the clutch hose lightly going from the lower end to upper end and bleed the air off the reservoir e With the reservoir cap off slowly pump the clutch lever several times until no air bubbles can be seen rising up through the fluid from the holes at the bottom of the reser voir OBleed the air completely from the master cylinder by this operation e Remove the rubber cap from the bleed valve on the mas ter cylinder e Attach a clear plastic hose A to the bleed valve and run the other end of th
522. ty Light Headlight High Headlight Low Run the immobilizer amplifier lead through the clamp and fit it facing outward as shown in the figure Immobilizer Amplifier Lead Connector Vehicle down Sensor Lead Connector Meter Unit Lead Connector Run the main harness and immobilizer amplifier lead through the clamp Headlight Relay High Clamp Hold the main harness and insert the clamp into the middle air inlet duct 17 20 APPENDIX Cable Wire and Hose Routing 68095166 6 APPENDIX 17 21 Cable Wire and Hose Routing 10 11 12 13 14 15 16 17 18 19 20 21 Clamp 23 24 25 26 27 22 Right Turn Signal Light Lead Connector Clamp Hold the right turn signal light lead and insert the clamp into the middle air inlet duct Front Wheel Rotation Sensor Lead Connector Clamp Hold the main harness and insert the clamp into the middle air inlet duct Headlight Relay Low Clamp Hold the main harness and insert the clamp into the middle air inlet duct Right Switch Housing Lead and Horn Lead Right Switch Housing Lead Connector Run the right switch housing horn headlight and front wheel rotation sensor leads through the clamp Run the horn lead through the inside of the front fork Run the right switch housing lead through the outside of the front fork Clamp Run only the right switch housing lead through
523. ubricant is not available a heavy oil such as SAE 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication e f the chain appears especially dirty clean it before lubri cation CAUTION The O rings between the side plates seal in the lu bricant between the pin and the bushing To avoid damaging the O rings and resultant loss of lubri cant observe the following rules Use only kerosene or diesel oil for cleaning of the O ring of the drive chain Any other cleaning solution such as gasoline or trichloroethylene will cause de terioration and swelling of the O ring Immediately blow the chain dry with compressed air after clean ing Complete cleaning and drying the chain within 10 minutes 2 32 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Apply oil to the sides of the rollers so that oil will penetrate to the rollers and bushings Apply the oil to the O rings so that the O rings will be coated with oil e Wipe off any excess oil Oil Applied Areas A O rings B Drive Chain Slack Inspection NOTE OCheck the slack with the motorcycle setting on its side stand OCheck the slack with the motorcycle setting on its center stand center stand equipped models OClean the chain if it is dirty and lubricate it if it appears dry e Check the wheel alignment see Wheel Alignment Inspec tion e Rotate the rear wheel to find the position where the chain
524. uel Line Inspectlor oit e tute rhet IRE E a EE 3 115 Grip cand Gables ucc on o rto ed s beta pt ba d b be Ee 3 117 Free Play Inspection a ope troc exte nte e OE RR end tea 3 117 Free 3 117 Cable Installation sats toan 3 117 Cable Lubrication oS Aan als 3 117 dhrotle Body ASSy fats ep NR n nta e vta du teri usn e MER eee 3 118 Idle Speed Inspection Adjustment pp 3 118 Throttle Bore Cle annie cer 3 118 Synchronization Inspection Adjustment pp 3 118 Throttle Body Assy Removal pp 3 118 Throttle Body Assy Installatio ett reo ce e e 3 121 Throttle Body Assy 3 123 Throttle Body Assy Assembly pp 3 124 IBN EET 3 126 Air Cleaner Element Removal eene nnne nennen nennt neni 3 126 Air Cleaner Element Installation ooo eee obesse 3 126 Air Cleaner Element Inspection Nt 3 126 Air Cleaner Element Holder Removal pp 3 126 Air Cleaner Element Holder Installation Nt 3 126 Air Cleaner Oil Draining 3 127 Rear Air Inlet Duct Removal ad cce uere tu aderire qa 3 127 Rear Air Inlet Duct Installation 3 127 Front and Middle Air Inlet Duct Removal pp 3 128 Front an
525. uel Pump Bolts 9 8 1 0 87 in lb 2 Canister 3 Separator 4 Fitting 5 Red Hose 6 Blue Hose 7 Green Hose 8 White Hose 9 ABS Equipped Models 10 CAL and SEA Models 11 Other than CAL SEA and TH Models L Apply a non permanent locking agent R Replacement Parts S Follow the specified tightening sequence 3 10 FUEL SYSTEM DFI System DFI System 5 4 39 9 07 9 9 6617204095 C DFI System P N S SH SS AS S ECU Crankshaft Sensor Camshaft Position Sensor Main Throttle Sensor Subthrottle Sensor Subthrottle Valve Actuator Inlet Air Pressure Sensor Atmospheric Pressure Sensor Water Temperature Sensor Inlet Air Temperature Sensor Gear Position Switch Vehicle down Sensor Fuel Injectors Delivery Pipe Pressure Regulator Fuel Filter Fuel Pump Speed Sensor Oxygen Sensor Equipped Models Air Switching Valve Battery 12 V 14 Ah FUEL SYSTEM DFI 3 11 3 12 FUEL SYSTEM DFI System E BL BL W w BL 1 W BK BK WBK yn i 8 ds m w 8L av BR BK BR BK BR BK a BR BR BL W BR Y R Y R gt BL BKAY BR BK BR BK
526. uel line clogged Inspect and repair see chapter 3 Fuel pump operates intermittently and often DFI fuse blows Fuel pump trouble Inlet air pressure sensor trouble Cracked or obstructed inlet air pressure sensor hose Atmospheric pressure sensor trouble Water temperature sensor trouble Inlet air temperature sensor trouble Main throttle sensor trouble Fuel pump bearings may wear Replace the fuel pump see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect and repair or replace see chapter 3 Inspect Inspect Inspect Inspect see chapter 3 see chapter 3 see chapter 3 see chapter 3 Subthrottle sensor trouble Inspect see chapter 3 Subthrottle valve actuator trouble lt Inspect see chapter 3 Knocking Fuel poor quality or incorrect Fuel change Use the gasoline recommended in the Owner s Manual Spark plug incorrect Replace it with the correct plug see chapter 2 Stick coil trouble Inspect see chapter 16 ECU trouble Inspect see chapter 3 Engine vacuum not synchronizing Inspect and adjust see chapter 2 Inlet air pressure sensor trouble Inspect see chapter 3 Atmospheric pressure sensor trouble Inspect see chapter 3 3 36 FUEL SYSTEM DFI DFI System Troubleshooting Guide Symptoms or Possible Causes Water temperature sensor trouble Inlet air temper
527. uge 57001 1290 875712905 C Vacuum Gauge 57001 1369 225 222 ST571369ST C Hand Tester 57001 1394 7571394ST C Throttle Sensor Setting Adapter 1 57001 1400 875714005 C Peak Voltage Adapter 57001 1415 4 875714155 C Needle Adapter Set 57001 1457 T571457ST C Throttle Sensor Setting Adapter 57001 1538 Sensor Harness Adapter 57001 1561 875715615 Fuel Pressure Gauge Adapter 57001 1593 7571593ST C FUEL SYSTEM DFI 3 21 Special Tools and Sealant Fuel Hose Kawasaki Bond Silicone Sealant 57001 1607 56019 120 7571607ST C 875601205 3 22 FUEL SYSTEM DFI DFI Servicing Precautions Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system OThis 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 ODo not reverse the battery cable connections This will damage the ECU OTo 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 OTake care not to short the cable that are directly con nected to the battery positive terminal to the chassis grou
528. uge Indicator Unit Meter Unit Circuit 9 1 Meter Unit 14 Crankshaft Sensor 2 Dimmer Switch High Beam 15 ECU 3 Turn Signal Switch Right 16 Frame Ground 1 4 Turn Signal Switch Left 17 Water proof Joint 1 5 ABS Hydraulic Unit ABS Equipped Models 18 Ignition Fuse 10 A 6 Oil Pressure Switch 19 ECU Fuse 15 A 7 Gear Position Switch 20 Fuse Box 2 8 Speed Sensor 21 Ignition Switch 9 Fuel Level Sensor 22 Main Fuse 30 A 10 Joint Connector 2 23 Battery 12 V 14 Ah 11 Fuel Reserve Switch 24 Frame Ground 2 12 Water proof Joint 2 25 Engine Ground 13 Water Temperature Sensor 26 Immobilizer Amplifier Immobilizer Equipped Models ELECTRICAL SYSTEM 16 87 Immobilizer System Equipped Models This motorcycle is equipped with an immobilizer system to protect the motorcycle from theft This system provides a theft proof device by means of matching a code between the inbuilt key transponder and ECU Electronic Control Unit If the code does not match ignition system injectors and sub throttle valve actuator will not operate and the engine will not start Abstract e Do not keep more than one immobilizer key of any system on a key ring Jamming of the key code signal may occur and the operation of the system may be affected e The warning indicator light LED will flash for a period of 24 hours once the ignition switch has been switched off and the key removed This flashing can be set to
529. uid isopropyl alcohol or ethyl alcohol for cleaning of the brake parts Do not use any other fluid for cleaning these parts Gasoline engine oil or any other petroleum distillate will cause deterio ration 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 When handling the disc pads or disc be careful that no disc brake fluid or any oil gets on them Clean off any fluid or oil that inadvertently gets on the pads or disc with a high flash point solvent Do not use one which will leave an oily residue Replace the pads with new ones if they cannot be cleaned satisfacto rily Brake fluid quickly ruins painted surfaces any spilled fluid should be completely wiped up imme diately If any of the brake line fittings or the bleed valve is opened at any time the AIR MUST BE BLED FROM THE BRAKE LINE Brake Hose Brake Hose and Pipe Removal Installation e Refer to the Brake Hose and Pipe Replacement in the Periodic Maintenance chapter Brake Hose and Pipe Inspection e Refer to the Brake Hose and Pipe Damage and Instal lation Condition Inspection in the Periodic Maintenance chapter BRAKES 12 29 12 30 BRAKES Anti Lock Brake System Equipped Models Parts Location 5 Front Wheel Rotation Sensor Front Wheel Rotation Sensor Rotor Rear Wheel Rotation Sens
530. uivalent one NOTE OCharging rates will vary depending on how long the battery has been stored temperature and the type of charger used Let battery sit 30 minutes after initial charge then check voltage using a voltmeter If it is not at least 12 6 V repeat charging cycle e After charging is completed press down firmly with both hands to seat the strip of caps A into the battery don t pound or hammer When properly installed the strip of the caps will be level with the top of the battery CAUTION Once the strip of the caps is installed onto the bat tery never remove the caps nor add water or elec trolyte to the battery NOTE ensure maximum battery life and customer satisfac tion it is recommended the battery be load tested at three times its amp hour rating for 15 seconds Re check voltage and if less than 12 6 V repeat the charging cycle and load test If still below 12 6 V the battery is defective 8 08019851 C 8 08010851 6 16 32 ELECTRICAL SYSTEM Battery Precautions 1 No need of topping up No topping up is necessary in this battery until it ends its life under normal use Forcibly prying off the seal cap to add water is very dangerous Never do that 2 Refreshing charge If an engine will not start a horn sounds weak or lamps are dim it indicates the battery has been discharged Give refresh charge for 5 to 10 hours with charge current shown in the specificat
531. uld damage the DFI or electrical system parts 9617572051 Troubleshooting the DFI System OAfter measurement remove the needle adapters and ap ply silicone sealant to the seals A of the connector B for waterproofing Sealant Kawasaki Bond Silicone Sealant 56019 120 e Always check battery condition before replacing the DFI parts A fully charged battery is a must for conducting accurate tests of the DFI system e 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 e Measure the coil winding resistance when the DFI part is cold at room temperature e Do not adjust or remove the throttle and subthrottle sen sor e Do not directly connect a 12 V battery to a fuel injector Insert a resistor 5 7 or a bulb 12 V x 3 3 4 W in series between the battery and the injector e The DFI parts have been adjusted and set with precision Therefore they should be handled carefully never strike sharply as with a hammer or allowed to drop on a hard surface Such a shock to the parts can damage them e Check wiring and connections from the ECU connector to the suspected faulty DFI parts using the hand tester special tool analog tester rather than a digital tester Special Tool Ha
532. ulty ECU in the ABS hydraulic unit Replace the ABS hydraulic unit xIf the ABS indicator light LED unlit ABS system is nor mal service code is not stored temporary failure 6114288851 C ABS Pump Motor Relay Inspection Service Code 35 e Do the 1st step test OCheck the ABS pump motor relay fuse 30 A A xIf the fuse blown proceed the 2nd step If the fuse correct proceed the 4th step 148145 e Do the 2nd step test ODisconnect the ABS hydraulic unit connector OCheck for continuity between the red and light blue lead terminals of the ABS hydraulic unit connector A lf there is the continuity in the lead replace the ABS hy draulic unit lf there is not the continuity in the lead proceed the 3rd step 6114131851 C 12 50 BRAKES Anti Lock Brake System Equipped Models e Do the 3rd step test OCheck for continuity between the red lead terminal of the main harness side connector A and red lead terminal of the fuse box B If there is the continuity in the lead replace the fuse x lf there is not the continuity the lead replace or repair the main harness e Do the 4th step test OCheck the battery terminal voltage between the red lead terminal of the fuse box A and ground Special Tool Hand Tester 57001 1394 Battery Terminal Voltage Standard Battery Voltage If the battery terminal voltage is not within the specifica tion pro
533. um and Fork Installation e Apply engine oil to the shift drum forks and rods e Install the shift rods A e Install the forks as shown in the figure OPosition the one with shortest ears B on the drive shaft and place the pin in the center groove on the shift drum OThe two forks C on the output shaft are identical NOTE OThe forks have marks 049 D 030 E and position them so that their marks face the engine left side e Apply a non permanent locking agent to the threads of the shift drum bearing holder screws and tighten them Torque Shift Drum Bearing Holder Screws 4 9 N m 0 50 kgf m 43 in Ib Shift Drum Disassembly e Remove the shift drum see Shift Drum and Fork Re moval e While holding the shift drum with a vise remove the shift drum cam holder bolt Shift Drum Cam Holder Bolt A Dowel Pin B Shift Drum Assembly e Be sure to install the dowel pin e Apply a non permanent locking agent to the threads of the shift drum cam holder bolt and tighten it Torque Shift Drum Cam Holder Bolt 12 N m 1 2 kgf m 106 in Ib 9113396851 C 8113395 52 C 6113397851 CRANKSHAFT TRANSMISSION 9 45 Transmission Shift Fork Bending Inspection e Visually inspect the shift forks and replace any fork that is bent A bent fork could cause difficulty in shifting or allow the transmission to jump out of gear when under power 90 A Shift Fork Gear Groove Wear Inspection
534. ump drive gear shaft e Install the water hose A and the air bleeder hose B for the water pump body as shown in the figure e Tighten Torque Radiator Water Hose Clamp Screws 2 0 N m 0 20 kgf m 18 in Ib 4 10 COOLING SYSTEM Water Pump e Install the water pump cover A e Tighten Torque Water Pump Cover Bolts B 9 8 N m 1 0 kgf m 87 in Ib e Install the water hose C as shown in the figure e Tighten Torque Radiator Water Hose Clamp Screws D 2 0 N m 0 20 kgf m 18 in Ib e Install Pad E Removed Parts see appropriate chapters Water Pump Impeller Inspection e Visually inspect the water pump impeller A If the surface is corroded or if the blades are damaged replace the water pump assy COOLING SYSTEM 4 11 Radiator Radiator and Radiator Fan Removal e Remove Middle Fairings see Middle Fairing Removal in the Frame chapter Coolant Drain see Coolant Change in the Periodic Maintenance chapter Clamp Screws A Loosen Reserve Tank Hose B Air Bleeder Hose C for Thermostat Housing Water Hose D Oil Cooler Outlet Hose E Upper Radiator Mounting Bolt F e Remove Radiator Fan Motor Lead Connector A Clamp Screw B Loosen Water Hose C Lower Radiator Mounting Bolt D Upper Radiator Mounting Bolt E Radiator F CAUTION Do not touch the radiator core This could damage the radiator fins resulting in loss of cooling effi ciency
535. und e Remove Rear Sprocket Nuts A Rear Sprocket B Rear Sprocket Installation e Install the sprocket facing the tooth number marking A outward e Tighten the rear sprocket nuts Torque Rear Sprocket Nuts 69 Nm 7 0 kgf m 51 ft Ib e Install the rear wheel see Rear Wheel Installation in the Wheels Tires chapter Coupling Installation e Apply high temperature grease to the following Coupling Grease Seal Lips A Coupling Internal Surface B Ball Bearing C GKO05086BS1 C FINAL DRIVE 11 9 Sprocket Coupling e Install Collar A Coupling Coupling Bearing Removal e Remove Coupling Grease Seal Circlip A Special Tool Inside Circlip Pliers 57001 143 e Remove the bearing A by tapping from the wheel side Special Tool Bearing Driver Set B 57001 1129 5501 OO S 55 Coupling Bearing Installation e Replace the bearing with a new one e Press in the bearing A until it is bottomed Special Tool Bearing Driver Set B 57001 1129 e Pack the bearing with high temperature grease e Replace the circlip with a new one Special Tool Inside Circlip Pliers 57001 143 8 05068851 C e Replace the grease seal with a new one e Press in the grease seal so that the seal surface is flush with the end of the hole OApply high temperature grease to the grease seal lips Special Tool Bearing Driver Set 57001 1129 11 10 FINAL DR
536. und and it must be repaired or re placed e Narrow down suspicious locations by repeating the con tinuity tests from the ECU connectors If no abnormality is found in the wiring or connectors the DFI parts are the next likely suspects Check the part starting with input and output voltages However there is no way to check the ECU itself If an abnormality is found replace the affected DFI part If no abnormality is found in the wiring connectors and DFI parts replace the ECU OAfter inspection be sure to connect all the DFI electrical connectors Do not turn the ignition switch ON while the DFI electrical connectors and ignition system connectors are disconnected Otherwise the ECU memorizes ser vice codes as open circuit GC17222D82 C 6017029281 FUEL SYSTEM 3 29 Troubleshooting the DFI System DFI Diagnosis Flow Chart Problem occurs Confirm problems Gather information from rider Turn the ignition switch ON Warning indicator light does Warning indicator light goes Warning indicator light blinks not go on or blink and on and FI warning message and immobilizer warning warning message and and FI warning symbol are message and immobilizer warning symbol are not displayed alternately on the warning symbol are displayed displayed on the LCD LCD alternately on the LCD Conduct non self diagnosis inspection Conduct self diagnosis Conduct self diagnosis
537. up is worn damaged softened rotted or swollen the piston assembly should be replaced to renew the cup lf fluid leakage is noted at the clutch lever the piston as sembly should be replaced to renew the cup e Check the dust cover E for damage xIf it is damaged replace the piston assembly e Check that the relief F and supply G ports are not plugged xIf the small relief port becomes plugged the clutch will drag Blow the ports clean with compressed air e Check the piston return spring H for any damage xIf the spring is damaged replace it q a Gro9005BSi C 6 8 CLUTCH Clutch Slave Cylinder Clutch Slave Cylinder Removal e Remove Left Middle Fairing see Middle Fairing Removal in the Frame chapter Coolant Reserve Tank see Coolant Change in the Peri odic Maintenance chapter Banjo Bolt A Clutch Slave Cylinder Bolts B Slave Oylinder C CAUTION Immediately wash away any clutch fluid that spills It may damage painted surfaces Pull off the clutch pipe A by prying the damper B out of the grooves of the subframe This prevents the pipe from distorting e Perform the following if the clutch slave cylinder is to be removed but not disassembled CAUTION If the clutch slave cylinder is removed and left alone the piston will be pushed out by spring force and the clutch fluid will drain out ORemove the clutch slave cylin
538. upt Other conditions Large brake lever stroke Large pedal stroke BRAKES 12 39 Anti Lock Brake System Equipped Models Pre Diagnosis Inspection 1 There shouldn t be a lot of play in the wheel bearing R pce wheel orans NG Check brake fluid level in brake reservoir Replenish brake fluid OK 1 Check for brake fluid leakage Repair brake line OK Check brake lever and brake pedal function Repair or replace master cylinder OK NG Check brake pad and brake disc Replace faulty parts OK i N Front and rear wheels should rotate smoothly without G Repair or replace caliper brake drag There shouldn t be excessive axle bending or disc runout 01140128 12 40 BRAKES Anti Lock Brake System Equipped Models Pre Diagnosis Inspection 2 No Unlit Check the ABS indicator light LED Check the power source wiring and meter o Does the indicator light light up with unit the ignition switch ON Yes lit Drive at 6 km h 3 7 mph or above for one minute or more When the motorcycle is running does the indicator light go off No Count the number of times the indicator light blinks in Ask the rider if the problem the self diagnosis mode to find the service code happens again ABS is normal 61141118 F Self diagnosis Outline When the indicator light has blinked or come on the ABS hydraulic unit memorizes and
539. ur faces of the upper and lower bearing inserts A e Apply molybdenum disulfide oil solution to the threads B and seating surface C of the connecting rod nuts e Install the inserts so that their nails D are on the same side and fit them into the recess of the connecting rod and cap CAUTION Wrong application of oil and grease could cause bearing damage 6105060181 C 9 4 0 6105037851 CRANKSHAFT TRANSMISSION 9 17 Crankshaft and Connecting Rods OWhen installing the inserts A be careful not to damage the insert surface with the edge of the connecting rod B D or the cap C One way to install inserts is as follows Installation D to Cap Installation E to Connecting Rod Push F Spare Dowel Pin G Connecting Rod Bolts H e Remove debris and clean the surface of inserts e Install the cap on the connecting rod aligning the weight and diameter marks 6105038851 C e Install the crankshaft see Crankshaft Installation e Install each connecting rod on its original crankpin OThe connecting rod big end is bolted using the plastic region fastening method OThis method precisely achieves the needed clamping force without exceeding it unnecessarily allowing the use of thinner lighter bolts further decreasing connecting rod weight OThere are two types of the plastic region fastening One is a bolt length measurement method and other
540. urpose perfectly match valve and valve seat area FINISHED check valve head for damage width to specification GEI5143B 5 34 ENGINE TOP END Throttle Body Holder Throttle Body Holder Installation e Apply grease to the O rings A e Be sure to install the O rings e Install the clamps B as shown in the figure e Tighten the holder bolts following the tightening sequence 1 3 Torque Throttle Body Assy Holder Bolts C 9 8 N m 1 0 kgf m 87 in Ib Throttle Body Assy Holder Clamp Bolts D 2 0 0 20 kgf m 18 in Ib SOOO e RED 2 j LN a A GE14089BS2 C ENGINE TOP END 5 35 Muffler WARNING To avoid a serious burn do not remove the muffler when the engine is still hot Wait until the muffler cool down Muffler Body Removal Installation e Remove Lower Fairings see Lower Fairing Removal in the Frame chapter Rear Fairing see Rear Fairing Removal in the Frame chapter Equipped Models Muffler Body Clamp Bolts A Muffler Body Mounting Bolts B and Nuts e Pull the muffler bodies C backward GE 80498W2 C LLY A e Replace the muffler body gaskets A with new ones Olnstall the gaskets until they are bottomed B Olnstall the gaskets so that their chamfer sides C face the front 6 1 8056851 C 5 36 ENGINE TOP END Muffler e Fit A the project
541. urs in the system I ms N 0 i x 1105 _ FUEL SYSTEM 3 25 Troubleshooting the DFI System With the engine stopped and turned in the self diagnosis mode the service code error code A is displayed on the LCD by the number of two digits ERROR cong 31 oo 1109 _ 8 12 00 0 172400 When the service code A is displayed for first ask the rider about the conditions B of trouble and then start to determine the cause C of problem As a pre diagnosis inspection check the ECU for ground and power supply the fuel line for no fuel leaks and for correct pressure The pre diagnosis items are not indicated by the warning indicator light LED Fl warning message and FI warning symbol Don t rely solely on the DFI self diagnosis function use common sense 6617406651 C 3 26 FUEL SYSTEM DFI Troubleshooting the DFI System Even when the DFI system is operating normally the warning indicator light LED goes on and Fl warning message and Fl warning symbol may be displayed under strong electrical interference Additional measures are not required Turn the ignition switch OFF to stop the indicator light message and symbol If the warning indicator light LED of the motorcycle brought in for repair still goes on check the service code When the repair has been done the warning indicator light LED goes off and Fl warning message and Fl warning symbol
542. using 3 S E VE M Cylinder Head Jacket Air Bleeder Hose for Water Pump Cylinder Jacket Thermostat Housing Radiator Reserve Tank Hose Reserve Tank Air Bleeder Hose for Water Pump Outlet Hose Inlet Hose 011 Cooler Water Pump mum Hot Coolant Reserve Tank Overflow Hose gt Cold Coolant 60040828 6 COOLING SYSTEM 4 5 Coolant Flow Chart 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 less than 55 C 131 F the thermostat closes so that the coolant flow is restricted through the air bleeder hole causing the engine to warm up more quickly When coolant temperature is more than 58 62 C 136 144 F the thermostat opens and the coolant flows When the coolant temperature goes up beyond 95 C 203 F the radiator fan relay conducts to op erate 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 coolant temperature is below 90 C 194 F the fan relay opens and the radiator fan stops
543. ut shaft E Engine Sprocket Installation e Replace the sprocket washer and axle cotter pin e Install the engine sprocket onto the output shaft e Apply a non permanent locking agent to the threads of the chain guide bolts e Install the chain guide and tighten the bolts Torque Chain Guide Bolt 12 N m 1 2 kgf m 106 in Ib Chain Guide Bolts 9 8 Nm 1 0 kgf m 87 in Ib e Apply molybdenum disulfide oil solution to the threads and the seating surface of the engine sprocket nut e Tighten Torque Engine Sprocket Nut 125 N m 12 7 kgf m 92 2 ft Ib NOTE OTighten the nut while applying the rear brake e After torquing the engine sprocket nut bend the one side of the washer A over the nut e Adjust the drive chain slack after installing the engine sprocket see Drive Chain Slack Adjustment in the Pe riodic Maintenance chapter FINAL DRIVE 11 7 11 8 FINAL DRIVE Sprocket Coupling e Install the engine sprocket cover e Install the clamp A as shown in the figure and tighten the cover bolts Torque Engine Sprocket Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib e Install the removed parts see appropriate chapters Rear Sprocket Removal e Remove the rear wheel see Rear Wheel Removal in the Wheels Tires chapter CAUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the gro
544. uter Races Lower and Upper Ball Bearings OThe lower and upper ball bearings are identical 14 8 STEERING Steering Stem e Install the stem A through the head pipe and install the ball bearing B and inner race C on it e Install Stem Cap D Steering Stem Nut E e Settle the bearings in place as follows OTighten the steering stem nut with 55 N m 5 6 kgf m 41 ft Ib of torque first and loosen it a fraction of a turn until it turns lightly Afterward tighten it again with specified torque using a steering stem nut wrench A Special Tool Steering Stem Nut Wrench 57001 1100 Torque Steering Stem Nut 23 N m 2 3 kgf m 17 ft Ib e 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 e Hand tighten the stem locknut until it touches the claw washer e 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 e Install the stem head e Install the washer and temporary tighten the stem head nut e Install the front forks see Front Fork Installation in the Suspension chapter NOTE Tighten the upper front fork clamp bolts first next the stem head nut last the lower front fork clamp bolts Tighten the two lower front fork clamp bolts alternately two times to ensure even tightening torque Torque Front Fork Clamp B
545. val Installation GC17102B 5 FUEL SYSTEM DFI 3 59 Inlet Air Temperature Sensor Service Code 13 Inlet Air Temperature Sensor Circuit BR BK 3 BR BK BR BK ec 6GC17426CW2 1 ECU 2 Inlet Air Temperature Sensor 3 Water proof Joint 2 3 60 FUEL SYSTEM Water Temperature Sensor Service Code 14 Water Temperature Sensor Removal Installation CAUTION Never drop the water temperature sensor especially on a hard surface Such a shock to the sensor can damage it e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Remove Throttle Body Assy see Throttle Body Assy Removal Connector A Water Temperature Sensor B e Replace the gasket with a new one and tighten the water temperature sensor Torque Water Temperature Sensor 25 N m 2 5 kgf m 18 ft Ib e Fill the engine with coolant and bleed the air from the cool ing system see Coolant Change in the Periodic Mainte nance chapter Water Temperature Sensor Output Voltage Inspection NOTE OBe sure the battery is fully charged e Remove the ECU see ECU Removal ODo not disconnect the ECU connectors e Connect a digital meter A to the ECU connector B us ing the needle adapter set Special Tool Needle Adapter Set 57001 1457 Water Temperature Sensor Output Voltage Connections to ECU Connector Meter O lead terminal 25 Mete
546. vel sensor as shown in the figure Hollows B Front C e Apply a non permanent locking agent to the threads of the level sensor bolts and tighten them Torque Fuel Level Sensor Bolts 6 9 N m 0 70 kgf m 61 in Ib Fuel Reserve Switch Inspection e Fill the fuel tank with fuel e Close the fuel tank cap surely e Remove the fuel tank see Fuel Tank Removal in the Fuel System DFI chapter e Connect the test light A 12 V 3 4 W bulb in a socket with leads and the 12 V battery B to the fuel pump lead connector C Connections Battery 12 V 3 4 W Bulb one side 12 V 3 4 W Bulb other side BK R Lead Terminal Battery BK W Lead Terminal Special Tool Needle Adapter Set 57001 1457 the test light turn on the reserve switch is defective Replace the fuel pump e Remove the fuel pump see Fuel Pump Removal in the Fuel System DFI chapter e Connect the test light 12 V 3 4 W bulb in a socket with leads and the 12 V battery to the fuel pump lead connec tor as shown in the figure 12 V Battery A Test Light B Fuel Pump Lead Connector C Fuel Reserve Switch D lf the test light doesn t light replace the fuel pump NOTE Olt may take a long time to turn on the test light in case that the fuel reserve switch is inspected just after the fuel pump is removed Leave the fuel reserve switch with leads for inspection connected for few minutes 8 18241851 C 02188
547. ver Bolts 9 8 1 0 87 in lb L 2 Cam Sprocket Mounting Bolts 15 1 5 11 L 3 Camshaft Cap Bolts 12 1 2 106 in Ib S 4 Camshaft Chain Guide Bolts 12 1 2 106 in Ib S 5 Camshaft Chain Tensioner Mounting Bolts 9 8 1 0 87 in lb 6 Camshaft Position SensorBot 98 10 870 7 MO 5 8 5 9 Cylinder Head Cover Bots 98 10 S 10 RS n 12 13 Front Engine Mounting Bots Mi so 60 44 RS 14 15 Throttle Body Assy Holder Bots 98 10 s 16 17 L G Apply grease L Apply a non permanent locking agent M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts S Follow the specified tightening sequence SS Apply silicone sealant 5 4 ENGINE TOP END Exploded View GE02367885 C ENGINE TOP END 5 5 Exploded View Torque No Fastener Nm kgfm Remarks 1 Crankshaft Sensor Cover Bolts 9 8 1 0 87 L 1 2 Exhaust Pipe Manifold Holder Nuts 17 1 7 13 3 Muffler Body Clamp Bolts 17 1 7 13 4 Muffler Body Mounting Bolts 34 3 5 25 5 Oxygen Sensor Equipped Models L Apply a non permanent locking agent R Replacement Parts 5 6 ENGINE TOP END Exhaust System Exhaust System MANIFOLD MUFFLER BODY SPECIFICATION MARKETING CODE Honeycomb Type Honeycomb Type Catalyst Catalyst UE Gs 2 P No 39178 0119 ee B091 0916
548. y If the starter motor is not turn inspect the starter lockout switch gear position switch sidestand switch and relay box lf their parts are normality replace the ECU 6517009851 C ELECTRICAL SYSTEM 16 49 Ignition System 3rd Check e Inspect the engine for its secure stop after the following operations are completed e Run the engine to the following conditions Condition Transmission Gear 1st Position Clutch Lever Release Sidestand Up e Set the sidestand on the ground then the engine will stop x If whichever may not be stopped inspect the gear position switch starter lockout switch sidestand switch and relay box x lf their parts are normality replace the ECU IC Igniter Inspection OThe IC igniter is built in the ECU A e Refer to the following items Interlock Operation Inspection see Interlock Operation Inspection Ignition System Troubleshooting see Ignition System section ECU Power Supply Inspection see ECU Power Supply Inspection in the Fuel System DFI chapter 16 50 ELECTRICAL SYSTEM Ignition System Ignition System Troubleshooting Faulty ignition No spark No good Battery Inspection Charge or replace battery Good Ignition system wiring and connector 0998 Repair or replace inspection damaged part Good No good Spark plug inspection Replace spark plug Good No good Stick coil winding resistance inspection Replace stick coil G
549. y follow the instructions supplied by the manufacturer of the cleaning product e Warm up the engine and run it at normal operating tem perature for about ten minutes e Stop the engine and drain the cooling system e Fill the system with fresh water e Warm up the engine and drain the system e Repeat the previous two steps once more e Fill the system with a permanent type coolant and bleed the air from the system see Coolant Change in the Peri odic Maintenance chapter Coolant Reserve Tank Removal Installation e The coolant reserve tank is removed and installed dur ing coolant change see Coolant Change in the Periodic Maintenance chapter COOLING SYSTEM 4 9 Water Pump Water Pump Removal e Remove Coolant Drain see Coolant Change in the Periodic Maintenance chapter Engine Oil Drain see Engine Oil Change in the Periodic Maintenance chapter Clutch Slave Cylinder see Clutch Slave Cylinder Re moval in the Clutch chapter Engine Sprocket Cover see Engine Sprocket Removal in the Final Drive chapter e Remove Pad A Clamp Screw B Loosen Water Hose C Water Pump Cover Bolts D Water Pump Cover E e Loosen the clamp screw A e Remove the water hose B and the air bleeder hose C for the water pump body e Remove the water pump body D with impeller E Water Pump Installation e Turn the water pump shaft so that the slot A in its shaft fits onto the projection B of the oil p
550. y soap and water solution to the areas E as shown in the figure OWatching the pressure gauge squeeze the pump lever F and build up the pressure until the pressure reaches the maximum pressure Fuel Line Maximum Pressure Standard 300 kPa 3 06 kgf cm 43 psi CAUTION During pressure testing do not exceed the maxi mum pressure for which the system is designed e Watch the gauge for at least 6 seconds If the pressure holds steady the system is good lf the pressure drops at once or if bubbles are found in the area the line is leaking Replace the delivery pipe injectors and related parts ORepeat the leak test and check the fuel line for no leak age e Install the throttle body assy see Throttle Body Assy In stallation e Run the hoses correctly see Cable Wire and Hose Rout ing section in the Appendix chapter FUEL SYSTEM DFI 3 115 8617224052 C 3 116 FUEL SYSTEM DFI Fuel Injectors Fuel Injector Circuit Q3 ip Ep BL R w R BL Y BL Y BL Y WR BL BK BL BK BL G BL R BL R W R W R 7 R SR N GLY 9i D 1 Ex E D p or Bareja x 66172360 2 C ECU Joint Connector 3 Fuel Pump Frame Ground 1 Frame Ground 2 Joint Connector 2 Starter Relay Battery 12 V 14 Ah Main Fuse 30 A
551. y the same type and brand of fluid thereafter Recommended Disc Brake Fluid Grade DOTA e Follow the procedure below to install the rear brake fluid reservoir cap correctly OFirst tighten the rear brake fluid reservoir cap B clock wise 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 65130248 5 Brake Pad Wear Inspection e Remove the brake pads see Front Rear Brake Pad Re moval in the Brakes chapter e Check the lining thickness A of the pads in each caliper xIf 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 2 Front 4 0 mm 0 16 in 6513148881 0 Rear 5 0 mm 0 20 in Service Limit 1 mm 0 04 in 2 38 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Light Switch Operation Inspection e Turn on the ignition switch e 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 x lf it does not adjust the brake light switch e While holding the switch body turn the adjusting nut to adjust the switch Switch Body A Adjusting Nut B Light sooner as the body rises C Light later as the body lowers D CAUTION To avoid damaging the electrical connections
552. ystem DFI chapter Water Temperature Sensor Inspection e Refer to the Water Temperature Sensor Inspection in the Electrical System chapter COOLING SYSTEM 4 17 ENGINE TOP END 5 1 Engine Top End Exploded View Exhaust System Specifications Special Tools and Sealant Clean Air System Table of Contents Pir Suetorr Valve guo Air Suction Valve Installatig cc un puedo ni Air Suction Valve InSpecllOlt suscite el do oa asa ui sse Air Switching Valve Removal Jio rise if itc qoae eta d is acs fecta na reb Air Switching Valve Installation pt Air Switching Valve Operation Test sre ertt bia Ede Air Switching Valve Unit Test rrt n re RR pee Exe Clean Air System Hose Inspection siete rie teme ae bec md e teile e Cylinder Head Cover Cylinder Head Cover Removal pp Cylinder Head Cover Installation Camshaft Chain Tensioner Camshaft Chain Tensioner Removal 00440 8 Camshaft Chain Tensioner Installation pp Camshaft Camshaft Chain Camshaft Removal Camshaft Installation Camshaft Camshaft Cap Wear pp Camshaft Runout

- Rage Motorsport

Contents

Download Pdf Manuals

Related Search

Related Contents