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Be sure the battery is fully charged.

1. ea eL oS 2 W BL UNE y poster des Pg 22 E 26 t D o D zz Siero 6C17173BW2 6 A ECU L Subthrottle Valve Actuator J Subthrottle Sensor m Throttle Body Assy Connector 3 64 FUEL SYSTEM DFI Stick Coils 1 2 3 4 Service Code 51 52 53 54 Stick Coil 1 Ignition Coil Stick Coil 2 Ignition Coil Stick Coil 3 Ignition Coil Stick Coil 4 Ignition Coil Service Code 51 Service Code 52 Service Code 53 Service Code 54 a Removal Installation CAUTION Never drop the stick coils especially on a hard sur face Such a shock to the stick coil can damage it e See the Ignition System section in the Electrical System chapter Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Remove the ECU see this chapter Do not disconnect the ECU connector e Connect a digital voltmeter A as shown with the needle adapter set B OMeasure the input voltage to each primary winding of the ignition coils with the engine stopped and with the con nectors joined e Turn the ignition switch ON 6GC171289BS1 C Stick Coil Input Voltage at ECU Connections for Stick Coil 1 Meter BK lead terminal 39 Meter BK Y lead terminal 51 Connections for Stick Coil 2 Meter BK G lead terminal 38 Meter
2. BaACKUDS tetto ne D erc en duet eet edo Eeer Main Throttle Sensor Service Code 171 WEE Main Throttle Sensor Removal Adjustment m Input Voltage Inspection Output Voltage Inspection Resistance Inspection ie ret e een e E ERU SERERE ARRA ERE AERE AER die Inlet Air Pressure Sensor Service Code 12 40044 pide ef UE ee EE Input Voltage JInspechon emen nen nennen nenne Output Voltage Inspection Inlet Air Temperature Sensor Service Code 13 Hemovallnstallaton Output Voltage Inspection Sensor Resistance Inspection nennen Water Temperature Sensor Service Code 14 ee ENEE E re EE Output Voltage Inspection 3 2 FUEL SYSTEM DFI Sensor Resistance Inspection ns Atmospheric Pressure Sensor Service Code 15 Rer n Input Voltage Inspectionm eene nnn rennen nna Output Voltage Inspechon nennen Crankshaft Sensor Service Code 21 ted eta RE bep nei tard fe Crankshaft Sensor Removal Installation 8 Crankshaft Sensor Inspection neret neis Camshaft Position Sensor Service Code 23 Camshaft Position Sensor 51
3. bene e ardet ec bere heh eR ea e Rees Cable Installation nnn GCable Eubricatior te eet e e kre Stes Glutch Lever Installation Clutch tei t OH Ever am p ala x Cl tchi GOoVer iieri estt ne cer tet Lee SERE ias ea dp e SR EE Clutch Cover 2 Clutch Cover Installation tee Re eei He ede Dre EXE EM eda Release Shaft Release Shaft Installation reri eene a Clutch Cover Disassembly Ee EAR RER ele EE Ure EE 6 10 Gl tchr Removals iR eer P tabe e er Ra che Rr ee PEPPER eens dele a 6 10 Clutch ESE ha 6 10 Clutch Plate Assembly Inspectigom 6 12 Clutch Plate Assembly Adjustment ete eaaet ie nehme Ee be e 6 12 Clutch Plate Wear Damage Inspection mee 6 13 Clutch Plate Warp Inspechon enne nnne 6 13 Clutch Spring Free Length Measurement eese enne 6 13 6 2 CLUTCH Exploded View gt SC Qo GF02034BN5 Exploded View CLUTCH 6 3 Torque
4. 1 12 Technical Information Tail Brake Lights Employing LED 1 13 Technical Information KAWASAKI LOW EXHAUST EMISSION SYSTEM 1 15 Bingen 1 16 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 wires from the battery to prevent the engine ON S from accidentally turning over Disconnect the ground wire AOA NT A first and then the positive When completed with the Sep Zei hin e service first connect the positive wire to the positive 2 Ape terminal of the battery then the negative wire to the neg ative terminal DISASSEMBLY ASSEMBLY 68020248 5 Edges of Parts Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts GB02004B S
5. 2 37 Coolant Change 2 20 Front Fork Oil Leak Check 2 37 Engine Top End 2 22 Rear Shock Absorber Oil Leak Air Suction Valve Inspection 2 22 CHECK 2 37 Valve Clearance Inspection 2 22 Steering ET 2 37 Gi o nm 2 23 Steering Inspection 2 37 Clutch Adjust Inspection 2 23 Steering Adjustment 2 37 Engine Lubrication System 2 24 Steering Stem Bearing Engine Oil Change 2 24 Lubricatio theater edema 2 38 Oil Filter Change 2 25 Electrical System 2 39 Wheels Tires pp 2 25 Spark Plug Inspection 2 39 Tire Wear Inspection 2 25 General Lubrication 2 41 Air Pressure Inspection 2 26 Lubrication 2 41 Final Drive 2 27 Nut Bolt and Fastener Tightness 2 42 Drive Chain Slack Inspection 2 27 Tightness Inspection 2 42 Drive Chain Slack Adjustment 2 27 2 2 PERIODIC MAINTENANCE Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition The initial maintenance is vitally important and must not be neglected Period
6. 16 27 Charging Condition Inspection EE 16 27 le BEE ee CET lee ere ET EE Alternator Cover Rerrioval eicere er omne ear da Fun e Te RR ERU a d E RE ERE AERE cad Alternator Cover Installatigm itti e tegen Stator Coil Removal rennen nnne nnn nnne nnne Stator Alternator Rotor Remo Val nennen nne nh nn nnne nnne nnne Alternator Rotor Installation reco Ee ER Deer Eeer Alternator Inspection 11 111 002 0000001000000000000000 000000000000 Regulator Rectifier Inspection Charging Voltage InspeellDfizsis eiiis tous Fem ea atras thus eiecit toas Ignition KE DEE Crankshaft Sensor Removal lye Robe Crankshaft Sensor Installation pp 16 38 Crankshaft Sensor Inspechon 16 39 Crankshaft Sensor Peak Voltage Inspection 16 39 Timing Rotor Removal et etes etuer bate tic ate eee oer eee ee 16 40 Timing Rotor InstallatlOTe EE 16 40 Camshaft Position Sensor Removal pp 16 40 Camshaft Position Sensor 16 40 Camshaft Position Sensor Inspection nennen 16 41 Camshaft Position Sensor Peak Voltage Inspechon 16 41 Stick Coil Ignition Coil together with Spark Plug Cap 16 42 Stick Coil Ignition Coil together with Spark Plug Cap Installation
7. 1 4 18 4 2 COOLING SYSTEM Exploded View GD02023BN5 COOLING SYSTEM 4 3 Exploded View No Fastener Remarks N m kgf m ft Ib 1 Radiator hose clamp screws 2 0 0 20 17 in lb 2 Radiator fan bolts 8 3 0 85 74 in lb 3 Water pump impeller bolt 9 8 1 0 87 in lb 4 Water pump cover bolts 11 1 1 95 in Ib Water pump drain bolt 95 in Ib EN Water pipe bolts 95 in Ib Thermostat housing ground bolt 61 ml 8 Thermostat bracket bolt 61 in Ib 9 Radiator upper bolts 61 in Ib 10 Radiator lower bolts 7 0 0 70 61 in Ib 11 Radiator screen bolt 7 0 0 70 61 in Ib 12 Coolant reserve tank screws 7 0 0 70 61 in Ib 13 Radiator fan switch 18 1 8 13 14 Water temperature sensor 25 2 5 18 15 Mechanical seal 16 Oil pump rotor 17 Thermostat 18 To cylinder head 19 To cylinder G Apply grease 4 4 COOLING SYSTEM Coolant Flow Chart 2 IS e P di erg X UE COOLING SYSTEM 4 5 Coolant Flow Chart 1 Drain Bolt 10 Reserve Tank Hose 2 Water Pump 11 Reserve Tank Overflow Hose 3 Oylinder Jacket 12 Radiator Fan 4 Cylinder Head Jacket 13 Water Temperature Sensor 5 Thermostat Housing 14 Radiator Fan Switch 6 Radiator Cap 15 Hot Coolant 7 Radiator 16 Cold Coolant 8 Filter 17 Front 9 Reserve Tank Permanent type antifreeze is used as a coo
8. E a ECU F se Removal detener ca eea UR ERR PARAR RE RE E Pat as ECU Fuse Installation AAA ECU Fuse InSpeclion DEE ECU Main Relay Removal NEE ECU Main Relay Ijer oie E Fuel Line Fuel etre DEE deet Fuel Flow Rate Inspection pp Fuel Pump Fuel Pump Removal avrete Fuel Pump Installation 00220000 Operation INSPSCHON st et eerte eite Lent caet vela Gorka De Rer e EO Cela O Operating Voltage Inspechon nemen Pressure Regulator Removal Pump Screen Fuel Filter Fuel Pump 3 50 3 51 3 51 3 51 3 52 3 54 3 54 3 54 3 55 3 55 3 55 3 56 3 56 3 56 3 56 3 56 3 58 3 58 3 58 3 58 3 61 3 61 3 61 3 62 3 63 3 64 3 64 3 64 3 66 3 66 3 66 3 66 3 66 3 67 3 68 3 69 3 70 3 70 3 70 3 70 3 73 3 73 3 73 3 73 3 73 3 73 3 74 3 74 3 75 3 77 3 77 3 77 3 78 3 78 3 79 3 79 3 80 FUEL SYSTEM DFI 3 3 Fuel Pump Relay Removal Fuel Pump Relay Fuel Injectors Removal Installatiori terr ener eege Eee Audible Inspection Power Source Voltage Inspection pp Output Voltage Inspection Injector Signal Test Injector Resistance Injector Unit Test IMS PSCUON eS Injector Fuel Line Inspection Po rt
9. o av cotor nazv gst vie aex cotor sk Color 7 Horn Fuse 10A 8 Starter Circuit Relay 9 Turn Signal Fuse 10 W2L0059BN5 6 ELECTRICAL SYSTEM 16 17 Wiring Diagram Other than Canada Australia and Malaysia OY oil Grankshaft 55255 J See Sensor Pressure Side salten Stand ae Switch 25 Neutral 11 Switch E Ex 10 Inlet Air Temperature Sensor 1 Subthrottle Valve Actuator H 22 Fuel Injector 3 3 Fuel Injector 2 4 Fuel Injector 3 5 Fuel Injector 4 RE RI 11 Atmospheric Pressure 8 Speed Sensor ER m Sensor 9 Camshaft Position Sensor 354 12 Water Temperature Sensor 13 Inlet Air Pressure H Sensor i R BK D Y w Y G Y BL Alternator n Y av BR W x yH lim BK Y lll d d E 6 1 a aK R G YAR BK R UO BR Y P BL BK BL LO BR R LB BL Y BL amp BL BK BL R BK Y BK W BK Y 0 BK Li License Plate sn Light 12V8W Rear Right Turn P aay Signal Light 12218 BL J ri LI ER H LI H In GH 5 5 SCH Brake Light LED 12V0 5 3 8 Ee hs oe Seit BK Y
10. No Fastener Tonne Remarks N m kgf m ft Ib 1 Throttle cable plate bolt 6 0 0 60 52 in lb 2 Throttle body assy holder clamp bolts 2 0 0 20 17 3 Choke link holder screws 2 1 0 21 18 in Ib 4 Delivery pipe screws 3 4 0 35 30 in Ib 5 Fuel pump bolts 9 8 1 0 87 in lb 1 5 E Fuel level sensor bolts 6 9 0 7 62 in lb Bypass screws 0 2 0 02 1 7 in lb 8 Center adjusting screw 9 Fl indicator LED light 10 Meter unit 11 Throttle cable accelerator 12 Throttle cable decelerator 13 Choke cable 14 Injector connectors 15 Main throttle sensor connector grey 16 Subthrottle sensor connector black 17 Subthrottle valve actuator connector 18 Throttle body assy connector 19 Main throttle sensor 20 Subthrottle sensor 21 Injectors CL Apply cable lubricant EO Apply engine oil to the seals and O rings G Apply grease L Apply a non permanent locking agent S Follow the specified tightening sequence 3 6 FUEL SYSTEM DFI Exploded View FUEL SYSTEM DFI 3 7 Exploded View No Fastener Remarks N m kgf m ft Ib 1 Inlet air pressure sensor bolt 12 1 2 104 in Ib 2 Water temperature sensor 25 2 5 18 Vehicle down sensor bolts 2 0 0 20 17 in lb Camshaft position sensor bolt 12 1 2 104 Camshaft position sensor rotor bolt 12 1 2 104 in Ib L 6 Air cleaner duct holder screws 3 8 0 39 34 Air cleaner housing mounting bolts 9 8 1 0
11. 16 42 Stick Coil Ignition Coil together with Spark Plug Cap Inspection 16 43 Stick Coil Primary Peak Voltage xe mii besito et eau 16 43 Spark Plug un RE 16 44 16 2 ELECTRICAL SYSTEM Spark Plug Hl Ee 16 44 Spark Plug 16 44 Spark Pl g Gap Inspection tnt 16 44 Interlock Operation Inspection enne 16 45 IC Igniter ere ee 16 46 Electric Starter System ico eite babe n ta fa 16 49 Starter Motor 16 49 Starter Motor Installation 16 49 Starter Motor DissBsserbly oc ettet orte Eege 16 49 Starter Mot r ASSEM Dy e a dee Ecoute Ree 16 50 Br sh Inspaectionusa ss caeteri eris eet epe RV ce 16 51 Commutator Cleaning and Inspechon emen 16 51 Armature Inspection wire Aer Asi be ei d PE VERRE NE cerebri la put v edet i at 16 51 Brush Lead Inspection oit de Re tiet ee ets 16 52 Brush Plate and Terminal Bolt 16 52 starter Relay e se sve o eene ius 16 52 Lighting BE A Ha 16 54 Headlight Beam Horizontal 16 54 Headlight Beam Vertical Adjustment pp 16 54 Headlight Bulb Replacemer
12. Fairing Ron Fainng Ee BE Fairing Bracket REMOVa EE DEAL So EE EE Seat Cover Removal et He ee epe etre br tee EE EA Seat Cover E EE en BEE Mud Guard c ee ee et deele ee teet eu iiM eio e Mud Guard Installaatio n nen nnne nennen ener nennen nis elle TEE Front Fender Removal nene sensa insana Front Fender Installations ca t eh A eect oes Rear Fender Rear Removal Rear Fender Rear Installation Erame e EEN Frame Cover Removal ui eee Ae end hes hee Se ENEE Dee Eden Ae suede EE Ee Battery Gase teet tr ebbe Ae ERR ER Re RR Zen ee eR ek Zeg SE DEE ER El EE ee Elte ue TEE Side Stand Installations Ae Age Ange Rear VIeW MIITOFS ei ette e ha tee cetero eb eee Ente 15 2 FRAME Exploded View Sif GE E 2 Se I WA Dec E d LEY FRAME 15 3 Exploded View Torque No Fastener Remarks N m kgf m ft Ib 1 Footpeg bracket bolts 34 3 5 25 L 2 Side stand bracket bolts 49 5 0 36 3 Side stand bolt 44 4 5 33 4 Side stand switch bolt 8 8 0 90 78 in Ib G Apply grease L Apply a non permanent locking agent 15 4 FRAME Exploded View FRAME 15 5 Ex
13. Cable Wire and Hose Routing a 6809391805 APPENDIX 17 11 Cable Wire and Hose Routing P Clamp the position of branch harness and front right turn signal light lead Run the meter harness into the hole of cover Meter Set the cover to cover all of the connector Clamp the right and left switch housing lead and front left turn signal light lead To left switch housing To front left turn signal light To right switch housing Headlight high and low Running position light Install the lead with its inner side facing inward To front right turn signal light Clutch cable Starter cable Run the ignition switch lead in front of clutch and starter cable Run the leads for the clutch starter and the ignition switch in order from the head pipe and in front of these run the both throttle cables as decelerating one is outer Throttle cable Run the cable in rear of the main harness Brake hose Main harness Connect green tape side to left head lamp 17 12 APPENDIX Cable Wire and Hose Routing e E t 2 LAN APPENDIX 17 13 Cable Wire and Hose Routing 1 Clamp 2 Brake hose 3 Run the brake hose through the inside of the reservoir hose 4 Tight the bolt to the specified torque with the stopper for turning prevention applied 5 Seat lock 6 Se
14. No Fast R k astener kgf m ftlb emarks 1 Clutch lever clamp bolts 7 8 0 80 69 in Ib S 2 Clutch cover mounting bolts 11 1 1 95 3 filler plug 1 5 0 15 13 in lb 4 Clutch spring bolts 8 8 0 90 78 mb 5 Clutch hub nut 135 14 100 R CL Apply cable lubricant EO Apply engine oil G Apply grease M Apply molybdenum disulfide grease R Replacement Parts S Follow the specific tightening sequence W Apply water 6 4 CLUTCH Specifications Item Standard Service Limit Clutch Lever Free Play 2 3mm 0 08 0 12 in Clutch Clutch plate assembly Friction plate thickness Friction and steel plate warp Clutch spring free length 37 7 38 3 mm 1 48 1 51 in 2 72 2 88 mm 0 107 0 113 in 0 2 mm 0 008 in or less 80 6 mm 3 17 in 2 4 mm 0 094 in 0 3 mm 0 012 in 76 6 mm 3 02 in CLUTCH 6 5 Special Tool and Sealant Clutch Holder Kawasaki Bond Silicone Sealant 57001 1243 56019 120 6 6 CLUTCH Clutch Lever and Cable Clutch Lever Free Play Inspection e Refer to the Clutch in the Periodic Maintenance chapter Clutch Lever Free Play Adjustment e Refer to the Clutch in the Periodic Maintenance chapter Cable Removal e Slide the dust cover A at the clutch cable lower end out of place e Loosen the nuts B and slide the lower end of the clutch cable to give the cable plenty of play e Screw in the adjuster
15. Solvent Use a high flush point solvent when cleaning parts High flush point solvent should be used according to directions of the solvent manufacturer 800058 5 Cleaning vehicle before disassembly Clean the vehicle thoroughly before disassembly Dirt or H 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 68020088 5 Inspection Reuse of worn or damaged parts may lead to serious ac cident Visually inspect removed parts for corrosion discol W 8 oration or other damage Refer to the appropriate sections of this manual for service limits on individual parts Replace Y N the parts if any damage has been found or if the part is be N yond its service limit E 68020098 5 Replacement Parts Replacement parts must be KAWASAKI genuine or recommended by KAWASAKI Gaskets O rings oil seals grease seals
16. Camshaft Position Sensor Inspection Speed Sensor Service Code 24 25 dee t eeh ENEE EE Speed Sensor Removallnstallation Speed Sensor Inspechon ENEE Input Voltage Inspechon nenne nnne nnne Output Voltage Inspection Vehicle down Sensor Service Code 31 Ri EUM InstallatiQri i iiis ie i ex RE eH RE TERR ERE RR RR ER Re PUO BR I BR D E RR RH uu ER INSPECUON KE Subthrottle Sensor Service Code EE Subthrottle Sensor Input Voltage Inspechon nnn Output Voltage Inspechon nnne Resistance Inspechon Stick Coils 1 2 3 4 Service Code 51 52 53 BA 1 Input Voltage Inspechon nennen Subthrottle Valve Actuator Service Code 62 eet Ped t Subthrottle Valve Actuator Removal me nne rnm rennen tennis Audible INSPECUON TEE AETERNAM Resistance 21516157 170 2 eee pia ue veu di pa c aa ava ZEN ER Input Voltage Inspechon nennen A nnn nennen FEl Indicator NRI EE Bib aa oeo pM ECU ATi ECU Installation ECU Power Supply DEI Power
17. e Connect the peak voltage adapter A and a digital meter B to the connector C using the needle adapter set D Recommended Tool Peak Voltage Adapter Type KEK 54 9 B Brand KOWA SEIKI Special Tool Needle Adapter Set 57001 1457 Subthrottle Valve Actuator Input Voltage Connections to Harness Connector Meter BK BL lead 1 Meter P BL lead 2 Il Meter G lead 3 Meter W BL lead 4 e Measure the actuator input voltage with the engine stopped and with the connector joined e Turn the ignition switch ON 6Ci17167BS2 C Input Voltage at Actuator Standard about 8 5 10 5 V DC the reading is within the standard but the actuator doesn t operate replace it xIf the reading is out of the range check the wiring to ECU see wiring diagram in this section the wiring is good check the ECU for its ground and power supply see ECU section a x ea oS 2 W BL emend 22 pe ES t D o D d zz E K 6C17173BW2 6 A ECU L Subthrottle Valve Actuator J Subthrottle Sensor m Throttle Body Assy Connector 3 68 FUEL SYSTEM DFI FI Indicator LED Light Inspection Flow Chart Turn the ignition SW ON 4 No Flashes once then Does the LED light goes off or unlit Repair or replace the meter or wiring NG g
18. 5 28 Camshaft Chain 5 14 Piston Remowval 5 28 Camshaft Chain Tensioner Piston Installation 5 29 Removal EE 5 14 Cylinder Wear 5 30 Camshaft Chain Tensioner Piston Wear 5 30 Installation c 5 14 Piston Ring Piston Ring Groove Camshaft Camshaft Chain 5 15 e ent Le Lob e 5 31 Camshaft Removal 5 15 Piston Ring Groove Width 5 31 Camshaft Installation 5 15 Piston Ring Thickness 5 31 Camshaft Camshaft Cap Wear 5 16 Piston Ring End Gap 5 32 Camshaft Runout 5 17 Throttle Body Holder 5 33 Cam Wear eer enne 5 17 Throttle Body Holder Installation 5 33 Camshaft Chain Removal 5 17 5 34 Cylinder Head 5 18 Muffler Body Remowval 5 34 Cylinder Compression Exhaust Pipe Remowval 5 34 5 18 Muffler Body and Exhaust Pipe Cylinder Head Remowval 5 19 Installatiori ces 5 34 Cylinder Head Installation 5 19 5 2 ENGINE TOP END Exploded View GE02092BN5 ENGINE TOP END 5 3 Exploded View No Fastener Torque Remarks N m kgf m ft Ib 1 Ai
19. Choke lever pulled Push it see chapter 3 Too high fuel pressure Injector stuck open Water temperature sensor trouble Inlet air temperature sensor trouble Brown smoke Air cleaner duct loose Air cleaner O ring damaged Inspect see chapter 3 Inspect see chapter 3 Inspect and replace see chapter 3 Inspect and replace see chapter 3 Reinstall see chapter 3 Replace see chapter 3 3 32 FUEL SYSTEM DFI DFI System Troubleshooting Guide Symptoms or Possible Causes Actions chapter Too low fuel pressure Inspect fuel line and fuel pump see chapter 3 Water temperature sensor trouble Inspect and replace see chapter 3 Inlet air temperature sensor trouble Inspect and replace see chapter 3 FUEL SYSTEM DFI 3 33 Self Diagnosis Self diagnosis Outline Self diagnosis Outline The self diagnosis system has three modes and can be Switched to another mode by grounding the self diagnosis terminal User Mode The ECU notifies the rider of troubles in DFI system and ignition system by lighting the FI indicator when DFI system and ignition system parts are faulty and initiates fail safe function In case of serious troubles the ECU stops the injection ignition starter motor operation Dealer Mode 1 The FI indicator LED light emits service code s to show the problem s which the DFI system and ignition system has at the moment of diagnosis Dealer Mode
20. Exploded TEE lee Mee lee fe UN KO 0 EE Wheels TRIMS EE Front Wheel 00000 r paa nn iaa aen 4 Air Pressure Inspection Tren Ge Le EE Tire Removal Mi Gade a e a EE Gan Zeg dane RICH UE e E deed Eege deed Elle DEE Hub Bearing Removal iei oe pe eb itin ata ie Mer Ee RR Mees Bearing InstallallDH EEN 10 15 Hub Bearing DEE 10 15 10 2 WHEELS TIRES Exploded View 6J02043BW5 C WHEELS TIRES 10 3 Exploded View No Fastener Tongue Remarks N m kgf m ft Ib 1 Front axle clamp bolt 34 3 5 25 2 Front axle 108 11 80 3 Rear axle nut 108 11 80 G Apply grease R Replacement Parts WL Apply soap and water solution or rubber lubricant 10 4 WHEELS TIRES Specifications Item Standard Service Limit Wheels Rims Rim runout Axial 0 5 0 020 Radial 0 8 mm 0 031 Axle runout TIR 0 05 mm 0 0020 in or less TIR 0 2 mm 100 mm 3 94 in 0 008 in Wheel balance 10 g 0 35 oz less Balance weights 10 g 0 35 oz 20 g 0 71 oz 30g 1 06 oz 250 Air pressure 2 5 kgf cm 36 psi when cold Rear Ge 290 kPa 2 9 kgf cm 42 psi Tread depth Front BRIDGESTONE 3 4 mm 1 mm 0 13 in 0 04 in 1 6 mm 0 06 in AT CH DE Rear BRIDGESTONE 5 8 mm Up
21. If the clearance still remains out of the limit replace the cylinder head unit Camshaft Runout e Remove the camshaft 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 If the runout exceeds the service limit replace the shaft Camshaft Runout Standard TIR 0 02 mm 0 0008 in or less Service Limit TIR 0 1 mm 0 004 in Cam Wear e Remove the camshaft see Camshaft Removal e Measure the height A of each cam with a micrometer If the cams are worn down past the service limit replace the camshaft Cam Height Inlet Standard 36 746 36 854 mm 1 4467 1 4509 in Service Limit 36 65 mm 1 443 in Exhaust Standard 36 146 36 254 mm 1 4231 1 4273 in Service Limit 36 05 mm 1 419 in Camshaft Chain Removal e Split the crankcase see Crankshaft Transmission chap ter e Remove the camshaft chain A from the crankshaft sprocket GE11073BS1 6 6 11012251 6 5 18 ENGINE TOP END 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 Seats see Frame chapter Fuel Tank see Fuel System DFI chapter Stick Coils Spark Plugs Owner s Tool Spark Plug Wrench 16 mm 92110 1146 e Attach the compression gauge A and adapter B firmly into the
22. OConnect a commercially available digital meter C vac uum gauge D the fork oil level gauge E and the har ness adapter to the inlet air pressure sensor Special Tools Fork Oil Level Gauge 57001 1290 Sensor Harness Adapter 57001 1561 Inlet Air Pressure Sensor Output Voltage Connection to Adapter Meter BL sensor Y BL lead Meter Y W sensor BR BK lead OTurn the ignition switch ON 6GC17117BS1 C 0017119852 C 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 voltage using the following formula and chart Suppose Pg Vacuum Pressure gauge to Sensor Local Atmospheric Pressure absolute measured by a barometer Pv Vacuum Pressure absolute to Sensor Vv Sensor Output Voltage v FUEL SYSTEM 3 45 Inlet Air Pressure Sensor Service Code 12 then Pv PI Pg For example suppose the following data is obtained Pg 8 cmHg vacuum gauge reading 70 cmHg barometer reading Vv 32 V digital volt meter reading then Pv 70 8 62 cmHg abs Plot this Pv 62 cmHg at a point 1 on the chart and draw a vertical line through the point Then you can get the usable range 2 of the sensor output voltage Usable range 3 04 3 49 V Plot Vv 3 2 V on the vertical line Poi
23. e reen ev Grey LB Light L6 Har Green RIGHT SWITCH HOUSING CONNECTIONS Front Brake Light Switch Engine Stop Switch Starter Button Color BK Color r R Color BK R BK R Brake Lever GB trange GE Pink Purple CL Y Pulled In White Yellow 98052 00694 W2R0O069AW5 C 16 20 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems Learn and ob serve all the rules below ODo not reverse the battery lead 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 leads 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 leads that are directly con nected to the battery positive terminal to the chassis ground OTroubles may inv
24. e Be sure to place a piece of cloth around the pump outlet pipe and the delivery pipe e Remove the fuel pump outlet hose A Front B 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 Install the fuel pressure gauge adapter A between the fuel pump outlet pipe B and the delivery pipe C e Connect the pressure gauge D to the fuel pressure gauge adapter right side view Special Tools Oil Pressure Gauge 57001 125 Fuel Pressure Gauge Adapter 57001 1417 A WARNING Do not try to start the engine with the fuel hoses disconnected e Temporarily install the fuel tank E Clamps F e Turn the ignition switch ON The fuel pump will turn for 3 seconds and then stop CAUTION Do not drive the fuel pump without the fuel in the fuel tank e Measure the fuel pressure with the engine stopped Fuel Pressure Right after Ignition SW ON with pump running Standard 310 kPa 3 2 kgf cm 44 psi After 3 seconds from Ignition SW ON with pump stopped Standard 290 kPa 3 0 kgf cm 43 psi residual fuel pressure The system should hold the residual pressure about 30 seconds GC17180BS1 C Fuel Line FUEL SYSTEM DFI 3 75 e Sta
25. e Line up the slots A in the clutch lever and adjuster B and then free the cable from the lever e Free the clutch inner cable tip from the clutch release lever e Push the release lever toward the front of the motorcycle and tape the release lever to the clutch cover to prevent the release shaft from falling out e Pull the clutch cable out of the frame Cable Installation e Run the clutch cable correctly see Appendix chapter e Adjust the clutch cable see Clutch in the Periodic Main tenance chapter Cable Lubrication e Refer to the General Lubrication in the Periodic Mainte nance chapter Clutch Lever Installation e Install the clutch lever so that the mating surface A of the clutch lever clamp is aligned with the punch mark B e Tighten the upper clamp bolt first and then the lower clamp bolt There will be a gap at the lower part of the clamp after tightening Torque Clutch Lever Clamp Bolts 7 8 N m 0 80 kgf m 69 in Ib GF04010BS1 C Clutch Lever and Cable CLUTCH 6 7 Clutch Lever Adjustment The adjuster has 5 positions so that the clutch lever posi tion 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 5 and maximum at number 1 6 8 CLUTCH Clutch Cover Clutch Cover Removal e Remove E
26. nnns nnns 13 13 Rebound Damping Force 8410 13 13 Spring Preload Adjustment Pe eie bn sees 13 13 Rear Shock Absorber Removal pp 13 13 Rear Shock Absorber Installation pp 13 14 Rear Shock Absorber Inspection sse 13 14 eh e EE Swirigarm e EE te eu NEE te KEN Swingarm Bearing Removal Swingarm Bearing EE EE 13 17 Swingarm Bearing Sleeve Inspection 444410 00 13 17 Chain Guide Inspechon nennen nn enne nennen nnns neni 13 17 RE 13 18 Tiesrod Removal 13 18 Tie rod Installation 13 18 Rocker Arm REMOVA 13 18 Rocker Arm Installation nennen nne n 13 18 Rocker Arm Tie rod Bearing Sleeve Inspection pp 13 19 13 2 SUSPENSION Exploded View 1 GM02085BN5 SUSPENSION 13 3 Exploded View No Fastener Remarks N m kgf m ft Ib 1 Front fork clamp bolts Upper 20 2 0 14 2 Front fork clamp bolts Lower 20 2 0 14 AL 3 Front fork top plugs 25 2 5 18 4 Front fork bottom Allen bolts 30 3 1 22 L 5 Front axle clamp bolt 34 3 5 25 6 Right fork leg 7 Left fork leg AL Tighten the two clamp bolts alternately two times to ensure even tightening torque L Apply a non permanent locking agent R Replacement Parts 13 4 SUSPENSION Exploded View SUSPENS
27. 50 Coolant 50 Freezing Point 35 31 F Total Amount 2 9L 3 1 US qt e Fill the radiator up to the filler neck A with coolant NOTE OPour in the coolant slowly so that it can expel the air from the engine and radiator e Check the cooling system for leaks e Tap the radiator hoses to force any air bubbles caught inside e Fill the radiator up to the filler neck with coolant e Fill the reserve tank up to the F full level line A with coolant and install the cap B e Install the fuel tank see Fuel System DFI chapter e Start the engine and warm it up thoroughly until the radi ator fan turns on and then stop the engine e Check the coolant level in the reserve tank several times while the engine is cooling down and replenish as nec essary the coolant level is lower than the L level line add coolant to the level line CAUTION Do not add more coolant above the F level line 2 22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Engine Top End Air Suction Valve Inspection e Remove the air suction valve see Engine Top End chap ter e Visually inspect the reeds for cracks folds warps heat damage or other damage lf there is any doubt as to the condition of the reeds A replace the air suction valve as an assembly e Check the reed contact areas B of the valve holder for grooves scratches any signs of separation from the holder
28. Balance Weight Installation e Check if the weight portion has any play on the clip does discard it WARNING If the balance weight has any play on the rim the clip of the weight have been stretched Replace 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 0009 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 17 oz If the wheel requires an excess bal ance weight disassemble the wheel to find the cause e Slip the balance weight A onto the rib B by pushing or lightly hammering C the clip D Left Side E Right Side F CAUTION When installing the balance weight do not touch the brake disc The disc could be damaged e Check that the weight 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 A WARNING If the balance weight has any play on the rim the clip of the weight has been stretched Replace the loose balance weight Do not reuse balance weight Unbalanced wheels can create an unsafe riding cond
29. Color Green Mixed ratio Soft water 5096 Coolant 50 Freezing point 35 31 F Total amount 2 9 L 3 1 US qt Engine Top End Valve clearance Inlet 0 15 0 24 mm 0 0059 0 0094 in Exhaust 0 22 0 31 mm 0 0087 0 0122 in Clutch Clutch lever free play 2 3 mm 0 08 0 12 in Engine Lubrication System Engine oil Type API SE SF or SG SH or SJ with JASO Viscosity SAE 10W 40 Capacity 3 1 L 3 3 US qt when filter is not removed 3 3 L 3 5 US qt SS when filter is removed 3 8 L 4 0 US qt SSS when engine is completely dry Level Between upper and lower level lines after idling or running Wheels Tires Tread depth Front BRIDGESTONE 3 4 mm 0 13 in 1 mm 0 04 in 1 6 mm 0 06 in AT CH DE Rear BRIDGESTONE 5 8 mm 0 23 in Up to 130 km h 80 mph 2 mm 0 08 in Over 130 km h 80 mph 3 mm 0 12 in Specifications PERIODIC MAINTENANCE 2 11 Item Standard Service Limit Air pressure when cold Drive chain slack Drive chain 20 link length 25 35 mm 1 0 14 in 317 5 318 2 mm 12 50 12 53 in Front Up to 180 kg 397 Ib load 250 kPa 2 5 kgf cm 36 psi W i Rear Up to 180 kg 397 Ib load 290 kPa 2 9 kgf cm 42 psi AME Final Drive Brakes Brake fluid Grade Brake pad lining thickness Front Rear Brake light timing Front
30. D Right Switch Housing Front Brake EngineStarter Stop Button 1 Right Tura Signal Indicator Light L High Beam Indicat Light LED Neutral Indicator Light LED Dil Pressure Warn Indicator Light L FI Indicator Ligh OQdometer Trip Met Indicator Water temperature Fuel Level Gauge Tachometer Speedometer Meter Light LED Left Turn Signal Light LED Front Right Turn Signal ET Rowen Light Switch Regulator Rectifier ED or ing EP t LED er lock Gauge Indicator Light 12V21W sn ez Gity Light 12V5W BR W Headlight High 12V55W R BK BKZ Y Headlight Low 12 55 BK Y Front Left Turn Signal Light 12V21W BK Y BK Y Selen I L oe mimo Puch a GFF Push Released Released Lf ls Lo omo inf compo JT Left Switch Housing ECU Fuel 1 Horn Button S Main Pump 2 Turn Signal Switch Junction Box Relay Relay Joint Connector 3 Dimmer Switch 4 Starter Lockout Switch E E 8 Passing Button 2 Radiator Fan Fuse 15 3 Headlight Fuse 10 LEFT SWITCH HOUSING CONNECTIONS 4 Headlight Relay Horn Button Signal Switch Dimmer Switch starter Lockout Switch Passing Button 8 Taillihgt Fuse 10A 6 Ignition Fuse 10 Color
31. Do not disconnect the ECU connectors e Connect a digital voltmeter to the ECU connector using needle adapter set Special Tool Needle Adapter Set 57001 1457 e Measure the sensor output voltage with the engine stopped and the connector joined e Turn the ignition switch ON Inlet Air Temperature Sensor Output Voltage Connections to ECU Connector Meter Y lead terminal 18 Meter gt BR BK lead terminal 14 about 2 25 2 50 V at inlet air temperature 20 C 68 F e Turn the ignition switch OFF the output voltage is out of the standard remove the fuel tank and check the wiring And if the output voltage is 4 8 V the ECU is normal Standard x If the output voltage is within the standard check the ECU for its ground and power supply see ECU section in this chapter x If the wiring is good check the sensor resistance e Remove the needle adapter set and apply silicone sealant to the seals of the connector for waterproofing Silicone Sealant Kawasaki Bond 56019 120 Seals of ECU Connectors 00178271 P 6Ci7118BSi 6 3 48 FUEL SYSTEM DFI Inlet Air Temperature Sensor Service Code 13 Sensor Resistance Inspection e Remove the inlet air temperature sensor see this sec tion 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
32. Front Fork SUSPENSION 13 11 Front Fork Assembly e Check the top plug O ring and replace it with a new one e Replace the following parts with new ones Retaining Ring A Dust Seal B Oil Seal C Inner Guide Bushing D Outer Guide Bushing E Fork Bottom Allen Bolt Gasket F e Install the guide bushing on the end of the inner tube e Insert the cylinder unit and the spring into the inner tube and install the cylinder base B onto the cylinder end A that protrudes from the bottom Olnstall the cylinder base starting with its stepped end e Insert the inner tube cylinder unit washer spring and cylinder base as a set into the outer tube e Install the guide bushing into 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 57001 1288 OApply high temperature grease to the oil seal lips e Install the retaining ring into the outer tube e Install the dust seal by hand e Apply non permanent locking agent to the threads of the bottom Allen bolt C e Hold the front fork horizontally in a vise A e Hold the cylinder unit B with the special tools and tighten the bottom Allen bolt to secure the cylinder in place Torque Front Fork Bottom Allen Bolt 30 3 1 kgf m 22 16 Special Tools Fork Cylinder Holder Handle 57001 183 D Fork Cylinder Holder Adapter 57001 1057 E e Pour in the specified type
33. Headlight Low 12V55W amp e Sur er ev BK Y ay BK Y BK Y BK Y Front Left Turn Signal BK Y Running Position S Light 12V21 5W BK Y Left Switch Housing eY 6 BK Y Horn Button BK Y BK Y BL R BL Joint Connector A Fuel Main Pump Relay Relay Hazard Button Junction Box Turn Signal Switch mom Horn Fuse 10 Starter Circuit Relay Turn Signal Fuse iGA Dimmer Switch 1 ACC Fuse 10A 2 Radiator Fan Fuse 15 Starter Lockout Switch ge Radiator Fuxe LEFT SWITCH HOUSING CONNECTIONS 4 Headlight Relay Horn Button Hazard Button Siena Switch Dimmer Switch Starter Lockout witon 5 Taillihgt Fuse 10A 8 Ignition Fuse 10A Color Bk w gk v Color 6 ay Color D GY 6Celor R v sL v R BK Color BK BK R 1 8 9 Gebeess PE EE fe LE 210049045 6 Wiring Diagram Canada ELECTRICAL SYSTEM 16 13 WR L BK Kon BL Y Subthrottle Valve Actuator Fuel Injector 1 Fuel Injector 2 Fuel Injector 3 Fuel Injector 4 Subthrottle Sensor Main Throttle Sensor Speed Sensor Camshaft Position Sensor E ET E A d Y R BR W Y Meter Frame GroundG roundl Crankshaft L T Sensor Pressure Switch Side Stand SS Switch Neutral Tar Switch E BL R BK Y L 11 Y 8K BK Y an
34. OWhenever the DFI electrical connections are to be discon nected first turn off the ignition SW switch Conversely make sure that all the DFI electrical connections are firmly reconnected before starting the engine 3 16 FUEL SYSTEM DFI DFI Servicing Precautions OWhenever the DFI electrical connections are to be discon nected first turn off the ignition SW switch and discon nect the battery terminal Do not pull the lead only the connector Conversely make sure that all the elec trical connections are firmly reconnected before starting the engine OWhen disconnecting the vehicle down sensor connector raise the lock of the connector Push the lock of the other connectors 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 Clutch Cover B Torque Oil Filler Plug 1 5 N m 0 15 kgf m 13 in Ib FUEL SYSTEM DFI 3 17 Troubleshooting the DFI System Outline Outline When an abnormality in the system occurs the Fl indica tor LED Light Emitting Diode light goes on to alert the rider on the meter panel In addition the condition of the problem is stored in the memory of the ECU electronic control unit With the engine stopped and turned in the self diagnosis mode the service code A is indicated by the number of times the indicator LED light blink
35. Oil Pressure Warning In dicator Light LED Fl Indicator Light LED Odometer Trip Meter Clock Fuel Indicator Water Temperature Gauge Fuel Level Gauge Tachometer Speedometer Meter Light LED Left Turn Signal Indicator Light LED Meter Unit Joint Connector D Frame Ground Meter Ground Speed Sensor Fuel Reserve Switch Fuel Level Sensor GP17118BW2 Water Temperature Sen sor Oil Pressure Switch Neutral Switch Joint Connector A Ignition Switch Junction Box ACC Fuse 10 A Ignition Fuse 10 A Main Fuse 30 A Battery 12 V 8 Ah E C U Joint Connector B 16 74 ELECTRICAL SYSTEM Switches and Sensors Brake Light Timing Inspection e Refer to the Brakes in the Periodic Maintenance chapter Brake Light Timing Adjustment e Refer to the Brakes in the Periodic Maintenance chapter Switch Inspection e Using a hand tester check to see that only the con nections shown in the table have continuity about zero ohms OFor the handlebar switches and the ignition switch refer to the tables in the Wiring Diagram If the switch has an open or short repair it or replace it with a new one Special Tool Hand Tester 57001 1394 Rear Brake Light Switch Connections When brake pedal is pushed down When brake pedal is released When side stand is up When side stand is down Neutral Switch Connections When tran
36. e Prepare a plastic hose of the inside diameter 7 5 mm 0 30 in and a measuring cylinder e Remove the fuel tank bolt see Fuel Tank Removal 3 76 FUEL SYSTEM DFI Fuel Line 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 pump outlet hose e Remove the fuel pump outlet hose A from the fuel pump B and the delivery pipe C see Fuel Pump Removal Front D 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 plastic hose A to the fuel pump outlet pipe e Secure the plastic hose with a clamp B e Run the other side of the plastic hose into the measuring cylinder C Front D WARNING Wipe off spilled out fuel immediately Be sure to hold the measuring cylinder vertical e Temporarily instal the fuel tank and close the fuel tank cap e With the engine stopped turn the ignition switch ON The fuel pump should operate for 3 seconds and then should stop Repeat this several times until the plastic hose is filled with fuel CAUTION Do not drive the fuel pump without the fuel in the fuel tank e Measure the discharge for 3 seconds with the plastic hose filled with
37. e Run the leads cables and hoses correctly see Cable Wire and Hose Routing section in Appendix chapter e Install the removed parts see appropriate chapters e Adjust Throttle Cables see Fuel System DFI chapter Choke Cable see Fuel System DFI chapter Clutch Cable see Clutch chapter Drive Chain see Final Drive chapter e Fill the engine with engine oil see Engine Lubrication System in the Periodic Maintenance chapter e Fill the engine with coolant see Cooling System in the Periodic Maintenance chapter CRANKSHAFT TRANSMISSION 9 1 Crankshaft Transmission Table of Contents Exploded View 9 2 Starter Motor Clutch Inspection 9 22 Specifications rennen 9 6 Starter Motor Clutch Disassembly 9 22 Special Tools and Sealant 9 9 Starter Motor Clutch Assembly 9 22 Crankcase Splitting 9 10 Transmission 22 9 23 Crankcase Splitting 9 10 Shift Pedal Removal 9 23 Crankcase Assembly 9 10 Shift Pedal Installation 9 23 Crankshaft and Connecting Rods 9 13 External Shift Mechanism Crankshaft Removal 9 13 9 24 Crankshaft Installation 9 13 External Shift Mechanism Connecting Rod Removal 9 13 Installation ttes 9 25 Connecting Rod Installation 9
38. ning OTake care not to short the leads that are directly con nected to the battery positive terminal to the chassis ground OWhen charging remove the battery from the motorcycle This is to prevent ECU damage by excessive voltage ODo not turn the ignition SW ON while any of the DFI elec trical connectors are disconnected The ECU memorizes service codes not spray water the electrical parts DFI parts con nectors leads and wiring Never water a vehicle with connectors unplugged because seals don t work and ter minals could corrode 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 SW 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 prevent fuel spillage OTo prevent corrosion and deposits in the fuel system do not add to fuel any fuel antifreeze chemicals
39. 23 Position 006 signal output signal the signal is missing wiring short or open the to the ECU at the two ECU continues to ignite cylinders in the same Sensor cranking sequence following the last good signal Speed sensor must send 4 signals output signal 24 SE SE Se If the speed sensor system fails no signal wiring Speed jrotation of the engine and short or open the speedometer shows 0 and Sensor S 25 PES the ECU sets the top 6 gear position The gear position is decided by the signal of the speed sensor E E dO If the vehicle down sensor system has failures the output voltage Vd is more than usable range 31 ENER el en the ECU shuts off the fuel pum Sensor Vd 04V 44V e pare the fuel injectors and the ignition system FUEL SYSTEM DFI 3 39 Self Diagnosis Service Output Signal Usable Codes Fare Range or Criteria Backups ECN If the subthrottle sensor system fails the signal Subthrottle SHEET is out of the usable range wiring short or open 32 Output Voltage sensor the actuator locks sub throttle valve at full open 0 15 4 85 V En position Stick Coil The stick coil primary If the ignition primary winding 1 has failures no 51 41 Ignition winding must send signal wiring short or open the ECU shuts off Coil signals output voltage the injector 1 to stop fuel to the cylinder 1 continuously to the ECU though the
40. A e Unscrew the fuel pump bolts B and take out the fuel pump C and gasket e Discard the fuel pump gasket CAUTION Do not pull the leads C of the fuel pump If they are pulled the lead terminals may be damaged Fuel Pump Installation e Remove dirt or dust from the fuel pump A by lightly ap plying compressed air 6 178171 P 3 78 FUEL SYSTEM DFI Fuel Pump e Replace the fuel pump gasket A with a new one e Check that the fuel pump terminal A and band B are in place Front C 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 tightening sequence shown e Following the tightening sequence tighten the fuel 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 Operation Inspection NOTE OBe sure the battery is fully charged OJust listen to the pump sound in the fuel tank to confirm pump operation 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 lf the pump does not work as described above inspect the operating voltage Operating Voltage Inspection NOTE sure the battery is fully charged e Turn the ignition switch OFF e Remove the fuel tank bolt
41. B e Remove the terminal locknut A and terminal bolt B and then remove the brush with the brush plate C from the right hand end cover Starter Motor Assembly e Install the brush plate and brushes A and then put the armature B among the brushes e Install the O rings A as shown e Align the notch A in the brush plate with the end cover notch B and the mark C on the yoke Electric Starter System ELECTRICAL SYSTEM 16 51 e Align the line A marked on the yoke with the through bolt hole B Brush Inspection e Measure the length A of each brush If any is worn down to the service limit replace the carbon brush holder assembly B and the terminal bolt assembly C Starter Motor Brush Length Standard 12 mm 0 47 in Service Limit 8 5 mm 0 33 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 x If there is a high resistance or no reading between two segments
42. C located in almost the same depth with the sensor NOTE OThe sensor and thermometer must not touch the con tainer 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 table Inlet Air Temperature Sensor Resistance Standard 1 6 3 7 at 20 C 68 F 0 24 0 43 at 80 176 F If the measurement is out of the range replace the sensor lf the measurement is within the specified replace the ECU 80171028 5 ON 18 E EE SE ET 14 BR BK Y 80171388841 A ECU F Inlet Air Temperature Sensor Water Temperature Sensor Service Code 14 FUEL SYSTEM DFI 3 49 Removal Installation CAUTION Never drop the sensor especially on a hard surface Such a shock to the sensor can damage it e Remove the fuel tank see Fuel Tank Removal e Drain the coolant see Cooling System chapter e Disconnect the sensor connector and unscrew the water temperature sensor A Torque Water Temperature Sensor 25 2 5 kgf m 18 e Fill the engine with coolant and bleed the air from the cool ing system see Coolant Change in the Periodic Mainte nance chapter Output Voltage Inspection NOTE sure the bat
43. 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 xf there is any reading at all the armature has a short the starter motor must be replaced 6 11061051 6 8 11060851 C 16 52 ELECTRICAL SYSTEM Electric Starter System 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 Brush Lead Inspection e Using the x 1 O hand tester range measure the resis tance as shown Terminal Bolt and Positive Brush A Brush Plate and Negative Brush B Special Tool Hand Tester 57001 1394 there is not close to zero ohms the brush lead has an open Replace the terminal bolt assembly and or the brush holder assembly Brush Plate and Terminal Bolt Inspection e Using the highest hand tester range measure the resis tance as shown Terminal Bolt and Brush Plate A Terminal Bolt and Right hand End Cover B Special Tool Hand Tester 57001 1394 there is any reading the brush holder assembly and or terminal bolt assembly have a short Replace the brush holder assembly and the terminal bolt assembl
44. diagnosis Lafe d A Terminal vU sev 8 Signal Light 3K Y En M 12218 ret xe zzz Joint TT BK Y Connector BK Y E CZ BK Y gt BK Y 5 n BR EM 7 2 S i Color Code Fuse 5 EN 15 Black Rear Set Joint Connector B Blue Brake CH T ight Chocolate Switch Signal Yehicle Relay down 2 Engine De dark Green Ground French Model seo Mi Blue E Red Brake Lever thite Pulled In Yellow 98052 0059B W2RO059BN5 C Main Fuse 30A SWITCH CONNECTIONS Motor Taiti Tan RIGHT SWITCH HOUSING CONNECTIONS ey Front Brake Light Switch Engine Stop Switch Starter Button LOCK Color BK Color Y R Color 16 18 ELECTRICAL SYSTEM Wiring Diagram Malaysia Spark Plugs 1 2 3 44 Lu qe M x2 Fuel poe ack Fan Radiator zd eve Reserve Level Notor Fan Switch Switch MOM zz z D LEE GC E LB wy BK W BR BK BK Y BL BK BL W BK Y BL W Joint Connector D BK L amp wy BK Y BK Y BK Y BK Y BK Y Ignition Switch Right Switch Housing Front Engine Starter Brake Stop Button Light Switch BATTERY ALL parrenv ais ETT Regulator Rectifier Meter Unit 1 Right Turn Si
45. e Install the upper ends of the throttle cables in the grip e Fit the projection A of the right switch housing into the hole B of the handlebar e Turn the throttle grip and make sure thatthe throttle valves move smoothly and return by spring force e Check the throttle grip free play see Throttle Grip Free Play Inspection WARNING Operation with an incorrectly routed cable could re sult in an unsafe riding condition e Adjust Throttle Grip Free Play Choke Lever Free Play Idle Speed Throttle Body Assy Disassembly CAUTION Do not remove disassemble or adjust the main throttle sensor A subthrottle sensor B sub throttle valve actuator C throttle link mechanism D and throttle body assy E because they are adjusted or set 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 Push the lock and disconnect Main Throttle Connector gray A Subthrottle Connector black B Subthrottle Valve Actuator Connector CAUTION Never drop the throttle body assy especially on a hard surface Such a shock to the body assy can damage it e Push the lock and disconnect the injector connectors A e Remove Screws B Delivery Pipe C along with harness D and injectors necessary cut straps and take the harness off the
46. 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 GK05022BS1 C 6114010151 Sprocket Coupling FINAL DRIVE 11 13 Sprocket Wear Inspection e Visually inspect the engine and rear sprocket teeth for wear and damage the teeth are worn as illustrated replace the sprocket and inspect the drive chain wear see Drive Chain Wear Inspection Worn Tooth Engine Sprocket A Worn Tooth Rear Sprocket B Direction of Rotation C NOTE 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 see Wheels Tires chapter so that it will turn freely e Set a dial gauge A against the rear sprocket B near the teeth as shown 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 xIf the runout exceeds the service limit replace the rear sprocket Rear Sprocket Warp Standard 0 4 mm 0 016 in or less Service Limit 0 5 mm 0 020 in 6 05061151 6 6 05011151
47. e Tighten the front axle Torque Front Axle 108 N m 11 kgf m 80 ft Ib e Before tightening the clamp bolt on the right front fork leg pump the front fork up and down 4 or 5 times to allow 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 bolt A Torque Front Axle Clamp Bolt 34 N m 3 5 kgf m 25 16 e Install the front brake calipers see Brakes chapter e Check the front brake effectiveness see Brakes 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 Using the stand A raise the rear wheel off the ground e Remove Cotter Pin A Axle Nut B Axle C 6J04824 P 10 8 WHEELS TIRES Wheels Rims e Remove Caliper Mounting Bolts A Caliper B e Remove the drive chain A from the rear sprocket toward the left e Move the rear wheel back and remove the wheel from the rear caliper e Remove the rear wheel 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 Install the caliper bracket A onto the swinga
48. 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 WARNING The fuel could not be removed completely from the fuel tank Be careful for remained fuel spillage e Raise the fuel tank and disconnect the fuel pump lead connector A and fuel level sensor lead connector B GCO9033BS1 C FUEL SYSTEM DEI 3 95 Fuel Tank e Be sure to place a piece of cloth A around the fuel hose pump outlet joint B e While pinching the hose joint locks C with fingers pull the joint out along 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 a piece of clean cloth to prevent fuel spillage e Close the fuel tank cap e Remove the fuel tank and place it on a flat surface ODo not remove the pump inlet hose A Fuel Tank Installation e Note the above WARNING see Fuel Tank Removal e Route the hoses correctly see Appendix chapter e Check that the rubber dampers A are on the frame and the fue
49. the end of the lead to the battery terminal repeatedly The injector should click lf the injector does not click replace the injector xIf the injector clicks check the wiring again If the wiring is good replace the injector may be clogged or ECU Injector Fuel Line Inspection e While pinching the fuel pump outlet hose joint locks A with fingers pull the joint out along the delivery pipe see Fuel Tank Removal Cloth B Pump Outlet Hose Joint C 6617024451 FUEL SYSTEM 3 85 Fuel Injectors e Check the injector fuel line for leakage as follows OConnect a commercially available vacuum pressure pump A to the nipple of the delivery pipe B with a high pressure fuel hose C both ends connected with the clamps D as shown e Wu Torque Fuel Hose Clamp Screws 1 5 0 15 kgf m 13 d d oy e VATESI E OApply soap and water solution to the areas E as shown 7 gt IM OWatching the pressure gauge squeeze the pump lever S F and build up the pressure until the pressure reaches the maximum pressure 6617181851 6 Injector 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 lf the pressure holds steady the system is good lf the pressur
50. 1 O range and read the tester the tester does not read 0 the lead is defective Re place the lead or the wiring harness B C D E if necessary 8 07005 52 C ELECTRICAL SYSTEM 16 23 Battery Battery Removal CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition switch is ON as this could damage the ECU Electronic Con trol Unit Never reverse the connections of the battery this could damage the ECU e Remove Seats see Frame Chapter e Disconnect the negative cable A e Slide out the positive terminal cap B and then discon nect the positive cable CAUTION Be sure to disconnect the negative cable first e Remove the battery Battery Installation e Apply a light coat of grease on the terminals to prevent corrosion e Install the positive cable A first e Cover the terminal with the cap B e Install the negative cable C 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 ZR750 J1 9 5 CAUTION Be sure to use the electrolyte container with the same model name as the battery since the elec trolyte volume and specific gravity vary with the 6 08070151 battery type This is to prevent overfilling of the electrolyte shorti
51. 1110 92139 1109 92139 1108 Connecting Rod Bolt Stretch Usable Range New connecting rod Used connecting rod 0 24 0 36 mm 0 0094 0 0142 in 0 20 0 32 mm 0 0079 0 0126 in Specifications CRANKSHAFT TRANSMISSION 9 7 Item Standard Service Limit Crankshaft side clearance 0 05 0 20 mm 0 40 mm 0 0020 0 0079 0 0157 Crankshaft runout TIR 0 02 mm 0 0008 in TIR 0 05 mm less 0 0020 in Crankshaft main bearing insert journal clearance 0 020 0 044 mm 0 07 mm 0 0008 0 0017 in 0 0028 in Crankshaft main journal diameter 32 984 33 000 32 96 mm 1 2986 1 2992 in 1 2976 in Marking None 32 984 32 992 mm 1 2986 1 2989 in 1 32 993 33 000 mm 1 2989 1 2992 in Crankcase main bearing inside diameter 36 000 36 016 mm 1 4173 1 4179 in Marking O 36 000 36 008 mm 1 4173 1 4176 36 009 36 016 1 4177 1 4179 in Crankshaft main bearing insert thickness Brown 1 490 1 494 mm 0 0587 0 0588 1 494 1 498 0 0588 0 0590 in Blue 1 498 1 502 mm 0 0590 0 0591 in Crankshaft main bearing insert selection Crankcase Main Crankshaft Main Bearing Insert Bearing Inside Journal Diameter Diameter Marking Marking Size Color Part Number Journal No
52. 13 External Shift Mechanism Crankshaft Connecting Rod Inspechon 12 9 25 Cleaning aereas 9 16 Transmission Shaft Removal 9 26 Connecting Rod Bend 9 17 Transmission Shaft Installation 9 26 Connecting Rod Twist 9 17 Transmission Shaft Disassembly 9 26 Connecting Rod Big End Side Transmission Shaft Assembly 9 27 Clearance sseseeneeeeereerr eerren 9 17 Shift Drum and Fork Removal 9 30 Connecting Rod Big End Bearing Shift Drum and Fork Installation 9 30 Insert Crankpin Wear 9 18 Shift Drum Disassembly 9 30 Crankshaft Side Clearance 9 19 Shift Drum Assembly 9 30 Crankshaft Runout 9 20 Shift Fork Bending 9 31 Crankshaft Main Bearing Shift Fork Gear Groove Wear 9 31 Insert Journal Wear 9 20 Shift Fork Guide Pin Drum Starter Motor Clutch 9 22 Groove Wear pp 9 31 Starter Motor Clutch Gear Dog and Gear Dog Hole Removal Installation 9 22 9 31 9 2 CRANKSHAFT TRANSMISSION Exploded View eo ESENLI Lie va EE es 5414 GERS Oi E CRANKSHAFT TRANSMISSION 9 3 Exploded View No Fastener Remarks N m kgf m ft Ib 1 Breather
53. 2 The FI indicator light LED emits service code s to show the problem s which the DFI system and ignition system had in the past Self diagnosis Procedures Self diagnosis Procedures OWhen a problem occurs with the DFI system and ignition system the DFI indicator LED light A goes on NOTE OUse a fuly charged battery when conducting self diagnosis Otherwise the LED light blinks very slowly or doesn t blink OKeep the self diagnosis terminal grounded during self diagnosis with an auxiliary lead e Remove the seats see Frame chapter e Ground A the self diagnosis terminal B yellow lead to the battery terminal C or battery lead connector using a wire e Turn on the ignition switch e Connect an auxiliary lead E to the self diagnosis terminal G for grounding e To enter the self diagnosis dealer mode 1 ground A the self diagnosis indicator terminal to the battery terminal for more than 2 seconds C and then keep it grounded continuously D OCount the blinks of the LED light to read the service code Keep the auxiliary lead ground until you finish reading the service code 6617071851 6 3 34 FUEL SYSTEM DFI Self Diagnosis e To enter the self diagnosis dealer mode 2 open B and ground A the lead more than five times F within 2 sec onds C after the lead is first grounded and then keep it grounded continuously D for more than 2 seconds OCount
54. 2 5 18 4 Bleed valve 7 8 0 80 69 in lb 5 Rear master cylinder mounting bolts 25 2 5 18 6 Rear brake disc mounting bolts 27 2 8 20 L B Apply brake fluid G Apply grease L Apply a non permanent locking agent R Replacement Parts Si Apply silicone grease ex PBC grease 12 6 BRAKES Specifications Item Standard Service Limit Brake lever position Brake lever free play Pedal free play Pedal position Brake Lever Brake Pedal 5 way adjustable to suit rider Non adjustable Non adjustable About 47 mm 1 85 in below footpeg top Brake Fluid Grade DOT4 Brake Pads Lining thickness Front 4 5 mm 0 18 in 1 mm 0 04 in Rear 5 mm 0 20 in 1 mm 0 04 in Brake Discs Thickness Front 4 3 4 5 mm 0 17 0 18 in 4 0 mm 0 16 in Rear 4 8 5 2 mm 0 19 0 20 in 4 5 mm 0 18 in Runout Not more than 0 2 mm 0 008 in 0 3 mm 0 012 in BRAKES 12 7 Special Tool Jack 57001 1238 12 8 BRAKES Brake Lever Brake Pedal Brake Lever Position Adjustment The brake lever adjuster has 5 positions so that the brake lever position can be adjusted to suit the operator s hand 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 5 and maximum at number 1 Brake Pedal Position Inspection e Check that the brake ped
55. 3 4 mm 0 13 in Service Limit 1 mm 0 04 in 1 6 mm 0 06 in AT CH DE Rear Standard 5 8 mm 0 23 in Service Limit 2 mm 0 08 in Up to 130 km h 80 mph 3 mm 0 12 in Over 130 km h 80 mph WARNING To ensure safe handling and stability use only the recommended standard tires 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 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 Adjust the tire air pressure according to the specifications if necessary Air Pressure when cold Front Up to 180 kg 250 kPa 2 5 kgf cm 36 psi Rear 397 Ib 290 kPa 2 9 kgf cm 42 psi e Install the air valve cap certainly after air pressure inspec tion Torque Air Valve Cap 0 15 N m 0 015 kgf m 1 3 in Ib 6511000851 C PERIODIC MAINTENANCE 2 27 Periodic Maintenance Procedures Final Drive Drive Chain Slack Inspection NOTE OCheck the slack with the motorcycle setting on its side stand OClean the chain if it is dirty and lubricate it if it appears dry e Checkthe wheel alignment see Wheel Alignment Insp
56. 3 7 4 4 V with sensor arrow mark pointed up 0 4 1 4 V Non adjustable and non removal 4 75 5 25 V DC between BL and BR BK leads 0 48 0 52 V DC between BR and BR BK leads 3 6 3 8 V DC between BR and BR BK leads 4 6 about 5 7 about 8 5 10 5 V DC 2 3 mm 0 08 0 12 in 0 0 5 mm 0 0 02 in 3 14 FUEL SYSTEM DFI Special Tools Oil Pressure Gauge 57001 125 Fork Oil Level Gauge 57001 1290 Hand Tester 57001 1394 Throttle Sensor Setting Adapter 57001 1400 Fuel Pressure Gauge Adapter 57001 1417 Needle Adapter Set 57001 1457 Throttle Sensor Setting Adapter 57001 1538 7571538ST C Sensor Harness Adapter 57001 1561 1571561 5 Kawasaki Bond Silicone Sealant 56019 120 DFI Servicing Precautions FUEL SYSTEM DFI 3 15 D I 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 SW switch is on or while the engine is run
57. 33 6 40 6 mm 1 32 1 60 in from the Sensor Base Line E Sensor Base Line F e Using the hand tester A measure the resistance across the terminals in the fuel level sensor lead connector B Black Yellow C White Yellow D Special Tool Hand Tester 57001 1394 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 4 10 Empty position E 90 100 e Apply a non permanent locking agent to the threads of the level sensor mounting bolts and tighten it 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 Right Frame Cover see Frame chapter e Disconnect the fuel level sensor connector A Switches and Sensors ELECTRICAL SYSTEM 16 79 e Connect the test light A 12 V 3 4 W bulb a socket with leads and the 12 V battery B to the fuel level sensor connector C Connections Battery 12 V 3 4 W Bulb one side 12 V 3 4 W Bulb other side Blue Lead Terminal Battery BK Y Lead Terminal the test light turn on the reverse switch is defective Replace the fuel level sensor e Remove Fuel Level Sensor see Fuel Level Sensor Inspection e Connect the test light 12 V 3 4 W bulb in a
58. 34 3 5 25 L 6 Shift lever bolt 6 9 0 70 61 in Ib 7 Tie rod locknuts 6 9 0 70 61 in Ib 8 Neutral switch 15 1 5 11 EO Apply engine oil G Apply grease L Apply a non permanent locking agent R Replacement Parts 9 6 CRANKSHAFT TRANSMISSION Specifications Item Standard Service Limit Crankshaft Connecting Rods Connecting rod bend 0 2 100 mm 0 008 3 94 Connecting rod twist TIR 0 2 100 mm 0 008 3 94 in Connecting rod big end side clearance 0 13 0 38 mm 0 58 mm 0 0051 0 0150 in 0 023 in Connecting rod big end bearing insert crankpin 0 041 0 071 mm 0 11 mm clearance 0 0016 0 0028 in 0 0043 in Crankpin diameter 34 984 35 000 mm 34 97 mm 1 3773 1 3780 in 1 3768 in Marking None Connecting rod big end inside diameter None Marking Connecting rod big end bearing insert thickness Brown Black Blue Connecting rod big end bearing insert selection Crankpin Diameter Con rod Big End Bore Diameter 34 984 34 992 mm 1 3773 1 3776 in 34 993 35 000 mm 1 3777 1 3780 in 38 000 38 016 mm 1 4961 1 4967 in 38 000 38 008 mm 1 4961 1 4964 in 38 009 38 016 mm 1 4964 1 4967 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 Bearing Insert Marking Marking Size Color Part Number 92139
59. 43 ft Ib e Install the rear wheel see Wheels Tires chapter Coupling Bearing Removal e Remove Coupling Grease Seal Circlip A GK05034BSi 6 e Remove the bearing A by tapping from the wheel side Special Tool Bearing Driver Set 57001 1129 B 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 57001 1129 B e Pack the bearing with high temperature grease e Replace the circlip with a new one 6 05010451 11 12 FINAL DRIVE Sprocket Coupling 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 Coupling Installation e Grease the following and install the coupling Coupling Grease Seal A Coupling Internal Surface B Ball Bearing C 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 Spin A it by hand to check its condition is noisy does not spin smoothly or has any rough spots it must be replaced Coupling Bearing Lubrication
60. 5 4 0 55 48 in Ib L Connecting rod big end nuts see the text lt Crankshaft position rotor bolt 40 4 1 30 Oil pressure switch 15 1 5 11 SS Oil pressure switch terminal bolt 1 5 0 15 13 in Ib Oil passage plugs 20 2 0 14 L Crankshaft sensor cover bolts 11 1 1 95 in lb Shift pedal mounting bolt 34 3 5 25 L Gear positioning lever bolt 12 1 2 104 in lb Shift shaft return spring pin 29 3 0 22 L Shift drum cam holder bolt 12 1 2 104 in Ib L Footpeg bracket bolts 34 3 5 25 L Shift lever bolt 6 9 0 70 61 in lb 2 8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Nm kgf m ftlb Remarks Tie rod locknuts 6 9 0 70 61 in lb Neutral switch 15 1 5 11 Wheels Tires Front axle clamp bolt 34 3 5 25 Front axle 108 11 80 Rear axle nut 108 11 80 Final Drive Engine sprocket nut 125 13 92 MO Engine sprocket cover bolts 9 8 1 0 87 in lb Speed sensor cover bolts 6 9 0 70 61 in Ib L Rear sprocket nuts 59 6 0 43 Speed sensor bolt 6 9 0 70 61 in Ib 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 9 in Ib Brake lever pivot bolt locknut 5 9 0 60 52 in Ib Front brake reservoir cap screws 1 0 0 10 9 in Ib Front brake light switch screws 1 0 0 10 9 in lb Front master cylinder clamp bolts 8 8 0 90 78 in lb S Front caliper mounting bolts 34 3 5 25 Front brake disc mounting bolts 27 2 8 20 L Rear brake disc mounting bolts 27 2 8 20 L Rear Cali
61. 7 V OThen the 1 and FUEL segments should flush xIf this display function does not flush replace the meter assembly Tachometer Check e Connect the 12 V battery and terminals in the same man ner as specified in the Liquid Crystal Display LCD Seg ments Check e The revolutions per minute rpm equivalent to the input frequency is indicated in the oscillator A if the square wave illustrated as shown would be input into the termi nal 7 Olndicates approximately 6000 rpm in case the input fre quency would be approximately 200 Hz booboooc QQ000000 lt lt GP17114BS2 C 8 17115 52 C BE BS 10 15 ubt DUTY 50 ov GP17048BS1 C Meter Gauge Indicator Unit ELECTRICAL SYSTEM 16 71 e f the oscillator is not available the tachometer can be checked as follows OConnect the 12 V battery and terminals in the same man ner as specified in the Liquid Crystal Display LCD Seg ments Check OUsing an auxiliary wire quick open and connect the ter minal 1 to the terminal 7 repeatedly OThen the tachometer segment A should flick B x lf the segment does not flick replace the meter assembly LED Lights Inspection e Connect the 12 V battery and terminals in the same man ner as specified in the Liquid Crystal Display LCD Seg ments check Neutral Indicator Light LE
62. 8 0 80 69 in lb Clutch cover mounting bolts 11 1 1 95 in lb Oil filler plug 1 5 0 15 13 in Ib Clutch spring bolts 8 8 0 90 78 in lb Clutch hub nut 135 14 100 R PERIODIC MAINTENANCE 2 7 Torque and Locking Agent Fastener 191908 kgf m ft Ib Engine Lubrication Oil filler plug 1 5 0 15 13 in Ib Engine oil drain bolt 20 2 0 14 Oil filter 31 3 2 23 Holder mounting bolt 76 7 8 56 EO Oil pan bolts 11 1 1 95 in Ib Oil pipe holder bolts 13 1 3 113 in lb L OU pressure relief valve 15 1 5 11 L Oil pressure switch 15 1 5 11 SS Oil pressure switch terminal bolt 1 5 0 15 13 in lb Water pump cover bolts 11 1 1 95 in Ib Water pump impeller bolt 9 8 1 0 87 in lb Coolant drain plug water pump 11 1 1 95 in lb Oil passage plugs 20 2 0 14 L Engine Removal Installation Adjusting collar locknut 49 5 0 36 S Engine mounting bolts and nuts 44 4 5 33 S Front engine bracket bolts 44 4 5 33 S Rear engine bracket bolts 25 2 5 18 S Engine ground cable terminal bolt 9 8 1 0 87 Crankshaft Transmission Breather plate bolts 9 8 1 0 87 in lb L Crankcase bolts M9 L 81 mm 42 4 3 31 MO S Crankcase bolts M9 L 95 mm 42 4 3 31 MO S Crankcase bolts M8 27 2 8 20 S Crankcase bolts M7 20 2 0 14 S Crankcase bolts M6 12 1 2 104 in lb S Starter motor clutch bolts 12 1 2 104 in lb L Oil pipe holder bolts 13 1 3 113 in Ib L Shift drum bearing holder bolt 13 1 3 113 in Ib L Shift drum bearing holder screw
63. 80 kgf m 69 in Ib e Replace the fluid seal A with a new one OApply brake fluid to the fluid seal and install it into the cylinder by hand e Replace the dust seal B with a new one if it is damaged OApply brake fluid to the dust seal and install it into the cylinder by hand e Apply brake fluid to the outside of the piston and push it into the cylinder by hand e Replace the shaft rubber friction boot A and dust cover B if they are damaged e Apply a thin coat of PBC Poly Butyl Cuprysil grease to the caliper holder shafts C and holder holes D PBC is a special high temperature water resistance grease e Install the anti rattle spring A in the caliper as shown e Install the pads see Rear Brake Pad Installation e Wipe up any spilled brake fluid on the caliper with wet cloth Caliper Fluid Seal Damage e Refer to the Brakes in the Periodic Maintenance chapter Caliper Dust Seal Friction Boot Damage e Refer to the Brakes in the Periodic Maintenance chapter 6105040251 Calipers BRAKES 12 13 Caliper Piston and Cylinder Damage e Visually inspect the piston E and cylinder surfaces Replace the caliper if the cylinder and piston are badly Scores or rusty Fluid Seal A Dust Seal B Rubber Boot C Front Caliper J Rear Caliper K Caliper Holder Shaft Wear The caliper body must slide smoothly on the caliper holder shaft F If the b
64. 92139 1109 6105041751 None Blue 92139 1108 e Install the new inserts in the connecting rod and check insert crankpin clearance with the plastigage Bearing Insert Crankshaft Side Clearance e Insert a thickness gauge A between the crankcase main bearing and the crank web at the No 2 journal B to determine clearance the clearance exceeds the service limit replace the crankcase halves as a set NOTE OThe upper and lower crankcase halves are machined at the factory in the assembled state so the crankcase 8105019881 halves must be replaced as a set Crankshaft Side Clearance Standard 0 05 0 20 mm 0 0020 0 0079 in Service Limit 0 40 mm 0 0157 in 9 20 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods Crankshaft Runout e Measure the crankshaft runout If the measurement exceeds the service limit replace the crankshaft Crankshaft Runout Standard TIR 0 02 mm 0 0008 in or less Service Limit TIR 0 05 mm 0 0020 in Crankshaft Main Bearing Insert Journal Wear e Using a plastigage press gauge A measure the bear ing insert journal B clearance NOTE OTighten the crankcase bolts to the specified torque see Crankcase Assembly ODo not turn the crankshaft during clearance measure ment OJournal clearance less than 0 025 mm 0 00098 in can not be measured by plastigage however using genuine parts maintains the minimum s
65. A Inlet Air Pressure Sensor Hose B Front C Vacuum Gauge D Plugs E GSO5035BS1 2 16 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Install the fuel tank see Fuel System DFI chapter e Start the engine and warm it up thoroughly e Check the idle speed Tachometer A lf the idle speed is out of the specified range adjust it CAUTION Do not measure the idle speed by the tachometer of the meter unit While idling the engine inspect the engine vacuum using the vacuum gauge B Engine Vacuum Standard 29 7 1 333 kPa 225 10 mmHg at Idle Speed 1 100 50 r min rpm any vacuum is not within the specifications first syn chronize the 3 and 4 throttle valves to the 1 and 2 throttle valves by using the center adjusting screw A Special Tool Pilot Screw Adjuster C 57001 1292 B Front C Example 1 165 mmHg 2 190 mmHg 3 170 mmHg 4 200 mmHg e With the engine at the correct idle speed equalize the highest vacuum of 3 and 4 example 200 mmHg to the highest vacuum of 1 and 2 example 190 mmHg by turning the center adjusting screw NOTE OAfter adjustment the final vacuum measurement be tween the highest throttle valves may not be 200 mmHg in this example The goal is to have the highest two vacuums between the left 1 and 2 and right 3 and 4 banks be the same e Open and close the throttle af
66. BK R BK Y BK Y Subthrottle Valve Actuator Fuel Injector 1 Fuel Injector 2 Fuel Injector 3 Fuel Injector 4 Subthrottle Sensor Main Throttle Sensor Speed Sensor Camshaft Position Sensor ta A d Y Y R BR W Moter Frame Ss roundGround 7 601 Crankshaft Pressure 2159 side Switch Stand NS o Switch mr E Neutral Switch BL R BK Y Inlet Air Sensor Atmospheric Sensor Water Temperature Sensor Inlet Air Pressure Sensor Temperature L 11 Pressure Y 8K BK Y an Alternator BR W Y R BK HEI BK Y DO 26 9 R amp BK R VI BR Y DCH BK BL w BL R Y BR R BL Y BL G BL BK BL R BK Y BK W BK Y BK G License Plate Light 12V5W R R BK Y BK Y BK Y BK Y BK Y BK Y wy Y G BK Y Joint Connector 22 Engi Grou Vehicle Hain Fuse 30A Self diagnesis Terminal ne ad IGNITION SWITCH CONNECTIONS Tee DEER Rear Right Turn Signal Light 12 21 aY BK Y po pE BL R R Tail Brake Light LED 12V0 5 3 8 wy wy Kr wy Kr Left Turn Light Rear Signal 12 21 BK Y BK Y BK Y BK Y BK Y BK Y BK Y BK Y B Joint Connector Dark Green
67. BK Y eR bBK Y r BK Y D BK BK Y BL BL W BL W BL BK 1 Radiator Fan 5 Meter Ground 9 Fan Fuse 15A 2 Radiator Fan Switch 6 Frame Ground 10 Main Fuse 30 A 3 Joint Connector A 7 Joint Connector B 11 Battery 12 V 8 Ah 4 Joint Connector D 8 Junction Box 16 64 ELECTRICAL SYSTEM Meter Gauge Indicator Unit Meter Unit Removal e Remove Fairing see Frame chapter e Slide the dust cover A and remove the wiring connector B e Remove the meter unit by taking off the mounting screws C with the washers CAUTION Place the meter or gauge so that the face is up If a meter or gauge is left upside down or sideways for any length of time it will malfunction Meter Gauge Disassembly e Remove Meter Unit see Meter Unit Removal Screws A Lower Meter Cover B e Separate the meter assembly A and upper meter cover B ELECTRICAL SYSTEM 16 65 Meter Gauge Indicator Unit Electronic Combination Meter Unit Inspection e Remove the meter unit A 1 Ignition 10 Battery 2 Fuel Reserve Switch 11 Oil Pressure Warning 3 Unused Indicator Light LED 4 Fuel Level Sensor Ground 5 Neutral Indicator Light 12 Speed Sensor Supply LED Ground Voltage 6 FI Indicator Light 13 Right Turn Signal Light LED Ground LED 7 Tachometer Pulse 14 Left Turn Signal Indicator 8 Water Temper
68. BK Y lead terminal 51 Connections for Stick Coil 3 Meter BK W lead terminal 37 Meter BK Y lead terminal 51 Connections for Stick Coil 4 Meter BK O lead terminal 52 Meter BK Y lead terminal 51 Input Voltage at ECU Standard Battery Voltage 12 6 V or more x lf the reading is out of the standard check the wiring see next wiring diagram the reading is good the input voltage is normal Crank the engine and check the peak voltage of the stick coils see Electrical System chapter in order to check the pri mary coils FUEL SYSTEM 3 65 Stick Coils 1 2 3 4 Service Code 51 52 53 54 A ECU X Ignition Fuse 10 A f Sealed Battery M Stick Coils Y Junction Box Main Fuse 30 N Engine Stop Switch d Starter Relay T Ignition Switch e Joint Connector C 3 66 FUEL SYSTEM DFI Subthrottle Valve Actuator Service Code 62 Subthrottle Valve Actuator Removal CAUTION Do not remove the subthrottle valve actuator A since it has been adjusted and set with precision at the factory Never drop the actuator especially on a hard sur face Such a shock to the actuator can damage it Audible Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch ON and ensure that the actuator valves open and close make light sounds several times within seconds and
69. BTDC 66 ABDC 284 57 BBDC 31 ATDC 268 Forced lubrication wet sump API SE SF or SG API SH or SJ with JASO MA General Specifications GENERAL INFORMATION 1 9 Items Viscosity Capacity Drive Train Primary reduction system Type Reduction ratio Clutch type Transmission Type Gear ratios 1st 2nd 3rd 4th 5th 6th Final drive system Type Reduction ratio Overall drive ratio ZR750 J1 SAE 10W 40 3 8 L 4 0 US qt Gear 1 714 84 49 Wet multi disc 6 speed constant mesh return shift 2 571 36 14 1 941 33 17 1 555 28 18 1 333 28 21 1 200 24 20 1 095 23 21 Chain drive 2 867 43 15 5 382 Top gear Tail brake light Alternator Type Rated output Frame Type Tubular diamond Caster rake angle 24 5 Trail 104 mm 4 1 in Front tire Type Tubeless Size 120 70 ZR17 M C 58W Rear tire Type Tubeless Size 180 55 ZR17 M C 73W Front suspension Type Telescopic fork upside down Wheel travel 120 mm 4 7 in Rear suspension Type Swingarm uni trak Wheel travel 126 mm 5 0 in Brake Type Front Dual discs Rear Single disc Electrical Equipment Battery 12V 8 Ah Headlight Type Semi sealed beam Bulb 12 V 55 W x 2 55 W Hi Lo 12 V 0 5 3 8 W LED CA 12 V 0 5 5W LED Three phase AC 24 A 14 V 5 000 r min rpm Specifications are subject to change without notice and may not apply to every country AU Australia Model CA Canada Model MY Ma
70. C 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 shafts without binding after assembly 6113033851 C CRANKSHAFT TRANSMISSION 9 29 Transmission s ene tote 2 209 00000069006 EDDA Drive Shaft Output Shaft 2099 eS 1 1st Gear 18 Bushing 2 2nd Gear 19 Bushing 3 3rd Gear 20 Circlip 4 4th Gear 21 Ball Bearing 5 5th Gear 22 Collar 6 6th Top Gear 23 Washer 7 Toothed Washer 31 mm 1 22 in 24 Toothed Washer 8 Thrust Washer 30 mm 1 18 in 25 Oil Seal 9 Circlip 26 Thrust Washer 31 mm 10 Circlip 1 22 in 11 Bushing 27 Thrust Washer 33 mm 12 Bushing 1 30 in 13 Needle Bearing 28 Toothed Washer 14 Needle Bearing 29 Toothed Washer 15 Bearing Outer Race 30 Toothed Washer 35 mm 16 Steel Ball 1 38 in 61130801 3 C 17 Nut 9 30 CRANKSHAFT TRANSMISSION Transmission Shift Drum and Fork Removal e Remove Lower Crankcase Half see Crankcase Splitting Transmission Shafts External Shift Mechanism see External Shift Mecha nism Removal Bolt A and S
71. CAUTION Immediately dry the bolts and nuts with com pressed air after cleaning Clean and dry the bolts and nuts completely e Install new bolts in reused connecting rods e Apply a small amount of molybdenum disulfide oil to the following Threads A of Nuts and Bolts Seating Surfaces B of Nuts and Con 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 OTighten the hexagon nut by 2 corners Connecting Torque Angle Bolt Nut Rod Assy kgf m ft lb Attached to 18 1 8 13 0 Use the bolts new con rod 120 New attached to new con rod New 20 2 0 14 5 120 24 2 4 17 4 Replace the Used 120 Used bolts with new Ones TN 25 2 6 18 8 120 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 6105040481 C 6105040581 CRANKSHAFT TRANSMISSION 9 17 Crankshaft and Connecting Rods Connecting Rod Bend e Remove the connecting rod big end bearing inserts and reinstall the connecting rod big end cap e Select an arbor A of the same diameter as the c
72. Cr Self BK Y diagnesis E Terminal BK Y ea x EM zzz Joint ae ES Connector 6 3 gt gt 2m ECU 25 5 ni Fuse 154 Rear Brake pve uum Light K Signal Vehicle PO D Relay down Ade Main Fuse 30A BL R di BK Y Bx Y WY UA WY UA Wy BK Y BK Y BK Y BK Y BK Y BK Y BK Y BK Y Joint Connector B Inlet Air Temperature Atmospheric Pressure Water Temperature Sensor Inlet Air Pressure E U License Plate Light 12V5W Rear Right Turn Signal Light 12 214 Se Brake Light LEB 12V0 5 3 89 Rear Left Turn Signal Light i12V21N Color Code Brown cn Chocolate Be Derk Green 8 see ev LB Light Blue RIGHT SWITCH HOUSING CONNECTIONS Starter Button Color D LOCK front Brake Light Switch Engine Stop Switch Color BK Color BK R BK R Brake Lever E Red thite Pulled In Yellow 98052 0058B W2ROOSSBHS C 16 16 ELECTRICAL SYSTEM Wiring Diagram Other than Canada Australia and Malaysia Ignition Switch Fuel Fuel Reserve Level Switch Sensor 41 BK LE wey BK Y BK Y GA BK Y eK Y Joint Connector Spark Plugs Lj 1 2 43 44 eg d o Horn Rad Radiator ss 255 12V 2 5 Wotor Fan Switch Ignition Coils Ss z 5 gt ER a
73. DC x If the reading is within the standard range check the sen sor output voltage xIf the reading of input voltage is less than the standard range remove the ECU and check the wiring between these connections the wiring is good check the ECU for its ground and power supply see ECU section 3 52 FUEL SYSTEM Atmospheric Pressure Sensor Service Code 15 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 ECU Connector B Atmospheric Pressure Sensor Output Voltage Connections to ECU Meter G W lead terminal 4 Meter BR BK lead terminal 14 6017122881 6 Usable Range 3 74 4 26 V DC at the standard atmospheric pressure 101 32 kPa 76 cmHg abs NOTE OThe output voltage changes according to the local at mospheric pressure e Turn the ignition switch OFF If the output voltage is within the usable range check the ECU for its ground and power supply see this chapter lf the output voltage is out of the standard remove the seat cover and check the wiring And if the output voltage is 4 8 V the ECU is normal the wiring is good check the sensor for various vacuum If the output voltage for various vacuum is normal check the ECU for its ground and power supply see ECU section ODetermine the local altitude elevation If you know the l
74. DFI 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 6007010451 6 6007013851 6 4 14 COOLING SYSTEM Radiator e Install the cap A on a cooling system pressure tester B NOTE OWet 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 2 Standard 93 123 kPa 0 95 1 25 kgf cm 14 17 8 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 the fuel tank see Fuel System DFI chapter e Remove the 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 GD07001BS1 C COOLING SYSTEM 4 15 Thermostat Thermostat Removal e Drain the coolant see Cooling System in the Periodic Maintenance chapter
75. ECU trouble Crankshaft sensor trouble Stick coil trouble Fuel air mixture incorrect Air cleaner clogged poorly sealed or miss ing Air cleaner O ring damaged Air cleaner duct loose Water or foreign matter in fuel Throttle body assy holder loose Fuel to injector insufficient DFI Fuel tank air vent obstructed Fuel line clogged Fuel pump trouble DFI 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 IC igniter in ECU trouble Camshaft position sensor trouble Crankshaft sensor 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 Air suction valve trouble Vacuum switch valve trouble Catalytic converter melt down due to muffler overheating KLEEN Overheating Firing incorrect Spark plug dirty broken or maladjusted Spark plug incorrect IC igniter in ECU trouble Muffler overheating For KLEEN do not run the engine even if with only one cyli
76. In this case turn off the ignition switch and turn it on again to enter the Dealer 2 mode In this mode the system tells all the troubles which the DFI system had in both static and dynamic conditions Camshaft Position Sensor Removal Installation The camshaft position sensor detects the position of the camshaft and distinguishes the cylinder e See the Ignition system section in the Electric 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 signal e Crank the engine and measure the peak voltage of the camshaft position sensor see Electrical System chapter in order to check the sensor e Check the wiring for continuity using the following dia gram THIRD BR W A ECU G Camshaft Position Sensor 80617171841 C 3 56 FUEL SYSTEM DFI Speed Sensor Service Code 24 25 Speed Sensor Removail installation e See the Switches and Sensors section in the Electrical System chapter Speed Sensor Inspection e See the Switches and Sensors section in the Electrical System chapter Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Disconnect the speed sensor connector A and connect the harness adapter B between the harness connector and speed sensor connector Engine Sprocket Cover C e Connect a digita
77. Installation e Be sure to install the following parts Plug Hole Gaskets A Dowel Pins B e Apply engine oil to all cam parts and journals e If a new camshaft is to be used apply a thin coat of molyb denum disulfide grease to the cam surfaces NOTE OThe exhaust camshaft has a 1182 EX mark A and the inlet camshaft has a 1182 IN mark B Be careful not to mix up these shafts ee e OY 24 oi n Ki oO SIN Mero cn EISE UE Poe CC 5 16 ENGINE TOP END Camshaft Camshaft Chain 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 OThe timing marks of 1 4T must be aligned with the lower surface of crankcase of rear side B OThe timing marks must be aligned with the cylinder head upper surface C EX mark D IN mark E e Before installing the camshaft cap and chain guide install the camshaft chain tensioner body temporally e Install the camshaft cap and chain guide A 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 16 19 20 12 1 2 kgf m 104 in Ib Camshaft Chain Guide Bolts 17 18 12 1 2
78. ON The vehicle down sensor is turned ON and the LED light goes OFF 3 18 FUEL SYSTEM DFI Troubleshooting the DFI System OThe DFI part connectors A have seals B including the ECU e Join the connector and insert the needle adapters special tool C inside the seals B from behind the connector until the adapter reaches the terminal Special Tool Needle Adapter Set 57001 1457 CAUTION Insert the needle adapter straight along the terminal in the connector to prevent short circuit between terminals 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 the hand tester or 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 SW ON and measure the voltage with the connector joined CAUTION Incorrect reverse connection or short circuit by needle adapters could damage the DFI or electrical system parts OAfter measurement remove the needle adapters and ap ply silicone sealant to the seals A of the connector B for waterproofing Silicone Sealant Kawasaki Bond 56019 120 Seals of Connector e Always check battery condition before replacing the parts A fully charged battery is a must for conducting accurate tests of the DFI system e Trouble may invo
79. Pad Removal e Using compressed air remove the pistons OCover the piston area with a clean thick cloth A OBlow compressed air B into the hole for the banjo bolt to remove the piston 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 NOTE compressed air is not available with the brake hose still attached apply the brake lever to remove the pis ton The remaining process is as described above 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 Valve 7 8 0 80 kgf m 69 in Ib GL05067BS1 C Calipers BRAKES 12 11 e Replace the fluid seals A with new ones OApply brake fluid 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 brake fluid to the dust seals and install them into the cylinders by hand e Apply brake fluid to the outside of the pistons and push them into each cylinder by hand e Check the shaft rubber friction boot A and the dust cover B repl
80. Page Brake hoses 4 years 2 36 Brake fluid front and rear 2 years 2 32 Rubber parts of master cylinder and caliper 4 years 2 30 Spark plug 2 39 Air cleaner element 2 18 Engine 2 24 Oil filter 2 25 Fuel hoses 2 13 Coolant 2 20 Service more frequently when operating in severe conditions dusty wet muddy high speed or frequent starting stopping Throttle control system inspection Inspection of throttle grip play PERIODIC MAINTENANCE 2 5 Torque and Locking Agent The following tables list the tightening torque The table below relating tightening torque to for the major fasteners requiring use of a non thread diameter lists the basic torque for the permanent locking agent or liquid gasket bolts and nuts Use this table for only the bolts and nuts which do not require a specific torque Letters used in the Remarks column mean value All of the values are for use with dry AL Tighten the two clamp bolts alternately solvent cleaned threads EE Io ensure even EE Basic Torque for General Fasteners G Apply grease to the threads Threads Torque L Apply a non permanent locking agent to dia f the threads mm felb MO Apply molybdenum disulfide grease oil 5 34 49 0 35 0 50130 43 in Ib solution 20 Apply oil the threads and seating 9 face 8 14 19 1 4 1 9 10 0 13 5 R Replacement Parts 10 25 34 2 6 3 5 19 0 25 S Tight
81. Press in each bearing A right until they are bottomed Special Tool Bearing Driver Set 57001 1129 B e Replace the circlip with a new one e Replace the grease seals with new ones e Press in the grease seals A so that the seal surface flush B with the end of the hole OApply high temperature grease to the grease seal lips Special Tool Bearing Driver Set 57001 1129 C Hub 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 lf bearing play roughness or binding is found replace the bearing e Examine the bearing seal B for tears or leakage x If the seal is torn or is leaking replace the bearing 6406060651 6 6J05000481 6 6J05000581 6 6J06002BSi 6 FINAL DRIVE 11 1 Final Drive Table of Contents leie Ee E 11 2 Specificatioris co cbe Fe nd reed dre e e Pe d Eel 11 4 jer cc LEE 11 5 Drive Chain e 11 6 Drive Chain Slack mener 11 6 Drive Chain Slack Adjustment ere tetra ea pce p 11 6 Drive Chain Wear Inspection 11 6 Drive Chain Lubricatig
82. Rear Electrical System Spark plug gap AT Republic of Austria CH Swiss Confederation DOT4 4 5 mm 0 18 in 5 mm 0 20 in Pulled ON ON after about 10 mm 0 39 in of pedal travel 0 7 0 8 mm 0 028 0 031 mm DE Federal Republic of Germany 1 mm 0 04 in 1 mm 0 04 in 2 12 PERIODIC MAINTENANCE Special Tools Steering Stem Nut Wrench 57001 1100 Jack 57001 1238 FE e Oil Filter Wrench 57001 1249 Pilot Screw Adjuster C 57001 1292 Hand Tester 57001 1394 Spark Plug Wrench Owner s Tool 92110 1146 Z B 819211465 C PERIODIC MAINTENANCE 2 13 Periodic Maintenance Procedures Fuel System DFI Fuel Hose and Connection Inspection OThe fuel hoses are designed to be used throughout the motorcycle s life without any maintenance however if the motorcycle is not properly handled the high pressure in side the fuel line can cause fuel to leak A or the hose to burst Remove the fuel tank see Fuel System DFI chapter and check the fuel hoses Replace the hose if any fraying cracks B or bulges C are noticed e Check that the hoses are routed according to Cable Wire and Hose Routing section in the Appendix chapter Replace the hose if it has been sharply bent or kinked Hose Joints A Pump Outlet Hose B Pump Inlet Hose C Front D e Insert the pump outlet hose j
83. Removal e Refer to the Fuel System DFI chapter Water Temperature Sensor A Water Temperature Sensor Inspection e Refer to the Electrical System chapter for the Water Tem perature Sensor Inspection ENGINE TOP END 5 1 Engine Top End Table of Contents Exploded View 5 2 Cylinder Head Warp 5 20 Specifications 5 6 VIVE 5 21 Special Tools and Sealant 5 8 Valve Clearance Inspection 5 21 Clean Air 5 10 Valve Remowval 5 21 Air Suction Valve 5 10 Valve Installation 5 21 Air Suction Valve Installation 5 10 Valve Guide Removal 5 21 Air Suction Valve Inspection 5 10 Valve Guide Installation 5 22 Vacuum Switch Valve Removal 5 10 Valve to Guide Clearance Vacuum Switch Valve Installation 5 10 Measurement Wobble Vacuum Switch Valve Test 5 11 Method eet 5 22 Clean Air System Hose Valve Seat Inspection 5 23 Inspection 5 11 Valve Seat Repair 5 23 Cylinder Head Cover 5 12 Cylinder Pistons 5 28 Cylinder Head Cover Removal 5 12 Cylinder Remowval 5 28 Cylinder Head Cover Installation 5 12 Cylinder Installation
84. Rider 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 following sample diagnosis sheet will help prevent you from overlooking any areas and will help you decide if it is DFI system problem or a general engine problem 3 22 FUEL SYSTEM DFI Troubleshooting the DFI System Sample Diagnosis Sheet Rider name Registration No license plate No Year of initial registration Model Engine No Frame No Date problem occurred Mileage Environment when problem occurred Weather fine a cloudy n rain o snow a always n other Temperature hot o warm a cold very cold o always Problem chronic often once frequency Road street o highway mountain road n uphill o downhill bumpy o pebble Altitude normal o high about 1000 m or more Motorcycle conditions when problem occurred Fl indicator light up immediately after ignition SW ON and goes off after 1 2 sec
85. Sensor Signal Unused Camshaft Position Sensor Signal Unused Crankshaft Sensor Signal Unused ECU Power Source Circuit Ground to Bat tery Terminal Part Name OMDOVOZESErAc_ LTOAMVIOD gt SY ECU Electronic Control Unit Crankshaft Sensor Inlet Air Pressure Sensor Water Temperature Sensor Atmospheric Pressure Sensor Inlet Air Temperature Sensor Camshaft Position Sensor Speed Sensor Main Throttle Sensor Subthrottle Sensor Injectors 1 2 3 4 Subthrottle Valve Actuator Stick Coils 1 2 3 4 Engine Stop Switch Joint Connector D see Electrical System chapter Ground Terminal Ground Terminal ECU Main Relay Engine Stop Switch Signal Starter Lockout Switch Signal Electric Starter Button Signal Fuel Pump Relay Signal Subthrottle Valve Actuator Drive Signal Subthrottle Valve Actuator Drive Signal Unused Tachometer Signal Injector 2 Signal Injector 1 Signal Stick Coil 3 Signal Stick Coil 2 Signal Stick Coil 1 Signal Interlock Circuit Signal Self diagnosis Signal generated by grounding this terminal and shown by Fl indicator LED light Unused Battery Power ON OFF Signal Subthrottle Valve Actuator Drive Signal Subthrottle Valve Actuator Drive Signal External Diagnosis System Signal Fl Indicator LED Light Signal Injector 4 Signal Injector 3 Signal DFI System Gro
86. 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 usable range 1 110 1 590 kPa 11 3 16 2 kgf cm 161 230 psi 300 r min rpm 0 22 0 31 mm 0 0087 0 0122 in 0 15 0 24 mm 0 0059 0 0094 in 1 0 mm 0 039 in 0 5 mm 0 020 in TIR 0 01 mm 0 0004 in or less 3 955 3 970 mm 0 1557 0 1563 in 3 975 3 990 mm 0 1565 0 1571 in 4 000 4 012 mm 0 1575 0 1580 in 4 000 4 012 mm 0 1575 0 1580 in 0 09 0 18 mm 0 0035 0 0071 in 0 03 0 12 mm 0 0012 0 0047 in 45 32 60 0 5 1 0 mm 0 020 0 039 in 0 5 1 0 mm 0 020 0 039 in 21 6 21 8 mm 0 850 0 858 in 26 4 26 6 mm 1 0276 1 0472 in 0 5 mm 0 020 in 0 25 mm 0 0098 in TIR 0 05 mm 0 002 in 3 94 mm 0 155 in 3 96 mm 0 156 in 4 08 mm 0 161 in 4 08 mm 0 161 in 0 40 mm 0 016 in 0 33 mm 0 013 in ENGINE TOP END 5 7 Specifications Item Standard Service Limit Valve spring free length Exhaust 40 7 mm 1 602 in 38 9 mm 1 531 in Inlet 40 7 mm 1 602 in 38 9 mm 1 531 in Cylinder Pistons Cylinder inside diameter 68 400 68 412 mm 2 6929 2 6934 in 68 50 mm 2 6969 in Piston diameter 68 345 68 360 mm 2 6907 2 6913 in 68 21 mm 2 6854
87. View 1 8 GENERAL INFORMATION General Specifications Items ZR750 J1 Dimensions Overall length 2 080 mm 81 9 in Overall width 780 mm 30 7 in Overall height 1 055 mm 41 5 in Wheelbase 1 425 mm 56 1 in Road clearance 165 mm 6 5 in Seat height 815 mm 32 1 in Dry mass 195 kg 430 0 Ib Curb mass Front 111 kg 244 8 Ib Rear 107 kg 235 9 Ib Fuel tank capacity Performance Minimum turning radius Engine Type Cooling system Bore and stroke Displacement Compression ratio Maximum horsepower Maximum torque Carburetion system Starting system Ignition system Timing advance Ignition timing Spark plug Cylinder numbering method Firing order Valve timing Inlet Open Close Duration Exhaust Open Close Duration Lubrication system Engine oil Type 18 L 5 0 US gal 2 9 m 9 5 ft 4 stroke DOHC 4 cylinder Liquid cooled 68 4 x 50 9 mm 2 7 x 2 0 in 748 mL 45 64 cu in 11 3 79 kW 107 PS 10 500 r min rpm MY AU 80 kW 109 PS 11 000 r min rpm HR 78 2 kW 106 PS 11 000 r min rpm 75 Nm 7 6 kgf m 55 ft lb 8 200 r min rpm HR 73 N m 7 4 kgf m 54 ft lb 8 200 r min rpm FI Fuel Injection KEIHIN TTK34 x 4 Electric starter Battery and coil transistorized Electronically advanced digital igniter From 10 BTDC 1 100 r min rpm to 37 BTDC 5 800 r min rpm NGK CR9EK or ND U27ETR Left to right 1 2 3 4 1 2 4 3 38
88. WARNING Be sure that the outer cable end at the clutch lever is fully seated in the adjuster at the clutch lever or it could slip into place later creating enough cable play to prevent clutch disengagement e After the adjustment start the engine and check that the clutch does not slip and that it releases properly Engine Lubrication System 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 Change Replace the drain bolt gasket B with a new one e Tighten the drain bolt Torque Engine Oil Drain Bolt 20 2 0 kgf m 14 ft Ib e Pour in the specified type and amount of oil Engine Oil Grade API SE SF or SG API SH or SJ with JASO MA Viscosity SAE 10W 40 Capacity 3 11 3 3 US qt when filter is not removed 3 3 L 3 5 US qt when filter is removed 3 8 L 4 0 US qt when engine is completely dry 6509009851 C PERIODIC MAINTENANCE 2 25 Periodic Maintenance Procedures NOTE 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 riding area Oil Filter Change e Drain the engine oil see Engine Oil Change e Remove the oil filter A with the oil filter wrench B Special Tool Oil Filter Wrench 57001 1
89. and lift up the fuel tank 62178169 GC17170BS1 FUEL SYSTEM DFI 3 79 Fuel Pump e Connect the hand tester 25 V DC to the fuel pump con nector A with needle adapter set Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 OMeasure 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 Pump Operating Voltage at Pump Connections to Pump Connectors Tester Y R Lead Tester BK W Lead Operating Voltage at Pump Connector Standard Battery Voltage 12 6 V or more for 3 seconds and then 0 xIf 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 this chapter Pressure Regulator Removal OThe pressure regulator A is built into the fuel pump B and cannot be removed Pump Screen Fuel Filter Cleaning OThe pump screen A and fuel filter B are built into the pump and cannot be cleaned or checked If the pump screen or fuel filter is suspected of clogging or being damaged replace it with the fuel pump as a set 3 80 FUEL SYSTEM DFI Fuel Pump Fuel Pump Relay Removal CAUTION Never drop the relay especi
90. 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 instruments 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 Special Tool Catalog or Manual
91. 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 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 the fuel tank see Fuel Tank Removal e Remove the fuel pump inlet hose and the fuel pump see Fuel Pump section in this chapter 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 the fuel pump see Fuel Pump Installation e Install the fuel tank see Fuel Tank Installation COOLING SYSTEM 4 1 Cooling System Table of Contents E 4 2 Goolant FIOW en 4 4 eelere 4 6 Special Tools and 4 7 Ree EE 4 8 Coolant Deterioration Inspechon mnes 4 8 Coolant Level Inspechon nenne 4 8 Goolant EC He el WE 4 8 Coolant Filliig EE 4 8 Pressure Testing namis 4 9 Cooling System Flushing DEE 4 9 Coolant Reserve Tank Removal Ins
92. change to the mile and Mile and km and E km and display each time by pushing the RESET bottom while MODE bottom pushed in NOTE OMile Km Display can alternate between English and metric modes mile and km in the digital meter Make sure that km or mile according to local regulations is correctly displayed before riding x lf the display function does not work and adjust replace the meter assembly Speedometer Check e Connect the 12 V battery and terminals in the same man ner as specified in the Liquid Crystal Display LCD Seg ments Check e The speed equivalentto the input frequency is indicated in the oscillator A if the square wave illustrated as shown would be input into the terminal 16 Olndicates approximately 60 mph in case the input fre quency would be approximately 160 Hz Olndicates approximately 60 km h in case the input fre quency would be approximately 100 Hz CLOCK E CLOCK wie CLOCK ele CLOCK 6Pi7064BSi 6 6 17121851 6 NE E S DUTY 50 ov 8 17049851 6 16 68 ELECTRICAL SYSTEM Meter Gauge Indicator Unit e f the oscillator is not available the speedometer can be checked as follows Olnstall the meter unit ORaise the rear wheel off the ground using the jack OTurn on the ignition switch ORotate the rear wheel by hand OCheck that the speedometer shows the speed lf the speedometer does not work ch
93. circlips or cotter pins must be replaced with new ones whenever disassembled 68020108 5 Assembly Order In most cases assembly order is the reverse of disassem is bly however if assembly order is provided in this Service T Oc Manual follow the procedures given lt a oan Sei BRA X toy TE gt e 27 TS 68020118 S 1 4 GENERAL INFORMATION Before Servicing Tightening Sequence Bolts nuts or screws must be tightened according to the specified sequence to prevent case warpage or deformation which can lead to malfunction If the specified tightening sequence is not indicated tighten the fasteners alternating diagonally Tightening Torque Incorrect torque applied to a bolt nut or screw may lead to serious damage Tighten fasteners to the specified torque using a good quality torque wrench Often the tightening sequence is followed twice initial tightening and final tightening with torque wrench Force Use common sense during disassembly and assembly excessive force can cause expensive or hard to repair 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 per formance Remove old gaskets and clean the sealing surfaces thoroughly so
94. clamp 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 maladjusted Front fork bent Right and left front fork oil level uneven Shock absorption unsatisfactory Too hard Front fork oil excessive Front fork oil viscosity too high Rear shock absorber adjustment too hard Tire air pressure too high Front fork bent Too soft Tire air pressure too low Front fork oil insufficient and or leaking Front fork oil viscosity too low 17 22 APPENDIX Troubleshooting Guide Rear shock adjustment too soft Battery Trouble Front fork rear shock absorber spring weak Battery discharged Rear shock absorber oil leaking Charge insufficient Battery faulty too low terminal voltage Brake Doesn t Hold Battery lead making poor contact Air in the brake line Load excessive e g bulb of excessive Pad or disc worn wattage Brake fluid leakage Ignition switch trouble Disc warped Alternator trouble Contaminated pad Wiring faulty Brake fluid deteriorated Regulator rectifier trouble Primary or secondary cup damaged in master Battery overcharged cylinder Alternator trouble Master cylinder scratched inside Regulator rectifier trouble Battery faulty MODEL APPLICATION Year Model Beginning Frame No JKAZRDJ1C14A000001 2004 ZR750 J1 ZR750J 000001 JKAZR750J
95. 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 6105040651 6 6105040781 9 18 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Big End Bearing Insert Crankpin Wear e Measure the bearing insert crankpin B clearance with plastigage A 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 0 041 0 071 mm 0 0016 0 0028 in Service Limit 0 11 mm 0 0043 in lf the clearance is within the standard no bearing replace ment is required x lf the clearance is between 0 072 mm 0 00284 in and the service limit 0 11 mm 0 0043 in replace the bear ing inserts A with inserts painted blue B Check in sert crankpin clearance with the plastigage The clear ance may exceed the standard slightly but it must not be less than the minimum in order to avoid bearing seizure the clearance exceeds the service limit measure the diameter of the crankpins Crankpin Diameter Standard 34 984 35 000 mm 1 3773 1 3780 in Service Limit 34 97 m
96. e Remove Fuel Tank see Fuel System DFI chapter Thermostat Bracket Bolt A Ground Lead B Water Temperature Sensor Connector C Three Water Hoses D e Remove the thermostat housing E e Remove the screws A take off the cap B and take out the thermostat 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 Fill the radiator with coolant see Cooling System in the Periodic Maintenance chapter 6009004851 C Thermostat Inspection e Remove the thermostat and inspect the thermostat valve A at room temperature x lf the valve is open replace the thermostat with a new one RN 6009000851 6 4 16 COOLING SYSTEM 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 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 lf the measurement is out of the specified range replace the thermostat with a new one Thermostat Valve Opening Temperature 58 62 136 144 F 6009020252 C Hoses and Pipes COOLING SYSTEM 4 17 Hose Inst
97. fuel ORepeat this operation several times Amount of Fuel Flow Standard 67 mL or more for 3 seconds If the fuel flow is much less than the specified check the battery condition see Electrical System chapter If the battery is good replace the fuel pump e After inspection install the fuel tank see Fuel Tank In stallation e Start the engine and check for fuel leakage 80171848851 C FUEL SYSTEM DFI 3 77 Fuel Pump Fuel Pump Removal CAUTION Never drop the fuel pump especially on a hard sur face Such a shock to the pump can damage it WARNING Gasoline is extremely flammable and can be explo sive under certain conditions Make sure the 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 immediately 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 e Remove the fuel pump inlet hose
98. h B CAUTION If possible do not quick charge If the quick charge is done due to unavoidable circumstances do stan dard charge later on Terminal Voltage less than 11 5 V Charging Method 0 9 A x 20h NOTE Olncrease the charging voltage to a maximum voltage of 25 V if the battery will not accept current initially Charge for no more than 5 minutes at the increased voltage then check if the battery is drawing current If the battery will accept current decrease the voltage and charge by the standard charging method described on the battery case If the battery will not accept current after 5 min utes replace the battery Battery A Battery Charger B Standard Value C Current starts to flow D e Determine battery condition after refreshing charge ODetermine the condition of the battery 30 minutes after completion of the charge by measuring the terminal volt age according to the table below Criteria Judgement 12 6 V or higher Good 12 0 lower than 12 6 V Charge insufficient Recharge lower than 12 0 V Unserviceable Replace Battery Standard Charge Time 11 gt 1 1 1 L 1 1 11 6 11 8 12 0 12 2 12 4 12 6 12 8 13 0 GP08007BS1 C 8 08011451 C ELECTRICAL SYSTEM 16 29 Charging System Alternator Cover Removal e Remove Left Frame Cover see Frame chapter Clamp open A Alternator Lead Connecto
99. is out of the range check the throttle input voltage see Input Voltage Inspection of Main Throt tle Sensor in the Fuel System DFI chapter e Remove the vacuum gauge hoses and install the vacuum hoses and rubber caps on the original position as shown Vacuum Switch Valve Hose small A Inlet Air Pressure Sensor Hose B Front C Air Cleaner Element Cleaning NOTE dusty areas the element should be cleaned more frequently than the recommended interval OAfter riding through rain or on muddily roads the ele ment should be cleaned immediately A WARNING If dirt or dust is allowed to pass through into the throttle assy the throttle may become stuck possi bly causing accident CAUTION If dirt gets through into the engine excessive en gine wear and possibly engine damage will occur WARNING Clean the element in a well ventilated area and take care that there are no sparks or flame anywhere near the working area this includes any appliance with a pilot light Because of the danger of highly flammable liquids do not use gasoline or a low flash point solvent to clean the element 6505036851 PERIODIC MAINTENANCE 2 19 Periodic Maintenance Procedures e Remove the fuel tank see Fuel System DFI chapter e Remove the fuel tank bracket bolts and bracket A e Remove Air Cleaner Duct Holder Screws A e Remove the air cleaner duct ho
100. is worn damaged softened rotted or swollen the piston assembly should be replaced to renew the cups x If fluid leakage is noted at the brake lever the piston as sembly should be replaced to renew the cups Front Master Cylinder J e Check the dust covers E for damage xIf they are damaged replace them e Check the piston return springs F for any damage x If the springs are damaged replace them e Check that relief port G and supply port H are not plugged xIf the relief port becomes plugged the brake pads will drag on the disc Blow the ports clean with compressed air Rear Master Cylinder K AP E f hs TE ELI 1 6513049851 6 TA LJ V SCH GS13050BS2 C 2 32 PERIODIC MAINTENANCE Periodic Maintenance Procedures 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 horizontal by turning the handlebar when checking brake fluid level lf the fluid level is lower than the lower level line fill the reservoir to the upper level line C in the reservoir e Check that the brake fluid level in the rear brake reservoir A is above the lower level line B If the fluid level is lower than the lower level line remove the seats and fill the reservoir to the upper level line C Do not mix two brands of fluid C
101. kgf m 104 in Ib e Tighten the camshaft chain tensioner see Camshaft Chain Tensioner Installation e Install the cylinder head cover see Cylinder Head Cover Installation Camshaft Camshaft Cap Wear e Remove Camshaft Chain Guide Camshaft Cap 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 Torque Camshaft Cap Bolts 12 N m 1 2 kgf m 104 in Ib Camshaft Chain Guide Bolts 12 N m 1 2 kgf m 104 in Ib NOTE ODo not turn the camshaft when the plastigage is be tween the journal and camshaft cap Camshaft Journal Camshaft Cap Clearance Standard 0 028 0 071 mm 0 0011 0 0028 in Service Limit 0 16 mm 0 0063 in No 30 PIN 8 11045 52 C t EET gt b d 412 GE11046BS1 C 2 GE11072BS1 C ENGINE TOP END 5 17 Camshaft Camshaft Chain any clearance exceeds the service limit measure the diameter of each camshaft journal with a micrometer Camshaft Journal Diameter Standard 23 950 23 972 mm 0 9429 0 9438 Service Limit 23 92 mm 0 942 in xIf the camshaft journal diameter is less than the service limit replace the camshaft with a new one and measure the clearance again
102. or piston as necessary Replace the piston and or the piston rings Piston seizure Bad condition of piston ring and or piston ring grooves ENGINE TOP END 5 19 Cylinder Head Cylinder Head Removal e Drain the coolant see Cooling System chapter e Remove Exhaust Pipes see Exhaust Pipe Removal Coolant Drain Bolt A cylinder e Remove Cylinder Head Cover see Cylinder Head Cover Re moval Camshaft Position Sensor see Electrical System chap ter Camshafts see Camshaft Removal Throttle Body see Fuel System DFI chapter Water Hose Upper Engine Mounting Bolts both side A Front Camshaft Chain Guide e Remove the M6 cylinder head bolts B and then the M10 cylinder head bolts A e Take off the cylinder head 6 14036851 6 Cylinder Head Installation NOTE SP 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 8 A e Apply molybdenum disulfide oil solution to both sides A of the cylinder head bolt washers B and the thread of head bolts C E e Tighten the M10 cylinder head bolts following the tighten ing sequence 1 10 Torque Cylinder Head Bolts M10 First 20 N m 2 0 kgf m 14 5 ft lb Final Used Bolts 49 Nm 5 0 kgf m 36 ft Ib New Bolts 54 N m 5 5 kgf m 40 ft Ib e Tighten the M6 cylinde
103. or heat damage e f there is any doubt as to the condition of the reed contact areas replace the air suction valve as an assembly e If any carbon or other foreign particles have accumulated between the reed and the reed contact area wash the valve assembly clean with a high flash point solvent CAUTION Do not scrape off the deposits with a scraper as this could damage the rubber requiring replacement of the suction valve assembly Valve Clearance Inspection NOTE OValve clearance must be checked and adjusted when the engine is cold at room temperature e Remove Pickup Coil Cover Cylinder Head Cover see Engine Top End chapter e Position the crankshaft at 1 4 piston TDC Mark A for 1 4 Pistons Timing Mark crankcase halves mating surface B e Using the thickness gauge A measure the valve clear ance between the cam and the valve lifter Valve Clearance Standard Inlet 0 15 0 24 mm 0 0059 0 0094 Exhaust 0 22 0 31 mm 0 0087 0 0122 in PERIODIC MAINTENANCE 2 23 Periodic Maintenance Procedures OWhen positioning 4 piston 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 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 Measur
104. plate bolts 9 8 1 0 87 in lb L 2 Crankcase bolts M9 L 81 mm 42 4 3 31 MO S 3 Crankcase bolts M9 L 95 mm 42 4 3 31 MO S 4 Crankcase bolts 8 27 2 8 20 S 5 bolts M7 20 2 0 14 S 6 bolts M6 12 1 2 104 in Ib S 7 Starter motor clutch bolts 12 1 2 104 in Ib L 8 pipe holder bolts 13 1 3 113 in Ib L 9 Shift drum bearing holder screw 5 4 0 55 48 in Ib L 10 Shift drum bearing holder bolt 13 1 3 113 in Ib L 11 Connecting rod big end nuts see the text 55 15 45 13146 20 4 1 14 95 iib 17 Do not apply any grease or oil EO Apply engine oil G Apply grease L Apply a non permanent locking agent LG Apply liquid gasket Kawasaki Bond 92104 1066 M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts S Tightening the fasteners following the specified sequence SS Apply silicone sealant Kawasaki Bond 56019 120 9 4 CRANKSHAFT TRANSMISSION Exploded View 6102088BN5 CRANKSHAFT TRANSMISSION 9 5 Exploded View Torque No Fastener Remarks N m kgf m ft Ib 1 Shift pedal mounting bolt 34 3 5 25 L 2 Gear positioning lever bolt 12 1 2 104 in Ib 3 Shift shaft return spring pin 29 3 0 22 L 4 Shift drum cam holder bolt 12 1 2 104 in Ib L 5 Footpeg bracket bolts
105. pressure 4 000 r min rpm oil temp 90 194 255 314 kPa 2 6 3 2 kgf cm 37 46 psi ENGINE LUBRICATION SYSTEM 7 7 Special Tools and Sealant Oil Pressure Gauge 10 kgf cm Oil Filter Wrench 57001 164 57001 1249 Oil Pressure Gauge Adapter PT3 8 Kawasaki Bond Silicone Sealant 57001 1233 56019 120 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 CAUTION Racing the engine before the oil reaches every part can cause engine seizure If the engine oil gets extremely low or if the oil pump or oil passages clog up or otherwise do not function properly the oil pressure warning light will light If this light stays on when the engine is running above idle speed stop the engine immed
106. seal and oil seal e Apply high temperature grease to the oil seal lips A e Press the new oil seal into the housing with a bearing driver B until it stops at the bottom surface C of the housing Special Tool Bearing Driver Set 57001 1129 CAUTION Be careful not to damage the sealing surface of the mechanical seal e Press the new mechanical seal into the housing with bear ing driver A until its flange B touches the surface C of the housing Special Tool Bearing Driver 57001 382 Mechanical Seal Inspection e Visually inspect the mechanical seal lf any one of the parts is damaged replace the mechani cal seal as a unit Impeller Sealing Seat Surface A Rubber Seal B Mechanical Seal C 6006016851 C 6006017851 6 4 12 COOLING SYSTEM Radiator Radiator and Radiator Fan Removal The radiator fan is connected directly to the bat tery The radiator fan may start even if the ignition switch is off NEVER TOUCH THE RADIATOR FAN UNTIL THE RADIATOR FAN CONNECTOR IS DIS CONNECTED TOUCHING THE FAN BEFORE THE CONNECTOR IS DISCONNECTED COULD CAUSE INJURY FROM THE FAN BLADES e Drain the coolant see Cooling System in the Periodic Maintenance chapter e Remove Fuel Tank see Fuel System DFI chapter Radiator Fan Motor Connector A e Remove Fan Switch Lead Connector A Radiator Lower Bolt B Radiator Upper Bolt left C Left Radiator Hos
107. source voltage is normal check the output voltage of the injectors 3 82 FUEL SYSTEM DFI Fuel Injectors Output Voltage Inspection e Turn the ignition switch OFF e Remove the ECU see ECU section e Connect a digital voltmeter A to the ECU connector B with the needle adapter set C Special Tool Needle Adapter Set 57001 1457 Injector Output Voltage Connections to Injector 1 Meter BL R lead terminal 36 Meter Battery Terminal Connections to Injector 2 Meter BL G lead terminal 35 Meter Battery Terminal Connections to Injector Meter BL BK lead terminal 49 Meter Battery Terminal Connections to Injector 4 Meter BL Y lead terminal 48 Meter Battery Terminal e Turn the ignition switch ON Output Voltage at Injector Connector Standard Battery Voltage 12 6 V or more the output voltage is normal perform Injector Signal Test x If the output voltage is out of the standard turn the ignition switch OFF remove the fuel tank and check the injector wiring for continuity Injector Wiring Inspection ECU Connector Injector Connectors Terminal 36 Injector 1 Terminal BL R Terminal 35 Injector 2 Terminal BL G Terminal 49 Injector 3 Terminal BL BK Terminal 48 Injector 4 Terminal BL Y x If the wiring is good inspect the resistance of the injectors see Injector Resistance Inspectio
108. spark plug hole OUsing the starter motor turn the engine over with the throt tle fully open until the compression gauge stops rising the compression is the highest reading obtainable Special Tools Compression Gauge 57001 221 Compression Gauge Adapter M10 X 1 0 57001 1317 Cylinder Compression Usable Range 1 110 1 590 kPa 11 3 16 2 kgf cm 161 230 psi 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 113 in Ib The following table should be consulted if the obtainable compression reading is not within the us able range Problem Diagnosis Remedy Action Cylinder compression Carbon accumulation on piston and in is higher than usable combustion chamber possibly due to Remove the carbon deposits range damaged valve stem oil seal and or and replace damaged parts if damaged piston oil rings This may be necessary indicated by white exhaust smoke Incorrect cylinder head gasket thickness Replace the gasket with a standard part Replace damaged check gasket and cylinder head warp Cylinder compression ilaweElbah ussbls Gas leakage around cylinder head range Bad condition of valve seating Incorrect valve clearance Incorrect piston cylinder clearance Repair if necessary Adjust the valve clearance Replace the piston and or cylinder Inspect the cylinder and replace repair the cylinder and
109. surface Such a shock to the part can damage it Removal e Remove Fuel Tank see Fuel System chapter Water Temperature Sensor Connector A Inlet Air Pressure Sensor Bolt B e Raise the inlet air pressure sensor C and disconnect the inlet air pressure sensor connector and the vacuum hose Installation NOTE OThe inlet air pressure sensor is the same part as the at mospheric sensor except that the sensor has a vacuum hose and different wiring e Install Vacuum Hose Inlet Air Pressure Sensor Torque Inlet Air Pressure Sensor Bolt 12 N m 1 2 kgf m 104 in Ib Input Voltage Inspection NOTE OBe sure the battery is fully charged OThe inspection is the same as Input Voltage Inspection of the main throttle sensor or the atmospheric pressure sensor e Turn the ignition switch OFF e Remove the ECU see this chapter Do not disconnect the ECU connectors e Connect a digital voltmeter A to the connector B with the needle adapter set Special Tool Needle Adapter Set 57001 1457 e Measure the input voltage with the engine stopped and with the connectors joined 6617114851 6 e Turn the ignition switch ON Inlet Air Pressure Sensor Input Voltage Connections to ECU Meter BL lead terminal 1 Meter gt BR BK lead terminal 14 Standard 4 75 5 25 V DC x If the reading is within the standard range check the sen sor output voltage x If the r
110. switch housing and take out the accelerator cable upper end A and the decelerator cable upper end B 3 90 FUEL SYSTEM DFI Throttle Body Assy e Remove the bolt A and the throttle cable plate B from the throttle body front side e Remove the throttle cable lower ends from the throttle pulley e Remove Choke Cable Upper End From choke lever Choke Cable Lower End A e After removing the throttle body assy stuff pieces of lint free clean cloth into the throttle body 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 shown with each bolt heads facing outwards Cylinder Head B e Tighten Torque Throttle Body Assy Holder Clamp Bolts 2 0 0 20 kgf m 17 in Ib e Tighten Torque Air Cleaner Duct Clamp Bolts A 2 0 0 20 kgf m 17 in Ib e Run the vacuum hoses as shown in the Cable Wire and Hose Routing section of the Appendix chapter e Fitthe accelerator cable end A and the decelerator cable end B into the throttle pulley e Tighten the throttle plate bolt e Check fuel leakage from the throttle body assy A WARNING Fuel spilled from the carburetors is hazardous 6GC17162BS1 C FUEL SYSTEM DFI 3 91 Throttle Body Assy e Apply a thin coating of grease to the throttle cable upper ends
111. that circuit Installation of a fuse with a higher rating may cause damage to wiring and components GP19040181 C APPENDIX 17 1 Appendix Table of Contents Cable Wire and Hose Routing pp 17 2 Ulee een e DEE 17 18 17 2 APPENDIX Cable Wire and Hose Routing APPENDIX 17 3 Om P Fixes by the left side clamp of the tank Run the tank drain hose under the bracket for the side cover Air cleaner drain hose Cooling reserve tank hose Run the hose inside the under ring Fuel tank drain hose Fixes by the swingarm clamp Fuel level sensor Fixes by the right side clamps two places of the tank Run the lead outside the frame Fuel level sensor lead Cable Wire and Hose Routing 17 4 APPENDIX Cable Wire and Hose Routing 09 2 902 7 9 69 69 69 O 0 COGO 9 4909 6 O OOOO 69 oi 43 ED 88 60 107 18963 9 09 EDN G9 60 4260 07 6269 GO 2 O E a is N OS 6809388BN5 APPENDIX 17 5 Cable Wire and Hose Routing NOOR WD A Clutch cable Meter ground Clamp Ignition switch connector Ignition switch connector Inlet air pressure sensor To ignition coil Fan motor connector Connect the con nector on the inlet air pressure sensor Clamp To fuel pump To fuel level gauge and fuel reserve switch To pickup co
112. that no gasket material or other material remains Install new gaskets and replace used O rings when re assembling Liquid Gasket Locking Agent For applications that require Liquid Gasket or a Locking agent clean the surfaces so that no oil residue remains be fore applying liquid gasket or locking agent Do not apply them excessively Excessive application can clog oil pas sages and cause serious damage I Gr Gs e A 223 sf 4 68020128 5 68020138 5 68020148 5 68020158 5 68020188 5 GENERAL INFORMATION 1 5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place apply small amount of oil to the con tact area Be sure to maintain proper alignment and use smooth movements when installing Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is gt n absolutely necessary Replace with new ones whenever ua removed Press bearings with the manufacturer and size marks facing out Press the bearing into place by putting Rs l pressure on the correct bearing race as shown AB BR Br 3 Pressing the incorrect race can cause pressure between fe SE the inner and outer race and result in bearing damage 68020188 5 Oil Seal Grease Seal Do not remove pressed oil or grease seals unless removal is necessary Replace with new ones whenever removed 44 r Pres
113. the valve guide with the valve guide reamer A even if the old guide is reused OTurn the reamer in a clockwise direction until the reamer turns freely in the guide Never turn the reamer counter clockwise or it will be dulled OOnce the guides are reamed they must be cleaned thor oughly Special Tool Valve Guide Reamer 4 57001 1274 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 x If the reading exceeds the service limit replace the guide NOTE OThe reading is not actual valve valve guide clearance because the measuring point is above the guide Valve Valve Guide Clearance Wobble Method Inlet Standard 0 03 0 12 mm 0 0012 0 0047 in Service Limit 0 33 mm 0 013 in Exhaust Standard 0 09 0 18 mm 0 0035 0 0071 in Service Limit 0 40 mm 0 016 in GE15046BS1 C GE15007BS2 C Valves ENGINE TOP END 5 23 Valve Seat Inspection e Remove the valve see Valve Removal e Check the valve seating surface A be
114. the ECU is good and check the starter system circuit Olf the starter motor turned ECU is defective Replace the ECU 2nd Check Raise the rear wheel off the ground with a stand 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 Side Stand Up e Set the side stand on the ground then the engine will stop If whichever may not be stopped inspect the starter lock out switch side stand switch and junction box xIf their parts are normality replace the ECU 16 46 ELECTRICAL SYSTEM Ignition System IC Igniter Inspection OThe IC Igniter is built in the ECU A e Refer to the Interlock Operation Inspection Ignition System Troubleshooting chapter and Fuel System DFI chapter for ECU Inspection ELECTRICAL SYSTEM 16 47 Ignition System Ignition System Troubleshooting Faulty ignition No spark No good Battery Inspection Charge or replace battery Good Ignition system wiring No good Repair or replace 7 2 and connector inspection damaged part Good No good Spark plug inspection Fm Replace spark plug Good No good Stick coil winding resistance inspection gt Replace stick coil Good No good Voltage is less than Stick coil prima
115. the blinks of the LED light to read the service code Keep the auxiliary lead ground until you finish reading the service code Auxiliary Lead E Self diagnosis Terminal G NOTE OTo enter the dealer mode 2 from the dealer mode 1 turn off the ignition switch once Service Code Clearing Procedures Service Code Clearing Procedures e Enter the self diagnosis dealer mode 2 see Self diagnosis Procedures NOTE OMake sure to keep the grounding until the following opening and grounding starts e Pull the clutch lever in more than 5 seconds and then release it e Repeat opening B and grounding A the lead self diagnosis terminal more than five times F within 2 seconds C after the lead is grounded and then keep it grounded continuously D for more than 2 seconds Auxiliary Lead E Self diagnosis Terminal G 6C17072BS1 6C17072BS1 C FUEL SYSTEM 3 35 Self Diagnosis Turn the ignition SW switch OFF Turn the ignition SW and self diagnosis mode starts using an auxiliary lead Dealer Dealer Dealer Mode 1 Dealer Mode 2 Ground the self diagnosis terminal Ground and open the self diagnosis for more than 2 seconds and then terminal more than five times within 2 keep it grounded seconds and then keep it grounded FI indicator LED light blinks to display the service code for more t
116. the bulb with alcohol or soap and water solution e Replace the headlight bulb ELECTRICAL SYSTEM 16 55 Lighting System e Fit the projection A of the bulb in the hollow B of the headlight e Install the hook C e Fit the dust cover A with the arrow mark upward onto the bulb B firmly as shown Good C Bad D Arrow Mark E e After installation adjust the headlight aim see this chap ter 8 12025 51 6 Headlight Removal Installation e Remove Fairing see Frame chapter e Disconnect the headlight connectors A OFor the european model disconnect the city light connec tor e Remove Bolts A Headlight Assy B e Headlight installation is revers of removal Torque Headlight Mounting Bolts 5 9 N m 0 60 kgf m 52 in Ib 16 56 ELECTRICAL SYSTEM Lighting System City Light Bulb Replacement European Model e Remove the fairing see Frame chapter e Pull out the socket A together with the bulb e Pull the bulb A out of the socket CAUTION Do not turn the bulb Pull the bulb out to prevent damage to the bulb Do not use bulb rated for greater wattage then the specified valve e Replace the bulb with a new one ELECTRICAL SYSTEM 16 57 Lighting System Headlight Tail Light Circuit CA AS jp i BK Y BK Y BK Y BK Y BK Y BK Y R BL 61 BK Y R BL BK Y GP
117. the cap inside and cap insert outside Olnstall the inserts so that their nails D 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 OWhen installing the inserts A be careful not to damage the insert surface with the edge of the connecting rod B 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 Install the cap on the connecting rod aligning the weight and diameter marks e Remove debris and clean the surface of inserts e Apply molybdenum disulfide oil MO to the threads and seating surfaces of the big end nuts and bolts 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 ofthe plastic region fastening One is a bolt length measurement method and other 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 CAUTIO
118. 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 tighten the stem head bolt with specified torque e Install the steering stem head bolt plug e Install the front fork see Suspension chapter NOTE OTighten the fork upper clamp bolts first next the stem head nut last the fork lower clamp bolts OTighten the two clamp bolts alternately two times to en sure even tightening torque Torque Steering Stem Head Bolt 108 11 kgf m 80 ft lb Front Fork Clamp Bolts Upper 20 N m 2 0 kgf m 14 ft Ib Front Fork Clamp Bolts Lower 20 N m 2 0 kgf m 14 16 A WARNING Do not impede the handlebar turning by routing the cables harnesses and hoses improperly see Ap pendix chapter e Install the removed parts see appropriate chapters Stem Bearing Lubrication e Referto the Steering in the Periodic Maintenance chapter Steering Stem Warp e Whenever the steering stem is removed or if the steering cannot be adjusted for smooth action check the steering stem for straightness x lf the steering stem A is bent replace the steering stem 6515011851 C GNO5025BS1 C STEERING 14 9 Handlebar Handlebar Removal e Rem
119. the terminal bolt Torque Pressure Switch Terminal Bolt 1 5 0 15 kgf m 13 in Ib e Apply grease to the terminal ENGINE REMOVAL INSTALLATION 8 1 Engine Removal Installation Table of Contents Exploded TEE 8 2 eret gero RR T DEDECUS 8 4 Engine Removal InstallatiQri o 8 5 gie e nn EE 8 5 Engine InstallatiOn o sc Ld ues 8 7 8 2 ENGINE REMOVAL INSTALLATION Exploded View ENGINE REMOVAL INSTALLATION 8 3 Exploded View No Fastener We Remarks kgf m ft Ib 1 Adjusting collar locknut 49 5 0 36 S 2 Upper engine mounting bolts 44 4 5 33 S 3 Rear engine bracket bolts 25 2 5 18 S 4 Front engine bracket bolts 44 4 5 33 S 5 Middle engine mounting nut 44 4 5 33 S 6 Lower engine mounting nut 44 4 5 33 S 7 Engine ground cable terminal bolt 9 8 1 0 87 in lb 8 Adjusting Collar 9 Middle Engine Mounting Bolt 10 Lower Engine Mounting Bolt S Follow the specific tightening sequence 8 4 ENGINE REMOVAL INSTALLATION Special Tool Engine Mount Nut Wrench 57001 1450 7571450ST C ENGINE REMOVAL INSTALLATION 8 5 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 t
120. throttle grip doesn t return properly check the throt tle cable routing grip free play and cable damage Then lubricate the throttle cable e Run the engine at the idle speed and turn the handlebar all the way to the right and leftto ensure that the idle speed doesn t change x lf the idle speed increases check the throttle grip free play and the cable routing necessary adjust the throttle cable as follows e Loosen the locknut A e Turn the adjuster B until the proper amount of free play can be obtained e Tighten the locknut against the adjuster securely If the throttle grip free play can not be adjusted with the adjuster use the adjusters in the middle of the throttle cables e Loosen the locknut and screw the adjuster at the upper end of the accelerator cable all the way in e Tighten the locknut against the adjuster securely e Remove the fuel tank see Fuel System DFI chapter e Loosen the locknuts A and turn the lower adjusters B until the proper amount of throttle grip free play is ob tained e Tighten the locknuts against the adjusters securely xIf the throttle grip free play can not be adjusted with the lower adjusters use the adjuster at the upper end of the cable again 05058121 PERIODIC MAINTENANCE 2 15 Periodic Maintenance Procedures Idle Speed Inspection e Start the engine and warm it up thoroughly e With the engine idling turn the handlebar to b
121. voltage is normal check the sensor output voltage the input voltage is less than the standard remove the ECU and check the wiring between these connectors ODisconnect the ECU and sensor connectors Wiring Connection ECU Connector A Throttle Sensor Connector B BL lead ECU terminal 1 BR BK lead ECU terminal 14 lf the wiring is good check the ECU for its ground and power supply see ECU section 8017193 52 C Main Throttle Sensor Service Code 11 FUEL SYSTEM DFI 3 41 Output Voltage Inspection e Measure the output voltage at the main throttle sensor in the same way as input voltage inspection Note the following e Disconnect the main throttle sensor gray A and con nect the harness adapter B between these connectors Special Tool Throttle Sensor Harness Adapter 57001 1538 e Start the engine and warm it up thoroughly e Check idle speed to ensure the throttle opening is correct Idle Speed Standard 1 100 50 r min rpm the idle speed is out of the specified range adjust it see Idle Speed Inspection in the Periodic Maintenance chapter e Turn off the ignition switch e Measure the output voltage of the sensor with the engine stopped and with the connector joined e Turn the ignition SW ON Main Throttle Sensor Output Voltage Connections to Adapter Meter W sensor Y W lead Meter gt BK sensor BR BK lead Standa
122. 0 240 260 280 300 320 40 20 0 2 40 i 17 8 A4 26 7 489 i i 400 714 93 3 116 i 420 1140 138 160 PERIODIC MAINTENANCE 2 1 Periodic Maintenance Table of Contents Periodic Maintenance Chart 2 2 Drive Chain Wear Inspection 2 28 Torque and Locking 2 5 Drive Chain Lubrication 2 29 Specifications 2 10 Brakee 2 29 Special Tools 2 12 Brake Pad Wear Inspection 2 29 Periodic Maintenance Procedures 2 13 Rear Brake Light Switch Fuel System DFI 2 13 Inspection Adjustment 2 29 Fuel Hose and Connection Caliper Fluid Seal Damage 2 30 Inspection 1 2 13 Caliper Dust Seal Friction Boot Throttle Control System RE desit itecto taut 2 30 Inspection rentes 2 14 Master Cylinder Inspection Visual Idle Speed Inspection 2 15 2 31 Engine Vacuum Synchronization Brake Fluid Level Inspection 2 32 Inspection eee 2 15 Brake Fluid Change 2 32 Air Cleaner Element Cleaning 2 18 Brake Line Bleeding 2 34 Cooling System 2 20 Brake Hoses and Connections Radiator Hose and Connection Inspechon 4 2 2 36 Inspection pp 2 20
123. 1 6 Brakes Brake Pad Wear Inspection e Remove the brake pads see Brakes chapter e Check the lining thickness A of the pads in each caliper x If the lining thickness of either pad is less than the service limit B replace both pads in the caliper as a set Pad Lining Thickness Standard Front 4 5 mm 0 18 in Rear 5 mm 0 20 in Service Limit 1 mm 0 04 in Rear Brake Light Switch Inspection Adjustment e Turn on the ignition switch e Check the operation of the rear brake light switch by de pressing the brake pedal The brake light should go on after about 10 mm 0 39 in of the pedal travel A 2 30 PERIODIC MAINTENANCE Periodic Maintenance Procedures x lf it does not adjust and inspect the brake light switch e While holding the switch body turn the adjusting nut A to adjust the switch CAUTION To avoid damaging the electrical connections in side the switch be sure that the switch body does not turn during adjustment e Remove the right side cover see Frame chapter e Disconnect the connector A e Using a hand tester inspect to see that only the connec tion shown in the table have continuity about zero ohms Special Tool Hand Tester 57001 1394 Rear Brake Light Switch Connections BL When brake pedal is pushed down When brake pedal is released lf the switch has an open or short replace it with a new one Ca
124. 11 Throttle Output Voltage in the D J method Sensor 0 2 48V Also the main throttle sensor system and inlet air pressure fails the ECU locks ignition timing into the ignition timing at closed throttle position and sets the DFI in the a N method niet Air Inlet Air Pressure If the inlet air pressure sensor system fails the 12 Press re absolute signal Pv is out of the usable range wiring short Pv 100 mmHg 900 or open the ECU sets the DFI in the a N Sensor mmHg method Inlet Air If the inlet air temperature sensor fails the signal Inlet Air Temperature ie 13 Tempera Ta 47 C 178 C is out of the usable range wiring short or open ture Sensor the ECU sets Ta at 40 C Water Tem If the water temperature sensor system fails the Water Temperature 225 14 perature Tw 30C 120 signal is out of the usable range wiring short or Sensor open the ECU sets Tw at 80 C Atmo Absolute Atmospheric If the atmospheric pressure sensor system fails 15 spheric Pressure the signal is out of the usable range wiring short Pressure Pa 100 mmHg 900 or open the ECU sets Pa at 760 mmHg the Sensor mmHg standard atmospheric pressure Crankshaft sensor must 21 Crankshaft send 23 signals output If crankshaft sensor generates other than 23 Sensor signal to the ECU at the signals the engine stops by itself one cranking Cam sensor must send If the camshaft position sensor system fails Camshaft ee KC
125. 12108BW2 C Oli ols BK Y BK Y BK Y BK Y vilem 1 3 BK Y BK Y BK Y BK Y GP12055BN2 C AS Australia 8 High Beam Indicator 15 Passing Button CA Canada Light LED 16 Main Fuse 30 A 1 Ignition Switch 9 Joint Connector D 17 Battery 12 V 8 Ah Meter Ground 10 City Light European 18 Taillight LED Alternator Model 19 License Plate Light 11 Headlight High 20 Joint Connector B Taillight Fuse 10 A Headlight Fuse 10 A 2 3 4 Headlight Diodes 5 6 7 Junction Box Headlight Low 13 14 Joint Connector A Dimmer Switch 21 Running Position Light 22 Frame Ground 16 58 ELECTRICAL SYSTEM Lighting System Turn Signal Light Circuit M OY gt ME sky 10 N 9 cA MY only BR Other than MY Other than CA GPi2il1BN3 C CA Canada model 6 Front Left Turn Signal 15 Ignition Switch MY Malaysia model Light 16 Rear Right Turn Signal 1 Joint Connector D 7 Joint Connector A Light 2 Meter Unit 8 Frame Ground 17 Rear Left Turn Signal 3 Right Turn Signal Indica 9 Hazard Button Light tor Light LED 10 Turn Signal Switch 18 Joint Connector B 4 Left Turn Signal Indicator 11 Meter Ground 19 Main Fuse 30 Light LED 12 Turn Signal Relay 20 Battery 12 V 8 Ah 5 Front Right Turn Signal 13 Junction Box Light 14 Turn
126. 249 e Replace the filter with a new one e Apply engine oil to the gasket A before installation e Tighten the filter with the oil filter wrench Torque Oil Filter 31 3 2 kgf m 23 ft Ib NOTE OHand tightening of the oil filter can not be allowed since it does not reach to this tightening torque Pour in the specified type and amount of oil see Engine Oil Change Wheels Tires Tire Wear Inspection As the tire tread wears down the tire becomes more sus ceptible to puncture and failure An accepted estimate is that 90 of all tire failures occur during the last 10 of tread life 9096 worn So it is false economy and unsafe to use the tires until they are bald e Remove any imbedded stones or other foreign particles from the tread e Visually inspect the tire for cracks and cuts replacing the tire in case of damage Swelling or high spots indicate internal damage requiring tire replacement 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 SAE 201 50 SAE 201 40 SAE 101 50 SAE 10W 40 SAE 108 30 20 10 0 10 20 30 40 C 6509011851 6805040281 6 2 26 PERIODIC MAINTENANCE Periodic Maintenance Procedures Tread Depth Front Standard
127. 4 Starter Relay 16 54 ELECTRICAL SYSTEM Lighting System This models adopt the daylight system and have a head light relay in the junction box In these models the head light does not go on when the ignition switch and the 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 Turn the horizontal adjuster A on the headlight with the screwdriver in or out until the beam points straight ahead Headlight Beam Vertical Adjustment e Turn the vertical adjusters A on the headlight with the screwdriver 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 s to the proper angle according to local regulations Headlight Bulb Replacement e Remove Headlight Connector A Headlight Bulb Dust Cover B e Remove Hook A Headlight Bulb B CAUTION When handling the quartz halogen bulb never touch the glass portion with bare hands Always use a clean cloth Oil contamination from hands or dirty rags can reduce bulb life or cause the bulb to explode NOTE OClean off any contamination that inadvertently gets on
128. 5 in lb Water pipe bolts 11 1 1 95 in lb Thermostat housing ground bolt 7 0 0 70 61 in lb Thermostat bracket bolt 7 0 0 70 61 in lb Radiator upper bolts 7 0 0 70 61 in Ib Radiator lower bolts 7 0 0 70 61 in lb Radiator screen bolt 7 0 0 70 61 in lb Coolant reserve tank screws 7 0 0 70 61 Radiator fan switch 18 1 8 13 Water temperature sensor 25 2 5 18 Engine Top End Air suction valve cover bolts 9 8 1 0 87 in lb Cylinder head cover bolts 9 8 1 0 87 S Camshaft cap bolts 12 1 2 104 in Ib S Camshaft chain guide bolts 12 1 2 104 in Ib S Cylinder head bolts M10 new bolts 54 5 5 40 MO S Washer Cylinder head bolts M10 used bolts 49 5 0 36 MO S Washer Cylinder head bolts M6 12 1 2 104 in Ib S Cylinder head jacket plugs 22 2 2 16 L Throttle body holder bolts 13 1 3 113 in Ib Throttle body assy holder clamp bolts 2 0 0 20 17 Camshaft sensor bolt 12 1 2 104 in Ib Camshaft sensor rotor bolt 12 1 2 104 in Ib L Front camshaft chain guide bolt upper 25 2 5 18 Front camshaft chain guide bolt lower 12 1 2 104 in Ib Rear camshaft chain guide bolt 25 2 5 18 Camshaft chain tensioner mounting bolts 11 1 1 95 mb Camshaft chain tensioner cap bolt 28 2 9 21 Spark plugs 13 1 3 113 in Ib Coolant drain plug Cylinder 9 8 1 0 87 in lb Exhaust pipe manifold holder nuts 17 1 7 12 Muffler body clamp bolt 17 1 7 12 Muffler body mounting bolt 30 3 0 22 Crankshaft sensor cover bolts 11 1 1 95 in lb Clutch Clutch lever clamp bolts 7
129. 6 BRAKES 12 1 Brakes Table of Contents Exploded Specifications Special Tool Brake Lever Brake Pedal Brake Lever Position Adjustment Brake Pedal Position Inspection Brake Pedal Position Adjustment Calipets ice cete reris Front Caliper Removal Rear Caliper Removal Caliper Installation Front Caliper Disassembly Front Caliper Assembly Rear Caliper Disassembly Rear Caliper Assembly Caliper Fluid Seal Damage Caliper Dust Seal Friction Boot Front Brake Pad Installation Rear Brake Pad Removal Rear Brake Pad Installation 12 2 12 6 12 7 12 8 12 8 12 8 12 8 12 9 12 9 12 9 12 9 Brake Pad Wear Inspection Master Cylinder Front Master Cylinder Removal Front Master Cylinder Installation Rear Master Cylinder Removal Rear Master Cylinder Installation Front Master Cylinder Disassembly Rear Master Cylinder Disassembly Master Cylinder Assembly Master Cylinder Inspection Visual Inspectior Brake Brake Disc Brake Disc Installation
130. 8 APPENDIX Cable Wire and Hose Routing G 42 44 647 Gg 2 457672769 89 8909 Go E ee en P P gs WS es SC E U ZONI V 6809390BN5 APPENDIX 17 9 Cable Wire and Hose Routing P Tail light Clamp Atmospheric pressure sensor To ECU fuse Junction Box To self diagnosis indicator terminal Pickup coil and oil pressure switch Fuel pump Fuel level gauge and fuel reserve switch To inlet air temperature sensor Fan motor connector Inlet air pressure sensor Water temperature sensor Engine harness Meter ground lgnition switch lead Frame ground with thermostat Right switch housing lead Left switch housing lead Running position light Headlights Turn signal lights To fun motor lgnition coil Vehicle down sensor To rear brake switch Starter relay Regulator rectifier To battery positive cable Connect the battery negative cable and battery Battery ECU Turn signal light relay Fuel pump relay ECU main relay License light Rear right turn signal light Rear left turn signal light Band Battery negative cable Back view Battery negative cable Run the cable through under the cross pipe Throttle cable accelerator Throttle cable decelerator Clutch cable Run the clutch cable inside the chain tensioner 17 10 APPENDIX
131. 8078 Cylinder Pistons ENGINE TOP END 5 29 e Remove the piston pins Special Tool Piston Pin Puller Assembly 57001 910 A 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 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 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 1T mark B faces up e Install the second ring C so that the 2T mark D faces up OApply molybdenum disulfide oil solution to the piston rings 8 16059851 6 GE16060BSi C 6 16061851 6 5 30 ENGINE TOP END Cylinder Pistons NOTE Olf a new piston is used use new piston ring e Install the piston with its marking hollow facing forward e Fit a new piston pin snap ring into the side of the piston so that the ring opening A do
132. 87 in lb 8 Air cleaner duct clamp bolts 2 0 0 20 17 inb 9 Air cleaner housing screws 1 2 0 12 10 in Ib Air cleaner housing tapping screws 1 2 0 12 10 in Ib Speed sensor bolt 6 9 0 70 62 in Ib L 12 Inlet air pressure sensor 13 Stick coils see Electrical System chapter 14 ECU 15 Fuel pump relay 16 ECU main relay 17 Atmospheric pressure sensor 18 Crankshaft sensor see Electrical System chapter 19 Inlet air temperature sensor 20 Vacuum switch valve see Engine Top End chapter 21 Air suction valves 22 Grommet L Apply a non permanent locking agent 3 8 FUEL SYSTEM DFI DFI Parts Location Gs S 9 Asa Ay GC17254BW2 DFI 1 2 19474809092 SS SS Te Wi SS e DFI Parts this chapter Water temperature Sen sor DFI Inlet Air Pressure Sensor DFI 3 Injectors DFI 4 5 Inlet Fuel Pump DFI Air Temperature Sensor DFI Sealed Battery Junction Box ECU Fuse 15 A ECU DFI Stick Coils Throttle Body Assy Self diagnosis Terminal Neutral Switch Vehicle Down Sensor DFI Atmospheric Pressure Sensor DFI Delivery Pipe ECU Main Relay Fuel Pump Relay DFI Turn Signal Relay Subthrottle Sensor DFI Main 6017255BN2 Throttle Sensor DFI Ignition Switch Fl Indicator LED Light DFI Crankshaft Sensor Camshaft Position Sen sor Fu
133. 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 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 OAfter the caliper removal if compressed air will not be available for disassembling the caliper remove the pis ton before detaching the brake hose see Rear Caliper Disassembly 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 3 5 kgf m 25 16 Caliper Mounting Bolts Rear 25 2 5 18 16 Brake Hose Banjo Bolt 25 Nm 2 5 kgf m 18 ft lb e Check the fluid level in the brake reservoirs e Bleed the brake line see Bleeding the Brake Line e Check the brake for good braking power no brake drag and no fluid leakage WARNING Do not attempt to drive the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against the disc The brakes will not function on the first appli cation of the lever or pedal if this is not done 12 10 BRAKES Calipers Front Caliper Disassembly e Remove Front Caliper see Caliper Removal Brake Pads and Springs see Brake
134. A at the point where it has worn the most x lf the disk has worn past the service limit replace it Measuring Area B Front Disc Thickness Standard 4 3 4 5 mm 0 17 0 18 in Service Limit 4 0 mm 0 16 in Rear Disc Thickness Standard 4 8 5 2 mm 0 19 0 20 in Service Limit 4 5 mm 0 18 in Brake Disc Warp e Jack up the motorcycle so that the wheel is off the ground see Wheels Tires chapter Special Tool Jack 57001 1238 OFor front disc inspection turn the handlebar fully to one side e Set up a dial gauge against the disc A as shown and measure disc runout while turning B the wheel by hand If runout exceeds the service limit replace the disc Disc Runout Standard Not more than 0 2 mm 0 008 in Service Limit 0 3 mm 0 012 in Special Tool Jack 57001 1238 6108040151 C Brake Fluid BRAKES 12 19 Brake Fluid Level Inspection e Refer to the Brakes in the Periodic Maintenance chapter Brake Fluid Change e Refer to the Brakes in the Periodic Maintenance chapter Brake Line Bleeding e Refer to the Brakes in the Periodic Maintenance chapter 12 20 BRAKES Brake Hose Brake Hose Removal Installation CAUTION Brake fluid quickly ruins painted or plastic sur faces any spilled fluid should be completely wiped up immediately with wet cloth e When removing the brake hose take care not to spill the brake fluid on the
135. Brake Disc Brake Disc Warp Brake Flug Brake Fluid Level Inspection Brake Fluid Change Brake Line Bleeding Brake Brake Hose Removal Installation Brake Hose 12 20 12 20 12 2 BRAKES Exploded View BRAKES 12 3 Exploded View No Fastener Torang Remarks N m kgf m ft Ib 1 Front caliper mounting bolts 34 3 5 25 2 Brake hose banjo bolts 25 2 5 18 3 Bleed valve 7 8 0 80 69 in lb 4 Brake lever pivot bolt 1 0 0 10 9 in Ib Si 5 Brake lever pivot bolt locknut 5 9 0 60 52 in lb 6 Front brake disc mounting bolts 27 2 8 20 L 7 Front brake light switch screws 1 0 0 10 9 ml 8 Front brake reservoir cap screws 1 0 0 10 9 9 Front master cylinder clamp bolts 8 8 0 90 78 S B Apply brake fluid L Apply a non permanent locking agent R Replacement Parts S Follow the specific tightening sequence Wa i Apply silicone grease ex PBC grease 12 4 BRAKES Exploded View 0 O lt VW 2 aua 0 BRAKES 12 5 Exploded View No Fastener Torang Remarks N m kgf m ft Ib 1 Rear master cylinder push rod locknut 18 1 8 13 2 Rear caliper mounting bolts 25 2 5 18 3 Brake hose banjo bolts 25
136. But the diluted coolant must be returned to the correct mixture ratio within a few days If coolant must be added often or the reservoir tank has run completely dry there is probably leakage in the cooling system Check the system for leaks Coolant ruins painted surfaces Immediately wash away any coolant that spills on the frame engine wheels or other painted parts Coolant Draining e Refer to the Cooling System in the Periodic Maintenance chapter Coolant Filling e Refer to the Cooling System in the Periodic Maintenance chapter Coolant COOLING SYSTEM 4 9 Pressure Testing e Remove the fuel tank see Fuel System DFI chapter e Remove the radiator cap and install a cooling system pressure tester A on the filler neck B NOTE OWet the cap sealing surfaces with water or coolant to prevent pressure leaks e Build up pressure in the system carefully until the pres sure reaches 123 kPa 1 25 kgf cm 17 8 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 17 8 psi e Watch the gauge for at least 6 seconds xIf 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
137. Check e Connect the variable rheostat A to the terminal 8 as shown e Check that the number of segments matches the resis tance value of the variable rheostat Resistance Temperature Warning Value Meter Indicate A 209 8 50 122 F 8 17047851 6 St 17 D Flash e any display function does not work replace the meter assembly SS X x 4 qd 4 9 xx 62 See A lt GP17113BN2 16 70 ELECTRICAL SYSTEM Meter Gauge Indicator Unit Fuel Level Gauge Inspection e Connect the 12 V battery and terminals in the same man ner as specified in the Liquid Crystal Display LCD Seg ments Check e Connect a variable rheostat A to terminal 4 and 9 as shown e Check that the number of segment B matches the resis tance value of the variable rheostat Resistance Q Number of Segments 0 16 5 F 6 11 5 34 5 5 26 5 52 5 4 41 5 70 5 3 56 5 88 5 2 71 5 above E 1 lf this display function does not work replace the meter assembly e Connect an other variable rheostat C to terminal 2 and 9 as shown e Set the hand tester D to the DC 10 V range and connect it to terminals of the variable rheostat as shown e When the 1 segment E appears adjust the variable rheostat C so that the terminal voltage is less than 5
138. Crankshaft Sensor Service Code 21 Start the engine and switch the diagnosis mode to Dealer 1 mode to know all the problem that the DFI system has at the time of self diagnosis If the engine cannot be started the self diagnosis system does not detect dynamic condi tion of the crankshaft sensor In this case turn off the igni tion switch and turn it on again to enter the Dealer 2 mode In this mode the system tells all the troubles which the DFI system had in both static and dynamic conditions Crankshaft Sensor Removal Installation e See the Ignition System section in the Electrical System chapter Crankshaft Sensor Inspection OThe crankshaft sensor has no power source and when the engine stops the crankshaft sensor generates no sig nals e Crank the engine and measure the peak voltage of the crankshaft sensor see Electrical System chapter in or der to check the sensor e Check the wiring for continuity using the following dia gram cams 24 A ECU Crankshaft Sensor ea x ea i BK 80172618481 Camshaft Position Sensor Service Code 23 FUEL SYSTEM DFI 3 55 Start the engine and switch the diagnosis mode to Dealer 1 mode to know all the problem that the DFI system has at the time of self diagnosis If the engine cannot be started the self diagnosis system does not detect dynamic condi tion of the camshaft position sensor
139. D e Compress B the fork A upside down to draw out the oil into the suitable container C e Pour in the specified amount of oil DS B Fork Oil Viscosity KAYABA 34 610 C Or Capacity when changing 385 mL 13 01 US oz e X oil OMove the outer tube up and down a few times to remove ee the air that is trapped the fork oil in order to stabilize ee the oil level Front Fork SUSPENSION 13 9 e Hold the outer tube vertically in a vise and compress the fork completely e Wait until the oil level stabilizes e Use the fork oil level gauge A to measure the distance between the top of the inner tube to the oil level Special Tool Fork Oil Level Gauge 57001 1290 OSet the oil level gauge stopper B so that the distance C from the bottom of the stopper to the lower end of the pipe is the standard oil level distance OA correct measurement can not be obtained unless the level gauge pipe is placed in the center of the inner tube Oil Level fully compressed without spring Standard 115 2 mm 4 53 0 08 in OPlace the stopper of the level gauge at the top E of the inner tube D and pull the handle slowly to draw out the excess oil from fork into the gauge thus attaining the stan dard level Olf not oil is drawn out there is not enough oil in the fork Pour in some more oil and measure again e Repeat the same procedure for adjusting the other fork e Install t
140. D A FI Indicator Light LED B Oil Pressure Warning Indicator Light LED C Right Turn Signal Indicator Light LED D Left Turn Signal Indicator Light LED E High Beam Indicator Light LED F e Using the auxiliary leads connect a 12 V battery to the meter unit connector as follows Neutral Indicator Light LED Battery Negative Terminal To Terminal 5 FI Indicator Light LED Battery Negative Terminal To Terminal 6 Oil Pressure Warning Indicator Light LED Battery Negative Terminal To Terminal 11 GPi7116BSi 6 6Pi7117BSi 6 8 17052851 6 6Pi7054BSi C GPi7053BSi 6 16 72 ELECTRICAL SYSTEM Meter Gauge Indicator Unit Right and Left Turn Signal Indicator Light LED For Right Turn Signal Indicator Light LED Battery Positive Terminal to Terminal 13 For Left Turn Signal Indicator Light LED Battery Positive Terminal to Terminal 14 GP17051BS1 C High Beam Indicator Light Battery Positive Terminal to Terminal 15 GP17050BS1 C e f each LED lights does not go on replace the meter as sembly Meter Gauge Indicator Unit ELECTRICAL SYSTEM 16 73 Meter Circuit O0 QOQOCOOOOLO 09 2 6 Right Turn Signal Indica tor Light LED High Beam Indicator Light LED Neutral Indicator Light LED
141. 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 preparing this manual we divided the prod uct into its major systems These systems be came the manual s chapters All information for a particular system from adjustment through disassembly and inspection is located in a sin gle chapter The Quick Reference Guide shows you all of the product s system and assists in locating their chapters Each chapter in turn has its own comprehensive Table of Contents The Periodic Maintenance Chart is located in the Periodic Maintenance chapter The chart gives a time schedule for required maintenance operations If you want spark plug information for exam ple go to the Periodic Maintenance Chart first The chart tells you how frequently to clean and gap the plug Next use the Quick Reference Guide to locate the Periodic Maintenance chap ter Then use the Table of Contents on the first page of the chapter to find the Spark Plug sec tion 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 son
142. ION 13 5 Exploded View No Fastener Torque Remarks N m kgf m ft Ib 1 Rear shock absorber nuts upper and lower 34 3 5 25 2 Swingarm pivot shaft nut 108 11 80 3 Swingarm pivot shaft locknut 98 10 72 4 Rocker arm nut 34 3 5 25 5 Tie rod bolts 59 6 0 43 13 6 SUSPENSION Specifications Item Standard Front Fork per one unit Fork inner tube outside diameter Air Pressure Fork spring setting Damper setting Fork oil viscosity Fork oil capacity Fork oil level Fork spring free length Rear Shock Absorber Rebound damping force Spring preload Gas pressure 41 mm 1 61 in Atmospheric pressure Non adjustable Non adjustable Non adjustable KAYABA KHL34 G10 452 4 mL 15 28 0 135 US oz completely dry approx 385 mL 13 01 US oz when changing oil 115 2 mm 4 53 0 08 in below from inner tube top with fully compressed without fork spring 277 2 mm 10 91 in Service limit 272 mm 10 71 in Number 2 Adjustable Range Number 1 4 4th position Adjustable Range 1st 7th position 980 kPa 10 kgf cm 142 psi Non adjustable SUSPENSION 13 7 Special Tools Fork Cylinder Holder Handle 57001 183 Fork Cylinder Holder Adapter 57001 1057 Oil Seal amp Bearing Remover 57001 1058 Bearing Driver Set 57001 1129 Jack 57001 1238 Ko SAVE e UN Fork Oil S
143. Inlet Air Sensor Atmospheric Sensor Water Temperature Sensor Inlet Air Pressure Sensor Temperature Pressure Alternator BR W Y R BK HEI BK Y DO 26 9 R amp BK R VI BR Y DCH BK BL w BL R Y BR R BL Y BL G BL BK BL R BK Y BK W BK Y BK G License Plate BK Y BK Y BK Y BK Y gt gt Ma Joint Connector 6 E f e 25 E Fuse 5 15 Turn 22 Vehicle Engi Grou Nain Fuse 30A Selt diagnosis Terminal 22 Se gt EE Rear Brake puel Light R Switch ne nd IGNITION SWITCH CONNECTIONS Tee DEER aY BK Y wy wy Kr wy Kr BK Y BK Y BK Y BK Y BK Y BK Y BK Y BK Y B Joint Connector RIGHT SWITCH HOUSING CONNECTIONS JL BL R aL BK Y BK Y R R BK Y BK Y 8 Light 12V5W Rear Right Turn Signal Light 12 21 Tail Brake Light LED 12V0 5 5W Left Turn Light Rear Signal 12 21 Dark Green e reen ev Grey LB Light L6 Har Green Front Brake Light Switch Engine Stop Switch Starter Button Color BK Color r R Color BK R BK R Brake Lever White GB trange GE Pink Purple CL Y Pulled In Yellow 98052 00490 W2R0049CW5 6 16 14 ELECTRICAL SYSTEM Wiring Diag
144. JA000001 O This digit in the frame number changes from one machine to another Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Consumer Products amp Machinery Company Part No 99924 1323 01 Printed in Japan
145. ME ORG PRODUCT Honeycomb Type Catalyst Canada ZR750 J1 P No 18091 0132 WVTA FULL H ZR750 J1H P No 18091 0137 UK WVTA FULL Hi ZR750 J1H Mark KHI K 461 WVTA 78 2 H ZR750 J1H EPA Noise Emission Control Information Non Catalyst P No 39178 0025 Mark KHI M 093 Honeycomb Type Catalyst P No 18091 0134 Australia ZR750 J1 P No 18091 0138 Malaysia ZR750 J1 Mark KHI K 476 GE02094B F UK U K Model Full Full Power 78 2 Horsepower 78 2 kW 106 3 ps H Honeycomb Type Catalyst 5 6 ENGINE TOP END Specifications Item Standard Service Limit Clean Air System Vacuum switch valve closing pressure Open Close 41 49 kPa 310 370 mmHg 6 0 7 1 psi Camshafts Cam height Exhaust Inlet Camshaft journal camshaft cap clearance Camshaft journal diameter Camshaft bearing inside diameter Camshaft runout 36 146 36 254 mm 1 4231 1 4273 in 36 746 36 854 mm 1 4467 1 4509 in 0 028 0 071 mm 0 0011 0 0028 in 23 950 23 972 mm 0 9429 0 9438 in 24 000 24 021 mm 0 9449 0 9457 in TIR 0 02 mm 0 0008 in or less 36 05 mm 1 419 in 36 65 mm 1 443 in 0 16 mm 0 0063 in 23 92 mm 0 942 in 24 08 mm 0 948 in TIR 0 1 mm 0 004 in Cylinder Head Cylinder compression Cylinder head warp Valves Valve clearance Exhaust Inlet Valve head thickness Exhaust Inlet Valve stem bend Valve stem diameter Exhaust Inlet
146. N OFF Bt tt 1 1 1 2sec 3s 1 8s 0 5s 3s 1 58 1 58 80170738414 Olf the problem is with the following parts the ECU cannot memorize these problems the Fl indicator LED light doesn t go on and no service codes can be displayed FI Indicator LED Light Fuel Pump Fuel Pump Relay DFI Main Relay ECU Power Source Wiring and Ground Wiring see ECU Inspection in this chapter Fuel Injectors How to Erase Service Codes How to Erase Service Codes OEven if the ignition SW is turned OFF the battery or the ECU are disconnected or the problem is solved all service codes remain in the ECU ORefer to the Service Code Clearing Procedure for the service code erasure Self Diagnosis FUEL SYSTEM DFI 3 37 Service Code Table Service Code Table Service FI Indicator LED Light Problems Code 11 eee Main throttle sensor malfunction wiring open or short Inlet air pressure sensor malfunction wiring open or 1101 Inlet air temperature sensor malfunction wiring open 2 Water temperature sensor malfunction wiring open 14 fL D SSH 15 ITT Atmospheric pressure sensor malfunction wiring open or short 21 Crankshaft sensor malfunction wiring open or short Camshaft position sensor malfunction wiring open TU kd JULIUUUL Speed sensor mal
147. N 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 6105020881 C CRANKSHAFT TRANSMISSION 9 15 Crankshaft and Connecting Rods 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 e Install new bolts in reused connecting rods e Dent both bolt head and bolt tip with a punch as shown e Before tightening use a point micrometer A to measure the length of new connecting rod bolts and record the val ues to find the bolt stretch Connecting Rod B Mark here with a punch C Nuts D F
148. OTo make the 32 grind fit a 32 cutter into the holder and slide it into the valve guide OTurn the holder one turn at a time while pressing down very lightly Check the seat after each turn CAUTION The 32 cutter removes material very quickly Check the seat outside diameter frequently to pre vent overgrinding OAfter making the 32 grind return to the seat O D mea surement 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 O D measurement step above 6 15011951 6 6 15012151 6 6 15012251 6 5 26 ENGINE TOP END Valves xIf the seat width is too wide make the 60 A grind de scribed below x lf 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 O D are within the ranges specified above OPut a little coarse grinding com
149. OX sortem Pre 16 80 Junction Box Fuse Circuit Inspechon 99 16 80 Starter Circuit Headlight Relay 16 81 Diode Circuit Inspection 16 82 gi 16 83 30 A Main Fuse Removal 16 83 Junction Box Fuse Removal nennen 16 83 Fuse Iristallatigri i ite e EM o ERROR cates Re 16 83 15 A ECU Fuse Removal nennen 16 83 NIE le Ge e tert e RR T ERE TR ba dee de o e a ee ade aa Roue Ta 16 84 ELECTRICAL SYSTEM 16 3 Parts Location 1 Starter Lockout Switch Camshaft Position Sen O P 0 sor Radiator Fan Switch Starter Motor Alternator Speed Sensor Neutral Switch Side Stand Switch Water Temperature Sen sor Battery Junction Box Front Brake Light Switch Stick Coils Crankshaft Sensor Rear Brake Light Switch Starter Relay and Main Fuse 17 18 19 20 21 ECU Fuse Turn Signal Relay Diode Rectifier ECU Electronic Control Unit Oil Pressure Switch 22 Radiator Fan 16 4 ELECTRICAL SYSTEM Exploded View Other than CA ELECTRICAL SYSTEM 16 5 Exploded View N Fast Torque Remarks astener Nm kgfm ftlb Meter mounting screws 1 2 0 12 10 in Ib Tail brake light mounting screws 1 2 0 12 10 in Ib License plate light mounting screws 1 2 0 12 10 in Ib Front brak
150. Outer Rotor and Inner Rotor Oil Pump Installation e Install the outer rotor A into the crankcase e Install the pin B inner rotor C and oil water pump shaft D OTurn the pump shaft so that the slot E in its shaft fits onto the projection F of the pump drive gear shaft e Fit the pin A of the oil pump cover B into the hole C in the crankcase 6009011451 6 7 12 ENGINE LUBRICATION SYSTEM Oil Pump e Install Pins A Water Pump Body B e Install Impeller A Washer and Bolt B e Tighten Torque Water Pump Impeller Bolt 9 8 N m 1 0 kgf m 87 in Ib e Install Pins C Water Pump Cover and Bolts Torque Water Pump Cover Bolts 11 Nm 1 1 kgf m 95 in Ib e Install Water Pipes A e Tighten Torque Water Pipe Bolts B 11 1 1 kgf m 95 in Ib Oil Pump Drive Gear Removal e Remove Clutch see Clutch chapter Oil Pan see Oil Pan Removal Circlip A and Washer Oil Pump Drive Gear Oil Pump Drive Gear Installation e Apply molybdenum disulfide oil solution to the journal por tions A on the oil pump gear shaft B e Install Washers C e Install the new circlip D into the groove of the oil pump drive gear shaft 6009030851 C ENGINE LUBRICATION SYSTEM 7 13 Oil Pressure Measurement Oil Pressure Measurement e Remove the oil passage plug and attach the adapter A and gauge B to the plug hole Special Tools Oi
151. Peg aet or rx s hl cena awe Throttle Grip and Cables Throttle Grip Play Inspection Adjustment 1111 Choke Lever Ope tratlori nei cda tee teste tere eee a eee ede Choke Lever Play Inspection M be ERU a e Yo ka os e pte D Ra Euer dud Choke Lever Play Adjustment Cable Removal Installation pp Cable Lubrication and Inspechon eee Throttle Body Assy Idle Speed Inspecti Sl por T Engine Vacuum Synchronization Inspection Adiusiment High Altitude Performance 0 4 2 Throttle Body Assy Throttle Body Assy Throttle Body Assy Throttle Body Assy Air Cleaner IU EU e EE Disasserbly s eege EE deu PSSOMDIY EE Element Removal Installatiori ntn reet ene heh nbn E cR pA Rn P scans Mee CN ge UE UL EE Air Cleaner Housing Removal Fuel Tank Fuel Tank Removal Fuel Tank Installation Fuel Tank and Cap Fuel Tank Cleaning If S PS CUO RES 3 80 3 80 3 81 3 81 3 81 3 81 3 82 3 83 3 84 3 84 3 84 3 87 3 87 3 87 3 87 3 87 3 87 3 87 3 88 3 88 3 88 3 88 3 88 3 90 3 91 3 92 3 93 3 93 3 93 3 93 3 94 3 94 3 95 3 96 3 96 3 4 FUEL SYSTEM DFI Exploded View FUEL SYSTEM DFI 3 5 Exploded View
152. 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 A 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 6008060251 ENGINE LUBRICATION SYSTEM 7 11 Oil Pump Oil Pump Removal e Drain Coolant see Cooling System in the Periodic Mainte nance chapter Engine Oil see Engine Lubrication System in the Peri odic Maintenance chapter e Remove Water Pipe Bolts A Water Pipes B e Remove Water Pump Cover Bolts A Clamp B Water Pump Cover C e Remove Impeller Bolt A Washer Impeller B Water Pump Body Oil Pump Cover Oil Water Pump Shaft
153. RE ER EA 14 8 Stesring Stem Varps EE 14 8 DUI 14 9 Handlebar Removal 2 202 0 14 9 Handlebar Installation case aee SEENEN dea 14 9 14 2 STEERING Exploded View PORE cK a SAO SU S 2 Lou gt Kg lt lt SS Ye STEERING 14 3 Exploded View N Fastener E Remarks 4 asten Nm kgfm ftlb 1 Steering stem nut 27 2 8 20 2 Steering stem head bolt 108 11 80 3 Front fork clamp bolts Upper 20 2 0 14 4 Front fork clamp bolts Lower 20 2 0 14 AL 5 Handlebar clamp bolts 25 2 5 18 S 6 Handlebar lower clamp nuts 34 3 5 25 7 Switch housing screws 3 5 0 36 31 in lb 8 Steering stem head bolt plug AD Apply adhesive AL Tighten the two clamp bolts alternately two times to ensure even tighten torque G Apply grease L Apply a non permanent locking agent R Replacement Parts S Follow the specific tightening sequence 14 4 STEERING Special Tools Steering Stem Nut Wrench 57001 1100 Bearing Driver Set 57001 1129 Steering Stem Bearing Driver 57001 1344 Jack 57001 1238 Steering Stem Bearing Driver Adapter 57001 1345 STEERING 14 5 Steering Steering Inspection e Referto the Steering in the Periodic Maintenance chapter Steering Adjustment e Referto the Steering in the Periodic Maintenance c
154. Remove Camshaft Position Sensor Connector A Injector Harness Connector B e Remove the vacuum switch valve hose from the air cleaner housing e Remove Breather Hose End A Engine Ground Cable Terminal Bolt B e Support the engine with a suitable stand A OPut a plank B onto the suitable stand for engine balance e Remove Right and Left Upper Engine Mounting Bolts A Front Engine Bracket Bolts B Front Engine Bracket C ENGINE REMOVAL INSTALLATION 8 7 Engine Removal Installation e Remove the middle and lower engine mounting nuts A and bolts e Remove Rear Engine Bracket Bolts B Rear Engine Bracket C e Using the nut wrench A loosen the locknut B Special Tool Engine Mount Nut Wrench 57001 1450 e Using the Hexagon Wrench turn the adjusting collar A counter clockwise to mark the gap between the engine and frame adjusting collar e Remove the drive chain A from the output shaft B e Using the stand take out the engine Engine Installation e Support the engine A with a suitable stand B OPut a plank onto the suitable stand for engine balance e Screw the adjusting collar fully by hand e Install the engine ground cable Torque Engine Ground Cable Terminal Bolt 9 8 1 0 kgf m 87 in Ib 8 8 ENGINE REMOVAL INSTALLATION Engine Removal Installation e Install the engine mounting bolts and nuts following the specified installing seq
155. Shift Mechanism Installation e Install the gear positioning lever A as shown Spring B Collar C Bolt D e Tighten Torque Gear Positioning Lever Bolt 12 N m 1 2 kgf m 104 in Ib e Apply grease to the O rings on the oil pipe ends e Apply a non permanent locking agentto the oil pipe holder bolts and tighten them Torque Oil Pipe Holder Bolts 13 1 3 kgf m 113 in Ib External Shift Mechanism Inspection e Examine the shift shaft A for any damage lf the shaft is bent straighten or replace it xIf the serration B are damaged replace the shaft xIf the springs C are damaged in way replace them xIf the shift mechanism arm D is damaged in any way replace the arm e Check the return spring pin A is not loose 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 22 e Check the gear positioning lever B and its spring for breaks or distortion xIf the lever or spring are damaged any way replace them e Visually inspect the shift drum cam C x If they are badly worn or if they show any damage replace it MU A 6113131851 6 9 26 CRANKSHAFT TRANSMISSION Transmission Transmission Shaft Removal e Split the crankcase see Crankcase Splitting e Remove the drive shaft A and output shaft B Transmission Shaft Installat
156. Side Stand F Side Stand Installation e Apply grease to the sliding area B of the side stand A e Tighten the bolt and lock them with the nut Torque Side Stand Bolt 44 N m 4 5 kgf m 33 ft lb e Hook the spring e Install the side stand switch OApply a non permanent locking agent to the thread of the Switch bolt Torque Side Stand Switch Bolt 8 8 N m 0 90 kgf m 78 in Ib 6020006851 C FRAME 15 17 Rear View Mirrors Rear View Mirrors Removal Loosen the lower hexagonal area A for tightening to re SS H Ws move the rear view mirror from the holder 25 LZ CAUTION Eust LU B ES A Do not force to tighten and or loosen the upper hexagonal area Adapter B with a pair of span Disassembly of this area is Not Available ners Non permanent locking agent D is already applied to the threads of this inner area Forcible loosen ing may damage the adapter and or the turning mechanism of the stay C Rear View Mirrors Installation e Screw the mounting area of the right rear view mirror into the holder all the way and tighten the lower hexagonal area for tightening securely Lower Hexagonal Area for Tightening A Upper Hexagonal Area Adapter B Rear View Mirror Right C e Turn the stay A to assure the safe conditions of the rear with the operator sat on the motorcycle e Adjust the rear view mirror slightly with its mirror B Olns
157. Signal Fuse 10 A Turn Signal Light Bulb Replacement For the European Malaysian and Australian Models e Unscrew the screw A and remove the lens B ELECTRICAL SYSTEM 16 59 Lighting System e Push and turn the bulb A counterclockwise and remove it 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 For the Canadian Model e Unscrew the screw A e Unscrew the screws A e Push and turn the bulb A counterclockwise and remove it 16 60 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 Turn Signal Relay Inspection e Remove Seats see Frame chapter Upper Seat Cover see Frame chapter Turn Signal Relay A 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 Load The Number of Turn Flashing times Wattage W c m Signal Lights T 21 or 23 140 250 2 42 or 46 75 95 Cycle s per minute Corrected to one light burned out T
158. This manual is brought to you by www magnamaniac com Kawasaki Z750 Motorcycle Service Manual 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 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 ech 1 NIO AJIO ej Ool Ol ol B Oo INN e Appendix 2750 Kawasaki Motorcycle Service Manual All rights reserved 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 Department 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 possible The right i
159. Voltage Adapter Type KEK 54 9 B Brand KOWA SEIKI Connections Camshaft Position Sensor Lead Adapter Hand Tester Black lt Red Yellow RC 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 0 2 V or more x If the peak voltage is lower than the standard inspect the camshaft position sensor 16 42 ELECTRICAL SYSTEM Ignition System Stick Coil Ignition Coil together with Spark Plug Cap Removal e Remove the fuel tank see Fuel System DFI chapter e Remove the thermostat bracket bolt A e Disconnect Water Temperature Sensor Connector B Left Switch Housing Connector C Olf removing the stick coil 2 or 3 e Disconnect the stick coil connectors A e Pull the stick coil 1 B off the spark plug e Take out the camshaft position sensor connector C from the bracket see Camshaft Position Sensor Removal e Pull the stick coil 2 D off the spark plug CAUTION Do not pry the connector part of the coil while re moving the coil e Remove the stick coil harness A from the bracket e Remove Stick Coil Connector 4 B disconnect Stick Coil 4 C Stick Coil Connector 3 D disconnect e Pull the main harness upward and remo
160. ace them with new ones if they are damaged e Apply a thin coat of PBC Poly Butyl Cuprysil grease to the caliper holder shafts C and holder holes D PBC is a special high temperature water resistance grease e Install the anti rattle spring A e Install the pads see Front Brake Pad Installation e Wipe up any spilled brake fluid on the caliper with wet cloth Rear Caliper Disassembly e Remove the rear caliper e Remove the pads and anti rattle spring see Rear Brake Pad Removal e Using compressed air remove the piston OCover the piston area with a clean thick cloth B OBlow compressed air A into the hole for the banjo bolt to remove the piston WARNING To avoid serious injury never place your fingers or palm inside the caliper opening If you apply com pressed air into the caliper the piston may crush your hand or fingers e Remove the dust seal and fluid seal e Remove the bleed valve and rubber cap NOTE compressed air is not available with the brake hose still attached apply the brake pedal to remove the pis ton The remaining process is as described above 6105040251 6 12 12 BRAKES Calipers 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 valve and rubber cap Torque Bleed Valve 7 8 0
161. aced in order to keep the fork legs balanced to ensure stability Fork Spring Free Length Standard 277 2 mm 10 91 in Service Limit 272 mm 10 71 in 8 04172851 C 6 04062551 C 8 04041351 C Rear Shock Absorber SUSPENSION 13 13 Rebound Damping Force Adjustment e Turn the damper adjuster A to adjust the rebound damp ing OAlign the numbered mark B of the adjuster OThe standard adjuster setting for average build rider of 68 kg 150 Ib with no passenger and no accessories is position 2 If the damper s effectiveness is not suited to the operating conditions adjust it to an appropriate position by referring to the table below Rebound Damping Adjustment Adjuster Damping Shock Road Driving 72 Absorber Load e Position Force Conditions Speed Hardness 1 Weak Soft Good Street 2 T T T T 3 i J 4 Strong Hard Bad Highway Spring Preload Adjustment e Remove the mud guard see Frame chapter e Using the hook wrench A turn the adjusting nut B to adjust the spring preload OThe standard adjuster setting for average build rider of 68 kg 150 Ib with no passenger and no accessories is 4th position Spring Preload Setting Standard Position 4th position Adjustable Range 1st to 7th position e f the compression of the spring is not suited to the op erating conditions adjust it to an appropriate position by referring to the tab
162. ail Brake Light LED Removal e Remove Seats see Frame chapter Upper Seat Cover see Frame chapter e Disconnect the tail brake light LED connectors A and rear turn signal connectors B e Open the clamp C 8 12040251 C ELECTRICAL SYSTEM 16 61 Lighting System e Unscrew the bolts A e Unscrew the mounting screws A e Remove the tail brake light LED B OPull out the mount portion C Tail Brake Light LED Installation e Tighten the tail brake light mounting screws Torque Tail Brake Light Mounting Screws 1 2 N m 0 12 kgf m 10 in Ib 16 62 ELECTRICAL SYSTEM Radiator Fan System Fan System Circuit Inspection e Disconnect the lead connector A from the radiator fan Switch e Using an auxiliary wire A connect the radiator fan switch leads If the fan rotates inspect the fan switch lf the fan does not rotate inspect the following Leads and Connectors Main Fuse and Fan Fuse Fan Motor Fan Motor Inspection e Remove the fuel tank see Fuel System DFI chapter e Disconnect the 2 pin connector A in the fan motor leads OPull the lead until come out the connector e Using two auxiliary wires A supply battery B power to the fan motor x lf the fan does not rotate the fan motor is defective and must be replaced ELECTRICAL SYSTEM 16 63 Radiator Fan System Radiator Fan Circuit 08 o BK Y BK Y oN 5 SE
163. ain slack after installing the chain see Drive Chain Slack Adjustment FINAL DRIVE 11 7 Drive Chain Drive Chain Replacement e Remove Chain Cover see Drive Chain Removal Engine Sprocket Cover see Engine Sprocket Removal EK JOINT TOOL 50 Body A 3 uo Handlebar B 9 2 Cs AG Cutting amp Riveting Pin C For Cutting D For Riveting E Plate Holder A F Plate Holder B G Gauge H GK04016BSi 6 e Grind A pin head to make it flat e Set cutting amp riveting pin B as shown e Screw pin holder until it touches chain pin e Be sure that cutting pin hits center of chain pin e Screw handlebar A into body e Turn pin holder with wrench B clockwise to extract chain pin GK04018BSi 6 11 8 FINAL DRIVE Drive Chain e Replace the link pin link plate and grease seals e Apply grease to the link pins A and grease seals B C e Engage the drive chain on the engine and rear sprockets e Insert the link pins in the drive chain ends e Install the grease seals C e Install the link plate so that the mark D faces out e Push link plate by hand or plier to fix it e In case of O ring chain be sure to set O rings correctly e Set plate holder A A and plate holder B B on the body e Fit plate holder A to link plate e Turn pin holder by hand until plate holder B touches the other link plate e Turn pin ho
164. ain that all the electrolyte has flowed out e Tap the bottom the same way as above if there is any electrolyte left in the container e Now pull the container gently out of the battery e Let the battery sit for 20 minutes During this time the electrolyte permeates the special separators and the gas generated by chemical reaction is released 8 08003851 C 8 08010451 C ffe L gt 8 08010551 C 8 08010851 C ELECTRICAL SYSTEM 16 25 Battery e Fit the seal cap A tightly into the filler ports until the seal caps are at the same level as the top of the battery NOTE ODo not hammer Press down evenly with both hands CAUTION Once you installed the seal caps after filling the bat tery never remove it nor add any water or elec trolyte Initial Charge While a sealed battery can be used after only filling with electrolyte a battery may not be able to sufficiently move a starter motor to start an engine in the cases shown in the table below where an initial charge is required before use However if a battery shows a terminal voltage of 12 6 V or more using a digital voltmeter after 10 minutes of filling no initial charge is necessary Kawasaki recommended chargers OptiMate 111 Yuasa 1 5 Amp Automatic Charger Battery Mate 150 9 If the above chargers are not available use equivalent one NOTE OTo measure battery terminal voltage
165. al A is in the correct position Footpeg B Pedal Position Standard About 47 mm 1 85 in C below top of footpeg 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 the push rod locknut has been loosened e Remove the bolts A and remove the guard bracket B e Loosen the locknut A and turn the push rod with the hex head B to achieve the correct pedal position lf the length C shown is 70 1 mm 2 76 0 04 ml the pedal position will be within the standard range e Tighten Torque Rear Master Cylinder Push Rod Locknut 18 1 8 kgf m 13 ft Ib e Check the brake light switch operation see Brakes in the Periodic Maintenance chapter Calipers BRAKES 12 9 Front 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 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 OAfter the caliper removal if compressed air will not be available for disassembling the caliper remove the pis ton before detaching the brake hose see Front Caliper Disassembly Rear Caliper Removal e Loosen the banjo bolt
166. al System chapter Oil Filter see Engine Lubrication System chapter x lf the crankshaft is to be removed remove the pistons see Engine Top End chapter e Remove the upper crankcase bolts OFirst loosen the M6 bolts M6 Bolts A M7 Bolts B 8 Bolts C e Remove the oil pan relief valve oil screen and oil pipes see Engine Lubrication System chapter e Remove the lower crankcase bolts OFirst loosen the M7 bolts M7 Bolts A M9 Bolts B e Tap lightly around the crankcase mating surface with a plastic mallet and split the crankcase Take care not to damage the crankcase 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 e With a high flash point solvent clean off the mating sur faces of the crankcases halves and wipe dry e Using compressed air blow out the oil passages in the crankcase halves 6104055851 C 6104132851 C CRANKSHAFT TRANSMISSION 9 11 Crankcase Splitting e Apply liquid gasket to the breather plate mating surface A 1 to 1 5 mm 0 04 to 0 06 in thick and then install the breather plate Sealant Three Bond 1207B e Apply a non permanent locking agent to the threads and tighten the bolts A Torque Breather Plate Bolts 9 8 1 0 kgf m 87 in lb e Install the breather hose A OAlign the white mark on the hose with the w
167. al 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 Before Servicing 1 2 Model Identification 1 7 General Specifications 1 8 Technical Information Air Inlet System 1 10 Technical Information New Ignition Interlock Sidestand
168. allation e Install the hoses and pipes being careful to follow bend ing direction Avoid sharp bending kinking flattening or twisting e Run the hoses in accordance with the Cable Wire and Hose Routing section 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 Hose Clamp Screws 2 0 0 20 kgf m 17 in Ib Hose Inspection e Refer to the Cooling System in the Periodic Maintenance chapter ZZ SSS la 6010020151 4 18 COOLING SYSTEM Radiator Fan Switch Water Temperature Sensor CAUTION The fan switch or the water temperature sensor should never be allowed to fall on a hard surface Such a shock to their parts can damage them Radiator Fan Switch Removal e Drain the coolant see Cooling System in the Periodic Maintenance chapter e Remove Radiator Fan Switch Lead Connector A Radiator Fan Switch B Radiator Fan Switch Installation e Tighten Torque Radiator Fan Switch 18 N m 1 8 kgf m 13 ft lb e Fill the coolant see Cooling System in the Periodic Main tenance chapter Radiator Fan Switch Inspection e Refer to the Electrical System chapter for the Radiator Fan Switch Inspection Water Temperature Sensor
169. ally on a hard surface Such a shock to the relay can damage it e Remove the seat cover see Frame chapter e Remove the fuel pump relay A from the tongue of the storage compartment e Disconnect the connector Fuel Pump Relay Inspection e Remove the fuel pump relay see above e Connect the hand tester A and one 12 V battery B to the relay connector C as shown Special Tool Hand Tester 57001 1394 Relay Coil Terminals 1 and 2 Relay Switch Terminals 3 and 4 Testing Relay Tester range 1 range Criteria When battery is connected 0 When battery is disconnected gt lf the relay does not work as specified replace the relay W Y wv W Y on PARK 16NITION Om BR BR BATTERY JGcy OS w el D ib Ts Gr ore W AIE R wa 6017265BN2 A ECU Y Junction Box f Sealed Battery N Engine Stop Switch Z Fuel Pump Relay for fuel g Fuel Pump T Ignition Switch pump and injectors j Joint Connector B X Ignition Fuse 10 A d Starter Relay k Main Fuse 30 FUEL SYSTEM DFI 3 81 Fuel Injectors Removal Installation e Refer to the Throttle Body Assy Disassembly Assembly Audible Inspection e Start the engine e Apply the tip of a screwdriver A to the injector C Put the grip end onto your ear and listen whether the injector is clicking or
170. alve 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 to 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 ofthe cutter A represent the following OU oua Dess Rud Cutter angle B OST AD uti ten 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 f
171. alve full opening lift 58 62 136 144 8 mm 0 31 in or more 75 167 F COOLING SYSTEM 4 7 Special Tools and Sealant Bearing Driver Kawasaki Bond Silicone Sealant 57001 382 56019 120 Bearing Driver Set 57001 1129 4 8 COOLING SYSTEM Coolant Coolant Deterioration Inspection e Remove the left side cover see Frame chapter e Visually inspect the coolant A 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 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 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 perpendicular Do not use the sidestand If 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 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
172. and repair see chapter 16 Carbon accumulating on valve seating surface Repair see chapter 5 Engine overheating Other Engine oil viscosity too high Drive train trouble Brake dragging see Overheating of Troubleshooting Guide see chapter 17 Change see chapter 2 Inspect drive chain see chapter 2 and sprocket see chapter 11 Inspect caliper fluid seal damage or clogging of master cylinder relief and supply ports see chapter 12 Clutch slipping Inspect friction plates for wear see chapter 6 Engine overheating Vacuum switch valve trouble Air suction valve trouble Intermittent any DFI fault and its recovery see Overheating of Troubleshooting Guide see chapter 17 Inspect and replace see chapter 5 Inspect and replace see chapter 5 Check that DFI connectors are clean and tight and examine wires for signs of burning or fraying see chapter 3 3 30 FUEL SYSTEM DFI DFI System Troubleshooting Guide Poor Running or No Power at High Speed Symptoms or Possible Causes Firing incorrect Spark plug dirty broken or maladjusted Spark plug cap trouble Spark plug cap shorted or not in good contact Spark plug incorrect IC igniter in ECU trouble Actions chapter Clean spark plug and adjust plug gap see chapter 2 Inspect stick coil see chapter 16 Reinstall or inspect stick coil see chapter 16 Replace it with the correct plug see c
173. ar e Check for uneven groove wear by inspecting the ring seat ing 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 Top Standard 0 04 0 08 mm 0 0016 0 0031 in Service Limit 0 18 mm 0 0071 in Second Standard 0 02 0 06 mm 0 0008 0 0024 in Service Limit 0 16 mm 0 0063 in Piston Ring Groove Width e Measure the piston ring groove width OUse a vernier caliper at several points around the piston Piston Ring Groove Width Top A Standard 0 83 0 85 mm 0 0327 0 0335 in Service Limit 0 93 mm 0 037 in Second B Standard 0 81 0 83 mm 0 0319 0 0327 in Service Limit 0 91 mm 0 036 in xIf the width of any of the two grooves is wider than the service limit at any point replace the piston Piston Ring Thickness e Measure the piston ring thickness OUse the micrometer to measure at several points around the ring Piston Ring Thickness Top A Standard 0 77 0 79 mm 0 0303 0 0311 in Service Limit 0 70 mm 0 028 in Second B Standard 0 77 0 79 mm 0 0303 0 0311 in Service Limit 0 70 mm 0 028 in xIf any of the measurements is less than the service limit on either of the rings replace all the rings NOTE OW
174. ar into the head it will be impossible to adjust the clearance and the cylin der head must be replaced 8 15011851 C Valves ENGINE TOP END 5 25 e Measure the outside diameter of the seating surface with a vernier caliper xIf the outside diameter of the seating surface is too small repeat the 45 grind until the diameter is within the spec ified range Widened Width A of engagement by machining 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 xIf 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 xIf the outside diameter A of the seating surface is too large make the 32 grind described below xIf 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 O D is within the specified range
175. at lock cable 17 14 APPENDIX Cable Wire and Hose Routing QQ G 4 2 5 6 ES Esse EAE say v Pr IS amita D 11 T Ai KA 12 6 eM pear ze sis CY im ELT I T5 al 6809393 5 C APPENDIX 17 15 Cable Wire and Hose Routing 1 5 Cam sensor lead Run the lead between the convex area of cap center and bolt head to secure the coupler Fan switch horn lead Cap Clutch cable Run the cable through forward the water hose Air suction valve Water hose Thermostat Radiator Water hose Head Thermostat Inlet air pressure sensor Vacuum hose Run the vacuum hose under the throttle cable to connect with the inlet air pres sure sensor Throttle cable accelerator Throttle cable decelerator Vacuum balance tube Choke Cable Run the cable through left side of hose Hose air suction valve air cleaner Stick coil Fuel pump Fuel hose To inlet air pressure sensor To air suction valve Plate Throttle body Radiator fan lead Run the lead through forward the water hose 17 16 APPENDIX Cable Wire and Hose Routing APPENDIX 17 17 Cable Wire and Hose Routing OP Gab Bend the bracket as shown to secure the lead Bend the bracket In
176. atmospheric pres sure change due to high altitude and the ECU compen sates the change 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 Fuel Tank see Fuel Tank Removal Vacuum Switch Valve Vacuum Hose A from air cleaner housing B Front C e Remove the vacuum hoses from the positions A shown Front B GC17155BS1 C FUEL SYSTEM DFI 3 89 Throttle Body Assy e Loosen Throttle Assy Holder Clamp Bolts A Air Cleaner Duct Clamp Bolts B e Remove Right and Left Side Covers see Frame chapter Coolant Reserve Tank see Cooling System in the Peri odic Maintenance chapter Crankcase Breather Hose Right and Left Air Cleaner Housing Mounting Bolts A e Move A the air cleaner housing backwards e Pull B the throttle body assy out of the holders C e Slide A the throttle body assy B right and remove it e Loosen the locknut and screw in the throttle cable adjuster fully to give the cables plenty of play e Remove the right handlebar
177. ature Light LED Sensor 15 High Beam Indicator Light 9 Ground LED 16 Speed Sensor Pulse CAUTION 6p17039BS2 0 Do not drop the meter unit Place the meter unit so that it faces upward If the meter unit is left upside down or sideways for a long time or dropped it will malfunction Do not short each terminals Liquid Crystal Display LCD Segments Check e Use the harness adapter for meter inspection Special Tool Harness Adapter 57001 1542 OOOOOOOO e Using the auxiliary wires connect the 12 V battery to the meter unit connector as follows OConnect the battery positive terminal to the terminal 10 OConnect the battery negative terminal to the terminal 9 6Pi7040BSi 6 e Connect the terminal 1 to the terminal 10 OThe tachometer LCD segments momentarily to it last readings two times and segment movement is reversal OWhen the terminals are connected all the LCD segments A and LED warning lights B appear for three seconds xIf the LCD segments and LED warning light will not ap pear replace the meter assembly e Disconnect the terminal 1 OAI the LCD segments LED warning light disappear lf the segments do not disappear replace the meter as sembly 6 17111851 6 16 66 ELECTRICAL SYSTEM Meter Gauge Indicator Unit MODE AND RESET BUTTON Operation Check e Connect the 12 V battery and terminals in the same man ner as specified
178. brication System chapter Water Pump Installation e Refer to the Oil Pump Installation in the Engine Lubrica tion System chapter Water Pump Inspection e Check the drainage outlet passage A at the bottom of the water pump body for coolant leaks the mechanical seal is damaged the coolant leaks through the seal and drains through the passage Re place the mechanical seal unit Water Pump Impeller Disassembly Assembly e The sealing seat and rubber seal may be removed easily by hand e Apply coolant around the surfaces of the rubber seal and sealing seat e Install the rubber seal A and sealing seat B into the impeller by pressing them by hand until the seat stops at the bottom of the hole e Tighten the water pump impeller bolt by special torque Torque Water Pump Impeller Bolt 9 8 N m 1 0 kgf m 87 in Ib 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 impeller Water Pump Housing Disassembly CAUTION Do not damage the hole wall of the water pump housing e Insert a bar A into the pump housing B and hammer evenly around the circumference of the mechanical seal bottom C 6D06015BS1 C COOLING SYSTEM 4 11 Water Pump e Take the oil seal A out of the housing B with a hook C Water Pump Housing Assembly CAUTION Do not reuse the mechanical
179. c pads and disc use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning of the brake parts Do not use any other fluid for cleaning these parts Gasoline engine oil or any other petroleum distillate will cause 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 disc brake e Apply brake fluid to the removed 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 ex PBC grease Brake Lever Pivot Bolt Brake Lever Pivot Contact Push Rod Contact Dust Covers e Tighten Torque Brake Lever Pivot Bolt 1 0 0 10 kgf m 9 in Ib Brake Lever Pivot Bolt Locknut 5 9 0 60 kgf m 52 in lb Master Cylinder Inspection Visual Inspection e Refer to the Brakes in the Periodic Maintenance chapter 6107011052 C 12 18 BRAKES Brake Disc Brake Disc Removal e Remove the wheel see Wheels Tires chapter e Unscrew the mounting bolts and take off the disc Brake Disc Installation e Install the brake disc on the wheel so that the marked side A faces out 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 e Measure the thickness of each disc
180. chapter Spark plug dirty broken or gap maladjusted Clean spark plugs and adjust plug gap see chapter 2 Too low fuel pressure Inspect see chapter 3 Fuel pump trouble Inspect see chapter 3 Main throttle sensor trouble Inspect see chapter 3 Inlet air temperature sensor trouble Water temperature sensor trouble Atmospheric pressure sensor trouble Inlet air pressure sensor trouble Vacuum switch valve broken Air suction valve trouble After fire Crankshaft sensor trouble Spark plug burned or gap maladjusted Inlet air temperature sensor trouble Water temperature sensor trouble Atmospheric pressure sensor trouble Inlet air pressure sensor trouble Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect and replace see chapter 5 Inspect and replace see chapter 5 Inspect see chapter 3 Inspect see chapter 16 Adjust plug gap or replace plug see chapter 2 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Fuel injector trouble Inspect see chapter 3 Inspect see chapter 3 Run on dieseling Ignition switch trouble Inspect and replace see chapter 16 Engine stop switch trouble Inspect and repair or replace see chapter 16 Fuel injector trouble Inspect see chapter 3 Loose terminal of battery lead or ECU ground lead Inspect
181. cover see Alternator Cover Installa tion Alternator Rotor Removal e Remove Alternator Cover see Alternator Cover Removal e Wipe oil off the outer circumference of the rotor e Hold the alternator rotor steady with the rotor holder A and remove the rotor bolt B and washer Special Tool Rotor Holder 57001 1543 e Using the flywheel puller A and rotor puller B remove the alternator rotor from the crankshaft Special Tools Rotor Puller M16 M18 M20 M22 x 1 5 57001 1216 Flywheel Puller M38 x 1 5 57001 1405 NOTE OScrew in the puller while tapping the head C of the puller with a hammer 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 Apply a thin coat of molybdenum disulfide grease to the crankshaft C and the face D of the starter clutch gear GPO9045BS1 C GPO9046BS1 C GPOS054BS1 C Charging System ELECTRICAL SYSTEM 16 31 e Install the starter gear A e Again clean the crankshaft tapered portion B and dry there e Fit the woodruff key C securely in the slot in the crank shaft before installing the alternator rotor e Install the alternator r
182. cover gasket with a new one e Apply silicone sealant A to the cylinder head as shown Sealant Kawasaki Bond Silicone Sealant 56019 120 GEO9014BS1 C e Install Dowel Pins A Plug Hole Gaskets B GEO9015BS1 C e Install the washer A with the metal side faces upward GEO9010BS1 C Cylinder Head Cover ENGINE TOP END 5 13 e Tighten the cover bolts following the specified tightening sequence Torque Cylinder Head Cover Bolts B 9 8 N m 1 0 kgf m 87 in Ib e Install the removed parts see appropriate chapters 6 09016851 6 5 14 ENGINE TOP END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION This is a non return type camshaft chain tensioner The push rod does not return to its original position once it moves out to take up camshaft chain slack Observe all the rules listed below When removing the tensioner do not take out the mounting bolts only halfway Retightening the mounting bolts from this position could damage the tensioner and the camshaft chain Once the bolts are loosened the tensioner must be removed and reset as described in Camshaft Chain Ten sioner Installation Do not turn over the crankshaft while the tensioner is removed This could upset the camshaft chain timing and damage the valves e Remove Fuel Tank see Fuel System DFI chapter Cap Bolt A Washer B Spring C Rod D
183. crankcase bolts in the order listed Torque Crankcase Bolts 8 A 27 2 8 kgf m 20 ft Ib Crankcase Bolts M7 20 N m 2 0 kgf m 14 16 L 85 mm 3 35 in B L 50 mm 1 97 in C Crankcase Bolts M6 12 N m 1 2 kgf m 104 in Ib L 60 mm 2 36 in D L 40 mm 1 57 in E L 90 mm 3 54 in F Clamp G 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 6th gear and 6th to 1st OWhen the output shaft stays still the gear can not be shifted to 2nd gear or other higher gear positions 4 Eo Ar 4 Ez kr y mg 6 I 22 6104058851 C 6104133851 C CRANKSHAFT TRANSMISSION 9 13 Crankshaft and Connecting Rods Crankshaft Removal e Split the crankcase see Crankcase Splitting e Remove the crankshaft A 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 e Apply molybdenum disulfide oil solution to the crankshaft main bearing inserts e Install the crankshaft with the camshaft chain A hanging on it Connecting Rod Removal
184. crew B Shift Drum Bearing Holder C e Pull out the shift rods D and take off the shift forks Pull out the shift drum E Shift Drum and Fork Installation e Install the shift rods A noting the groove position The rods are identical e Position the one with shortest ears B on the drive shaft and place the pin in the center groove in the shift drum C OThe two forks D on the output shaft are identical e Install the forks so that its 266 and 267 side faces clutch side e Apply a non permanent locking agent to the threads of the shift drum bearing holder bolt and screw and tighten them Torque Shift Drum Bearing Holder Bolt 13 N m 1 3 kgf m 113 in Ib Shift Drum Bearing Holder Screw 5 4 N m 0 55 kgf m 48 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 104 in Ib 6113013481 C CRANKSHAFT TRANSMISSION 9 31 Transmission Shift Fork Bending e Visually inspect the shift forks and replace any fork that is bent A bent fork could cause difficulty in shifting or allow the transmi
185. de livery pipe 3 92 FUEL SYSTEM DFI Throttle Body Assy CAUTION Never drop the injector especially on a hard sur face Such a shock to the injector can damage it e Pull out the injectors along with the delivery pipe A necessary remove the injectors from the delivery pipe Replace the O rigs of the indicators necessary cut straps and take the harness off the de livery pipe Throttle Body Assy Assembly OReplace the O rings A of injectors and the seals B with the new ones e Before assembling blow away dirt or dust from the throttle body and delivery pipe by applying compressed air e Apply engine oil to the new O rings of each injector C insert them into the delivery pipe D and confirm whether the injectors turn smoothly or not e Install the injectors along with the delivery pipe assy into the throttle bodies E Torque Delivery Pipe Screws 3 4 N m 0 35 kgf m 30 in Ib e Connect all the connectors A including the subthrot tle valve actuator connector B and bind the leads with straps C e Insert the each hoses onto the throttle body fittings e Install the throttle body assy see Throttle Body Assy In stallation GC17164BS1 C Air Cleaner FUEL SYSTEM DFI 3 93 Element Removal Installation e Refer to the Air Cleaner Element Cleaning in the Periodic Maintenance chapter Air Cleaner Oil Draining A drain hose i
186. ditional electric heated bulb more than 5 times longer uses lower voltage expends lower wattage approx 1 5 and is quicker responsing Due Position of LED Installation The resistors the diodes and the Zener diodes are mounted in the electronic circuits A of the LED which supplies the steady current and voltage to the light Light Emitting Diode LED The Light Emitting Diode LED A is an element of semi conductor diode that converts applied voltage to light The LED emits luminous beams by the collision of nega tive charge electrons A and positive charge holes B when applied the forward voltage and current to the PN junction diode C 66806090851 6 1 14 GENERAL INFORMATION Technical Information Tail Brake Lights Employing LED The emitting color differs according to the materials of semi conductors Materials of Semi Conductor and Emitting Color Materials of Semi Conductor Emitting Color GaAsP GaAlAs GaP Gan Ga Gallium As Arsenic P Phosphorus N Nitrogen Al Aluminum GENERAL INFORMATION 1 15 Technical Information KAWASAKI LOW EXHAUST EMISSION SYSTEM Since the emission regulations become more severe Kawasaki has adopted a type of simplified KAWASAKI LOW EXHAUST EMISSION SYSTEM KLEEN which have no catalyst protection sys tem according to each regulation of different countries The muffler with built in catalyst has the same
187. durability as the conventional muffler however do not use leaded gasoline and do not coast with the ignition system OFF Running the engine without ignition damages catalyst Refer to the ZX900E Service Manual Part No 99924 1255 for more information about the KLEEN theory maintenance and handling precautions including the secondary air injection system Honeycomb Type Catalytic Converter OThe converter is a three way catalytic converter and its surface is covered with alumina upon which platinum and rhodium are applied and has a cylindrical metallic honeycomb structure made by bending a corrugated sheet and a flat sheet of stainless steel into a spiral of increasing diameter The honeycomb structure is convenient for the catalytic converter because it has a large surface area but small size to react effectively and has low exhaust resistance In addition its inherent strength helps resist vibration and has simple structure welded directly on the silencer OGenerally the temperature of the exhaust gas must be higher than activation temperature so the converters are installed in the exhaust manifold rear end where the temperature of exhaust gas is still high And the converters will be activated even under low load conditions OAfter the exhaust gas is diluted with the secondary air injection the catalytic converter works well because of rich oxygen to reduce CO HC and NOx Accordingly we can keep the exhaust gas emission within reg
188. e D e Remove Radiator Upper Bolt right A Right Radiator Hose B e Remove the radiator CAUTION Do not touch the radiator core This could damage the radiator fins resulting in loss of cooling effi ciency e f necessary remove Radiator Fan Mounting Bolts A Radiator Fan B GDO7011BS1 C Radiator COOLING SYSTEM 4 13 Radiator and Radiator Fan Installation e Installation is the reverse of removal e Install the radiator bracket collars A as shown Rubber Damper B 30 40 C Radiator D Bracket E e Tighten Torque Radiator Lower Bolts F 7 0 N m 0 70 kgf m 61 Radiator Upper Bolts G 7 0 N m 0 70 kgf m 61 Radiator Inspection e Check the radiator core xIf there are obstructions to air flow remove them the corrugated fins A are deformed carefully straighten them xf 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 Radiator Cap Inspection e Remove Fuel Tank see Fuel System
189. e subthrottle valve actuator with a stepping motor built in it ECU and subthrottle sensor The subthrottle valve is built in the each throttle body The subthrottle control system operates on the signal supplied from the ECU The open close oper ation of the subthrottle valve is performed by the subthrottle actuator which is controlled by the ECU to change the current direction into the motor of the subthrottle valve actuator The subthrottle sensor detects the subthrottle valve actuator movement by measuring voltage and the ECU determines the subthrottle valve angle based on the operation map When turning the ignition switch ON every time the ECU automatically drives the subthrottle valve from fully closed position to fully opened position The ECU memorizes these positions and turns back the subthrottle valve to the original point to confirm the subthrottle valve idling voltage dA Ee SEND Al ol WENN OA S I5 VW A bd 2v CAS SS GEI 68B06115BN2 C A Subthrottle Valves E ECU Electric Control Unit B Subthrottle Valve Actuator F Air Cleaner Side C Subthrottle Sensor G Crankshaft Sensor D Main Throttle Sensor H Speed Sensor 1 12 GENERAL INFORMATION Technical Information New Ignition Interlock Sidestand Outline The New Ignition Interlock Sidestand System applied to ZR750 J1 models that cannot function if gears are engaged and or the sidestand is not lif
190. e Disconnect the water temperature sensor connector A e Remove the water temperature sensor B see Fuel Sys tem DFI chapter GPi8003BS2 C 16 76 ELECTRICAL SYSTEM Switches and Sensors e Suspend the sensor A in a container of coolant so that the temperature sensing projection E and threaded por tion E are submerged e Suspend an accurate thermometer B in the coolant NOTE OThe sensor and thermometer must not touch the con tainer 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 Electronic Control Unit 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 C Resistance kQ Terminal 1 3 0 155 2 46 0 143 0 32 0 011 0 1426 0 0041 Temperature 20 C 68 F 80 C 176 F 110 C 230 F Resistance for Water Temperature Gauge D Resistance Q Terminal 2 Body 50 C 122 F 210 40 120 C 248 F 21 2 1 5 Temperature Speed Sensor Inspection e Disconnect Speed Sen
191. e Remove the mounting bolts E and take off the camshaft chain tensioner Camshaft Chain Tensioner Installation e Release the stopper A and push the push rod B into the tensioner body C e Install the tensioner body so that the stopper faces up ward e Tighten the tensioner mounting bolts A Torque Camshaft Chain Tensioner Mounting Bolts 11 N m 1 1 kgf m 95 in Ib e Install the rod spring and washer e Tighten the cap bolt B Torque Camshaft Chain Tensioner Cap Bolt 28 2 9 kgf m 21 16 e Turn the crankshaft 2 turns clockwise to allow the ten sioner to expand and recheck the camshaft chain timing Camshaft Camshaft Chain ENGINE TOP END 5 15 Camshaft Removal e Remove Cylinder Head Cover see Cylinder Head Cover Re moval Pickup Coil Cover e Position the crankshaft at 1 4 piston 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 Chain Guide Camshaft Caps B Camshafts C e Stuff a clean cloth into the chain tunnel to keep any parts from dropping into the crankcase CAUTION The crankshaft may be turned while the 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 could damage both the chain and the sprocket Camshaft
192. e Split the crankcase see Crankcase Splitting e Remove the connecting rod nuts A e Remove the 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 connecting rods from the crankshaft 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 or no mark 8105060181 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 9 14 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods e Apply molybdenum disulfide grease A to the outer sur face of the upper insert and the inner surface of the con necting rod big end e Apply molybdenum disulfide oil B to the inner surfaces of upper and lower bearing inserts OThe molybdenum disulfide oil is a mixture of engine oil and molybdenum disulfide grease with a weight ratio 10 1 ODo not apply any grease or oil C to
193. e cable should move freely A within the cable housing lf cable movement is not free after lubricating if the cable is frayed B or if the cable housing is kinked C replace the cable 6904040381 6604011481 6 6904020281 6 2 42 PERIODIC MAINTENANCE Periodic Maintenance Procedures Nut Bolt and Fastener Tightness 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 there are loose fasteners retighten 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 in this section For each fastener first loosen it by 1 2 turn then tighten it lf cotter pins are damaged replace them with new ones Nut Bolt and Fastener to be checked Wheels Front Axle Front Axle Clamp Bolt Rear Axle Nut Rear Axle Nut Cotter Pin Brakes Front Master Cylinder Clamp Bolts Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts Brake Lever Pivot Nut Brake Pedal Bolt Brake Rod Joint Cotter Pin Suspension Front Fork Clamp Bolts Front Fender Mounting Bolts Rear Shock Absorber Mounting Nuts Swingarm Pivot Shaft Nut S
194. e 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 pump outlet hose see Fuel Tank Installation e Run the hoses correctly see Cable Wire and Hose Rout ing section in Appendix chapter 3 86 FUEL SYSTEM DFI Fuel Injectors 35 36 13 parts Q so 49 p zl BL Y BL Y BL BK BL BK BL G BL G e rez PE BR Y R 2 6C17288BW3 A ECU Y Junction Box f Sealed Battery K Fuel Injectors Z Fuel Pump Relay for fuel j Joint Connector B N Engine Stop Switch pump an injectors k Main Fuse 30 A T Ignition Switch d Starter Relay X Ignition Fuse 10 A e Joint Connector C FUEL SYSTEM 3 87 Throttle Grip and Cables Throttle Grip Play Inspection Adjustment e Refer to the Throttle Control System Inspection in the Pe riodic Maintenance chapter Choke Lever Operation ODo not use the choke lever except when the engine has a starting difficulty like cold weather 10 C 50 F or below or at high altitude DFI system has an automatic choke system using a water temperature sensor and an atmospheric pressure sensor which provide startability NOTE OPull A the choke lever fully when using The choke doesn t work with the lever knob halfway OWhen f
195. e is replaced Do not reuse the air valve 6J05033BS1 C Tires WHEELS TIRES 10 13 e Install a new valve in the rim ORemove the valve cap lubricate the stem seal with a soap and water solution or rubber lubricant and pull B the valve stem A 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 e Apply a soap and water solution or rubber lubricant to the rim flange and tire beads 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 e Check the tire rotation mark on the front and rear tires and install them on the rim accordingly Tire Rotation Mark A Rotation 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 using a suitable commer cially 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 A WARNING Be sure to install the valve c
196. e light switch screw 1 0 0 10 9 in Ib Starter locknut switch screws L Left switch housing screws 0 36 31 Right switch housing screws i 0 36 31 in Ib 0 60 52 in lb 1 2 3 4 5 6 7 8 9 Tail brake lights LED 10 Vibration Resistance Bulb 11 Install the rear brake spring as shown Longer Side A L Apply a non permanent locking agent AU Australia CA Canada EUR European Community 16 6 ELECTRICAL SYSTEM Exploded View GP02132BN5 ELECTRICAL SYSTEM 16 7 Exploded View No Fastener Remarks N m kgf m ft Ib 1 Water temperature sensor 25 2 5 18 SS 2 Spark plugs 13 1 3 113 in Ib 3 Alternator lead holding plate bolt 11 1 1 95 in Ib L 4 Starter motor mounting bolts 11 1 1 95 in Ib 5 Stator coil bolts 11 1 1 95 in Ib 6 Alternator rotor bolt 110 11 81 7 Starter motor clutch bolts 12 1 2 104 L 8 Alternator cover bolts 11 1 1 95 9 Crankshaft sensor bolts 5 9 0 60 52 in lb 10 Crankshaft sensor cover bolts 11 1 1 95 in Ib 11 Timing rotor bolt 39 4 0 29 12 Camshaft position sensor bolt 12 1 2 104 in Ib L 13 Radiator fan switch 18 1 8 13 14 Starter relay cable terminal bolts 3 9 0 40 35 L 15 pressure switch terminal bolt 1 5 0 15 13 in lb G 16 Oil pressure switch 15 1 5 11 SS 17 Radiator fan 18 Crankshaft sensor 19 Camshaft position sensor 20 Start
197. e oil to the O ring on the camshaft position sensor e Apply a non permanent locking agent to the sensor bolt e Tighten Torque Camshaft Position Sensor Bolt 12 N m 1 2 kgf m 104 in Ib ELECTRICAL SYSTEM 16 41 Ignition System Camshaft Position Sensor Inspection e Remove Fuel Tank see Fuel System DFI chapter Camshaft Position Sensor Lead Connector A discon nect e Set the hand tester to the x 10 O range and connect it to the yellow and black leads in the connector Special Tool Hand Tester 57001 1394 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 Camshaft Position Sensor Resistance 400 460 e Using the highest resistance range of the tester mea sure the resistance between the camshaft position sensor leads and chassis ground x Any tester reading less than infinity gt indicates a short necessitating replacement of the camshaft position sen sor Camshaft Position Sensor Peak Voltage Inspection e Remove Fuel Tank see Fuel System DFI chapter Camshaft Position Sensor Lead Connector A discon nect e Set the hand tester B to the 10 V DC range e Connect the peak voltage adapter C to the hand tester and camshaft position sensor leads in the connector Special Tool Hand Tester 57001 1394 Recommended Tool Peak
198. e sensor 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 Main Throttle Sensor Output Voltage Connections to Adapter Meter W sensor BR lead Meter gt BK sensor BR BK lead Standard 0 48 0 52 V DC at idle throttle opening 3 6 3 8 V DC at full throttle opening the output voltage is out of the standard inspect the subthrottle sensor resistance lf the output voltage is normal check the wiring for conti nuity Wiring Connection ECU Connector A Subthrottle Sensor Connector B BR lead ECU terminal 3 BR BK lead ECU terminal 14 xIf the wiring is good check the ECU for its ground and power supply see ECU section 6017194852 C Subthrottle Sensor Service Code 32 FUEL SYSTEM DFI 3 63 Resistance 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 e Measure the subthrottle sensor resistance Throttle Sensor Resistance Connections BL lead C BR BK lead D Standard 4 6 x lf the reading is out of the range replace the throttle body assy the reading is within the range but the problem still exists replace the ECU see this chapter 6617116851 6
199. e the seats see Frame chapter e Remove the junction box A e Pull off the connectors A from the junction box B e Make sure all connector terminals are clean and tight and none of them have been bent Clean the dirty terminals and straighten slightly bent ter minals e Check conductivity of the numbered terminals with the hand tester ORefer to the Junction Box Internal Circuit x lf the tester does not read as specified replace the junc tion box Special Tool Hand Tester 57001 1394 Fuse Circuit Inspection Tester Tester Tester Tester Connection Reading Q Connection Reading Q 1 1A 1 2 4 6 5 6 10 6 7 6 17 Junction Box ELECTRICAL SYSTEM 16 81 Starter Circuit Headlight Relay Inspection e Remove the junction box see Junction Box Fuse Circuit Inspection e Check conductivity of the following numbered terminals by connecting the hand tester and one 12 V battery to the junction box as shown ORefer to the Junction Box Internal Circuit xIf the tester does not read as specified replace the junc tion box Special Tool Hand Tester 57001 1394 Relay Circuit Inspection with the battery disconnected Headlight Relay Tester Connection Tester Reading Q Starter Circuit Relay 12 11 The actual reading varies with the hand tester used Apply tester positive lead Apply tester negative l
200. e vacuum lower the pressure applied to the vacuum switch valve and check the valve opera tion When the vacuum is low the vacuum switch valve should permit air to flow When the vacuum raises to valve closing pressure it should stop air flow Spring A Diaphragm B Valve C Low Vacuum D Secondary Air Flow E x If the vacuum switch valve does not operate as described replace it with a new one NOTE OTo check air flow through the vacuum switch valve just blow through the air cleaner hose Vacuum Switch Valve Closing Pressure Open Close Standard 41 49 kPa 310 370 mmHg 6 0 7 1 psi High Vacuum A Secondary air cannot flow B 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 vacuum switch valve 1 and 4 carbu retor holders and air suction valve covers they are not correct them Replace them if they are damaged 8 04010451 6 8 04010651 6 5 12 ENGINE TOP END Cylinder Head Cover Cylinder Head Cover Removal e Remove Fuel Tank see Fuel System DFI chapter Vacuum Switch Valve and Hoses Stick Coils see Electrical System chapter Air Suction Valve Covers A e Remove the cylinder head cover bolts A and take off the cover O 95 S 16 a Gs Cylinder Head Cover Installation e Replace the head
201. ead Relay Circuit Inspection with the battery connected Battery Connection Tester Connection Tester Reading Q Headlight Relay Starter Circuit Relay 9 13 11 12 7 8 13 11 0 Not The actual reading varies with the hand tester used Apply tester positive lead Apply tester negative lead 16 82 ELECTRICAL SYSTEM Junction Box Diode Circuit Inspection e Remove the junction box e Check conductivity of the following pairs of terminals Diode Circuit Inspection Tester 13 8 13 9 12 11 12 14 15 14 16 14 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 junction box must be replaced NOTE OThe actual meter reading varies with the meter used and the individual diodes but generally speaking the lower reading should be from zero to one half the scale Junction Box Internal Circuit A Accessory Fuse 10A E Ignition Fuse 10 A B Fan Fuse 15 A F Headlight Fuse 10 A C Turn Signal Relay Fuse G Headlight Relay 10A H Headlight Diodes D Horn Fuse 10 A Starter Diode GP19060182 C J Starter Circuit Relay K Interlock Diodes L Taillight Fuse 10 A Fuse ELECTRICAL SYSTEM 16 83 30 A Main F
202. eading is less than the standard range remove the ECU and check the wiring between these connectors the wiring is good check the ECU for its ground and power supply see ECU section 3 44 FUEL SYSTEM DFI Inlet Air Pressure Sensor Service Code 12 Output Voltage Inspection NOTE OThe output voltage changes according to the local at mospheric pressure e Measure the output voltage at the ECU in the same way as input voltage inspection Note the following Inlet Air Pressure Sensor Output Voltage Connections to ECU Meter Y BL lead terminal 17 Meter BR BK lead terminal 14 Usable Range 3 74 4 26 V DC at the standard atmospheric pressure 101 32 kPa 76 cmHg abs e Turn the ignition switch OFF lf the output voltage is within the usable range check the ECU for its ground and power supply see this chapter the output voltage is out of the usable range remove the fuel tank and check the wiring If the output voltage is 4 8 V the ECU is normal If the wiring is good check the sensor for various vacuum the output voltage for various vacuum is normal check the ECU for its ground and power supply see ECU sec tion e Remove the inlet air pressure sensor A and disconnect the vacuum hose from the sensor ODo not disconnect the sensor connector e Connect an auxiliary hose B to the inlet air pressure sen sor e Temporarily install the inlet air pressure sensor
203. eal Driver 57001 1288 Fork Oil Level Gauge 57001 1290 Hook Wrench 57001 1539 875715395 C Swingarm pivot Nut Wrench 57001 1541 875715415 C 13 8 SUSPENSION Front Fork Front Fork Removal e Remove Front Wheel see Tires Wheels chapter Front Fender see Frame chapter Fairing see Frame chapter Loosen the handlebar bolt upper fork clamp bolt and fork top plug before hand if the fork leg is to be disassembled NOTE OLoosen the top plug after loosening the upper fork clamp bolt e Loosen the upper fork clamp bolt and lower fork clamp bolts A e With a twisting motion work the fork leg down and out Front Fork Installation e Install the fork with the upper end of the inner tube flush A against the top surface of the stem head B e Tighten Torque Front Fork Clamp Bolts Lower 20 2 0 kgf m 14 ft lb Front Fork Top Plug 25 N m 2 5 kgf m 18 ft lb NOTE 6M04040781 OTighten the top plug before tightening the upper fork clamp bolt OTighten the two clamp bolts alternately two times to en sure even tightening torque e Tighten Torque Front Fork Clamp Bolt Upper 20 N m 2 0 kgf m 14 ft lb e Install the removed parts see appropriate chapters Front Fork Oil Change gt e Remove the front fork see Front Fork Removal c e Remove B Top Plug A Collar B Fork Spring Seat C D E M Fork Spring
204. eal surfaces are flush with the housing end C as shown e Apply grease to the sliding surfaces A on the footpeg holder B e Apply a non permanent locking agent to the shift pedal mounting bolt C e Tighten Torque Shift Pedal Mounting Bolt 34 N m 3 5 kgf m 25 ft Ib Footpeg Bracket D Shift Pedal E Oil Seals F 6113130851 6 9 24 CRANKSHAFT TRANSMISSION Transmission e Install the footpeg bracket A e Tighten Torque Footpeg Bracket Bolts B 34 N m 3 5 kgf m 25 ft Ib e Install the shift lever A aligning the mark previously marked e Tighten Torque Shift Lever Bolt 6 9 N m 0 70 kgf m 61 in Ib e Install the shift pedal B as shown About 90 C OTo adjust the pedal position loosen the front locknut D left hand threads and rear locknut E and then turn the tie rod F e Tighten Torque Locknuts 6 9 0 70 kgf m 61 in Ib External Shift Mechanism Removal e Remove Engine Oil drain see Engine Lubrication System chap ter Shift Pedal see Shift Pedal Removal Clutch see Clutch chapter Oil Pipe Holder Bolts A Oil Pipe Holders B Oil Pipe C and O rings e Remove the shift shaft assembly A while pulling the shift mechanism arm B to the direction of the arrow CRANKSHAFT TRANSMISSION 9 25 Transmission e Remove Gear Positioning Lever Bolt A Gear Positioning Lever B Collar and Spring External
205. ec tion e Rotate the rear wheel to find the position where the chain is tightest e Measure the vertical movement chain slack A midway between the sprockets xIf the chain slack exceeds the standard adjust it Chain Slack Standard 25 35 mm 1 0 1 4 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 xIf the chain is too loose turn out the left and right chain adjuster D evenly the chain is too tight turn in the left and right 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 left wheel alignment indicator F should align with the same swingarm mark or position G that the right 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 108 N m 11 kgf m 80 ft Ib e Turn the wheel measure the chain slack again at the tight est position and readjust if necessary 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 wit
206. eck the bypass screw and its hole for carbon deposits x If any carbon accumulates wipe the carbon off the bypass screw and the hole using a cotton pad penetrated with a high flash point solvent bopoodU wv OReplace the O ring with a new one LID II 0 OCheck the tapered portion E of the bypass screw for Q wear or damage If the bypass screw is worn or damaged replace it e Turn in the bypass screw until it seats fully but not tightly Torque Bypass Screw 0 2 N m 0 02 kgf m 1 7 in lb 6505015851 6 2 18 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Back out the same number of turns counted when first turned in This is to set the screw to its original position NOTE OA throttle body has different turns out of the bypass screw for each individual unit When setting the bypass screw use the turns out determined during disassem bly Use the specifications in this manual only if the orig inal number is unknown e Repeat the same procedure for other bypass screws e Repeat the synchronization x lf the vacuums are correct check the output voltage of the main throttle sensor see Output Voltage Inspection of Main Throttle Sensor in the Fuel System DFI chapter Main Throttle Sensor Output Voltage Connections to ECU Meter Y W lead terminal 2 Meter gt BR BK lead terminal 14 Standard 0 99 1 03 V DC at idle throttle opening lf the output voltage
207. eck the speed sen sor electric source voltage and speed sensor The electric source voltage and speed sensor are normal replace the meter assembly Speed Sensor Electric Source Check e Connect the 12 V battery and terminals in the same man ner as specified in the Liquid Crystal Display LCD Seg ments Check e Set the hand tester to the DC 25 V range and connect it to the terminals 12 and 9 x lf the voltage is less than 8 V replace the meter assembly Odometer Check e Check the odometer with the speedometer in the same value indicated in the odometer is not added replace the meter assembly NOTE OThe data is maintained even if the battery is discon nected OWhen the figures come to 999999 they are stopped and locked Trip Meter Check e Check the trip meter with the speedometer in the same lf value indicated in the trip meter is not added replace the meter assembly e Check that when the RESET button is pushed for more than two seconds the figure display turns to 0 0 x lf the figure display does not indicate 0 0 replace the me ter assembly GP17046BS1 C 8155 j 8151 GP17122BS1 C 253 j 20 GP17123BS1 C ELECTRICAL SYSTEM 16 69 Meter Gauge Indicator Unit Water Temperature Meter Check e Connect the 12 V battery and terminals in the same man ner as specified in the Liquid Crystal Display LCD Seg ments
208. ection OFit the coils securely CAUTION Do not tap the coil head while installing the coil OBe sure the stick coils are installed by pulling up A it lightly e Connect the connectors e Install Thermostat Bracket Bolt see Cooling System chapter Fuel Tank see Fuel System DFI chapter 2272 SS 0 59999 Nr N SOON 6517005851 C GP10120BS1 C PERIODIC MAINTENANCE 2 41 Periodic Maintenance Procedures General Lubrication 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 Motor Oil Rear Brake Rod Joint Points Lubricate with Grease Throttle and Choke Inner Cable Upper Ends A Clutch Lever Pivot Brake Lever Pivot Apply silicone grease Brake Pedal Pivot Side Stand Cables Lubricate with Cable Lubricant Choke Cable Throttle Cables Clutch Cable 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 th
209. ection for detail in this chapter e Use a fully charged battery and a digital meter D which can be read two decimal places voltage or resistance Resistance Check Method OThis method is simple No need for a fully charged battery and the needle adapter Just do the following especially when a sensor A is suspect e Turn the ignition SW OFF and disconnect the connectors e Inspect the sensor resistance using a digital meter see each sensor inspection in this chapter e Inspect the wiring and connectors B for continuity using the hand tester C analog tester rather than a digital meter Special Tool Hand Tester 57001 1394 the sensor the wiring and connections are good in spect the ECU for its ground and power supply see this chapter If the ground and power supply are good the ECU is suspect Replace the ECU 6017134852 C 8017135 52 C FUEL SYSTEM DFI 3 21 Troubleshooting the DFI System DFI Diagnosis Flow Chart Problem occurs General fuel system throttle assy air cleaner fuel tank etc Confirm problems Gather information from rider Does Fl indicator LED light go on NO unlit YES goes on Conduct self diagnosis inspection Conduct non self diagnosis inspection Conduct general fuel system inspection 00171658 5 Inquiries to
210. eed crankshaft sensor output voltage This method is called D J method low speed mode As the engine speed increases and the engine load turns middle to heavy the ECU determines the injection quantity by calculating from the throttle opening throttle sensor output voltage and the engine speed This method is called a method high speed mode This depends on the number of stopped cylinders 3 40 FUEL SYSTEM DFI Main Throttle Sensor Service Code 11 Main Throttle Sensor Removal Adjustment CAUTION Do not remove or adjust the main throttle sensor A since it has been adjusted and set with precision at the factory Never drop the sensor especially on a hard surface Such a shock to the sensor can damage it Main Throttle Sensor Connector gray B Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Disconnect the main throttle sensor gray A and con nect the harness adapter B between these connectors e Connect a digital meter to the harness adapter lead Special Tool Throttle Sensor Harness Adapter 57001 1538 e Measure the sensor input voltage with the engine stopped and with the connector joined e Turn the ignition switch ON Main Throttle Sensor Input Voltage Connections to Adapter Meter R sensor BL lead Meter gt BK sensor BR BK lead Standard 4 75 5 25 V DC e Turn the ignition switch OFF the input
211. eel e Remove the wheel and support it without the tire by the axle e Measure the rim runout radial A and axial B with a dial gauge If rim runout exceeds the service limit check the hub bear ings the problem is not due to the bearings replace the wheel Rim Runout Service Limit Axial TIR 0 5 mm 0 020 in Radial 0 8 mm 0 031 in A 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 6512013851 6 6J04026BS2 C 10 10 WHEELS TIRES Wheels Rims Axle Inspection e Remove the front and rear axles e Visually inspect the front and rear axle for damages lf 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 axle runout exceeds the service limit replace the axle Axle Runout 100 mm 3 94 in Standard TIR 0 05 mm 0 0020 in or less Service Limit TIR 0 2 mm 0 008 in Balance Inspection e Remove the wheel 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 I
212. eeve B needle bearing C and clutch housing D e Remove the spacer Clutch Installation e Install the following parts on the drive shaft Spacer A Needle Bearing B Sleeve C Clutch Housing D Spacer E Clutch Hub F Washer G Nut H GFO6050BS2 C CLUTCH 6 11 Clutch Olnstall the spacer A so that the tapered side B faces inward Olnstall the washer A so that the OUTSIDE mark faces outward OReplace the clutch hub nut with a new one OHolding the clutch hub tighten the clutch hub nut Special Tool Clutch Holder 57001 1243 Torque Clutch Hub Nut 135 N m 14 kgf m 100 ft Ib e Install the spring seat A and spring B as shown Clutch Hub C e Install the friction plates and steel plates starting with a friction plate and alternating them 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 the last friction plate A fitting the tangs in the grooves in the housing as shown GFO00401 1 6 12 CLUTCH Clutch e Apply molybdenum disulfide grease to the pusher ends A and install the bearing B pusher C spring D and washer E in the clutch spring plate F OApply engine oil to the needle bearing e Install the clutch spring plate springs and spring holders and tighten the clutch spring bolts Torque Clu
213. el Pump Screen Return Fuel Check Valve Pressure Regulator Fuel Filter FUEL SYSTEM DEI 3 9 DFI Parts Location 1 2 10 13 22 and 24 are not included 3 10 FUEL SYSTEM DFI DEI Wiring Diagram m S Wy peek aay HS a 252825 GC O9 WR we wy BR BK BL BR BR BK DI BR BK BL BL W BR BK 5 v BL BR BK BL BK Y BK Y R R BK R BK R BK G BK W R DO BK Y Y Y R BR W Y E Y BK BK BR W R R BK R BK Y SN BK Y BK Y a a 6 e BATTERY _ BR W 18 p E BR BR W Y R R G BK R 6C17256BN5 C FUEL SYSTEM DFI 3 11 DFI Wiring Diagram Terminal Names Power Supply to Sensors Main Throttle Sensor Signal Subthrottle Sensor Signal Atmospheric Pressure Sensor Signal Water Temperature Sensor Signal Unused Ignition Switch Signal Unused Camshaft Position Sensor Signal Unused Crankshaft Sensor Signal Unused Power Supply to ECU Injectors and Fuel Pump Ground to sensors Unused Vehicle down Sensor Signal Inlet Air Pressure Sensor Signal Inlet Air Temperature Sensor Signal Unused Speed
214. en the fasteners following the speci 12 44 61 45 62 33 45 fied sequence S Si Apply silicone grease grease 4 Wl ege SS Apply silicone sealant 16 115 155 11 5 16 0 83 115 18 165 225 17 0 23 0 125 165 20 225 325 23 33 165 240 pe Fe o Pals Fuel System Inlet air pressure sensor bolt 12 1 2 104 in lb Water temperature sensor 25 2 5 18 Vehicle down sensor bolts 2 0 0 20 17 Camshaft position sensor bolt 12 1 2 104 in Ib Camshaft position sensor rotor bolt 12 1 2 104 in Ib L Throttle cable plate bolt 6 0 0 60 52 in lb Throttle body assy holder clamp bolts 2 0 0 20 17 in lb Choke link holder screws 2 1 0 21 18 in Ib Delivery pipe screws 3 4 0 35 30 in Ib Bypass screws 0 2 0 02 1 7 mb Air cleaner duct holder screws 3 8 0 39 34 Air cleaner housing mounting bolts 9 8 1 0 87 Air cleaner duct clamp bolts 2 0 0 20 17 in lb Air cleaner housing screws 1 2 0 12 10 in Ib Air cleaner housing tapping screws 1 2 0 12 10 in Ib Speed sensor bolt 6 9 0 70 62 in Ib L Fuel pump bolts 9 8 1 0 87 in lb L S Fuel level sensor bolts 6 9 0 70 62 in Ib Cooling System Radiator hose clamp screws 2 0 0 20 17 in lb Radiator fan bolts 8 3 0 85 74 in lb Water pump impeller bolt 9 8 1 0 87 in lb Water pump cover bolts 11 1 1 95 in lb 2 6 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Torque Remarks N m kgf m ft Ib Water pump drain bolt 11 1 1 9
215. engine keeps running Stick Coil The stick coil primary If the ignition primary winding 2 has failures no 52 42 Ignition winding must send signal wiring short or open the ECU shuts off Coi signals output voltage the injector 2 to stop fuel to the cylinder 2 continuously to the ECU though the engine keeps running Stick Coil The stick coil primary If the ignition primary winding 3 has failures no 53 3 Ignition winding must send signal wiring short or open the ECU shuts off Coi signals output voltage the injector 3 to stop fuel to the cylinder 3 continuously to the ECU though the engine keeps running Stick Coil The stick coil primary If the ignition primary winding 4 has failures no 54 4 Ignition winding must send signal wiring short or open the ECU shuts off Coil signals output voltage the injector 4 to stop fuel to the cylinder 4 continuously to the ECU though the engine keeps running The actuator operates Subthrottle and close of the If the subthrottle valve actuator fails the signal is 62 Valve subthrottle valve by the out of the usable range wiring short or open the Actuator pulse signal from the ECU stops the current to the actuator ECU Note 1 D J Method and a N Method When the engine load is light like at idling or low speed the ECU determines the injection quantity by calculating from the throttle vacuum inlet air pressure sensor output voltage and engine sp
216. ensor bolts 5 9 0 60 52 in lb Camshaft position sensor bolt 12 1 2 104 in Ib L Timing rotor bolt 39 4 0 29 Starter motor mounting bolts 11 1 1 95 in lb Switch housing screws 3 5 0 36 31 in Ib Radiator fan switch 18 1 8 13 Water temperature sensor 25 2 5 18 SS Oil pressure switch 15 1 5 11 SS Oil pressure switch terminal bolt 1 5 0 15 13 in lb G Neutral switch 15 1 5 11 Speed sensor bolt 6 9 0 70 61 in Ib Fuel level sensor bolts 6 9 0 70 61 in Ib Front brake light switch screw 1 0 0 10 9 in Ib Meter mounting screws 1 2 0 12 10 in Ib Tail brake light mounting screws 1 2 0 12 10 in Ib License plate light mounting screws 1 2 0 12 10 in Ib Headlight mounting bolts 5 9 0 60 52 in lb Starter lockout switch screws L Starter motor clutch bolts 12 1 2 104 in Ib L Starter relay cable terminal bolts 3 9 0 40 35 L Regulator rectifier bolts 6 9 0 70 61 in lb Regulator rectifier bracket bolts 6 9 0 70 61 in Ib Speed sensor cover bolts 6 9 0 70 61 in Ib L Side stand switch bolt 8 8 0 90 78 in Ib 2 10 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Fuel System Throttle grip free play 2 3 mm 0 08 0 12 in Idle speed 1 100 50 r min rpm Bypass screws turn out 2 1 4 for reference Engine vacuum 29 7 1 333 kPa 225 10 mmHg Air cleaner element Paper filter Cooling System Coolant Type recommended Permanent type of antifreeze
217. er B between these connectors e Connect a digital meter to the harness adapter lead Special Tool Throttle Sensor Harness Adapter 57001 1538 e Measure the sensor input voltage with the engine stopped and with the connector joined e Turn the ignition switch ON Subthrottle Sensor Input Voltage Connections to Adapter Meter sensor BL lead Meter gt BK sensor BR BK lead Standard 4 75 5 25 V DC e Turn the ignition switch OFF the input voltage is normal check the sensor output voltage xIf the input voltage is less than the standard remove the ECU and check the wiring between these connectors ODisconnect the ECU and sensor connectors Wiring Connection ECU Connector A Subthrottle Sensor Connector B BL lead ECU terminal 1 BR BK lead ECU terminal 14 the wiring is good check the ECU for its ground and power supply see ECU section GCi7193BS2 C 3 62 FUEL SYSTEM Subthrottle Sensor Service Code 32 Output Voltage Inspection e Remove the throttle body assy see Throttle Body Assy Removal e Measure the output voltage at the subthrottle sensor in the same way as input voltage inspection Note the fol lowing e Disconnect the subthrottle sensor black A and black connect the harness adapter B between these connec tors Special Tool Throttle Sensor Harness Adapter 57001 1538 e Measure the output voltage of th
218. er Replacement iere e eet dee EA 7 8 lel ium 7 9 Oll Pan RemoVval naciones eti bete eene 7 9 Installation ino ee ee A RR 7 9 Oil Pressure Relief Valve 7 10 Oil Pressure Relief Valve Removal emere 7 10 Oil Pressure Relief Valve Installation mme 7 10 Oil Pressure Relief Valve Inspechon mme 7 10 SINE 7 11 IR Eilen EI 7 11 Oil Pump Installation nnn 7 11 Oil Pump Drive Gear Removal mene enm ener nennen nnne 7 12 Oil Pump Drive Gear Installation Ime 7 12 Oil Pressure Measurement 7 13 Oil Pressure Measurement nenne sense nnns 7 13 Pressure SWIELCh s i eod t baia 7 14 Oil Pressure Switch Removal enm nnne nnne nnn 7 14 Oil Pressure Switch Installation 7 14 7 2 ENGINE LUBRICATION SYSTEM Exploded View Exploded View ENGINE LUBRICATION SYSTEM 7 3 Torque No Fastener kgf m ftlb Remarks 1 Oil filler plug 1 5 0 15 13 in Ib 2 Engine oil drain bolt 20 2 0 14 3 Oil filter 31 3 2 23 EO R 4 Holder mounting bolt 76 7 8 56 EO 5 pan bolts 11 1 1 95 6 pipe holder bolts 13 1 3 113 in Ib L 7 Oil pressure relief valve 15 1 5 11 L 8 Oil pressure switch 15 1 5 11 SS 9 pressure switch terminal bolt 1 5 0 15 13 in lb G 10 Water pump cover bolts 11 1 1 95 11 Water pump impeller b
219. er cable Run the starter cable through under the throttle cable Run the clutch cable between the water hose and the main harness Throttle cable decelerator Throttle cable accelerator No slip of cable Frame 10 15 mm 0 39 0 59 in Frame outside Back view 17 6 APPENDIX Cable Wire and Hose Routing 9 DA QAO 2 OW 22353 A Y B SS A A et x Td A ks M NC SZ A WV lt ZX Zan A Z d e to M IC Ze S gg MP 7 ESTA e 68B09389BN5 C APPENDIX 17 7 Cable Wire and Hose Routing P Run the main harness through lower and right side of the thermostat Frame ground with thermostat bracket Ignition switch connector Meter ground Engine harness Water temperature sensor Inlet air pressure sensor Clamp To pickup coil and oil pressure switch To fuel level gauge and fuel reserve switch To fuel pump Regulator rectifier Run the lead through the inside of the pipe Speed sensor To side stand switch Neutral switch To alternator To ignition coil Horn Cam sensor Fan switch Run the harness between the engine bracket and the left side space of the heat cover Starter cable Band Run the cam sensor lead through the inside of the horn lead 17
220. er relay main fuse 21 Stick coils 22 Ignition switch G Apply grease L Apply a non permanent locking agent M Apply molybdenum disulfide grease SS Apply silicone sealant 16 8 ELECTRICAL SYSTEM Exploded View Le 0 DZ ae 2 2 M C 22 gt E SO gt VW x d Ge DNF 2 Gs 27 SO amp Go RE ELECTRICAL SYSTEM 16 9 Exploded View No Fastener Torque Remarks N m kgf m ft Ib 1 Regulator rectifier bolts 6 9 0 70 61 2 Fuel level sensor bolts 6 9 0 70 61 3 Side stand switch bolt 8 8 0 90 78 in Ib L 4 Neutral switch 15 1 5 11 5 Speed sensor bolt 6 9 0 70 61 in Ib L 6 Speed sensor cover bolts 6 9 0 70 61 in lb L 7 Regulator rectifier bracket bolts 6 9 0 70 61 in Ib 8 Engine ground cable terminal bolt 9 8 1 0 87 9 Turn signal relay 10 Junction box 11 12 13 14 15 16 17 Apply a non permanent locking agent ECU Electrical Unit Control 15 A ECU fuse Fuel reserve switch Diode Rectifier Speed sensor Regulator rectifier Battery 12 V 8 Ah 16 10 ELECTRICAL SYSTEM Specifications Item Standard Battery Type Capacity Voltage Charging System Type Alternator output voltage Stator coil resistance Charging voltage regulator rectifier output voltage Ignition System Crankshaft sensor resistance Crankshaft
221. es 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 Install the cylinder see Cylinder Installation Cylinder Wear e Since there is a difference in cylinder wear in different di rections take a side to side and a front to back measure ment at each of the two locations total of four measure ments shown in the figure xIf any of the cylinder inside diameter measurements ex ceeds the service limit replace the cylinder 10 mm 0 39 in A 60 mm 2 36 in B Cylinder Inside Diameter Standard 68 400 68 412 mm 2 6929 2 6934 in Service Limit 68 50 mm 2 6969 in Piston Wear e Measure the outside diameter A of each piston 5 mm 0 20 in B up from the bottom of the piston at a right angle to the direction of the piston pin If the measurement is under service limit replace the pis ton Piston Diameter Standard 68 345 68 360 mm 2 6907 2 6913 in Service Limit 68 21 mm 2 6854 in GE16062BS1 C GE16063BS1 C GE16064BS1 C Cylinder Pistons ENGINE TOP END 5 31 Piston Ring Piston Ring Groove We
222. es will make them slippery and can cause an accident and injury Since coolant is harmful to the human body do not use for drinking e Place a container under the water pump drain bolt A then remove the drain bolt e Remove the fuel tank see Fuel System DEI chapter e Remove the radiator cap A in two steps First turn the cap counterclockwise to the first stop Then push and turn it further in the same direction and remove the cap OThe coolant will drain from the radiator and engine e Remove Left Side Cover see Frame chapter Reserve Tank Screws A e Turn over B the reserve tank remove the cap C and pour the coolant into a suitable container e Install the reserve tank Torque Coolant Reserve Tank Screws 7 0 N m 0 70 kgf m 61 in Ib e Tighten the drain bolt with the gasket OReplace the drain bolt gasket with a new one Torque Water Pump Drain Bolt 11 N m 1 1 kgf m 95 in Ib PERIODIC MAINTENANCE 2 21 Periodic Maintenance Procedures e When filling the coolant choose a suitable mixture ratio by referring to the coolant manufacturer s directions CAUTION Soft or distilled water must be used with the an tifreeze in the cooling system If hard water is used in the system it causes scale accumulation in the water passages and consider ably reduces the efficiency of the cooling system Water and Coolant Mixture Ratio when shipping Soft Water
223. est again turn the ignition switch OFF and then ON e Turn the ignition switch OFF e Remove the needle adapter set and apply silicone sealant to the seals of the connector for waterproofing Silicone Sealant Kawasaki Bond 56019 120 Seals of Vehicle down Sensor Connector the output voltage is normal the wiring is suspect Check the wiring xIf the wiring is good check the ECU for its ground and power supply see ECU section the output voltage is out of the specified replace the vehicle down sensor 6GCi7126BS2 C 3 60 FUEL SYSTEM Vehicle down Sensor Service Code 31 BATTERY Goo 1 op Ld 2 Y S ve 6017263882 A ECU a ECU Fuse 15 A f Sealed Battery S ECU Main Relay b Vehicle down Sensor j Joint Connector B T Ignition Switch d Starter Relay k Main Fuse 30 Subthrottle Sensor Service Code 32 FUEL SYSTEM DFI 3 61 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 sensor especially on a hard surface Such a shock to the sensor can damage it Subthrottle Sensor Connector black B Input Voltage Inspection NOTE sure the battery is fully charged e Turn the ignition switch OFF e Disconnect the subthrottle sensor black A and connect the harness adapt
224. eter BK BL sensor BK lead D Standard About 0 05 0 07 V DC NOTE Olf you rotate the engine sprocket the output voltage will be increased 80617144851 6 x If the reading is out of the range check the speed sensor operation see Electrical System chapter and the wiring to ECU see wiring diagram in this section the reading speed sensor operation and wiring are good check the ECU for its ground and power supply see ECU section ei A ECU H Speed Sensor W Speedometer Unit 80617172841 3 58 FUEL SYSTEM DFI Vehicle down Sensor Service Code 31 Removal CAUTION Never drop the down sensor especially on a hard surface Such a shock to the sensor can damage it e Remove Connection and Vehicle down Sensor A Bolts B Installation e The UP mark A of the sensor should face upward Torque Vehicle down Sensor Bolts 2 0 0 20 kgf m 17 1 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 down sensor is held in place by the sensor brackets Inspection NOTE OBe sure the battery is fully charged e Connect a digital volt meter A to the connector of the vehicle down sensor B with the need
225. f the wheel stops of its own accord in various positions it is well balanced x lf the wheel always stops in one position adjust the wheel balance Balance Adjustment e f the wheel always stops in 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 lf 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 standard screwdrivers A B between the rib C and the weight D as shown e Pry the weight with two screwdrivers and remove the bal ance weight 6J04043BS1 C 6J04076BS1 C 6J04077BS1 6J04073BS1 C Wheels Rims WHEELS TIRES 10 11 CAUTION When removing the balance weight do not touch the brake disc The disc could be damaged Do not tap the screwdrivers The rim could be dam aged
226. for braking action Air however is easily compressed When air enters the brake lines brake lever or pedal movement will be partially used in compressing the air This will make the lever or pedal feel spongy and there will be a loss in braking power WARNING Be sure to bleed the air from the brake line when ever brake lever or 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 the reservoir cap and diaphragm e Fill the reservoir with fresh brake fluid to the upper level line in the reservoir e With the reservoir cap off 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 reser voir OBleed the air completely from the master cylinder by this operation e Remove the rubber cap from the bleed valve on the caliper e Attach a clear plastic hose to the bleed valve and run the other end of the hose into a container PERIODIC MAINTENANCE 2 35 Periodic Maintenance Procedures 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 c
227. fuel in tank Supply fuel see Owner s Manual Fuel pump not rotating Inspect see chapter 3 Fuel injector trouble Inspect and replace see chapter 3 Fuel tank air vent obstructed Inspect and repair see chapter 3 Fuel filter or pump screen clogged Inspect and replace fuel pump see chapter 3 Fuel pressure regulator clogged Inspect and replace fuel pump see chapter 3 Fuel line clogged Engine flooded Spark plug dirty broken or gap maladjusted Inspect and repair see chapter 3 Clean spark plugs and adjust plug gap see chapter 2 FUEL SYSTEM DFI 3 25 DEI System Troubleshooting Guide Symptoms or possible Causes Actions chapter When flooded don t crank engine with throttle Starting technique faulty fully opened No spark or spark weak Ignition and engine stop switches not ON Turn both switches ON Clutch lever not pulled in and gear not in neutral whether sidestand up or not Pull the lever in and shift the gear in neutral Though clutch lever pulled in sidestand up and Sidestand down and clutch lever pulled in whether gear not in neutral gear in neutral or not Vehicle down sensor coming off Reinstall see chapter 3 Vehicle down sensor trouble Inspect see chapter 3 ECU ground or power supply trouble Inspect see chapter 3 Battery voltage low Inspect and charge see chapter 16 Spark plug di
228. function wiring open or short 25 mL First 24 is displayed and then 25 repeatedly 31 Vehicle down sensor malfunction wiring open short 32 Subthrottle sensor malfunction wiring open or short 51 Stick Ignition coil 1 malfunction wiring open or short 52 Stick Ignition coil 2 malfunction wiring open or short 53 Stick Ignition coil 3 malfunction wiring open or short 54 LH Ln Stick Ignition coil 4 malfunction wiring open or short 62 nnn Li Subthrottle valve actuator malfunction wiring open or short 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 DEI system has no fault and the mechanical parts of the DFI system and the engine are suspect 3 38 FUEL SYSTEM DFI Self Diagnosis Backups Backups OThe ECU takes the following measures to prevent engine damage when the DFI or the ignition system parts have troubles Service Output Signal Usable Codes VOLES Range or Criteria SSES If the main throttle sensor system fails the signal is out of the usable range wiring short or open the ECU locks ignition timing into the ignition Main Main Throttle Sensor timing at closed throttle position and sets the
229. g This is to prevent ECU Electrical Control Unit damage Do not install the battery backwards The negative side is grounded This is to prevent damage to the diodes and ECU Crankshaft Sensor Removal e Remove Right Frame Cover see Frame chapter Crankshaft Sensor Lead Connector A e Remove Rubber Boot slide out A Oil Pressure Switch Lead Terminal B Crankshaft Sensor Cover Bolts C with Clamps Crankshaft Sensor Cover D e Remove the crankshaft sensor A by taking off the crank shaft sensor bolts B 16 38 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Installation e Route the crankshaft sensor lead correctly see Cable Wire and Hose Routing in Appendix chapter e Tighten Torque Crankshaft Sensor Bolts 5 9 N m 0 60 kgf m 52 in Ib e Apply silicone sealant A to the crankshaft sensor lead grommet and crankcase halves mating surface on the front and rear sides of the crankshaft sensor cover mount Sealant Kawasaki Bond Silicone Sealant 56019 120 e Install the clamps A direction as shown e Tighten Torque Crankshaft Sensor Cover Bolts 11 Nm 1 1 kgf m 95 in Ib e Hold the sensor lead A with the clamp B Upper Crankcase C e Install oil pressure switch lead terminal A securely Olnstall the lead terminal direction upward Torque Pressure Switch Terminal Bolt 1 5 0 15 kgf m 13 in Ib e Install the removed pa
230. g from 2nd to 4th of stem nut D and bend the 2 claws downward E e Tighten Torque Steering Stem Head Bolt 108 N m 11 kgf m 80 ft Ib Front Fork Clamp Bolts Upper 20 N m 2 0 kgf m 14 ft Ib e Check the steering again x lf the steering is still too tight or too loose repeat the ad justment Steering Stem Bearing Lubrication e Remove the steering stem see 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 and adjust the steering 6515011851 C 88050680251 C PERIODIC MAINTENANCE 2 39 Periodic Maintenance Procedures Electrical System Spark Plug Inspection e Remove Fuel Tank see Fuel System DFI chapter e Unscrew the thermostat bracket bolt A e Disconnect Water Temperature Sensor Connector B Left Switch Housing Connector C Olf removing the spark plug 2 or 3 e Disconnect Stick Coil Connectors A Pull out the stick coil 1 B e Take out the camshaft position sensor connector C from the bracke
231. g inside diameter and mark the 85 4 3 2 1 upper crankcase half in accordance with the inside diam eter Crankcase Main Bearing Inside Diameter Marks 5 or no mark e Tighten the crankcase bolts to the specified torque see Crankcase Assembly NOTE OThe mark already on the upper crankcase half should almost coincide with the measurement 6105011581 6 Crankcase Main Bearing Inside Diameter Marks Q 36 000 36 008 mm 1 4173 1 4176 in None 36 009 36 016 mm 1 4177 1 4179 e Select the proper bearing insert A in accordance with the combination of the crankcase and crankshaft coding Size Color B 6105041781 Crankcase Main Crankshaft Main Bearing Inside Journal Diameter Diameter Marking Marking Size Color Part Number Journal Nos 92028 1868 3 5 B O ARN 92028 1829 1 2 4 None 1 Black 92028 1867 3 5 O None 92028 1828 1 2 4 92028 1866 35 N N BI d 92028 1827 1 2 4 The bearing inserts for Nos 1 2 and 4 journals have an oil groove respectively Bearing Insert e Install the new inserts in the crankcase halves and check insert journal clearance with the plastigage 9 22 CRANKSHAFT TRANSMISSION Starter Motor Clutch Starter Motor Clutch Removal Installation e Refer to the Alternator Rotor Removal and Installation in the Electrical System chapter Starter Motor Clutch Inspection e Remove Alternator Cover see Electrical System chapter Sta
232. g of the oil seal CLUTCH 6 9 Clutch Cover e Fit the spring A as shown Viewed from Rear B Release Shaft C Clutch Cover D Clutch Cover Disassembly e Remove Oil Seal A Needle Bearings e Remove Circlip A Oil Level Gauge B Clutch Cover Assembly e Replace the needle bearings and oil seal with new ones NOTE Olnstall the needle bearings so that the manufacture s mark face out e Install the needle bearings A and oil seal B position as shown Press the bearing until the bottom C Press the bearing so that the bearing surface D is flush with the housing end of clutch cover E GF05018BSi 6 e Apply water to the rubber of the oil gauge A and press it so that the projections B face inside e Install a new circlip so that the circlip ends C do not warp over the projection D 8 05019851 6 6 10 CLUTCH Clutch Clutch Removal e Remove Engine Oil drain see Engine Lubrication System in the Periodic Maintenance chapter Clutch Cover see Clutch Cover Removal Clutch Spring Bolts A Clutch Springs Clutch Spring Plate B with thrust bearing and pusher C spring and washer e Remove Friction Plates Steel Plates Spring Spring Seat Clutch Hub Nut A OHolding the clutch hub B remove the nut and washer Special Tool Clutch Holder C 57001 1243 e Remove Clutch Hub Spacer e Using the two 4 mm 0 16 in screws A pull out the sl
233. gf m 18 16 e Bleed the brake line see Brakes in the Periodic Mainte nance chapter e Check the brake for good braking power no brake drag and no fluid leakage Front Master Cylinder Disassembly e Remove the front master cylinder see Front Master Cylin der Removal e Remove the reservoir cap and diaphragm and pour the brake fluid into a container e Unscrew the locknut and pivot bolt and remove the brake lever e Pull the dust cover A out of place and remove the circlip B e Pull outthe piston C secondary cup D primary cup E and return spring F CAUTION Do not remove the secondary cup from the piston since removal will damage it 6107010851 C Master Cylinder BRAKES 12 17 Rear Master Cylinder Disassembly NOTE ODo not remove the push rod clevis for master cylinder disassembly since removal requires brake position ad justment e Remove the rear master cylinder see Rear Master Cylin der Removal e Slide the dust cover on the push rod out of place and remove the circlip e Pull out the push rod with the piston stop e Take off the piston A secondary cup B primary cup and return spring D CAUTION Do not remove the secondary cup from the piston since removal will damage it Master Cylinder Assembly e Before assembly clean all parts including the master cylinder with brake fluid or alcohol CAUTION Except for the dis
234. gnal Indicator Light LED 2 High Beam Indicator Light LED 3 Neutral Indicator Light LEB 4 Gil Pressure Warning Indicator Light LED 5 FI Indicator Light LED 6 Odometer Trip Meter Clack Indicator Water temperature Gauge Fuel Level Gauge Tachometer Speedometer Weter Light LED Left Turn Signal Indicator Light LED EE Front Right Turn Signal Light 12V21W iil nsi Um Headli i Eo ie efo 505 228 S R BK BK Y Headlight Low 12V55W H er BL Y Gy BK Y ay BK Y BK Y BK Y BK Y BK Y Front Left Turn Signal BK Y Switch Housing ECU Fuel Main Pump Relay Relay Light 12V21W SET Horn Button Hazard Button 6 Passing Button L 1 2 Joint Connector 3 Turn Signal Switch TES i pimper Sutton 5 Junction Box Horn Fuse 10 Starter Gircuit Relay Turn Signal Fuse 164 1 ACC Fuse 10 Starter Lockout Switch Sur d Race Oke LEFT SWITCH HOUSING CONNECTIONS 4 Headlight Relay Horn Button Hazard Button Turn Signal Switch Dimmer Switch Starter Lockout Switch Passing Button E Ed Golor BK WIBK Y Color Gy Color 0 amp Y Color R vl sr v R BR Color BK BK R Color 1 e 8 9 EE W2L0069AW5 6 Wiring Diagram Malaysia ELECTRICAL SYSTEM 16 19 9 WR L
235. h charge If by chance an excessive amount of gas is gener ated due to overcharging the relief valve releases the gas to keep the battery normal 3 When you do not use the motorcycle for months Give a refresh charge before you store the motorcycle and store it with the negative cable removed Give a refresh charge once a month during storage Battery life If the battery will not start the engine even after sev eral refresh charges the battery has exceeded its use ful life Replace it Provided however the vehicle s starting system has no problem A WARNING Keep the battery away from sparks and open flames during charging since the battery gives off an ex plosive gas mixture of hydrogen and oxygen When using a battery charger connect the battery to the charger before turning on the charger This proce dure prevents sparks at the battery terminals which could ignite any battery gases No fire should be drawn near the battery or no ter minals should have the tightening loosened The electrolyte contains sulfuric acid Be careful not to have it touch your skin or eyes If touched wash it off with liberal amount of water Get medical attention if severe ELECTRICAL SYSTEM 16 27 Battery Interchange The sealed battery can fully display its performance only when combined with the proper vehicle electric system Therefore replace a sealed battery only on a motorcycle which was originally equ
236. hain from the rear sprocket toward the right e Disengage the drive chain A from the engine sprocket B e Pull the engine sprocket off the output shaft C Engine Sprocket Installation e Replace the sprocket washer and axle cotter pin e Install the engine sprocket so that OUTSIDE letters A face outward e Apply molybdenum disulfide oil to the threads of the out put shaft and the seating surface of the engine sprocket nut e After torquing the engine sprocket nut bend the one side of the washer over the nut NOTE OTighten the nut while applying the rear brake e Tighten Torque Engine Sprocket Nut 125 N m 13 kgf m 92 ft Ib Engine Sprocket Cover Bolts 9 8 1 0 kgf m 87 in Ib e Adjust the drive chain slack after installing the sprocket see Drive Chain Slack Adjustment in the Periodic Main tenance chapter GK05035BS1 C FINAL DRIVE 11 11 Sprocket Coupling Rear Sprocket Removal e Remove the rear wheel see 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 ground e Remove the rear sprocket nuts A e Remove the 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 59 N m 6 0 kgf m
237. han 2 seconds Locate the problem with the service code table and check and repair DEI or ignition system according to inspection procedure on all service codes Remove the auxiliary lead ending the self diagnosis mode NG Make sure the FI indicator LED light doesn t go ON OK Run the engine for several minutes at idling and run the motorcycle at 30 km h 18 NG mph or above in order to confirm no problem END 80171668 5 3 36 FUEL SYSTEM Self Diagnosis How to Read Service Codes How to Read Service Codes OService codes are shown by a series of long and short blinks of the Fl indicator LED light as shown below ORead 10th digit and unit digit as the Fl indicator LED light blinks 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 Then after completing all codes the display is repeated until the self diagnosis indicator terminal is open Olf there is no problem no code and unlight OFor example if two problems occurred in the order of 21 12 the service codes are displayed from the lowest number in the order listed 12 21 12 21 repeated Self Diagnosis indicator terminal Grounded Dpen _ 2 is i0th digit 0 56 0 5s a digit is is 0 5s Fl Indicator LED Light O
238. hand tester reading infinity for any 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 gt indicates a short necessitating stator replacement lf 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 Special Tool Hand Tester 57001 1394 Regulator Rectifier Inspection e Remove Bolts A Regulator Rectifier B Connector C disconnect Rectifier Circuit Check BR e Check conductivity of the following pair of terminals W BK Y Rectifier Circuit Inspection W BK1 W BK2 W BK3 BK Y BK1 BK Y BK2 BK Y BK3 The resistance should be low in one direction and more than ten times as much in the other direction If any two BK 1 BK2 BK3 leads are low or high in both directions the rectifier is Moses defective and must be replaced NOTE OThe actual meter reading varies with the meter used and the individual rectifier but generally speaking the lower reading should be from zero to one half the scale Tester connection Regulator Circuit Check To test the regulator out of circuit use three 12 V batte
239. hange the brake fluid in the brake line completely if the brake fluid must be refilled but the type and brand of the brake fluid that is already in the reservoir are unidentified After changing the fluid use only the same type and brand of fluid thereafter Recommended Disc Brake Fluid Grade DOT4 e Follow procedure below to 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 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 65130248 5 PERIODIC MAINTENANCE 2 33 Periodic Maintenance Procedures 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 the brake and hold it B 3 Close the bleed valve C 4 Relea
240. hapter 14 6 STEERING Steering Stem Stem Stem Bearing Removal e Remove Inner Cover see Frame chapter Fairing and Bracket see Frame chapter Front Wheel see Wheels Tires chapter Handlebar see Handlebar Removal Steering Stem Head Bolt Plug Steering Stem Head Bolt A and Washer Front Fork Clamp Bolts Lower Loosen Steering Stem Head e Remove the brake hose clamp bolt A and take the hose B off the steering stem C e Remove the front fork see Suspension chapter e Bend the claw washer tabs A e Pushing up the stem base and remove the steering stem locknut B and claw washer C Stem Cap D e Remove the steering stem nut A Special Tool Steering Stem Nut Wrench 57001 1100 B e Remove the stem cap e Remove the upper stem bearing inner race e To remove the bearing outer races C pressed into the head pipe B insert a bar A into the recesses 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 bearing inner race which is pressed onto the steering stem with a suitable commercially avail able chisel GNO5010381 C Steering Stem STEERING 14 7 Stem Stem Bearing Installation e Replace the bearing outer races with new ones e Ap
241. hapter 16 Clean spark plugs and adjust plug gap see chapter 2 Inspect the stick coil see chapter 16 Spark plug cap shorted or not in good contact Reinstall or inspect stick coil see chapter 16 Spark plug incorrect Replace it with the correct plug see chapter 16 IC igniter in ECU trouble Inspect see chapter 16 Crankshaft sensor trouble Inspect see chapter 16 Stick coil trouble Inspect see chapter 16 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 cleaner duct loose Reinstall see chapter 3 Air cleaner O ring damaged Replace see chapter 3 Fuel tank air vent obstructed Inspect and repair see chapter 3 Throttle body assy loose Throttle body assy O ring damage Choke lever pulled Fuel filer or pump screen clogged Fuel pressure regulator clogged Fuel line clogged Inlet air pressure sensor trouble Inlet air temperature sensor trouble Thermostat trouble Reinstall see chapter 3 Replace see chapter 3 Push it 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 Inspect see chapter 3 Inspect see chapter 3 Inspect and replace see chapter 4 Unstable rough
242. hapter 16 Inspect see chapter 16 Crankshaft sensor trouble Inspect see chapter 16 Stick coil trouble Inspect see chapter 16 Fuel air mixture incorrect Choke lever pulled Push it see chapter 3 Air cleaner clogged poorly sealed or missing Clean element or inspect sealing see chapter 3 Air cleaner duct loose Reinstall see chapter 3 Air cleaner O ring damaged Replace see chapter 3 Water or foreign matter in fuel Throttle body assy loose Throttle body assy O ring damaged Fuel tank air vent obstructed Fuel line clogged Fuel pump operates intermittently and often ECU fuse blows Fuel pump trouble Change fuel Inspect and clean fuel system see chapter 3 Reinstall see chapter 3 Replace see chapter 3 Inspect and repair see chapter 3 Inspect and repair see chapter 3 Pump bearings may wear Replace the pump see chapter 3 Inspect see chapter 3 Inlet air temperature sensor trouble Inspect see chapter 3 Main throttle sensor trouble Inspect Atmospheric pressure sensor trouble Inspect see chapter 3 Inlet air pressure sensor trouble see chapter 3 Inspect see chapter 3 Cracked or obstructed inlet air pressure sensor hose Inspect and repair or replace see chapter 3 Injector clogged Visually inspect and replace see chapter 3 Compression low Spark plug loose Reins
243. he 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 Drain Engine Oil see Engine Lubrication System in the Peri odic Maintenance chapter Coolant see Cooling System in the Periodic Mainte nance chapter e Remove Seats see Frame chapter Fuel Tank see Fuel System chapter Side Covers see Frame chapter Frame Covers see Frame chapter Clutch Cable Lower End see Clutch chapter Exhaust Pipe Assy and Muffler Body see Engine Top End chapter Throttle Body Assembly see Fuel System DFI chapter Shift Lever see Crankshaft Transmission chapter e Remove Radiator Hose Clamps A Loosen Radiator Hoses B e Disconnect Crankshaft Sensor Lead Connector see Electrical Sys tem chapter Stick Coil Harness Connector C e Pull off the connectors from the engine and free the wiring from the clamps e Remove Starter Motor Lead see Electrical System chapter Alternator Lead Connector see Electrical System chap ter Neutral Switch Lead Connector A Side Stand Switch Lead Connector B Speed Sensor Connector C e Remove Left Radiator Hose see Cooling System chapter Engine Sprocket see Final Drive chapter 6H04011081 C 6104021851 6 8 6 ENGINE REMOVAL INSTALLATION Engine Removal Installation e
244. he fork spring A fork spring seat B and collar C e Inspect the top plug O ring and replace it with a new one e Install the front fork see Front Fork Installation Front Fork Disassembly e Remove the front fork see Front Fork Removal e Remove the top plug A with O ring take out the collar B spring seat C and spring D e Drain the fork oil see Fork Oil Change e Remove the Allen bolt C from the bottom of the fork Special Tools Fork Cylinder Holder Handle 57001 183 D Fork Cylinder Holder Adapter 57001 1057 E NOTE OHold the outer tube in a vise A stop the cylinder unit B from turning by using the special tools and unscrew the Allen bolt 6M04040382 C 6404040481 6 6404040281 6 6404013881 6 13 10 SUSPENSION Front Fork e Remove the cylinder unit A washer and the spring B from the inner tube e Remove the following from the top of the outer tube Dust Seal A Retaining Ring B e Separate the inner tube A from the outer tube B NOTE OFrom the compressed state firmly pull down the outer tube a few times towards the direction of elongation e Remove the following from the inner tube Guide Bushing inner A Guide Bushing outer B Washer C Oil Seal D e Remove the cylinder base A from the bottom of the outer tube 00048147 P 00048149 gt 00048150
245. he water temperature sensor see this section e Refer to the Electrical System chapter for water temper ature sensor inspection FUEL SYSTEM DFI 3 51 Atmospheric Pressure Sensor Service Code 15 CAUTION Never drop the sensor especially on a hard surface Such a shock to the sensor can damage it NOTE OThe atmospheric pressure sensor is the same part as the inlet air pressure sensor except that the inlet air pressure sensor has the vacuum hose and different wiring Removal e Turn the ignition switch off e Remove the seat cover see Frame chapter e Remove the atmospheric pressure sensor A from the rubber damper in the frame e Disconnect the sensor connector Input Voltage Inspection NOTE OBe sure the battery is fully charged OThe inspection is the same as Input Voltage Inspection of the throttle sensor and the inlet air pressure sensor e Turn the ignition switch OFF e Remove the ECU see this chapter Do not disconnect the ECU connectors e Connect a digital voltmeter A to the connector B with the needle adapter set Special Tool Needle Adapter Set 57001 1457 e Measure the input voltage with the engine stopped and with the connectors joined e Turn the ignition switch ON 6617114851 6 Atmospheric Pressure Sensor Input Voltage Connections to ECU Meter BL lead terminal 1 Meter gt BR BK lead terminal 14 Standard 4 75 5 25 V
246. hen 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 6 16065851 6 6 16070751 6 9 io 6 16070851 6 5 32 ENGINE TOP END Cylinder Pistons Piston Ring End Gap e Place the piston ring A inside the cylinder using the pis ton 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 Top Standard 0 30 0 40 mm 0 0118 0 0157 Service Limit 0 7 mm 0 028 in Second Standard 0 45 0 55 mm 0 0177 0 0217 in Service Limit 0 8 mm 0 031 in x lf the end gap of either ring is greater than the service limit replace all the rings GE16066BS1 C Throttle Body Holder ENGINE TOP END 5 33 Throttle Body Holder Installation e Be sure to install the O rings A e Install the clamps B as shown and so that its hole fit on the projection C of the holder e Tighten Torque Throttle Body Holder Bolts D 13 1 3 113 in Ib Throttle Body Assy Holder Clamp Bolts E 2 0 0 20 kgf m 17 in Ib GE17001BS2 C 5 34 ENGINE TOP END Muffler WARNING To avoid a serious burn do not remove the muffler when the engine is still hot Wait
247. hin 30 degree OLoosen once and tighten again when the slot goes past the nearest hole GK04035BSi 6 1M07000BS1 2 28 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Bend the cotter pin A over the nut WARNING If the rear axle nut is not securely tightened or the cotter pin is not installed an unsafe riding condi tion may result Drive Chain Wear Inspection e Remove Chain Cover Screws A Chain Cover B Mud Guard C see Frame chapter e Rotate the rear wheel to inspect the drive chain for dam aged rollers and loose pins and links lf there is any irregularity replace the drive chain 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 several places If 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 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
248. hite mark on the pipe Olnstall the clamp B so that its head faces to right side Breather Plate C e Install Crankshaft and Connecting Rods Camshaft Chain A Transmission Shafts and Gears Dowel Pins B Shift Drum Shift Forks and Shift Rods e Before fitting the lower case on the upper case check the following OBe sure to hang the camshaft chain on the crankshaft OCheck to see that the shift drum and transmission gears are in the neutral position 6104057851 6 9 12 CRANKSHAFT TRANSMISSION Crankcase Splitting e Apply liquid gasket A to the mating surface of the lower crankcase half Sealant Kawasaki Bond Silicone Sealant 92104 1066 CAUTION Do not apply liquid gasket around the crankshaft main bearing inserts and oil passage holes e Fit the lower crankcase to the upper crankcase e Apply molybdenum disulfide oil to the seating surface A on the lower crankcase for the M9 bolts B Washer C e Tighten the lower crankcase bolts using the following steps OFollowing the sequence numbers on the lower crankcase half tighten the M9 bolts 1 6 L 81 mm 3 19 in Torque Crankcase Bolts M9 42 N m 4 3 31 ft lb OTighten the M9 bolts 7 10 L 95 mm 3 74 in with washers Torque Crankcase Bolts M9 42 N m 4 3 31 ft lb OTighten the M7 bolts A Torque Crankcase Bolts M7 20 N m 2 0 kgf m 14 ft Ib e Tighten the upper
249. i uere ere Gd oe Aes tt erede EE 16 54 Headlight Removal Installation 4 nennen nnns 16 55 City Light Bulb Replacement European Model 16 56 Turn Signal Light Bulb Replacement 2222222 0122 16 58 Turn Signal Relay Inspector suc ere ette D p euch 16 60 Tail Brake Light LED Removal ar aa ed Mae one aie 16 60 Tail Brake Light LED Installation rt ede REENEN EE rer ncaa 16 61 Radiator EH EE 16 62 Fan System Circuit InSpectiOn ii iini Rete eta esch deeg de Eder ERR I ag eee E De i Pb aud 16 62 Fan Motor IrispectlOn eese tet HR T 16 62 Meter Gauge Indicator Unit 16 64 dee E SER OA E DER RR ed 16 64 Meter Gauge Disassembly EE 16 64 Electronic Combination Meter Unit Inspection nennen 16 65 owitches arnd E 16 74 Brake Light Timing Inspection EE 16 74 Brake Light Timing Adjustment pp 16 74 Switch nee e EE 16 74 Radiator Fan Switch Inspection pp 16 74 Water Temperature Sensor Inspection 9 1 16 75 Speed Sensor 2222 20 001001000000000000000000000000 nnne nnne 16 76 Fuel Level Sensor Inspechon 1 16 78 Fuel Reserve Switch Inspectiom essen nennen nnne 16 78 Diode Rectifier InSpectiOni iur pete tapar utere dee dE des ER dS B 16 79 Junction B
250. iately and find the cause Engine Oil Change e Refer to the Engine Lubrication System in the Periodic Maintenance chapter Oil Filter Replacement e Refer to the Engine Lubrication System in the Periodic Maintenance chapter ENGINE LUBRICATION SYSTEM 7 9 Cil Pan Oil Pan Removal e Remove Engine Oil drain see Engine Lubrication System in the Periodic Maintenance chapter Exhaust Pipe Assy and Muffler Body see Engine Top End chapter Oil Pan Bolts A Oil Pan B Oil Pan Installation e Clean the oil screen A e Install the oil screen so that the crankcase rib B fits the slot C of the oil screen e Apply engine oil to the O rings on the oil pipe x lf 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 e Install the clamp A at an angle of within 45 B as shown e Replace the oil pan gasket with a new one e Tighten Torque Oil Pan Bolts C 11 N m 1 1 kgf m 95 in Ib 6006008851 6 7 10 ENGINE LUBRICATION SYSTEM Oil Pressure Relief Valve Oil Pressure Relief Valve Removal e See Oil Pan Removal Oil Pressure Relief Valve Installation e See Oil Pan Installation Oil
251. ic Inspection SEEN Ve dad ODOMETER READING first gt km x 1000 mile x 1000 amp 1116112118 See INSPECTION Every 0 6 4 7 5 12 15 20 24 Page Steering system Steering play inspect year e e 2 37 Steering stem bearings lubricate 2 years 2 38 Brake system Brake hoses leak inspect e e e 2 36 Brake hoses damage inspect e 9 o e AI 2 36 Brake hose installation condition inspect e e e 2 36 2 effectiveness play drag year MIN Vie e SCH Brake pad wear inspect e e 2 29 Brake fluid level inspect 6month e e 2 32 Brake light switch operation inspect e 4 o 2 29 Wheels and tires Tire air pressure inspect year e Wheels tires damage inspect Tire tread wear abnormal wear inspect e Wheel bearings damage inspect year 9 e Suspensions Front forks rear shock absorber operation R 2 2 damping and smooth stroke Front forks rear shock absorber oil leak inspect year e e e 2 37 Rocker arm wear inspect e e e Rocker arm operation e Tie rods operation e e e Drive train Drive chain lubrication condition inspect 1 000 km 2 29 Drive chain slack inspect 1 000 km 2 27 Drive chain wear inspect e e e 2 28 Drive chain guide wear inspect e e 9 Electrical system Spark plug condition inspect Ligh
252. idling Fuel injector trouble Inspect see chapter 3 Main throttle sensor trouble Inspect see chapter 3 Crankshaft sensor trouble Inspect see chapter 3 Throttle valves not synchronizing aN Inspect see chapter 2 DEI System Troubleshooting Guide FUEL SYSTEM DFI 3 27 Symptoms or Possible Causes Actions chapter Inlet air temperature sensor trouble Inspect see chapter 3 Water temperature sensor trouble Atmospheric pressure sensor trouble Inspect see chapter 3 Inspect see chapter 3 Fuel pressure too low or too high Inspect see chapter 3 Battery voltage low Inspect and charge see chapter 16 Incorrect idle speed Water temperature sensor trouble Inspect see chapter 3 Main throttle sensor trouble Inspect see chapter 3 Engine stalls easily Fuel pump trouble Inspect see chapter 3 Fuel injector trouble Inspect see chapter 3 Main throttle sensor trouble Inspect see chapter 3 Camshaft position sensor trouble Fuel pressure too low or too high Inspect see chapter 3 Inlet air pressure sensor trouble Water temperature sensor trouble Inlet air temperature sensor trouble Fuel line clogged Fuel pressure too low or too high Fuel pressure regulator trouble Crankshaft sensor trouble Stick coil trouble Compres
253. ie rod Nuts 59 N m 6 0 kgf m 43 ft lb Rear Shock Absorber Nut 34 N m 3 5 kgfm 25 ft lb Rocker Arm Removal e Using the jack raise the rear wheel off the ground Special Tool Jack 57001 1238 e Squeeze the brake lever slowly and hold it with a band e Remove Lower Rear Shock Absorber Nut and Bolt A Lower Tie rod Nut and Bolt B Rocker Arm Nut C and Bolt Rocker Arm D Rocker Arm Installation e Tighten Torque Rocker Arm Nut 34 N m 3 5 kgf m 25 ft lb Tie rod Nut 59 N m 6 0 kgf m 43 ft Ib Rear Shock Absorber Nut 34 N m 3 5 kgfm 25 ft Ib Tie rod Rocker Arm SUSPENSION 13 19 Rocker Arm Tie rod Bearing Sleeve Inspection e Visually inspect the rocker arm tie rod sleeves and needle bearings 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 xIf 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 STEERING 14 1 Steering Table of Contents Exploded VEW E 14 2 Ne EE EE 14 4 jg eee 14 5 Steering NSPE O CIE 14 5 nie BET un EE 14 5 Steering Stem EE 14 6 Stem Stem Bearing Removal nemen 14 6 Stem Stem Bearing Installatigom mmm 14 7 Stem Bearing Lubricallon eoe tenere ee a deh ima eom PA ee E
254. il and oil pressure switch Band Main harness Starter relay To rear brake switch Connect the battery negative cable and battery Battery negative cable Self diagnosis indicator terminal Turn signal relay Fuel pump relay ECU main relay License light connector Tail light connector Rear right turn signal light connector Rear left turn signal light connector Atmospheric pressure sensor ECU fuse Junction box Battery positive cable ECU Run the lead of ECU under the end sur face of battery case Starter lead Regulator rectifier Vehicle down sensor Inlet air temperature sensor To side stand switch 51 52 To neutral Switch To speed sensor Alternator Engine harness Water temperature sensor Ignition switch lead Frame ground To cam sensor fan switch horn The harness passes on the clutch cable Battery case Damper Front Brake hose Run the Throttle Cable together with the Right Grip Switch wire through the of Cowl Bracket clamp Run the wire thought the center of the frame which has to be located nearer to the center than the cable Right switch housing lead Run the Clutch Cable the Starter Cable and the Left Grip Switch wire through of the Cowl Bracket clamp Run the wire through the center of the frame which has to be located nearer to the center than the cable Left switch housing lead Start
255. in Piston cylinder clearance 0 040 0 067 mm 0 0016 0 0026 Piston ring groove clearance Top 0 04 0 08 mm 0 0016 0 0031 in 0 18 mm 0 0071 in Second 0 02 0 06 mm 0 0008 0 0024 in 0 16 mm 0 0063 in Piston ring groove width Top 0 83 0 85 mm 0 0327 0 0335 in 0 93 mm 0 037 in Second 0 81 0 83 mm 0 0319 0 0327 in 0 91 mm 0 036 in Piston ring thickness Top 0 77 0 79 mm 0 0303 0 0311 in 0 70 mm 0 028 in Second 0 77 0 79 mm 0 0303 0 0311 in 0 70 mm 0 028 in Piston ring end gap Top 0 30 0 40 mm 0 0118 0 0157 in 0 7 mm 0 028 in Second 0 45 0 55 mm 0 0177 0 0217 in 0 8 mm 0 031 in 5 8 ENGINE TOP END Special Tools and Sealant Compression Gauge 57001 221 Valve Spring Compressor Assembly 57001 241 Piston Pin Puller Assembly 57001 910 Valve Seat Cutter 45 24 57001 1113 Valve Seat Cutter 45 527 5 57001 1114 Valve Seat Cutter 32 525 57001 1118 Valve Seat Cutter 32 528 57001 1119 Valve Seat Cutter Holder Bar 57001 1128 Valve Spring Compressor Adapter 20 57001 1154 Valve Guide Arbor 4 57001 1273 ENGINE TOP END 5 9 Special Tools and Sealant Valve Guide Reamer 4 Valve Seat Cutter 60 525 57001 1274 57001 1328 Valve Seat Cutter Holde
256. in rotor magnetism which may be caused by dropping or hitting the alternator by leaving it near an electromagnetic field or just by aging will result in low output e To check the alternator output voltage do the following procedures OTurn off the ignition switch ORemove the left frame cover see Alternator Cover Re moval ODisconnect the alternator lead connector A OConnect the hand tester as shown in the table 1 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 Reading Range Tester to Tester to 4 000 rpm 250 V AC One Black Another Black 42 V r moie lead lead x lf the output voltage shows the value in the table the al ternator operates properly x 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 ONote the readings total 3 measurement Table 2 Stator Coil Resistance Tester Connections Reading Range Tester to Tester to x10 One Black Another Black 03 040 lead lead ELECTRICAL SYSTEM 16 33 Charging System xIf there is more resistance than shown in the table or no
257. in the Liquid Crystal Display LCD Seg ments Check e Check that the display change to the ODO TRIP and CLOCK displays each time the MODE button A is pressed Olf the fuel level gauge flashed display change to ODO TRIP CLOCK and FUEL the display function does not work replace the meter assembly e Indicate the clock mode e Check that when the RESET button in CLOCK mode is pushed for more than two seconds the meter display turns to the clock set mode OBoth the hour and minute display start flashing e n the HOUR MINUTE setting mode press the RESET button again to effect the HOUR setting mode OThe hour display flashes on the display e Press the MODE button to set the hour GP17112BS1 C ODO 8155 m 263 y 423 CLOCK GP17119BS2 C EN ENEN Se 23 GP17120BS1 C CLOCK CLOCK 4 23 a CLOCK W GP17062BS1 C ELECTRICAL SYSTEM 16 67 Meter Gauge Indicator Unit e In the HOUR setting mode press the RESET button to effect the MINUTE setting mode OThe minute display flashes on the display e Press the MODE button to set the minute e In the MINUTE setting mode press the RESET button to return to the HOUR MINUTE setting mode e Press the MODE button to complete the time setting process OThe clock starts counting the seconds as soon as the MODE button is pressed e Indicate the ODO mode e Check that the display A B
258. in 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 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 cleaner duct loose Air cleaner O ring damaged 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
259. ing Valve A lf the valve clearance is not within the specified range first record the clearance and then adjust it Clutch Clutch Adjust Inspection e Pull the clutch lever just enough to take up the free play A e Measure the gap between the lever and the lever holder xIf the gap is too wide the clutch may not release fully If the gap is too narrow the clutch may not engage fully In either case adjust it Clutch Lever Free Play Standard 2 3 mm 0 08 0 12 in A WARNING To avoid a serious burn never touch the engine or exhaust pipe during clutch adjustment e Turn the adjuster A so that 5 6 mm 0 20 0 24 in B of threads are visible e G9 e 65 65 6 15020151 6 e 52525890 6 15020251 6 2 24 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Slide the dust cover A at the clutch cable lower end out of place e Loosen both adjusting nuts B at the clutch cover as far as they will go e Pull the clutch outer cable C tight and tighten the adjust ing nuts against the cover D e Slip the rubber dust cover back onto place e Turn the adjuster at the clutch lever until the free play is correct e Push the release lever A toward the front of the motor cycle until it becomes hard to turn OAt this time the release lever should have the proper an gle shown 60 B xIf the angle is wrong check the clutch and release parts for wear A
260. 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 If any plates show signs of damage or if they have worn past the service limit replace them with new ones Friction Plate Thickness Standard 2 72 2 88 mm 0 107 0 113 in Service Limit 2 4 mm 0 094 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 lf any plate is warped over the service limit replace it with a new one Friction and Steel Plate Warp Standard 0 2 mm 0 008 in or less Service Limit 0 3 mm 0 012 in Clutch Spring Free Length Measurement e Measure the free length of the clutch springs A any spring is shorter than the service limit it must be replaced Clutch Spring Free Length Standard 80 6 mm 3 17 in Service Limit 76 6 mm 3 02 in 6 06060251 6 8 06060351 6 ENGINE LUBRICATION SYSTEM 7 1 Engine Lubrication System Table of Contents Exploded di 7 2 Engine Ol e c TE 7 4 leede 7 6 Special Tools and 7 7 Engine Oiland Oil E 7 8 Oil Level Inspechon 7 8 Engine Qi CHANG CEET 7 8 Oil Filt
261. ion e Check to see that the set pins A and set rings B are in place e Install the drive shaft and output shaft into the upper crankcase half e Apply engine oil to the bearings OThe bearing set pins and rings must match properly with the holes or grooves in the bearing outer races When they are properly matched there is no clearance A be tween the crankcase and the bearing outer races 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 Transmission Shaft Disassembly e Remove the transmission shafts see Transmission Shaft Removal e Remove the circlips disassemble the transmission shafts e The 5th gear A on the output shaft has three steel balls assembled into it for the positive neutral finder mecha nism Remove the 5th gear OSet the output shaft in a vertical position holding the 3rd gear B OSpin the 5th gear quickly C and pull it off upward 24 I LES G113082B 5 CRANKSHAFT TRANSMISSION 9 27 Transmission e Remove the ball bearing A from each shafts Special Tools Bearing Puller 57001 135 B Bearing Puller Adapter 57001 317 C 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 a
262. ipped 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 Battery charging condition can be checked by measuring battery terminal voltage with the digital voltmeter A e Remove the seats see Frame chapter e Disconnect the battery cables CAUTION Be sure to disconnect the negative cable first e Measure the battery terminal voltage 6008010851 NOTE OMeasure with a digital voltmeter which can be read to one decimal place voltage xf the reading is below the specified refreshing charge is 150 1 3 required y o 1 Battery Terminal Voltage 12 5 Standard 12 6 V or more gt i 120 3 0 11 5 E 25 50 75 100 Refreshing charge Battery Charge is required Note Good cposoro4s1 Refreshing Charge e Remove the battery A see Battery Removal e Do refresh charge by following method according to the battery terminal voltage WARNING This battery is sealed type Never remove seal cap B even at charging Never add water Charge with current and time as stated below 8 08011051 6 16 28 ELECTRICAL SYSTEM Battery Terminal Voltage 11 5 less than 12 6 V Standard Charge 0 9Ax5 10h Quick Charge 40Ax1 0h Battery Terminal Voltage V A Charge Time
263. it micrometer pins into punch marks E e Apply a small amount of molybdenum disulfide oil to the following Threads of Nuts and Bolts Seating Surfaces of Nuts and Con rods e Tighten the big end nuts until the bolt elongation reaches the length specified in the table e Check the length F of the connecting rod bolts xIf the stretch is more than the usable range the bolt has stretched too much An overelongated bolt may break in use EE _ Bolt Sal Stretch after tightening before tightening Connect Usable Range of ing Rod Bolt Connecting Rod Assy Bolt Stretch Use the bolts Attached to 0 24 0 36 mm New attached to new con rod 0 0094 0 0142 new con rod in Replace the 0 20 0 32 mm Used bolts with new 0 0079 0 0126 ones in 9 16 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods 2 Rotation Angle Method you don t have a point micrometer you may tighten the nuts using the Rotation Angle Method e Be sure to clean the bolts and nuts thoroughly with a high flash point solvent because the new bolts and nuts are treated with an anti rust solution Clean the bolts and nuts in a well ventilated area and take care that there is no spark or flame any where near the working area This includes any ap pliance with a pilot light Because of the danger or highly flammable liquids do not use gasoline or low flash point solvents to clean them
264. ith the disc brake observe the cautions listed below 1 Never reuse old brake fluid 2 Do not use fluid from a container that has been left unsealed or that has been open for a long time 3 Do not mix two types and brands of fluid for use in the brake This lowers the brake fluid boiling point and could cause the brake to be ineffective It may also cause the rubber brake parts to deteriorate 4 Don t leave the reservoir cap off for any length of time to avoid moisture contamination of the fluid 5 Don t change the fluid in the rain or when a strong wind is blowing 6 Except for the disc pads and disc use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning of the brake parts Do not use any other fluid for cleaning these parts Gasoline engine oil or any other petroleum distillate will cause 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 7 When handling the disc pads or disc be careful that no disc brake fluid or any oil gets on them Clean off any fluid or oil that inadvertently gets on the pads or disc with a high flash point solvent Do not use one which will leave an oily residue Replace the pads with new ones if they cannot be cleaned satisfacto rily 8 Brake fluid quickly ruins painted surfaces any spilled fluid should be completely wiped up imme diately 9 If any
265. ition 6404074851 6 GJO4075BS1 6 10 12 WHEELS TIRES Tires Air Pressure Inspection e Refer to the Air Pressure Inspection in the Periodic Main tenance chapter Tire Inspection e Refer to the Tire Wear Inspection in the Periodic Mainte nance chapter Tire Removal e Remove Wheel see Front Wheel Removal Rear Wheel Re moval Disc s 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 tires 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 tir
266. l Pressure Gauge 10 kgf cm 57001 164 Oil Pressure Gauge Adapter PT 3 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 lf the oil pressure is much lower than the standard check the oil pump relief valve and or crankshaft bearing insert wear immediately xIf the reading is much higher than the standard check the oil passages for clogging Oil Pressure Standard 255 314 kPa 2 6 3 2 kgf cm 37 46 psi 4 000 rpm oil temp 90 194 F e Stop the engine e Remove the oil pressure gauge and adapter WARNING Take care against burns form hot engine oil that will drain through the oil passage when the gauge adapter is removed e Apply a non permanent locking agent to the oil passage plug and install it Torque Oil Passage Plug Right 20 N m 2 0 kgf m 14 ft lb 7 14 ENGINE LUBRICATION SYSTEM Oil Pressure Switch Oil Pressure Switch Removal e Remove Engine Oil drain see Engine Lubrication System in the Periodic Maintenance 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 Ib e Install the switch lead direction upward e Tighten
267. l meter to the harness adapter leads Special Tool Throttle Sensor Setting Adapter 57001 1400 e Measure the sensor input voltage with the engine stopped and with the connector joined e Turn the ignition switch ON Speed Sensor Input Voltage Connection to Adapter Meter BL sensor P lead C Meter BK BL sensor BK lead D Standard About 9 11 V DC at Ignition SW xIf the reading is out of the range check the wiring see wiring diagram in this section and meter see Electrical System chapter the reading is good check the output voltage e Turn the ignition switch OFF Output Voltage Inspection e Before this inspection inspect the input voltage see Input Voltage Inspection NOTE sure the battery is fully charged e Turn the ignition switch OFF 6C17262BS1 GC17158BS1 C FUEL SYSTEM DFI 3 57 Speed Sensor Service Code 24 25 e Disconnect the speed sensor connector A and connect the harness adapter B between the harness connector and speed sensor connector Engine Sprocket Cover C e Connect a digital meter to the harness adapter leads Special Tool Throttle Sensor Setting Adapter 57001 1400 e Measure the sensor output voltage with the engine stopped and with the connector joined e Turn the ignition switch ON 80617262851 6 Speed Sensor Output Voltage at Sensor Connections to Adapter Meter Y W sensor Y lead C M
268. l tank e Check that the dampers A are in place on the fuel tank as well xIf the dampers are damaged or deteriorated replace them 3 96 FUEL SYSTEM Fuel Tank e Insert the pump outlet hose joint A straight onto the de livery pipe B until the hose joint clicks C Front D 3 5 x cx z SCH e 9000 SG 55 xS 555 d Ze d gc R 9 E 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 When the hose joint is correctly installed it should slide on the delivery pipe about 5 mm 0 2 in A WARNING SCH nee CC x e Se WEE 5050000005000 125506505 ire o __ Make sure the hose joint is installed correctly on the SS delivery pipe by sliding the joint or the fuel could leak 6617182851 C does not slide reinstall the hose joint e Connect the fuel pump and the fuel level sensor connec tors and the battery lead terminal Fuel Tank and Cap 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 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
269. lant to protect the cooling system from rust and corro sion 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 55 131 F or more 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 62 136 144 F the thermostat opens and the coolant flows When the coolant temperature goes up beyond 95 101 C 203 214 F the radiator fan switch conducts to operate the radiator fan The radiator fan draws air through the radiator core when there is not sufficient air flow such as at low speeds This increases up the cooling action of the radiator When the coolant temperature goes down from the operation temperature by 3 8 C 37 46 F the fan switch opens and the radiator fan stops 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
270. lator trouble res pressure and replace fuel pump see Main throttle sensor trouble Inspect see chapter 3 Fuel pressure may be low Inspect see chapter 3 Fuel pump trouble Inspect see chapter 3 Fuel injector trouble Inspect see chapter 3 Inlet air pressure sensor trouble Inspect see chapter 3 Atmospheric pressure sensor trouble Inspect see chapter 3 Inlet air temperature sensor trouble Inspect see chapter 3 3 26 FUEL SYSTEM DFI System Troubleshooting Guide Symptoms or possible Causes Actions chapter Cylinder piston worn Inspect and replace see chapter 5 Piston ring bad worn weak broken or sticking Inspect and replace see chapter 5 Piston ring groove clearance excessive Inspect and replace see chapter 5 Cylinder head gasket damaged Replace see chapter 5 Cylinder head warped Inspect and replace see chapter 5 No valve clearance Valve guide worn Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulating on seating surface Poor Running at Low Speed Symptoms or Possible Causes Spark weak Battery voltage low Spark plug dirty broken or gap maladjusted Spark plug cap trouble Adjust see chapter 2 Inspect and replace see chapter 5 Inspect and replace see chapter 5 Inspect and repair or replace see chapter 5 Actions chapter Inspect and charge see c
271. laysia Model HR with Honeycomb Catalytic Converter Model Restricted model 1 10 GENERAL INFORMATION Technical Information Air Inlet System Subthrottle Control System The ZR750 J1 employs large bore throttle bodies to increase power output However sudden changes in throttle opening can cause hesitation and jerky throttle response with a single butterfly valve in a large bore Therefore two throttle valves are placed in each inlet tract the main throttle valve located closest to the cylinder and a subthrottle valve placed further up the inlet tract The main throttle valve is operated by the rider when the throttle grip is turned clockwise or counterclockwise while the subthrottle valve is operated by a stepping motor controlled by the ECU The subthrottle valve automatically adjusts air inlet to more precisely match engine demand so that when the main throttle is opened quickly there is no hesitation or jerky response The subthrottle valves allow the fuel injection system to provide smooth throttle response similar to that of a constant velocity carburetor no matter how quickly the throttle is opened gt Airflow Throttle Body me Mixture Fuel Flow 6806094BN2 A Main Throttle Valve D Vacuum Piston B Subthrottle Valve E Inlet Air C Throttle Valve GENERAL INFORMATION 1 11 Technical Information Air Inlet System Operation The subthrottle control system consists of the subthrottle valv
272. lder B backward e Clean the element by tapping it lightly to loosen dust e Blow away the remaining dust by applying compressed air A from the outside to the inside from the clean side to the dirty side e Visually inspect the element for no tears or no breaks and inspect the sponge gaskets B also xIf the element or gasket has any tears or breaks replace the element e Install the element A with the flat side B facing for wards e Fit the tongue C of the air cleaner duct holder into the slot of the housing the air cleaner duct holder Torque Air Cleaner Duct Holder Screws 3 8 0 39 kgf m 34 in Ib 2 20 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cooling System Radiator Hose and Connection Inspection OThe high pressure inside the radiator hose can cause coolant to leak A or the hose to burst if the line is not properly maintained Visually inspect the hoses for signs of deterioration Squeeze the hoses A hose should not be hard and brittle nor should it be soft or swollen Replace the hose if any fraying cracks B or bulges C are noticed e Check that the hoses are securely connected and clamps are tightened correctly Torque Radiator Hose Clamp Screws 2 0 0 20 kgf m 17 in Ib 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 tir
273. lder by wrench clockwise until two pins of link come into groove of plate holder A e Take off plate holder e Set plate holder B A and cutting amp riveting pin B as shown GK04020BS1 C GK04021BS1 C GK04023BS1 C GK04024BS1 C Drive Chain FINAL DRIVE 11 9 e Turn pin holder until riveting pin touches link pin e Turn wrench clockwise until tip of riveting pin hits of link pin e Rivet it e Some work for the other link pin e After staking check the staked area of the link pin for cracks e Measure the outside diameter A of the link pin and link plates width B Link Pin Outside Diameter Standard 5 6 6 0 mm 0 22 0 24 in Link Plates Outside Width Standard 17 45 17 60 mm 0 687 0 693 in x If the reading exceeds the specified length cut and rejoin the chain again e Check Movement of the Rollers Chain Slack GK04026BSi 6 GK04028BSi 6 11 10 FINAL DRIVE Sprocket Coupling Engine Sprocket Removal e Remove Speed Sensor Connector A Engine Sprocket Cover Bolts B Engine Sprocket Cover C with Speed Sensor 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 Using the jack raise the rear wheel off the ground Special Tool Jack 57001 1238 e Loosen the drive chain see Slack Adjustment e Remove the drive c
274. le adapter set C Vehicle down Sensor Power Source Voltage Connections to Sensor Meter W Y lead D Meter gt BK Y lead E e Turn the ignition switch ON and measure the power source voltage with the connector joined Power Source Voltage at Sensor Standard Battery Voltage 12 6 V or more e Turn the ignition switch OFF there is no battery voltage check the following Battery see Electrical System chapter ECU Main Fuse 15 A Wiring for Vehicle down Sensor Power Source see next diagram If the power source is normal check the output voltage 8017125 52 C Vehicle down Sensor Service Code 31 FUEL SYSTEM DFI 3 59 e Turn the ignition switch OFF e Remove the sensor e Connect a digital volt meter A to the connector with nee dle adapter set B Special Tool Needle Adapter Set 57001 1457 Vehicle down Sensor Output Voltage Connections to Sensor Meter gt Y G lead D Meter BK Y lead E 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 C 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 tilted 60 70 or more right or left 3 7 4 4 V with sensor arrow mark pointed up 0 4 1 4 V NOTE Olf you need to t
275. le below Spring Preload Adjustment Adjuster Damping sad Load Road Driving Position Force Conditions Speed Hardness 1st Weak Soft Light Good Low ji T T T 7th Strong Hard Heavy Bad Highway Rear Shock Absorber Removal e Using the jack raise the rear wheel off the ground Special Tool Jack 57001 1238 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 shock absorber or the motorcycle may tall over It could cause an accident and injury 6H04011081 C 13 14 SUSPENSION Rear Shock Absorber e Remove Lower Shock Absorber Nut A Lower Shock Absorber Bolt B e Remove Upper Shock Absorber Nut A Upper Shock Absorber Bolt B e Remove the shock absorber A from upside Rear Shock Absorber Installation e Tighten Torque Rear Shock Absorber Nuts 34 N m 3 5 kgf m 25 ft Ib Rear Shock Absorber Inspection e Remove the rear shock absorber e Visually inspect the following items Smooth Stroke Oil Leakage Crack or Dent x If there is any damage to the rear shock absorber replace it e Visually inspect the rubber bushing show any signs of damage replace it SUSPENSION 13 15 Swingarm Swingarm Removal e Raise the rear wheel off the ground with jack Special Tool Jack 57001 1238 e Remove Chain Cover see Final Drive chapte
276. lead in the crankshaft sensor connector 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 1 9 V or more Special Tool Hand Tester 57001 1394 Recommended Tool Peak Voltage Adapter Type KEK 54 9 B Brand KOWA SEIKI x lf the tester reading is not specified one check the crank shaft sensor 16 40 ELECTRICAL SYSTEM Ignition System Timing Rotor Removal fce e Remove the crankshaft sensor cover see Crankshaft Sensor Removal e Remove the timing rotor A OHolding the timing rotor with the flywheel amp pulley holder B and remove the bolt C Special Tool Flywheel amp Pulley Holder 57001 1343 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 16 e Install the crankshaft sensor cover see Crankshaft Sen sor Installation Camshaft Position Sensor Removal e Remove Fuel Tank see Fuel System DFI chapter Camshaft Position Sensor Lead Connector A discon nect OPush the tongue B upside and take out the connector from the bracket e Remove Camshaft Position Sensor Bolt A Camshaft Position Sensor B Camshaft Position Sensor Installation e Apply grease or engin
277. ligned 6113040851 6 e Replace any circlips removed with new ones e Install the circlips A so that the opening B is aligned with a spline groove C 6113010251 6 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 9 28 CRANKSHAFT TRANSMISSION Transmission NOTE OWhen the toothed washers 28 29 are assembled onto the output shaft note the following OWhen the tangs A of the toothed washer 29 shall be assembled they should be installed into the notch B of the toothed washer 28 see Page 9 29 e Fit the steel balls into the 5th gear holes in the output shaft aligning three oil holes D 5th Gear A Output Shaft B Steel Balls
278. ling Gauge incorrect Water temperature gauge broken Water temperature sensor broken Cooling system component incorrect Radiator fan switch trouble 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 housing unevenly worn No clutch lever play Clutch inner cable trouble Clutch release mechanism 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 lever play excessive Clutch release mechanism trouble 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 Ab
279. liper Fluid Seal Damage The fluid seals A around the piston maintain the proper pad disc clearance If the seals are not satisfactory pad wear will increase and constant pad drag on the disc will raise brake and brake fluid temperature e Remove the calipers see Brakes chapter e Replace the fluid seals under any of the following condi tions a fluid leakage around the pad b brakes over heat c there is a large difference in inner and outer pad wear d the seal is stuck to the piston x lf the fluid seal is replaced replace the dust seals B as well Also replace all seals every other time the pads are changed Caliper Dust Seal Friction Boot Damage e Remove the calipers see Brakes chapter e Check that the dust seals B and friction boots C are not cracked worn swollen or otherwise damaged e f they show any damage remove the caliper bracket and replace them 6513047851 6513048851 C PERIODIC MAINTENANCE 2 31 Periodic Maintenance Procedures Master Cylinder Inspection Visual Inspection e Remove the master cylinders see Brakes chapter e Disassemble the front and rear master cylinders 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 lf a master cylinder or piston shows any damage replace them e Inspect the primary cup C and secondary cup D lf a cup
280. looded do not crank the engine with the throt tle fully opened like a carburetor This promotes engine flooding because more fuel is supplied automatically by the DFI system Choke Lever Play Inspection e Push the choke lever A fully and ensure by your finger that the choke cam B has the specified play Choke Lever Free Play Standard 0 0 5 mm 0 0 02 in e Pull C the choke lever fully and ensure that the choke cam turns the choke link D xIf the free play is incorrect adjust the choke cable Choke Lever Play Adjustment e Remove the fuel tank see Fuel Tank Removal e Loosen the locknut A and turn the adjuster B until the cable has the proper amount of free play e Tighten the locknut against the adjuster securely Cable Removal Installation e Refer to the Throttle Assy section in this chapter for re moval installation of the throttle cables and choke cable Cable Lubrication and Inspection e Refer to the General Lubrication in the Periodic Mainte nance chapter 3 88 FUEL SYSTEM DFI Throttle Body Assy Idle Speed Inspection e Refer to the Idle Speed Inspection in the Periodic Main tenance chapter Engine Vacuum Synchronization Inspection Adjustment e Refer to the Engine Vacuum Synchronization Inspection in the Periodic Maintenance chapter High Altitude Performance Adjustment e Any modification is not necessary in this model since the atmospheric pressure sensor senses
281. lose 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 Repeat the above steps for the other caliper 8513051 52 C e Remove the clear plastic hose e Install the reservoir cap e Tighten Torque Front Brake Reservoir Cap Screws 1 0 0 10 kgf m 9 e Follow procedure below to 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 LO that the cap is seated on the reservoir body then tighten Acker p lt the cap an additional 1 6 turn D while holding the brake fluid reservoir body A tor 65130248 5 e Tighten the bleed valve and install the rubber cap Torque Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib e Check the fluid level e After bleeding is done check the brake for good braking power no brake drag and no fluid leakage 2 36 PERIODIC MAINTENANCE Periodic Maintenance Procedures WARNING When working w
282. lts is applied the regulator rectifier may be dam aged Do not apply 24 V more than a few seconds If 24 volts is applied for more than a few seconds the regulator rectifier may be damaged xIf the test light did not light when the 24 V was applied momentarily to the voltage monitoring terminal the regu lator rectifier is defective Replace it the regulator rectifier passes all of the tests described it may still be defective If the charging system still does not work properly after checking all of the components and the battery test the regulator rectifier by replacing it with a known good unit 8 10000451 C 8 10000551 C 8 10000851 C Charging System ELECTRICAL SYSTEM 16 35 Charging Voltage Inspection e Check the battery condition see Battery section e Warm up the engine to obtain actual alternator operating conditions e Remove the seats see Frame chapter e Check that the ignition switch is turned off and connect the hand tester A to the battery terminals B Special Tool Hand Tester 57001 1394 A e Start the engine and note the voltage readings at various 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 read ings should also rise Bu
283. lve 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 coil winding resistance when the DFI part is cold at room temperature e Make sure all connectors in the circuit are clean and tight and examine wires for signs of burning fraying short etc Deteriorated wires and bad connections can cause reappearance of problems and unstable operation of the DFI system lf any wiring is deteriorated replace the wiring 6C17045BS1 C 6017037351 Troubleshooting the DFI System FUEL SYSTEM DFI 3 19 e Pull each connector A apart and inspect it for corrosion dirt and damage xIf 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 xf the tester does not read 0 the lead is defective Re place the lead or the main harness or the sub harness OIf 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 g
284. m 1 3768 in If any crankpin has worn past the service limit replace the crankshaft with a new one If the measured crankpin 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 Crankpin Diameter Marks None 34 984 34 992 mm 1 3773 1 3776 in Q 34 993 35 000 mm 1 3777 1 3780 in A Crankpin Diameter Marks or no mark 6105041881 C 6105041781 6105040BS1 C CRANKSHAFT TRANSMISSION 9 19 Crankshaft and Connecting Rods 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 38 000 38 008 mm 1 4961 1 4964 in O 38 009 38 016 mm 1 4964 1 4967 in Big End Cap A Connecting Rod B Weight Mark Alphabet C Diameter Mark Around Weight Mark D or no mark 6105060181 e Select the proper bearing insert A in accordance with the combination of the connecting rod and crankshaft coding Size Color B Con rod Big End Crankpin Inside Diameter Diameter Marking Marking Part Number Noe O Brom 92139 1110 None None Black
285. maladjusted remedy it backfiring afterfiring hesitation when acceleration engine oil viscosity too high brake dragging engine overheating clutch slipping other choke lever pulled out fully push it in fully spark plug loose tighten it spark plug dirty broken or gap maladjusted remedy it spark plug incorrect replace it knocking fuel poor quality or incorrect use high octane gasoline brake dragging clutch slipping engine overheating engine oil level too high engine oil viscosity too high other 3 24 FUEL SYSTEM DFI System Troubleshooting Guide D I 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 OThe ECU may be involved in the DFI electrical and ignition system troubles If these parts and circuits checked out good be sure to check the ECU for ground and power supply If the ground and power supply are checked good replace the ECU Engine Doesn t Start Starting Difficulty Symptoms or possible Causes Actions chapter Starter motor not rotating Ignition and engine stop switches not ON Turn both switches ON Starter lockout switch or ne
286. n in chapter e Remove the needle adapter e Apply silicone sealant to the seals of the ECU connector for waterproofing 6C17267BS1 Fuel Injectors FUEL SYSTEM DFI 3 83 Injector Signal Test e Prepare two test light sets with male terminals as shown Rating of Bulb A 12 V x 3 3 4 W Terminal Width B 1 8 mm 0 071 in Terminal Thickness C 0 8 mm 0 031 in CAUTION Do not use larger terminals than specified above A larger terminal could damage the injector main har ness connector female leading to harness repair or replacement Be sure to connect bulbs in series The bulb works as a current limiter to protect the solenoid in the injector from excessive current e Remove the fuel tank see Fuel Tank Removal e Remove connectors for injector A e Connect each test light set B to the injector sub harness connector C e Turn the ignition switch ON e While cranking the engine with the starter motor watch the test lights the test lights flicker at regular intervals the injector circuit in the ECU and the wiring are good Perform the Injector Resistance Inspection Olnjector signals can be also confirmed by connecting the hand tester x 10 V AC instead of the test light set to the injector main harness female connector Crank the engine with the starter motor and check to see if the hand oscillates at regular intervals Special Tool Hand Teste
287. nder 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 do not start the engine under misfire due to spark plug fouling or poor connection of the stick coil For KLEEN do not coast the motorcycle with the ignition switch off Turn the igni tion switch ON and run the engine IC igniter in ECU trouble Fuel air mixture incorrect Throttle body assy holder loose Air cleaner duct loose Air cleaner poorly sealed or missing Air cleaner O ring damaged Air cleaner clogged Compression high Carbon built up in combustion chamber 17 20 APPENDIX Troubleshooting Guide 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 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 switch trouble Radiator fan relay trouble Fan motor broken Fan blade damaged Water pump not turning Water pump impeller damaged Over Coo
288. nector A 3 Dimmer Switch E EI 22 Starter Lockout Switch e 8 Passing Button 2 Radiator Fan Fuse 15A 3 Headlight Fuse 10 LEFT SWITCH HOUSING CONNECTIONS 4 Headlight Relay Horn Button Turn Signal Switch Dimmer Switch Starter Lockout Switch Passing Button 8 Taillihgt Fuse 10A 6 Ignition Fuse 10 Color Bk w gk v Color D 0 GY Color R BL R BK Color BK BK R Color R BKIBL Y 7 Horn Fuse 10 8 Starter Circuit Relay 9 Turn Signal Fuse 10 W2L0058BN5 6 Wiring Diagram Australia ELECTRICAL SYSTEM 16 15 SC F LI EB et LL T I amp EN eat z GER s Ze m 1 Subthrottle Valve Actuator 2 Fuel Injector 1 3 Fuel Injector 2 K EE 4 Fuel Injector 3 found Grown 5 Fuel Injector 4 6 Subthrottle Sensor 7 Wain Throttle Sensor 8 Speed Sensor 9 Camshaft Position Sensor Switch Neutral Switch A d Y BL BR BK BL Crankshaft oi Sensor Pressure Side A Stand BL R BK Y Sensor ge 11 EN a9 Sensor 12 13 Sensor Alternator BR W Y R H BK BK BK BK BK BK BK 8K BK Y ay n a aK R G BK R UO BR Y P BL BK BL LO BR R BL Y BL amp BL BK BL R BK Y BK W BK Y 0 BK R R BK Y BK Y BK Y vi
289. nector C T Ignition Switch Y Junction Box f Sealed Battery U Fl Indicator LED Light d Starter Relay Main Fuse 30 A 3 70 FUEL SYSTEM DFI ECU CAUTION Never drop the ECU especially on a hard surface Such a shock to the ECU can damage it ECU Removal e Remove Seats see Frame chapter Junction Box A e Take the ECU A out along with the harness e Disconnect the ECU lead connectors B ECU Installation e Connect the ECU connectors noting the length of the locks Longer Lock A Shorter Lock B ECU Power Supply Inspection e Visually inspect the terminals A of the ECU connectors the connector is clogged with mud or dust blow it off with compressed air Replace the main harness if the terminals of the main harness connectors are cracked bent or otherwise dam aged Replace the ECU if the terminals of the ECU connectors are cracked bent or otherwise damaged ECU FUEL SYSTEM DFI 3 71 e With the ECU connectors A connected check the fol lowing ground lead for continuity with the ignition switch OFF using a tester and needle adapter set ECU Grounding Inspection 26 50 or 51 BK Y Terminal Battery Terminal 0 Engine Ground Battery Terminal 0 lf no continuity check the connector the engine ground lead or main harness and repair or replace them if nec essary Batter
290. ng the battery life and deteriora tion of the battery performance 16 24 ELECTRICAL SYSTEM Battery CAUTION Do not remove the aluminum seal sheet A sealing the filler ports B until just before use e Check to see that there is no peeling tears or holes in the seal sheet on the top of the battery e Place the battery on a level surface e Remove the seal sheet NOTE OA battery whose seal sheet has any peeling tears or holes requires a refreshing charge initial charge e Take the electrolyte container out of the vinyl bag e Detach the seal cap A from the container NOTE ODo not discard the seal cap because it is used as the battery plugs later ODo not peel back or pierce the seals B on the container e Place the electrolyte container upside down aligning the six seals with the six battery filler ports e Push the container down strongly enough to break the seals Now the electrolyte should start to flow into the battery NOTE ODo not tilt the container as the electrolyte flow may be interrupted e Make sure air bubbles A are coming up from all six filler ports OLeave the container this way for 5 minutes or longer NOTE Olf no air bubbles are coming up from a filler port tap B the bottom of the bottle two or three times Never remove the container from the battery CAUTION Fill the electrolyte into the battery until the con tainer is completely emptied e Be cert
291. ngine Oil drain see Engine Lubrication System in the Periodic Maintenance chapter Clutch Cable Lower End A Clutch Cover Mounting Bolts B e Turn the release lever A toward the rear as shown and remove the clutch cover B About 90 C 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 56019 120 e Replace the clutch cover gasket with a new one e Tighten the clutch cover mounting bolts Torque Clutch Cover Mounting Bolts 11 N m 1 1 kgf m 95 in Ib Release Shaft Removal CAUTION Do not remove the clutch release lever and shaft assembly unless it is absolutely necessary If re moved the oil seal replacement may be required e Remove the clutch cover see Clutch Cover Removal e Pull the lever and shaft assembly straight out of the clutch cover Release Shaft Installation e Apply high temperature grease to the oil seal lips on the upper ridge of the clutch cover e Apply oil to the needle bearings in the hole of the clutch cover e Apply molybdenum disulfide grease to the pusher holding portion A on the release shaft e Install the washer B and spring C e Insert the release shaft straight into the upper hole of the clutch cover GF05025BS1 C CAUTION When inserting the release shaft be careful not to remove the sprin
292. normal Engine Noise Knocking IC igniter in ECU trouble Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Overheating Piston slap Cylinder piston clearance excessive Cylinder piston worn Connecting rod bent Piston pin piston pin hole worn 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 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 APPENDIX 17 21 Troubleshooting Guide Engine mount loose Crankshaft bearing worn Primary gear worn or chipped Camshaft chain tensioner trouble Camshaft chain sprocket guide worn Air suction valve damaged Vacuum switch 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 cha
293. not OA sound scope B can also be used e Do the same for the other injectors lf all the injectors click at a regular intervals the injectors are good The trouble may be related to the fuel line requiring fuel pressure inspection see Fuel Line section in this chapter OThe click interval becomes shorter as the engine speed rises If any injector s doesn t click the DFI circuit or the injector is suspect Perform Power Source Voltage Inspection first 80617189851 6 Power Source Voltage Inspection e Remove the ECU see ECU section Do not disconnect the ECU connector e Connect a digital meter A to the ECU connector B us ing the needle adapter C Special Tool Needle Adapter Set 57001 1457 OMeasure the power source voltage with the engine stopped and with the connector joined e Turn the ignition switch ON 6617266851 6 Injector Power Source Voltage at ECU Connections Meter W Y terminal 13 Meter gt Battery Terminal Service Limit Voltage 12 6 V or more x If the meter doesn t read as specified check the following Main Fuse 30 A see Electrical System chapter Fuel Pump Relay see DFI Power Source section Power Source Wiring see Wiring Diagram below OTo check the W R leads between the injector connector and the fuel pump relay remove the fuel tank see Fuel Tank Removal and the seat cover see Frame chapter lf the power
294. nsor Neutral Switch Junction Box Ignition Fuse 10 A Starter Lockout Switch Diode ECU Main Relay ECU Fuse 15 A Vehicle down Sensor H Y BK Y BK Y BK Y BK Y GP10121BW4 C 18 Main Fuse 30 A 19 Battery 12 V 8 Ah 20 ECU Electrical Control Unit 21 Joint Connector A 22 Joint Connector B 23 Joint Connector C 24 Joint Connector D ELECTRICAL SYSTEM 16 49 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 Slide back the rubber cap A e Remove the starter motor terminal nut B e Remove the mounting bolts A e Pull out the starter motor B Starter Motor Installation CAUTION Do not tap the starter motor shaft or body Tapping the shaft or body could damage the motor e When installing the starter motor clean the starter mo tor legs A and crankcase B where the starter motor is grounded e Replace the O ring A with a new one e Apply grease to the O ring e Tighten Torque Starter Motor Mounting Bolts 11 N m 1 1 kgf m 95 in Ib Starter Motor Disassembly e Take off the starter motor through bolts A and remove both end covers B and pull the armature out of the yoke C CO CR 16 50 ELECTRICAL SYSTEM Electric Starter System OThe brush plate A and brushes come off with the right hand end cover
295. nstallation e Install the needle bearings so that the manufacturer s marks face in e Install the ball bearing so that the manufacturer s marks faces out Special Tool Bearing Driver Set 57001 1129 A Swingarm Bearing Sleeve Inspection CAUTION Do not remove the bearings for inspection Remove may damage them e Inspect the needle bearings A and ball bearing B in stalled in the swingarm OThe rollers and ball in bearing normally wear very little and wear is difficult to measure Instead of measuring visually inspect the bearing for abrasion discoloration or other damage lf the needle bearings ball bearing and sleeve show sings of abnormal wear discoloration or damage re place them as a set Chain Guide Inspection e Visually inspect the chain guide A Replace the chain guide if it shows any signs of abnormal wear or damage 8 06060451 6 6M06035BSi C 13 18 SUSPENSION Tie rod Rocker Arm Tie rod Removal e Remove the side stand see Frame chapter e Using the jack raise the rear wheel off the ground Special Tool Jack 57001 1238 e Squeeze the brake lever slowly and hold it with a band A GH04011081 C e Remove Lower Rear Shock Absorber Bolt and Nut A Upper and Lower Tie rod Nuts and Bolts B Tie rods C Tie rod Installation e Install the tie rods so that the marked side faces the bolts and nuts e Tighten Torque T
296. nt 3 Results In the chart Vv is within the usable range and the sensor is normal Pv 24 55 cmHg Vv volt cmHg 40 45 50 5 25 30 35 32 35 40 50 60 70 73 ID TO Pv abs 6017034983 3 46 FUEL SYSTEM DFI Inlet Air Pressure Sensor Service Code 12 Pv 55 86 cmHg 1 1 73 80 90 100 113 ID lt gt T0 gt abs 11 66170350 3 Vv Inlet Air Pressure Sensor Output Volt 10 Idling age V Digital Meter Reading Pv Throttle Vacuum Pressure absolute TO Throttle Full Open zi EE Hee ST Standard of Sensor Output Voltage v UR Usable Range of Sensor Output Voltage v 80171378481 C A ECU C Inlet Air Pressure Sensor Inlet Air Temperature Sensor Service Code 13 FUEL SYSTEM DFI 3 47 Removal Installation CAUTION Never drop the sensor especially 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 e Put the inlet air temperature sensor into the grommet Output Voltage Inspection NOTE OBe sure the battery is fully charged OThe output voltage changes according to the inlet air temperature e Remove the ECU see this chapter
297. ocal atmospheric pressure using a barometer substitute the atmospheric pressure for Pv throttle vacuum in the vacuum sensor chart see inlet air pressure sensor section in this chapter OGet the usable range of the atmospheric pressure sensor output voltage in the same way as Output Voltage Inspection of the inlet air pressure sensor and check if Va output voltage is within the usable range or not you know the local altitude use the following chart For example Suppose the local altitude is 1300 m 4200 ft and the sensor output voltage Va is 3 3 V Plot this H 1300 m at a point 1 on the following 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 2 3 64 V Plot Va 3 3 V on the vertical line Point 3 Results In the chart Va is within the usable range and the sensor is normal FUEL SYSTEM DFI 3 53 Atmospheric Pressure Sensor Service Code 15 3 2 2 400 0 5001 1000 1500 2000 2500 3000 1 1 m 1 1 1 1310 0 2000 4000 6000 8000 10000 NC Cu 6617035193 Va Atmospheric Pressure Sensor Output ST Standard of Sensor Output Voltage v Voltage v H Altitude m or feet UR Usable Range of Sensor Output Voltage v 6617150 1 A ECU E Atmospheric Pressure Sensor 3 54 FUEL SYSTEM
298. ody does not slide smoothly one pad will wear more than the other pad wear will increase and con stant drag on the disc will raise brake and brake fluid tem perature e Check to see that the caliper holder shaft are not badly worn or stepped and that the rubber friction boots D are not damaged xIf the rubber friction boot is damaged replace the rubber friction boot To replace the friction boot remove the pads and the caliper bracket If the caliper holder shaft is damage replace the caliper bracket 6105068851 C 12 14 BRAKES Brake Pads Front Brake Pad Removal e Remove the caliper from the disc e Draw out the holder shaft pin A and take off the holder shaft B e Remove the pad C on the piston side e Push the holder D towards the piston and remove the pad of the other side E from the holder shaft F Front Brake Pad Installation e Push the caliper pistons in by hand as far as they will go e Install the anti rattle spring in its correct position e Install the pad on the piston side first then install the other pad on the holder e Install the caliper see Caliper Installation 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 Brake Pad Removal e Remove the caliper with the h
299. oes on Yes goes on Does the LED light go off Yes goes off Check the LED light and the wiring Good after 1 2 seconds No stays on DFI and ignition systems are considered to be normal p Does the LED light go off No stayed on DFI and ignition systems after 10 20 seconds are abnormal Run the engine with idling Turn the ignition SW OFF End of inspection Turn the ignition SW OFF Go to self diagnosis DFI and ignition systems NO are normal v Ask the rider if the problem occurs again Yes occurs Replace the ECU FUEL SYSTEM DFI 3 69 Indicator LED Light LED Light Inspection e Remove the meter unit see Electrical System chapter e Using two auxiliary leads supply battery power to the FI indicator LED light A 12 V Battery B FI Indicator LED Light Check Connector Meter Connector C disconnected BR W Lead Terminal 1 of the Meter Battery Terminal BR R Lead Terminal 6 of the Meter Battery Terminal Criterion The LED light should light xIf the LED light does not go on replace the meter unit Connection 6Ci7094BSi 6 ON ran BATTERY C 60617175 2 A ECU X Ignition Fuse 10 A e Joint Con
300. of oil see Front Fork Oil Change 6M04175BSi 6 6404042081 6 6404013881 6 13 12 SUSPENSION Front Fork Inner Tube Outer Tube Inspection e Visually inspect the inner tube A and repair any nicks or rust by using an oil stone the damage is not repairable replace the inner tube Since damage to the inner tube damages the oil seal slip replace the oil seal whenever the inner tube is repaired or replaced CAUTION If the inner tube is badly nicked or bent replace it Excessive bending followed by subsequent straightening can weaken the inner tube e Place the inner tube in the outer tube B and pump them back and forth manually to check for smooth operation x If the movementis not smooth replace both the inner tube and the outer tube A WARNING Replace the inner and outer tubes with new ones if they are bent because it is dangerous to use them by repairing them Make sure to inspect the inner and outer tubes of the other side Dust Seal Inspection e Inspect the dust seal A for any signs of deterioration or damage Replace it if necessary Fork Spring Inspection e Measure the free length B of the fork spring A If the measured length is shorter than the service limit the spring must be replaced If the free length of the replace ment spring and that of the remaining spring vary greatly the remaining spring should also be repl
301. of the brake line fittings or the bleed valve is opened at any time the AIR MUST BE BLED FROM THE BRAKE LINE Brake Hoses and Connections Inspection Inspect the brake hose and fittings for deterioration cracks and signs of leakage OThe high pressure inside the brake line can cause fluid to leak A or the hose to burst if the line is not properly main tained Bend and twist the rubber hose while examining it Replace the hose if any cracks B or bulges C are no ticed Tighten any loose fittings GL10020181 C PERIODIC MAINTENANCE 2 37 Periodic Maintenance Procedures Suspension Front Fork Oil Leak Check e Visually inspect the front forks A for oil leakage scoring or scratches on the inner surface of the inner tubes Replace or repair any defective parts if necessary Rear Shock Absorber Oil Leak Check e Visually inspect the shock absorber A for oil leakage If the oil leakage is found on it replace the shock absorber with a new one Steering Steering Inspection e Lift the front wheel off the ground using the jack Special Tool Jack 57001 1238 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 steering is too tight e Feel for steering looseness by pushing and pulling
302. oint A straight onto the de livery pipe B until the hose joint clicks C Front D 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 When the hose joint is correctly installed it should slide on the delivery pipe about 5 mm 0 20 in does not slide 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 e Check that the inlet hose A is onto the pipe fully and the plate clamps B are installed beyond the raised rib C 1 2 mm 0 039 0 079 in D 6505012851 6 6505032851 6 SE S 225052 0 ES 552 09 PRS 0600006900 E 5 SN 55 di XO ita Ge di ee oe 25 XXX 559 ee 99 di d 555 E DS E 86170548581 6 2 14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Throttle Control System Inspection Throttle Grip Play Inspection e Check the throttle grip free play A x lf the free play is incorrect adjust the throttle cable Throttle Grip Free Play Standard 2 3 mm 0 08 0 12 in e Check that the throttle grip moves smoothly from close to full open and the throttle closes quickly and completely in all steering positions by the return spring xIf the
303. olt 9 8 1 0 87 12 Coolant drain plug water pump 11 1 1 95 13 Oil passage plugs 20 2 0 14 L EO Apply engine oil G Apply grease L Apply a non permanent locking agent MO Apply molybdenum disulfide oil mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts SS Apply silicone sealant Kawasaki Bond 56019 120 W Apply water 7 4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart Engine Oil Flow Chart ENGINE LUBRICATION SYSTEM 7 5 P Camshaft Oil Passage Oil Passage Hole in Alternator Rotor Bolt Starter Clutch Oil Passage Hole Main Oil Passage Crankshaft Oil Passage Oil Filter Oil Pressure Switch Cil Pipe Oil Pump To Drive Shaft Oil Pipe To Output Shaft Drive Shaft Oil Passage Hole Output Shaft Oil Passage Hole Inlet Camshaft Exhaust Camshaft To Air Cleaner Drive Shaft Relief Valve Oil Screen Engine Oil Drain Bolt Output Shaft 7 6 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil Type API SE SF or SG API SH or SJ with JASO MA Viscosity SAE 10W 40 Capacity 3 1 L 3 3 US gt when filter is not removed 3 3 L 3 5 US gt when filter is removed 3 8 L 4 0 US gt when engine is completely dry Level Between upper and lower level lines Oil Pressure Measurement Oil
304. oltage low Battery voltage low Spark plug dirty broken or maladjusted Stick coil wiring trouble Stick coil not in good contact Spark plug incorrect IC igniter in ECU trouble Camshaft position sensor trouble Crankshaft sensor trouble Stick coil trouble Fuel air mixture incorrect 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 APPENDIX 17 19 Troubleshooting Guide Air cleaner duct loose 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 warped Cylinder head gasket damaged Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Other IC igniter in ECU trouble Throttle body assy not synchronizing Engine oil viscosity too high Drive train trouble Brake dragging Air suction valve trouble Vacuum switch valve trouble Engine overheating Clutch slipping Poor Running or No Power at High Speed Firing incorrect Spark plug dirty broken or maladjusted Stick coil wiring trouble Stick coil not in good contact Spark plug incorrect Camshaft position trouble IC igniter in
305. olve 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 tight 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 OColor Codes BK Black G Green P Pink BL Blue GY Gray PU Purple BR Brown LB Light blue R Red CH Chocolate LG Light green W White DG Dark green O Orange Y Yellow OElectrical Connectors Female Connectors A 8 06010151 C ELECTRICAL SYSTEM 16 21 Precautions Male Connectors B 8 06010251 6 16 22 ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection e Visually inspect the wiring for signs of burning fraying etc If any wiring is poor replace the damaged wiring e Pull each connector A apart and inspect it for corrosion dirt and damage 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
306. on 11 6 Drive Ghain Removal t et Ret a ertet or Pee HR D 11 6 Drive Chain 11 6 Drive Chain 11 7 eelef e le ne EE 11 10 Engine Sprocket Removal E erat doa dee on 11 10 Engine Sprocket e EE 11 10 Rear Sprocket eene nnn n nnne n nne nenne rne 11 11 Rear Sprocket Installation 11 11 Coupling Bearing ne RE 11 11 Coupling Bearing Installation pp 11 11 Coupling Installation 11 12 Coupling Bearing Inspection sec Lose 11 12 Coupling Bearing bubrication ii ire bb tr na eee Pap ek eene deht 11 12 Coupling Damper Inspechon nnns 11 12 Sprocket Wear Inspection 11 13 Rear Sprocket Warp Inspection nnne 11 13 11 2 FINAL DRIVE Exploded View FINAL DRIVE 11 3 Exploded View No Fastener Torque Remarks Nm kgfm ft Ib Engine sprocket cover bolts 9 8 1 0 87 in lb Engine sprocket nut MO Rear sprocket nuts Speed sensor cover bolts L Speed sensor bolt L Rear axle nut G Apply grease HO Apply heavy oil L Apply a non permanent locking agent MO Apply molybdenum disulfide oil R Replacement Parts OO gt 11 4 FINAL DRIVE Specifications Item Standard Service Limit Dri
307. onds LED light normal lights blinks immediately after ignition SW and stays on DFI problem lights up immediately after ignition SW ON but goes off after about 10 seconds DFI problem unlights LED light ECU or its wiring fault sometimes lights up probably wiring fault Starting starter motor not rotating difficulty starter motor rotating but engine doesn t turn over starter motor and engine don t turn over no fuel flow n no fuel in tank a no fuel pump sound engine flooded do not crank engine with throttle opened which promotes engine flooding no spark choke lever is not pulled fully when using the lever pull it fully when using other Engine stops right after starting when opening throttle grip when closing throttle grip when moving off when stopping the motorcycle when cruising other FUEL SYSTEM 3 23 Troubleshooting the DFI System Poor running at low speed Poor running or no power at high speed choke lever pulled out fully push it in fully very low choke speed adjust choke cable very low idle speed a very high idle speed rough idle speed battery voltage is low charge the battery spark plug loose tighten it spark plug dirty broken or gap
308. onnect 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 Connecting Rod Twist 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 lf 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 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
309. ore 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 GJO5034BS1 6 6J05030781 6 6J05036BSi 6 10 14 WHEELS TIRES Tires e Check to see that the rim lines A on both sides of the tire sidewalls are parallel with the rim flanges x lf 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 Tire Inspection e Install the brake disc s so that the marked side faces out see Brakes chapter e Adjust the wheel balance see Balance Adjustment e Install the air valve cap 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 lt is generally under stood that higher running durability is obtained by perma nent internal repair
310. ose installed e Draw out the holder shaft pin A and take off the holder shaft B e Remove the pad C on the piston side e Push the holder D towards the piston and remove the pad of the other side E from the holder shaft F Rear Brake Pad Installation e Push the caliper piston in by hand as far as it will go e Install the anti rattle spring in its correct position e Install the pad on the piston side first then install the other pad on the holder e Install the caliper see Caliper Installation WARNING Do not attempt to drive the motorcycle until a full brake pedal is obtained by pumping the brake pedal until the pads are against the disc The brake will not function on the first application of the pedal if this is not done Brake Pad Wear Inspection e Refer to the Brakes in the Periodic Maintenance chapter Master Cylinder BRAKES 12 15 Front Master Cylinder Removal e Disconnect the front brake light switch connectors A e Remove the banjo bolt B to disconnect the brake hose from the master cylinder C see Brake Hose Removal In stallation e Unscrew the clamp bolts A and take off the master cylin der as an assembly with the reservoir brake lever and brake switch installed Front Master Cylinder Installation e Install the front master cylinder so that the punch mark A of the handlebar is aligned with the mating surface B of the master cylinder clamp to level the
311. oth sides handlebar movement changes the idle speed the throttle cables may be improperly adjusted or incorrectly routed or damaged Be sure to correct any of these conditions before riding see Cable Wire and Hose Routing section in the Appendix chapter WARNING Operation with improperly adjusted incorrectly routed or damaged cables could result in an unsafe riding condition e Check idle speed xf the idle speed is out of the specified range adjust it Idle Speed Standard 1 100 50 r min rpm Engine Vacuum Synchronization Inspection NOTE OThese 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 the fuel tank see Fuel System DFI chapter e Pull off the vacuum hoses and the rubber cap s from the right fitting of each throttle body Pull off the vacuum switch valve hose thick A from the air cleaner housing B Front C CAUTION Do not remove the inlet air pressure sensor hoses on the left fitting of each throttle body e Connect a commercially available vacuum gauge to these right fittings of the throttle body as shown e Connect a highly accurate tachometer to one of the stick coil primary leads e Plug Vacuum Switch Valve Hose thick and its Air Cleaner Housing Hole Vacuum Hoses of Throttle Assy see the next figure Vacuum Switch Valve Hose small
312. otor A while turning B the starter clutch gear C e Install the washer A so that the chamfer side B faces outward NOTE OConfirm the alternator rotor fit or not to the crankshaft before tightening it with specified torque Olnstall the rotor and tighten it with 70 7 0 52 of torque ORemove the washer and rotor bolt OCheck the tightening torque with rotor puller the rotor is not pulled out with 20 N m 2 0 kgf m 15 of drawing torque it is installed correctly xIf the rotor is pulled out with under 20 N m 2 0 15 ft lb of drawing torque clean off any oil dirt or flaw of the crankshaft and rotor tapered portion and dry them with a clean cloth Then confirm that it is not pulled out with above torque e Tighten the alternator rotor bolt while holding the alterna tor rotor steady with the rotor holder Special Tool Rotor Holder 57001 1543 Torque Alternator Rotor Bolt 110 N m 11 kgf m 81 ft Ib 16 32 ELECTRICAL SYSTEM Charging System e Apply a thin coat of molybdenum disulfide grease to the shaft A and install it and starter idle gear B 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
313. ove Handlebar Holder Plugs Clutch Lever Assembly A Left Handlebar Switch Housing B Front Brake Master Cylinder C Right Handlebar Switch Housing D Handlebar Holder Bolts E e Remove the handlebar holder F and then pull out the handlebar e Remove the cotter pins A e Remove the mounting nuts B washers and handlebar lower clamps C Handlebar Installation e Install the handlebar lower clamps A noting the letters L B and R C e Tighten Torque Handlebar Lower Clamp Nuts 34 N m 3 5 kgf m 25 ft lb e Align the punch mark A on the handlebar and the corner edge B on the lower clamp e Tighten the front clamp bolts first and then the rear clamp bolts There will be a gap A at the rear part of the clamp after tightening Torque Handlebar Clamp Bolts 25 N m 2 5 kgf m 18 ft Ib e Install the removed parts see appropriate chapters FRAME 15 1 Frame Table of Contents leie e i r IE Seats MI Rear Seat emoVval esos eet tts tos ed Rear Seat Installation o eI ek ood vec nter aie Zeg Front Seat En Le Ce Front EE e EE ee e Side Cover Rernoval d n t einblenden side Cover Installations cet eR sue ellen e Inner Gover Removal tie catenin aT ae Inner Cover Installation 3 2 ect
314. ove the valve Special Tools Valve Spring Compressor Assembly 57001 241 A Adapter 620 57001 1154 B 6 15043851 6 Valve Installation e Replace the oil seal with a new one PV e Apply a thin coat of molybdenum disulfide grease to the valve stem before valve installation B e Install the springs so that the closed coil end faces down A wards 6 D Valve Stem A Oil Seal B Spring Seat C Closed Coil End D Valve Spring White E Retainer F Split Keepers G 6 15028851 6 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 GE15045BS1 6 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 4 57001 1273 5 22 ENGINE TOP END Valves Valve Guide Installation e Apply oil to the valve guide outer surface before installa tion e Heat the area around the valve guide hole to about 120 150 C 248 302 F e Drive the valve guide in from the top of the head using the valve guide arbor The flange stops the guide from going in too far Special Tool Valve Guide Arbor 4 57001 1273 e Wait until the cylinder head cools down and then ream
315. painted or plastic parts e When removing the brake hose temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum e There are washers on each side of the brake hose fitting Replace them with new ones when installing e When installing the hoses avoid sharp bending kinking flattening or twisting and route the hoses according to Cable Wire and Hose Routing section in General Infor mation chapter e Tighten Torque Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft lb e Bleed the brake line after installing the brake hose see Brakes in the Periodic Maintenance chapter Brake Hose Inspection e Refer to the Brakes in the Periodic Maintenance chapter SUSPENSION 13 1 Suspension Table of Contents Exploded ET 13 2 eelere 13 6 Speclal TOOls aoc ee Pr d SEN SHARE 13 7 Front do 13 8 Eront Fork Removal diete et s ts a FO ERR TCR NAR 13 8 Front Fork dl UE Is EE 13 8 Front Fork 13 8 Front Fork DISaSsSmbly oue Bata Gr 13 9 Front Fork Assembly T te ee nes 13 11 Inner Tube Outer Tube 13 12 D st Seal een 13 12 elei le Min Geer e toc EE 13 12 Rear Shock Absorber nennen nennen
316. pect see chapter 3 Inlet air temperature sensor trouble Inspect see chapter 3 Water temperature sensor trouble Atmospheric pressure sensor trouble Subthrottle sensor trouble Subthrottle valve actuator trouble Stick coil trouble Engine oil level to high Spark plug dirty broken or gap maladjusted Stumble Too low fuel pressure Fuel injector trouble Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect and replace see chapter 16 Repair see chapter 7 Clean spark plugs and adjust plug gap see chapter 2 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Main throttle sensor malfunction Inspect see chapter 3 Subthrottle sensor trouble Subthrottle valve actuator trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Inlet air pressure sensor trouble Inspect see chapter 3 Inspect see chapter 3 Surge Unstable fuel pressure Fuel injector trouble Water temperature sensor trouble Backfiring when deceleration Fuel pressure regulator trouble Inspect and replace fuel pump or kinked fuel line Inspect and repair fuel line see chapter 3 Inspect see chapter 3 Inspect see chapter 3 DEI System Troubleshooting Guide FUEL SYSTEM DFI 3 29 Symptoms or Possible Causes Actions
317. per mounting bolts 25 2 5 18 Rear master cylinder mounting bolts 25 2 5 18 Rear master cylinder push rod locknut 18 1 8 13 Suspension Front fork clamp bolts Upper 20 2 0 14 Front fork clamp bolts Lower 20 2 0 14 AL Front fork top plugs 25 2 5 18 Front fork bottom Allen bolts 30 3 1 22 L Front axle clamp bolt 34 3 5 25 ub un absorber nuts upper and 34 3 5 25 Swingarm pivot shaft nut 108 11 80 Swingarm pivot shaft locknut 98 10 72 Uni trak Rocker arm nut 34 3 5 25 Tie rod nuts 59 6 0 43 Steering Steering stem head bolt 108 11 80 Steering stem nut 27 2 8 20 Handlebar clamp bolts 25 2 5 18 S PERIODIC MAINTENANCE 2 9 Torque and Locking Agent Fastener E Remarks kgf m ft Ib Handlebar lower clamp nuts 34 3 5 25 Switch housing screws 3 5 0 36 31 in Ib Front fork clamp bolts Upper 20 2 0 14 Front fork clamp bolts Lower 20 2 0 14 AL Frame Footpeg bracket bolts 34 3 5 25 L Side stand bolt 44 4 5 33 Side stand switch bolt 8 8 0 90 78 Front fender bracket bolts 8 8 0 90 78 in lb L Front fender bolts 3 9 0 40 35 in lb L Side stand bracket bolts 49 5 0 36 Electrical System Spark plugs 13 1 3 113 in lb Alternator rotor bolt 110 11 81 Stator coil bolts 11 1 1 95 in lb Alternator lead holding plate bolt 11 1 1 95 in lb L Engine ground cable terminal bolt 9 8 1 0 87 in lb Alternator cover bolts 11 1 1 95 in lb Crankshaft sensor cover bolts 11 1 1 95 Crankshaft s
318. ploded View Torque No Fastener eh Remarks N m kgf m ft Ib 1 Front fender bracket bolts 8 8 0 90 78 in lb L 2 Front fender bolts 3 9 0 40 35 in lb 15 6 FRAME Exploded View 6002093895 C FRAME 15 7 Seats Rear Seat Removal e Insert the ignition switch key into the seat lock A turning the key clockwise pulling up on the rear of the seat B and pulling the seat backward Rear Seat Installation e Slip the rear seat hooks A into the hollow cubic bracket B on the frame e Insert the seat latch C into the latch hole D e Push down the rear part of the seat until the lock clicks 28 Front Seat Removal e Remove Rear Seat see Rear Seat Removal Mounting Bolt A Seat Bracket B e Remove the front seat C by pulling the rear of it up and backward Front Seat Installation e Slip the front seat hook A under the brace B on the fuel tank bracket 15 8 FRAME Side Covers Side Cover Removal e Remove the bolt A e Pull the side cover B evenly outward to clear the stop pers Side Cover Installation e Insert the tabs A into the holes B e Install the bolt FRAME 15 9 Fairings Inner Cover Removal e Remove Inner Cover Screws A and Washers Inner Cover B Inner Cover Installation e Fit the projection A on the inner cover B into the hole C in the fairing e Install the washers and inner cover
319. ply grease to the outer races and drive them into the head pipe at the same time Special Tool Bearing Driver Set 57001 1129 A e Replace the bearing inner races and oil seal with new ones e Apply grease to the oil seal e Drive the lower ball bearing inner race applied the grease onto the stem Special Tools Steering Stem Bearing Driver 57001 1344 A Steering Stem Bearing Driver Adapter 57001 1345 B e Apply grease the lower ball bearing A and install it onto the stem e Apply grease to the upper ball bearing B and inner race C e Install the stem A through the head pipe and install the ball bearing B and inner race C on it e Install the stem cap D and steering stem nut E e Settle the inner races in place as follows OTighten the steering stem nut with 39 N m 4 0 kgf m 29 ft lb of torque first and loosen it a fraction of a turn until it turns lightly Afterward tighten it again with specified torque using a stem nut wrench A in the direction shown OCheck that there is no play and the steering stem turns smoothly without rattles If not the steering stem bearings may be damaged Special Tool Steering Stem Nut Wrench 57001 1100 Torque Steering Stem Nut 27 N m 2 8 kgf m 20 ft lb GNO5015BSi 6 GNO50604S1 14 8 STEERING Steering Stem e Install the claw washer A so that its bent side B faces upward and engage the bent claws with
320. pound 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 Lapper A Valve Seat B Valve C e The seating area should be marked about in the middle of the valve face lf 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 Engine Top End in the Periodic mainte nance chapter GE15012381 C GE15012081 ENGINE TOP END 5 27 Valves Valve Seat Repair START Machinist s dye on seat 45 Grind Tool 45 Cutter Purpose make seating area smooth and round Measure Seating Area O D Tool Vernier Caliper Purpose check seat O D against spec 45 Grind Tool 45 Cutter Purpose increase O D of seat area to spec Machinist s dye on seat 32 Grind Tool 32 Cutter Purpose reduce O D of seat area to spec Measure Seat Width Tool Vernier Caliper Purpose check seat width against spec 45 Grind Machinist s Tool 45 Cutter dye on seat Purpose increase width of seat area beyond spec to inc
321. r 4 Valve Seat Cutter 60 627 57001 1275 57001 1409 gt Fork Oil Level Gauge Spark Plug Wrench Owner s Tool 57001 1290 92110 1146 SS q 819211465 C Compression Gauge Adapter M10 x 1 0 Kawasaki Bond Silicone Sealant 57001 1317 56019 120 5 10 ENGINE TOP END Clean Air System Air Suction Valve Removal e Remove Fuel Tank see Fuel System DFI chapter Connector A from Clamp B Air Suction Valve Cover Bolts C and Clamp Air Suction Valve Cover D Air Suction Valve Air Suction Valve Installation e Install the air suction valve A so that its wider side B of the reed valve case faces the front e Tighten Torque Air Suction Valve Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib Air Suction Valve Inspection e Refer to the Engine Top End in the Periodic Maintenance chapter Vacuum Switch Valve Removal e Remove Fuel Tank see Fuel System DFI chapter Vacuum Switch Valve A Vacuum Switch Valve Installation e Install the vacuum switch valve so that the vacuum fitting A faces left side e Route the hoses correctly see Appendix chapter Clean Air System ENGINE TOP END 5 11 Vacuum Switch Valve Test e Remove Vacuum Switch Valve see Vacuum Switch Valve Re moval e Connect a vacuum gauge A and syringe B or fork oil level gauge to the vacuum hoses as shown Special Tool Fork Oil Level Gauge 57001 1290 Air Flow C e Gradually raise th
322. r Mud Guard see Frame chapter Brake Hose Clamp A Rear Wheel see Wheels Tires chapter Lower Shock Absorber Nut and Bolt A Upper Tie rod Nut and Bolt B e Remove the both frame cover see Frame chapter e Unscrew the swingarm pivot locknut A using the nut wrench B Special Tool Swingarm Pivot Nut Wrench 57001 1541 e Unscrew the swingarm pivot nut A and loosen the swingarm pivot shaft B Pull off the pivot shaft and remove the swingarm 13 16 SUSPENSION Swingarm Swingarm Installation OPlace the collar A on the stopper B inside the frame C e Insert the pivot shaft into the frame from the right side e Tighten the pivot shaft so that the clearance D between the collar and the frame come to zero mm e Tighten Torque Swingarm Pivot Shaft Nut 108 N m 11 kgf m 80 ft lb e Tighten the pivot locknut using the socket wrench Special Tool Swingarm Pivot Nut Wrench 57001 1541 Torque Swingarm Pivot Shaft Locknut 98 10 kgf m 72 ft lb e Install the removed parts see appropriate chapters Swingarm Bearing Removal e Remove Swingarm Collar A Grease Seals B Sleeve C Circlip right side D e Remove the ball bearing and needle bearings Special Tool Oil Seal amp Bearing Remover 57001 1058 A GMOG036BS1 C GM06037BS2 C 6 06060351 C SUSPENSION 13 17 Swingarm Swingarm Bearing I
323. r 57001 1394 x If the test light doesn t flicker or the tester needle doesn t oscillates check the wiring and connectors again If the wiring is good check the injector voltage If the wiring is good inspect the ECU for its ground and power supply see ECU section 6617024251 6 6617024351 6 3 84 FUEL SYSTEM DFI Fuel Injectors Injector Resistance Inspection e Remove the fuel tank see Fuel Tank Removal e Disconnect the connector from the injector A see Throt tle Body Assy Disassembly Assembly e Measure the injector resistance with the hand tester B Special Tool Hand Tester 57001 1394 Injector Resistance Connections to Injector Meter Meter 1 WIR BL R Terminal 2 WIR Terminal 3 WIR BL BK Terminal 4 WIR BL Y Terminal Standard about 11 7 12 3 20 C 68 F x lf the reading is out of the range perform the Injector Unit Test lf the reading is normal perform the Injector Unit Test for confirmation Injector Unit Test e Use two leads A and the same test light set B as in Injector Signal Test Rating of Bulb C 12 V x 3 3 4 W 12 V Battery D CAUTION Be sure to connect the bulb in series The bulb works as a current limiter to protect the solenoid in the injector from excessive current e Connect the test light set to the injector E as shown Open and connect F
324. r B e Place a suitable container under the alternator cover A and remove the cover bolts B e Pull the alternator cover outside 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 56019 120 e Check that knock pins B are in place on the crankcase e Install a new gasket and the alternator cover e Tighten Torque Alternator Cover Bolts 11 N m 1 1 kgf m 95 in Ib Stator Coil Removal e Remove Alternator Cover see Alternator Cover Removal Holding Plate Bolt A and Plate Alternator Lead Grommet B Stator Coil Bolts C e Remove the stator coil D from the alternator cover 16 30 ELECTRICAL SYSTEM Charging System Stator Coil Installation e Apply a non permanent locking agent to the threads of the stator coil bolts and tighten them Torque Stator Coil Bolts 11 1 1 kgf m 95 in Ib e Secure the alternator lead with a holding plate and tighten the bolt OApply a non permanent locking agent to the threads of the plate bolt Torque Alternator Lead Holding Plate Bolt 11 N m 1 1 kgf m 95 e Apply silicone sealant to the circumference of the alter nator lead grommet and fit the grommet into the notch of the cover securely Sealant Kawasaki Bond Silicone Sealant 56019 120 e Install the alternator
325. r head bolts 11 12 Torque Cylinder Head Bolts M6 12 1 2 kgf m 104 onn e in Ib 5 20 ENGINE TOP END Cylinder Head e Install Front Camshaft Chain Guide A O ring B Collar C e Tighten Torque Front Camshaft Chain Guide Bolt Upper D 25 2 5 kgf m 18 ft Ib Front Camshaft Chain Guide Bolt Lower E 12 1 2 kgf m 104 in Ib e Install the removed parts see appropriate chapters Cylinder Head Warp e Clean the cylinder head e Lay a straightedge across the lower surface of the cylinder head at several positions 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 If the cylinder head is warped more than the service limit replace it lf 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 GE14039BS2 C GE14038BS1 C ENGINE TOP END 5 21 Valves Valve Clearance Inspection e Refer to the Engine Top End in the Periodic Maintenance chapter Valve Removal e Remove the cylinder head see Cylinder Head Removal e Remove the 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 rem
326. r suction valve cover bolts 9 8 1 0 87 in lb 2 Cylinder head cover bolts 9 8 1 0 87 in lb S 3 Camshaft cap bolts 12 1 2 104 in Ib S 4 Camshaft chain guide bolts 12 1 2 104 in Ib S 5 Cylinder head bolts M10 new bolts 54 5 5 40 Geer 5 Cylinder head bolts M10 used bolts 49 5 0 36 MOE Washer 6 Oyindermeadtols u 12 S t 8 TwoWebodyhoderbots 13 13 mnb 79 Throttle body assy holder clamp bots 20 020 irinib 104 inib mit 18 E 104 inib 18 95 in 21 GERS EO Apply engine oil L Apply a non permanent locking agent M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts S Follow the specific tightening sequence SS Apply silicone sealant Kawasaki Bond 56019 120 5 4 ENGINE TOP END Exploded View 6 02093 45 ENGINE TOP END 5 5 Exploded View N Fast Remark astener emarks N m kgf m ft Ib 1 Coolant drain plug cylinder 9 8 1 0 87 in lb 2 Exhaust pipe manifold holder nuts 17 1 7 12 3 Muffler body clamp bolt 17 1 7 12 4 Muffler body mounting bolt 30 3 0 22 5 Crankshaft sensor cover bolts 11 1 1 95 in Ib 6 1T marked side faces up 2T marked side faces up 8 Hollow mark faces forward EO Apply engine oil R Replacement Parts Exhaust System MANIFOLD SILENCER ITEM NA
327. ram Australia Ignition Switch Front Brake Light Stop Switch Right Switch Housing Engine Starter Button Spark Plugs 1 2 3 44 es zx Fuel We Radiator Si 3 Lived Horn Fan a SE 12V 2 54 Motor Fan Switch Ignition a Coils Sa 5 55 ER as gt aa ER SES Joint Connector D BK Y BK Y BK Y BK Y Regulator Rectifier 1 Right Turn Signal L oe mimo Push a GFF Push Released Released Lf J Ls Lo omo inf compo JT Indicator Light LED 2 High Beam Indicator Light LED 3 Neutral Indicator Light LED 4 011 Pressure Warning Indicator Light LED 5 Fl Indicator Light LED 6 Odometer Trip Meter Clock Indicator 7 Water temperature Gauge 8 Fuel Level Gauge 9 Tachometer 10 Speedometer 11 Meter Light LED 12 Left Turn Signal Indicator Light LED Front Right Turn Signal Fait E Light 12V21W e di LE sc JEE Headlight High H za See 12V58N 552558050 ct 58 258 5554555 58 R BK BK SY Headlight Low 12 55 e et BL Y er ep BK Y BK Y BK Y BK Y 4 BK Y Front Left Turn Signal BK Y Left Switch Housing ECU Fue Light 12V21W BK Y 1 Horn Button Main Pump 2 Turn Signal Switch Junction Box Relay Relay n e Joint Con
328. rd 0 99 1 03 V DC at idle throttle opening 4 19 4 39 V DC at full throttle opening the output voltage is out of the standard inspect the main throttle sensor resistance If the output voltage is normal check the wiring for conti nuity Wiring Connection ECU Connector A Throttle Sensor Connector B Y W lead ECU terminal 2 BR BK lead ECU terminal 14 the wiring is good check the ECU for its ground and power supply see ECU section 68017260852 C 3 42 FUEL SYSTEM DFI Main Throttle Sensor Service Code 11 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 6kQ If the reading is out of the range replace the throttle body assy xIf the reading is within the range but the problem still exists replace the ECU see this chapter GC17116BS1 C ON 2 1 U BL BR BK Y W Y W BR BK BL 6617136 1 C A ECU Main Throttle Sensor m Throttle Body Assy Connector FUEL SYSTEM 3 43 Inlet Air Pressure Sensor Service Code 12 CAUTION Never drop the sensor especially on a hard
329. rease O D 60 Grind Tool 60 Cutter Purpose reduce seat width to specification Lap Valve Tools Valve Lapper Grinding Compound Purpose perfectly match valve FINISHED and seat area check valve head for damage 5 28 ENGINE TOP END Cylinder Pistons Cylinder Removal e Remove Cylinder Head see Cylinder Head Removal Water Hose A e Remove the cylinder B Cylinder Installation NOTE new cylinder is used use new piston ring e Install the dowel pins A and new cylinder gasket B e Apply engine oil to the cylinder bore e The piston ring openings must be positioned as shown in the 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 Oil Ring Steel Rails C Oil Ring Expander D Hollow E 30 40 F e Position the crankshaft at 2 3 piston TDC e Prepare two auxiliary head bolts with their head cut Olnstall the two cylinder head bolts A diagonally in the crankcase e Install the cylinder block B Pistons C OFirst insert the 2 3 pistons and then rotate the crank shaft at 90 angle Olnsert the piston rings with your thumbs or the thin screwdriver Piston Removal e Remove the cylinder see Cylinder Removal e Place a clean cloth under the pistons and remove the pis ton pin snap ring A from the outside of each piston 0 15
330. reservoir e The master cylinder clamp must be installed with the ar row 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 Front Master Cylinder Clamp Bolts 8 8 0 90 kgf m 78 in lb e Replace the washers on each side of the hose fitting with new ones e Tighten the brake hose banjo bolt Torque Brake Hose Banjo Bolt 25 N m 2 5 kgf m 18 ft Ib e Bleed the brake line see Brake Line Bleeding in the Pe riodic Maintenance chapter e Check the brake for good braking power no brake drag and no fluid leakage 12 16 BRAKES Master Cylinder Rear Master Cylinder Removal e Unscrew the brake hose banjo bolt A on the master cylin der see Brake Hose Removal Installation e Pull off the reservoir hose lower end B and drain the brake fluid into a container Loosen the master cylinder mounting bolts C lightly e Remove the cotter pin D NOTE OPull off the joint pin while pressing down the brake pedal e Unscrew the master cylinder mounting bolts and remove the master cylinder Rear Master Cylinder Installation e Replace the cotter pin A with a new one e Replace the washers on each side of hose fitting with new ones e Tighten the following bolts Torque Rear Master Cylinder Mounting Bolts 25 N m 2 5 kgf m 18 ft Ib Brake Hose Banjo Bolt 25 N m 2 5 k
331. rew and or idle adjusting screw maladjusted Air passage clogged Air cleaner clogged poorly sealed or miss ing Compression Low Fuse blown Spark plug loose rotating but engine doesn t Cylinder head not sufficiently tightened Starter clutch trouble Vehicle down sensor DFI coming off 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 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 No fuel flow No fuel in tank Fuel pump trouble Poor Running at Low Speed Spark weak Fuel tank air vent obstructed Fuel filter clogged Fuel line clogged Engine flooded Clean spark plug and adjust plug gap Starting technique faulty When flooded do not crank the engine with the throttle fully opened This promotes engine flood because more fuel is supplied automatically by DFI No spark spark weak Vehicle down sensor DFI coming off Ignition switch not ON Engine stop switch turned OFF Clutch lever not pulled in or gear not in neu tral Battery v
332. ries and a test light 12 V 3 6 W bulb in a socket with leads CAUTION The test light works as an indicator and also a cur rent limiter to protect the regulator rectifier from ex cessive current Do not use an ammeter instead of a test light e Check to be sure the rectifier circuit is normal before con tinuing 16 34 ELECTRICAL SYSTEM Charging System e Do the 1st step regulator circuit test OConnect the test light and the 12 V battery to the regula tor rectifier as shown OCheck BK1 BK2 and BK3 terminal respectively x If the test light turns the regulator rectifier is defective Replace it lf the test light does not turn on continue the test e Do the 2nd step regulator circuit test OConnect the test light and the 12 V battery in the same manner as specified in the Regulator Circuit Test 1st Step OApply 12 V to the voltage BR terminal OCheck BK1 BK2 and terminal respectively x If the test light turns on the regulator rectifier is defective Replace it xIf the test light does not turn on continue the test e Do the 3rd step regulator circuit test OConnect the test light and the 12 V battery in the same manner as specified in the Regulator Circuit Test 1st Step OMomentarily apply 24 V to the voltage BR terminal by adding a 12 V battery OCheck BK1 2 and terminals respectively CAUTION Do not apply more than 24 volts If more than 24 vo
333. rm stop B e Engage the drive chain with the rear sprocket e Insert the axle from the right side of the wheel and tighten the axle nut Torque Rear Axle Nut 108 N m 11 kgf m 80 ft Ib 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 degree OLoosen once and tighten again when the slot goes past the nearest hole 1 07000851 Wheels Rims WHEELS TIRES 10 9 e Bend the cotter pin A over the nut If the rear axle nut is not securely tightened or the cotter pin is not installed an unsafe riding condi tion may result e Adjust the drive chain slack after installation see Final Drive chapter e Check the rear brake effectiveness 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 Wheel Inspection e Raise the front rear wheel off the ground Special Tool Jack 57001 1238 e Spin the wheel lightly and check for roughness or binding If roughness or binding is found replace the hub bearings e Inspect the wheel for small cracks dents bending or warp xIf there is any damage to the wheel replace the wh
334. round 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 ground 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 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 no abnormality is found the wiring connectors and DFI parts replace the ECU OLead Color Codes BK Black G Green P Pink BL Blue GY Gray PU Purple BR Brown LB Light blue R Red CH Chocolate LG Light green W White DG Dark green O Orange Y Yellow 6617029251 6 3 20 FUEL SYSTEM DFI Troubleshooting the DFI System OThere are two ways to inspect the DFI system One is voltage Check Method and the other is Resistance Check Method Voltage Check Method OThis method is conducted by measuring the input voltage B to a sensor A first and then the output voltage C from the sensor OSometimes this method can detect a fault of the ECU e Refer to each sensor inspection s
335. rt the engine and let it idle e Measure the fuel pressure with the engine idling Fuel Pressure idling Standard 310 kPa 3 2 kgf cm 46 psi NOTE OThe gauge needle will fluctuate Read the pressure at the average of the maximum and minimum indications lf the fuel pressure is normal the fuel circulation system fuel pump pressure regulator and oil passage is no faults Check the DFI electronic control system injectors sensors crankshaft sensor and ECU lf the fuel pressure is much lower than specified check the following Fuel Pump Inlet Hose Clogging Fuel Line Leakage Fuel Pump Operation check the sound of the pump Amount of Fuel Flow see Fuel Flow Rate Inspection lf the fuel pressure is much higher than specified check the following Delivery Pipe Clogging Injector Clogging e Remove the fuel pressure gauge and adapter e Install the fuel tank see Fuel Tank Installation Fuel Flow Rate Inspection NOTE OBe sure the battery is fully charged 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 Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately e Turn the ignition switch and engine stop switch OFF e Wait until the engine cools down
336. rter Idle Gear e Turn the starter motor clutch gear A by hand The starter motor clutch gear should turn clockwise B freely but should not turn counterclockwise C If the clutch does not operate as it should or if it makes noise go to the next step e Remove and disassemble the starter motor clutch and visually inspect the clutch parts x lf there is any worn or damaged part replace it NOTE OExamine the starter motor clutch gear as well Replace it if it is worn or damaged Starter Motor Clutch Disassembly e Remove Alternator Rotor see Electrical System chapter Starter Motor Clutch Bolts A and Starter Motor Clutch Starter Motor Clutch Assembly e Be sure to install the one way clutch A so that its flange B fits in the holder recess C e Apply a non permanent locking agent to the threads of the starter motor clutch bolts and tighten them Torque Starter Motor Clutch Bolts 12 N m 1 2 kgf m 104 in Ib CRANKSHAFT TRANSMISSION 9 23 Transmission Shift Pedal Removal e Mark A the position of the shift lever B on the shift shaft so that it can be installed later in the same position e Remove Shift Lever Bolt C Shift Lever e Remove Footpeg Bracket Bolts A Footpeg Bracket B e Remove the bolt A footpeg B and shift pedal C Shift Pedal Installation e Apply grease to the oil seal lip e Press the oil seals A in the shift pedal housing B so that the oil s
337. rts see appropriate chapters Ignition System ELECTRICAL SYSTEM 16 39 Crankshaft Sensor Inspection e Remove Right Frame Cover see Frame chapter Crankshaft Sensor Lead Connector A e Set the hand tester to the x 100 O range and connect lead to the yellow black lead and lead to the black lead in the connector Special Tool Hand Tester 57001 1394 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 Crankshaft Sensor Resistance 376 564 e Using the highest resistance range of the tester measure the resistance between the crankshaft sensor leads and chassis ground x Any tester reading less than infinity gt indicates a short necessitating replacement of the crankshaft sensor as sembly 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 Right Frame Cover see Frame chapter Crankshaft Sensor Lead Connector see Crankshaft Sensor Removal e Set the hand tester B to the x 10 V DC range and con nect it a commercially available peak voltage adapter A as shown in the diagram e Connect the black lead of the adapter to black lead and red lead to yellow
338. rty broken or gap maladjusted Gong sparkplug and Adjust plyggap B66 Chapter Spark plug cap trouble Inspect stick coil see chapter 16 Spark plug cap shorted or not in good contact Reinstall or inspect stick coil see chapter 16 Spark plug incorrect Replace it with the correct plug see chapter 16 IC igniter in ECU trouble Inspect see chapter 16 Ge starter lockout or sidestand switch Inspect each switch see chapter 16 Crankshaft sensor trouble Inspect see chapter 16 Stick coil trouble Inspect see chapter 16 Ignition switch shorted Inspect and replace see chapter 16 Engine stop switch shorted Inspect and repair or replace see chapter 16 Starter system wiring shorted or open Inspect and repair or replace see chapter 16 Main 30 A or ignition fuse blown Inspect and replace see chapter 16 Fuel air mixture incorrect Air cleaner clogged poorly sealed or missing Clean or reinstall see chapter 3 Leak from oil filler cap crankcase breather hose Inspect and repair or replace see chapter 3 or air cleaner drain hose P P P P Water or foreign matter in fuel Change fuel Inspect and clean fuel system see Water temperature sensor trouble Inspect Crankshaft sensor trouble Inspect Compression low Spark plug loose Reinstall see chapter 16 Cylinder head not sufficiently tightened down Tighten see chapter 5 see chapter 3 see chapter 3 chapter 3 Fuel pressure regu
339. ry peak voltage inspection the sp cified value No good Stick coil is defective Voltage is zero Inspect Replace stick coil aralm st zen 1 Lower resistance in a hand tester Use KAWASAKI Hand Tester 2 Crankshaft sensor peak voltage 3 Camshaft position sensor peak voltage No good Good Inspect 1 Adapter connection is incorrect or Replace bad parts No good adapter is defective or inspect them with 2 Ignition Switch and engine stop switch KAWASAKI Hand 3 Crankshaft peak voltage Tester 4 Camshaft position sensor peak voltage Good Replace bad parts Inspect the ECU Power Supply Good Inspect the wiring ECU is defective Replace ECU Connection and related parts GP10058B 16 48 ELECTRICAL SYSTEM Ignit ion System Ignition System Circuit co JO OP E zA S SS Y R R BK R BK R d 1 BR W R R BK R BK BK Y BESSER ee E BK Y BIN BEE SOS T E T W BL BK G Li BK W 1 2 3 4 gt U x BK Y E E BK Y Y BK Y R BR W lgnition Switch Engine Stop Switch Starter Button Spark Plugs Stick Coils Side Stand Switch Crankshaft Sensor Camshaft Position Sen SOT Throttle Se
340. s When due to a malfunction the FI indicator LED light re mains lit ask the rider about the conditions B under which the problem occurred and try to determine the cause C e First conduct a self diagnosis inspection and then a non self diagnosis inspection The non self diagnosis items are not indicated by the Fl indicator LED light Don t rely solely on the DFI self diagnosis function use common sense 255 455 EE Even when the DFI system is operating normally the FI indicator LED light A may light up under strong electrical in terference No repair needed Turn the ignition SW switch OFF to stop the indicator light When the FI indicator LED light goes on and the motor cycle is brought in for repair check the service codes When the repair has been done the LED light doesn t go on But the service codes stored in memory are not erased to preserve the problem history and the LED light can dis play the codes in the self diagnosis mode The problem history is referred when solving unstable problems When the motorcycle is down the vehicle down sensor is turned OFF and the ECU shuts off the fuel injectors and ignition system The FI indicator LED light blinks but the fault code cannot be displayed The ignition SW 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 SW OFF and then
341. s O 1 Brown 92028 1868 3 5 92028 1829 1 2 4 1 Black 92028 1867 3 5 92028 1828 1 2 4 Blue 92028 1866 3 5 92028 1827 bearing inserts for Nos 1 2 and 4 journals have an oil groove respectively Transmission Shift fork ear thickness Gear groove width 5 9 6 0 mm 0 232 0 236 in 5 8 mm 0 228 in 6 25 mm 0 246 in 6 05 6 15 mm 0 238 0 242 in 9 8 CRANKSHAFT TRANSMISSION Specifications Item Standard Service Limit Shift fork guide pin diameter 6 9 7 0 mm 6 8 mm 0 272 0 276 in 0 268 in Shift drum groove width 7 05 7 20 mm 7 3 mm 0 278 0 283 in 0 287 in CRANKSHAFT TRANSMISSION 9 9 Special Tools and Sealant Bearing Puller Kawasaki Bond Silicone Sealant 57001 135 56019 120 Bearing Puller Adapter Kawasaki Bond Silicone Sealant 57001 317 92104 1066 9 10 CRANKSHAFT TRANSMISSION Crankcase Splitting Crankcase Splitting e Remove the engine see Engine Removal Installation chapter e Set the engine on a clean surface and hold the engine steady while parts are being removed e Remove Crankshaft Sensor see Electrical System chapter Clutch see Clutch chapter External Shift Mechanism see External Shift Mecha nism Removal Starter Motor see Electrical System chapter Oil Pump see Engine Lubrication System chapter Alternator Rotor see Electric
342. s connected to the bottom of the air cleaner to drain water or oil accumulated in the cleaner part e Visually check the drain hose A if the water or oil accu mulates any water or oil accumulates the hose remove the plug B from the drain hose and drain it A WARNING Be sure to reinstall the plug in the drain hose after draining Oil on tires will make them slippery and can cause an accident and injury Air Cleaner Housing Removal e Remove the engine see Engine Removal Installation chapter OThe throttle body assy is removed during engine removal e Remove the right and left air cleaner housing bolts e Move the air cleaner housing A forwards and remove it from the right side of the frame 3 94 FUEL SYSTEM DFI Fuel Tank Fuel Tank Removal 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 e Remove Seats see Frame chapter Fuel Tank Bolt A Fuel Tank Drain Hose e Disconnect the battery terminal e Turn both ignition switch and engine stop switch OFF e Wait until the engine cools down e Open the fuel tank cap A to lower the pressure in the tank ODuring tank removal
343. s new oil seals with manufacture and size marks facing Y out Make sure the seal is aligned properly when installing de 68020198 5 Circlips Cotter Pins Replace circlips or cotter pins that were removed with new X ones Install the circlip with its sharp edge facing outward Och and its chamfered side facing inward to prevent the clip from being pushed out of its groove when loaded Take care 4 not to open the clip excessively when installing to prevent 4 Won ll deformation i y 68020208 5 Lubrication It is important to lubricate rotating or sliding parts during ZR E assembly to minimize wear during initial operation Lubri H T ow Y cation points are called out throughout this manual apply SA A the specific oil or grease as specified 4 J d GB000218 5 1 6 GENERAL INFORMATION Before Servicing Direction of Engine Rotation When rotating the crankshaft by hand the free play amount of rotating direction will affect the adjustment Ro tate the crankshaft to positive direction clockwise 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 68020228 5 68020228 5 GENERAL INFORMATION 1 7 Model Identification ZR750 J1 Left Side View ZR750 J1 Right Side
344. s 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 2003 Kawasaki Heavy Industries Ltd First Edition 1 Sep 16 2003 M ABDC AC ATDC BBDC BDC BTDC C DC gt LIST OF ABBREVIATIONS ampere s after bottom dead center alternating current after top dead center before bottom dead center bottom dead center before top dead center degree s Celsius direct current farad s degree s Fahrenheit foot feet gram s hour s liter s rpm TDC TIR Dose 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 Read OWNER S MANUAL before operating 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
345. s 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 recommended Repair methods may vary slightly from make to make Follow the repair methods indicated by the manufacturer of the repair tools and materials so that safe results can be obtained 6J05037BS1 C Hub Bearing WHEELS TIRES 10 15 Hub Bearing Removal e Remove the wheel and take out the following Collars Coupling out of rear hub Grease Seals Circlip e Use the bearing remover to remove the hub bearings A CAUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Please blocks under the wheel so that the disc does not touch the ground Special Tools Bearing Remover Head 20 x 22 57001 1293 C Bearing Remover Shaft 13 57001 1377 B Hub Bearing Installation e Before installing the wheel bearings blow any dirt or for eign particles out of the hub with compressed air to pre vent contamination of the bearings e Replace the bearings with new ones NOTE Olnstall the bearings so that the marked side faces out e Install the bearings by using the bearing driver set which does not contact the bearing inner race e
346. screws Fairing Removal e Remove Fairing Mounting Bolts A both side Headlight Connectors Fairing Installation e Install the headlight connectors e Fit the projections A on the fairing bracket into the holes B in the fairing e Tighten the fairing mounting bolts Fairing Bracket Removal e Remove Fairing see Fairing Removal Meter Unit see Electrical System chapter Turn Signal Light Nuts A and Lights Rubber Cover B Clamps C Bolts D Fairing Bracket E 15 10 FRAME Seat Covers Seat Cover Removal e Remove Seats Screws A e Push the central pin and then remove the quick rivets A e Pull the front portions A of the seat cover outside B and then remove the seat cover backward Seat Cover Installation e Installation is reverse of removal e Putthe projections A into the grommets B on the frame FRAME 15 11 Mud Guard Mud Guard Removal e Remove Chain Cover see Final Drive chapter Bolt A Clamp B e Lift up the mud guard A and then pull it out backward Mud Guard Installation e Put the projections A into the grommets B 15 12 FRAME Fenders Front Fender Removal e Remove Front Wheel see Wheels Tires chapter Brake Hose Clamps Front Reflector Bolts A Bolts B both side e Remove the front fender C Front Fender Installation e Apply a non permanent locking agent to the threads of
347. se the brake D NOTE OThe 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 ORear Brake Repeat the above steps for the other bleed valve e Remove the clear plastic hose e Install the reservoir cap e Tighten Torque Front Brake Reservoir Cap Screws 1 0 N m 0 10 kgf m 9 in Ib e Follow procedure below to 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 e Tighten the bleed valve and install the rubber cap Torque Bleed Valve 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 6 13052BS2 C 65130248 5 2 34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Line Bleeding The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper
348. see chapter 3 Inspect and repair or replace see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 3 28 FUEL SYSTEM DFI DFI System Troubleshooting Guide Symptoms or Possible Causes Actions chapter Main throttle sensor trouble Inspect see chapter 3 Subthrottle sensor trouble Inspect see chapter 3 Subthrottle valve actuator trouble Water temperature sensor trouble Inspect see chapter 3 Atmospheric pressure sensor trouble Inspect see chapter 3 Inspect see chapter 3 Inlet air pressure sensor trouble Loose injector connectors Crankshaft sensor trouble Stick coil trouble Loose terminal of battery lead or engine ground lead Delay of ignition timing Inspect see chapter 3 Remedy see chapter 3 Inspect and repair or replace see chapter 16 Inspect and repair or replace see chapter 16 Inspect and repair see chapter 16 Inspect crankshaft sensor and IC igniter in ECU see chapter 16 Poor acceleration Choke lever pulled Push it see chapter 3 Too low fuel pressure Inspect see chapter 3 Water or foreign matter in fuel Change fuel Inspect and clean fuel system see chapter 3 Clogged fuel filter or pump screen Inspect and replace fuel pump see chapter 3 Fuel pump trouble Inspect see chapter 3 Fuel injector trouble Ins
349. sensor peak voltage Camshaft Position Sensor resistance Camshaft Position Sensor peak voltage Interlock Operation Voltage Stick coil Primary winding resistance Secondary winding resistance Primary peak voltage Spark plug Spark plug gap Sealed Battery 12 V 8 Ah 12 6 V or more Three phase AC 42 V or more 03 040 14 7 0 5 V 376 564 1 9 V or more 400 460 O 0 2 V or more 4 V or more 1 04 1 56 10 8 16 2 88 V or more 0 7 0 8 mm 0 028 0 031 Electric Starter System Starter motor Brush length Commutator diameter 12 mm 0 47 in Service limit 8 5 mm 0 33 in 28 mm 1 10 in Service limit 27 mm 1 06 in Switch and Sensor Rear brake light switch timing Engine oil pressure switch connections Fan switch connections Rising temperature Falling temperature Water temperature sensor resistance Fuel level sensor resistance Fuel position Empty position ON after about 10 mm pedal travel When engine is stopped ON When engine is running OFF From OFF to ON 93 103 C 199 217 F Fan stops with the temperature 3 8 C 38 46 F lower than the operation temperature range ON Less than 0 5 OFF More than 10 MO in the text 4 100 90 100 Q ELECTRICAL SYSTEM 16 11 Special Tools and Sealant Rotor Puller M16 M18 M20 M22 x 1 5 Needle Adapter 57001 1216 57001 1457 CG 8 5714575 C Flywheel amp Pulley Holder Harne
350. set to the x 250 V DC range OConnect the adapter to the lead wire peak voltage adapter A which is connected between the stick coil connector and stick coil Olnstall the new spark plug D into each stick coil E and ground them onto the engine ECU F Battery G Recommended Tool Peak Voltage Adapter Type KEK 54 9 B Brand KOWA SEIKI Special Tools Hand Tester 57001 1394 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 8 10011952 C 4 6GP100702S1 6 16 44 ELECTRICAL SYSTEM Ignition System WARNING avoid extremely high voltage shocks do not touch the spark plugs or tester connections e Turn the ignition switch and the 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 88 V or more e Repeat the test for the other stick coil the reading is less than the specified value check the following Stick Coils see Stick Coil Inspection Crankshaft Sensor see Crankshaft Sensor Inspection x lf the stick coils and crankshaft sensor are normal check the ECU see Fuel System DFI chapter Spark Plug Removal e Refer to the Electrical Sy
351. sion Low Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect and repair see chapter 3 Inspect see chapter 3 Inspect fuel pressure and replace fuel pump see chapter 3 Inspect see chapter 16 Inspect see chapter 16 Inspect see chapter 3 Spark plug loose Reinstall see chapter 16 Cylinder head not sufficiently tightened down Tighten see chapter 5 No valve clearance Adjust see chapter 2 Cylinder piston worn Inspect and replace see chapter 5 Piston ring bad worn weak broken or sticking Inspect and replace see chapter 5 Piston ring groove clearance excessive Inspect and replace see chapter 5 Cylinder head gasket damaged Replace see chapter 5 Cylinder head warped Inspect and replace see chapter 5 Valve guide worn or stem seal damaged Inspect and replace see chapter 5 Valve spring broken or weak Inspect and replace see chapter 5 Valve not seating properly valve bent worn or carbon accumulating on seating surface Camshaft cam worn Hesitation Too low fuel pressure Clogged fuel line Cracked or obstructed inlet air pressure sensor hose Fuel pump trouble Fuel injector trouble Inlet air temperature sensor trouble Inspect and repair or replace see chapter 5 Inspect and replace see chapter 5 Inspect see chapter 3 Inspect and repair
352. smission is in neutral When transmission is not in neutral DEAE Oil Pressure Switch Connections When engine is stopped Ge When engine is running a Engine lubrication system is in good condition Thr Radiator Fan Switch Inspection e Disconnect the connector A Switches and Sensors ELECTRICAL SYSTEM 16 75 e Remove the fan switch A e Suspend the switch A in a container of coolant so that the temperature sensing projection and threaded portion are submerged e Suspend an accurate thermometer B in the coolant so that the sensitive portions are located in almost the same depth NOTE OThe switch and thermometer must not touch the con tainer sides 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 switch across the terminals at the temperatures shown in the table Special Tool Hand Tester 57001 1394 xIf the hand tester does not show the specified values re place the switch Fan Switch Resistance Rising temperature From OFF to at 93 103 C 199 217 F Falling temperature Fan stops with the temperature 3 8 C 38 46 F lower than the operation temperature range ON Less than 0 5 O OFF More than 10 MO Water Temperature Sensor Inspection e Remove the fuel tank see Fuel System DFI chapter
353. socket with leads and the 12 V battery to the fuel pump connector as shown 12 V Battery A Test Light B Fuel Pump Connector C Fuel Reserve Switch D x If the test light doesn t light replace the fuel level sensor 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 level sensor is removed Leave the fuel reserve switch with leads for inspection connected for ten 10 minute Diode Rectifier Inspection e Remove the fairing see Frame chapter e Cut the vinyl tape A e Disconnect the diode B e Set the hand tester to the x 100 O range Special Tool Hand Tester 57001 1394 e Check the continuity between the diode terminals in both directions x lf there is continuity in one direction forward direction but no continuity infinity in the reverse direction the diode is normal The diode is defective if there is continuity after changing the direction or it if remains with no continuity NOTE OThe actual resistance measurement in the forward direction varies with the tester used and the individual diodes Generally speaking it is acceptable if the tester s indicator swings approximately halfway GPi8044BSi 6 8 18040251 6 16 80 ELECTRICAL SYSTEM Junction Box The junction box A has fuses B relays and diodes The relays and diodes can not be removed Junction Box Fuse Circuit Inspection e Remov
354. sor Connector A e Remove Engine Sprocket Cover B see Final Drive chapter 8 18070352 C Switches and Sensors ELECTRICAL SYSTEM 16 77 e Remove Bolts A Speed Sensor Cover e Remove Bolt A e Take out the speed sensor B e Connect the speed sensor connector A with the battery B 10 kO resistor C and hand tester D as shown 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 screw driver OThen the tester indicator should flick B xIf the tester indicator does not flick replace the speed sensor e Apply a non permanent locking agent to the sensor bolt and sensor cover bolts Torque Speed Sensor Bolt 6 9 N m 0 70 kgf m 61 in Ib Speed Sensor Cover Bolts 6 9 N m 0 70 kgf m 61 in Ib DG25V 8 8070151 6 16 78 ELECTRICAL SYSTEM Switches and Sensors Fuel Level Sensor Inspection e Remove Fuel Tank see Fuel System DFI chapter e Open the clamps A e Remove 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 lf the float does not move smoothly replace the sensor Float in Full Position A Float in Empty Position B Float Arm Stoppers C 105 2 112 2 mm 4 142 4 417 in from the Sensor Base Line D
355. sor trouble Throttle valves won t fully open Brake dragging Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect throttle cable and lever linkage see chapter 3 Inspect caliper fluid seal damage or clogging of master cylinder relief and supply ports see chapter 12 Clutch slipping Inspect friction plates for wear see chapter 6 Engine overheating water temperature sensor crankshaft sensor or speed sensor trouble see Overheating of Troubleshooting Guide in chapter 17 Engine oil level too high Repair see chapter 7 Engine oil viscosity too high Drive train trouble Camshaft cam worn Vacuum switch valve trouble Air suction valve trouble Catalytic converters melt down due to muffler overheating KLEEN Change see chapter 3 Inspect drive chain see chapter 2 and sprockets see chapter 11 Inspect and replace see chapter 5 Inspect and replace see chapter 5 Inspect and replace see chapter 5 Replace muffler see chapter 5 Exhaust Smokes Excessively White smokes Piston oil ring worn Inspect and replace see chapter 5 Cylinder worn Inspect and replace see chapter 5 Valve oil seal damaged Replace see chapter 5 Valve guide worn Replace the guide see chapter 5 Engine oil level too high Repair see chapter 7 Black smoke Air cleaner clogged Clean see chapter 3
356. ss Adapter 57001 1343 57001 1542 875715425 C Hand Tester Rotor Holder 57001 1394 57001 1543 e T 57571543 5 Flywheel Puller M38 x 1 5 Spark Plug Wrench Owner s Tool 57001 1405 92110 1146 819211465 C Lead Wire Peak Voltage Adapter Kawasaki Bond Silicone Sealant 57001 1449 56019 120 7571449ST C 16 12 ELECTRICAL SYSTEM Wiring Diagram Canada Fuel Fuel Radiator Level Horn Fan Redenwe bevel 19 9 5 Wotor Fan Switch Ignition Coils EIS Ba BR 8K BK Y BL W BK LG Wy BK Y Joint Connector D BK Y GA BK Y eK Y Ignition Switch IO Right Switch Housing Front Engine Starter Brake Stop Button Light Switch BATTERY Fe pan BATTERY Hana rent ion Regulator Rectifier 1 Right Turn Signal Indicator Light LED 2 High Beam Indicator Light LED 45 Neutral EE 4 Dil Pressure Warning i m Indicator Light LED 5 FI Indicator Light LED 6 Odometer Trip Meter Clock Indicator 7 Water temperature Gauge Pons ene EE 9 Tachometer 10 Speedometer 11 Meter Light LED 12 Left Turn Signal Indicator Light LED Front Right Turn Signal Running Position Light 12V21 5W er ay BK Y K Y BL R BL ight High
357. ssion to jump out of gear when under power 90 A Shift Fork Gear Groove Wear e Measure the thickness of the shift fork ears A and mea sure the width B of the gear grooves xIf 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 9 6 0 mm 0 232 0 236 Service Limit 5 8 mm 0 228 in xIf 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 e Measure the diameter of each shift fork guide pin A and measure the width B of each shift drum groove xIf the guide pin 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 Service Limit 6 8 mm 0 268 in lf 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 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 ee E 6113014551 6 6113133851 6 6113134851 6 6113135851 6 WHEELS TIRES 10 1 Wheels Tires Table of Contents
358. stall the lead upward Pickup coil and oil pressure switch Run the cable through inner side from the starter lead Install the exterior of the lead with staking area facing downward Battery negative cable Run the cable through under the cross pipe Starter lead Run the lead through outside of engine bracket and under the cross pipe Starter lead Run the lead through on the alternator lead 17 18 APPENDIX Troubleshooting Guide NOTE Spark plug dirty broken or gap malad ORefer to the Fuel System chapter for most justed 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 Starter lockout switch or neutral switch trou ble Starter motor trouble Battery voltage low Starter relay not contacting or operating Starter button not contacting Wiring open or shorted Ignition switch trouble Engine stop switch trouble Stick coil shorted or not in good contact Stick coil trouble Spark plug incorrect IC igniter in ECU trouble Camshaft position sensor trouble Neutral starter lockout or side stand switch trouble Crankshaft sensor trouble Ignition switch or engine stop switch shorted Wiring shorted or open Fuse blown Fuel air mixture incorrect Bypass sc
359. stem in the Periodic Mainte nance chapter Spark Plug Installation e Refer to the Electrical System in the Periodic Mainte nance chapter Spark Plug Inspection e Refer to the Electrical System in the Periodic Mainte nance chapter Spark Plug Gap Inspection e Refer to the Electrical System in the Periodic Mainte nance chapter Ignition System ELECTRICAL SYSTEM 16 45 Interlock Operation Inspection e Remove Seats see Frame chapter Junction Box see this chapter ODo not disconnect the connectors 1st Check e Measure the terminal voltage of the G BK lead in the junc tion box connector A in accordance with the following procedure Olnsert the needle adapter B in the Green Black lead ter minal OSet the tester C to the 25 V DC range connect it to the needle adapter and frame ground D Connection Tester Terminal G BK Lead Terminal Tester Terminal Frame Ground Condition Transmission Gear 1st Position Clutch Lever Release or Pulled In Side Stand gt Down Special Tool Needle Adapter Set 57001 1457 OTurn the ignition switch on ORead the voltage Interlock Operation Voltage Standard 4 V or more xIf the voltage is lower than the standard inspect the side stand switch starter lockout switch and junction box And their parts are normality replace the ECU x If the voltage is standard push the starter button to check as follows Olf the starter motor does not turn
360. t Pull out the stick coil 2 D CAUTION Do not pry the connector part of the coil while re moving the coil e Remove the stick coil sub harness connector A from the bracket e Remove Stick Coil Connector 4 B disconnect Stick Coil 4 C Stick Coil Connector 3 D disconnect e Pull the main harness upward and remove the stick coil 3 e Remove the spark plugs using the 16 mm plug wrench A Owner s Tool Spark Plug Wrench 16 mm 92110 1146 2 40 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Clean the spark plug preferably in a sandblasting device and then clean off any abrasive particles The plug may also be cleaned using a high flash point solvent and a wire brush or other suitable tool If the spark plug center electrode A and or side electrode B are corrected or damaged or if the insulator C is cracked replace the plug Use the standard spark plug or its equivalent e Measure the gaps D with a wire type thickness gauge x lf the gap is incorrect carefully bend the side electrode with a tool to obtain the correct gap Spark Plug Gap 0 7 0 8 mm 0 028 0 031 in e Insert the spark plug vertically into the plug hole with the spark plug installed in the plug wrench A Owner s Tool Spark Plug Wrench 16 mm 92110 1146 e Tighten Torque Spark Plugs 13 N m 1 3 kgf m 113 in Ib e Insert the coils as shown being careful of the coil heads A dir
361. t they must be kept under the specified voltage Charging Voltage Reading Range Tester to Tester to 25 V DC Battery Battery 14 2 15 2 V e Turn off the ignition switch to stop the engine and discon nect the hand tester x If 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 xIf 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 16 36 ELECTRICAL SYSTEM Charging System Charging System Circuit o zv dr ZS ER 1 Ignition Switch 4 Regulator Rectifier 7 Main Fuse 30 2 To Starter Circuit Relay 5 Joint Connector C 8 Load 3 Alternator 6 Battery 12V 8 Ah Ignition System ELECTRICAL SYSTEM 16 37 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 runnin
362. tall see chapter 16 Cylinder head not sufficiently tightened down Tighten see chapter 5 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 accumulating on the seating surface Knocking Carbon built up in combustion chamber Adjust see chapter 2 Inspect and replace see chapter 5 Inspect and replace see chapter 5 Inspect and replace see chapter 5 Replace see chapter 5 Inspect and replace see chapter 5 Inspect and replace see chapter 5 Inspect and repair or replace see chapter 5 Repair see chapter 5 DEI System Troubleshooting Guide FUEL SYSTEM DFI 3 31 Symptoms or Possible Causes Actions chapter Fuel poor quality or incorrect Use the gasoline recommended in the Owner s Manual Change fuel see chapter 3 Spark plug incorrect Replace it with the correct plug see chapter 16 Stick coil trouble Inspect see chapter 16 IC igniter in ECU trouble Inspect see chapter 16 Inlet air temperature sensor trouble Atmospheric pressure sensor trouble Miscellaneous Inspect see chapter 3 Inspect see chapter 3 aN Subthrottle sensor trouble Subthrottle valve actuator trouble Speed sen
363. tallation pp 4 9 MET MI 4 10 Water Pump Removal irt verdee Tv eee diebus dene RT eee alee 4 10 Water Pump Installation 4 10 Water Pump Inspection 4 10 Water Pump Impeller Disassembly Assembly e 4 10 Water Pump Impeller Inspection 4 10 Water Pump Housing Disassembly pp 4 10 Water Pump Housing Assembly pp 4 11 Mechanical Seal Inspection nennen nennen 4 11 Radiator ge P 4 12 Radiator and Radiator Fan 4 12 Radiator and Radiator Fan 4 13 Radiator InspectioTi oce Gries ttr ere ee eri Le eor e ce er a Eve erat 4 13 Radiator Cap 4 13 Radiator Filler Neck 4 14 Bun Le ELLIOTT 4 15 Thermostat HRemoval rear rra rre sene 4 15 Thermostat Installation eese 4 15 Thermostat Inspection enne eren rre rrr nennen ne 4 15 HOSES ANG PIPES e TM 4 17 Hose Installation BEE 4 17 HOSE NSPE CiO N 4 17 Radiator Fan Switch Water Temperature Sensor 100010 4 18 Radiator Fan Switch emere 4 18 Radiator Fan Switch Installation pp 4 18 Radiator Fan Switch Inspection 4 18 Water Temperature Sensor Removal eene 4 18 Water Temperature Sensor Inspection
364. tallation and adjustment of the left side are common with those of the right side Follow the procedure speci fied at the right side 15 18 FRAME Frame Frame Inspection e Visually inspect the frame for cracks dents bending or warp Olf there is any damage to the frame replace it WARNING A repaired frame may fail in use possibly causing an accident If the frame is bent dented cracked or warped replace it G009008BS1 C ELECTRICAL SYSTEM 16 1 Electrical System Table of Contents Parts Al ait ied a ee AS 16 3 Eelere Ee TEE 16 4 leede 16 10 Special Tools and mener enis 16 11 Wiring Return E 16 12 Wiring Diagram th carat 16 14 Wiring Diagram Other than Canada Australia and 16 16 Wiring Diagram Malaysia TT 16 18 om 16 20 Electrical Wining DEE 16 22 Wiring Inspection xiii e hei eet ET 16 22 cp 16 23 Glen Le EE 16 23 Battery Installations s oe e CE Duet eese Sea nether nbc 16 23 TR TTE 16 23 Initial Ghatge cp ce 16 25 LEVEL 16 26
365. tandard clearance Crankshaft Main Bearing Insert Journal Clearance Standard 0 020 0 044 mm 0 0008 0 0017 in Service Limit 0 07 mm 0 0028 in lf the clearance is within the standard no bearing replace ment is required x If the clearance is between 0 045 mm 0 0018 in and the service limit 0 07 mm 0 0028 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 32 984 33 000 mm 1 2986 1 2992 in Service Limit 32 96 mm 1 2976 in If any journal has worn past the service limit replace the crankshaft with a new one the measured journal diameters 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 32 984 32 992 mm 1 2986 1 2989 1 32 993 33 000 mm 1 2989 1 2992 in Crankshaft Main Journal Diameter Marks 1 or no mark 6105042051 51050304 5 6105041751 6105011451 CRANKSHAFT TRANSMISSION 9 21 Crankshaft and Connecting Rods e Measure the main bearin
366. tch Spring Bolts 8 8 N m 0 90 kgf m 78 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 OAssemble Clutch Hub B Spring Seat C Spring D Friction Plates E Steel Plates F Spring Plate G Springs H Spring Holders I Spring Bolts J Torque Clutch Spring Bolts 8 8 N m 0 90 kgf m 78 in Ib Clutch Plate Assembly Standard 37 7 38 3 mm 1 48 1 51 the length is not within the specified range adjust the length see Clutch Plate Assembly Adjustment 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 Spring Holders Springs Spring Plate e Replace the following steel plate s Part No Thickness 13089 1126 1 4 mm 0 055 in 13089 013 1 6 mm 0 063 in STD 13089 1073 2 0 mm 0 079 in NOTE ODo not use the steel plate of 1 4 mm 0 055 in and 2 0 mm 0 079 in thickness at the same time e Install the removed parts and inspect the clutch plate as sembly length Torque Clutch Spring Bolts 8 8 N m 0 90 kgf m 78 in Ib GF06012BS2 C Clutch CLUTCH 6 13 Clutch Plate Wear Damage Inspection e Visually
367. ted upward even though clutch lever pulled in which differs from the traditional one Refer to the tables below as to the engine starts and or the driving at each condition New Ignition Interlock Sidestand System Side Stand Gear Position Clutch Lever Engine Start Engine Run A Up Neutral Released Starts Continue running B Up Neutral Pulled in Starts Continue running C Up In Gear Released Doesn t start Continue running D Up In Gear Pulled in Starts Continue running E Down Neutral Released Starts Continue running F Down Neutral Pulled in Starts Continue running G In Gear Released Doesn t start Stops H In Gear Pulled in Doesn t start Stops Current Ignition Interlock Sidestand System Side Stand Gear Position Clutch Lever Engine Start Engine Run A Up Neutral Released Starts Continue running B Up Neutral Pulled in Starts Continue running C Up In Gear Released Doesn t start Continue running D Up In Gear Pulled in Starts Continue running E Down Neutral Released Starts Continue running F Down Neutral Pulled in Starts Continue running G Down In Gear Released Doesn t start Stops H Down In Gear Pulled in Start Continue running GENERAL INFORMATION 1 13 Technical Information Tail Brake Lights Employing LED Outline This model employs a tail brake light containing 21 Light Emitting Diodes LED The LED emits luminous beams over a longer life span than those emitted from a tra
368. ter each measurement and adjust the idle speed as necessary e Once the throttle valves have been synchronized inspect the main throttle sensor s output voltage to ensure proper operation procedure is at the end of this section PERIODIC MAINTENANCE 2 17 Periodic Maintenance Procedures one vacuum measurement is out of the standard measurement after synchronization adjust the bypass screws A Front B Special Tool Pilot Screw Adjuster C 57001 1292 e Adjust the lowest vacuum between 1 and 2 to the high est of 1 and 2 e Adjust the lowest vacuum between 3 and 4 to the high est of 3 and 4 e Open and close the throttle valves after each measure ment and adjust the idle speed as necessary e Inspect the vacuums as before lf all vacuums are within the specification finish the en gine vacuum synchronization If any vacuum can not be adjusted within the specification remove the bypass screws 1 4 and clean them 6505016851 6 OTurn in the bypass screw and count the number of turns until it seats fully but not tightly Record the number of turns Torque Bypass Screw 0 2 N m 0 02 kgf m 1 7 in lb CAUTION Do not over tighten them They could be damaged requiring replacement e Remove the bypass screw A spring B washer C and O ring D OCh
369. tery is fully charged e Remove the ECU see this chapter Do not disconnect the connectors e Connect a digital voltmeter A to the ECU connector B with the needle adapter set Special Tool Needle Adapter Set 57001 1457 e Measure the sensor output voltage with the engine stopped and the connector joined e Turn the ignition switch ON Water Temperature Sensor Output Voltage Connections to ECU Meter O lead terminal 5 Meter gt BR BK lead terminal 14 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 within the standard check the ECU for its ground and power supply see this chapter xIf the output voltage is out of the standard remove the fuel tank and check the wiring And if the output voltage is 4 8 V the ECU is normal x If the wiring is good check the water temperature sensor resistance e Remove the needle adapter set and apply silicone sealant to the seals of the connector for waterproofing Silicone Sealant Kawasaki Bond 56019 120 Seals of ECU Connectors 6Ci7121BSi 6 3 50 FUEL SYSTEM DFI Water Temperature Sensor Service Code 14 6C17139BN2 A ECU D Water Temperature Sensor V Coolant Temperature Gauge in Tachometer Sensor Resistance Inspection e Remove t
370. 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 sure the wires and cables are properly routed OThe bearings must be in good condition and properly lubricated in order for any test to be valid Steering Adjustment Adjust the steering if necessary e Remove Inner Cover see Frame chapter Fairing and Bracket see Frame chapter Handlebar see Steering chapter e Loosen the upper fork clamp bolts A on both side e Remove the steering stem head bolt plug and the stem head bolt B e Remove the steering stem head C together with the han dlebar installed 2 38 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Bend the claw washer tabs A e Remove the steering stem locknut B and claw washer C e Adjust the steering Special Tool Steering Stem Nut Wrench 57001 1100 B x If the steering is too tight loosen the stem nut A a fraction of a turn x lf 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 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 rangin
371. the bracket bolts e Tighten Torque Front Fender Bracket Bolts 8 8 0 90 kgf m 78 in Ib Front Fender Bolts 3 9 N m 0 40 kgf m 35 in Ib e Install the brake hose clamps to the front fender holes e Install the front wheel see Wheels Tires chapter Rear Fender Rear Removal e Remove Seats Seat Cover Diodes A pull out Stop and Turn Signal Light Lead Connectors B Seat Lock Mounting Bolts C Rear Fender Assy Bolts D e Remove Screws A and Washers Tail Lamp Assembly B e Remove Bolts A Storage Compartment B FRAME 15 13 Fenders e Remove Quick Rivets A Rear Fender Rear B Rear Fender Rear Installation e Put the projection A into the hole B e Put the projections A into the holes B e Installation is reverse of removal 15 14 FRAME Frame Cover Frame Cover Removal e Remove Bolts A Frame Cover B both side FRAME 15 15 Battery Case Battery Case Removal e Remove Seats Seat Cover Rear Fender Assy Side Covers Battery Reserver Tank Screws e Pull out the battery case A backward Battery Case Installation e Put the battery case attachments A at the projections B on the frame 15 16 FRAME Side Stand Side Stand Removal e Raise the rear wheel off the ground with the stand e Remove Side Stand Switch Bolt A Side Stand Switch B Spring C Side Stand Nut D Side Stand Bolt E
372. the coolant and install the radiator cap 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 Cooling System in the Pe riodic Maintenance chapter e Fill the cooling system with fresh water mixed with a flush ing compound CAUTION Do notuse a flushing compound which is harmful to the aluminum engine and radiator Carefully 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 Cooling System 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 Cooling System in the Periodic Maintenance chapter 6005015851 6 4 10 COOLING SYSTEM Water Pump Water Pump Removal e Refer to the Oil Pump Removal in the Engine Lu
373. the engine sprocket or lock the rear wheel severely damaging the motorcycle and causing it to go out of control For safely use only the standard chain It is an end less type and should not be cut for installation Standard Chain Make ENUMA Type EK520MVXL Link 112 Links 6512013851 C 6 04060651 C PERIODIC MAINTENANCE 2 29 Periodic Maintenance Procedures Drive Chain Lubrication e f a special lubricant 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 an O ring drive chain Any other cleaning solution such as gasoline or trichloroethylene will cause deterio ration and swelling of the O ring Immediately blow the chain dry with compressed air after cleaning Complete cleaning and drying the chain within 10 minutes 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 6 0406075
374. 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 14 17 8 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 14 17 8 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 Standard Coolant provided when shipping Type recommended Color Mixed ratio Freezing point Total amount Permanent type of antifreeze soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators Green Soft water 50 coolant 50 35 31 F 2 9 L 3 1 US qt reserve tank full level including radiator and engine Radiator cap Relief pressure 93 123 kPa 0 95 1 25 kgf cm 14 17 8 psi Thermostat Valve opening temperature V
375. then close at the idle throttle opening position e Turn the ignition switch OFF lf the actuator does not work as described above do the visual inspection Visual Inspection e Remove the throttle body assy see Throttle Body Assy Removal e Turn the ignition switch ON e Check to see that all the subthrottle valves A open and close smoothly If the subthrottle valves do not operate check the actuator internal resistance see Resistance Inspection Resistance Inspection e Turn the ignition switch OFF e Remove the throttle body assy see Throttle Body Assy Removal e Disconnect the subthrottle valve actuator connector A e Connect a digital meter to the subthrottle valve actuator connector A e Measure the subthrottle valve actuator resistance Subthrottle Valve Actuator Resistance Connections BK BL lead 1 P BL lead 2 lead 3 W BL lead 4 Standard About 5 7 Special Tool Hand Tester 57001 1394 the reading is out of the range replace the actuator along with the throttle body assy lf the reading is within the range check the input voltage see Input Voltage Inspection GC17168BS1 C FUEL SYSTEM DFI 3 67 Subthrottle Valve Actuator Service Code 62 Input Voltage Inspection NOTE sure the battery is fully charged e Turn the ignition switch OFF e Remove the throttle body assy see Throttle Body Assy Removal
376. to 130 km h 0 23 in 80 mph 2 mm 0 08 in Over 130 km h 80 mph 3 mm 0 12 in Standard tires Make Type Size Front BRIDGESTONE BATTLAX BT 019F RADIAL E 120 70 ZR17 M C 58 W Rear BRIDGESTONE BATTLAX BT 012R RADIAL E 180 55 ZR17 73 W A WARNING Use the same manufacturer s tires on both front and rear wheels AT Republic of Austria CH Swiss Confederation DE Federal Republic of Germany WHEELS TIRES 10 5 Special Tools Bearing Driver Set Bearing Remover Head 20 x 22 57001 1129 57001 1293 W Jack Bearing Remover Shaft 513 57001 1238 57001 1377 10 6 WHEELS TIRES Wheels Rims Front Wheel Removal e Remove Brake Caliper Mounting Bolts A e Loosen the front axle clamp bolt A e Remove the front axle B e Raise the front wheel off the ground Special Tool Jack 57001 1238 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 e Fit the collars A on the both sides of the hub Wheels Rims WHEELS TIRES 10 7
377. ts and switches operation year e Headlight aiming inspect year e Side stand switch operation year e PERIODIC MAINTENANCE 2 3 Periodic Maintenance Chart FREQUENCY Whichever ODOMETER READING Comas km x 1000 mile x 1000 first A 1 6 12 18 24 30 36 See INSPECTION Every 7 5 12 15 20 24 Page Fuel system DFI Air cleaner element clean Throttle control system play smooth return no drag inspect Choke operation inspect year Engine vacuum synchronization inspect Engine vacuum synchronization adjust Idle speed inspect Fuel hoses leak inspect Fuel hoses damage inspect Fuel hoses installation condition inspect Cooling system Coolant level inspect e Radiator hoses leak inspect year Radiator hoses damage inspect year Radiator hoses installation condition ver e year inspect Engine top end top Engine top end Air suction system damage inspect Intake exhaust valve clearance inspect Chassis Chassis parts lubricate Bolts and nuts tightness inspect e e e e 2 42 2 4 PERIODIC MAINTENANCE Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY Whichever comes ODOMETER READING Radiator hoses and O rings 2 20 first p km x 1000 mile x 1000 A 1 See CHANGE REPLACE ITEM Every 0 6
378. tween the valve B and valve seat C OMeasure the outside diameter D of the seating pattern on the valve seat x lf the outside diameter is too large or too small repair the seat see Seat Repair Valve Seating Surface Outside Diameter Standard Inlet 26 4 26 6 mm 1 0276 1 0472 in Exhaust 21 6 21 8 mm 0 850 0 858 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 too narrow or uneven J repair the seat see Valve Seat Repair Valve Seating Surface Width Standard Inlet 0 5 1 0 mm 0 020 0 039 in Exhaust 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 54 57001 1275 B Valve Seat Cutter Holder Bar 57001 1128 C For Inlet Valve Seat Valve Seat Cutter 45 527 5 57001 1114 Valve Seat Cutter 32 028 57001 1119 Valve Seat Cutter 60 527 57001 1409 For Exhaust Valve Seat Valve Seat Cutter 45 524 57001 1113 Valve Seat Cutter 32 625 57001 1118 Valve Seat Cutter 60 525 57001 1328 If the manufacturer s instructions are not available use the following procedure 6 15011752 C 6 15048851 6 5 24 ENGINE TOP END Valves Seat Cutter Operation Care 1 This valve seat cutter is developed to grind the v
379. uence OFirst hang the drive chain over the output shaft just before moving the engine into its final position in the frame OSecond insert the lower engine mounting bolt A OThird insert the middle engine mounting bolt B OFourth install the rear engine bracket C temporarily OFifth install the left upper engine mounting bolt A and tighten it Torque Left Upper Engine Mounting Bolt 44 N m 4 5 kgf m 33 ft lb OSixth tighten the adjusting collar A until the clearance between the crankcase B and frame bracket C come to 0 mm D OSeventh tighten the collar locknut E Torque Adjusting Collar Locknut 49 N m 5 0 kgf m 36 ft Ib Special Tool Engine Mount Nut Wrench 57001 1450 OEighth tighten the rear bracket bolts Torque Rear Engine Bracket Bolts 25 N m 2 5 kgf m 18 ft lb ONinth tighten securely Middle Engine Mounting Nut Lower Engine Mounting Nut Torque Engine Mounting Nuts 44 N m 4 5 kgf m 33 16 GHO4016BS1 C ENGINE REMOVAL INSTALLATION 8 9 Engine Removal Installation OTenth temporarily install Front Engine Bracket C Right Upper Engine Mounting Bolt A Front Engine Bracket Bolts B OEleventh tighten the right upper engine mounting bolt OLastly tighten the front engine bracket bolts Torque Right Upper Engine Mounting Bolt 44 N m 4 5 kgf m 33 ft lb Front Engine Bracket Bolts 44 N m 4 5 kgf m 33 ft lb
380. ulation OThis type of converter works more efficiently as a three way catalytic converter to reduce CO HC and NOx than the pipe type catalytic converter because of its more and denser catalysts 6B06116BN2 C 1 Manifold 2 Silencer 3 Honeycomb Type Catalyst 4 Mark for Manifold 5 Mark for Silencer 1 16 GENERAL INFORMATION Unit Conversion Table Prefixes for Units Units of Length Prefix km x 0 6214 mile mega M x 1000 000 m x 3 281 ft kilo k x 1000 mm x 0 03937 in centi C x 0 01 milli m x 0 001 micro x 0 000001 Units of Torque N m x 0 1020 kgf m N m x 0 7376 ft lb Units of Mass 8 4851 in Ib kg x 2 205 Ib kgfm x 9807 Nm g x 0 03527 oz kgf m x 7 233 ft lb kgf m x 86 80 in Ib Units of Volume L x 0 2642 US Units of Pressure kPa x 0 01020 kgf cm L x 0 2200 gal imp ka S 212 e 1 deos e kPa x 0 7501 cmHg L M ie kgf cm x 98 07 kPa E s kgficm x 14 22 psi 1 816 pint imp her 2 EC S SC mL x 0 03381 oe US 9 mL x 0 02816 oz imp mL x 0 06102 cu in Units of Speed km h x 0 6214 mph Units of Force N x 0 1020 kg 0 2248 Ib Units of Power kg x 9 807 N kW x 1 360 PS kg x 2 205 Ib kW x 1 341 PS x 0 7355 kW PS x 0 9863 HP Units of Temperature 9 C 40 o oF 4 32 68 104 248 284 40 20 0 20 40 60 176 212 80 100 120 140 160 180 200 22
381. und Ignition System Ground Stick Coil 4 Signal T Ignition Switch U Fl Indicator LED Light V Tachometer W X Speedometer Ignition Fuse 10 A Y Junction Box 5 Fuel Pump Relay ECU Fuse 15 A Vehicle down Sensor Starter Relay Joint Connector C Sealed Battery Fuel Pump Self diagnosis Terminal Joint Connector B Main Fuse 30A Throttle Body Assy Connector Connector Locks ECU Connector 3 12 FUEL SYSTEM DFI Specifications Item Standard Digital Fuel Injection System Idle Speed Throttle Assy Type Bore ECU Electronic Control Unit Make Type Usable engine speed Right after Ignition SW ON After 3 sec from Ignition SW ON With engine idling Fuel Pump Type Discharge Fuel Injectors Type Nozzle type Resistance Main Throttle Sensor Input voltage Output voltage at idle throttle opening Output voltage at full throttle opening Resistance Inlet Air Pressure Sensor or Atmospheric Pressure Sensor Input voltage Output voltage Inlet Air Temperature Sensor Resistance Output voltage at ECU Water Temperature Sensor Resistance Output voltage at ECU Speed Sensor Input voltage at sensor Output voltage at sensor Vehicle down Sensor Detection method Detection angle Fuel Pressure high pressure line 1 100 50 r min rpm Four barrel type 34 mm 1 34 in Denso Digital memory t
382. until the muffler cool down Muffler Body Removal e Remove Muffler Body Clamp Bolt A Muffler Body Mounting Bolt B e Pull the muffler body backward Exhaust Pipe Removal e Remove Radiator Lower Bolt see Cooling System chapter Muffler Body Clamp Bolt A Exhaust Pipe Manifold Holder Nuts B Exhaust Pipe C Gaskets D GE18012BS1 C Muffler Body and Exhaust Pipe Installation e Replace the exhaust pipe gaskets A and muffler body connection gasket B with new ones and install them Olnstall the muffler body connection gasket until it is bot tomed so that the chamfer side feces muffler body C e Install Muffler Body Exhaust Pipe D e Tighten Torque Exhaust Pipe Manifold Holder Nuts E 17 N m 1 7 kgf m 12 ft Ib Muffler Body Mounting Bolt F 30 N m 3 0 kgf m 22 ft Ib Muffler Body Clamp Bolt G 17 N m 1 7 kgf m 12 ft Ib ENGINE TOP END 5 35 Muffler Olnstall the muffler body clamp bolt as shown Upper Side H Outside I MOS ELIT IN GE18013BN2 e Thoroughly warm up the engine wait until the engine cools down and retighten all the bolts and nuts CLUTCH 6 1 Clutch Table of Contents Exploded IET 6 2 leede E Special Tool Sealant 2 2 Clutch Lever and Cable Clutch Lever Free Play Inspection ebrei nad eebe Clutch Lever Free Play
383. use Removal e Remove Right Side Cover see Frame chapter 30 A Main Fuse Connector A e Pull outthe main fuse B from the starter relay with needle nose pliers Junction Box Fuse Removal e Remove the seats see Frame chapter e Unlock the hook to lift up the lid A e Pull the fuses B straight out of the junction box with nee dle nose pliers 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 fuse of proper amperage e Install the junction box fuses on the original position as specified on the lid 15 A ECU Fuse Removal e Remove Seats see Frame chapter e Unlock the hook to pull the lid A Pull out the ECU Fuse from the fuse box 16 84 ELECTRICAL SYSTEM Fuse Fuse Inspection e Remove the fuse see Fuse Removal e Inspect the fuse element is blown out replace the fuse Before replacing blown fuse always check the amperage in the affected circuit If the amperage is equal to or greater than the fuse rating check the wiring and related components for a short circuit Housing A Fuse Element B Terminals C Blown Element D NOTE 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
384. use a digital volt meter which can be read one decimal place voltage 8 08010851 6 Condition requiring initial charge Charging method At low temperatures lower than 0 0 9 x 2 3 hours Battery has been stored in high temperature and humidity Seal has been removed or broken peeling tear or hole Battery two years or more years old from date of manufacture Battery manufacturing date is printed on battery top Example 12 10 01 T1 Day Month Year Mfg location 0 9A x 15 20 hours 16 26 ELECTRICAL SYSTEM Battery Precautions 1 No need of topping up No topping up is necessary in this battery until it ends its life under normal use Forcibly prying offthe seat cap to add water is very dangerous Never do that Refreshing charge If an engine will not start a horn sounds weak or lamps are dim it indicates the battery has been dis charged Give refresh charge for 5 to 10 hours with charge current shown in the specification see the this chapter When a fast charge is inevitably required do it fol lowing precisely the maximum charge current and time conditions indicated on the battery CAUTION This battery is designed to sustain no unusual deterioration if refresh charged according to the method specified above However the battery s performance may be reduced noticeably if charged under conditions other than given above Never remove the seal caps during refres
385. utral switch trouble Inspect see chapter 16 Starter motor trouble Inspect see chapter 16 Battery voltage low Inspect and charge see chapter 16 Starter relays not contacting or operating Inspect the starter relay see chapter 16 Starter button not contacting Inspect and replace see chapter 16 Starter system wiring open or shorted Ignition switch trouble Engine stop switch trouble Main 30 A or ignition fuse blown Starter motor rotating but engine doesn t turn over Starter clutch trouble Starter idle gear trouble Engine won t turn over Valve seizure Cylinder piston seizure Camshaft seizure Connecting rod small end seizure Inspect the wiring see chapter 16 Inspect and replace see chapter 16 Inspect and repair or replace see chapter 16 Inspect and replace see chapter 16 Inspect see chapter 9 Inspect see chapter 9 Inspect and replace Inspect and replace Inspect and replace Inspect and replace see chapter 5 see chapter 5 see chapter 5 see chapter 9 Connecting rod big end seizure Inspect and replace Crankshaft seizure Inspect and replace see chapter 9 Transmission gear or bearing seizure Inspect and replace see chapter 9 Balancer bearing seizure see chapter 9 Inspect and replace see chapter 9 No fuel flow No or little
386. ve Chain Chain slack 25 35 mm 1 0 1 4 in 20 link length 317 5 318 2 mm 12 50 12 53 in 323 mm 12 7 in Standard chain Make ENUMA Type EK520MVXL Link 112 links Sprockets Rear sprocket warp 0 4 mm 0 016 in or less 0 5 mm 0 020 in FINAL DRIVE 11 5 Special Tools Bearing Driver Set Jack 57001 1129 57001 1238 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 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 in the Periodic Main tenance chapter Drive Chain Removal e Remove Rear Wheel see Wheels Tires chapter Chain Cover Screws A Chain Cover B Mud Guard C see Frame chapter Swingarm see Suspension chapter Engine Sprocket Cover see this chapter e Disengage the drive chain A from the engine sprocket B and take it off the chassis Drive Chain Installation e Engage the drive chain to the engine sprocket e Install Swingarm see Suspension chapter Rear Wheel see Wheels Tires chapter Engine Sprocket Cover see this chapter Mud Guard see Frame chapter Chain Cover e Adjust the ch
387. ve the stick coil 3 Stick Coil Ignition Coil together with Spark Plug Cap Installation e Install the coil using the following steps Olnsert the coil as shown being careful of the coil heads A direction GP10120BS1 C OBe sure the stick coils are installed by pulling up A it lightly OConnect the connectors CAUTION Do not tap the coil head while installing the coil e Install the removed parts see appropriate chapters ELECTRICAL SYSTEM 16 43 Ignition System Stick Coil Ignition Coil together with Spark Plug Cap Inspection e Remove the stick coils see this chapter 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 Ignition Coil Winding Resistance Primary Windings 1 04 1 56 Secondary Windings 10 8 16 2 xIf the tester does not read as specified replace the coil Stick Coil Primary Peak Voltage NOTE OBe sure the battery is fully charged e Remove the stick coils see this chapter but do not re move the spark plugs e Measure the primary peak voltage as follows OConnect a commercially peak voltage adapter B into the hand tester C which is
388. wingarm Pivot Shaft Lock Nut Uni trak Link Nuts Steering Stem Head Bolt Handlebar Clamp Bolts Engine Throttle Cable Adjuster Locknuts Engine Mounting Bolts and Nuts Muffler Mounting Bolts Exhaust Pipe Holder Nuts Muffler Connecting Clamp Bolt Clutch Lever Pivot Nut Radiator Upper and Lower Bolts Others Sidestand Bolt Footpeg Stay Bolts FUEL SYSTEM 3 1 Fuel System DFI Table of Contents Exploded WieWis sisi atin Maat i RL le Ce de TEE DFIWinng E eelere de TEE Special TOOIS TN DFI Servicing Precautions pp DFI Servicing Precautlons Siet et i t rt Cte te Troubleshooting the DFI System EE emi LEI UNE Inquiries MT EE Inquiries to rete rr eie E DFI System Troubleshooting G lde 2 DFI System Troubleshooting Guide reader Code dee streicht idee ue e RE e ct ML EE Selidiagriosis e in Ee Le e Ee Self diagnosis Procedures 22 RR EEN EEGENEN Selfsdiagnosis Procedures ao ce EE Service Code Clearing Procedures pp Service Code Clearing Procedures eese nennen nine How to Read Service Codes nennen nnne nennen How to Read Service eee enemies How to Erase Service How to Erase Service Codes Service tee Service Code Table ei nece tee eii Eee Macedon dre ch coon dene daveb cd Tes BACKUPS
389. xIf a fuse fails during operation inspect the DFI system to determine the cause and then replace it with a new fuse of proper amperage e Refer to the Electrical System chapter for the ECU fuse installation ECU Fuse Inspection e Refer to the Electrical System chapter for the ECU fuse inspection ECU Main Relay Removal CAUTION Never drop the relay especially on a hard surface Such a shock to the relay can damage it e Remove the seat cover see Frame chapter e Remove the ECU main relay A from the tongue of the storage compartment and disconnect the connector ECU Main Relay Inspection e Remove the ECU main relay see above e Connect the hand tester A and one 12 V battery B to the relay connector C as shown Special Tool Hand Tester 57001 1394 Relay Coil Terminals 1 and 2 Relay Switch Terminals 3 and 4 Testing Relay Tester range 1 range Criteria When battery is connected 0 When battery is disconnected xIf the relay does not work as specified replace the relay 3 74 FUEL SYSTEM DFI Fuel Line Fuel Pressure Inspection NOTE OThis inspection can determine which trouble the system has mechanical or electrical trouble Olt is preferable to measure the fuel pressure while run ning the motorcycle just when trouble occurred in order to know symptom well OBe sure the battery is fully charged e Remove the fuel tank see Fuel Tank Removal
390. y Starter Relay Inspection e Remove the battery negative cable from the battery negative terminal see Battery Removal e Remove the right side cover e Pull out the starter relay e Disconnect the connector A e Disconnect the starter motor cable B and battery positive cable from the starter relay C CAUTION The battery positive cable with the rubber cap is connected directly to the battery positive termi nal even when the ignition switch off so take care not to short the removed cable to chassis ground Gp P Electric Starter System ELECTRICAL SYSTEM 16 53 e Connect the hand tester A and 12 V battery B to the starter relay C as shown Special Tool Hand Tester 57001 1394 x If the relay does not work as specified the relay is defec tive Replace the relay Testing Relay Tester Range x 1 range Criteria When battery is connected 0 When battery is disconnected Electric Starter Circuit 6 11010751 6 e 9 e 2 1 Ignition Switch 8 Side Stand Switch 15 Main Fuse 30 2 Joint Connector D 9 Joint Connector A 16 Battery 12 V 8 Ah 3 Engine Stop Switch 10 Starter Lockout Switch 17 Joint Connector B 4 Starter Button 11 Neutral Switch 18 Meter Ground 5 Junction Box 12 Diode 19 Frame Ground 6 Starter Circuit Relay 13 Starter Motor 7 Ignition Fuse 10A 1
391. y B Tester C Special Tool Needle Adapter Set 57001 1457 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 this chapter figure Battery C ECU Power Source Inspection Meter between Terminal 13 W Y and Connections Battery Terminal between Terminal 43 W BK and Battery Terminal Ignition SW OFF Terminal 13 W Y 0 V Terminal 43 W BK 12 6 V or more Both Battery Voltage 12 6 V or Ignition SW ON more xIf the meter does not read as specified check the follow ing Main Fuse 30 A see Electrical System chapter ECU Fuse 15 A see DFI Power Source section ECU Main Relay see DFI Power Source section Power Source Wiring see wiring diagram below xIf the inspection checks good the ECU is damaged Re place the ECU The ECU itself cannot be checked or ser viced 6Ci7091BSi 6 80617092851 6 3 72 FUEL SYSTEM DFI ECU ECU Power Source Circuit larem us e BATTERY 62 03 1 6Cc17141BN2 A ECU a ECU Fuse 15 A f Sealed Battery S ECU Main Relay d Starter Relay j Joint Connector B T Ignition Switch e Joint Connector C k Main Fuse 30 DFI Power Source FUEL SYSTEM DFI 3 73 ECU Fuse Removal e Refer to the Electrical System chapter for the ECU fuse removal ECU Fuse Installation
392. ype with built in IC igniter sealed with resin 100 12 240 r min rpm 310 kPa 3 2 kgf cm 46 psi with fuel pump running 290 kPa 2 9 kgf cm 43 psi with fuel pump stopped 310 kPa 3 2 kgf cm 46 psi with fuel pump running In tank friction pump 67 mL or more for 3 seconds INP 285 One spray type with 4 holes about 11 7 12 3 at 20 C 68 F Non adjustable and non removable 4 75 5 25 V DC between BL and BR BK leads 0 99 1 03 V DC between Y W BR BK leads 4 19 4 39 V DC between Y W BR BK leads 4 6 4 75 5 25 V DC between BL and BR BK leads 3 74 4 26 V DC at standard atmospheric pressure see this text for details 1 6 3 7 at 20 C 68 F 0 24 0 43 at 80 176 about 2 25 2 50 V 20 68 F see Electrical System chapter about 2 80 2 97 V 20 68 F about 9 11 V DC at Ignition SW ON about 0 05 0 07 V DC at Ignition SW ON and 0 km h Magnetic flux detection method More than 60 70 for each bank Specifications FUEL SYSTEM DFI 3 13 Item Standard Detection time Output voltage Subthrottle Sensor Input voltage Output voltage at idle throttle opening Output voltage at full throttle opening Resistance Subthrottle Valve Actuator Resistance Input voltage Throttle Grip and Cables Throttle grip free play Choke Cable Choke cable free play Within 0 5 1 0 sec with the sensor tilted 60 70 or more

Be sure the battery is fully charged.

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