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Kawasaki VN2000 A1 Vulcan 03 Service Manual ENG

1. 3 26 FUEL SYSTEM DFI DFI System Troubleshooting Guide NOTE OThis is not an exhaustive list giving every possible cause for each problem listed It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties 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 Starter lockout switch or neutral switch trouble see chapter 16 Starter motor trouble Inspect see chapter 16 Battery voltage low Inspect and charge see chapter 16 Inspect the starter relay see chapter 16 Starter button not contacting Inspect and replace see chapter 16 Starter system wiring open or shorted Inspect the wiring see chapter 16 Ignition switch trouble Inspect and replace see chapter 16 Engine stop switch trouble Inspect and repair or replace see chapter 16 Main 30A or ignition fuse blown Inspect and replace see chapter 16 Starter motor rotating but engine doesn t turn over Starter clutch trouble Inspect see chapter 9 Starter idle gear trouble Inspect
2. Speed Sensor Service Code 24 Speed Sensor Remowval Installation Speed Sensor Inspection Input Voltage Inspection Output Voltage Inspection Gear Position Switch Service Code Gear Position Switch Remowval Installation Gear Position Switch Inspection Vehicle down Sensor Service Code Vehicle down Sensor Removal Vehicle down Sensor Inspection Subthrottle Sensor Service Code Subthrottle Sensor Removal Adjustment Input Voltage Inspection Output Voltage Inspection Resistance Inspection Oxygen Sensor not activated Service Code 33 Oxygen Sensor Remowval Installation Oxygen Sensor Inspection Oxygen Sensor Heater Fuel Injectors 1 2 Service Code 3 57 3 58 3 61 3 62 3 62 3 64 3 64 3 64 3 64 3 64 3 66 3 66 3 66 3 68 3 68 3 68 3 68 3 70 3 70 3 70 3 71 3 72 3 73 3 73 3 73 3 74 3 75 3 75 3 2 FUEL SYSTEM DFI Injector Installation Audible Inspection Power Source Voltage Inspection Output Voltage Inspection Injector Signal Test
3. E 7 15 Oil Pressure 7 15 Relief Valve 7 16 7 2 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart 8804036 45 e 2 a ws Lm VS ENGINE LUBRICATION SYSTEM 7 3 Engine Oil Flow Chart Feeding Oil Flow Scavenging Oil Flow Oil in Transmission Room Oil Screen Feed Pump Oil Pressure Switch Oil Filter Relief Valve To Left Side Crankshaft Inlet Oil Line from Left Crankcase Half Oil Filter in Rocker Shaft 10 Oil Line in Push Rod 11 Rocker Arm 12 HLA Hydraulic Lash Adjuster 13 Oil in Rocker Case 14 Outlet Return Oil Line to Crank Room 15 Chain Tensioner for Balancer Drive Chain 16 Chain Tensioner for Camshaft Chain 17 To Right Side Crankshaft 18 Oil Pipe for Camshaft 19 Oil Jet 20 Oil in Clutch Room 21 Check Valve 22 Scavenge Pump for Clutch Room 23 Oil in Crank Room 24 Scavenge Pump for Crank Room 25 Oil Line from Right Crankcase Half to Outer Transmission Cover 26 Oil Line in Input Shaft 27 Oil Line in Output Shaft 28 From Oil Line in Right Crankcase Half 29 Oil Line in Connecting Rod Big End 30 From Oil Line in Left Crankcase Half 31 Left Side Crankshaft 32 Oil Line for Cooling Stator 33 Oil Line for Cam Damper
4. 16 52 Armature 16 53 Brush Assy Inspection 16 53 Brush Plate and Terminal Bolt 16 53 Starter Relay Inspection 16 54 Starter Control Relay Inspection 16 54 Lighting System 16 56 Headlight Beam Horizontal Adjustment 16 56 Headlight Beam Vertical Adjustment Headlight Bulb Replacement City Light Bulb Replacement Europe Model Tail Brake Light Bulb Replacement 16 58 Automatic Turn Signal Canceling se d e eben itn 16 61 Wiring Inspection 16 61 Distance Sensor Inspection 16 61 Turn Signal Switch Inspection 16 62 Turn Signal Control Relay 16 62 Turn Signal Light Bulb Replacement 16 63 Radiator Fan System 16 66 Fan Motor Inspection 16 66 Meter 16 68 Meter Unit Removal 16 68 Meter Unit Installation 16 68 16 2 ELECTRICAL SYSTEM Meter Unit Disassembly Meter Unit Assembly Meter Unit Inspection
5. Belt wear and damage inspect Electrical System Spark plug condition Inspect Lights and switches operation inspect Headlight aiming inspect year Side stand switch operation inspect year Engine stop switch operation inspect year e e e 2 32 PERIODIC MAINTENANCE 2 3 Periodic Maintenance Chart FREQUENCY Whichever ODOMETER READING comes x 1000 km first x 1000 mile 1 6 12 18 24 30 36 See INSPECTION Every 0 6 4 7 5 12 15 20 24 Page Fuel System e 2 Idle speed inspect e e e e 2 33 Fuel leak fuel hose and pipe inspect year e e 2 33 Fuel hoses and pipe damage inspect Fuel hoses and pipe installation condition inspect Cooling System Coolant level inspect Coolant leak radiator hose and pipe inspect Radiator hose and pipe damage inspect Radiator hose and pipe installation condition inspect Evaporative Emission Control System CAL eek leh ise Evaporative emission control system function inspect Air Suction System Air suction system damage inspect Chassis parts lubricate year e 2 36 Bolts and nuts tightness inspect e 2 37 Service more frequently when operating in severe conditions dusty wet muddy high speed or frequent starting
6. 4 14 Radiator Cap 4 15 Radiator Filler Neck Inspection 0 10 20 0 020 002 001000000000000000000000000000000000 4 15 EI EP 4 16 Thermostat RemoVal cte betreten ele 4 16 Thermostat nennen neret 4 16 Thermostat Inspection p ree pretende eere e re ese ver a Peg ga 4 17 FIOSES ANG Pipes oet 4 18 aa EET 4 18 Hose Irispection ea dn ae on eas 4 18 4 2 COOLING SYSTEM Exploded View COOLING SYSTEM 4 3 Exploded View Torque No Fastener Nm kaim ilb Remarks 1 Water temperature sensor DFI 12 1 2 104 in Ib 2 Water pipe bolts 9 8 1 0 87 in lb 3 Radiator fan bolts 8 3 0 85 74 4 Reserve tank bolts 6 9 0 70 61 5 Radiator cover bolts 11 1 1 97 in lb 6 Water pump impeller bolt 12 1 2 104 Lh 7 Water pipe drain bolt 1 0 87 in lb pump air bleeder bolt 0 80 69 i 10 Mechanical seal 11 Double seal bearing 12 Oil seal 13 Ball bearing 14 Thermostat 15 Radiator cap 16 Radiator 17 Radiator Fan R Replacement parts Lh Left hand threads G Apply grease L Apply a non p
7. Periodic Maintenance Procedures Steering System Steering Play Inspection Steering Play Adjustment Steering Stem Bearing Brake System Brake Fluid Leak Brake Hose and PIpB Brake Hose Damage and Installation Connection Tire Air Pressure Inspection Wheel Tire Damage Inspection Tire Tread Wear Inspection Wheel Bearing Damage Suspensions Front Forks Rear Shock Absorber Operation Inspection Front Fork Oil Leak Inspection Rear Shock Absorber Oil Leak Inspection Swingarm Pivot Lubrication Clutch and Drive Train Clutch Operation Belt Deflection Inspection Belt Deflection Adjustment Wheel Alignment Inspection Adjustment Belt Wear and Damage Electrical System Spark Plug Condition Inspection Lights and Switches Operation IX 14 0733 c3 13 o 2X lA oo 2 19 2 20 2 20 2 20 2 21 2 21 2 21 2 23 2 24 2 25 2 27 2 27
8. rco N LO LE LO SSS SST tot e NAINA ex ex ex ex ex BR BK BR BK BL W Lj BL W BL W BR BK BR BK rF X LE boom Y 4 BR BK 4 AF Y BK BL 6C17316BN2 1 ECU 2 Joint Connector 3 Subthrottle Sensor FUEL SYSTEM DFI 3 73 Oxygen Sensor not activated Service Code 33 Oxygen Sensor Removal Installation e Refer to Oxygen Sensor Removal and Installation in the Electrical System chapter Oxygen Sensor Inspection e Warm up the engine thoroughly e Turn the ignition SW OFF e Remove the seats see Frame chapter e Connect a digital voltmeter A to the oxygen sensor con nector B main harness side using the needle adapter set C Special Tool Needle Adapter Set 57001 1457 Oxygen Sensor Output Voltage Connections to Oxygen Sensor Connector Meter BL Y lead Meter BR BK lead e Remove the air switching valve hoses A both sides from the fittings B e Install C the suitable plugs D both sides on the fittings and shut off the secondary air e Turn the ignition SW ON e Start the engine and let it idle e Measure the output voltage of the sensor with the con nector joined Oxygen Sensor Output Voltage with Plugs Standard 0 7 0 8 V e Next remove the plugs A both sides from the fittings B with idling
9. 1 7 General 8 1 9 Technical Information Oxygen nnn 1 11 Technical Information Electric Solenoid Operated Decompressor 1 16 Technical Information Dual Balancer Shaft 1 17 UnitConversion Table 1 19 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 J 7 from accidentally turning over Disconnect the ground wire Al first and then the positive When completed with the a service first connect the positive wire to the positive ee terminal of the battery then the negative wire to the neg 2 ative terminal DISASSEMBLY ASSEMBLY Edges of Part
10. co e ey edle ex ex ex ex ex ex 1 ECU 2 3 Main Throttle Sensor BR BK v w BL W BL W DR Y Ww BR BK 4 AF Y BK BL GC17294BW2 3 48 FUEL SYSTEM Inlet Air Pressure Sensor Service Code 12 Removal CAUTION Never drop the sensor especially on a hard surface Such a shock to the part can damage it e Remove the fuel tank see Fuel Tank section in this chap ter e Disconnect the inlet air pressure sensor connector A e Unscrew the inlet air pressure sensor bolt B and remove the sensor D e Disconnect the vacuum hose C from the sensor Front E Installation NOTE OThe inlet air pressure sensor is the same part as the atmospheric pressure sensor except for a vacuum hose and different wiring e Route the vacuum hose correctly see Cable Wire and Hose Routing section in the Appendix chapter Make sure it doesn t get pinched or kinked e Install the inlet air pressure sensor A OBe sure he frame ground terminal B is in position OThe stopper C must not be on the sensor holder D e Tighten the inlet air pressure sensor bolt securely e Install the fuel tank see this chapter Input Voltage Inspection NOTE OBe sure the battery is fully charged OThe inspection is the same as Input Voltage Inspection ofthe throttle sensor and the atmospheric pressu
11. 9 30 Shift Pedal Installation 9 30 External Shift Mechanism 9 31 External Shift Mechanism Installation 9 32 External Shift Mechanism 9 35 Transmission Removal 9 35 Transmission Installation 9 35 Shift Drum Disassembly 9 36 Shift Drum Assembly 9 36 Transmission Disassembly 9 36 Transmission Assembly 9 37 Shift Fork Bending 9 37 Shift Fork Gear Groove Wear 9 38 Shift Fork Guide Pin Drum Groove 9 38 Gear Dog and Gear Dog Hole Damage eee oret 9 38 Ball Bearing Needle Bearing and Oil Sre E 9 40 Ball Bearing and Outer Race Replacement 9 40 Ball and Needle Bearing Wear 9 40 Oil Seal Inspection 9 41 9 2 CRANKSHAFT TRANSMISSION Exploded View ox AO 5 NEN CRANKSHAFT TRANSMISSION 9 3 Exploded View Fastener Remarks Connecting rod big end bolts Balancer chain sprocket nut 125 Camshaft chain sprocket bolt 29 Upper balancer chain guide bolts E 104 Lower balancer chain guide bolts 104 Balance chain tensioner bolts 104 in Ib
12. Clutch Installation Starter Clutch Disassembly Starter Clutch Assembly Starter Clutch Inspection Starter Torque Limiter Check Primary Chain Wear Clutch Plate Assembly Inspection Clutch Plate Assembly Adjustment of Contents Friction and Steel Plate Wear and Damage Inspection Friction or Steel Plate Warp Clutch Housing Finger Inspection Outer Clutch Hub Spline Inspection Cam Damper Inspection Clutch Spring Free Length Measurement 6 2 6 4 6 6 6 6 6 6 6 7 6 7 6 8 6 9 6 12 6 17 6 17 6 17 6 18 6 18 6 18 6 19 6 19 6 19 6 20 6 20 6 20 6 20 6 2 CLUTCH Exploded View GF02041BN5 CLUTCH 6 3 Exploded View No Fastener Remarks ft lb Primary chain upper guide bolts 87 in lb 1 2 Primary chain lower guide bolts 87 in lb ee E Inner clutch cover bolts 104 S see Text Outside plate bolts 87 in lb L Clutch hub nut 101 Clutch spring bolts 87 Outer clutch cover bolts 104 in Ib S see Text Plug on outer clutch cover 14 Fock coe f 2 15 Clutch release lever bolt 5 9 52 12 Starter locko
13. 15 19 Left Footboard ep bc det tus NN EUR eae S 15 19 Side Stand Installation soe ncini ec iie e tete ere e e lebat oa teil ane eck E es 15 20 DOWMTUBDG sits 15 21 iei eit 15 21 Downtube 15 22 in lej amp d Po 15 23 Headlight Cover BRermoVval eet eee 15 23 Headlight Cover Installalighi ios eon eben eue i dentes edens 15 23 m 15 24 Fra Me INSPOCUOM ce 15 24 15 2 FRAME Exploded View 6002099 5 C FRAME 15 3 Exploded View No Fastener Torque Remarks N m kgf m ft Ib 1 Front downtube nuts 88 9 0 65 5 2 9 engine bracket nuts 59 6 0 43 5 3 engine mounting bolts 44 4 5 33 5 4 Lower engine bracket bots s 60 49 s 5 Reardowntube bots ws 8 S 6 Side stand mounting 44 45 33 S T Side stand mounting 4 45 3 S 5 Adustbots os i0 Simb S 9 Fotewdbadebos 3 35 25 710 Front engine mounting n 4 45 35 S 711 Adjusting bolt locknuts 4 so 3 S 12 Reerengmemoudngnus 59 80
14. LED Light Inspection Indicator Light Inspection Air Switching Valve Air Switching Valve Operation Air Switching Valve Unit Test Decompression Solenoid Decompression Solenoid Switch and Fuel Level Sensor Inspection Fuel Reserve Switch Inspection Speed Sensor Removal Speed Sensor Installation Speed Sensor Inspection Oxygen Sensor Removal Oxygen Sensor Installation Oxygen Sensor Inspection Front Brake Light Switch 2 2 Rear Brake Light Switch Check Adjustment Water Temperature Sensor Water Temperature Sensor Installation Water Temperature Sensor Gear Position Switch Removal Gear Position Switch Installation Gear Position Switch Inspection Switch Inspection Relay BOK Relay Box Removal Relay Circuit Inspection Diode Circuit Inspection ECU Fuse Removal Fuse Box Fuse Removal Fuse Installation
15. o TON e eo r eio x OG Op eio cea iO LO LO F r t ME c9 co e e exe ex ex cx Se SET al Ore EE Ep 80172978482 1 2 Inlet Air Pressure Sensor FUEL SYSTEM DFI 3 53 Inlet Air Temperature Sensor Service Code 13 Removal Installation CAUTION Never drop the sensor especially on a hard surface Such a shock to the sensor can damage it e Remove the air cleaner housing see Air Cleaner Housing Removal in this chapter e Take the inlet air temperature sensor B out of the air cleaner housing Output Voltage Inspection NOTE OBe sure the battery is fully charged e Remove the ECU see this chapter Do not disconnect the ECU connectors e Connect a digital voltmeter A to the ECU connector B using needle adapter set C Special Tool Needle Adapter Set 57001 1457 Inlet Air Temperature Sensor Output Voltage Connections to ECU Connector Meter R lead terminal 22 Meter gt lead terminal 25 e Measure the sensor output voltage with the engine stopped and the connector joined e Turn the ignition switch ON Output Voltage at ECU Standard about 2 25 2 50 V at inlet air temperature 20 C 68 F NOTE OThe output voltage changes according to the inlet air temperature Turn the ignition switch OFF
16. the end gap of either ring is greater than the service limit replace all the rings GE16070781 GE16070881 C GE16049BS1 C 5 46 ENGINE TOP END Mufflers Upper Muffler Removal e Remove Right Side Cover A see Frame chapter Clamp Screws B Loosen Clamp Bolt C e Detach the clamps D by sliding them up or forward e Remove the upper exhaust pipe cover E e Remove Clamp Bolt A Loosen Upper Muffler Bracket Bolts B Upper Muffler C Lower Muffler Removal e Remove Upper Muffler see above Clamp Screw A Loosen Clamp Bolt B Detatch the clamp C by sliding it forward Remove the lower rear exhaust pipe cover D e Remove Clamp Bolt A Loosen Lower Muffler Bracket Bolts B Lower Muffler C Exhaust Manifold Removal e Loosen the clamp screws A e Detach the clamps B by sliding them up or forward Remove the lower front exhaust cover C 108114 ENGINE TOP END 5 47 Mufflers Free the O2 sensor lead A from the clamps B and dis connect the sensor lead connector C California Eu rope and UK model Remove the exhaust pipe holder nuts A Remove the exhaust pipe B Muffler Exhaust Pipe Installation Replace the exhaust pipe holder gasket A with new ones e Install the exhaust pipe holder A so that its UP mark B faces upward e In
17. lt XO gt T lt rp N reo sr ed MEME MP ME XE MPOXE CO CO C co CL CN Cg ononrann lt a M GC17375BW2 1 ECU 5 Battery 2 Oxygen Sensor 6 Joint Connector 3 Decompression Fuse 10A 7 Frame Ground 4 ECU Main Fuse 30A Oxygen Sensor Heater Inspection e Set the hand tester A to the x 10 range and connect it to the terminals in the oxygen sensor lead connector B Black C Black D Special Tool Hand Tester 57001 1394 Oxygen Sensor Resistance Standard 14 1 19 3 O at 20 C 68 F lf the tester reading is not as specified replace the oxygen sensor with a new one GP18070BS1 C FUEL SYSTEM DFI 3 97 Subthrottle Motor Driver Service Code 85 Subthrottle Motor Driver Removal Installation e Subthrottle motor driver is the internal circuit of the ECU Subthrottle motor driver itself can not be removed from the ECU Subthrottle Motor Driver Inspection e Service code 85 is appeared replace the ECU 3 98 FUEL SYSTEM DFI Oxygen Sensor Incorrect Output Voltage Service Code 94 Oxygen Sensor Removal Installation e Refer to Oxygen Sensor Removal and Installation in the Electrical System chapter Oxygen Sensor Inspection e Warm up the engine thoroughly e Turn the ignition SW OFF e Remove the sea
18. Fuse Inspection 16 4 ELECTRICAL SYSTEM Exploded View ELECTRICAL SYSTEM 16 5 Exploded View Fastener Remarks Spark plugs Lm Alternator stator coil mounting bolts 104 Crankshaft sensor mounting bolts 61 in Ib Speed sensor mounting bolt 87 Gear position switch mounting bolts 43 in Ib Gear position switch lead clamp bolts 43 in lb 8 Side stand switch mounting bolt es os 78 Regulator rectifier bolts 78 10 Front Brake Light Switch L Apply a non permanent locking agent G Apply grease SS Apply silicone sealant Three Bond TB1211F Si Apply silicone grease 16 6 ELECTRICAL SYSTEM Exploded View NS GP02139BN5 ELECTRICAL SYSTEM 16 7 Exploded View Fastener Remarks Oxygen sensor Water temperature sensor E 104 in lb Camshaft position sensor bolt 87 in lb 4 Fuse Box 5 ECU Electronic Control Unit 6 Starter Control Relay 7 Inlet Air Pressure Sensor 8 Vehicle down Sensor 9 Relay Box 10 Turn Signal Control Relay 11 Atmospheric Pressure Sensor 12 Inlet Air Temperature Sensor L Apply a non permanent locking agent 16 8 ELECTRICAL SYSTEM Exploded View ELECTRICAL SYSTEM 16 9 Exploded View No Fastener Decompression solenoid bolts Remarks 87 in lb Starter lockout switch screw 10 in Ib
19. Y Remove the auxiliary lead ending the self diagnosis mode NG Make sure the FI indicator LED light and Fl symbol do not go ON m ped gt 2 on OK S NG Run the engine for several minutes at idling and run the motorcycle at 30 km h 18 mph or above in order to confirm no problem i i OK joo pm GC17276B S How to Read Service Codes OService codes are shown by a series of long or short blinks of the FI indicator LED light as shown below 3 40 FUEL SYSTEM DFI Self Diagnosis 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 Open is i0th digit 0 56 0 5s a digit is is 0 5s Fl Indicator LED Light ON s K bk K 3 K 3 D D D D D 2sec 3s 1 8s 0 5s 3s 1 5s 1
20. e Measure the output voltage of the sensor with the con nector joined Oxygen Sensor Output Voltage without Plugs Standard approx 0 1 V the reading is within range with plugs 0 7 0 8 V without plugs approx 0 1 V the oxygen sensor is good x If the reading is without range replace the oxygen sensor 3 74 FUEL SYSTEM DFI Oxygen Sensor not activated Service Code 33 N lt XO gt 9 lt rp N ro sr ex M LO uU xp CMECXE MEME MP ME XE MPCXE CL CN COCMOOTON Sg lt M GC17375BW2 1 ECU 5 Battery 2 Oxygen Sensor 6 Joint Connector 3 Decompression Fuse 10A 7 Frame Ground 4 ECU Main Fuse 30A Oxygen Sensor Heater Inspection e Set the hand tester A to the x 10 range and connect it to the terminals in the oxygen sensor lead connector B Black C Black D Special Tool Hand Tester 57001 1394 Oxygen Sensor Resistance Standard 14 1 19 3 O at 20 C 68 F lf the tester reading is not as specified replace the oxygen sensor with a new one GP18070BS1 C FUEL SYSTEM DFI 3 75 Fuel Injectors 1 2 Service Code 41 42 Fuel Injector 1 Front Fuel Injector for Front Cylinder Service Code 41 Fuel Injector 2 Rear Fuel Injector for Rear Cylinder
21. e After the adjustment start the engine and check that the clutch does not slip and that it releases properly Belt Deflection Inspection NOTE OBelt deflection must be checked and adjusted when the belt is cold at room temperature OBelt deflection also should be checked at first 1000 km ride after belt replacement Check to see if wheel alignment is properly adjusted OThe left and right notches on the belt adjuster should point to the same marks or positions on the swingarm xIf they do not adjust wheel alignment see Wheel Align ment Inspection Adjustment 2 22 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Using the jack and jack attachment under the frame pipe ribs lift the rear wheel off the ground see Rear Wheel Removal in the Wheels Tires chapter e Visually inspect the belt for damage see Belt Wear and Damage Inspection xIf the belt is damaged replace it with a new one e Mark the initial belt position C on the belt cover window e Using the tension gauge A push up 45 N 4 5 kgf 10 Ib of force from under and on the center of the belt at the gauge of the lower belt cover B e Measure the deflection length between mark D and C of the belt NOTE OPush the belt by the gauge until the top surface A of the stopper comes to the 45 N loaded scale B marked 45N OPush up on the center of the belt An inaccurate reading will occur if the edge of the belt is pushed
22. 6C17045BS1 C 6017037381 FUEL SYSTEM DFI 3 21 Troubleshooting the DFI System 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 connections B for continuity using the hand tester C special tool analog tester rather than a digital meter Special Tool Hand Tester 57001 1394 lf 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 6617271852 C Trouble may involve one 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 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
23. Self diagnosis Procedures Service Code Clearing Procedures How to Read Service Codes How to Erase Service Codes Service Code Table Backups sonia dis Main Throttle Sensor Service Code Main Throttle Sensor Removal Adjustment Input Voltage Inspection Output Voltage Inspection Resistance Inspection Inlet Air Pressure Sensor Service Input Voltage Inspection Output Voltage Inspection Inlet Air Temperature Sensor Service Coda 13 ct scan tesis Remowval Installation Output Voltage Inspection Sensor Resistance Inspection Water Temperature Sensor Service Output Voltage Inspection Water Temperature Sensor Resistance Inspection Atmospheric Pressure Sensor Service Code 15 Installation 3 56 3 57 3 57 3 57 Input Voltage Inspection Output Voltage Inspection Crankshaft Sensor Service Code Crankshaft Sensor Removal Installation Crankshaft Sensor Inspection Camshaft Position Sensor Service Camshaft Position Sensor Removal Installation Camshaft Position Sensor
24. 0 7 4 ENGINE LUBRICATION SYSTEM Exploded View 8 ee ENGINE LUBRICATION SYSTEM 7 5 Exploded View Fastener Remarks Rocker shaft oil pipe bolts EN 8 se in Ib Cylinder head oil pipe banjo bolts Oil filter 17 5 1 75 12 5 4 forpasas 30 21 Oil passage adapter drain plug 9 8 1 0 87 in lb Relief valve 15 1 5 11 L Camshaft oil pipe bolt 9 8 1 0 87 in lb 8 Oi pipe bolt 116 os see 1 _ Oil pipe bolt L30 104 in lb Oil pump drive sprocket bolt 21 Oil APP chain tensioner bolt 104 in lb Te oe Rin Inside plate bolt 87 Outside plate bolt 87 Clutch cover drain plug Oil passage adapter Oil pan plug Oil pipe stopper bolt 6 9 61 in lb 38 38 Sr 11 Oil pan bolts Left oil pan drain plug Right oil pan drain plug 24 Oil screen for crank room 25 Oil screen for transmission room 26 Scavenge pump for crank room 27 Scavenge pump for transmission room 28 Feed pump EO Apply engine oil G Apply grease L Apply a non permanent locking agent MO Apply molybdenum disulfide oil R Replacement Parts SS Apply silicone sealant Kawasaki Bond 56019 120 for oil pressure switch Three Bond TB1211F for oil pan 7 6 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil
25. A WARNING Be sure to hold the front brake when removing the rear wheel or the motorcycle may fall over It could cause an accident and injury e Remove Caliper Mounting Bolts A Caliper B e Remove Axle Nut Cotter Pin A Axle Nut B WHEELS TIRES 10 9 Wheels Rims e Pull out the axle and move the rear wheel toward the front A to disengage the wheel from the drive belt B e Move the rear wheel back and remove it CAUTION Do not lay the wheel directly 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 62048242 P Rear Wheel Installation e Apply grease to the grease seal of the wheel e Insert the collars A on both sides of the hub e Install the caliper bracket A onto the swingarm stop B e Engage the drive belt A with the wheel coupling B e Insert the axle from the left side of the rear wheel e Tighten Torque Rear Axle Nut 108 N m 11 kgf m 80 ft Ib Rear Caliper Mounting Bolts 34 N m 3 5 kgf m 25 16 A WARNING If the axle nut is not securely tightened an unsafe riding condition may result 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 ag
26. Remove the oil filler cap dipstick A wipe it dry and thread in the oil filler cap dipstick fully clockwise then remove again to check the oil level Check that the engine oil level is between the H High B and L Low C levels on the dip stick NOTE OSituate the motorcycle so that it is perpendicular to the ground Olf the motorcycle has just been used wait 2 3 minutes for all the oil to drain down Olf the oil has just been changed or the oil temperature is low start the engine and run it at idle speed until the oil temperature in the transmission room goes up about 50 C 122 F Do not run the engine at high engine speed This fills the oil filter with oil Stop the engine then wait 2 3 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 immediately and find the cause xIf the oil level is too high remove the excess oil using a syringe or some other suitable device xIf the oil level is too low add the correct amount of oil through the oil filler opening Use the same type and make of oil that is already in the engine NOTE Olf the engine oil type and make are unknown use a
27. Brake Brake Hose Removal Installation 12 14 12 14 12 15 12 16 12 16 12 16 12 16 12 17 12 18 12 18 12 18 12 18 12 18 12 19 12 19 12 19 12 22 12 22 12 2 BRAKES Exploded View GLO2093BW5 C BRAKES 12 3 Exploded View Fastener Remarks Brake hose banjo bolts Front brake reservoir cap screws 13 in Ib Brake lever pivot bolt 87 in lb Front brake light switch screw 10 in Ib Front master cylinder clamp bolts 78 Brake disc bolts 20 8 Front caliper mounting bolts Front caliper assembly bolts Front brake pad pins Caliper bleed valves 69 Dm brake fluid L Apply a non permanent locking agent G Apply grease R Replacement Parts S Follow the specific tightening sequence Si Apply silicone grease or PBC grease 12 4 BRAKES Exploded View BRAKES 12 5 Exploded View No Fastener Rear master cylinder mounting bolts Remarks 1 2 Rear master cylinder push rod locknut 3 Brake hose banjo bolts Caliper bleed valves 3 Brake pedal demp bolt 17 18 Rear caliper mounting bolts Brake disc bolts B Apply brake fluid G Apply grease L Apply a non permanent locking agent R Replacement Parts Si Apply silicone grease or PBC grease 5 8 69 in Ib 34 3 5 25 27
28. Radiator Hose and O ring Replacement Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Remove Thermostat A Bracket B see Thermostat Removal in the Cooling System chapter Upper Engine Bracket C see Engine Removal Instal lation chapter e Loosen the radiator hose clamps and remove the hoses D e Unscrew the bolts and remove the water pipes E and O rings F e Apply grease to the new O ring and install the water pipes e Torque the water pipe bolts G Torque Water Pipe Bolts 9 8 N m 1 0 kgf m 87 in Ib OFor the water pipe bolt on the rear cylinder apply a non permanent locking agent L e Install the new radiator hose and tighten the hose clamps securely e Fill the coolant see Coolant Change in the Periodic Main tenance chapter e Check the cooling system for leaks 85808014883 FUEL SYSTEM DFI 3 1 Fuel System DFI Table of Contents Exploded DFI Parts Specifications Special Tools and Sealant DESY SGI DFI Servicing Precautions Troubleshooting the DFI System Qultline s iiir ite nnne Inquiries to Rider DFI System Troubleshooting Guide Self Diagnosis Self diagnosis Outline
29. Speedometer Unit fenneeter Ed _ eo 90000 ight Low Front Right Turn Joint Connector BK Y BK Y BK Y BK Y Front Accessory Connectors TE KY B BL Bk Y RIF x Y m Busy BK Y Signal Light 12y21W Front Left Turn a Signal Light 124219 EET im Ee Torn Signal Control Relay Pressure P witeh 0 Side Stand Switch Frame Fuse Box Ground 1 up Fuse Left Handlebar Switches 2 Accessory Fuse 10 i 3 Radiator Fan Fuse 20 E su DO LL 4 Decompression Solenoid Fuse 10 Seiten 8 Turn Signal Fuse 10A Soden shane SEEN TiHeadlight Fuse 10A 8 Taillight Fuse 10A 9 Ignition Fuse 10A LEFT HANDLEBAR SWITCH CONNECTIONS 10 Horn Fuse 10 Starter Lockout Switch Horn Button Button Dimmer Switch Jurn Signal Switch Color Color R7 BR ay GY luteh Level Push 19 Released Pulled in Relay Box 1 Starter Circuit Relay 2 EGU Relay 3 Fuel Pump Relay 4 Headlight Relay 5 Fan Relay 210039 5 C ELECTRICAL SYSTEM 16 21 Wiring Diagram Other than United States Canada Australia and Malaysia Sub throttle Valve Actuator Camshaft Position Sensor Sub
30. 1 2 3 Front brake light switch screw KR Fuel pump mounting bolts 10 in Ib Fuel level sensor mounting bolts es om 61 Ls 87 in Ib Starter motor terminal nut 87 in Ib Starter motor terminal locknut Starter motor assembly bolts 95 Starter motor mounting bolts Pas ro 87 fl 43 in lb O 0 Starter Relay L Apply a non permanent locking agent R Replacement Parts S Follow the specific tightening sequence EO Apply engine oil 16 10 ELECTRICAL SYSTEM Exploded View ELECTRICAL SYSTEM 16 11 Exploded View Fastener Remarks Turn signal light lens screws 8 7 in lb Front turn signal light screws 61 in Ib Tail brake gnt unit nuts 52 in lb Reartum signal ightserws om emn License plate light lens mounting screws 2 10 in Ib CA Canada Model 16 12 ELECTRICAL SYSTEM Specifications Item Battery Type Model name Capacity Voltage Charging System Alternator type Battery charging voltage Alternator output voltage no load Stator coil resistance Regulator rectifier Type Resistance Standard Sealed Battery FTZ16 BS 12 V 18 Ah 12 6 V or more Three phase AC with delta connection and rare earth single magnet rotor 14 2 15 2 V 3 000 r min rpm 70 95 V 3 000 r min rpm 0 18 0 22 0 Load dumping regulator with full
31. A WARNING Do not attempt to ride 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 Check the brake pedal position and adjust it if necessary Check the rear brake light switch operation and adjust the switch if necessary see Periodic Maintenance chapter 12 10 BRAKES Calipers Front Caliper Removal e Loosen the banjo bolt A at the brake hose lower end and tighten it loosely Unscrew the caliper mounting bolts CAUTION Do not loosen the caliper assembly bolt C Take out only the caliper mounting bolts for caliper re moval Loosening the caliper assembly bolts will cause brake fluid leakage Immediately wash away any brake fluid that spills Take off the caliper e Unscrew the banjo bolt and remove the brake hose from the caliper Rear Caliper Removal e Remove Caliper Mounting Bolts A Brake Hose B Rear Caliper C Caliper Installation e Install the caliper and brake hose lower end OReplace the washer on each side of hose fitting with new ones e Tighten the caliper mounting bolts and banjo bolt Torque Front Caliper Mounting Bolts 25 N m 2 5 kgf m 18 ft Ib Rear Caliper Mounting Bolts 34 N m 3 5 kgf m 25 ft lb Brake Hose Banjo Bolt 25 N m 2 5 kgf m 18 ft Ib e Check the fluid level i
32. 5 40 ENGINE TOP END Cylinder Head 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 Too small 45 Grind Machinist s Tool 45 Cutter dye on seat Purpose increase O D of seat area to spec 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 Too narrow Too wide 45 Grind Machinist s Tool 45 Cutter dye on seat Purpose increase width of seat area beyond spec to increase 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 ENGINE TOP END 5 41 Cylinders Piston Cylinder Removal Remove the cylinder head see this chapter Remove the coolant drain plug A and washer B to drain the coolant from the front cylinder C Remove the cylinder mounting bolt A Tap lightly up the cylinder with a plastic mallet to separate from the crankcase Remove the cylinder base gasket Front Cylinder B Piston Removal Remove the cylinder block see this chapter e Place a piece of clean cloth under the piston and remove the piston pin snap r
33. Coolant Change Radiator Hose and O ring Replacement 2 30 2 31 2 32 2 32 2 32 2 33 2 33 2 34 2 34 2 34 2 35 2 35 2 36 2 36 2 36 2 36 2 37 2 39 2 39 2 39 2 41 2 42 2 45 2 46 2 47 2 49 2 49 2 50 2 53 2 2 PERIODIC MAINTENANCE Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition The initial maintenance is vitally important and must not be neglected Periodic Inspection FREQUENCY Whichever ODOMETER READING x 1000 km x 1000 mile INSPECTION Steering System Steering play inspect Steering stem bearing lubricate Brake System Brake fluid leak brake hose and pipe inspect vo Brake hose damage inspect year Brake hose installation condition inspect year Brake operation effectiveness no drag inspect ae Brake fluid level inspect Brake pad wear inspect Wheels and Tires Tire air pressure inspect Wheel tire damage inspect Tire tread wear abnormal wear inspect Wheel bearing damage inspect year Suspensions Front forks rear shock absorber operation smooth stroke inspect Front forks rear shock absorber oil leak inspect Swingarm pivot lubrication Clutch and Drive Train Clutch operation play disengagement
34. e Turn the engine stop switch to run position e Push the start button and run the engine e Turn the engine stop switch to stop position e Immediately the engine should be stop xIf the engine does not stop inspect or replace the follow ing item Engine Stop Switch see Electrical System chapter xIf the engine stop switch is good condition replace the ECU Fuel System DFI Throttle Control System Inspection e Check the throttle grip free play A xIf the free play is incorrect adjust the throttle cable see below Throttle Grip Free Play Standard 2 3 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 x lf the 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 left to ensure thatthe idle speed doesn t change x lf the idle speed increases check the throttle grip free play and the cable routing e f necessary adjust the throttle cable as follows OLoosen the locknuts A and screw the adjusters B all the way in so as to give the throttle grip plenty of play rear view OTurn out the adjuster of the decelerator cable D until there is no play OTighten the locknut against the adjuster
35. gt 10 E N O TON OHOMOMI STON e co r c O e o m O D rco N 6C17370BN2 1 ECU 2 Subthrottle Valve Actuator FUEL SYSTEM DFI 3 93 Air Switching Valve Service Code 64 Air Switching Valve Removal Instalation e See the Engine Top End chapter Air Switching Valve Inspection e See the Air Switching Valve Unit Test in the Electrical Sys tem chapter e Remove the fuel tank and check the wiring continuity us ing the following diagram 6017368BN2 1 ECU 7 Ignition Fuse 10A 13 Starter Relay 2 Joint Connector 8 ECU Fuse 10A 14 Battery 3 Air Switching Valve 9 Relay Box 15 ECU Main Relay 4 Engine Stop Switch 10 ECU Main Relay 16 Frame Ground 5 Ignition Switch 11 Fuel Pump Relay 6 Fuse Box 12 Main Fuse 30A 3 94 FUEL SYSTEM DFI Decompression Solenoid Service Code 66 Decompression Solenoid Removal Installation e See Decompression Release Mechanism Removal and Installation section in the Engine Top End chapter Decompression Solenoid Inspection e Remove the outer camshaft cover see Decompression Mechanism Removal in the Engine Top End chapter e Set the neutral gear Push the starter button and check that the rod A is pulled B in the solenoid C when the starter button is pushed NOTE OThe rod in the solenoid returns to the original position when the starter
36. whether sidestand up or not Though clutch lever pulled in but sidestand up and gear not in neutral Vehicle down sensor coming off Sidestand down and clutch lever pulled in whether gear in neutral or not Reinstall see chapter 3 Vehicle down sensor trouble Inspect see chapter 3 ECU ground or power supply trouble Battery voltage low Spark plug dirty broken or gap maladjusted Inspect see chapter 3 Inspect and charge see chapter 16 Clean spark plug and adjust plug gap see chapter 2 Spark plug cap or high tension wiring trouble Inspect the ignition coil see chapter 16 Spark plug cap shorted or not in good contact Reinstall or inspect the cap see chapter 16 Spark plug incorrect Replace it with the correct plug see chapter 16 IC igniter in ECU trouble Inspect see chapter 16 Neutral starter lockout or sidestand switch trouble Crankshaft sensor trouble Inspect each switch see chapter 16 Inspect see chapter 16 Ignition 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 30A or ignition fuse blown Inspect and replace see chapter 16 Fuel air mixture incorrect Air cleaner clogged poorly sealed or missing
37. 0 3 mm 0 01 in 6108010151 C BRAKES 12 19 Brake Fluid Brake Fluid Level Inspection e Refer to Brake Fluid Level Inspection in Periodic Mainte nance chapter Brake Fluid Change Refer to Brake Fluid Change in Periodic Maintenance chapter Brake Line Bleeding The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action Air however is easily compressed When air enters the brake lines brake lever or pedal movement will be partially used in compressing the air This will make the lever or pedal feel spongy and there will be a loss in braking power A WARNING Be sure to bleed the air from the brake line when ever brake lever or 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 almost the same as for the front brake e Remove the reservoir cap and 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 A at the bottom of the reservoir e Install the reservoir cap 12 20 BRAKES Brake Fluid e Remove the r
38. Battery Terminal Connections for Injector 2 Meter BL G lead terminal 37 Meter Battery Terminal e Turn the ignition SW ON e Start the engine Standard Battery Voltage 12 5 V or more e Turn the ignition SW OFF xIf the output voltage is normal perform Injector Signal Test If the output voltage is out of the standard turn the ignition SW OFF remove the fuel tank and check the injector wiring for continuity Injector Wiring Inspection ECU Connector Injector Connectors Terminal 13 Injector 1 Terminal W R Terminal 13 Injector 2 Terminal W R Terminal 38 Injector 1 Terminal BL R Terminal 37 Injector 2 Terminal BL G x If the wiring is good inspect the resistance of the injectors see Injector Resistance Inspection in chapter Injector Signal Test e Prepare two test light sets with male terminals as shown Rating of Bulb 12V x 3 3 4 W Terminal Width B 1 8 mm Terminal Thickness C 0 8 mm CAUTION Do not use larger terminals than specified above A larger terminal could damage the injector main 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 GC17346BS1 C 6017024281 3 80 FUEL SYSTEM DFI Fuel Injectors 1 2 Service Code 41 42 e Remo
39. Diameter Mark D or no mark CAUTION If the connecting rods bearing inserts or crank shaft are replaced with new ones select the bearing insert and check clearance with a plastigage before assembling engine to be sure the correct bearing inserts are installed e Apply molybdenum disulfide oil to the inside A of the big end bearing inserts OThe molybdenum disulfide oil is a mixture of engine oil and molybdenum disulfide grease with a weight ratio 10 1 bearing inserts are replaced install them as follows ODo not apply molybdenum disulfide oil to the outside B of the inserts or the inside C of the connecting rod and cap Olnstall the inserts so that their nails D are on the same side and fit into the recess of the connecting rod and cap 6105082851 C 6105064851 C 9 20 CRANKSHAFT TRANSMISSION Crankshaft Connecting Rods 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 Dowel Pin G Connecting Rod Big End Bolts H Suitable Blocks J e Be sure the dowel pins A on the caps B are in position e Install the cap on the connecting rod aligning the diame ter mark OLeft side connecting rod A is for the rear cylinder and right side connecting
40. FUEL SYSTEM DFI 3 123 Evaporative Emission Control System Separator Operation Test A WARNING Gasoline is extremely flammable and can be explo sive under certain conditions Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Turn the ignition switch OFF Remove the seat and left side cover see Frame chapter e Connect the hoses to the separator e Disconnect the breather hose from the separator and in ject about 20 mL of gasoline A into the separator B through the hose fitting e Disconnect the evaporative fuel return hose C from the fuel tank D e Run the open end of the return hose into the container level with the tank top E Start the engine and let it idle x If the gasoline in the separator comes out of the hose the separator works well If it does not replace the separator with a new one 3 124 FUEL SYSTEM Evaporative Emission Control System Fuel Tank Air Switching Valve Hose Reserve Tank Hose og breather Red return is White vacuum Throttle Body Assy White Red amp P vacuum 8 a return a T M Blue front RN purge breather V breather 122 pos op Separator 0 a ES 27 9 Canister Ny 6613010 5 COOLING SYSTEM 4 1 Cooling System Table of Conten
41. Impeller Sealing Seat Surface A Rubber Seal B e Visually inspect the impeller A If the surface is corroded or if the blades are damaged replace the impeller COOLING SYSTEM 4 11 Water Pump Mechanical Seal Replacement Remove the water pump impeller see Water Pump Re moval in this chapter e Pry the mechanical seal flange off with a small chisel A e Pull the mechanical seal out of the right crankcase with needle nose pliers Discard the mechanical seal CAUTION Be careful not to damage the water pump shaft and the inner sealing surface of the crankcase NOTE OSince the replacement mechanical seal has an adhe sive coated body do not apply a liquid gasket to the exterior surface of the body e Press A the mechanical seal B by using a suitable 28 mm socket C and a bearing driver D until its flange touches the step E Gap F Special Tool Bearing Driver Set 57001 1129 xIf the seal and ball bearings are damaged replace the mechanical seal ball bearings and oil seal by splitting the crankcase e Split the crankcase see Crankshaft Transmission chap ter e Remove the water pump impeller e Pull out the water pump shaft from the inside of the right crankcase e Take the bearing A out of the right crankcase using the bearing remover Special Tools Bearing Remover Shaft 57001 1265 B Bearing Remover Head 10 x 12 57001 1266 C e Using a thin b
42. Kawasaki VN2000 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 me a a NIO NIIA e Appendix VULCAN 2000 Kawasaki VN2000 Motorcycle Service Manual All rights reserved No parts of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Quality Assurance 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 is reserved to make changes at any time without prior notice and without incurring an oblig
43. Remove Needle Bearing A Special Tool Oil Seal amp Bearing Remover B 57001 1058 Upper Side e Remove Sleeve A Oil Seals B Remove Needle Bearing A Special Tool Oil Seal amp Bearing Remover B 57001 1058 Swingarm Bearing Installation e Apply plenty of grease to the needle bearings and sleeve e Be sure to install the needle bearings so that the man ufacturer s marks are faced out This prevents bearing damage e Position the following bearings as shown using a suitable bearing driver in the bearing driver set Special Tool Bearing Driver Set 57001 1129 13 22 SUSPENSION Swingarm Left Side A Swingarm B Needle Bearing C 24 0 4 mm 0 94 0 016 in D Ball Bearing until bottom end E Circlip F Oil Seal G 1 5 0 4 mm 0 059 0 016 in H Collar Right Side A Swingarm B Needle Bearing C 14 0 4 mm 0 55 0 016 in D Oil Seal Sleeve Upper Side A Swingarm B Needle Bearing C 6 5 0 4 mm 0 26 0 016 in D Oil Seals Swingarm Bearing Sleeve Inspection CAUTION Do not remove the bearings for inspection Remove may damage them e Inspect the swingarm sleeves A needle bearings B and ball bearing C installed in the swingarm The rollers and balls in the bearing normally wear very lit tle and wear is difficult to measure Instead of measuring inspect the bearings in the swingarm for abrasio
44. Rocker Case Cover Removal e Remove the engine see Engine Removal Installation chapter e Remove the rocker case cover bolts and take off the rocker case cover from the rocker case Front Rocker Case Cover Bolts A and Washers B Front Rocker Case Cover C Front D GE19004BS1 C Rocker Case Cover Installation e Replace the cover gaskets A with a new one e Be sure the dowel pins B are in position Front Rocker Case C Rear Rocker Case D GE19006BWi C e Tighten the cover bolts to the specified torque Torque Rocker Case Cover Bolts 12 N m 1 2 kgf m 104in Ib OFirst tighten the center bolt A and tighten the bolts B alternating diagonally Tighten all the bolts two times in the same method GE19005BS1 C 5 16 ENGINE TOP END Rocker Case Rocker Case Removal e Remove the engine see Engine Removal Installation chapter e Remove the throttle body assy see Fuel System DFI chapter e Remove the rocker case covers see this chapter e Position the 1 or 2 piston TDC as follows ORemove the spark plugs ORemove the plug A on the outer clutch cover B OTurn the crankshaft counterclockwise A and position 1 piston at TDC observing the piston movement through the spark plug hole Front Spark Plug Hole B Front C OFor the 2 piston position it at TDC in a similar way ENGINE TOP END 5 17 Rocker Case OAnother way to position each piston at T
45. and pull it out e Remove the wedge base type bulb A pull the bulb straight out of the socket B CAUTION Do not turn the bulb Pull the bulb out to prevent damage to the bulb Do not use bulb rated for greater wattage than the specified value e Disconnect the tail brake light lead connector A e Turn the tail brake light bulb socket A counterclockwise B and pull it out e Align the arrow A of the new bulb socket with the arrow B end of the housing and turn the socket clockwise e Install the tail brake light unit e Tighten Torque Tail Brake Light Unit Mounting Nuts 5 9 N m 0 60 kgf m 52 in Ib 16 60 ELECTRICAL SYSTEM Lighting System Headlight Tail Light Circuit DLI BK Y DL I R BL tit BK Y BK Y BL BK Y w N gt 0 Ignition Switch Joint Connector High Beam Indicator Light Headlight Hi Headlight Lo Taillight Fuse 10 A Headlight Fuse 10 A Joint Connector Alternator Relay Box Headlight Relay License Plate Light Tail Brake Lights Joint Connector Frame Ground Dimmer Switch Starter Relay 18 19 20 21 GP12117BW4 C Main Fuse 30 Battery Running Position Lights US and Canada Models City Light Other than US Canada Australia and Malaysia Models ELECTRICAL SYSTEM 16 61 Automatic Turn Si
46. check the ECU for its ground power supply and wiring shorted x lf the input voltage is within the standard range remove the fuel tank and check wiring from ECU to the subthrottle sensor for continuity x If the wiring is good check the output voltage of the sub throttle sensor OBO 6C17127BS1 C FUEL SYSTEM DFI 3 71 Subthrottle Sensor Service Code 32 Output Voltage Inspection e Measure the output voltage at the ECU in the same way as input voltage inspection Note the following Digital Voltmeter A Connector B Special Tool Needle Adapter Set 57001 1457 Subthrottle Sensor Output Voltage Connections to ECU Meter Y lead terminal 24 Meter gt lead terminal 25 Turn the ignition switch ON Measure the output voltage when the subthrottle valve is fully opened or completely closed by hand Output Voltage at ECU 1 08 4 60 V DC at subthrottle Standard valve full opening to closing NOTE OThe throttle sensor is operating correctly if the following voltages are obtained 1 08 VDC or slightly higher with the subthrottle valve at the closed position 4 60 VDC or slightly lower with the subthrottle valve at the fully open position CAUTION Do not remove or adjust the subthrottle sensor It has been adjusted and set with precision at the fac tory Never drop the sensor can especially on a hard
47. driver in or out until the beam points straight ahead OTurn the adjuster clockwise to face the headlight to the left xIf the headlight beam points too low or high adjust the vertical beam Headlight Beam Vertical Adjustment Remove the cap A e Turn the vertical adjuster A in the headlight in or out with a screwdriver to adjust the headlight vertically OTurn the adjuster clockwise to face the headlight up 6517014851 C PERIODIC MAINTENANCE 2 31 Periodic Maintenance Procedures NOTE OON high beam the brightest points should be slightly below horizontal with the motorcycle on its wheels and the rider seated Adjust the headlight to the proper an gle according to local regulations OFor US model the proper angle is 0 4 degrees below horizontal This is 50 mm 2 drop at 7 6 25 ft measured from the center of the headlight with the motorcycle on its wheels and the rider seated 50 mm 2 in A Center of Brightest Spot B 7 6 m 25 ft C Side Stand Switch Operation Inspection e Inspect the side stand switch A operation accordance to below table Sidestand Switch Operation Side Gear Clutch Engine Stand Start Engine Run Up Neutral Starts Gonne leased running Up Neutral Pulled in Starts running Re Doesn t Continue Up In Gear leased start running Up In Gear Pulled in Starts GONNE ru
48. face Such a shock to the pump can damage it 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 Remove the fuel tank see Fuel Tank Removal 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 e Unscrew the fuel pump bolts A and take out the fuel pump B 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 e Replace the fuel pump gasket A with a new one GC10016BS1 C GC10015BS1 C FUEL SYSTEM DFI 3 83 Fuel Pump Service Code 45 e Check that the terminals A and band B are in place e Apply a non permanent locking agent to the threads of the fuel pump bolts e Tighten th
49. see chapter 3 Throttle body assy loose Reinstall see chapter 3 Throttle body assy O ring damaged Replace see chapter 3 Fuel tank air vent obstructed Inspect and repair see chapter 3 Fuel line clogged Inspect and repair see chapter 3 Fuel pump operates intermittently and often DFI fuse blows Fuel pump trouble Pump bearings may wear Replace the pump see chapter 3 Inspect see chapter 3 Inlet air temperature sensor trouble Throttle sensor malfunction Inspect see chapter 3 Inspect see chapter 3 Atmospheric pressure sensor trouble Inspect see chapter 3 Inlet air pressure sensor trouble Inspect see chapter 3 Cracked or obstructed inlet air pressure sensor hose Injector clogged Compression low Inspect and repair or replace see chapter 3 Visually inspect and replace see chapter 3 Spark plug loose Reinstall see chapter 16 Cylinder head not sufficiently tightened down Tighten see chapter 5 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 Cylinder head warped Inspect and replace see chapter 5 Valve spring broken or weak Replace see chapter 5 Inspect and replace see chapter 5 3 34 FUEL S
50. 11 7 12 3 at 20 C 68 F x lf the reading is out of the range perform the Injector Unit Test the reading is normal perform the Injector Unit Test for confirmation 6017024381 FUEL SYSTEM DFI 3 81 Fuel Injectors 1 2 Service Code 41 42 Injector Unit Test e Use two wires 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 Sealed Battery D CAUTION Be sure to connect the bulb in series The bulb works as a current limiter to protect the solenoid in the injector from excessive current e Connect the test light set to the injector E as shown e Open and connect F the end of the wire to the battery terminal repeatedly The injector should click x If the injector does not click replace the injector x If the injector clicks check the wiring again If the wiring is good replace the injector may be clogged or ECU 6017024481 GC17347BW2 1 ECU 6 ECU Fuse 15A 2 Injector 1 7 Ignition Fuse 10A 3 Injector 2 8 Relay Box 4 Engine Stop Switch 9 ECU Main Relay 5 Ignition Switch 10 Fuel Pump Relay 11 Main Fuse 30A 12 Starter Relay 13 Battery 14 Fuse 30A 15 Joint Connector 3 82 FUEL SYSTEM DFI Fuel Pump Service Code 45 Fuel Pump Removal CAUTION Never drop the fuel pump especially on a hard sur
51. 18 Air cleaner cover 19 Air cleaner element 20 Air cleaner housing 21 Inlet air temperature sensor L Apply a non permanent locking agent R Replacement Parts G Apply grease 3 8 FUEL SYSTEM DFI DFI Parts Location GC17321BW2 KEO ge Ignition Coil 1 Fuel Pump Ignition Coil 2 Atmospheric Sensor Main Fuse 30A Fuse Box Vehicle Down Sensor ECU Sealed Battery Relay Box Pressure ole pm ANNI Lake CPS ORAE XO MORE Crankshaft Sensor Air Switching Valve Injector 2 Injector 1 Water Temperature Sen sor Main Throttle Sensor Subthrottle Sensor Subthrottle Valve Actua tor Inlet Air Pressure Sensor 2 22 23 24 6017322BN2 Camshaft Position Sen sor Inlet Air Temperature Sensor Oxygen Sensor Califor nia Europe and UK Mod els Gear Position Switch Speed Sensor FUEL SYSTEM DFI 3 9 DFI Parts Location 3 10 FUEL SYSTEM DFI DFI Parts Location FUEL SYSTEM DFI 3 11 Specifications Item Standard Throttle Grip Free Play Air Cleaner Element 2 3 mm 0 08 0 12 in Viscous paper element ECU Electronic Control Unit Type Fuel Pressure high pressure line Right after Ignition SW ON After pump runs 3 sec and stops With engine idling Throttle Sensor Input voltage Output voltage Resistance Atmospheric Pressu
52. 2 28 Headlight Aiming Inspection Side Stand Switch Operation Engine Stop Switch Operation Throttle Control System Idle Speed Inspection Fuel Hose and Connection Cooling Coolant Level Inspection Radiator Hose and Connection Evaporative Emission Control System Inspection CAL Evaporative Emission Control System Inspection Air Suction System Air Switching Valve Operation Otrs a iin ea Chassis Parts Lubrication Bolts and Nuts Tightness Replacement Parts Brake Hose and Pipe Replacement Brake Fluid Change Master Cylinder Rubber Parts Replacement Caliper Rubber Parts Replacement Spark Plug Replacement Air Cleaner Element Engine Oil Change Oil Filter Replacement Fuel Hose Replacement
53. 5 3 4 49 0 35 0 50 30 43 inl S n the fasteners following the speci 5 fied sequence 8 14 19 1 4 1 9 10 0 13 5 SS Apply silicone sealant 10 25 34 2 6 3 5 19 0 25 Si Apply silicone grease ex PBC grease 12 44 61 4 5 62 33 45 504 14 73 98 74 10 0 54 72 Si Stake the fasteners to prevent loosening 16 Ra AL Tighten the two clamp bolts alternately 18 165 225 17 0 23 0 125 165 two times to ensure even tightening 20 225 325 23 33 165 240 torque Fastener Remarks N m kgf m ft Ib Fuel System Fuel pump bolts 9 8 1 0 87 in lb 5 1 Water temperature sensor 12 1 2 104 in Ib Oxygen sensor 44 4 5 33 Gear position switch mounting bolts 6 9 0 70 61 in Ib Gear position switch lead clamp bolts 6 9 0 70 61 in Ib Camshaft position sensor bolt 9 8 1 0 87 L Fuel level sensor mounting bolts 6 9 0 70 61 in Ib L Speed sensor mounting bolt 9 8 1 0 87 in lb L Delivery joint bolts 9 8 1 0 87 in lb L Throttle body assy holder bolts 9 8 1 0 87 in lb L Inlet manifold bolts 9 8 1 0 87 in lb L Air cleaner housing bolts 9 8 1 0 87 in lb Air cleaner housing Allen bolts 9 8 1 0 87 in lb Cooling System Water temperature sensor 12 1 2 104 in Ib Water pipe bolts 9 8 1 0 87 in Ib Radiator fan bolts 8 3 0 85 74 in lb Reserve tank bolts 6 9 0 70 61 in Ib Radiator cover bolts 11 1 1 97 in lb Water pump impeller bolt 12 1 2 104 in Ib Lh Water pipe drain bolt 9 8 1 0
54. 57001 1238 57001 1457 Hand Tester Flywheel amp Pulley Holder Adapter 57001 1394 57001 1547 8 5714575 C 875715475 C Flywheel amp Pulley Holder Jack Attachment 57001 1343 57001 1571 ST5715718T C 16 14 ELECTRICAL SYSTEM Wiring Diagram United States and Canada Air Radiator Switching Fan Regulator Valve RA Atmospheric Inlet A Pressure Air Right Handlebar Switches i Front Brake Light Switch GOO gt Fuel Sensor 2 Engine Stop Switch Level 3 Starter Button ee Sensor e Light T Switch gt BSS Ignition Boils MM Speedometer Unit 222 1 Odoneter Trip Meter Clock 25 e Liquid Grystal Display ix 2 Speedometer zz 3 Fuel Meter 4 llluminator LED 5 Fuel Indicator LED WHT I 1 6 Hater Temperature Warning FI eases 5 282 TT 011 Pressure Warning Indicator LED 27222 5 2 zi J Wode Switch T 8 Reset Switch 9 High Beam Indicator Light 12V 12 10 Signal Indicator Light 12V1 12W H 1 LED Light Emitting Diode d i i Ignition Switch ini aR aR Y m ay a MINI Joint Speedometer Unit uus uide l t R BL R BL ae eo 90000 BL Headlight High R BK 12v65wW BK Y Headlight Low BL Y 12 55 BK Y Front Right Tura Signal Running Position Light 12V21 5W Front Left Turn Signal Running Po
55. 87 in lb GP18069BS1 C ELECTRICAL SYSTEM 16 85 Switch and Sensors Speed Sensor Inspection e Remove Speed Sensor see Speed Sensor Removal Connect the speed sensor connector A with a battery B 10 kQ 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 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 Oxygen Sensor Removal California and Europe models e Remove Seats see Frame chapter Right Cover see Frame chapter e Disconnect the oxygen sensor lead connector A e Remove Upper Exhaust Pipe Cover A see Mufflers section in Engine Top end chapter B Oxygen Sensor e Remove Oxygen Sensor A GP18071BS1 C 16 86 ELECTRICAL SYSTEM Switch and Sensors Oxygen Sensor Installation California and Europe models CAUTION Never drop the Oxygen Sensor A especially on a hard surface Such a shock to the unit can damage it Do not touch the sensing part B and filter holes C of the sensor to prevent oil contact Oil contamina tion from hands can reduce sensor performance ORefer to General Information for oxygen sensor handling Tighten Torque Torque Oxygen Sensor 44 N m 4 5 kgf m 33 ft lb e Run the oxygen senso
56. Bolt Clamps Bolts Alternator Lead Crankshaft Position Sensor Lead 17 8 APPENDIX Cable Wire and Hose Routing Oa 6 YB OGY LY KY A a ooo ari NA PSS ue gt OA ZILLI E SBI S eee B RUN Z am SN Le ees reed oe ae i OG Viewed from 6809411BN5 APPENDIX 17 9 Cable Wire and Hose Routing OMDNOOAWND Front Frame Ground Terminal Clamp Frame Ground Terminal Lead Put the frame ground terminal so that the flat side faces downward Accessory Lead Terminals Inlet Air Pressure Sensor Insert the clamp in the frame Main Harness Clamp Damper Fuel Tank Tubes Blue and Red Clamp 020 Clamp 015 Breather Tube Coolant Reservoir Tube Insert the clamp in the frame Horn Insert the radiator fan lead connector to the bracket Alternator Leads Clamp the clutch cable and side stand switch lead Main Harness Clamp Alternator Leads Side Stand Switch Lead Connector Alternator Leads Oil Pressure Warning Light Switch Lead and Crankshaft Position Sensor Lead Connector Main Harness Horn Radiator Horn Lead Europe Model 17 10 APPENDIX Cable Wire and Hose Routing 225556650650 CSCIC KK KS SERN 555 4020 52020102025 05990 5 2 555252555 ISRN 555555559 5 Viewed fr
57. C Oil Ring Expander D Opening Positions E e Face the circle mark A on the front piston B toward the front side C and the circle mark D on the rear piston E toward the rear side F as shown NOTE Olnstall the front piston B to the right side connecting rod G while install the rear piston E to the left side connecting rod H OThe front and rear pistons are the same but they should be installed in their original positions CAUTION Incorrect installation of the piston could cause pis ton seizure and result in severe engine damage GE16046BS1 C GE16075BS1 C ENGINE TOP END 5 43 Cylinders Piston e Fit a new piston pin snap ring into the side of the piston so that the ring opening A does not coincide with the slit B of the piston pin hole e Apply molybdenum disulfide oil to the outer surface of the piston pin OThe molybdenum disulfide oil is a mixture of engine oil and molybdenum disulfide grease with a weight ratio 10 OWhen installing the piston snap ring compress it only enough to install it and no more e Apply molybdenum disulfide oil to the cylinder bore e Apply molybdenum disulfide oil to the front and rear of the piston skirt e Install the rear cylinder first with the rear piston at TDC NOTE Olf a new piston or cylinder is used check piston to cylin der clearance see Piston Cylinder Clearance and use new piston r
58. Digital Voltmeter A Connector B Special Tool Needle Adapter Set C 57001 1457 Main Throttle Sensor Output Voltage Connections to ECU Meter Y W lead terminal 23 Meter gt BR BK lead terminal 25 e Start the engine and warm it up thoroughly e Check idle speed to ensure throttle opening is correct Idle Speed Standard 900 50 r min rpm xIf the idle speed is out of the specified range adjust the idle speed see Idle Speed Inspection in Periodic Mainte nance chapter e Turn the ignition switch OFF e Measure the output voltage with the engine stopped and with the connector joined e Turn the ignition switch ON e Measure the output voltage when the throttle is fully opened or completely closed Output Voltage at ECU Standard 1 02 4 62 V DC at idle throttle opening to full throttle opening NOTE OThe throttle sensor is operating correctly if the following voltages are obtained 1 02 VDC or slightly higher with the throttle at the idle position 4 62 VDC or slightly lower with the throttle at the fully open position CAUTION Do not remove or adjust the main throttle sensor It has been adjusted and set with precision at the factory Never drop the sensor can especially on a hard sur face A shock to the sensor can damage it NOTE OThe standard voltage marked with an asterisk refers to the value when the voltage reading at the Input Voltage Inspection shows 5V exactl
59. Engine stop switch turned off Clutch lever not pulled in and gear not in neutral whether sidestand up or down Though clutch lever pulled in sidestand up and gear not in neutral Start Starting Battery voltage low Spark plug dirty broken or gap malad justed Spark plug cap or high tension wiring trou ble Spark plug cap shorted or not in good con tact Spark plug incorrect IC igniter in ECU trouble Gear position starter lockout or sidestand switch trouble Crankshaft sensor trouble Ignition coil trouble Ignition switch or engine stop switch shorted Wiring shorted or open Fuse blown Fuel air mixture incorrect Air cleaner clogged poorly sealed or miss ing Compression Low Spark plug loose Cylinder head not sufficiently tightened down Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Decompression mechanism sticks open engine stalls when moving off HLA hydraulic lash adjuster damaged worn seizure or spring broken HLA oil passage clogged Poor Running at Low Speed Spark weak Battery voltage low Spark plug dirty broken or maladjusted Spark plug cap or high tension wiring trou ble Spark plug cap shorted or not in good con tact Spark plug incorrect
60. Injector Resistance Inspection Injector Unit Test Fuel Pump Service Code 45 Fuel Pump Removal Fuel Pump Installation Pressure Regulator Removal Pump Screen Fuel Filter Cleaning east Operation Inspection Operating Voltage Power Source Voltage Inspection Operating Voltage Inspection Ignition Coils 1 2 Service Code Input Voltage Inspection Starter Control Relay Service Code Starter Control Relay Removal and Installation Starter Control Relay Inspection Radiator Fan Relay Service Code Radiator Fan Relay Remowval Installation Radiator Fan Relay Inspection Subthrottle Valve Actuator Service Code 2 eric tutti eli Subthrottle Valve Actuator 2 Subthrottle Valve Actuator 1 Resistance Inspection Input Voltage Inspection Air Switching Valve Service Code Air Switching Valve Remowval Instalation Air Switching Valve Inspection Decompression Solenoid Service COG 6B uz veil t thori uade Decompression Solenoid Removal Installation Decompression Solenoid 1 5 Oxygen Sensor Heater Service Cod
61. Service Code 42 CAUTION Never drop the injector especially on a hard sur face Such a shock to the injector can damage it Injector Removal Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Disconnect the battery lead 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 Check to see that the battery lead terminal is discon nected e Remove Fuel Tank see this chapter Throttle Body Assy see this chapter e Disconnect the fuel hose joint connector A see Fuel Line section in this chapter e Unscrew the delivery joint bolts B and lift up the delivery joint C with the injectors D Front E e Remove the injectors from the delivery joint Injector Installation OThe front and rear injectors are the same e Replace the seal A and O ring B with new ones and install them onto the injector C e Apply engine oil to the O ring and install them onto the injector CAUTION To avoid air and fuel leak be careful not to get dirt or dust on the O ring Be careful not to damage the O ring 3 76 FUEL SYSTEM DFI Fuel Injectors 1 2 Service Code 41 42 e Apply engine oil to the O ring A and ins
62. 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 sleeve or pivot bearings worn Wheel rim warped or not balanced Wheel bearing worn Handlebar nuts loose Steering stem head nut loose Front rear axle runout excessive 17 60 APPENDIX Troubleshooting Guide except DFI Handlebar pulls to one side Brake Doesn t Hold Frame bent Swingarm bent or twisted Swingarm pivot shaft runout excessive Steering maladjusted Front fork bent Right and or left front fork oil level incorrect Shock absorption unsatisfactory Too hard Front fork oil excessive Front fork oil viscosity too high Rear shock absorber adjustment too hard Tire air pressure too high Front fork bent Too soft Tire air pressure too low Front fork oil insufficient and or leaking Front fork oil viscosity too low Rear shock adjustment too soft Front fork rear shock absorber spring weak Rear shock absorber oil leaking Air in the brake line Pad or disc worn Brake fluid leakage Disc warped Contaminated pad Brake fluid deteriorated Primary or secondary cup damaged in mas ter cylinder Master cylinder scratched inside Battery Trouble Battery discharged Charge insufficient Battery faulty too low terminal voltage Battery leads making poor contact Load excessive e g bulb of
63. Throttle Cable Adjuster Locknuts Engine Mounting Bolts and Nuts Shift Pedal Bolts Muffler Mounting Bolt and Nut Exhaust Pipe Holder Nuts Clutch Lever Pivot Nut Radiator Mounting Bolt Radiator Bracket Bolts Others Side Stand Bolt and Nut Footboard Bracket Bolts Footpeg Bracket Mounting Bolts Downtube Bolts PERIODIC MAINTENANCE 2 39 Periodic Maintenance Procedures Replacement Parts Brake Hose and Pipe Replacement CAUTION Brake fluid quickly ruins painted surfaces any spilled fluid should be completely washed away immediately e When removing the brake hose A take care not to spill the brake fluid on the painted or plastic parts e Immediately wash away any brake fluid that spills e Install new brake hoses and pipes e There are washers B on each side of the brake hose fitting Replace them with new ones when installing e Tighten the banjo bolts C on the hose fittings Torque Brake Hose Banjo Bolts 25 2 5 kgf m 18 ft Ib e When installing the hoses A avoid sharp bending ing flattening or twisting and route the hoses according to Cable Wire and Hose Routing section in the General Information chapter e Fill the brake line after installing the brake hose see Brake Fluid Change Brake Fluid Change NOTE OThe procedure to change the front brake fluid is as fol lows Changing the rear brake fluid is almost the same as for the front brake e Level the br
64. Tighten the bleed valves and install the rubber caps Torque Caliper Bleed Valves 7 8 N m 0 80 kgf m 69 in Ib Front Brake Reservoir Cap Screws 1 5 N m 0 15 kgf m 13 in Ib 6109040652 C PERIODIC MAINTENANCE 2 41 Periodic Maintenance Procedures OFor the rear brake caliper A change the brake fluid for two bleed valves B 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 see Brakes chapter Master Cylinder Rubber Parts Replacement Front Master Cylinder Disassembly e Remove the front master cylinder e Remove the reservoir cap A plate B and diaphragm C e Unscrew the locknut D and pivot bolt E and remove the brake lever e Pull the dust cover F out of place and remove the circlip Special Tool Inside Circlip Pliers 57001 143 Pull out the piston assy and return spring I Rear Master Cylinder Disassembly NOTE ODo not remove the push rod A for master cylinder dis assembly since removal requires brake pedal position adjustment e Remove the rear master cylinder see Brakes chapter e Slide the dust cover B out of place and remove the cir clip C Special Tool Inside Circlip Pliers 57001 143 e Pull out the push rod with the piston stop D e Take off the piston assy E and return spring F e Replace Diaphragm G Bra
65. Units of Length Prefix Symbol Power Km 22 mile m x 3 281 ft mega X LOO O00 mm x 0 03937 in kilo k x 1 000 centi 0 01 n 70 00 Units of Torque micro u x 0 000001 0 4020 kgf m N m x 0 7376 ft lb N m x 8 851 in Ib Units of Mass kgf m x 9 807 N m kg x 2 205 Ib 7 233 ft lb g x 0 03527 OZ kgf m x 86 80 Units of Volume Units of Pressure L x 0 2642 gal US kPa x 0 01020 kgf cm L x 02200 gal imp kPa x 0 1450 L x 1 057 qt US kPa x 0 7501 cm Hg L x 0 8799 qt imp kgf cm 98 07 kPa L x 2 113 pint US kgf cm 14 22 psi L x 1 816 pint imp cmHg x 1 333 kPa mL x 0 03381 oz US 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 kgf Units of Power N x 0 2248 db kW 1 360 PS kg X um ON kW x 1341 HP kg x 225 b PS x 0 7355 kW PS x 0 9863 HP Units of Temperature _ 40 oF oF 4 32 68 104 176 212 248 284 40 20 10 20 40 60 80 100 120 140 160 1180 200 1220 240 260 280 300 320 40020 0 01 i i 80 400 120 114040 160 17 8 44 26 7 48 9 71 1 93 3 116 138 PERIODIC MAINTENANCE 2 1 Periodic Maintenance Table of Contents Periodic Maintenance Chart Torque and Locking Agent Specifications Special Tools
66. a T Headlight Fuse 8 Taillight Fuse 104 9 Ignition Fuse 10 LEFT HANDLEBAR SWITCH CONNECTIONS 10 Horn Fuse 104 Released Pulled in W2L0040EN5 ELECTRICAL SYSTEM 16 17 Wiring Diagram California Sub Sub Fuel Fuel throttle Injectorinjeotor throttle Water Valve Temperature Sensor s n Actuator nlet Speed 2 Position senso M Main Air Saitoh t Throttle Temperature Sensor Sensor 2 22 Crankshaft Sensor n Camshaft Decompression Position Solenoid Sensor aar Oxygen Sensor Connector Kawasaki Diagnostic System Connector EHE curd Self diagnosis Terminal Joint Connector Electronic Control Unit Rear Accessory Connectors FEES Joint Connector License Plate Light 12V5W Tail Brake Lights 1221 50 Fuel Rear Right Turn Signal Reserve Light 12V21W Switch Fuel Rear Left Turn Signal Vehicle Pump Light 12V218 down Sensor Battery 12V18 h Starter Starter Relay Motor Main Fuse 304 Color Code Brask BL Bie cu Chocolate CH Chocolate DG Dark Green e creen cy tray Front Brake Light Switch Engine Stop Switch Starter Button Color BK BK Y R Color BK R Brake Lever OFF Free 2 0040 5 C 16 18 ELECTR
67. located in almost the same depth 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 the hand tester measure the internal resistance of the sensor across the terminal and the body at the tem peratures shown in the table If the measurement is out of the range replace the sensor Water Temperature Sensor Resistance Temperature Resistance kQ 20 C 4 F 18 80 2 37 0 C 32 F about 6 544 40 C 104 F 1 136 0 095 100 C 212 F 0 1553 0 0070 Reference Information Gear Position Switch Removal e Remove Transmission Cover see Crankshaft Transmission chapter Gear Position Switch Lead Clamp Bolts A Gear Position Switch Lead Clamp B Gear Position Switch Mounting Bolts C Gear Position Switch D 8 18055 52 C 16 88 ELECTRICAL SYSTEM Switch and Sensors Gear Position Switch Installation e Apply silicone sealant to the gear position switch lead grommet Sealant Three Bond TB1211F e Apply a non permanent locking agent Gear Position Switch Mounting Bolts Gear Position Switch Lead Clamp Bolts Tighten Torque Gear Position Switch Mounting Bolts 4 9 N m 0 50 kgf m 43 in Ib Gear Position Switch Lead Clamp Bolts 4 9 0 50 kgf m 43 in Ib Gear Position Swi
68. mode the service code A is indicated by the number of times the FI indicator LED light blinks When due to a malfunction the FI indicator LED light and FI symbol remains lit ask the rider about the conditions B under which the problem occurred and try to determine the cause Don t rely solely on the DFI self diagnosis function use common sense First conduct a self diagnosis inspection and then a non self diagnosis The non self diagnosis items are not indi cated by the FI indicator LED light Even when the DFI system is operating normally the FI indicator LED light and Fl symbol may light up under strong electrical interference No repair needed Turn the ignition SW switch OFF to stop the indicator light and Fl symbol When the FI indicator LED light and Fl symbol go on and the motorcycle is brought in for repair check the service codes When the repair has been done the LED light and FI symbol do not go on 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 OSometime this method can detect a fault of the ECU ORefer to each Sensor Inspection section 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 6
69. throttle Sensor Fuel Fuel 1gjester Injegtot Decompression ister Solenoid Temperature Sensor y Gear Position Switch Inlet Air Temperature Sensor 5 Crankshaft i Sensor Wain Throttle Sensor Joint 792 Connector Kawasaki Diagnostic Systen Connector Yo wt Ky 1 Self diagnosis Terminal Joint Connector Electronic Control Unit Accessory nectors License Plate Light 12050 Tail Brake Lights 1221 88 Rear Right Turn Signal Light 12V21N Rear Left Turn Signal Light 12V21W Fuel Reserve Switch Fuel Vehicle Pump down Sensor Starter Motor Starter Relay Main Fuse 304 Battery 12V18 h Color Code Black BL cu Chocolate o8 Dark Green a ree Lev tray Lee fiat ght IGNITION SWITCH CONNECTIONS Tena Tane RIGHT HANDLEBAR SWITCH GONNECTIONS Starter Button BK R Orange Color Front Brake Light Switch Engine Stop Switch olor BK R Y R Brake Lever OFF Free 2 0039 5 C 16 22 ELECTRICAL SYSTEM Electrical Parts Location Left Handlebar Switches A Starter Lockout Switch B Ignition Switch C Headlight D Front Brake Light Switch E Rig
70. with electric starter Valve Valve clearance Valve head Exhaust thickness Inlet Valve stem bend Valve stem diameter Exhaust Inlet Non adjustable Auto adjuster 0 6 mm 0 236 in 0 6 mm 0 236 in TIR 0 01 mm 0 00039 in or less 5 955 5 970 mm 0 23445 0 23504 in 5 965 5 980 mm 0 3 mm 0 0118 in 0 3 mm 0 0118 in TIR 0 05 mm 0 0020 in 5 94 mm 0 2339 in 5 95 mm 0 2343 in 0 23484 0 23543 in ENGINE TOP END 5 9 Specifications Item Standard Service Limit Valve guide inside diameter Exhaust Inlet Valve valve guide clearance 6 000 6 012 mm 6 08 mm 0 2394 in 0 23622 0 23669 in 6 000 6 012 mm 6 08 mm 0 2394 in 0 23622 0 23669 in wobble method Exhaust 0 07 0 12 mm 0 27 mm 0 0106 in 0 0028 0 0047 in Inlet 0 04 0 10 mm 0 25 mm 0 0098 in 0 0016 0 0039 in Cam Height Push Rod Length and Runout 8 02000351 C Cam Height maximum A Valve Head Thickness 8 02000551 C Valve Head Thickness A Valve Stem Diameter B 45 C Valve Stem Bend 8 02000851 Push Rod Length Push Rod Runout B GE03002BS1 C Camshaft Journals 8 03003851 C 928 mm 1 1024 A 922 mm 0 8661 in B 5 10 ENGINE TOP END Specifications Item Standard Service Limit Valve seat s
71. x If the output voltage is out of the specified check the ECU for its ground and power supply see ECU section in this chapter If the ground and power supply are good re move the air cleaner housing check the wiring between the ECU and the inlet air temperature sensor xIf the wiring is good check the sensor resistance 6C17298BS1 3 54 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 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 kQ at 80 C 176 F 00171008 lf the measurement is out of the range replace the sensor the measurement is within the specified replace the ECU O ODOM OID TON ODOM OID SON H
72. 2 8 20 L 12 6 BRAKES Specifications Item Standard Service Limit Brake Lever Brake Pedal Brake lever position Brake lever free play Pedal free play Pedal position No 1 Non adjustable Non adjustable About 117 mm 4 61 in height from pedal top to footboard top 5 way adjustable Brake Fluid Grade Brake Pads Pad lining thickness Front Rear Brake Discs Thickness Runout DOT4 4 0 mm 0 157 in 7 5 mm 0 295 in 4 8 5 2 mm 0 189 0 205 in 6 8 7 2 mm 0 268 0 283 in TIR 0 15 mm 0 0059 in or less 1 mm 0 04 in 1 mm 0 04 in 4 5 mm 0 18 in 6 0 mm 0 24 in TIR 0 3 mm 0 01 in BRAKES 12 7 Special Tool Inside Circlip Pliers 57001 143 xe 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 Adjustment Check that the brake pedal A is in the correct position Pedal Position Standard About 117 mm 4 61 in B height from pedal top to footboard C top NOTE OUsually it s not necessary to adjust the pedal position but always adjust it when pu
73. 4 ENGINE REMOVAL INSTALLATION Specifications Jack Jack Attachment 57001 1238 57001 1571 ST5715718T C Socket Wrench 57001 1347 ENGINE REMOVAL INSTALLATION 8 5 Engine Removal Installation Engine Removal e Support the rear part of the frame on the jack A and the attachment jack B Special Tools Jack 57001 1238 Jack Attachment 57001 1571 e Squeeze the brake lever slowly and hold it with a band A A WARNING Be sure to hold the front brake when removing the engine or the motorcycle may fall over It could cause an accident and injury CAUTION Be sure to hold the front brake when removing the engine or the motorcycle may fall over The engine or the motorcycle could be damaged e Drain Coolant see Cooling System chapter Engine Oil see Engine Lubrication System chapter e Remove Battery Cables Fuel Tank see Fuel DFI System chapter Air Cleaner Housings see Fuel DFI System chapter Air Switching Valve with Hoses see Engine Top End chapter Exhaust Pipes and Mufflers see Engine Top End chap ter Clutch Cable see Clutch chapter Engine Pulley see Final Drive chapter Shift Pedals and rod see Crankshaft Transmission chapter Radiator see Cooling System chapter Thermostat Removal see Cooling System chapter Throttle Cable Upper Ends see Throttle Body Assy Re moval e Disconnect Inlet Air Pressure Sensor Hoses A Vacuum Hose B Subhar
74. 8 Bearing retainer screws at output shaft Pes or 61 Bearing retainer bolts Speed sensor bolt 9 8 1 0 87 in lb Bearing retainer screws at pulley shaft 61 Crankcase boite 96 104 in Ib 14 15 Apply a non permanent locking agent to the tap end of this stud only 16 Left Crankcase Half 17 Right Crankcase Half EO Apply engine oil L Apply a non permanent locking agent LG Apply liquid gasket Kawasaki Bond 92104 1064 MO Apply molybdenum disulfide oil to the threads and the seating surface The molybdenum disul fide oil is a mixture of engine oil and molybdenum disulfide grease with a weight ratio 10 1 S Follow the specific tightening sequence G Apply grease US United States America Model CA Canada Model MY Malaysian Model 9 4 CRANKSHAFT TRANSMISSION Exploded View 6102094 5 CRANKSHAFT TRANSMISSION 9 5 Exploded View Fastener Remarks Outer transmission cover bolts 104 in Ib 5 see text Inner transmission cover bolts 104 in Ib 5 see text Transfer gear nut Output shaft 145 R MO Lh 4_ Transfer gear nut Pulley shaft re ose se Gear set lever nut 69 in lb Shift shaft return spring pin Rear shift lever bolt 18 Cr 284 Shift drum cam bolt 2 104 in Ib Rear shift rod locknut 4 87 in lb Front shift rod locknut 87 in lb Engine pulley mounting nut
75. 87 Water pump air bleeder bolt 7 8 0 80 69 in Ib Radiator screen screws 6 9 0 70 61 in Ib 2 6 PERIODIC MAINTENANCE Torque and Locking Agent Fastener porque Remarks Engine Top End Rocker case cover bolts 12 1 2 104 in Ib S AL Rocker case bolts 15 1 5 11 5 Oil pipe banjo bolts 54 5 5 40 Oil pipe bolts 9 8 1 0 87 in lb Upper cylinder head nuts 610 mm 15 1 5 11 first 5 Upper cylinder head nuts 610 mm 29 3 0 21 final S MO Upper cylinder head nuts 612 mm 29 3 0 21 first 5 MO Upper cylinder head nuts 612 mm 88 9 0 65 final 5 MO Lower cylinder head nuts 25 2 5 18 S Water jacket plugs 22 2 2 16 L Water jacket plugs 15 1 5 11 L Rocker shaft bolts 12 1 2 104 in Ib Cylinder mounting bolts 25 2 5 18 L Coolant drain bolt 9 8 1 0 87 in lb Push rod cover bolts 12 1 2 104 in Ib Camshaft chain guide bolts 12 1 2 104 in Ib L Camshaft chain tensioner bolts 12 1 2 104 in Ib Inner camshaft cover bolts 12 1 2 104 in Ib Stopper pin plug 2 5 0 25 22 in Ib L Middle camshaft cover bolts 12 1 2 104 in Ib Middle camshaft cover bolts L 35 mm 12 1 2 104 in Ib Camshaft end cover bolts 12 1 2 104 in Ib Decompression solenoid bolts 9 8 1 0 87 in Ib Outer camshaft cover bolts 12 1 2 104 in Ib Muffler bracket bolts 25 2 5 18 Muffler cover clamp screws 6 9 0 7 61 in Ib Clutch Primary chain upper guide bolts 9 8 1 0 87 in lb Primary chain lower guide bolts 9 8 1 0 87 in lb Cam damper bolt 69 7 0 51 Inner clutch cover bol
76. Adjustment Cable Removal Installation Cable Lubrication and Inspection Throttle Body Assy Idle Speed Idle Speed Adjustment Throttle Bore Cleaning High Altitude Performance Adjustment Throttle Body Assy and Intake Manifold Removal Throttle Body Assy and Intake manifold Installation Air 2222 Element Air Cleaner Housing Remowval Air Cleaner Housing Installation FUG Tank tto reri Fuel Tank Removal Fuel Tank Installation Fuel Tank and Cap Inspection Fuel Tank Cleaning Evaporative Emission Control Canister Installation Canister Inspection Periodic lt ispection ise 3 95 3 96 3 97 FUEL SYSTEM DFI 3 3 Separator Inspection Periodic Separator Operation Test 3 123 1 5 3 122 Hose Inspection Periodic 3 122 3 4 FUEL SYSTEM DFI Exploded View FUEL SYSTEM DFI 3 5 Exploded View Torque No Fastener NR kgfm ftlb Remarks 1 Fuel pump bolts 9 8 1 0 87 in lb S L 2 Water temperature senso
77. B to the starter relay C as shown x If the relay does not work as specified the relay is defec tive Replace the relay Testing Relay Tester Range 1 range Criteria When battery is connected 0 O When battery is disconnected Starter Control Relay Inspection e Remove Seats see Frame chapter Tool Case see Frame chapter Starter Control Relay A Connect the hand tester A and a 12 V battery B to the starter control relay C as shown xIf the relay does not work as specified the relay is defec tive Replace the relay Testing Relay Hand Tester Range x 1 Criteria When battery is connected gt 00 When battery is disconnected gt 9 Relay Coil Terminals 1 and 2 Relay Switch Terminals 3 and 4 GP11046BS2 C ELECTRICAL SYSTEM 16 55 Starter Motor Electric Starter Circuit EK Y R R BK R BR R R G BK R GPi1043BN4 C 1 Fuse Box T Gear Position Switch 13 Starter Lockout Switch 2 Ignition Fuse 10 A 8 Relay Box 14 Side Stand Switch 3 Engine Stop Switch 9 Starter Circuit Relay 15 Starter Relay 4 Starter Button 10 ECU 16 Starter Motor 5 Joint Connector 11 Joint Connector 17 Main Fuse 30 A 6 Starter Control Relay 12 Ignition Switch 18 Battery 16 56 ELECTRICAL SYSTEM Lighting System This model adopts the daylight system and has head light relay in the r
78. Bearing Retainer Bolts B at Balancer Bearing Retainer Screws C at Output Shaft Right Crankcase Half Inside D Right Crankcase Half Outside E Bearing Retainer Screws F at Pulley Shaft Torque Bearing Retainer Screws at Output Shaft 6 9 N m 0 7 kgf m 61 in Ib Bearing Retainer Screws at Pulley Shaft 6 9 N m 0 7 kgf m 61 in Ib 8104122852 C e Apply molybdenum disulfide oil to the transmission gears ball bearings shift drum and crankshaft main bearing OThe left shaft B of the crankshaft A is longer than the right shaft C 6I048175 P e Check to see that the following parts are in position in the right crankcase half Front Balancer Shaft A Crankshaft B Rear Balancer Shaft C Transmission Assy D and Shift Drum E Shift Forks and Shift Rods F Pulley Shaft G Water Pump Shaft H Oil Pump Shaft J 9 14 CRANKSHAFT TRANSMISSION Crankcase OPosition the right side connecting rod A to the front and left side connecting rod B to the rear as shown Olnstall the front A and rear B balancers so that their splined shaft ends face downward toward the right crankcase half noting the shapes C of their opposite shaft end Olnstall the pulley shaft A so that the shorter side B from the flange to the shaft end faces downward toward the right crankcase half e Apply grease the O ring A and put it to the right crankcase half B
79. Bracket Rear Bolt B Right Footboard Bracket Assembly C e Remove Cotter Pin A Joint Pin B and Washer C e Remove Rear Brake Fluid Reservoir Cover Bolt A Rear Brake Fluid Reservoir Cover B e Remove Rear Brake Fluid Reservoir Bolt A Rear Brake Fluid Reservoir B Remove the brake hose C from the clamps D e Remove Cover Bolts A Cover B Brake Hose Banjo Bolt C Rear Master Cylinder Mounting Bolts D Rear Master Cylinder E d MC 85 6107042851 C 12 16 BRAKES Master Cylinder Rear Master Cylinder Installation Replace the cotter pin with a new one e Install the washer A e Insert the cotter pin B to the hole of the joint pin C and separate D the cotter pin ends e Use a new flat washer on each side of the brake hose fitting e Paste the pad A to the cover B as shown in the figure C about 5 mm 0 20 in D about 15 mm 0 59 in e Tighten Torque Footboard Bracket Bolts 34 N m 3 5 kgf m 25 ft Ib Rear Master Cylinder Mounting Bolts 25 N m 2 5 kgf m 18 ft lb Brake Hose Banjo Bolt 25 N m 2 5 kgf m 18 ft Ib e Bleed the brake line see Brake Line Bleeding e Check the brake for good braking power no brake drag and no fluid leakage A WARNING Do not attempt to ride 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
80. Electrical System Spark plug IZFR6F 11 Spark plug 1 0 1 1 mm 0 039 0 043 in AT Republic of Austria CH Swiss Confederation DE Federal Republic of Germany PERIODIC MAINTENANCE 2 13 Special Tools Inside Circlip Pliers 57001 143 ar Steering Stem Nut Wrench 57001 1100 Spark Plug Wrench Hex 16 57001 1262 Jack Attachment 57001 1571 Jack 57001 1238 Oil Filter Wrench 57001 1249 ST5715718T C Drive Belt Tension Gauge 57001 1585 ST571585ST C 2 14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering System Steering Play Inspection e Check steering as follows OUse the jack A and jack attachment B under the frame pipe and a commercially available jack C under the en gine to lift the front wheel off the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1571 OWith the front wheel pointing straight ahead alternately tap each end of the handlebar The front wheel should swing fully right and left 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 OFeel for steering looseness by pushing and pulling A the fork 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 Be
81. Front Brake Light Switch A see Electrical System chapter Rear Brake Light Switch see Electrical System chapter Harness see Wiring Inspection in Electrical System chapter Wheel and Tires Tire Air Pressure Inspection 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 to 186 kg 410 Ib 250 kPa 2 5 kgf cm 36 psi Up to 186 kg 410 Ib 290 kPa 3 0 kgf cm 42 psi A WARNING To ensure safe handling and stability use only the recommended standard tires for replacement in flated to the standard pressure Use the same man ufacture s tires on both front and rear wheels NOTE OMost countries may have their own regulations requiring a minimum tire tread depth be sure to follow them OCheck and balance the wheel when a tire is replaced with a new one see Wheels Tires chapter Wheel Tire Damage Inspection e Remove any imbedded stones A or other foreign parti cles B from 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 Visually inspect the wheel for cracks cuts and dents dam age any damage is found replace the wheel if nece
82. Harness Rear Fender Clamp Push Clamp the white mark of the rear harness at this position 10 Rear Harness Connector Insert the clamp of the rear harness in the fender 11 Turn Signal Light Lead Connector 12 Tail Brake and License Plate Light Lead 13 Rear Harness 14 Right Turn Signal Light Lead 15 Left Turn Signal Light Lead Connector 16 Cover 17 Grommet 17 26 APPENDIX Cable Wire and Hose Routing Viewed from Upper Side Viewed from Left Side GBO9424BW5 C APPENDIX 17 27 Cable Wire and Hose Routing 5 Position the mark of the hose at right side and tighten the clamp Water Hose First Install the hose to thermostat Clamp Radiator Assembly Clamp Position the mark of the hose at right side and tighten the clamp Water Hose Front Align the marks and install the water hose until the center of the paint mark and then tighten the clamp Clamp Clamp Water Hose Clamp Water Hose Clamp Clamp O ring Water Pipe 17 28 APPENDIX Cable Wire and Hose Routing APPENDIX 17 29 Cable Wire and Hose Routing OMDNOOAWND Clamp Align the marks and tighten the clamp Clamp Align the marks and tighten the clamp Clamp Water Temperature Sensor Thermostat Clamp Align the marks and tighten the clamp Wat
83. OTurn the adjuster of the accelerator cable C until the proper amount of throttle grip free play is obtained and tighten the locknut against the adjuster PERIODIC MAINTENANCE 2 33 Periodic Maintenance Procedures Idle Speed Inspection Start the engine and warm it up thoroughly OAt first the engine will run fast to decrease warm up time fast idle OGradually the fast idle will lower to a certain RPM auto matically This is the idle speed e Check the idle speed Idle Speed Standard 900 50 r min rpm e With the engine idling turn the handlebar to both 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 A WARNING Operation with improperly adjusted incorrectly routed or damaged cables could result in an unsafe riding condition xf the idle speed is out of the specified range adjust it e Start the engine and warm it up thoroughly OWait until fast idle speed lowers to a certain value e Turn the adjusting screw A until the idle speed is correct OOpen and close the throttle a few times to make sure that the idle speed is within the specified range Readjust if necessary Front B Fuel Hose and Connection Inspection OThe fuel hose A is designed to be used throughout the motorcycle s
84. Position Switch Lead Clamp Run the decompression solenoid camshaft sensor lead straight Calmp Clamps Put the Clamp around the lead Run the lead from upper to lower and clamp it Do not slacken the lead 17 16 APPENDIX Cable Wire and Hose Routing Lx SS Him 7 y A EH 556 E 546 6809407 45 C APPENDIX 17 17 Cable Wire and Hose Routing Vacuum Tube White California Model Insert the throttle body lead connector in the thermostat bracket Throttle Body Lead Clamp Air Tube Tube Green California Model Air Switching Valve Water Temperature Sensor Breather Tube Coolant Reservoir Tube Black Brown Pipe Thermostat Cap Vacuum Tube White White Pipe Throttle Body California Model Tube Green Green Pipe Air Cleaner California Model Throttle Cables Air Switching Valve Water Temperature Sensor 17 18 APPENDIX Cable Wire and Hose Routing 0 JJ LET o 227 NN amp pg 4 S po mM ag It O el APPENDIX 17 19 Cable Wire and Hose Routing Front Main Harness Install the frame ground terminal so that it is parallel to seat rail Insert the clamp in the bracket Fit the seat lock cable in the bracket Insert the clamp
85. SW ON about 0 05 0 07 V DC at Ignition SW ON and 0 km h Non adjustable and non removable 4 75 5 25 V DC between BL W and BR BK leads 1 02 4 62 V DC between Y and BR BK leads at idle throttle opening to full throttle opening 4 6kO 3 12 FUEL SYSTEM DFI Specifications Item Standard Subthrottle Valve Actuator Resistance about 5 7 Input Voltage about 8 5 10 5 V DC Oxygen Sensor Output Voltage rich 0 7 0 8 V Output Voltage lean approx 0 1 V Heater Resistance 14 1 19 3 Q at 20 C 68 F FUEL SYSTEM DFI 3 13 Special Tools and Sealant Oil Pressure Gauge 5 kg cm 57001 125 Needle Adapter Set 57001 1457 Ba T571457ST C Fork Oil Level Gauge 570101 1290 Kawasaki Bond Silicone Sealant 56019 120 Hand Tester 57001 1394 Throttle Sensor Setting Adapter 57001 1400 Fuel Pressure Gauge Adapter 57001 1593 7571593ST C Fuel Hoses 57001 1607 7571607ST C 3 14 FUEL SYSTEM DFI DFI System DFI System Wiring Diagram 090909 07 08 zo ak BESS zz 2522 5555 FEET 555 oto 8 gt B 8 gt x 258 5 z a Ir i 2 IGNITION i BATTERY al H TTI WM qa 112 e s n lt P i ipii LG BK FLa BK ii LG R 5 FF Hit D 9
86. Switch Inspection e Fill the fuel tank with fuel Close the fuel tank cap surely e Remove Left Engine Cover see Frame chapter Fuel Pump Lead Connector A e Connect the test light B 12 V 3 4 W bulb in a socket with leads and the 12 V battery C to the fuel level sensor lead connector Connections Battery 12 V 3 4 W Bulb one side 12 V 3 4 W Bulb other side R BK Lead Terminal D Battery BK W Lead Terminal E xIf the test light turn on the reserve switch is defective Replace the fuel pump e Remove Fuel Pump see Fuel System chapter e Connect the test light 12 V 3 4 W bulb in a socket with leads and the 12 V battery to the fuel pump lead connec tor as shown 12 V Battery A Test Light B Fuel Pump Lead Connector C Fuel Reserve Switch D x lf the test light doesn t light replace the fuel pump NOTE Olt may take a long time to turn on the test light in case that the fuel reserve switch is inspected just after the fuel level sensor is removed Leave the fuel reserve switch with leads for inspection connected for few minutes Speed Sensor Removal e Remove Battery Case see Frame chapter Bolt A Speed Sensor B Speed Sensor Installation e Apply grease to the O ring A on the speed sensor B D Washer US Canada and Malaysia models e Tighten Non permanent Locking Agent Speed Sensor Mounting Bolt C Torque Speed Sensor Mounting Bolt 9 8 N m 1 0 kgf m
87. Tighten Torque Front Brake Pad Pin 15 N m 1 5 kgf m 11 ft Ib e Install the pad spring and bolts e Tighten Torque Front Brake Pad Spring Bolts 2 9 N m 0 30 kgf m 26 in Ib 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 BRAKES 12 13 Brake Pads Rear Brake Pad Removal Remove the caliper with the hose installed see Caliper Removal e Remove Snap Pin A Pad Pin B e Remove the jaw side pad A and then remove the piston side pad B Jaw C Rear Brake Pad Installation e Before installation clean the pads with a high flash point solvent e Push A the caliper pistons in by hand as far as they will go e Be sure to install the snap pin for the caliper A WARNING Do not attempt to ride the motorcycle until a full pedal is obtained by pumping the brake lever or pedal until the pads are against the disc The brakes will not function on the first application of the lever or pedal if this is not done Brake Pad Wear Inspection e Refer to Brake Pad Wear Inspection in the Periodic Main tenance chapter 12 14 BRAKES Master Cylinder Front Master Cylinder Removal e Disconnect the front brake light switch connector A e Draw out the brake fluid from the reservoir
88. To Engine Speed Sensor Connector Bracket Front Put the accessory terminals under the rear harness connector 17 22 APPENDIX Cable Wire and Hose Routing Viewed from Upper Side APPENDIX 17 23 Cable Wire and Hose Routing Vehicle down Sensor Main Harness Left Side Insert the clamp in the battery case Fit the relay box in the tab of the battery case Relay Box Put the damper on the relay box Fit the starter control relay on the battery case Turn Signal Control Relay Main Harness Left Side Battery Lead Connector White Atmospheric Pressure Sensor ECU Main Fuse 30 A Battery Lead Starter Motor Lead Starter Relay Fuse Box Battery Lead Insert the battery lead connector black in the battery case Run the battery lead under the connector Battery ECU Insert the ECU in the tab of the battery case and fit it 17 24 APPENDIX Cable Wire and Hose Routing ene ee 5 QF m gt gt a Cy 444 w 5 2 Viewed from 6809418BN5 APPENDIX 17 25 Cable Wire and Hose Routing Install the grommet in the rear fender Run the rear harness between the rear fender and fender brace Fit the rear harness in the recess of the cover Grommet Rear
89. Type API Service Classification SE SF or SG class API Service Classification SH or SJ class with JASO MA Viscosity SAE 10W 40 Capacity 4 4L 4 7 US qt when filter is not removed 4 6 L 4 9 US qt when filter is removed 5 5 L 5 8 US qt when engine is completely disassembled and dry Level 26 f Between upper and lower level lines Wait 2 3 minutes after idling or running Oil Pressure Measurement Oil pressure 2 000 r min rpm Oil temp 90 C 194 F 127 167 kPa 1 3 1 7 kgf cm 18 24 psi ENGINE LUBRICATION SYSTEM 7 7 Special Tools and Sealant Oil Pressure Gauge 5 kg cm 57001 125 Oil Filter Wrench 57001 1249 Oil Pressure Gauge Adapter PT 1 8 Kawasaki Bond Silicone Sealant 56019 120 57001 1033 7 8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter Because of the semi dry sump lubrication system the en gine oil level indicated on the dipstick will fluctuate depend ing on the motorcycle s position and engine speed when the engine is shut off To ensure a proper reading of the engine oil level follow the Oil Level Inspection procedures closely 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 Situate the motorcycle so that it is vertical
90. Valve Guide Reamer 06 57001 1596 5157156 5 Compression Gauge Adapter M14 x 1 25 57001 1590 7571590ST C Valve Guide Arbor 5 7 57001 1564 875715645 C Compression Gauge 57001 221 Spark Plug Wrench Hex 16 57001 1262 Piston Ring Compressor Grip 57001 1095 Valve Spring Compressor Assembly 57001 241 Valve Spring Compressor Adapter 628 2 57001 243 Valve Seat Cutter 45 641 5 57001 1117 In Valve Seat Cutter 32 638 5 57001 1122 5 12 ENGINE TOP END Special Tools and Sealant Valve Seat Cutter 60 041 57001 1124 Valve Seat Cutter Holder 6 57001 1576 Valve Seat Cutter Holder Bar 57001 1128 Piston Ring Compressor Belt 95 108 57001 1358 Valve Seat Cutter 45 040 57001 1496 875714965 C Valve Seat Cutter 32 044 57001 1515 875715155 C Piston Pin Puller Assembly 57001 1568 ST571588ST Bearing Driver Set 57001 1129 ENGINE TOP END 5 13 Clean Air System Air Suction Valve Removal Remove the rocker case covers see this chapter Remove the air suction valves Front Rocker Case A Front Air Suction Valve B Air Suction Valve Installation e Install each air suction valve so that its wider side A of the reed faces left Air Suction V
91. a DFI system problem or a general engine problem 3 24 FUEL SYSTEM DFI Troubleshooting the DFI System Sample Diagnosis Sheet Registration No license plate No Year of initial registration Engine No Frame No Date problem occurred Mileage fine a cloudy n rain o snow n always n other hot warm n cold very cold o always chronic a often once street highway o mountain road n uphill downhill Altitude normal high about 1000 m or more Motorcycle conditions when problem occurred Fl indicator light up immediately after ignition SW ON and goes off after engine oil pressure is LED light high enough with engine running normal lights up immediately after ignition SW ON and stays on after engine oil pressure is high enough with engine running DFI problem lights up immediately after ignition SW ON but goes off after about 10 seconds though engine oil pressure is high enough with engine running DFI problem unlights LED light ECU or its wiring fault sometimes lights up probably wiring fault Starting starter motor not rotating difficulty starter motor rotating but engine doesn t turn over starter motor and
92. adjusting bolt 9 8 1 0 87 in lb 5 Upper adjusting bolt locknut 49 5 0 36 5 Lower adjusting bolt locknut 49 5 0 36 5 Upper rear engine mounting nut 59 6 0 43 5 Lower rear engine mounting nut 59 6 0 43 5 Upper engine bracket nuts 59 6 0 43 S AL Upper engine mounting bolts 44 4 5 33 5 Lower engine bracket bolts 59 6 0 43 5 Front engine mounting nut 44 4 5 33 5 Rear downtube bolts14 108 11 0 80 S AL Crankshaft Transmission Connecting rod big end bolts 59 6 0 43 MO Balancer chain sprocket nut 125 13 0 92 2 MO Camshaft chain sprocket bolt 29 3 0 Camshaft balancer gear bolts 83 8 5 2 8 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Upper balancer chain guide bolts Lower balancer chain guide bolts Balance chain tensioner bolts Bearing retainer screws at output shaft Bearing retainer bolts Speed sensor bolt Bearing retainer screws at pulley shaft Crankcase bolts 8 Crankcase bolts 6 Outer transmission cover bolts Inner transmission cover bolts Transfer gear nut Output shaft Transfer gear nut Pulley shaft Gear set lever nut Shift shaft return spring pin Rear shift lever bolt Front shift lever clamp bolt Shift dram cam bolt Rear shift rod locknut Front shift rod locknut Engine pulley mounting nut Wheels Tires Front axle nut Front axle clamp bolts Rear axle nut Tire air valve nuts Tire air valve cap Final Drive Engine pulley inside cover bolts Engine pulley mounting nut Rear
93. and chart Suppose Pg Vacuum Pressure gauge of Throttle Assy Local Atmospheric Pressure absolute measured by a barometer Pv Vacuum Pressure absolute of Throttle Assy Vv Sensor Output Voltage v then Pv PI Pg For example suppose the following data is obtained Pg 8 cmHg vacuum gauge reading 70 cmHg barometer reading Vv 3 2 V digital volt meter reading then Pv 70 8 62 cmHg abs Plot this Pv 62 cmHg at a point 1 on the chart and draw a vertical line through the point Then you can get the usable range 2 of the sensor output voltage Usable range 3 08 3 48 V Plot Vv 3 2 V on the vertical line Point 3 Results In the chart Vv is within the usable range and the sensor is normal 6017119852 C FUEL SYSTEM DFI 3 51 Inlet Air Pressure Sensor Service Code 12 76 80 90 cmHg PS 101 32 120 kPa PS Pv abs GC17120BW4 C Vv Inlet Air Pressure Sensor Output Volt ID Idling age V Digital Meter Reading TO Throttle Full Open Pv Throttle Vacuum Pressure absolute ST Standard of Sensor Output Voltage v Ps Standard Atmospheric Pressure abso lute UR Usable Range of Sensor Output Voltage v 3 52 FUEL SYSTEM Inlet Air Pressure Sensor Service Code 12 N oo lt lt o r lt
94. 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 in the wiring connectors and DFI parts replace the ECU OThe following diagnosis flow chart illustrates the above procedures OWire 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 6017029281 FUEL SYSTEM DFI 3 23 Troubleshooting the DFI System DFI Diagnosis Flow Chart Problem occurs General fuel system throttle body assy air cleaner fuel tank etc Confirm problems Gather information from rider Does NO unlit FI indicator LED light and FI symbol go on YES goes on Conduct self diagnosis inspection Conduct non self diagnosis inspection Inquiries to Rider Refer to the next sample diagnosis chart Conduct general fuel system inspection GC17211B F OEach rider reacts to problems in different ways so it is important to confirm what kind of symptoms the rider has encountered OTry to find out exactly what problem occurred under exactly what conditions by asking the rider knowing this information may help you reproduce the problem OThe diagnosis sheet will help prevent you from overlooking any areas and will help you decide if it is
95. and then tighten the clamp Green Mark 21 Coolant Tube 22 White Tube 23 Clamp 24 Clamp 5 17 52 APPENDIX Cable Wire and Hose Routing APPENDIX 17 53 Cable Wire and Hose Routing California Model Front Canister Clamp Green Tube Clamp Coolant Reservoir Band Clamp Blue Tube about 35 Clamps Clamps Blue Tube Clamp Separator Holder Red Tube Clamp White Tube Bracket 17 54 APPENDIX Cable Wire and Hose Routing 9 2 Ser Lay pee ite C 222 Li 2 TFN 6 a FAN X o APPENDIX 17 55 Cable Wire and Hose Routing California Model Air Switching Valve Hold the tube in the clamp of the frame Run the green tubes under the white tube Run the white tube between the damper and frame Put the clamp so that the projection side faces to coolant tube side Coolant Tube Run the coolant tube right side the water hose Blue Tube Coolant Tube Clamps Except California Model Blue Tube Red Tube Engine Breather Tube Clamps Coolant Tube Engine Breather Tube Blue Tube Run the blue tube under the engine breather tube Red Tube Run the blue tube under the engine breather t
96. and unstable operation of the DFI system lf any wiring is deteriorated replace the wiring e Pull each connector A apart and inspect it for corrosion dirt and damage If the connector is corroded or dirty clean it carefully If it is damaged replace it Connect the connectors securely 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 the tester does not read 0 the lead is defective Re place the lead 6C17384BS1 3 22 FUEL SYSTEM Troubleshooting the DFI System OIf both ends of a harness A are far apart ground B the one end C using an auxiliary wire D and check the continuity between the end E and the ground F This enables to check a long harness for continuity If the harness is open repair or replace the harness 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 in the wiring or connectors the DFI parts are the next likely suspects Check the part starting with input
97. be defective then the rotor magnets have probably weakened and the rotor must be replaced ORepeat the test for the other black leads ORepeat the test for the inside alternator connector x10 Regulator Rectifier Removal e Remove Regulator Rectifier Mounting Bolts A Regulator Rectifier B e Disconnect the connectors A from the regulator rectifier Regulator Rectifier Installation e Run the regulator rectifier leads according to the Cable Wire and Hose Routing section in the Appendix chapter e Tighten Torque Regulator Rectifier Bolts 8 8 N m 0 90 kgf m 78 in Ib 8 09020851 16 38 ELECTRICAL SYSTEM Charging System Regulator Rectifier Inspection e Remove the regulator rectifier see Regulator Rectifier Removal BK1 BK2 BK3 GPOSO76BS1 C e Set the hand tester to the x 1 kO range and make the measurements shown in the table Special Tool Hand Tester 57001 1394 e Connect the hand tester to the regulator rectifier the tester readings are not as specified replace the regulator rectifier CAUTION Use only Kawasaki Hand Tester 57001 1394 for this test A tester other than the Kawasaki Hand Tester may show different readings If a megger or a meter with a large capacity battery is used the regulator rectifier will be damaged Regulator Rectifier Resistance Unit Tester Lead
98. brake effectiveness A WARNING Do not attempt to ride the motorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against the disc The brakes will not function on the first application of the lever if this is not done Steering Stem Warp e Whenever the steering stem is removed or if the steering cannot be adjusted for smooth action check the steering stem for straightness If the steering stem A is bent replace the steering stem GNO5029BS1 C STEERING 14 11 Steering Stem Bearing Stem Bearing Removal e Remove the steering stem see this chapter Drive out the bearing outer races from the head pipe Special Tool Head Pipe Outer Race Remover A 57001 1107 NOTE Olf either steering stem bearing is damaged it is recom mended that both the upper and lower bearings includ ing outer races be replaced with new ones Remove the lower inner race A which is pressed onto the steering stem using a chisel Grease Seal B Tap here C Stem Bearing Installation Replace the bearing outer races with new ones e Apply grease to the outer races and drive them into the head pipe at the same time Special Tools Head Pipe Outer Race Press Shaft A 57001 1075 Head Pipe Outer Race Driver B 57001 1077 Replace the stem bearing inner races with new ones e Apply grease to the lower inner race A and drive it onto the stem base Special Too
99. button is released xlIf the rod is not pulled in the solenoid check the sole noid resistance see Decompression Solenoid Inspection in the Electrical System chapter and check the wiring for continuity using the following diagram If wiring and the decompression solenoid are good check the ECU for its ground and power supply see this chap ter If the ground and power supply are good replace the ECU lt Qo lt lt TYN 9 ro lt CG e i lt e co r TOA LO xr P xr CO cO co Cu BL BK BL BK W Y 4t eit BK BK SIN eit BK Y GC17372BW2 1 ECU 4 Fuse 2 Decompression Solenoid 5 ECU Main Fuse 30A 3 Decompression Fuse 10A 6 Battery FUEL SYSTEM DFI 3 95 Oxygen Sensor Heater Service Code 67 Oxygen Sensor Heater Removal Installation The oxygen sensor heater is bult in the oxygen sensor So the heater itself can not be removed Remove the oxy gen sensor see Oxygen Sensor Removal Installation the Electrical System chapter Oxygen Sensor Heater Inspection e Remove Seats see Frame chapter Right Cover see Frame chapter e Disconnect the oxygen sensor lead connector A Oxygen Sensor Heater Inspection Set the hand tester A to the x 1
100. calipers at several points around the piston Piston Ring Groove Width Standard Service Limit Top 1 225 1 240 mm 1 32 mm 0 048228 0 048819 in 0 05197 in Second 1 21 1 23 mm 1 31 mm 0 04764 0 04843 in 0 05157 the width of any of the two grooves is wider than the service limit at any point replace the piston Piston Ring Thickness Measure the thickness of the top A and second B rings OUse a micrometer to measure at several points around the ring Piston Ring Thickness Standard Service Limit Top 1 17 1 19 mm 1 10 mm 0 04606 0 04685 in 0 0433 Second 1 17 1 19 mm 1 10 mm 0 04606 0 04685 in 0 0433 in lf any of the measurements is less than the service limit on either of the rings replace all the rings NOTE OWhen using new rings in a used piston check for un even groove wear The rings should fit perfectly parallel to the groove sides If not replace the piston Piston Ring End Gap 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 Standard Service Limit Top 0 25 0 35 mm 0 7 mm 0 0098 0 0138 in 0 028 in Second 0 40 0 55 mm 0 8 mm 0 0157 0 0217 in 0 031 in Oil 0 3 0 9 mm 1 2mm 0 012 0 035 in 0 0472 in
101. camshaft po sition sensor bolt Torque Camshaft Position Sensor Bolt 9 8 N m 1 0 kgf m 87 e Install the decompression push rod G after installing the camshaft end cover e Install the decompression solenoid OConnect the camshaft position sensor lead connectors Al the clamp and grommet as shown OTorque the decompression solenoid bolts D Torque decompression Solenoid Bolts 9 8 N m 1 0 kgf m 87 16 ODo not make the lead E slacken as much as possible GE22008BS1 C GE22013BS1 C ENGINE TOP END 5 25 Decompression Mechanism e Be sure that the decompression lever A moves back end forth B smoothly e Position the grommet A and route the decompression solenoid leads B and bend C the clamp e Install the outer camshaft cover Torque Outer Camshaft Cover Bolts 12 1 2 kgf m 104 in Ib Oil Seal Inspection e Inspect the oil seal A on the camshaft end cover B Replace if the lips are misshapen discolored indicating that the rubber has deteriorated hardened or otherwise damaged Spring Tension Since the spring A becomes shorter as it weakens check its free length B to determine its condition the spring is shorter than the service limit it must be replaced Spring Free Length Standard 56 5 mm 2 22 in Service Limit 55 4 mm 2 18 in Decompression Solenoid Inspection Refer to the Decompr
102. chapter Make sure they do not get pinched or kinked ORoute hoses with a minimum of bending so that the air or vapor will not be obstructed 3 120 FUEL SYSTEM DFI Fuel Tank e Check that the rubber dampers A are in place xIf the dampers are damaged or deteriorated replace them e Pull A the joint lock B fully as shown e Insert the fuel hose joint A straight onto the tank outlet pipe B e Push A the joint lock B until the hose joint clicks C in the photo the fuel hose joint has been removed for clarity FUEL SYSTEM DFI 3 121 Fuel Tank e Push and pull A the hose joint B up and down more than two times and make sure it is locked and doesn t come off A WARNING Make sure the hose joint is installed correctly on the delivery pipe or the fuel could leak x lf it comes off reinstall the hose joint Connect the fuel pump meter and the fuel level sensor connectors 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 Check to see if the breather pipe B in the tank is not clogged x If the breather pipe is clogged blow the breather free with compressed air x lf the tank cap breather is clogged replace the tank cap CAUTION Do not apply compressed air to the air vent holes C in the tank cap This could damage and clog the labyrinth i
103. 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 Reinstall see chapter 3 FUEL SYSTEM DFI 3 29 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions chapter Throttle valves or actuator trouble Push in see chapter 3 Fuel filter or pump screen clogged Inspect and replace fuel pump see chapter 3 Fuel pressure regulator clogged Inspect fuel pressure and replace fuel pump see chapter 3 Fuel line clogged Inspect and repair see chapter 3 Thermostat trouble Inspect and replace see chapter 4 Inlet air temperature sensor trouble Inspect see chapter 3 Inlet air pressure sensor trouble Inspect see chapter 3 Unstable rough idling Throttle valves or actuator trouble Inspect see chapter 3 Fuel injector trouble Inspect see chapter 3 Inlet air temperature sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Atmospheric pressure sensor trouble 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 Throttle sensor trouble Inspect see chapter 3 Throttle valves or actuator trouble Inspect se
104. commonly referred to as the Act s tampering provisions Sec 203 a The following acts and the causing thereof are prohibited 3 A for any person to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title prior to its sale and delivery to the ultimate purchaser or for any manufacturer or dealer knowingly to remove or render inoperative any such device or element of design after such sale and delivery to the ultimate purchaser 3 B for any person engaged in the business of repairing servicing selling leasing or trading motor vehicles or motor vehicle engines or who operates a fleet of motor vehicles know ingly to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title follow ing its sale and delivery to the ultimate purchaser NOTE OThe phrase remove or render inoperative any device or element of design has been generally interpreted as follows 1 Tampering does not include the temporary removal or rendering inoperative of de vices or elements of design in order to perform maintenance 2 Tampering could include a Maladjustment of vehicle components such that the emission standards are ex ceeded b Use of replacement parts or accessories which adversely affect the performance or durability of the motorc
105. damaged Replace see chapter 5 Cylinder head warped 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 Inspect and repair or replace see chapter 5 carbon accumulating on seating surface Compression release mechanism sticks open Inspect and repair or replace see chapter 5 Engine stalls when moving off HLA hydraulic lash adjuster damaged Inspect and replace see chapter 5 worn seizure or spring broken HLA oil passage clogged Inspect and repair or replace see chapter 5 Poor Running at Low Speed Symptoms or Possible Causes Actions chapter Spark weak Battery voltage low Inspect and charge see chapter 16 Spark plug dirty broken or gap maladjusted Clean spark plugs and adjust plug gap see chapter 2 Inspect the ignition coil see chapter 16 Spark plug cap shorted or not in good contact Reinstall or inspect the cap see chapter 16 Spark plug incorrect 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 Ignition 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
106. driven to the counterclockwise by crankshaft sprocket that rotate to the clockwise viewed from the righr side The hydraulically operated chain tensioner is located be tween crankshaft and rear balancer shaft The hydraulic chain tensioner is supplied the oil pressure from lubrication feed pump Two chain guides applied one is between the crankshaft and front balancer shaft and another is under the crankshaft sprocket e 3 a r 1 Front Balancer Shaft 7 Hydraulic Chain Ten 2 Rear Balancer Shaft sioner 3 Front and Rear Balancer 8 Chain Guide under Sprocket Crankshaft 4 Balancer Drive Chain 9 Chain Guide between 5 Crankshaft Crankshaft and Front 6 Balancer Drive Sprocket Balancer Shaft 1 18 GENERAL INFORMATION Technical Information Dual Balancer Shaft System a e 19 K FS RAI LL eee 9 T DET ng MET HN A d R fO i PEZ 2 Z7 22 1 J GB06123BW3 1 Front Balancer Shaft 6 Balancer Drive Sprocket 9 Chain Guide under 2 Rear Balancer Shaft 7 Hydraulic Chain Ten Crankshaft 3 Front and Rear Balancer sioner 10 Front Sprocket 8 Chain Guide between 11 Left 4 Balancer Drive Chain Crankshaft and Front 5 Crankshaft Balancer Shaft GENERAL INFORMATION 1 19 Unit Conversion Table Prefixes for Units
107. e Be sure the dowel pins C are in position 6104123851 C CRANKSHAFT TRANSMISSION 9 15 Crankcase e Apply liquid gasket A to the mating surface of the left crankcase B Sealant Kawasaki Bond Liquid Gasket Black 92104 1064 OBe sure liquid gasket is applied to the lower ends C in dicated in the figure ODo not drop liquid gasket into the oil passages D OAfter tightening the crankcase bolts wipe up the liquid gasket seeping out around the mating surface NOTE OMake the application finish within 20 minutes when the liquid gasket to the mating surface of the left crankcase half is applied OMoreover fit the case and tighten the case bolts just after finishing the application of the liquid gasket 6104124BN2 e Tighten the left crankcase bolts as follows OFirst tighten the 8 mm bolts A and next 6 mm bolts B temporarily OFirst torque the 8 mm bolts and next 6 mm bolts Torque 8 mm Crankcase Bolts 29 N m 3 0 kgf m 22 ft Ib 6 mm Crankcase Bolts 12 N m 1 2 kgf m 104 ft Ib e Check the following turn freely Crankshaft C 6104125851 Front D and Rear E Balancer Shafts Oil Pump Shaft F Drive Shaft G and Output Shaft H Pulley Shaft J 9 16 CRANKSHAFT TRANSMISSION Crankcase Tighten the right crankcase bolts as follows OFirst tighten the 8 mm bolts A and next 6 mm bolts B temporarily OFirst torque the 8 mm bolts and nex
108. e Install the fuel pressure gauge adapter A special tool between the fuel tank outlet pipe B and the inlet pipe C to the delivery joint D OPut the fuel pressure gauge adapter outside the frame e Connect the pressure gauge E special tool to the fuel pressure gauge adapter Fuel Tank F Fuel Pump G Front H Fuel Flow Special Tools Fuel Pressure Gauge Adapter 57001 1593 Fuel Hoses 57001 1607 Oil Pressure Gauge 57001 125 Temporarily install the removed parts A WARNING Do not try to start the engine with the fuel hoses disconnected 8017328 52 C e Turn the ignition SW ON The fuel pump will turn for 3 seconds and then stop e Measure the fuel pressure with the engine stopped Fuel Pressure right after Ignition SW ON with pump running Standard 304 kPa 3 1 kgf cm 44 psi after 3 seconds from Ignition SW ON with pump stopped Standard 280 kPa 2 9 kgf cm 41 psi residual fuel pressure The system should hold the residual pressure about 30 seconds 3 106 FUEL SYSTEM DFI Fuel Line e Start the engine and let it idle e Measure the fuel pressure with the engine idling Fuel Pressure idling Standard 304 kPa 3 1 kgf cm 44 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 n
109. end and flange end Standard 32 5 mm 1 28 in Usable Range 27 5 37 5 mm 1 08 1 48 in SUSPENSION 13 7 Special Tools Inside Circlip Pliers 57001 143 e Jack 57001 1238 a gt sg as 7 je Fork Cylinder Holder Handle 57001 183 Fork Oil Level Gauge 570101 1290 Fork Cylinder Holder Adapter Jack Attachment 57001 1571 57001 1057 Oil Seal amp Bearing Remover 57001 1058 Bearing Driver Set 57001 1129 ST5715718T C Hook Wrench 57001 1580 7571580ST C Fork Oil Seal Driver 49 57001 1589 875715895 C 13 8 SUSPENSION Front Fork Fork Oil Change e Remove Front Wheel see Wheels Tires chapter Front Fender see Frame chapter Nacelle see Frame chapter Handlebar from handlebar clamp e Loosen the front fork upper clamp bolt A e Remove the cap B e Cover the fuel tank with a cloth A e Push down the top plug B and remove the stopper ring C e Remove Collar A Front Fork B e Remove Rubber Damper A Cover B 4 QUMBIS SUSPENSION 13 9 Front Fork e Remove Washer A Spring B e Drain the fork oil A into a suitable container OPump the inner tube up and down at least ten times to expel the oil from the fork e Fill the front fork with the specified o
110. 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 other Engine stops right after starting when opening throttle grip when closing throttle grip when moving off when stopping the motorcycle when cruising other Poor running very low fast idle speed at low speed o 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 maladjusted adjust it backfiring afterfiring FUEL SYSTEM DFI 3 25 Troubleshooting the DFI System hesitation when acceleration engine oil viscosity too high brake dragging engine overheating clutch slipping other Poor running spark plug loose tighten it or no power o spark plug dirty broken or gap maladjusted remedy it at high speedo 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
111. excessive wattage Ignition switch trouble Alternator trouble Wiring faulty Regulator rectifier trouble Battery overcharged Alternator trouble Regulator rectifier trouble Battery faulty MODEL APPLICATION Model Beginning Frame No JKBVNMA104A000001 or VN2000 A1 JKBVNWO00AAA000001 or VNWO00A 000001 L1 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 1320 02 Printed in Japan
112. front and rear balancer sprocket bolts Special Tool Flywheel amp Pulley Holder 57001 1343 B 9 26 CRANKSHAFT TRANSMISSION Balancer Mechanism e Remove the balancer chain sprocket A and balancer sprockets B with the chain C Balancer Mechanism Installation Align the marks A on the following with the colored chain link B as shown Balancer Chain Sprocket C Front Balancer Sprocket D Rear Balancer Sprocket E e Install the balancer chain sprocket and balancer sprock ets by aligning F the wide grooves with the wide teeth on the following shafts Crankshaft G Front Balancer Shaft H Rear Balancer Shaft J 6106010BN2 CRANKSHAFT TRANSMISSION 9 27 Balancer Mechanism Temporally tighten the balancer chain sprocket nut A and balancer sprocket bolts B OPut the washers C to the balancer shafts D OPut the washer E to the crankshaft so that its OUT SIDE F mark faces outward e Push A the chain tensioner ratchet B and push down C the tensioner shoe D CAUTION Be careful the oil remaining in the tensioner body dashes out e Engage the first teeth A of the ratchet B with second groove C of the plunger D 6106012851 C e Insert the suitable stopper pin A into the chain tensioner body B through the link plate C 9 28 CRANKSHAFT TRANSMISSION Balancer Mechanism e Install Chain Guides A Chain Ten
113. gj030004 tif 6J04086BS1 10 12 WHEELS TIRES Wheels Rims Balance Adjustment the wheel always stops in one position provisionally attach a balance weight A on the rim at the marking using adhesive tape WARNING Use only the genuine balance weights 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 1 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 two screwdrivers and remove the balance weight 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 damaged 6J04087BS1 C 6J04073BS1 C WHEELS TIRES 10 13 Wheels Rims Balance Weight Installation e Check if the weight portion has any p
114. go on inspect or re place the following item Headlight Low Beam Bulb see Electrical System chap ter Headlight Fuse 10 A see Electrical System chapter Dimmer Switch see Electrical System chapter Headlight Relay in Relay Box see Electrical System chapter Harness see Wiring Inspection in Electrical System chapter 6517013851 C 2 30 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Set the dimmer switch to high beam position e The low beam A and high beam B headlights should go on The high beam indicator light C should go on If the high beam headlight and or high beam indicator light does not go on inspect or replace the following item Headlight High Beam Bulb see Electrical System chap ter Dimmer Switch see Electrical System chapter Turn off the engine stop switch e The low beam and high beam headlights should stay go ing on xIf the headlights and high beam indicator light does go off inspect or replace the following item Headlight Relay in Relay Box see Electrical System chapter e Turn off the ignition switch e The headlights and high beam indicator light should go off Headlight Aiming Inspection e Inspect the headlight beam for aiming the headlight beam points to one side rather than straight ahead adjust the horizontal beam Headlight Beam Horizontal Adjustment Remove the cap A Turn the horizontal adjuster on the headlight with a screw
115. housing bolts and Allen bolts A e Pull the air cleaner housing A and disconnect the follow ing Air Switching Valve Hose B Inlet Air Temperature Sensor Connector C Crankcase Breather Hose D e Remove the air cleaner housing 3 116 FUEL SYSTEM Air Cleaner Air Cleaner Housing Installation e Check that oil is in the breather drain cap A necessary drain the oil in the cap e Fit the idle speed screw A in the recess B on the air cleaner housing e Be sure the dampers A and collors B are in position Olnstall the damper A into the air cleaner housing C as shown Smaller Diameter D Larger Diameter E Torque Air Cleaner Housing Bolts 9 8 N m 1 0 kgf m 87 in Ib Air Cleaner Housing Allen Bolts 9 8 N m 1 0 kgf m 87 16 ieee 6C07024BS1 C FUEL SYSTEM DFI 3 117 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 Disconnect the battery terminal To avoid fire do not remove the fuel tank when the engine is still hot Wait until it cools down To make fuel spillage minimum draw the fuel out from the fuel tank with a pump as much as possible when the engine is cold Be prepared for fue
116. inspection Check 2 e Connect a variable rheostat A to the terminal 12 and battery negative lead as shown e Check that the number of segments B matches the re sistance value of the variable rheostat OWhen terminal 12 is connected one segment should ap pear about 10 15 seconds Resistance Q Number of Segments 50 5 100 3 210 1 Resistance values are standard and they have tolerance xIf this indicator function does not work replace the meter unit GP17096BS1 C GP17098BS1 C GP17099BS2 C ELECTRICAL SYSTEM 16 75 Meter Gauge LED Light Inspection Connect the leads the same circuit as for the LCD Seg ments Inspection Check 2 Fuel Level Warning Indicator LED Light Connect an about 30 resistor A to the terminal 15 and battery negative lead Fuel Level Warning Indicator LED Light Connections Battery Negative Lead to Terminal 15 OThe fuel level warning indicator LED light B should go on lf the fuel level warning indicator LED light does not go on replace the meter unit Oil Pressure Warning Indicator LED Light and LCD Symbol e Connect the lead to the terminal 3 and battery negative lead Oil Pressure Warning Indicator LED Light Connections Battery Negative Lead to Terminal 3 OThe oil pressure warning indicator LED light A and sym bol B in the LCD should go on xIf the LED
117. is released Side Stand Switch Connections E When side stand is up When side stand is down Oil Pressure Switch Connections When engine is stopped When engine is running Engine lubrication system is in good condition 16 90 ELECTRICAL SYSTEM Relay Box The relay box A has relays and diodes The relays and diodes can not be removed Relay Box Removal e Remove Battery See Battery Removal ECU see Fuel System chapter Take out the relay box A and disconnect the connectors B Relay Circuit Inspection e Remove the relay box e Check conductivity of the following numbered terminals by connecting the hand tester and one 12 V battery to the relay box as shown see Relay Box Internal Circuit lf the tester does not read as specified replace the relay box ELECTRICAL SYSTEM 16 91 Relay Box Relay Circuit Inspection with the battery disconnected Tester Connection Tester Reading Q Headlight Relay 11 16 12 13 ECU Main Relay Fuel Pump Relay Starter Circuit Relay Fan Relay The actual reading varies with the hand tester used Relay Circuit Inspection with the battery connected Battery Tester Tester Connection Connection Reading ih ECU Main Relay Fuel Pump Relay 7 1 Fan Relay 18 20 17 19 0 Battery Tester Connection Tester Connection DC 25V Range Reading HE 6 V S
118. 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 or the hose to burst Remove the fuel tank see Fuel System DFI chap ter and check the fuel hose Replace the fuel hose if any fraying cracks B or bulges C are noticed e Check that the hose joints are securely connected e When installing the fuel hoses avoid sharp bending kink ing flattening or twisting Replace the hose if it has been sharply bent or kinked flattening or twisting 6505034851 C 2 34 PERIODIC MAINTENANCE Periodic Maintenance Procedures 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 with the motor cycle held upright The coolant level should be between the F full level and the L low level In the photo the mufflers have been removed for clarity Front A Reserve Tank B Coolant Level Hose C F Level D L Level E If the coolant level is lower than the L level remove the reserve tank cap then add coolant to the F level CAUTION For refilling add the specified mixture of coolant and soft water Adding water alone dilutes the coolant and degrades its anticorrosion properties The diluted coolant can attack the aluminum engine parts In an emergency soft water
119. light and or symbol do not go on replace the meter unit E ole e 35 0 GP17100BS2 C GP17101BS2 C 16 76 ELECTRICAL SYSTEM Meter Gauge FI Indicator LED Light and LCD Symbol Connect the lead to the terminal 2 and battery negative lead FI Indicator LED Light Connections Battery Negative Lead to Terminal 2 OThe FI indicator LED light A and symbol B in the LCD should go on xIf the LED light and or symbol do not go on replace the meter unit Water Temperature Warning Indicator LED Light and LCD Symbol e Connect the lead to the terminal 4 and battery negative lead Water Temperature Warning Indicator LED Light Connections Battery Negative Lead to Terminal 4 OThe water temperature warning indicator LED light A and symbol B in the LCD should go on xIf the LED light and or symbol do not go on replace the meter unit Indicator Light Inspection e Connect the leads in the same circuit as for the LCD Seg ments Inspection Check 2 GP17102BS2 C GP17103BS2 C ELECTRICAL SYSTEM 16 77 Meter Gauge Neutral Indicator Light Connect the lead to the terminal 1 and battery negative lead Neutral Indicator Light Connections Battery Negative Lead to Terminal 1 OThe neutral indicator light A should go on x If the indicator light does not go on inspect the bul
120. not due to the bearings replace the wheel Rim Runout Service Limit Axial 0 5 mm 0 02 in Radial 0 8 mm 0 03 in Never attempt to repair a damaged wheel If there is any damage besides wheel bearings the wheel must be replaced to insure safe operational condi tion Axle Inspection e Visually inspect the front and rear axles for damage 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 If axle runout exceeds the service limit replace the axle Axle Runout 100 mm 3 94 in Standard TIR 0 05 mm 0 002 in or less Service Limit TIR 0 2 mm 0 008 in Wheel Balance OTo improve stability and decrease vibration at high speed the front and rear wheels must be kept balanced e Check and balance the wheels when required or when a tire is replaced with a new one 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 If the wheel stops of its own accord in various positions it is well balanced x If the wheel always stops in one position adjust the wheel balance gj030021 tif
121. or more no refresh charge is quired however if the read is below the specified refresh charge is required V esee em 4 Battery Terminal Voltage Standard 12 6 V or more Terminal Voltage 5 0 25 50 75 100 Refreshing charge Battery Charge is required Refreshing Charge e Remove the battery A see Battery Removal e Do refresh charge by following method according to the battery terminal voltage This battery is sealed type Never remove sealing cap B even at charging Never add water Charge with current and time as stated below 8 09001251 C ELECTRICAL SYSTEM 16 33 Battery Terminal Voltage 11 5 less than 12 6 V Standard Charge 1 8 A x 5 10 h see following chart Quick Charge 9Ax1h CAUTION If possible do not quick charge If quick charge is done unavoidably do standard charge later on Terminal Voltage less than 11 5 V Charging Method 1 8 A x 20 h NOTE Olncrease the charging voltage to a maximum voltage of 25 V if the battery will not accept current initially Charge forno more than 5 minutes at the increased voltage then check if the battery is drawing current If the battery will accept current decrease the voltage and charge by the standard charging method described on the battery case If the battery will not accept current after 5 min utes replace the battery Battery A Battery Charger B Stan
122. see chapter 9 Engine won t turn over Valve seizure Inspect and replace see chapter 5 Cylinder piston seizure Inspect and replace see chapter 5 Camshaft seizure Inspect and replace see chapter 5 Connecting rod small end seizure Inspect and replace see chapter 9 Crankshaft seizure Inspect and replace see chapter 9 Transmission gear or bearing seizure Inspect and replace see chapter 9 Balancer bearing seizure Inspect and replace see chapter 9 No or little 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 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 Inspect and repair see chapter 3 Engine flooded Spark plug dirty broken or gap maladjusted Clean spark plugs and adjust plug gap FUEL SYSTEM 3 27 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions chapter Cr 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 Pull the lever in and shift the gear in neutral
123. speed sensor power supply voltage xIf the speed sensor and speed sensor power supply volt age are normal replace the meter unit 1 CLOCK 2 ie 7 7 GP17094BS1 Duty 50 OV 8 17095 52 C 16 74 ELECTRICAL SYSTEM Meter Gauge Speed Sensor Power Supply Voltage Inspection e Connect the leads in the same circuit as for the LCD Seg ment Inspection Check 2 e Set the hand tester A to DC25 V check the voltage be tween terminal 10 and battery negative lead Connections Hand Tester Terminal 10 Hand Tester Battery Negative Terminal Special Tool Hand Tester 57001 1394 xIf the voltage is less than 6 V replace the meter unit ODO Meter Inspection e Connect the leads in the same circuit as for the Speedometer Inspection e Push the mode button to ODO A e Raise the input frequency of the oscillator to quickly see the result of this inspection x If the value indicated by the odo meter does not increase replace the meter unit TRIP Meter Inspection e Connect the leads in the same circuit as for the Speedometer Inspection e Push the mode button to TRIP A e Rise the input frequency of the oscillator to quickly see the result of this inspection xIf the value indicated by the trip meter does not increase replace the meter unit Fuel Level Gauge Inspection e Connect the leads in the same circuit as for the LCD seg ment
124. stopping For higher odometer readings repeat at the frequency interval established here CAL California 2 4 PERIODIC MAINTENANCE Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY Whichever ODOMETER READING comes x 1000 km first x 1000 mile 48 See CHANGE REPLACE ITEM 30 Brake hoses and pipes Brake fluid Page Oil filter Fuel hose Radiator hose and O ring 3 year 2 53 Service more frequently when operating in severe conditions dusty wet muddy high speed or frequent starting stopping For higher odometer readings repeat at the frequency interval established here PERIODIC MAINTENANCE 2 5 Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non permanent locking agent or liquid gasket Letters used in the Remarks column mean L Apply a non permanent locking agent to the threads G Apply grease to the threads The table below relating tightening torque to thread diameter lists the basic torque for the bolts and nuts Use this table for only the bolts and nuts which do not require a specific torque value All of the values are for use with dry solvent cleaned threads Basic Torque for General Fasteners MO Apply molybdenum disulfide grease oil Threads Torque solution dia mm O Apply oil to the threads and seating sur
125. 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 Play Adjustment Adjust the steering if necessary e Remove Nacelle see Frame chapter Handlebar see Steering chapter Stem Head Nut A Washer e Loosen the upper fork clamp bolts on both sides e Remove O ring A Steering Stem Head B PERIODIC MAINTENANCE 2 15 Periodic Maintenance Procedures Remove the claw washer e Adjust the stem nut A with the stem nut wrench B by tightening to the specified torque Special Tool Steering Stem Nut Wrench 57001 1100 Torque Steering Stem Nut 4 9 0 50 kgf m 43 in Ib e Install the stem head e Tighten the following in the order listed Torque Stem Head Nut 108 N m 11 kgf m 80 ft Ib Upper Fork Clamp Bolts 20 N m 2 0 kgf m 15 in Ib ORun the throttle cables brake hose and clutch cable in accordance with the Cable Wire and Hose Routing sec tion in the Appendix chapter e Check and adjust the steering and throttle cables after installation Do not attempt to ride the motorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against the disc The brakes will not function on the first application of the lever if this is not done Steering Stem Bearing Lubrication e Remove the steering stem see Steering chapter e Using a hig
126. terminal 20 Meter gt BR BK lead terminal 25 617295881 Output Voltage Usable Range 3 80 4 20 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 OThe atmospheric sensor output voltage is based on a nearly perfect vacuum in the small chamber of the sensor So the sensor indicates absolute atmospheric pressure 1 the output voltage is normal check the output voltage for atmospheric pressure other than 76 cmHg abs see Inlet Air Pressure Sensor section in this chapter If the output voltage changes within the usable range as atmo spheric pressure changes the sensor is normal and the ECU is suspect Replace the ECU xIf the output voltage is out of the usable range replace the sensor N WO gt lt uo lt c5 KO c o lt c e EIER ES BEP DERI E lt BR B BL W BR BK BR BK BR BK G W BL W o o GC17302BW2 1 ECU 2 Joint Connector 3 Atmospheric Pressure Sensor FUEL SYSTEM DFI 3 59 Atmospheric Pressure Sensor Service Code 15 If you need to check the atmospheric pressure sensor for various altitudes other t
127. the brake lever slowly and hold it with a band A CAUTION Be sure to hold the front brake when removing the shock absorber or the motorcycle may fall over The motorcycle could be damaged Be sure to hold the front brake when removing the shock absorber or the motorcycle may fall over It could cause an accident and injury e Remove Seats see Frame chapter Battery Cover Left Side Cover see Frame chapter Hose Cover Screws A both sides Hose Cover B e Remove Rear Shock Absorber Front Mounting Bolt and Nut A 13 18 SUSPENSION Rear Shock Absorber e Remove Rear Shock Absorber Rear Mounting Bolt A and Nut por 2 OLifting up the rear wheel a little pull out the rear mounting B bolt _ e Remove gt Rear Shock Absorber 4 FIT eal a Rear Shock Absorber Installation e Apply grease to the needle bearing and oil seals A e Install the rear shock absorber so that the rebound damp ing adjuster A faces upside e Tighten the rear shock absorber nuts to the specified torque Torque Rear Shock Absorber Bolt and Nut 59 N m 6 0 43 ft Ib Rear Shock Absorber Inspection Remove the rear shock absorbers A e Visually inspect the following items Smooth Stroke B Oil Leakage see Periodic Maintenance chapter Crack or Dent x lf there is any damage to the rear shock absorber one unit feels weaker th
128. the clutch lever and screw in the adjuster e Line up the slots A in the clutch lever locknut B and adjuster C 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 outer clutch cover to prevent the release shaft from falling out e Pull the clutch cable out of the frame Clutch Cable Installation e Run the clutch cable correctly see Appendix chapter e Adjust the clutch cable see clutch in the Periodic Main tenance chapter Clutch Cable Lubrication e Refer to General Lubrication in the Periodic Maintenance chapter Clutch Lever Installation e Install the clutch lever so that the punch mark A on the handlebar is aligned with the mating surface B of the clutch lever clamp CLUTCH 6 7 Clutch Outer Clutch Cover Removal Drain the engine oil see Engine Lubrication System in the Periodic Maintenance chapter Remove the left footboard see Frame chapter e Remove Clutch Cable see this chapter Release Lever Bolt A Release Lever B Outer Clutch Cover Bolts C Outer Clutch Cover D Outer Clutch Cover Installation e Be sure the dowel pins A are in position e Replace the gasket B with a new one e Install the outer clutch cover OEngage A the gear of the release shaft B with the gear of the pull rod C OTighten th
129. the clutch operation e Check the brake effectiveness A WARNING Do not attempt to ride 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 brake will not function on the first appli cation of the lever or pedal if this is not done CRANKSHAFT TRANSMISSION 9 1 Crankshaft Transmission Table of Contents Exploded Specifications Special Tools and Sealants Crankcase Disassembly Crankcase Assembly Starter Clutch Disassembly Starter Clutch Assembly Starter Clutch Inspection Starter Torque Limiter Check Crankshaft Connecting Rods Connecting Rod Removal Connecting Rod Installation Crankshaft Connecting Rod Cleaning asit n Avene Connecting Rod Bend Connecting Rod Twist Connecting Rod Big End Side Connecting Rod Big End Bearing Crankshaft Runout Crankshaft Main Bearing Journal Balancer Mechanism Removal Balancer Mechanism Installation 9 22 9 23 9 24 9 24 9 25 9 25 9 26 Transmission 2 2 9 30 Shift Pedal Removal
130. the plastic hose is filled with fuel e Measure the discharge for 3 seconds with the plastic hose filled with fuel 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 connect the fuel hoses and install the fuel tank see Fuel Tank Installation e Start the engine and check for no fuel leakage 8017325 52 C FUEL SYSTEM DFI 3 109 Throttle Grip and Cables Throttle Grip Free Play Inspection e Refer to Throttle Control System Check in the Periodic Maintenance Chapter Throttle Grip Free Play Adjustment e Loosen the locknuts A and screw the adjusters B all the way in so as to give the throttle grip plenty of play e Turn out the adjuster of the decelerator cable D until there is no play e Tighten the locknut against the adjuster e Turn the adjuster of the accelerator cable C until the proper amount of throttle grip free play is obtained and tighten the locknut against the adjuster A WARNING Operation with incorrectly routed or improperly ad justed cables could result in an unsafe riding con dition Cable Removal Installation OSee Throttle Body Assy and Intake Manifold section in this chapter for removal installation of the throttle cables and choke cable Cable Lubrication and Inspection e Wheneve
131. the tester to the x 1 O range and read the tester e Measure the secondary winding resistance as follows ORemove the plug caps by turning them counterclockwise OConnect the tester between the spark plug High Tension cables OSet the tester to the x 1 kO range and read the tester Measure primary winding resistance A Measure secondary winding resistance B Ignition Coil C Ignition Coil Winding Resistance Primary Windings 1 9 2 5 0 Secondary Windings 10 16 xIf the tester does not read as specified replace the coil OTo install the plug cap turn it clockwise Spark Plug Removal e Remove Fuel Tank for Rear Spark Plug see Fuel System chap ter Spark Plug Caps A e Remove the spark plug using the 16 mm 0 63 in plug wrench vertically Special Tool Spark Plug Wrench Hex16 57001 1262 CAUTION The insulator A of the spark plug may break if when the wrench is inclined during loosening B Inclined Spark Plug Wrench C Contact Spark Plug and Plug Wrench D Bad E Vertically Spark Plug Wrench F Good GP101289BS1 C GP10132BS1 C 16 44 ELECTRICAL SYSTEM Ignition System Spark Plug Installation e Insert the spark plug in the plug hole and finger tighten it first e Using the plug wrench A vertically tighten the plug CAUTION The insulator of the spark plug may break if when the wrench is inclined during tightening Special Tool Spa
132. torque following the tight ening sequence 1 Front Downtube Nuts A 2 Lower Engine Bracket Bolts B 3 Front Engine Mounting Nut C 4 Rear Downtube Bolts D Tighten Torque Front Downtube Nuts 88 N m 9 0 kgf m 65 ft lb Lower Engine Bracket Bolts 59 N m 6 0 kgf m 43 ft lb Front Engine Mounting Nut 44 N m 4 5 kgf m 33 ft lb Rear Downtube Bolts 108 N m 11 kgf m 80 ft Ib NOTE OTighten the tow downtube mounting bolts A D alter nately two times to ensure even tightening torque GO11001BS2 C FRAME 15 23 Headlight Cover Headlight Cover Removal e Remove Headlight Unit see Electrical System chapter Headlight Upper Cover Bolts A and Washers Headlight Upper Cover B e Remove Headlight Holder Bolts A Headlight Holder B e Remove Headlight Cover Bolts A both sides Headlight Cover Bolts B Headlight Covers C both sides Headlight Cover Installation e Install Headlight Covers Headlight Cover Bolts Headlight Holder A e Tighten the holder bolts to the specified torque following the tightening sequence as shown 1 Bolt B 2 Bolt C 3 Bolts D no sequence e Install Headlight Upper Cover Bolts and Washers Headlight Upper Cover 6019000851 C 15 24 FRAME Frame Frame Inspection e Visually inspect the frame A for cracks dents bending Or warp xIf there is any damage to the frame replace it repaired f
133. tube Temporarily assemble the inner and outer tubes and pump A them back and forth manually to check for smooth operation If you feel binding or catching the inner and outer tubes must be replaced A WARNING A straightened inner or outer fork tube may fail in use possibly causing an accident Replace a badly bent or damaged inner or outer tube and inspect the other tube carefully before reusing it Dust Seal Inspection Inspect the dust seal A for any signs of deterioration or damage Replace them if necessary Spring Tension e Since the spring becomes shorter as it weakens check its free length A to determine its condition xf the spring of either fork leg is shorter than the service limit it must be replaced xIf the length of a replacement spring and that of the re maining spring vary greatly the remaining spring should also be replaced in order to keep the fork legs balanced for motorcycle stability Spring Free Length Standard 470 9 mm 18 54 in Service Limit 461 mm 18 1 in GMO4183BS1 C 0200048105 P 6 040317 5 8 04011851 C 13 16 SUSPENSION Rear Shock Absorber Rebound Damping Force Adjustment e Remove the seats see Frame chapter e To adjust the rebound damping force turn the rebound damping adjuster A to the desired position OThe standard adjuster setting for an average build rider of 68 kg 150 Ib with no passenger
134. voltage is out of the specified check the ECU for its ground and power supply see this chater If the ground and power supply are good remove the fuel tank and check the wiring between the ECU and the water tem perature sensor for continuity x If the wiring is good check the water temperature sensor resistance D GC17300BS1 C 3 56 FUEL SYSTEM DFI Water Temperature Sensor Service Code 14 Water Temperature Sensor Resistance Inspection e Remove the water temperature sensor see this section e Suspend the sensor A in a container of machine oil so that the heat sensitive portion and threaded portion are submerged e Suspend a thermometer B with the heat sensitive por tion C located in almost the same depth with the sensor NOTE OThe sensor and thermometer must not touch the con 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 Water Temperature Sensor Resistance Standard 1 055 1 199 at 40 C 104 F 0 151 0 162 at 100 C 212 F If the measurement is out of the range replace the sensor the measurement is within the specified the ECU is suspect Replace the ECU e Clean off machin
135. wave rectifier in the text Ignition System 3 needle arcing distance Primary winding resistance Secondary winding resistance Primary peak voltage Spark plug Spark plug gap Spark plug cap resistance Crankshaft sensor Crankshaft sensor peak voltage Crankshaft sensor resistance Crankshaft sensor air gap 19 2 50 10 16 210 V or more 1 0 1 1 mm 0 039 0 043 in 3 75 6 25 3 0 V or more 420 5200 1 0 mm 0 04 in Non measurable and non adjustable Electric Starter System Starter motor Brush length Commutator diameter Ignition coil 6 mm 0 24 in or more 12 5 mm 0 49 in Service limit 5 mm 0 20 in 28 mm 1 10 in Service limit 27 mm 1 06 in Air Switching Valve Air switching valve resistance 18 22 at 20 C 68 F Decompression Solenoid Decompression solenoid resistance 3 03 Switch and Sensor Fuel level sensor resistance Rear brake light switch timing Engine oil pressure switch resistance Water temperature sensor resistance FULL position 3 50 EMPTY position 213 219 O ON after about 10 mm 0 39 in pedal travel When engine is stopped ON When engine is running OFF in the text ORefer to Fuel System chapter for specifications of DFI parts ELECTRICAL SYSTEM 16 13 Special Tools Spark Plug Wrench Hex 16 Filler Cap Driver 57001 1262 57001 1454 7571454ST C Jack Needle Adapter Set
136. with a means like the fork oil level gage e Pull the bolt caps out Remove the banjo bolt C to disconnect the brake hose from the master cylinder see Brake Hose stallation e Unscrew the clamp bolts B and take off the master cylin der as an assembly with the reservoir brake lever and brake switch installed CAUTION Immediately wash away any brake fluid that spills Front Master Cylinder Installation e Set the front master cylinder A to match its mating sur face B to the punched mark C of the handlebar 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 A after tightening Torque Front Master Cylinder Clamp Bolts 8 8 N m 0 90 kgf m 78 16 e Install the bolt caps e Use a new flat washers A on each side of the brake hose fitting e Tighten the brake hose banjo bolt B Torque Brake Hose Banjo Bolt 25 N m 2 5 kgf m 18 ft Ib e Replenish the fluid in the reservoir and bleed the brake line see Bleeding the Brake Line e Check the brake for good braking power no brake drag and no fluid leakage BRAKES 12 15 Master Cylinder Rear Master Cylinder Removal i e Remove Right Footboard see Frame chapter Muffler and Exhaust Manifold see Engine Top End chapter Rear Brake Light Switch Lead Connector disconnect Right Footboard Bracket Front Bolt A Right Footboard
137. 0 2 FUEL SYSTEM DFI 3 17 DFI System Terminal Names Power Supply to Sensors Unused Radiator Fan Signal Subthrottle Valve Actuator Signal 3 Subthrottle Valve Actuator Signal 1 Unused Engine Stop Switch Output Signal Unused Self diagnosis Terminal Back up Power Supply from Battery Water Temperature Sensor Output Signal Power Supply to ECU from ECU Relay Unused Gear Position Sensor Output Signal Oxygen Sensor Output Signal Subthrottle Valve Actuator Signal 4 Subthrottle Valve Actuator Signal 2 Inlet Air Pressure Sensor Output Signal Atmospheric Pressure Sensor Output Signal Unused Inlet Air Temperature Output Signal Main Throttle Sensor Output Signal Subthrottle Sensor Output Signal Ground for Sensors Ground for ECU Ground for Power Unused Camshaft Position Sensor Output Signal Crankshaft Sensor Output Signal Oxygen Sensor Heater Signal Fuel Pump Relay Signal Decompression Solenoid Signal Fl Indicator LED Light Water Temperature Warning Light Air Switching Valve Signal Injector 2 Signal Injector 1 Signal Injector Coil 1 Signal Starter Control Relay Signal Vehicle down Sensor Output Signal Unused Crankshaft Sensor Output Signal Interlock Circuit Signal Speed Sensor Output Signal Gear Position Switch Neutral Output Signal Starter Button Output Signal Starter Lockout
138. 0 range and connect it to the terminals in the oxygen sensor lead connector B Black C Black D Special Tool Hand Tester 57001 1394 Oxygen Sensor Resistance Standard 14 1 19 3 O at 20 C 68 F x lf the tester reading is not as specified replace the oxygen sensor with a new one GP18070BS1 C x lf he tester reading is specified check the power source voltage Inspection NOTE OBe sure the battery is fully charged e Connect a digital voltmeter A to the oxygen sensor con nector 4P using the needle adapter C Special Tool Needle Adapter Set 57001 1457 e Measure the power source voltage with the engine b MON stopped and with the oxygen sensor connector joined Oxygen Sensor Power Source Voltage Connections to Oxygen Sensor Connector Tester W Y lead D Tester gt Battery Terminal E Standard Battery Voltage Oxygen Sensor F the reading is incorrect check the following Battery ECU Main Fuse 30A Decompression Fuse 10A x lf the reading is good the power source voltage is normal Inspect the Red Black lead between the oxygen sensor connector and the ECU for continuity using the following diagram xIf the wiring is good inspect the ECU for its ground and power supply see ECU section in this chapter If the ground and power supply are good replace the ECU 3 96 FUEL SYSTEM DFI Oxygen Sensor Heater Service Code 67 N
139. 001 1100 180 mm 7 09 in B Force C OLoosen the stem nut ORetighten the stem nut to the specified torque Torque Steering Stem Nut 4 9 N m 0 50 kgf m 43 in Ib OFor the torque of 4 9 N m 0 50 kgf m 43 pull the wrench at the hole by 27 N 2 8 kgf 6 Ib force 14 10 STEERING Steering Stem e Install the claw washer e Install the fork legs A and push it up tightly against the stem bottom e Temporarily tighten the lower fork clamp bolts e Install Steering Stem Head B with Handlebar O ring C Washer D Stem Head Nut E d Plug F GNO5027BS1 e Temporarily tighten the upper fork clamp bolts G OCheck that the top end A of the inner tube is flush with the upper surface B of the steering stem head Otherwise reinstall the fork leg e Tighten the fork upper clamp bolts and then the stem head nut and finally the fork lower clamp bolts Torque Upper Fork Clamp Bolts 20 N m 2 0 kgf m 15 ft Ib Steering Stem Head Nut 108 N m 11 kgf m 80 ft Ib Lower Fork Clamp Bolts 34 N m 3 5 kgf m 25 ft lb NOTE OTighten the two clamp bolts alternately two times to en sure even tightening torque GNO5028BS1 C e Install the removed parts e Check and adjust the following items after installation Steering see Periodic Maintenance chapter Throttle Cables see Fuel System chapter Headlight Aim see Periodic Maintenance chapter e Check the front
140. 039 0 043 in e Use the standard spark plug or its equivalent Spark Plug IZFR6F 11 Remove stone O K for continued use it not near edge of the belt Inspect the pulley for damage iy NN NS SS TIEREN lt gt 2222 3 555 6517009851 C 2 28 PERIODIC MAINTENANCE Periodic Maintenance Procedures Lights and Switches Operation First Step Turn on the ignition switch The following lights should go on according to below table Li Neutral Position City Tail cense Indicator Models Lights Light light Plate light E in B Fight meter unit United States goSs on Canada goes on Europe goes on goes goes goes on Malaysia 8965 gone goes x If the light does not go on inspect or replace the following item Battery see Electrical System chapter Applicable Bulb see Electrical System chapter Main Fuse 30 A and Taillight Fuse 10 A see Electrical System chapter Ignition Switch see Electrical System chapter Gear Position Switch for neutral indicator light see Electrical System chapter Harness see Wiring Inspection in Electrical System chapter e Turn off the ignition switch e The all lights should go off x If the light does not go off replace the ignition switch Second Step e Turn the ignition switch to P Park position e The taillight a
141. 093BS1 C ELECTRICAL SYSTEM 16 73 Meter Gauge e Set the minute push the reset button to return to the HOUR MINUTE mode ePush the mode button to complete the time setting process OThe clock starts counting the seconds as soon as the mode button is pushed Speedometer Inspection e Connect the leads in the same circuit as for the LCD Seg ment Inspection check 2 e Connect the oscillator A to the terminal 11 The vehi cle speed that corresponds to the input frequency will be displayed when a short wave form such as the one show in the diagram is input Example for United States Model An input frequency of 1450 Hz will display about 60 mph for Europe and Australia Models An input frequency of 870 Hz will display about 60 km h for United Kingdom Model An input frequency of 1390 Hz will display about 60 mph for Canada and Malaysia Models An input frequency of 910 Hz will display about 60 mph lf the meter does not function correctly replace the meter unit an oscillator is unavailable check the speedometer as follows Olnstall the meter unit OUse the jack and the attachment jack to lift the rear wheel Special Tools Jack 57001 1238 Jack Attachment 57001 1571 OTurn the ignition switch ON OTurn the rear wheel by hand to see if the speedometer shows the vehicle speed that corresponds to the wheel rotation lf it does not show properly inspect the speed sensor and
142. 1 ECU 7 Ignition Fuse 10 12 Starter Relay 2 Joint Connector 8 Relay Box 13 Battery 3 Engine Stop Switch 9 ECU Main Relay 14 Fuse 30A 4 Ignition Switch 10 Fuel Pump Relay 15 Frame Ground 5 Fuse Box 11 Main Fuse 30A 16 Fuel Pump FUEL SYSTEM DFI 3 87 Ignition Coils 1 2 Service Code 51 52 Ignition Coil 1 Ignition Coil for Front Cylinder Service Code 51 Ignition Coil 2 Ignition Coil for Rear Cylinder Service Code 52 Removal Installation CAUTION Never drop the ignition coils especially on a hard surface Such a shock to the ignition coil can dam age it e See Ignition Coil Removal Installation of the Ignition Sys tem section in the Electrical System chapter Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition SW OFF e Remove the ECU see this chapter Do not disconnect the ECU connector e Connect a digital voltmeter A as shown using two nee dle adapters 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 SW ON Ignition Coil Input Voltage at ECU Connections for Ignition Coil 1 Meter BK lead terminal 39 Meter Battery Terminal Connections for Ignition Coil 2 Meter BK G lead terminal 52 Meter Battery Terminal Standard Battery Voltage 12 5 V or more x If the reading is out of th
143. 16 41 Ignition System A WARNING The ignition system produces extremely high volt age Do not touch the spark plugs ignition coils or spark plug high tension cables while the engine is running or you could receive a severe electrical shock CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition switch is on or while the engine is running This is to prevent IC igniter damage in the ECU Do not install the battery backwards The negative side is grounded This is to prevent damage to the IC igniter in the ECU and the diodes Ignition Coil Removal e Remove Left Engine Cover see Frame chapter Fuel Tank for Rear Ignition Coil see Fuel System chap ter Spark Plug Caps Ignition Coil Mounting Nuts A e Remove Primary Leads A Ignition Coil B 16 42 ELECTRICAL SYSTEM Ignition System Ignition Coil Installation Connect the primary leads to the ignition coil terminals and run the secondary cables according to the Cable Wire and Hose Routing section in the Appendix chapter A Front Ignition Coil R G Lead BK Lead B Rear Ignition Coil R G Lead BK G Lead C Bracket D Clamps e Do not position the secondary cables A inside the cover B as shown e Run the cables C at positions of the figure Ignition Coil Inspection e Remove the ignition coils see this chapter e Measure the arcing dis
144. 177 18 10 13 the punch marks 14 Drive Shaft 15 Output Shaft 16 Pulley Shaft EO Apply engine oil L Apply a non permanent locking agent Lh Left hand Threads MO Apply molybdenum disulfide oil R Replacement Parts G Apply grease CAL California Model EU European Model 9 6 CRANKSHAFT TRANSMISSION Specifications Item Standard Service Limit Crankshaft Connecting Rods Connecting rod bend Connecting rod twist Connecting rod big end side clearance Connecting rod big end bearing insert crankpin clearance Crankpin diameter Marking None Marking None Connecting rod big end bearing insert thickness Brown Black Blue 0 08 0 30 mm 0 0031 0 0118 in 0 026 0 057 mm 0 001024 0 0022 in 54 981 55 000 mm 2 1646 2 1654 in 54 981 54 991 mm 2 1646 2 16500 in 54 992 55 000 mm 2 16504 2 1654 in 58 000 58 019 mm 2 2835 2 2842 in 58 000 58 010 mm 2 2835 2 28386 in 58 011 58 019 mm 2 28390 2 2842 in 1 483 1 487 mm 0 05839 0 05854 in 1 487 1 491 mm 0 05854 0 05870 in 1 491 1 495 mm 0 05870 0 05886 in TIR 0 2 100 mm 0 08 3 94 in TIR 0 2 100 mm 0 08 3 94 in 0 5 mm 0 0197 in 0 10 mm 0 0039 in 54 97 mm 2 1642 in Connecting rod big end bearing insert selection Con rod Big End Bore Diameter Crankpin Diameter Marking Connecting
145. 2038135 P 1 8 GENERAL INFORMATION Model Identification VN2000 A1 Europe Left Side View VN2000 A1 Europe Right Side View 60038137 P GENERAL INFORMATION 1 9 General Specifications Items VN2000 A1 Dimensions Overall length 2 535 mm 99 80 in Overall width 1 025 mm 40 35 AU 985 mm 38 8 Overall height 1 155 mm 45 47 Wheelbase 1 735 mm 68 31 in Road clearance 135 mm 5 32 in Seat height 680 mm 26 8 in Dry mass 340 kg 750 Ib Curb mass Front 176 kg 388 Ib Rear 195 kg 429 Ib Fuel tank capacity 21 L 5 5 US gal Fuel Unleaded and high octane gasoline see VN2000 A1 Owner s Manual Performance Minimum turning radius 3 2 m 10 5 ft Engine Type 4 stroke OHV V2 cylinder Cooling system Bore and stroke Displacement Compression ratio Maximum horsepower Maximum torque Carburetion system Starting system Ignition system Timing advance Ignition timing Front Rear Spark plugs Cylinder numbering method Firing order Valve timing Inlet Open Close Duration Exhaust Open Close Duration Lubrication system Engine oil Type Viscosity Capacity Liquid cooled 103 x 123 2 mm 4 06 x 4 850 in 2 053 mL 125 3 cu in 9 5 1 76 kW 103 PS 94 800 r min rpm CA CAL US 177 N m 18 05 kgf m 130 6 ft Ib 3 200 r min rpm CA CAL US DFI Digital Fuel Injection System Electric starter Battery and coil tra
146. 4 Air Switching Valve Inspection 5 13 Valve Clearance Adjustment 5 34 Clean Air System Hose Valve Removal ee 5 35 5 14 Valve Installation 5 35 Rocker Case 5 15 Valve Guide Removal 5 35 Rocker Case Cover Removal 5 15 Valve Guide Installation 5 35 Rocker Case Cover Installation 5 15 Valve Guide Wear Wobble Rocker C856 teer 5 16 Method etn 5 36 Rocker Case Removal 5 16 Valve Seat Inspection 5 36 Rocker Case Installation 5 18 Valve Seat Repair 5 36 Rocker Arm Assembly 5 21 Cylinders Piston 5 41 HLA Remowval 5 21 Cylinder Removal 5 41 HLA Air Bleeding 5 21 Piston Remowval 5 41 HLA Installation 5 22 Cylinder Piston Installation 5 42 Decompression Mechanism 5 23 Cylinder Wear 5 44 Decompression Mechanism Piston Wear 5 44 Removal ibn 5 23 Piston Ring Piston Ring Groove Decompression Mechanism Weal ciet 5 44 Installation ee 5 24 Piston Ring Groove Width 5 45 Oil Seal Inspectio
147. 4 in If the clearance is out of this range remove the front wheel again and check the axle wheel hub and other related parts for damage Tighten the caliper mounting bolts Torque Front Caliper Mounting Bolts 25 N m 2 5 kgf m 18 ft lb Check the front brake effectiveness A WARNING Do not attempt to ride the motorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against the disc The brakes will not function on the first application of the lever if this is not done 6J04014BS1 C 10 8 WHEELS TIRES Wheels Rims Rear Wheel Removal e Remove Muffler see Engine Top End chapter Rear Fender see Frame chapter Upper Belt Cover see Frame chapter Using the jack A and jack attachment B under the frame pipe lift the rear wheel off the ground CAUTION Be sure to put the front wheel ON the ground when removing the rear wheel or the motorcycle may fall over The motorcycle could be damaged Be sure to put the front wheel ON the ground when removing the rear wheel or the motorcycle may fall over It could cause an accident and injury Special Tools Jack 57001 1238 Jack Attachment 57001 1571 Squeeze the brake lever slowly and hold it with a band A CAUTION Be sure to hold the front brake when removing the rear wheel or the motorcycle may fall over The motorcycle could be damaged
148. 49 s Side stand switch mounting bolt 88 090 78 in lb 5 Apply oil G Apply grease L Apply a non permanent locking agent S Follow the specific tightening sequence see Engine Removal Installation chapter 15 4 FRAME Exploded View FRAME 15 5 Exploded View Torque No Fast Remarks dud N m kgf m ft lb 1 Footpeg bracket bolts 25 2 5 18 G Apply grease 15 6 FRAME Exploded View FRAME 15 7 Exploded View Torque No Fast Remarks kgf m ft Ib 1 Muffler bracket mounting bolts 25 2 5 18 CAL California model 15 8 FRAME Exploded View FRAME 15 9 Exploded View S Follow the specific tightening sequence 15 10 FRAME Special Tools Jack Attachment 57001 1571 Jack 57001 1238 FRAME 15 11 Seats Rear Seat Removal e Remove Right Side Cover see Right Side Cover Removal Remove the rear seat A by pulling the looped seat latch B and then pulling the rear seat up to the front Rear Seat Installation e Slip the rear seat hook A into the brace B on the rear fender and put the stopper C into the hole D in the seat bracket e Push down the front part of the rear seat until the lock with a click Front Seat Removal e Remove Rear Seat see Rear Seat Removal Front Seat Mounting Bolts A e Remove the front seat B by pulling the rear seat up to the rea
149. 5s 6C17073BW1 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 ECU Main Relay ECU Power Source Wiring and Ground Wiring see ECU Inspection in this chapter 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 Service Code Clearing Procedure for the service code erasure FUEL SYSTEM DFI 3 41 Self Diagnosis Service Code Table Service FI Indicator LED Light Problems 1 ON Main throttle sensor malfunction wiring open or short Inlet air pressure sensor malfunction wiring open or short Inlet air temperature sensor malfunction wiring open or short Water temperature sensor malfunction wiring open or short Atmospheric pressure sensor malfunction wiring open or short Crankshaft sensor malfunction wiring open or short Camshaft position sensor malfunction wiring open or short Speed sensor malfunction wiring open or short Gear position sensor malfunction wiring open or short Vehicle down sensor malfunction wiring open or short Subthrottle sensor malfunction wiring open or short Oxygen sensor inactication wiring open o
150. 9BN2 1 ECU 6 Ignition Fuse 10A 11 Starter Relay 2 Radiator Fan 7 Fan Fuse 20A 12 Battery 3 Ignition Switch 8 Relay Box 13 ECU Main Relay 4 Frame Ground 9 Fan Relay 5 Fuse Box 10 Main Fuse 30A 3 90 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 Subthrottle Valve Actuator Inspection Remove the air cleaner housing see Air Cleaner Housing Removal Turn the ignition switch ON e Check to see that all subthrottle valves A open and close smoothly If the subthrottle valves do not operate check the actuator internal resistance see Resistance Inspection Resistance Inspection Turn the ignition switch OFF Remove the fuel tank see this chapter e Disconnect the subthrottle valve actuator connector A Connect a digital meter to the subthrottle valve actuator connector A Measure the subthrottle valve actuator resistance Subthrottle Valve Actuator Resistance Connections BK lead 1 P lead 2 lead 3 WI BL lead 4 Standard About 5 7 Q lf the reading is out of the range replace the throttle body assy the reading is within the range check the input volta
151. 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 6 57001 1596 GE14044BS1 C bi P 5 36 ENGINE TOP END Cylinder Head Valve Guide Wear Wobble Method Olf a small bore gauge is not available inspect the valve guide wear by measuring the valve to guide clearance with the wobble method as indicated below The reading is not actual valve to guide clearance because the mea suring point is above the guide 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 to valve guide clearance e Repeat the measurement in a direction at a right angle 90 to the first x If the reading exceeds the service limit replace the guide Valve to Guide Clearance Wobble Method Standard Service Limit Exhaust 0 07 0 12 mm 0 27 mm 0 0028 0 0047 in 0 0106 in Inlet 0 04 0 10 mm 0 25 mm 0 0016 0 0039 in 0 0098 in Valve Seat Inspection Remove the valve see Valve Removal e Check the valve seat surface A between the valve B and valve seat C OMeasure the outside diameter D of the seating patt
152. ANSMISSION Crankcase Remove the left crankcase bolts 8 mm Bolts 1 A 96 mm Bolts 12 B Remove the right crankcase bolts 8 mm Bolts 1 A 96 mm Bolts 12 B e Turn the right crankcase down e Lift up the left crankcase OUsing the pry points split the crankcase halves Pry Point Front A Pry Point Rear B 6104117851 C CRANKSHAFT TRANSMISSION 9 11 Crankcase Remove the following from the right crankcase Balancer Shafts A Crankshaft B Transmission Gear Assy C see Transmission Re moval Pulley Shaft D Water Pump Shaft E see Cooling System chapter Remove the following from the left crankcase Oil Pump Shaft F see Engine Lubrication System chapter Relief Valve G see Engine Lubrication System chap ter CAUTION The right and left crankcase halves are machined at the factory in the assembled state so the crankcase halves must be replaced as a set Crankcase Assembly e With a high flash point solvent clean off the mating sur faces of the crankcase halves and wipe dry e Using compressed air blow out the oil passages in the crankcase halves e Support the crankcase bearing boss with a suitable re tainer A e Using a press and the bearing driver set C install a new bearing B or and race by pushing the bearing outer race until it bottoms out CAUTION Support the crankcase bearing boss when pushin
153. Adapter R BK Crankshaft Sensor Y OBe sure the battery is fully charged Hand Tester Range DC 10 V 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 crankshaft sensor peak voltage e Repeat the measurements 5 or more times for one crank shaft sensor Crankshaft Sensor Peak Voltage Standard 3 0 V or more xIf the reading is less than the specified value replace the crankshaft sensor lf the reading is normal check the ECU see Fuel System chapter lf the peak voltage adapter is not available the coil can be checked for a broken or badly shorted winding with the hand tester special tool NOTE 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 Disconnect the crankshaft sensor lead connector e Set the hand tester A to the x 100 O range and wire it to the crankshaft sensor lead connector B Connections Tester Connections Crankshaft Sensor Y BK x lf there is more resistance than the specified value the coil has an open wire and must be replaced Much less than this resistance means the coil is shorted and must be replaced Crankshaft Sensor Resistance Standard 420 5200 e Using the highest resistance range of the tester measure the resistance
154. C at the standard atmospheric pressure 101 32 kPa 76 cmHg abs NOTE OThe output voltage changes according to the local at mospheric pressure OThe vacuum sensor output voltage is based on a nearly perfect vacuum in the small chamber of the sensor So the sensor indicates absolute vacuum pressure x lf the output voltage is out of the usable range replace the sensor x If the output voltage is normal check the inlet air pressure sensor for vacuum other than 76 cmHg abs check the output voltage as follows GC17296BS1 3 50 FUEL SYSTEM DFI Inlet Air Pressure Sensor Service Code 12 e Remove the inlet air pressure sensor A and disconnect the vacuum hose from the sensor ODo not disconnect the sensor connector Connect an auxiliary hose B to the inlet air pressure sen sor Temporarily install the inlet air pressure sensor OConnect a commercially available digital meter C vac uum gauge D and the fork oil level gauge E to the inlet air pressure sensor Special Tools Fork Oil Level Gauge 57001 1290 Inlet Air Pressure Sensor Output Voltage Connection to Sensor Meter Y BL lead Meter BR BK lead OTurn the ignition switch ON OMeasure the inlet air pressure sensor output voltage from various vacuum readings while pulling the handle of the fork oil level gauge OCheck the inlet air pressure sensor output voltage using the following formula
155. C17277BS1 00173178 5 8017270852 C 3 20 FUEL SYSTEM DFI Troubleshooting the DFI System OThe DFI part connectors A have seals B including the ECU e Join the connector A and insert the needle adapter spe cial tool C inside the seal 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 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 DFI parts A fully charged battery is a must for conducting accurate tests of the DFI system
156. Cable A Decelerator Cable B e Install the throttle body assy OApply a non permanent locking agent to the throttle body assy holder bolts and torque them Torque Throttle Body Assy Holder Bolts 9 8 N m 1 0 kgf m 87 in lb e Stake A the cable clip B on the throttle cable holder C 3 114 FUEL SYSTEM DFI Throttle Body Assy e Apply a thin coating of grease to the throttle cable upper ends 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 front view e Turn the throttle grip and make sure that the throttle valves move smoothly and return by spring force e Check the throttle grip free play see Throttle Grip Free Play Inspection A WARNING Operation with an incorrectly routed cable could re sult in an unsafe riding condition FUEL SYSTEM DFI 3 115 Air Cleaner Element Removal e Remove Air Cleaner Cover Screws A Air Cleaner Cover B e Unscrew the air cleaner element scerw A and remove the air cleaner element B A WARNING If dirt or dust is allowed to pass through into the throttle assy the throttle may become stuck possi bly causing an accident CAUTION If dirt gets through into the engine excessive en gine wear and possibly engine damage will occur Air Cleaner Housing Removal e Remove the air cleaner
157. California Air Resources Board Addi tionally Kawasaki has incorporated an evaporative emission control system 3 in compliance with applicable regulations of the California Air Resources Board on vehicles sold in California only 1 Crankcase Emission Control System This system eliminates the release of crankcase vapors into the atmosphere Instead the vapors are routed through an oil separator to the inlet side of the engine While the engine is operating the vapors are drawn into combustion chamber where they are burned along with the fuel and air supplied by the fuel injection system 2 Exhaust Emission Control System This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this motorcycle The fuel ignition and exhaust systems of this motorcycle have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels The exhaust system of this model motorcycle manufactured primarily for sale in California in cludes a catalytic converter system 3 Evaporative Emission Control System Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere In stead fuel vapors are routed into the running engine to be burned or stored in a canister when the engine is stopped Liquid fuel is caught by a vapor separator and returned to the fuel tank The Clean Air Act which is the Federal law covering motor vehicle pollution contains what is
158. Clean or reinstall see chapter 3 Leak from oil filler cap crankcase breather hose or air cleaner drain hose Inspect and repair or replace see chapter 3 Water or foreign matter in fuel Fuel pressure regulator trouble Change fuel Inspect and clean fuel system see chapter 3 Inspect fuel pressure and replace fuel pump see chapter 3 Throttle sensor trouble Inspect see chapter 3 Fuel pressure may be low Inspect see chapter 3 Fuel pump trouble Inspect see chapter 3 Fuel injector trouble Inlet air pressure sensor trouble Inspect see chapter 3 Inspect see chapter 3 Atmospheric pressure sensor trouble Inspect see chapter 3 3 28 FUEL SYSTEM DFI DFI System Troubleshooting Guide Symptoms or Possible Causes Actions chapter Inlet air temperature sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Throttle valves or actuator trouble Inspect see chapter 3 Crankshaft sensor trouble Inspect see chapter 3 Compression SSS y SOS Spark plug loose Reinstall see chapter 16 Cylinder head not sufficiently tightened down Tighten see chapter 5 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
159. Connection BK2 BK3 BK Y 500 500 500 lt 500 500 500 500 500 lt E Tester Lead Connection ELECTRICAL SYSTEM 16 39 Charging System Charging System Circuit GP09075BW3 C 1 Ignition Switch 5 Main Fuse 30 2 Alternator 6 Starter Relay 3 Regulator Rectifier 7 Battery 4 Joint Connector 8 Load 16 40 ELECTRICAL SYSTEM Ignition System Ignition System Troubleshooting Faulty ignition Malfunctioned engine Ignition system wiring and connector inspection No good __ Repair or replace No good Spark plug inspection Replace No good Plug cap inspection Replace Good Voltage is less than the Ignition coil primary peak voltage inspection specified value Good No good Voltage is OK Voltage is zero or Peak voltage measurement almost zero is repeated 5 or more times Yes Ignition coil is defective Inspect Inspect Adapter connection is 1 Lower resistance a incorrect or adapter hand tester Use is defective KAWASAKI Hand Tester engine stop switch 3 Crankshaft sensor Ignition switch and 2 Battery voltage Battery voltage peak voltage Replace Crankshaft sensor peak voltage No good Replace bad parts ECU is defective Replace bad parts or inspect the with KAWASAKI Hand Tester GP10090B ELECTRICAL SYSTEM
160. DC aligning D the projection E on the middle camshaft cover with the rear decompression pin F e Install the rocker case on the cylinder head OFit the lower end A and upper end B of the push rod C to the tappet D and rocker arm E as shown the rocker case does not fit the cylinder head turn the crankshaft counterclockwise by one rotation 360 fur ther e Torque the rocker case bolts Torque Rocker Case Bolts 15 N m 1 5 kgf m 11 ft Ib OFirst tighten the six inside bolts A and then tighten the four outside bolts B GE20006BS2 C GE20005BS1 C ENGINE TOP END 5 21 Rocker Case Rocker Arm Assembly Prepare flat end bar A and a block B with a recess C e Press the oil chamber D for the HLA into the rocker arm end E until the chamber end is even with the step F of the hole Olnstall the oil chamber so that the air bleed hole G is placed as shown This makes HLA bleeding easier HLA Removal Remove the rocker case see this chapter Remove the rocker arms e Pull the HLA hydraulic lash adjuster B out of the rocker arm A with your fingers CAUTION Be careful not to damage or deform an HLA by tap ping it during removal or installation Do not drop the HLA or hit it sharply If it is dam aged the plunger will not operate smoothly HLA Air Bleeding e Fill a container with engine oil e Prepare a thumbtack a
161. DC is as follows ORemove the outer camshaft cover and camshaft end cover see Decompression Mechanism Removal in this chapter OTurn the crankshaft couterclockwise and position 1 pis ton at TDC aligning A the projection B on the middle camshaft cover with the front decompression pin C OTurn the crankshaft counterclockwise and position 2 pis ton at TDC aligning D the projection E on the middle camshaft cover with the rear decompression pin F e Unscrew the rocker case bolts and remove the rocker cases Front Rocker Case Bolts A Front Rocker Case B e Remove the oil pipe bolt A and pull B the oil pipe C Front Rocker Case D e Remove the rocker shaft bolts A and pull out the rocker shafts Front Rocker Case B 5 18 ENGINE TOP END Rocker Case NOTE OMark and record the rocker shafts so that they can be reinstalled in their original positions If the rocker shaft does not be pulled out easily pull it out by tightening the removed rocker shaft bolt A into the shaft B Front Rocker Case C e Remove the lash adjuster if necessary see HLA Re moval CAUTION The cylinder head and rocker case are machined in the assembled state so they must be used as a set Be careful not to mix them up for front and rear cylinders Rocker Case Installation e Be sure the oil filters A are at the end of the intake side rocker shafts B nesessary replace t
162. E MEME MP ME XE MPOXE CO C COCMOEOTON Sg ononrann x x a BL Y GC17375BW2 1 ECU 2 Oxygen Sensor 3 Decompression Fuse 10A 4 ECU Main Fuse 30A Oxygen Sensor Heater Inspection Set the hand tester A to the x 10 range and connect it to the terminals in the oxygen sensor lead connector B Black C Black D Special Tool Hand Tester 57001 1394 Oxygen Sensor Resistance Standard 14 1 19 3 O at 20 C 68 F lf the tester reading is not as specified replace the oxygen ee sensor with a new one 3 100 FUEL SYSTEM DFI FI Indicator LED Light Inspection Flow Chart Turn the ignition SW ON Does the LED light go on Yes goes on Run the engine with idling Does the LED light go off o stays on Does the LED light go off after 10 20 seconds Turn the ignition SW OFF No DFI and ignition systems are normal No Yes goes off stayed on Repair or replace the meter or wiring unlit Check the LED light oil pressure switch and the wiring Good DFI and ignition systems are considered to be normal DFI and ignition systems are abnormal Turn the ignition SW OFF End of inspection Go to self diagnosis Ask the rider if the problem occurs again Yes occurs Replace the ECU No 66172128 F F
163. ELECTRICAL SYSTEM 16 79 Meter Gauge Meter Unit Circuit O 3 Meter Unit Odometer Trip Meter Clock LCD Speedometer Fuel Meter Illuminator LED Fuel Indicator LED Water Temperature Warning Fl Oil Pressure Warning Indicator LED Mode Button Reset Button High Beam Indicator Light Turn Signal Indicator Light Neutral Indicator Light Speed Sensor Fuel Level Sensor GPi7ilO0BW3 C Turn Signal Control Relay Fuel Reserve Switch Oil Pressure Warning Light Switch Joint Connector Frame Ground Gear Position Switch Electronic Control Unit Joint Connector Water Temperature Sensor Fuse Box Ignition Fuse 10 A Ignition Switch Main Fuse 30A Battery 16 80 ELECTRICAL SYSTEM Air Switching Valve Air Switching Valve Operation Test e Pull the air switching valve hose A out of the right air cleaner base e Start the engine and run it at idle speed e Plug the air switching valve hose end with your finger and feel vacuum pulsing in the hose xIf there is no vacuum pulsation check the hose line for leak If there is no leak check the air switching valve see Air Switching Valve Unit Test e Apply a soap and water solution or rubber lubricant to the end of the air switching valve hose A and install the hose on the fitting B Air Switching Valve Unit Test e Remove the air swi
164. ELS TIRES Tires Air Pressure Inspection Adjustment e Refer to Tire Inspection in the Periodic Maintenance chap ter Tire Inspection e Refer to Tire Inspection in the Periodic Maintenance chap ter Tire Removal Remove the following Wheel see Front Wheel Removal Rear Wheel Re moval Brake Disc see Brakes chapter Valve Core let out the air 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 Remove the tire from the rim using a commercially avail able tire changer NOTE OThe tires cannot be removed with hand tools because they fit the rims too tightly Tire Installation A WARNING To ensure safe handling and stability use only the standard tires for replacement inflated to the stan dard pressure 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 val
165. EM Battery Battery Removal CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition switch in ON as this could damage the ECU Electronic Con trol Unit Never reverse the connections of the battery this could damage the ECU e Turn off the ignition switch e Remove Seats see Frame chapter Screws A Battery Cover B e Disconnect the negative cable A from the battery first e Slide the red cap out e Disconnect the positive cable B from the battery e Pull the battery C out of the case e Clean the battery using a solution of baking soda and wa ter Be sure that the wire connections are clean Battery Installation e Visually inspect the surface of the battery container any sings of cracking or electrolyte leakage from the sides of the battery e Face the terminal forward A and put the battery into the battery case CAUTION Do not install the battery backwards e Connect the positive cable B red cap to the terminal first and then the negative cable C to the terminal e Apply a light coat of grease on the terminals to prevent corrosion e Cover the terminals with the red cap CAUTION If each battery cable is not correctly disconnected or connected sparks can arise at electrical connec tions causing damage to electrical and DFI parts e Put the battery cover on the battery e Tighten the scr
166. FT TRANSMISSION Crankcase e Install Oil Pan see Engine Lubrication System Oil Filter see Periodic Maintenance chapter Alternator Rotor see Electrical System chapter Clutch see Clutch chapter Exhaust Shift Mechanism see this chapter Balancer Mechanism see this chapter Camshaft see Engine Top End chapter Starter Motor see Electrical System chapter Pistons see Engine Top End chapter Engine see Engine Removal Installation chapter Starter Clutch Disassembly e Refer to Starter Clutch Disassembly in the Clutch chapter Starter Clutch Assembly e Refer to Starter Clutch Assembly in the Clutch chapter Starter Clutch Inspection e Refer to Starter Clutch Inspection in the Clutch chapter Starter Torque Limiter Check e Refer to Starter Torque Limiter Check in the Clutch chap ter CRANKSHAFT TRANSMISSION 9 19 Crankshaft Connecting Rods Connecting Rod Removal Remove the crankshaft e Remove the connecting rod big end bolts and take off the rod and cap along with the bearing inserts from the crankshaft A NOTE OMark and record the locations of the connecting rods B and their big end caps C with the bearing inserts left attached so that they can be installed in their original positions CAUTION To prevent damage to the crankpin surfaces do not allow the connecting rod bolts to bump against the crankpins Connecting Rod Installation Big End Cap A Connecting Rod B OUT Mark C
167. FT TRANSMISSION Transmission e Unscrew the bolts A and remove the water pipes B e Remove the bolts C and pull down the rear master cylin der D with the hoses e Remove Reserver Tank Cap Gear Position Sensor Lead Connector Inner Transmission Cover Bolts E Inner Transmission Cover F e Remove the outer and inner belt cover on the engine left side see Final Drive chapter e Unscrew the rear shift lever bolt and remove the rear shift lever see Shift Pedal Removal e Remove the circlip A on the shift shaft B e Remove the shift shaft A while pushing B the shift mechanism arm C towards the shift shaft e Unscrew the nut A and remove the gear set lever B and its spring C External Shift Mechanism Installation e Install the gear set lever A collar B spring C and spacer D in the stud and tighten the nut E Torque Gear Set Lever Nut 78 N m 0 8 kgf m 69 in Ib 6113150851 C CRANKSHAFT TRANSMISSION 9 33 Transmission OApply the spring end A to the wall B of water pump room e Put the washer A on the shift shaft B and install the shift mechanism assy C e Be sure that the spring A and pin B are in position e Be sure that the dowel pins C are in position e Replace the gasket for inner transmission cover with a new one e Install the inner transmission cover OApply silicone sealant to the grommet for the gear potion switch lead Se
168. Fuel Indicator LED TTITT I 1 6 Water Temperature Warning FI eases 5 ze TT 011 Pressure Warning Indicator LED 275222 5 2 zi J Wode Switch T 8 Reset Switch 9 High Beam Indicator Light 12V 12 10 Signal Indicator Light 12V1 12W H 1 LED Light Emitting Diode d i Ignition Switch hl aR aR Y ey ay at aM Joint Speedometer Unit eee Ee e R BL R BL ae eo o0oo0oeGcoo Headlight High R BK 12 65 BK Y Headlight Low 12 55 BK Y Front Right Tura Signal Running Position Light 12V21 5W Front Left Turn Signal Running Position Light 12 21 5 Joint Connector BK Y BK Y BK Y BK Y Front Accessory Connectors KY 1 I TEES aa v a BL Y Y R D e AKZ Y BR BK Torn Signal PT Control Relay 11 eil D Pressure Switch 0 Side Stand Switch Frame Fuse Box Relay Box Ground 1 up Fuse 1 Starter Circuit Relay Left Handlebar Switches 2 Accessory Fuse 10 2 ECU Relay 1 Starter Lockout Switch 3 Radiator Fan Fuse 20 3 Fuel Pump Relay 2 Horn Button 4 Decompression Solenoid Fuse 10A 4 Headlight Relay 3 Dimmer Switch Feu EUM na vi 5 Relay Turn Signal Fuse
169. Fuel Tank Breather Tube Blue Blue Pipe Fuel Tank Blue Fitting California Model Fuel Tank Return Tube Red Red Pipe Fuel Tank Red Fitting California Model Breather Tube Cover lead Starter Motor Lead Pipe Assembly White Brown Blue Green Red 17 40 APPENDIX Cable Wire and Hose Routing Viewed from Right Side Viewed from Upper Side 68809420845 APPENDIX 17 41 Cable Wire and Hose Routing To Thermostat Clamp Clamp Align the marks and install the coolant tube until the center of the paint mark and then tighten the clamp Pipe Assembly Clamp To Coolant Reservoir Starter Motor Clamp 10 Starter Motor Lead 11 Clamp 12 Align the marks and install the coolant tube until the center of the paint mark and then tighten the clamp 13 Clamp 14 Engine Ground Lead 15 Clamp 16 Starter Motor Lead 17 To Thermostat 18 Clamp 19 Pipe Assembly 20 Coolant Tube AON CI 17 42 APPENDIX Cable Wire and Hose Routing Viewed from A 6809429BN5 APPENDIX 17 43 Cable Wire and Hose Routing Air Cleaner Housing Rear Cylinder Fitting Front Cylinder Fitting To Rear Cylinder Fitting Red Paint Marks Throttle Cables White Paint Marks To Air Cleaner Housing Fitting Air Switching Valve To Front Cylinder Fittin
170. IC igniter in ECU trouble Crankshaft sensor trouble Ignition coil trouble Fuel air mixture incorrect Air cleaner clogged poorly sealed or miss ing Fuel tank air vent obstructed Throttle body assy loose APPENDIX 17 57 Troubleshooting Guide except DFI Throttle body assy O ring damage Air cleaner duct loose Air cleaner O ring damaged Fuel pump DFI trouble Compression low Spark plug loose Cylinder head not sufficiently tightened down Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head warped Cylinder head gasket damaged Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Decompression mechanism sticks open engine stalls when moving off HLA seizure Backfiring when deceleration Air switching valve broken Air suction valve trouble Other IC igniter in ECU trouble Engine oil viscosity too high Drive train trouble Brake dragging Engine overheating Clutch slipping Air suction valve trouble Air switching valve trouble Poor Running or No Power at High Speed Firing incorrect Spark plug dirty broken or maladjusted Spark plug cap or high tension wiring trou ble Spark plug cap shorted or not in good con tact Spark plug incorrect IC igniter in ECU trouble Crankshaft sensor trouble Ignition coil trouble Fuel air mixture incorrect Air cleaner clogged poorly sea
171. ICAL SYSTEM Wiring Diagram Australia and Malaysia Right Handlebar Swit i Front Brake Light 2 Engine Stop Switch 3 Starter Button Speedometer Unit 1 Qdometer Trip Meter Glock Liquid Crystal Display Radiator Regulator Fan Rectifier Alternator Spark 2 Plugs ches Sua 000 Rear Brake Light a Switch I sas Ignition H 00116 22822 25 2722 Air Switching Valve Atmospheric Inlet Pressure Air Sensor Pressure Fuel Sensor Level Sensor wY 2 Speedometer 3 Fuel Meter 4 1 lluminator LED 3 Fuel Indicator LED 6 Water Temperature Warning FI Oil Pressure Warning Indicator J Wode Switch 8 Reset Switch 9 High Beam Indicator Light i2 1 10 Signal Indicator Light 12 11 Neutral Indicator Light 12V1 12 LED Light Emitting Diode Ignition Switch BR BR Y er ay aL R BL a R Speedometer Unit eo o0oo0oeGcoo ight Low Front Right Turn Joint Connector R BL R BL 72 Joint Connector BK Y BK Y BK Y BK Y Front Accessory Connectors KY BL B Bk Y Busy BK Y Signal Light 12y21W Front Left Turn Signal Light 12421 asa 1 2 15 4 2 0 5 I9 Turn Signal af D Control Relay ui 176 oil 9 Pressure P witeh 0 Sid
172. NDIX 17 3 Cable Wire and Hose Routing Insert the of the grip up to the punch mark Align the mating surface with the punch mark After the installation confirm the punch mark Left Switch Housing Lead Clamp Left Switch Housing Lead The gap is 2 3 mm 0 08 0 12 in Clutch Cable Clutch Lever Assembly Punch Mark Run the cable and lead from the recess of the headlight upper cover to front of the steering stem head Left Switch Housing Lead Connector Stem Cover Brake Hose Right Switch Housing Lead Connector Run the cables brake hose and lead from the recess of the headlight upper cover to front of the steering stem head Throttle Cables Clamp Right Switch Housing Lead Right Switch Housing Lead Align the mating surface with the punch mark After the installation confirm the punch mark Throttle Cables Right Switch Housing Lead Clamp Brake Hose Clamp Left Switch Housing Lead Ignition Switch Lead Right Switch Housing Lead Connector Insert the connector in the Cover Clamp Left Switch Housing Lead Ignition Switch Lead Brake Hose Run the front right turn signal light lead between the headlight cover and steering stem base Run the front left turn signal light lead between the headlight cover and steering stem base Clamp Right and Left Turn Signal Light Leads and Right Switch Housing Lead Ignition Switc
173. OD t io TO N KOS o m D LD rco N BR BK BR BK BR BK R 6C17299BW2 1 ECU 2 Joint Connector 3 Inlet Air Temperature Sensor FUEL SYSTEM DFI 3 55 Water Temperature Sensor Service Code 14 Removal Installation CAUTION Never drop the sensor especially on a hard surface Such a shock to the sensor can damage it e Remove the fuel tank see this chapter e Disconnect the sensor connector A and unscrew the water temperature sensor B Torque Water Temperature Sensor 12 N m 1 2 kgf m 104 in Ib e Fill the engine with coolant and bleed the air from the cooling system see Coolant Filling in the Cooling System chapter Output Voltage Inspection NOTE OBe sure the battery is fully charged OThe output voltage changes according to the coolant temperature in the engine e Remove the ECU see this chapter Do not disconnect the connectors e Connect a digital voltmeter A to the ECU connector B using two needle adapters C Special Tool Needle Adapter Set 57001 1457 e Measure the output voltage of the sensor with the engine stopped and the connector joined e Turn the ignition SW ON Water Temperature Sensor Output Voltage Connections to ECU Meter O lead terminal 12 Meter gt lead terminal 25 Standard 3 38 V at coolant temperature 25 C e Turn the ignition SW OFF x If the output
174. Pe ps oo a Y R i 1 al 2 1 1 o est 0 BL Y 1 6 BL 5 5 tt _ s D l 1 W BK 7 e 4 NS 5 nii R Y BR Y 2 IL R BK 1 G BL BL G C BK G Bl L 11 HE i Ln 80173208485 FUEL SYSTEM DFI 3 15 DFI System Part Name Fl Indicator LED Light Speedometer Ignition Switch Engine Stop Switch Starter Button Ignition Coil 1 Ignition Coil 2 Air Switching Valve Atmospheric Pressure Sensor Inlet Air Pressure Sensor Water Temperature Sensor Joint Connector Main Throttle Sensor Subthrottle Sensor Injector 2 Injector 1 Subthrottle Valve Actuator Inlet Air Temperature Sensor Crankshaft Sensor Camshaft position Sensor Gear Position Switch Speed Sensor Oxygen Sensor California and European Models Self diagnosis Terminal ECU Electric Control Unit Fuel Pump Frame Ground Battery Main Fuse 30A Vehicle down Sensor Relay Box Fuel Pump Relay ECU Main Relay Compression Release Solenoid Fuse 10A ECU Fuse 10A Ignition Fuse 10A Fuse Box 3 16 FUEL SYSTEM DFI DFI System 39 38 37 36 35 34 33 32 31 30 29 28 27 260524930210 sists 661709
175. Pedal Position Adjustment Brake Pedal Removal Brake Pedal Installation Calipets ier ex tex Front Caliper Removal Rear Caliper Remowval Caliper Installation Front Caliper Disassembly Front Caliper Assembly Rear Caliper Disassembly Rear Caliper Assembly Caliper Fluid Seal Damage Caliper Dust Boot and Friction Boot Darti8g8 Caliper Piston and Cylinder 12 2 12 6 12 7 12 8 12 8 12 8 12 8 12 9 Rear Brake Pad Removal Rear Brake Pad Installation Brake Pad Wear Inspection Master Cylinder Front Master Cylinder Removal Front Master Cylinder Installation Rear Master Cylinder Removal Rear Master Cylinder Installation Front Master Cylinder 1 5 Rear Master Cylinder Disassembly Master Cylinder Assembly Master Cylinder Inspection Brake Discs Brake Disc Removal Brake Disc Installation Brake Disc Brake Disc Warp Brake Fluid Brake Fluid Level Inspection Brake Fluid Change Brake Line Bleeding
176. Periodic Maintenance chapter High Beam Bulb e Turn the High beam bulb socket A counterclockwise B and pull it out 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 OClean off any contamination that inadvertently gets on the bulb with alcohol or a soap and water solution e Replace the low beam bulb with a new one e Fit the projection A into the groove B in the housing e Push the socket in turn it clockwise and release it Olt should lock in position 16 58 ELECTRICAL SYSTEM Lighting System City Light Bulb Replacement Europe Model Remove the headlight unit see Headlight Bulb Replace ment e Pull out the socket A together with the bulb e Remove the wedge base type bulb A pull the bulb straight out of the socket B CAUTION Do not turn the bulb Pull the bulb out to prevent damage to the bulb Do not use bulb rated for greater wattage than the specified value Tail Brake Light Bulb Replacement e Remove Bolts A and Washers Cover B e Disconnect Tail Brake Light Lead Connector A e Remove Tail Brake Light Unit Mounting Nuts A Tail Brake Light Unit ELECTRICAL SYSTEM 16 59 Lighting System e Turn the license light bulb socket A counterclockwise B
177. States of America Model CA Canada Model AL Tighten all the bolts alternating diagonally two times to ensure even tightening torque 5 4 ENGINE TOP END Exploded View GE02100BN5 ENGINE TOP END 5 5 Exploded View No Fastener Remarks N m kgf m ft lb Rocker shaft bolts 12 1 2 104 Cylinder mounting bolts 25 2 5 18 L Coolant drain bolt 1 0 87 in lb 104 in Ib Camshaft chain guide bolts 104 in lb 1 2 3 4 Push rod cover bolts 5 6 Camshaft chain tensioner bolts 7 Inner camshaft cover bolts Middle camshaft cover bolts 10 Middle camshaft cover bolts L 35 mm 1 0 1 Camshaft end cover bolts 12 Decompression solenoid bolts 13 Outer camshaft cover bolts 14 Decompression Solenoid 15 Decompression Lever 16 Push Rod Decompression 17 Holder 18 Decompression Shafts 19 Spacers 20 Hydraulic Lash Adjusters 21 Push Rods Rocker Arm 22 Tappets M Apply molybdenum disulfide grease R Replacement Parts MO Apply molybdenum disulfide oil L Apply a non permanent locking agent SS Apply silicone sealant Three Bond TB1211F 9 8 12 12 L 12 p 9 ssp a po 98 DENN 5 2 4 1 1 1 1 104 in lb 104 in lb 2 2 2 104 in Ib 2 0 87 104 in Ib 5 6 ENGINE TOP END Exploded View ENGINE TOP END 5 7 Exploded View Torque No Fast Remarks ek dd Nm kgf
178. Stator Installation 16 35 Charging Voltage Inspection 16 35 Alternator Inspection 16 36 Regulator Rectifier Removal 16 37 Regulator Rectifier Installation 16 37 Regulator Rectifier Inspection 16 38 Ignition 16 40 Ignition Coil Remowval 16 41 Ignition Coil Installation 16 42 Ignition Coil Inspection 16 42 Spark Plug Removal 16 43 Spark Plug Installation 16 44 Spark Plug Cleaning Inspection 16 44 Ignition Coil Primary Peak Voltage Ue EE 16 44 Crankshaft Sensor Removal 16 45 Crankshaft Sensor Installation 16 45 Crankshaft Sensor Inspection 16 45 Camshaft Position Sensor 16 47 Camshaft Position Sensor Installation 16 47 Camshaft Position Sensor 16 47 Interlock Operation Inspection 16 47 IC Igniter Inspection 16 48 Starter 16 50 Starter Motor Removal 16 50 Starter Motor Installation 16 50 Starter Motor Disassembly 16 50 Starter Motor Assembly 16 51 Brush Inspection 16 52 Commutator Cleaning and
179. Switch Output Signal Injextor 3 Output Signal Communication for DIAG Unused Ground for Ignition System Ignition Coil 2 Signal 3 18 FUEL SYSTEM DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system OTo maintain the correct fuel air mixture F A there must be no inlet air leaks the DFI system Be sure to install the oil filler cap oil level gauge A after filling the engine oil Outer Transmission Cover B Front C 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 lead connections This will damage the ECU ODo not disconnect the battery leads or any other electrical connections when the ignition SW switch is on or while the engine is running Otherwise surge damages the connector terminals or the DFI parts 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 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 DFI elec trical conne
180. T TRANSMISSION Transmission Shift Pedal Removal e Unscrew the rear shift pedal clamp bolt A and take off the rear shift pedal B e Unscrew the bolts A and remove the left footboard B e Unscrew the rear shift lever bolt A and remove the front shift pedal B with the shift rod C 6113119851 C Shift Pedal Installation e Apply grease A to the front shift pedal shaft mark B of the rear shift lever CRANKSHAFT TRANSMISSION 9 31 Transmission e Install the front the rear shift pedal on the front shift pedal shaft so that the punched mark A on the rear shift pedal boss is aligned with the punched mark B on the front shift pedal shaft e Loosen the locknuts A and turn the shift rod B to adjust shift pedal center Shift Pedal Position C 24 mm 0 94 in OThe rear locknut has left hand threads e Torque Torque Rear Shift Lever Bolt 25 N m 2 5 kgf m 18 ft Ib Front Shift Lever Clamp Bolt 25 N m 2 5 kgf m 18 ft lb Shift Rod Locknuts 9 8 N m 1 0 kgf m 87 in Ib DN Nee 16 ERE E ED y Dy Loi 7 S _ g ES SS SO i i External Shift Mechanism Removal e Remove the mufflers see Engine Top End chapter e Remove Fuel Level Gauge Oil Filler Cap A Oil Pipe Bolt B Outer Transmission Cover Bolt C e Remove the outer transmission cover D with the oil pipe E 9 32 CRANKSHA
181. Torque Clutch Spring Bolt 9 8 N m 1 0 kgf m 87 in Ib CLUTCH 6 15 Clutch e Install the oil pipe A to the inner clutch cover B OApply grease to the O rings C D Olnstall Valve E Spring F Oil Pipe A with O ring C O ring D Positioning Plate G Inside Pipe Bolt H Torque Inside Pipe Bolts 9 8 N m 1 0 kgf m 87 in Ib e Torque the chain guide bolts J and washer K and chain guides L Torque Primary Chain Guide Bolts 9 8 N m 1 0 kgf m 87 in Ib e Be sure the dowel pins M are in position GF06052BN2 e Apply liquid gasket A to the mating surface of the inner clutch cover B NOTE OMake the application finish 20 minutes when the liquid gasket to the mating surface of the inner clutch cover is applied Sealant Kawasaki Bond Liquid Gasket Black 92104 1064 8 06054881 C 6 16 CLUTCH Clutch e Install the inner clutch cover e Tighten the inner clutch cover bolts to a snug fit e First torque the No 1 bolt and torque from the No 2 to the No 14 following the tightening order e For the No 9 10 11 bolts torque them again NOTE OThere are grommet for stator leads on the back side of the 9 10 11 bolts and torque valve of bolts falls in tightening one time Torque Inner Clutch Cover Bolts 12 1 2 104 in Ib OClamp B the stator C and crankshaft sensor D leads see Cable Wire and Hose Routing in the Appendi
182. Turn the ignition switch ON Output Voltage at Sensor Standard About 0 05 0 07 V DC xf the reading is out of the range check the speed sensor see Electrical System chapter and the wiring to ECU see wiring diagram in this section xIf the reading speed sensor and wiring are good replace the ECU GC17306BS1 C AN CO lt O C gt 00 lt XO xt C gt r Io 16 0 lt 10 ME ME ME ME ME CO c co e ex AINA ex ex ex ex ex 00 r e e aA 16 8 i 6017307BN2 1 ECU 2 Meter Assembly 3 Speed Sensor 3 66 FUEL SYSTEM DFI Gear Position Switch Service Code 25 Gear Position Switch Removal Installation e See the Switches and Sensors section in the Electrical System chapter Gear Position Switch Inspection e See the Switches and Sensors section in the Electrical System chapter NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Remove the seats see Frame chapter e Connect a digital meter A to the sensor connector B with the needle adapter set C Special Tool Needle Adapter Set 57001 1457 Gear Position Switch Input Voltage at Neutral Position Connector to Sensor Meter lead Meter gt Frame Gr
183. U The oxygen sensor must send signals output voltage continuously to the ECU If the subthrottle stepping driver fails the ECU stops the current to the subthrottle valve actuator If the oxygen sensor output voltage is incorrect the ECU stops oxygen sensor feed back mode 1 a N Method the DFI control method from medium to heavy engine load When the engine load is light like at idling or low speed the ECU determines the injection quantity by calculating from the throttle vacuum vacuum sensor output voltage and engine speed crankshaft sensor output voltage This method is called D J method As the engine speed increases and the engine load turns middle to heavy the ECU determines the injection quantity by calculating from the throttle opening throttle sensor output voltage and the engine speed This method is called a N method This depends on the number of stopped cylinders FUEL SYSTEM DFI 3 45 Main Throttle Sensor Service Code 11 The main throttle sensor is a rotating variable resistor that change output voltage according to throttle operating The ECU senses this voltage change and determines fuel injec tion quantity and ignition timing according to engine rpm and throttle opening Input Terminal A Output Terminal B Ground Terminal C Main Throttle Sensor Removal Adjustment CAUTION Do not remove or adjust the main throttle sensor A since it has been adjusted and set with precisio
184. UEL SYSTEM DFI 3 101 FI Indicator LED Light LED Light Inspection OThe FI indicator LED light A goes ON when the ignition SW is turned ON and the LED light goes OFF when the engine oil pressure is high enough the engine is running This is to ensure that the FI indicator LED light has not burned out and the DFI system and the ignition system function properly ORefer to the Meter Gauge section in the Electrical System chapter for LED Light Inspection A WARNING This inspection may produce sparks Keep the bat tery and the meter unit away from the fuel tank lf the LED light is ubnormal replace the meter unit the FI indicator LED light is normal the wiring ECU has trouble Check the wiring see next diagram If the wiring is good check the ECU for its ground and power supply see ECU section GC17329BS1 C R Y R Y JON IGNITION Oot BATTERY GC17330BW2 A ECU E Main Fuse 30A FI Indicator LED Light F Battery C Ignition Switch G Ignition Fuse 10A D Starter Relay 3 102 FUEL SYSTEM ECU ECU Removal CAUTION Never drop the ECU especially on a hard surface Such a shock to the ECU can damage it e Remove Seats see Frame chapter Rear Shock Absorber see Suspension chapter Tool Case see Frame chapter e Pull the ECU A out along with the harness lf necessary push the lock and disco
185. YSTEM DFI DFI System Troubleshooting Guide Symptoms or Possible Causes Actions detailed reference Valve not seating properly valve bent worn Inspect and repair or replace see chapter 5 or carbon accumulating on the seating surface Compression release mechanism sticks open Inspect and repair or replace see chapter 5 engine stalls when moving off HLA hydraulic lash adjuster damaged worn and replace see chapter 5 seizure or spring broken Knocking Carbon buit up in combustion chamber Repair see chapter 5 Fuel poor quality or incorrect Use high octone Change fuel see chapter 3 gasoline recommended in the Owner s Manual Spark plug incorrect Replace it with the correct plug see chapter 16 Ignition coil trouble Inspect see chapter 16 IC igniter in ECU trouble Inspect see chapter 16 Inlet air temperature sensor trouble Inspect see chapter 3 Atmospheric pressure sensor trouble Inspect see chapter 3 Miscellaneous Throttle valves won t fulley open Inspect throttle cable and lever linkage see chapter 3 Brake dragging 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 see Overheating of Troubleshooting Guide in chapter 17 Engine oil viscosity too high Change see chapter 3 Drive belt t
186. accumulating on seating surface Camshaft cam worn Inspect and replace see chapter 5 Compression release mechanism Inspect and repair or replace see chapter 5 HLA hydraulic lash adjuster damaged Inspect and replace see chapter 5 HLA oil passage clogged Inspect and repair or replace see chapter 5 Hesitation Too low fuel pressure Inspect see chapter 3 Clogged fuel line Inspect and repair see chapter 3 Cracked or obstructed inlet air pressure Inspect and repair or replace see chapter 3 sensor hose Fuel pump trouble Inspect see chapter 3 Fuel injector trouble Inspect see chapter 3 Inlet air temperature sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Atmospheric pressure sensor trouble Inspect see chapter 3 Inlet air pressure sensor trouble Inspect see chapter 3 Crankshaft sensor trouble Inspect and repair or replace see chapter 16 Ignition coil trouble Inspect and repair or replace see chapter 16 Loose terminal of battery lead or engine Inspect and repair see chapter 16 ground lead Delay of ignition timing Inspect pickup coil and IC igniter in ECU y see chapter 16 Poor acceleration 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 Inspect see chapter 3 and repla
187. ack Brown Pipe Thermostat Cap Throttle Cables Breather Tube Fuel Tank Breather Tube Blue Blue Pipe Blue Fitting of Fuel Tank California Model Fuel Tank Return Tube Red Red Pipe Red Fitting of Fuel Tank California Model Starter Motor Lead Starter Relay Lead Lead Canister California Model Separator California Model Coolant Reservoir Tube Black Brown Pipe Coolant Reservoir Coolant Reservoir Fuel Tank Breather Tube Blue Blue Pipe Right Under of Frame Except California Model Pipe Assembly Cover Vacuum Tube White White Pipe Throttle Body California Model Green Tube Green Green Pipe Air Switching Valve and Air Cleaner California Model 17 50 APPENDIX Cable Wire and Hose Routing 6809432885 APPENDIX 17 51 Cable Wire and Hose Routing California Model Front Starter Motor Lead Clamp To Red Fitting of Fuel Tank To Blue Fitting of Fuel Tank To Thermostat To Air Switching Valve To Throttle Body 10 Bolt Position the red tape of the starter motor at diagonal lines in the figure 11 Clamp 12 Pipe Assembly 13 Green Tube 14 Align the marks and install the tubes until the center of the paint mark and then tighten the clamp 15 Clamp 16 Clamp 17 Blue Tube 18 Red Tube 19 Blue Tube 20 Align the marks and install the tubes until the center of the paint mark
188. ain when the slot goes past the nearest hole 1 07000851 10 10 WHEELS TIRES Wheels Rims e Bend the cotter pin A over the nut as shown e Visually inspect the tire for stuck any grease If any grease have stuck to the surface of the tire wash the tire clean with soap and water solution Check the rear brake effectiveness A WARNING Do not attempt to ride 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 Raise the front or rear wheel off the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1571 Spin A the wheel lightly and check for roughness or binding If roughness or binding is found replace the hub bearings e Inspect the roughness of the wheel bearing by pushing and pulling the wheel If roughness is found replace the hub bearing e Inspect the wheel for small cracks dents bending or warp xIf there is any damage to the wheel replace the wheel gj040201 tif WHEELS TIRES 10 11 Wheels Rims Remove the wheel and support it without the tire by the axle Measure the rim runout radiator A and axial B with a dial gauge lf the rim runout exceeds the service limit check the hub bearings Replace them if they are damaged x lf the problem is
189. ake Type Size Front BRIDGESTONE BATTLAX BTO20F 150 80R 16M C 71V Rear 7 0 mm 0 28 in Rear BRIDGESTONE BATTLAX BTO20R 200 60R 16M C 79V 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 Inside Circlip Pliers 57001 143 Bearing Remover Head 25 x 28 57001 1346 W Bearing Driver Set Bearing Remover Shaft 613 57001 1129 57001 1377 Jack Jack Attachment 57001 1238 57001 1571 Bearing Remover Head 20 x 22 57001 1293 W ST5715718T C 10 6 WHEELS TIRES Wheels Rims Front Wheel Removal e Unscrew the front brake caliper mounting bolts A and remove the brake calipers B with the hose installed e Loosen Front Axle Clamp Bolts Right Side Only A Front Axle B OUsing the special tool jack A and the jack attachment B under the frame pipe and a commercially available jack C under the engine lift the front wheel off the ground until the rear wheel touches the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1571 CAUTION Be sure to put the rear wheel ON the ground when removing the front wheel or the motorcycle may fall over The motorcycle could be damaged A WARNING Be sure to put the rear wheel ON the ground when remov
190. ake fluid reservoir e Remove the reservoir cap A plate B and diaphragm C GS13000BS1 C 2 40 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Follow the procedure below to install the rear brake fluid reservoir cap correctly OFirst tighten the rear brake fluid reservoir cap B clock wise C by hand until slight resistance is felt indicating that the cap is seated on the reservoir body then tighten the cap an additional 1 6 turn D while holding the brake fluid reservoir body A Remove the rubber cap from the bleed valve A on the front caliper B e Attach a clear plastic hose C to the bleed valve and run the other end of the hose into a container e Fill the reservoir with new brake fluid Temporarily install the reservoir cap Change the brake fluid as follows 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 ORepeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes Open the bleed valve A Pump the brake lever and hold it B Close the bleed valve C Release the brake lever D Front Brake Repeat the above steps for other caliper Remove the clear plastic hose e Install the reservoir cap
191. al aces Coupling Bearing Installation rri ene ue da ER Coupling Bearing Inspection and Lubrication 11 14 Rubber Damper ener 11 14 11 2 FINAL DRIVE Exploded View FINAL DRIVE 11 3 Exploded View Front Gear Case Torque Fastener ft lb Engine pulley inside cover bolts 104 in Ib Engine pulley mounting nut Rear axle nut Rear coupling stud bolts Ring screws 61 in Ib G Apply grease L Apply a non permanent locking agent R Replacement Parts MO Apply molybdenum disulfide oil 11 4 FINAL DRIVE Specifications Item Standard Service Limit Drive Belt Make Belt deflection 44 1 N 4 5 kgf force When installing new belt or engine is remounted GATES 133T 2 5 4 0 mm 0 10 0 16 in 2 5 mm 0 10 in FINAL DRIVE 11 5 Special Tools Inside Circlip Priers Pulley Holder 57001 143 57001 1572 _ j o 5 Z ST571572ST Oil Seal amp Bearing Remover Grip 57001 1058 57001 1591 875715915 C Bearing Driver Set 57001 1129 11 6 FINAL DRIVE Drive Belt The drive belt must be checked and adjusted in accor dance with the Periodic Maintenance Chart for safety and to prevent excessive wear If the belt becomes badly worn or maladjusted either too loose or too tig
192. al 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 V xIf the reading stays on battery voltage and never shows 0 V Check the ECU and fuel pump relay xIf 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 FUEL SYSTEM DFI 3 85 Fuel Pump Service Code 45 Power Source Voltage Inspection NOTE OBe sure the battery is fully charged e Remove the ignition coil bracket cover see Frame chap ter e Connect a digital voltmeter A to the fuel pump connector B 3P using the needle adapter C Special Tool Needle Adapter Set 57001 1457 e Measure the power source voltage with the engine stopped and with the pump connector joined e Turn the ignition SW ON Pump Power Source Voltage Connections to Pump Connector Tester gt Y R lead D Tester gt Battery Terminal E Standard Fuel Pump F x lf the reading is good the power source voltage is normal In
193. alant Three Bond TB1211F OTighten the inner transmission cover bolts to a snug fit OTorque the bolts following the tightening order No 1 No 15 OFor the No 1 and 2 bolts torque them again Torque Inner Transmission Cover Bolts 12 1 2 kgf m 104 in Ib 6113124851 C 9 34 CRANKSHAFT TRANSMISSION Transmission 6113149892 e Apply grease to the O rings and install the water pipes Torque Water Pipe Bolts 9 8 N m 1 0 87 in Ib e Be sure the dowel pins A are in position e Replace the gasket with a new one e Install the outer transmission cover with the oil pipe OTighten the outer transmission cover bolts to a snug fit OTorque the bolts following the tightening order No 1 No 9 and torque them again OApply a non permanent locking agent to the oil pipe bolt A and torque it Torque Outer Transmission Cover Bolts 12 N m 1 2 kgf m 104 in Ib Oil Pipe Bolt 9 8 N m 1 0 kgf m 87 in Ib 6113164851 C CRANKSHAFT TRANSMISSION 9 35 Transmission External Shift Mechanism Inspection Examine the shift shaft A for any damage xf the shaft is bent straighten or replace it lf the serrations B are damaged replace the shaft lf the spring C D is damaged in any way replace it lf the shift mechanism arm E is damaged any way replace the arm with the shaft e Check the return spring pin A is not loo
194. alves B Front Rocker Case C Rear Rocker Case D 8 04028851 C Air Suction Valve Inspection e Remove the air suction valve see this chapter e Visually inspect the reeds for cracks folds warps heat damage or other damage If there is any doubt as to the condition of the reeds A replace the air suction valve as an assembly e Check the reed contact areas B of the valve holder for grooves scratches any signs of separation from the holder or heat damage 6507014851 C Air Switching Valve Removal e Remove Fuel Tank see Fuel System Chapter e Disconnect the air switching valve connector A and pull off the hoses B e Remove the air switching valve C 4 a 2 048077 P Air Switching Valve Installation Route the hoses correctly see Appendix chapter Air Switching Valve Operation Test Refer to Air Switching Valve Operation Test in the Periodic Maintenance chapter Air Switching Valve Inspection Refer to Air Switching Valve Inspection in the Electrical System chapter 5 14 ENGINE TOP END Clean Air System Clean Air System Hose Inspection e Be certain that all the hoses are routed without being flat tened or kinked and are connected correctly to the right air cleaner base air switching valve and fittings on the rocker case covers they are not correct them Replace them if they are damaged ENGINE TOP END 5 15 Rocker Case Cover
195. an the other replace both shock absorbers as a set e Visually inspect the rubber bushings C lf they show any signs of damage replace them 6 05106851 C SUSPENSION 13 19 Swingarm Swingarm Removal e Remove Rear Wheel see Wheels Tires chapter Rear Shock Absorber see Rear Shock Absorber Re moval Rear Brake Caliper see Brakes chapter Mud Guard see Frame chapter Drive Belt Lower Cover see Frame chapter e Remove Cap Swingarm Pivot Shaft Nut A e Remove Swingarm Pivot Shaft A Swingarm B Swingarm Installation e Apply plenty of grease to the bearings and oil seals e Install Collar A e Install the swingarm and insert the swingarm pivot shaft from the right side e Tighten Torque Swingarm Pivot Shaft Nut 127 N m 13 kgf m 94 ft Ib e Install the removed parts see appropriate chapters e After installing the swingarm replenish the brake fluid into the reservoir and bleed the brake line see Brake Line Bleeding in Brakes chapter 13 20 SUSPENSION Swingarm Swingarm Bearing Removal e Remove Swingarm see Swingarm Removal Sleeve A and Collar B Left Side e Remove Oil Seal A e Remove Circlip A Special Tool Inside Circlip Pliers B 57001 143 e Remove Ball Bearing A Needle Bearing Special Tool Oil Seal amp Bearing Remover B 57001 1058 SUSPENSION 13 21 Swingarm Right Side Remove Oil Seal A
196. and Tester 57001 1394 Decompression Solenoid Resistance Standard 3 0 3 7 Q the tester reading is not as specified replace the de compression solenoid with a new one GP18067BS1 C ELECTRICAL SYSTEM 16 83 Switch and Sensors Fuel Level Sensor Inspection e Remove Fuel Tank see Fuel System chapter Open the clamps e Remove Bolts A Fuel Level Sensor B 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 GP18053BS1 C 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 x lf 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 3 5Q Empty position E 213 219 O e Install a new gasket A on the fuel tank B as shown C Hollows D Front Side e Apply a non permanent locking agent to the threads of the level sensor mounting bolts and tighten it Torque Fuel Level Sensor Mounting Bolts 6 9 N m 0 70 kgf m 61 in Ib GP18054BS1 C 16 84 ELECTRICAL SYSTEM Switch and Sensors Fuel Reserve
197. and no accessories 6 clicks turns out of the fully clockwise position Rebound Damping Force Adjustment Adjuster Damping Position Force 7 8 Weak Soft Light Good Low Counterclockwise Clockwise T 1 T 1 T T Softer t Harder STD 6 STD l l l l i 0 Strong Hard Heavy Bad High 8 7 6 5 4 3 2 1 adjuster turned fully tightened 8 05110851 C Spring Preload Adjustment e Remove Seats see Frame chapter Battery Cover Measure the length A of the spring preload setting posi tion as shown B Spring End C Flange End Spring Preload Setting Length Standard 32 5 mm 1 28 in Usable Range 27 5 37 5 mm 1 08 1 48 xIf the spring action feels too soft or to stiff adjust it e To adjust the spring preload loosen the locknut A and turn the adjusting nut B to the desired position SUSPENSION 13 17 Rear Shock Absorber e Using the hook wrenches A Adjust the spring preload Special Tool Hook Wrench 57001 1580 Spring Adjustment Position Spring Setting Load Terrain Speed Force 27 5 mm Weak Soft Light Smooth Low 1 08 in T t T t t 37 5 l 1 1 l 1 48 in Stronger Hard Heavy Rough High Tighten the locknut Rear Shock Absorber Removal e Lift the rear wheel off the ground using the jack and the attachment jack Special Tools Jack 57001 1238 Attachment Jack 57001 1571 Squeeze
198. and the inlet manifold by applying compressed air CAUTION Do not immerse the throttle body or throttle assy in a high flash point solvent for cleaning This could damage the throttle sensor on the throttle body FUEL SYSTEM DFI 3 113 Throttle Body Assy e Before Installation visually inspect the mating surfaces A for any damage like dent nick rust flaw and crack Nick or rust damage can sometimes be repaired by using emery paper first No 200 then 400 to remove sharp edges or raised areas lf the damage is not repairable replace the throttle body and or the inlet manifold to prevent leakage e With a high flash point solvent clean off the mating sur faces and wipe dry e Be sure to install the dowel pins B e Fit the new gasket C into the groove Be careful not to pinch the gasket between the mating surfaces e Be sure the two dowel pins are in position Replace the flange seal A with a new one e With a high flash point solvent clean off the flange sur face of the cylinder head and wipe dry e Install the flange B and seal in the direction shown Face the smaller diameter end upwards OThe seal should be centered on the flange OApply a non permanent locking agent to the inlet manifold bolts and torque them Torque Inlet Manifold Bolts 9 8 1 0 kgf m 87 in Ib e Install the lower end of the throttle cables in the throttle pulley Accelerator
199. anics in a properly equipped shop However it contains enough detail and basic in formation to make it useful to the owner who de sires to perform his own basic maintenance and repair work A basic knowledge of mechanics the proper use of tools and workshop proce dures must be understood in order to carry out maintenance and repair satisfactorily When ever the owner has insufficient experience or doubts his ability to do the work all adjust ments maintenance and repair should be car ried out only by qualified mechanics In order to perform the work efficiently and to avoid costly mistakes read the text thor oughly familiarize yourself with the procedures before starting work and then do the work care fully in a clean area Whenever special tools or equipment are specified do not use makeshift tools or equipment Precision measurements can only be made if the proper 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 Follow the Periodic Maintenance Chart in the Service Manual eBe alert for problems and non scheduled maintenance e Use proper tools and genuine Kawasaki Mo tor
200. ankshaft 6 12 CLUTCH Clutch Clutch Installation e Install the washer A to the crankshaft B OAlign the punch mark C on the washer with the punch mark D on the crankshaft e Apply molybdenum disulfide oil to the hatched portion E of the washer e Install the spacer A to the input shaft so that its stepped side B faces inward e Put the starter torque limiter A without the pinion e Install the collor B and starter clutch gear C to the input shaft D e Engage the chain A with the sprocket B and the one way clutch C with the clutch housing D as shown e Apply molybdenum disulfide oil to the inner surface E of the sprocket CLUTCH 6 13 Clutch e Put the spacer A on the sprocket B so that its dint C side faces outward as shown OTo prevent the spacer from dropping when the sprocket installing apply grease to the spacer Do not grease the oil passages D OAlign the pin E with the hole F on the spacer e Install the sprocket to the crankshaft so that the punch mark G on the sprocket is aligned with the punch mark H on the alternator rotor within the range of 30 degree J OApply molybdenum disulfide oil K to the X the surface shown with X marks e Install the sprocket A and the clutch housing B with the chain C turning clockwise D the starter clutch gear E e Install the needle bearing A to the input shaft turning counterclo
201. apter M14 x 1 25 57001 1590 B Cylinder Compression Usable Range 284 500 kPa 2 9 5 1 kg cm 41 72 psi 2200 r min rpm e Repeat the measurement for the other cylinder e Install the spark plugs Torque Spark Plugs 17 N m 1 7 kgf m 12 ft Ib 5 32 ENGINE TOP END Cylinder Head The following table should be consulted if the obtainable compression reading is not within the us able range Problem Diagnosis Remedy Action Carbon buildup on piston and in combustion Remove the carbon deposits chamber possibly due to damaged valve stem and replace damaged parts if valve guide stem oil seal and or damaged necessary Cylinder piston oil rings This may be indicated compression is higher than usable range Cylinder compression is lower than usable range by white exhaust smoke Incorrect cylinder head gasket thickness Replace the gasket with a standard part Damaged or missing compression release mechanism Gas leakage around cylinder head Replace the compression release mechanism parts Replace damaged gasket and check cylinder head warp Bad condition of valve seats valves and valve springs HLA seizure Incorrect piston cylinder clearance Repair them if necessary Replace the HLA Replace the piston and or cylinder Piston seizure Bad condition of piston ring and or piston ring grooves Inspect the cylinder and liner and replace repai
202. ar into the head HLA could not work and the cylinder head must be re placed GE11000481 5 38 ENGINE TOP END Cylinder Head e Measure the outside diameter A of the seat surface seat with vernier calipers x lf the seat is too small repeat the 45 grind B until the diameter is within the specified range Ground Voluum C NOTE ORemove all pittings or flaws from 45 ground surface OAfter grinding with 45 cutter apply thin coat of machin ist s dye to seat surface This makes seat surface dis tinct 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 x If the seat O D is too large make the 32 grind described below 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 e Grind the seat at a 32 angle A until the seat O D B is within the specified range x lf the seat O D is within the specified range measure the seat width as described below e To measure the seat width use vernier calipers to mea sure the width C of the 45 angle portion of the seat at several places ar
203. armature has a short and the starter motor must be replaced Special Tool Hand Tester 57001 1394 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 mo tor components 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 Assy Inspection e Using the x 1 O hand tester range measure the resis tance as follows Terminal Bolt and Positive Brushes A Brush Plate and Negative Brushes B OThe reading should be zero xIf there is not close to zero ohms the brush lead has an open Replace the terminal bolt assembly and 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 Negative Brush Holders B Terminal Bolt and Yoke C OThe reading should be infinite xf 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 assembly 16 54 ELECTRICAL SYSTEM Starter Motor Starter Relay Inspection Remove the right side covers see Frame chapter Remove the coolant reserve tank then the starter relay Connect the hand tester A and 12 V battery
204. ation 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 Second Edition 1 Jan 8 2003 K LIST OF ABBREVIATIONS pound s ABDC AC ATDC BBDC BDC BTDC C DC F ft kg kgf ampere s after bottom dead center m alternating current min after top dead center N before bottom dead center Pa bottom dead center PS before top dead center psi degree s Celsius r direct current r min rpm farad s TDC degree s Fahrenheit TIR foot feet V gram s mass W hour s Q mass force liter 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 EMISSION CONTROL INFORMATION To protect the environment in which we all live Kawasaki has incorporated crankcase emis sion 1 and exhaust emission 2 control systems in compliance with applicable regulations of the United States Environmental Protection Agency and
205. ature sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Atmospheric pressure sensor trouble Inspect see chapter 3 Inlet air pressure sensor trouble Inspect see chapter 3 Air switching valve broken Inspect and replace see chapter 5 Air suction valve trouble Inspect and replace see chapter 5 After fire Spark plug burned or gap maladjusted Adjust plug gap or replace plug see chapter 16 Crankshaft sensor trouble Inspect see chapter 3 Inlet air temperature sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Inlet air pressure sensor trouble Inspect see chapter 3 Fuel injector trouble Inspect see chapter 3 Run on dieseling Atmospheric pressure sensor trouble Inspect see chapter 3 Ignition switch trouble Inspect and replace see chapter 16 Engine switch trouble Inspect and repair or replace see chapter 16 Fuel injector trouble Inspect see chapter 3 Engine overheating see Overheating of Troubleshooting Guide see chapter 17 Other Engine oil viscosity too high Change see chapter 2 3 32 FUEL SYSTEM DFI DFI System Troubleshooting Guide Symptoms or Possible Causes Actions chapter Drive belt trouble Inspect and replace se chapter 11 Brake dragging Inspect caliper fluid seal damage or clogging of master cylinder relief and s
206. aulty Crankshaft Web Length Standard 103 85 103 95 mm 4 0886 4 0925 in Service Limit 103 6 mm 4 0787 in x If the length measurement is smaller than the service limit replace the crankshaft Otherwise replace the crankcase halves as a set CAUTION The right and left crankcase halves are machined at the factory in the assembled state so they must be replaced as a set CRANKSHAFT TRANSMISSION 9 25 Balancer Mechanism Balancer Mechanism Removal Drain the engine oil see Periodic Maintenance chapter e Remove Engine see Engine Removal Installation chapter Rocker Cases see Engine Top End chapter Camshafts see Engine Top End chapter Inner Clutch Cover see Clutch chapter e Remove Inner Camshaft Cover Bolts A Inner Camshaft Cover B Inner Clutch Cover see Clutch chapter e Hold the alternator rotor A to remove the camshaft chain sprocket bolt Special Tool Flywheel amp Pulley Holder 57001 1343 B Flywheel amp Pulley Holder Adapter 57001 1547 C Remove the following holding the alternator rotor Camshaft Chain Sprocket Bolts A Camshaft Chain Sprocket B Roller Balancer Chain Sprocket Nut C Washer e Remove Balancer Chain Guide Bolts D Balancer Chain Guide E Chain Tensioner Bolts F Chain Tensioner G Spacer H Oil Pipe Bolt J Oil Pipe K Holding the balancer sprocket A with the flywheel amp pul ley holder remove the
207. autions that should be followed servicing electrical systems ODo not reverse the battery cable connections This will burn out the diodes on the electrical parts OAlways check battery condition before condemning other parts of an electrical system A fully charged battery is a must for conducting accurate electrical system tests OThe electrical parts should never be struck sharply as with a hammer or allowed to fall on a hard surface Such a shock to the parts can damage them OTo prevent damage to electrical parts do not disconnect the battery 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 ODo not use a meter illumination bulb rated for other than voltage or wattage specified in the wiring diagram as the meter or gauge panel could be warped by excessive heat radiated from the bulb OTake care not to short the leads that are directly con nected to the battery positive terminal to the chassis ground OTroubles may involve one or in some cases all items Never replace a defective part without determining what CAUSED the failure If the failure was caused by some other item or items they too must be repaired or replaced or the new replacement will soon fail again OMake sure all connectors in t
208. axle nut Rear coupling stud bolts Ring screws Rear pulley mounting nuts Brakes Brake hose banjo bolts Front brake reservoir cap screws Brake lever pivot bolt Brake lever pivot bolt locknut Front brake light switch screw Front master cylinder clamp bolts Brake disc bolts 196 78 7 8 39 25 25 12 9 8 9 8 177 127 20 108 1 5 0 15 12 177 108 44 6 9 69 25 1 5 1 0 5 9 1 2 8 8 27 2 5 0 15 0 10 0 60 0 12 0 90 2 8 104 in Ib 104 in Ib 104 in Ib 61 in Ib 87 61 in lb 22 104 in Ib 104 in Ib 104 in Ib 145 58 69 in lb 30 18 18 104 in Ib 87 87 130 94 15 80 13 in lb 1 3 in lb 104 in Ib 130 80 33 61 in Ib 51 18 13 in lb 8 7 in lb 52 in lb 10 in lb 78 in lb 20 Remarks 5 5 S see text S see text MO Lh MO Lh MO AL MO Si PERIODIC MAINTENANCE 2 9 Torque and Locking Agent Fastener Front caliper mounting bolts Front caliper assembly bolts Front brake pad pins Caliper bleed valves Front brake pad spring bolts Rear master cylinder mounting bolts Rear master cylinder push rod locknut Brake pedal clamp bolt Rear caliper mounting bolts Suspension Upper front fork clamp bolts Lower front fork clamp bolts Cover stopper bolts Front axle clamp bolts Front fork bottom Allen bolts Rear shock absorber mounting bolt and nut Swingarm pivot shaft nut Steering Handlebar clamp bolts Han
209. b Check conductivity of the bulb with the hand tester lf the bulb is open replace the bulb x Even if the bulb is replacement but the indicator light does not go on replace the meter unit GP17104BS2 C Turn Signal Indicator Light e Connect the lead to the terminal 13 and 14 as follows Neutral Indicator Light Connections Battery Positive Lead to Terminal 13 Battery Negative Lead to Terminal 14 or Battery Positive Lead to Terminal 14 Battery Negative Lead to Terminal 13 OThe turn signal indicator light A should go on xIf the indicator light does not go on inspect the bulb e Check conductivity of the bulb with the hand tester If the bulb is open replace the bulb Even ifthe bulb is replacement but the indicator light does not go on replace the meter unit GP17105B83 16 78 ELECTRICAL SYSTEM Meter Gauge High Beam Indicator Light Connect the lead to the terminal 16 and battery positive lead High Beam Indicator Light Connections Battery Positive Lead to Terminal 16 OThe high beam indicator light A should go on If the indicator light does not go on inspect the bulb e Check conductivity of the bulb with the hand tester xIf the bulb is open replace the bulb x Even if the bulb is replacement but the indicator light does not go on replace the meter unit GP17106BS2 C
210. between the crankshaft sensor leads and chassis ground Any tester reading less than infinity indicates a short necessitating replacement of the crankshaft sensor assy 8 11000551 C 8 11000851 C ELECTRICAL SYSTEM 16 47 Ignition System Camshaft Position Sensor Removal e Remove Right Engine Cover Bolts Right Engine Cover Camshaft Position Sensor Connector A disconnect Camshaft Position Sensor Bolt B Camshaft Position Sensor C Camshaft Position Sensor Installation e Apply grease to the O ring on the camshaft position sen sor e Apply a non permanent locking agent to the camshaft po sition sensor bolt A Tighten Torque Camshaft Position Sensor Bolt kgf m 87 in lb e Do not slacken the part B of the camshaft position sensor lead Clamps C 9 8 Nm 1 0 Camshaft Position Sensor Inspection e Remove Camshaft Position Sensor see Camshaft Position Sen sor Removal e Connect the camshaft position sensor A with a battery B 10 kO resister 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 the camshaft position sensor surface with the Screw driver OThen the tester indicator should flick B x lf the tester indicator does not flick replace the camshaft position sensor Interlock Operation Inspection e Using a jack and attachment raise the rear wheel off the gro
211. bly 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 N m 0 80 kgf m 69 in Ib 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 Replace the O ring A e Apply brake fluid to the outside of the pistons and push them into each cylinder by hand e Be sure to install the O rings e Tighten Torque Front Caliper Assembly Bolts 21 N m 2 1 kgf m 15 ft Ib e Install the pads see Brakes chapter e Wipe up any spilled brake fluid on the caliper with wet cloth GLO5075BS1 C 8105040251 C GLO5076BS1 C 2 44 PERIODIC MAINTENANCE Periodic Maintenance Procedures Rear Caliper Disassembly e Remove the caliper with the hose installed see Brakes chapter Remove the pads see Brakes chapter e Pull out the caliper holder A e Insert a wooden board A 5 mm 0 2 in thick inside the caliper opening e Pump the brake pedal until the pistons B push the wooden board e Remove the board and pull out the piston A by hand OThese pistons can also be removed by disc
212. bolt 9 8 1 0 87 in lb L Gear position switch mounting bolts 4 9 0 50 43 L Gear position switch lead clamp bolts 4 9 0 50 43 in Ib L Side stand switch mounting bolt 8 8 0 90 78 in lb L Regulator rectifier bolts 8 8 0 90 78 in lb Oxygen sensor 44 4 5 33 Water temperature sensor 12 1 2 104 in Ib Camshaft position sensor bolt 9 8 1 0 87 in Ib L Decompression solenoid bolts 9 8 1 0 87 in lb Starter lockout switch screw 1 2 0 12 10 in Ib Front brake light switch screw 1 2 0 12 10 in Ib Fuel level sensor mounting bolts 6 9 0 70 61 in lb L Fuel pump mounting bolts 9 8 1 0 87 in Ib L S Starter motor terminal nut 9 8 1 0 87 in lb Starter motor terminal locknut 11 1 1 95 in lb Starter motor mounting bolts 9 8 1 0 87 in lb Starter motor assembly bolts 4 9 0 50 43 in Ib Turn signal light lens screws 1 0 0 10 8 7 in Ib Front turn signal light screws 6 9 0 70 61 in lb Tail brake light unit mounting nuts 5 9 0 60 52 in lb Rear turn signal light screws 6 9 0 70 61 in lb License plate light lens mounting screws 1 2 0 12 10 in Ib PERIODIC MAINTENANCE 2 11 Specifications Item Fuel System DFI Throttle grip free play Idle speed Air cleaner element Cooling System Coolant Type recommended Color Mixed ratio Freezing point Total amount Engine Top End Valve clearance Clutch Clutch lever free play Engine Lubrication System Engine oil Type Viscosity Capacity Tires Tread depth Front Air pressure when cold F
213. can be added but the diluted coolant must be returned to the cor rect mixture ratio within a few days If coolant must be added often or the reserve tank has run completely dry there is probably leakage in the cooling system Check the system for leaks Coolant ruins painted surfaces Immediately wash away any coolant that spills on the frame engine wheels or other painted parts 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 6506000851 C PERIODIC MAINTENANCE 2 35 Periodic Maintenance Procedures Evaporative Emission Control System Inspection CAL Evaporative Emission Control System Inspection e Inspect the canister as follows ORemove the rear inner cover see Frame chapter ORemove the holder A and take out the canister B ODisconnect the hoses C from the canister OVisually inspect the canister for cracks and other damage lf the canister has any cracks or bad damage replace it with a new one NOTE OThe canister is designed to work well through the m
214. ce fuel pump Fuel injector trouble Inspect see chapter 3 Inlet air temperature sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Ignition coil trouble Inspect and replace see chapter 16 Engine oil level too high Repair see chapter 7 Spark plug dirty broken or gap maladjusted Clean spark plugs and adjust plug gap see chapter 2 Stumble FUEL SYSTEM DFI 3 31 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions chapter Too low fuel pressure Inspect see chapter 3 Fuel injector trouble Inspect see chapter 3 Throttle sensor malfunction Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Inlet air pressure sensor trouble Inspect see chapter 3 Surge Unstable fuel pressure Fuel pressure regulator trouble Inspect and replace fuel pump or kinked fuel line Inspect and repair fuel line see chapter 3 Fuel injector trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Backfiring when deceleration Spark plug dirty broken or gap maladjusted Clean spark plugs and adjust plug gap see chapter 2 Too low fuel pressure Inspect see chapter 3 Crankshaft sensor trouble Inspect see chapter 3 Fuel pump trouble Inspect see chapter 3 Throttle sensor malfunction Inspect see chapter 3 Inlet air temper
215. ck that the display A changes to the CLOCK ODO and TRIP display each time the mode button B is pushed m CLOCK ODO TRIP lf the display does not work replace the meter unit e Push the mode button A to TRIP and push the reset button B more than 2 seconds The display shows 0 0 x If the display does not show 0 0 replace the meter unit GP17088BS1 C GP17089BS1 C GP17090BS1 C 16 72 ELECTRICAL SYSTEM Meter Gauge e Push the mode button A to CLOCK e Push the reset button B more than 2 seconds then the display turns to the HOUR MINUTE mode C Oln the HOUR MINUTE mode the numbers flash on the display Check that the flashing number changes to the HOUR MINUTE display each time the reset button is pushed gt HOUR MINUTE HOUR MINUTE 4 lf the display does not work replace the meter unit e Check that the time can be set xIf the time cannot be set replace the meter unit Clock Setting e n the HOUR MINUTE mode push the reset button again to effect the HOUR setting mode OThe hour display flashes on the display e Push the mode button to set the hour e n the HOUR mode push the reset button once to effect the MINUTE setting mode OThe minute display flashes on the display e Push the mode button to set the minute GP17091BS2 C GP17092BS1 C GP17
216. ckwise B the clutch housing C e Put the pinion A on the starter torque limiter B e Put the washer C on the pinion 8 06063 52 C P 67068142 P 6 14 CLUTCH Clutch e Apply A molybdenum disulfide oil to the X mark portions of the cam damper B and install it to the crankshaft C e Install Spring Holder D and Springs E Spring Retainer F and Cam Damper Bolt G Torque the retainer bolt using the clutch holder Torque Damper Bolt 69 N m 7 0 kgf m 51 ft lb Special Tool Clutch Holder 57001 1243 8 06038 52 C e Put the spacer A the input shaft B e Install the clutch hub C and put the washer D e Put the spring washer E so that its OUT SIDE mark F faces outward e Replace the clutch hub nut G with a new one e Torque the clutch hub nut G using the clutch holder OApply molybdenum disulfide oil to the nut flange portion and threads Torque Clutch Hub Nut 135 N m 14 0 kgf m 101 ft Ib Special Tool Clutch Holder 57001 1243 e Install the friction and steel plates H starting with a fric tion plate and alternating them CAUTION If new dry friction plates and steel plates are in stalled apply engine oil to the surface of each plate to avoid clutch plate seizure e Install Rod J GF06039BS2 C Thrust Bearing K Washer L Clutch Spring Plate M e Torque the clutch spring bolts
217. consent eed aeta err ein Ep 10 18 Hub Bearings Inspectiort ii o ec ete rper tans pet ERR pee RN M EDI et 10 19 H b Bearings EUbrealopicso s del Sess e 10 19 10 2 WHEELS TIRES Exploded View M 2 5 NN P 6402045 5 C WHEELS TIRES 10 3 Exploded View Fastener Remarks Front axle nut Front axle clamp bolts 18 Rear axle nut are are cps fos UNE TRE Tire air valve nuts 13 in lb G Apply grease R Replacement Parts AL Tighten the two clamp bolts alternately two times to ensure even tightening torque 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 mm 0 02 in Radial 0 8 0 03 Axle runout 100 mm TIR 0 05 mm 0 002 in or less TIR 0 2 mm 0 008 in Wheel balance 10 g 0 35 oz or less Balance weights Usable numbers 4 pieces or less Total weights 90 g 3 17 oz or less Tires Air pressure when cold Front Up to 186 kg 410 Ib load 250 kPa 2 5 kg cm 36 psi Up to 186 kg 410 Ib load 290 kPa 3 0 kg cm 42 psi Tread depth Front 4 3 mm 0 17 in 1 mm 0 04 in DE AT CH 1 6 mm 0 063 in Up to 130 km h 80 mph 2 mm 0 08 in Over 130 km h 80 mph 3 mm 0 1 in Standard tires M
218. coolant flows through the radiator cap and hose to the reserve tank to be stored there temporarily Conversely as the engine cools down the coolant in the radiator and the water jacket contracts and the stored coolant flows back to the radiator from the reserve tank The radiator cap has two valves One is a pressure valve which holds the pressure in the system when the engine is running When the pressure exceeds 0 95 1 25 kgf cm 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 0 95 1 25 kgf cm When the engine cools down another small valve vacuum valve in the cap opens As the coolant cools the coolant contracts to from a vacuum in the system The vacuum valve opens and allows the coolant from the reserve tank to enter the radiator COOLING SYSTEM 4 5 Coolant Flow Chart 5 al RV QUIT E SESS DR A 2 B 3 1 Water Pump 8 Radiator Fan 2 Water Hose 9 Reserve Tank 3 Water Pipe 10 Cylinder 4 Thermostat 11 Water Jacket 5 Radiator Cap 12 Cylinder Head 6 Reserve Tank Hose 13 Cold Coolant 7 Radiator 14 Hot Coolant 4 6 COOLING SYSTEM Specifications Coolant provided when shipping Type recommended Permanent type antifreeze soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators Color Green Mixed ratio Soft water 50 coola
219. cover D NOTE OThe water temperature warning LED light oil pressure warning LED light and FI indicator LED light can not be exchanged Turn out the socket A counterclockwise OThese sockets are for the high beam indicator light turn signal indicator light and neutral indicator light Meter Unit Assembly Insert the bulb A so that the projections B align with the grooves C in the panel and turn in the socket clockwise e Fit the grommet A in the lower meter cover e Install Holder B Screws C e Tighten the band D as shown 16 70 ELECTRICAL SYSTEM Meter Gauge Meter Unit Inspection LCD Segment Inspection Remove the meter unit see Meter Unit Removal A Meter Unit Lead Connector CAUTION Do not drop the meter unit Such a shock to the meter unit can damage it Place the meter facing up If a meter is left upside down or sideways for any length of time it will malfunction 1 Neutral Indicator Light 2 Fl Indicator LED Light 3 Oil Pressure Warning LED Light 4 Water Temperature Warning LED Light 5 Speed Signal for Turn Signal Control Relay 6 Unused 7 Battery 8 Ignition Neutral Indicator Light and Illumination 9 Battery High Beam Indicator Light and nation 10 Speed Sensor Supply Voltage 11 Speed Sensor Signal 12 Fuel Level Sensor Signal 13 Right Turn Signal Indicator Light 14 L
220. ct the harness adapter B between the harness connector and camshaft position sensor connector e Connect a digital meter to the harness adapter leads Special Tool Throttle Sensor Setting Adapter 57001 1400 Speed Sensor Input Voltage Connector to Sensor Meter gt BLlead C Meter BK lead D e Measure the sensor input voltage with the engine stopped and with the connector joined e Turn the ignition switch ON Input Voltage at Sensor About 4 75 5 25 V DC at Ignition Standard SW ON e Turn the ignition switch OFF the reading is out of the range check the ECU for its ground and power supply see ECU section If the ground and power supply are good the ECU is suspect Replace the ECU If the reading is good check the sensor output wiring from the sensor to the ECU see witing diagram in this section xIf the witing and sensor itself are good the ECU is sus pect GC17144BS1 C FUEL SYSTEM DFI 3 63 Camshaft Position Sensor Service Code 23 lt D lt AH OOP OD OMO lt ON HOGA OG ee oio Oe QN 6017304BN2 1 ECU 3 Camshaft Position Sensor 3 64 FUEL SYSTEM DFI Speed Sensor Service Code 24 Speed Sensor Removal installation e See the Switches and Sensors section in the Electrical System chapter Speed Sensor Inspection e See the Switches and Sensors section
221. ctions are firmly reconnected before starting the engine OConnect these connectors until they click A ODo not turn the ignition SW ON while any of the DFI elec trical connectors are disconnected The ECU memorizes fault codes not spray water on 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 OTo prevent corrosion and deposits in the fuel system do not add any fuel antifreeze chemicals to fuel 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 6017036881 FUEL SYSTEM DFI 3 19 Troubleshooting the DFI System Outline When an abnormality in the system occurs the Fl indica tor LED light A and FI symbol B go 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
222. cycle parts Special tools gauges and testers that are necessary when servicing Kawasaki motorcycles are introduced by the Special Tool Catalog or Manual Genuine parts provided as spare parts are listed in the Parts Catalog e Follow the procedures in this manual care fully Don t take shortcuts 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 mainte
223. d Dampers Middle Cover B e Remove Bolts A Inside Cover B and Guide Engine Pulley Cover Installation e Confirm the position of the damper A in the inside cover B as shown OFace the thin side of the damper to outside GK11001BS1 C e Install Guide A Inside Cover B e Tighten Torque Engine Pulley Inside Cover Bolts C D 12 N m 1 2 kgf m 104 in Ib C 30 mm 1 2 in D 55 mm 2 2 in GK11002BS1 C 11 10 FINAL DRIVE Pulley and Coupling Confirm the position of the damper A in the middle cover B as shown 4H GK11003BS1 C e Install Middle Cover A Dampers B Washers C Bolts D GK11004BS1 C e Confirm the position of the damper A in the middle cover B as shown OFace the thin side of the damper to outside e Install Outside Cover A Bolt B GK11005BS1 C Engine Pulley Removal e Remove the engine pulley cover see Engine Pulley Cover Removal e Loosen the belt fully see Drive Belt Tension Adjustment in the Periodic Maintenance chapter e Flatten out the bent washer FINAL DRIVE 11 11 Pulley and Coupling Hold the engine pulley A steady with the pulley holder B and remove the pulley mounting nut C Special Tool Pulley Holder 57001 1572 Grip 57001 1591 Pull out the engine pulley from the output shaft Engine Pulley Installation e Installation is reverse of re
224. d Green Black and Black Green Ignition Coil Leads Clamp the ignition coil lead and then bend the clamp along the bracket 17 14 APPENDIX Cable Wire and Hose Routing 0000 AZ 3401 1 A E tari hien rm 55 Z1 1 2222 4 e d IGE D Ca TT OS 99 1 6969 03909 02 0009 fA O 6B09409BN5 C APPENDIX 17 15 Cable Wire and Hose Routing Seat Lock Cable Rear Harness Clamp Fit the rear harness connector in battery case Accessory Lead Terminals Decompression Solenoid Camshaft Sensor Lead Connector Gear Position Switch Lead Connector Oxygen Sensor Lead Connector California and Europe Models Speed Sensor Lead Connector Clamp California Model Return Tube Red California Model Vacuum Tube White California Model Breather Tube Blue Clamp Coolant Reservoir Tube Black Tube Green California Model Cover Tool Case Oxygen Sensor California and Europe Models Clamp Decompression Solenoid Camshaft Sensor Lead Gear Position Switch Lead Coolant Reservoir Bracket Fuel Tank Breather Tube Blue except California Model Run the breather tube inside of brake hose and in the clamp of reservoir Coolant Reservoir Level Gauge Coolant Reservoir Brake Hose Speed Sensor Front Clamp Gear
225. dard Value C Current starts to flow D Determine the battery condition after refresh charge ODetermine the condition of the battery left for 30 minutes after completion of the charge by measuring the terminal voltage according to the table below Judgement 12 6 V or higher Good 12 0 lower than 12 6 V lower than 12 0 V Charge insufficient Recharge Unserviceable Replace Charge Time h 11 6 11 8 12 0 12 2 12 4 12 6 12 8 13 0 Battery Terminal Voltage V GPOS023BS1 C v B afa ig GPO8022BS1 C 16 34 ELECTRICAL SYSTEM Charging System Alternator Rotor Removal e Remove Clutch and Damper Cam see Clutch chapter Washer A e Install suitable 2 bolts M8 A in the rotor B and remove the rotor Alternator Rotor Installation e Align the punch mark A on the crankshaft with the punch mark B on the rotor e Face the projections of the washer A to inside and align the punch mark B on the crankshaft with the punch mark C on the washer Alternator Stator Removal e Remove Regulator Rectifier Crankshaft Sensor Lead Connector Oil Pressure Switch Lead Connector Alternator Rotor see Alternator Rotor Removal Crankshaft Sensor Mounting Bolts A Crankshaft Sen sor and Clamp Alternator Stator Coil Mounting Bolts B Alternator Stator Coil C ELECTRICAL SYSTEM 16 35 Charging System Alternato
226. disc Blow the ports clean with compressed air Front Master Cylinder J Rear Master Cylinder K EA ner 6107003851 C 6107020452 C 12 18 BRAKES Brake Discs Brake Disc Removal Remove the wheel see Wheels Tires chapter Unscrew the mounting bolts A and take off the disc Brake Disc Installation e Install the brake disc A on the wheel so that the marked side B faces out e Apply a non permanent locking agent to the threads of the brake disc bolts C e Tighten Torque Brake Disc Bolts 27 N m 2 8 kgf m 20 ft lb Brake Disc Wear e Measure the thickness of each disc A at the point where it has worn the most Measuring Area B Replace the disc if the sliding surface has worn past the service limit Front Disc Thickness Standard 4 8 5 2 mm 0 189 0 205 in Service Limit 4 5 mm 0 18 in Rear Disk Thickness Standard 6 8 7 2 mm 0 268 0 283 in Service Limit 6 0 mm 0 24 in Brake Disc Warp e Jack up the motorcycle so that the wheel is off the ground see Wheels Tires chapter OFor front disc inspection turn the handlebar fully to one side e Set up a dial gage againstthe disc A as shown and mea sure disc runout while turning B the wheel by hand If the runout exceeds the service limit replace the disc Disc Runout Standard TIR 0 15 mm 0 0059 in or less Service Limit
227. dlebar Switch Housing B e Remove Front Brake Master Cylinder A Right Handlebar Switch Housing B Throttle Grip C e Unscrew the clamp bolts A and remove the handlebar B from the stem head Handlebar Installation Apply 2 stroke oil to the threads of the handlebar clamp bolts e Tighten the handlebar clamp bolts Torque Handlebar Clamp Bolts 34 N m 3 5 kgf m 25 ft Ib OThe front half of the right handlebar switch housing has a small projection A e Fit the projection into the small hole B in the handlebar and install the housing 14 6 STEERING Handlebar e Set the left handlebar switch housing A to match its mat ing surface B to the punched mark C of the handlebar e Install the handlebar switch housing e Set the clutch lever assembly A to mutch its mating sur face B to the punched mark C of the handlebar e Install Front Brake Master Cylinder see Brakes chapter STEERING 14 7 Steering Steering Check Refer to Steering Check in the Periodic Maintenance chapter Steering Adjustment Refer to Steering Adjustment in the Periodic Maintenance chapter 14 8 STEERING Steering Stem Steering Stem Removal e Remove the front wheel see Tires Wheels chapter CAUTION Be sure to put the rear wheel on the ground when removing the steering or the motorcycle may fall over The motorcycle could be damaged A WARNING Be sure to put the rea
228. dlebar holder nuts Steering stem head nut Upper front fork clamp bolts Steering stem nut Lower front fork clamp bolts Frame Front downtube nuts Upper engine bracket nuts Upper engine mounting bolts Lower engine bracket bolts Rear downtube bolts Side stand mounting bolt Side stand mounting nut Adjust bolts Footboard bracket bolts Front engine mounting nut Adjusting bolt locknuts Rear engine mounting nuts Side stand switch mounting bolt Footpeg bracket bolts Muffler bracket mounting bolts Electrical System Spark plugs 25 21 15 7 8 2 9 25 17 25 34 20 34 4 2 25 23 127 34 34 108 20 4 9 34 88 59 44 59 108 44 44 9 8 34 44 49 59 8 8 25 25 18 Torque 2 5 2 1 1 5 0 80 0 30 2 5 1 7 2 5 3 5 2 0 3 5 0 43 2 5 2 3 6 0 13 3 5 3 5 11 2 0 0 50 3 5 9 0 6 0 4 5 6 0 11 4 5 4 5 1 0 3 5 4 5 5 0 6 0 0 90 2 5 2 5 1 8 18 15 11 69 26 in lb 18 12 18 25 15 25 37 in lb 18 17 43 94 25 25 80 15 43 in lb 25 65 43 33 43 80 33 33 87 in lb 25 33 36 43 78 18 18 13 Remarks AL AL 0200 0 0 2 10 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Alternator stator coil mounting bolts 12 1 2 104 in Ib L Crankshaft sensor mounting bolts 6 9 0 70 61 in lb Oil pressure switch 15 1 5 11 Ss Speed sensor mounting
229. e B and Cage of One way Clutch Sliding Surface C of Starter Clutch Gear Sliding Surface A of Clutch Housing f GF06042BS1 C GF06044BS1 C 6 18 CLUTCH Clutch Starter Torque Limiter Check Remove the torque limiter see Clutch Removal in this chapter and visually inspect it x lf the limiter has wear discoloration or other damage replace it as a set Gear A Friction Plates B Spring C Pinion D GFO6O45BS1 C Primary Chain Wear e Hold the chain taut with a force A of about 49 N m 5 kgf m 11 in lb in some manner and measure a 20 link length B Since the chain may wear unevenly take mea surements at several places If any measurement exceeds the service limit replace the chain Also replace the sprockets and the crankshaft when the chain is replaced 1st Pin C 2nd Pin D and 21st Pin E Primary Chain 20 Link Length Standard 190 50 190 97 mm 7 50000 7 51849 in Service 193 4 mm 7 6142 in Limit GE11020181 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 Plate G Spring Seat C Springs H Spring D Spring Holders I Friction Plate E Spring Bolts J Steel Plate F Torque Clutch Spring Bolts 9 8 N m 1 0 kgf m 87 in Ib Clutch Plate As
230. e First press each right bearing A in until it bottoms out Special Tool Bearing Driver Set C 57001 1129 B e Next install the following New Circlip Distance Collar Left Bearing 8 06025 52 C 6J06060881 6J05000481 C WHEELS TIRES 10 19 Hub Bearings Wheel Bearings OReplace the circlips with new ones Special Tool Inside Circlip Pliers 57001 143 Replace the grease seals with new ones Press in the grease seals A so that the seal surface is flush B with the end of the hole OApply high temperature grease to the grease seal lips Special Tool Bearing Driver Set C 57001 1129 Hub Bearings Inspection OSince the hub bearings are made to extremely close tol erance the clearance cannot 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 bearing play roughness or binding is found replace the bearing e Examine the bearing seal B for tears or leakage the seal is torn or is leaking replace the bearing Hub Bearings Lubrication NOTE OSince the hub bearings are packed with grease and sealed lubrication is not required 6J05000581 040004 tif FINAL DRIVE 11 1 Final Drive Table of Conte
231. e OT iiaeo Oxygen Sensor Heater Removal Installation Oxygen Sensor Heater Inspection 3 75 3 78 3 78 3 79 3 79 3 80 3 81 3 82 3 82 3 82 3 83 3 83 3 83 3 84 3 85 3 85 3 87 3 87 3 87 3 88 3 88 3 88 3 89 3 89 3 89 3 90 3 90 3 90 3 90 3 91 3 93 3 93 3 93 3 94 3 94 3 94 3 95 3 95 3 95 Oxygen Sensor Heater Subthrottle Motor Driver Service er Subthrottle Motor Driver Removal Installation Subthrottle Motor Driver Oxygen Sensor Incorrect Output Voltage Service Code 94 Oxygen Sensor Removal Installation Oxygen Sensor Inspection Oxygen Sensor Heater FI Indicator LED Light LED Light Inspection otc ECU ECU Installation ECU Power Supply Inspection Fuel Line esses Fuel Pressure Inspection Fuel Flow Rate Inspection Throttle Grip and Cables Throttle Grip Free Play Inspection Throttle Grip Free Play
232. e Stand Switch Frame Fuse Box Ground 1 up Fuse Left Handlebar Switches 2 Accessory Fuse 10 i 3 Radiator Fan Fuse 20 E du D LL 4 Decompression Solenoid Fuse 10 c Seiten 8 Turn Signal Fuse 10A TiHeadlight Fuse 10A 8 Taillight Fuse 10A 9 Ignition Fuse 10 LEFT HANDLEBAR SWITCH CONNECTIONS 10 Horn Fuse 10 Starter Lockout Switch Horn Button Dimmer Switch Jurn Signal Switch Color 67 Color Rex Color ay hutch Le Push Lo Omm L Oo p Released Pulled in Relay Box 1 Starter Circuit Relay 2 EGU Relay 3 Fuel Pump Relay 4 Headlight Relay 5 Fan Relay W2LO085CH5 6 ELECTRICAL SYSTEM 16 19 Wiring Diagram Australia and Malaysia Sub Sub Fuel Fuel Camshaft Decompression throttle InjectorInjector Position solenoid Water Valve 5 Temperature Senger pu 1 Actuator ensor Gear Inlet Position i Senso Wain Air nitch Throttle Temperature Sensor Sensor iz Crankshaft ae Sensor Speed Joint Connector Kawasaki Diagnostic System Connector wak UD ser Y diagnosis La Terminal Joint Connector 3 Electronic Control Unit Rear Accessory Gonnectors HT License Plate Light 12V5W Tail Brake Lights 1221 58 Fuel R
233. e 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 6J05003BS1 C 6J05005BS1 C 6J05004BS1 C WHEELS TIRES 10 17 Tires e Install the brake disc A so that the marked side B faces out e Apply a non permanent locking agent and tighten the brake disc bolts C Torque Brake Disc Bolts 27 N m 2 8 kgf m 20 ft Ib e Adjust the wheel balance Check and balance the wheel when a tire is replaced with a new one New tires are slippery and may cause loss of control and injury A break in period of 160 km 100 mi is necessary to establish nor mal tire traction During break in avoid sudden and maximum braking and acceleration and hard cor nering Tire Repair Currently two types of repair for tubeless tires have come into wide use One type is called a temporary external re pair which can be carried out without removing the tire from the rim and the other type is called permanent internal repair which requires tire removal It is generally under stood that higher running durability is obtained by perma nent internal repairs than by temporary external ones Also permanent internal repairs have the advantage of permitting a thorough e
234. e chapter 3 Engine stalls easily Fuel pump trouble Inspect see chapter 3 Fuel injector trouble Inspect see chapter 3 Throttle sensor trouble engine stops when Inspect see chapter 3 opening the throttle Fuel pressure too low or too high Inspect see chapter 3 Inlet air temperature sensor trouble Inspect see chapter 3 Fuel pressure too low or too high Inspect see chapter 3 Fuel pressure regulator trouble Inspect and replace see chapter 3 Crankshaft sensor trouble Inspect see chapter 16 Ignition coil trouble Inspect see chapter 16 Compression Low Spark plug loose Reinstall see chapter 16 Cylinder head not sufficiently tightened down Tighten see chapter 5 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 3 30 FUEL SYSTEM DFI DFI System Troubleshooting Guide Symptoms or Possible Causes Actions chapter 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 and repair or replace see chapter 5 carbon
235. e connector A e Using an auxiliary leads supply battery power to the fan motor lf the fan does not rotate the fan motor is defective and must be replaced ELECTRICAL SYSTEM 16 67 Radiator Fan System Radiator Fan Circuit 6 15011 3 C Relay Box Radiator Fan Relay Electronic Control Unit Water Temperature Sensor Joint Connector Radiator Fan Joint Connector Fuse Box Fan Fuse 10A 10 Ignition Fuse 10A 11 ECU Fuse 30A 12 Ignition Switch 13 Main Fuse 30A 14 Battery 16 68 ELECTRICAL SYSTEM Meter Gauge Meter Unit Removal e Remove Fuel Tank see Fuel System chapter Bolt A Remove the meter assembly B backward C e Remove Bolts A Meter Unit B CAUTION Never drop the meter unit especially on a hard sur face Such a shock to the unit can damage it Place the speedometer so that the face is up If the me ter is left upside down or sideways for any length of time it will malfunction Meter Unit Installation e Install Meter Unit A Dampers B Damper C Bracket D Bolts E Meter Cover F Bolt G Meter Unit Disassembly e Remove Meter Unit see Meter Unit Removal Bracket A Screws B Upper Meter Cover C GP17132BS2 C ELECTRICAL SYSTEM 16 69 Meter Gauge e Remove Screws A Holder B Remove the grommet C from the lower meter
236. e cylinder head nuts M10 M12 and then torque them folowing the specified tightening se quence Temporary Torque M10 Cylinder Head Nuts 15 N m 1 5 kgf m 11 ft Ib M12 Cylinder Head Nuts G 29 N m 3 0 kgf m 21 16 Torque M10 Cylinder Head Nuts F 29 N m 3 0 kgf m 21 ft Ib M12 Cylinder Head Nuts G 88 N m 9 0 kgf m 65 ft lb Front Cylinder Head H Rear Cylinder Head I Torque the lower cylinder head nuts after the cylinder head nuts are torqued Torque Lower Cylinder Head Nuts 25 N m 2 5 kgf m 18 ft Ib Cylinder Head Warp e Remove the cylinder head see this chapter Lay astraightedge across the lower surface of the cylinder head at several positions e Use a thickness gauge A to measure the space between the straight edge B and the head Cylinder Head Warp Standard Service Limit 0 05 mm 0 002 in x If they cylinder head is warped more than the service limit replace it x lf they 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 Valve Clearance Adjustment NOTE OSince the hydraulic lash adjusters constantly maintain zero clearance it is not necessary to inspect or adjust the valve clearance 48120 GE14032BWi ENGINE TOP END 5 35 Cylinder Head Valve Removal Remove the cylinder head see this chapter Swing
237. e fol lowing Power Source Wiring see wiring diagram of DFI Power Source section in this chapter ECU Main Fuse 30 A see DFI Power Source section ECU Main Relay see DFI Power Source section Ignition Fuse 10 A see Electrical System chapter xIf the inspection checks good the ECU is damaged Re place the ECU The ECU itself cannot be checked or ser viced IX Bn 80173684841 3 104 FUEL SYSTEM Fuel Line Fuel Pressure Inspection NOTE OThis inspection can determine which trouble the DFI system has mechanical or electrical trouble Olt is preferable to measure the fuel pressure while run ning the motorcycle when the trouble has occurred in order to know symptom well OBe sure the battery is fully charged e Remove the fuel tank see this chapter e Remove or disconnect Air Switching Valve see Engine Top End chapter Vacuum Hoses on Throttle Body Assy Injector Connectors e Push A the joint lock claws B e Pull A the joint lock B as shown e Pull the fuel hose joint C out of the delivery pipe A WARNING Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is disconnected fuel spills out from the hose and the pipe Cover the hose connec tion with a clean shop towel to prevent fuel spillage FUEL SYSTEM DFI 3 105 Fuel Line
238. e 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 Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately e Remove Thermostat Housing see Thermostat Removal in the Cooling System chapter Air Cleaner Housing see this chapter Air Switching Valve with Hoses see Engine Top End chapter e Disconnect Vacuum Hose A from Separator California Model Vacuum Hose B from Inlet Air Pressure Sensor Subharness Connector C FUEL SYSTEM DFI 3 111 Throttle Body Assy e Remove the screws and take off the right switch housing e Remove the accelerator cable end A and decelerator cable end B at the throttle grip e Disconnect the injection connectors A e Unscrew the bolts B and remove the throttle body assy C with the throttle cables from the intake manifold e Remove the injectors see this chapter e Unscrew the mounting bolts A and remove the intake manifold B e Remove Clip A Accelerator Cable End B Decelerator Cable End C e Disconnect Subthrottle Sensor Connector A Main Throttle Sensor Connector B Subthrottle Valve Actuator Connector C e Remove the subharness D from the throttle body assy 3 112 FUEL SYSTEM DFI Throttle Body Assy careful not to damage dent nick flaw and crack the flang
239. e fuel pump bolts to a snug fit following the tightening sequence shown e Following the tightening sequence tighten the pump bolts to the specified torque Torque Fuel Pump Bolts 9 8 1 0 kgf m 87 in Ib e Tighten the pump bolts again to check the tightness in the order shown 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 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 SW ON and make sure that the fuel pump operates make light sounds for 3 seconds and then stops e Turn the ignition SW OFF xIf the pump does not work as described above inspect the power source voltage GC10018BS1 C ETE CEH ine GC10017BS1 C 3 84 FUEL SYSTEM DFI Fuel Pump Service Code 45 Operating Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Remove the ignition coil bracket cover see Frame chap ter e Connect the hand tester 25 V DC to the fuel pump con nector A with needle adapter set Speci
240. e gap is the amount of friction or steel plate warp xIf any friction plate is warped over the service limit re place it and measure the spring plate gap and adjust it if necessary If any steel plate is warped over the service limit replace it with a new one of the same thickness Friction or Steel Plate Warp Standard 0 2 mm 0 0079 in or less Service Limit 0 3 mm 0 012 in GF13010781 6 20 CLUTCH Clutch Clutch Housing Finger Inspection e Visually inspect the fingers A of the clutch housing where the tangs B of the friction plates hit them x If they are badly worn or if there are groove cuts where the tangs hit replace the housing Also replace the friction plates if their tangs are damaged and measure the spring plate gap and adjust it if necessary Outer Clutch Hub Spline Inspection e Visually inspect where the teeth A on the steel plates wear against the splines B of the outer clutch hub there are notches worn into the splines replace the outer clutch hub Also replace the steel plate with a new one of the same thickness if their teeth are damaged Cam Damper Inspection Remove the clutch housing and sprocket with the primary chain see Clutch Removal in this chapter e Visually inspect the washer A spacer B bushing C sprocket D damper cam E and damper spring F Replace any damaged parts Clutch Spring Free Length Measurement e Measure the f
241. e mating surface and the plastic parts ODo not drop the throttle body assy especially on a hard surface A WARNING The throttle body assy should never be allowed to fall Throttle may become stuck possibly causing an accident e Stuff a piece of lint free clean cloth into the throttle body assy and the inlet ports of the cylinder heads to keep dirt out of the engine A WARNING If dirt or dust is allowed to pass through into the throttle bore the throttle may become stuck possi bly causing an accident CAUTION If dirt gets through into the engine excessive en gine wear and possibly engine damage will occur e Do not remove or adjust the throttle sensors A and sub throttle valve actuator B These parts are set at the fac tory and cannot be readjusted CAUTION Adjustment of some parts could result in poor performance requiring replacement of the throttle body Throttle Body Assy and Intake manifold Installation e Turn the throttle pulley A to check that the throttle valves move smoothly and return by spring force lf the throttle valves do not move smoothly replace the throttle body e Open the butterfly valves A and wipe any carbon off the throttle bores B around the valves using a piece of lint free cloth penetrated with a high flash point solvent e Clean the bores C of the inlet manifold D as well e Blow away dirt or dust from the throttle body
242. e oil that inadvertently gets on the sen sor especially on the terminals with a high flush point sol vent 6617030452 C NH CO r XO t SF OW TON gt TON 4C LCD t xb mb mb bob lt b 00 00 CM CN CN CN CN gt COP Oo lt NI FTTTTTTTTTTTTTTTTTTTTTTI FTTTTTTTTTTTTTTTTTTTTTTI BR B BR BK BR BK 0 GC17301BW2 1 ECU 2 Joint Connector 3 Water Temperature Sensor FUEL SYSTEM DFI 3 57 Atmospheric Pressure Sensor Service Code 15 Removal CAUTION Never drop the sensor especially on a hard surface Such a shock to the sensor can damage it e Turn the ignition switch OFF e Remove the left side cover see Frame chapter e Disconnect the atmospheric pressure sensor connector A e Remove the sensor bolt B e Remove the atmospheric pressure sensor C Installation NOTE OThe atmospheric pressure sensor is the same part as the inlet air pressure sensor except for different wiring and no hose e Install the atmospheric pressure sensor A OThe stopper B must not be on the sensor holder C e Tighten the atmospheric pressure sensor bolt securely e Install the left side cover see Frame chapter Input Voltage Inspection NOTE OBe sure the batte
243. e outer clutch cover bolts D to a snug fit OFirst torque the No 1 or 15 bolts and torque the remaining bolts counterclockwise OFor the No 1 2 3 4 bolts torque them again Torque Outer Clutch Cover Bolts 12 N m 1 2 kgf m 104 in Ib A x CY ITI PTS GF05022BN2 6 8 CLUTCH Clutch e Turn the release shaft A clockwise B viewed from H until it stops e Insert the release lever C to the release shaft OAlign the projection D on the outer clutch cover E with the slit F of the release lever e Torque the release lever bolt Torque Clutch Release Lever Bolt 5 9 N m 0 60 kgf m 52in Ib 8 05023 52 C Release Shaft Removal CAUTION Do not remove the clutch release lever and shaft assembly unless itis absolutely necessary If re moved the oil seal replacement may be required e Remove Outer Clutch Cover see this chapter Circlip A Washer B Release Shaft C Release Shaft Installation e Apply high temperature grease to the oil seal lip A on the lower ridge of the outer clutch cover e Apply oil to the bearings B in the hole of the outer clutch cover e Insert the release shaft C straight into the lower hole of the outer clutch cover CAUTION When inserting the release shaft be careful not to peel remove the spring of the oil seal CLUTCH 6 9 Clutch Clutch Removal Drain the engine o
244. e standard check the ECU for its ground and power supply see ECU section x If the reading is good remove the fuel tank and check the wiring between the ECU and the primary lead terminals at the ignition coils x If the wiring is good crank the engine and check the peak voltage of the ignition coils see Electrical System chap ter in order to check the primary coils GC17363BS1 C 3 88 FUEL SYSTEM DFI Starter Control Relay Service Code 55 Starter Control Relay Removal and Installation e Refer to Starter Control Relay Inspection in the Electrical System chapter Starter Control Relay Inspection e Refer to Starter Control Relay Inspection and Electric Starter Circuit in the Electrical System chapter FUEL SYSTEM DFI 3 89 Radiator Fan Relay Service Code 56 Radiator Fan Relay Removal Installation Radiator fan relay is bult in the relay box Remove the relay box see Electrical System chapter Radiator Fan Relay Inspection e See Relay Circuit Inspection in the Electrical System chapter Remove the relay box and ECU see this chapter Do not disconnect the relay box and ECU connectors Check the wiring for continuity using the following diagram lf wiring and radiator fan relay are good check the ECU for its ground and power supply see this chapter If the ground and power supply are good replace the ECU 112 65105 601736
245. e sure the battery is fully charged A WARNING Gasoline is extremely flammable and can be explo sive under certain conditions Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Turn the ignition switch OFF Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately Turn both ignition SW and engine stop SW OFF e Wait until the engine cools down e Open the fuel tank cap A to lower the pressure in the tank 3 108 FUEL SYSTEM DFI Fuel Line e Prepare a plastic hose of the inside diameter 7 5 mm x L about 400 mm and a measuring cylinder e Remove Seat see Frame chapter Fuel Tank Bolts e Raise the fuel tank e Stuff a clean shop towel around the fuel outlet hose joint OWhile pinching the locks of the hose joint 1 with fingers disconnect the joint see Fuel Tank Removal and insert the plastic hose A quickly onto the tank outlet pipe e Secure the plastic hose with a clamp B e Run the other side of the plastic hose into the measuring cylinder C e Temporarily install the fuel tank and close the fuel tank cap A WARNING Wipe off spilled out fuel immediately Be sure to hold the measuring cylinder vertical e With the engine stopped turn the ignition SW ON The fuel pump should operate for 3 seconds and then should stop Repeat this several times until
246. e the fuel tank see Fuel System DFI chapter e Remove or disconnect Air Switching Valve see Engine Top End chapter Vacuum Hoses on Throttle Body Assy see Fuel System DFI chapter Injector Connectors see Injector Removal in the Fuel System DFI chapter e Push A the joint lock claws B e Pull A the joint lock B as shown e Pull the fuel hose joint C out of the delivery pipe A WARNING Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is disconnected fuel spills out from the hose and the pipe Cover the hose connec tion with a clean shop towel to prevent fuel spillage 2 50 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Install the new fuel hose e Pull A the joint lock B fully as shown e Insert the fuel hose joint A straight onto the delivery pipe e Push B the joint lock C until the hose joint clicks e Push and pull A the fuel hose joint B back and forth more than two times and make sure it is locked and doesn t come off Make sure the fuel hose joint is installed correctly on the delivery pipe or the fuel could leak comes off reinstall the hose joint e Run the fuel hose in accordance with the Cable Wire and Hose Routing section in the Appendix chapter e Install the removed part Start the engine and check the fuel hose for leaks Coolant Change A WARNING To avo
247. e the starter motor is grounded e Replace the O ring A with a new one e Apply a small amount of engine oil to the O ring Torque Starter Motor Mounting Bolts 9 8 N m 1 0 kgf m 87 in lb Starter Motor Terminal Nut 9 8 N m 1 0 kgf m 87 in Ib Starter Motor Disassembly e Remove the starter motor see Starter Motor Removal e Take off the starter motor assembly bolts A and remove both end covers B and pull the armature out of the yoke e Take the positive carbon brushes A out of the brush hold ers e Take off the brush plate B with brush wire from the yoke C we ELECTRICAL SYSTEM 16 51 Starter Motor e Unscrew the terminal locknut A and remove the terminal bolt B Take the positive carbon brushes and wire assy C out of the yoke NOTE ODo not remove the negative carbon brushes A from the brush plate B Starter Motor Assembly e Holding the springs A with suitable plastic washers B insert the brushes in the brush holders OFit the brush wire into the holder groove e Align the tang C with the terminal bolt D e Tighten Torque Starter Motor Terminal Locknut 11 1 1 kgf m 95 e Put the armature A among the brushes and remove the plastic washers B Install the washer A e Fit the tang B of the brush plate into the left end cover groove C 16 52 ELECTRICAL SYSTEM Starter Motor e Appl
248. ear Right Turn Signal Reserve Light 12V21W Switch Fuel Rear Left Turn Signal Pump Light 12V21W Vehicle down Joint Connector Sensor 12V18Ah Starter finu Color Code Motor Ek f meet Main Fuse 84 304 CH Chocolate DG bark Green e creen Front Brake Light Switch Engine Stop Switch Starter Button BK R Y R color R BK R Brake Lever OFF Free W2ROOS5CHS C 16 20 ELECTRICAL SYSTEM Wiring Diagram Other than United States Canada Australia and Malaysia R BL R BL 72 Air Radiator Switching Fan Regulator aisernator Valve Brace E E Atmospheric Inlet A Pressure Air Right Handlebar Switches i Front Brake Light Switch GOO gt Fuel oi Santer 2 Engine Stop Switch Level 3 Starter Button ee Sensor e Light T Switch gt 555 Ignition Boils MM Speedometer Unit 222 1 Odoneter Trip Meter Clock 25 e Liquid Grystal Display ix 2 Speedometer zz 3 Fuel Meter 4 1 lluminator LED 5 Fuel Indicator LED TTITT I 1 6 Hater Temperature Warning FI e2Se Sz ze rt Oil Pressure Warning Indicator LED 27242 5 2 zi 7 Mode Switch 1 8 Reset Switch 9 High Beam Indicator Light 12V 12 10 Turn Signal Indicator Light 12V1 12W H 1 LED Light Emitting Diode d i i Ignition Switch ini aR Y ey ay at MINI doint 1
249. ect a digital volt meter A to the connector using two needle adapters B e Turn the ignition SW ON and measure the output voltage with the connector joined OTilt the sensor 40 50 or more C right or left then hold the sensor almost vertical D with the arrow mark pointed up and measure the output voltage Vehicle down Sensor Output Voltage Connections to Sensor Meter Y R lead E Meter BR BK lead F Standard with sensor tilted 40 50 or more right or left 0 65 1 35 V with sensor arrow mark pointed up 3 55 4 45 V NOTE Olf you need to test again turn the ignition SW OFF and then ON e Turn the ignition SW OFF e Remove the needle adapters and apply silicone sealant to the seals of the connector for waterproofing Silicone Sealant Kawasaki Bond 56019 120 Seals of Vehicle down Sensor Connector x lf the output voltage is out of the specified replace the vehicle down sensor the output voltage is normal the wiring is suspect Check the wiring GC17313BS2 C NK C lt OL lt KH lt OL TON gt KO LO lt NH gt COM D 10 SF CN gt o0 r 210 co a e Tee gt a ea BL W Y R BR BK BL W 6C17314BN2 A ECU B Vehicle down Sensor 3 70 FUEL SYSTEM DFI Subthrottle Sensor Service Code 32 The subthrottle sensor is a rotating
250. educe sealing per formance Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains Install new gaskets and replace used O rings when re assembling Liquid Gasket 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 08020188 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 absolutely necessary Replace with new ones whenever S gt removed Press bearings with the manufacturer and size a marks facing out Press the bearing into place by putting RRs pressure on the correct bearing race as shown 3 SN Pressing the incorrect race can cause pressure between Ig L AL the inner and outer race and result in bearing damage gt 08020188 5 Oil Seal Grease Seal Do not remove pressed oil or grease seals unless removal is necessary Replace with new ones whenever removed Press new oi
251. edures Air Suction System Air Switching Valve Operation Test e Pull the air switching valve hose A out of the right air cleaner base e Start the engine and run it at idle speed e Plug the air switching valve hose end with your finger and feel vacuum pulsing in the hose there is no vacuum pulsation check the hose line for leak If there is no leak check the air switching valve see Air Switching Valve Inspection in Electrical System chapter Others Chassis Parts Lubrication e Before lubricating each part clean off any rusty spots with rust remover and wipe off any grease oil dirt or grime e Lubricate the points listed below with indicated lubricant NOTE OWhenever the vehicle has been operated under wet or rainy conditions or especially after using a high pressure water spray perform the general lubri cation Points Lubricate with Grease Throttle Inner Cable Upper Ends A Clutch Inner Cable Upper End Clutch Lever Pivot Apply silicone grease Brake Lever Pivot Apply silicone grease Brake Pedal Pivot Side stand Cable Lubricate with Cable Lubricant 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 A with an aerosol ca ble lubricant B PERIODIC MAINTENANCE 2 37 Periodic Maintenance Procedures e With the cable disconnected at b
252. een any two measurements Service Limit 103 10 mm 4 05905 in or 0 05 mm 0 002 in difference between any two measurements Piston Wear Measure the outside diameter A of each piston 10 2mm B up from the bottom of the piston at a right angle to the direction of the piston pin xIf the measurement is under service limit replace the pis ton Piston Diameter Standard 102 965 102 980 mm 4 053732 4 054323 in Service Limit 102 82 mm 4 04802 in Piston Ring Piston Ring Groove Wear Check for uneven groove wear by inspecting the ring seat ing The rings should fit perfectly parallel to groove surfaces If not replace the piston and all the piston rings e With the piston rings in their grooves make several mea surements with a thickness gauge A to determine piston ring groove clearance Piston Ring Groove Clearance Standard Service Limit Top 0 035 0 070 mm 0 17 mm 0 00138 0 00276 in 0 00669 in Second 0 02 0 06 mm 0 16 mm 0 00079 0 00236 in 0 00630 in xIf the piston ring groove clearance is greater than the ser vice limit measure the ring thickness and groove width as follows to decide whether to replace the rings the piston or both GE16047BS1 C GE16048BS1 C GE16020881 C ENGINE TOP END 5 45 Cylinders Piston Piston Ring Groove Width e Measure the width of the top A and second B ring grooves OUse vernier
253. eft Turn Signal Indicator Light 15 Fuel Level Warning Indicator LED Light 16 High Beam Indicator Light CAUTION Do not short each terminals When inspecting the meter unit be sure to connect each connections Check 1 e Using the auxiliary leads connect a 12 V battery A to the meter unit lead connector terminals Connections Battery Positive Terminal Terminal 7 Battery Negative Terminal Terminal 9 OWhen the terminals are connected the speedometer nee dle momentary points to the last reading and then return to the 0 position the needle function does not work replace the meter unit GP17086BS1 C GP17087BS1 C ELECTRICAL SYSTEM 16 71 Meter Gauge Check 2 e Using the auxiliary lead connect the battery positive ter minal to terminal 8 e Verify that all the LCD segments the letters and num bers of the liquid crystal display to appear for 3 seconds and the speedometer needle momentary points to the last reading and then return to the 0 position Then the clock or meters operates normally depending on the mode se lected e Disconnect the terminal 8 e Verity that all the LCD segments and symbols disappear xIf the display function does not work replace the meter unit Mode Button Operation Checks e Connect the lead in the same circuit as for the LCD Seg ment Inspection Check 2 e Che
254. elay box The headlight does not go on when the ignition switch and the engine stop switch are first turned on The headlight comes on when the engine starts running and stays on even if the engine stalls The head light goes out when the ignition switch is turned off It also goes out while the starter button is depressed Headlight Beam Horizontal Adjustment Refer to Headlight Aiming Inspection in the Periodic Main tenance chapter Headlight Beam Vertical Adjustment Refer to Headlight Aiming Inspection in the Periodic Main tenance chapter Headlight Bulb Replacement e Remove the headlight rim bolts A on both sides e Pull the headlight unit B up e Pull the headlight connectors A e Remove the headlight dust cover B Low Beam Bulb e Push the hook A to unlock ELECTRICAL SYSTEM 16 57 Lighting System e Take out the low beam bulb A CAUTION When handling the quartz halogen bulb never touch the glass portion with bare hands Always use clean cloth Oil contamination from hands or dirty rags can reduce bulb life or cause the bulb to explode OClean off any contamination that inadvertently gets on the bulb with alcohol or a soap and water solution e Replace the headlight bulb e Fit the dust cover A with the TOP mark B upward onto the bulb C firmly as shown Good D Bad E e After installation adjust the headlight aim see Headlight Aiming Inspection in the
255. ely 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 Brake Pad Wear Inspection 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 see Brakes chapter Pad Lining Thickness Standard Front 4 0 mm 0 16 in Rear 7 5 mm 0 30 in Service Limit 1 mm 0 04 in Brake Light Switch Operation e Turn on the ignition switch e The brake light A should go on when the brake lever is applied or after the brake pedal is depressed about 10 mm 0 39 in does not adjust the brake light switch e While holding the switch body turn the adjusting nut to adjust the switch Switch Body A Adjusting Nut B Light sooner as the body rises C Light later as the body lowers D CAUTION To avoid damaging the electrical connections in side the switch be sure that the switch body does not turn during adjustment 65138120 P 2 18 PERIODIC MAINTENANCE Periodic Maintenance Procedures x lf it does not go on inspect or replace the following item Battery see Electrical System chapter Brake Light Bulb see Electrical System chapter Main Fuse 30 A and Taillight Fuse 10 A see Electrical System chapter
256. en Torque Side Stand Mounting Bolt Nut 44 N m 4 5 kgf m 33 ft lb e Install Spring D Side Stand Switch E e Apply a non permanent locking agent to the side stand switch mounting bolt F Tighten Torque Side Stand Switch Mounting Bolt 8 8 N m 0 90 kgf m 78 Check that the side stand switch mounting bolt is not loos ening e Run the side stand switch lead correctly see Cable Wire and Hose Routing section in Appendix chapter GO20007BS2 C FRAME 15 21 Downtube Downtube Removal e Using the jack and the jack attachment raise the rear wheel off the ground see Wheels Tires chapter Special Tools Jack 57001 1238 Jack Attachment 57001 1571 Right Side e Remove Muffler and Exhaust Pipes see Engine Top End chapter Right Footboard see Footboard Removal Brake Pedal and Rear Master Cylinder see Brake Sys tem chapter Lower Downtube Mounting Bolts A Engine Mounting Bolt B Engine Mounting Bracket Bolts C and Bracket Upper Downtube Mounting Bolts D Downtube E Left Side e Remove Left Footboard see Frame chapter Clutch Cable see Clutch chapter Horn A Side Stand Switch Lead Connector B e Remove Lower Downtube Mounting Bolts A Engine Mounting Bolt B Engine Mounting Bracket Bolts C and Bracket Upper Downtube Mounting Bolts D Downtube E 15 22 FRAME Downtube Downtube Installation Tighten the bolts to the specified
257. ener Nm karm Remarks 1 Upper front fork clamp bolts 20 2 0 15 2 Lower front fork clamp bolts 34 3 5 25 AL 3 Cover stopper bolts 4 2 0 43 37 in lb 4 Front axle clamp bolts 25 2 5 18 AL 5 Front fork bottom Allen bolts 23 2 3 17 L L Apply a non permanent locking agent R Replacement Parts G Apply grease AL Tighten the two clamp bolts alternately two times to ensure even tightening torque 13 4 SUSPENSION Exploded View GMO2090BW5 SUSPENSION 13 5 Exploded View Torque No Fast Remarks 9 N m ftlb 1 Rear shock absorber bolt and nut 59 6 0 43 2 Swingarm pivot shaft nut 127 13 94 G Apply grease R Replacement Parts 13 6 SUSPENSION Specifications Item Standard Front Fork per one unit Fork inner tube diameter 49 mm 01 9 Fork spring setting Non adjustable Air pressure Atmospheric pressure Non adjustable Rebound damper setting Non adjustable Fork oil viscosity SAE 10W 20 Fork oil capacity 605 2 5 mL 20 5 0 085 US oz completely disassembled and dry approx 515 mL 17 4 US oz when changing oil Fork oil level Fully compressed without fork spring below from inner tube top 203 mm 2 mm 7 99 0 08 in Fork spring free length 470 9 mm 18 54 in Service limit 461 mm 18 1 in Rear Shock Absorber Rebound damper setting 6 clicks out from the fully clockwise position Spring preload setting Length between spring
258. er 2 2 44 4 11 15 12 Ignition Coil Bracket Cover 88800 15 13 Ignition Coil Bracket Cover Installation 0 42 15 13 stot ick ECT S 15 14 Front Fender Removal cccccccccccececececcuueceeuueeseueeeueeeeeueeeuuaueeeueeeaueeeauueeauueeaueesaseeeaeeeenes 15 14 Rear Fender Removal ei le Ns 15 14 Rear Eender InstallatiOn i ii ro eret e ence ER 15 14 Batlery Case TOO Case tig m 15 15 Tool Case Removal ici le 15 15 Battery Case Removal 15 16 Footboard and S desta A 15 18 Right Footboard RE MOVall 15 18 Right Footboard Installation i dh aus tre cbe tb daten 15 18 Right Footboard Disassembly 15 18 Right Footboard Assembly Left Footboard Removal Left Footboard Installation Left Footboard Disassembly e c eren t pon et acid Phe deste
259. er 57001 1129 57001 1547 875715475 C CRANKSHAFT TRANSMISSION 9 9 Crankcase Crankcase Disassembly Drain the engine oil see Periodic Maintenance chapter e Remove Engine see Engine Removal Installation chapter Cylinder Blocks see Engine Top End chapter Pistons see Engine Top End chapter Starter Motor see Electrical System chapter Camshafts see Engine Top End chapter Balancer Mechanism see this chapter External Shift Mechanism see this chapter Clutch see Clutch chapter Alternator Rotor see Electrical System chapter Oil Filter see Periodic Maintenance chapter Oil Pan see Engine Lubrication chapter e Loosen Transfer Gear Nut A on Output Shaft Transfer Gear Nut B on Pulley Shaft NOTE OThe transfer gear nut on the output shaft has left hand threads Turn the nut clockwise and remove it Special Tool Gear Holder C 57001 1574 e Remove Transfer Gear Nuts Transfer Gears D e Temporarily install the balancer gear to the rear balancer shaft e Holding the rear balancer gear with the flywheel amp pulley holder remove the rear balancer sprocket bolt A see Balancer Mechanism Removal in this chapter Special Tool Flywheel amp Pulley Holder 57001 1343 e Remove Oil Pump Chain Tensioner Bolt B Spring C Chain Tensioner D Chain E Rear Balancer Sprocket F e Remove Collor A on Pulley Shaft B O ring C 91048171 P 9 10 CRANKSHAFT TR
260. er C If the manufacturer s instructions are not available use the following procedure Seat Cutter Operation Care 1 This valve seat cutter is developed to grind the valve seat for repair Therefore the cutter must not be used for other purposes than seat repair Do not drop or shock the valve seat cutter or the diamond particles may fall off Do not fail to apply engine oil to the valve seat cutter be fore grinding the seat surface Also wash off ground parti cles sticking to the cutter with washing oil CAUTION Do not use a wire brush to remove the metal par ticles from the cutter It will take off the diamond particles 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 During operation wash off any ground particles sticking to the cutter with washing oil After use wash it with washing oil and apply thin layer of engine oil before storing Operating Procedures e Clean the seat area carefully e Coat the seat with machinist s dye e Fit a 45 cutter A into the holder B and slide it into the valve guide e Press down lightly on the handle and turn it right or left C Grind the seat 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
261. er Hose Water Pipe Clamp Water Hose Front 17 30 APPENDIX Cable Wire and Hose Routing 6809423885 C APPENDIX 17 31 Cable Wire and Hose Routing Coolant Hose Clamp Clamp Coolant Level Gauge Tube Frame Bracket Clamp Clamp Coolant Reservoir Front 17 32 APPENDIX Cable Wire and Hose Routing APPENDIX 17 33 Cable Wire and Hose Routing 1 Front Brake Fluid Reservoir 2 6 mm 0 24 in 3 Brake Hose 4 Clamp 5 White Paint Mark 17 34 APPENDIX Cable Wire and Hose Routing Viewed from A APPENDIX 17 35 Cable Wire and Hose Routing _ Clamp Clamps Brake Hose Right Side Engine Side Insert the clamp in the regulator bracket Rear Brake Light Switch Rear Master Cylinder Insert the clamp in the coolant reservoir bracket Run the brake hose between the swingarm and frame Upper Side Cable Wire and Hose Routing gt 3 GG A O N N a cns S N S Hee NI L IL exo SwA 1 J e dl We SAS SENSN N on E l l _ if j APPENDIX 17 37 Cable Wire and Hose Routing Frame Ground Terminal Bolt Clamp Vacuum Tube W
262. er pump impeller damaged Over Cooling Cooling system component incorrect ECU trouble Thermostat trouble Clutch Operation Faulty Clutch slipping Friction plate worn or warped Steel plate worn or warped Spring plate free play maladjustment 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 Spring plate free play maladjustment 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 set lever binding Shift return spring weak or broken Shift return spring pin loose Shift mechanism arm spring broken Shift mechanism arm broken Jumps out of gear Shift fork ear worn bent Gear groove worn Gear dogs and or dog holes worn Shift drum groove worn Gear set lever spring weak or broken Shift fork guide pin worn Drive shaft output shaft and or gear splines worn Overshifts Gear set lever spring weak or broken Shift mechanism arm spring broken Abnormal Engine Noise Knocking IC
263. ermanent locking agent 4 4 COOLING SYSTEM Coolant Flow Chart Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion When the engine starts the water pump turns and the coolant circulates The thermostat is a wax pellet type which opens or closes as coolant temperature changes The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level When coolant temperature is below 58 62 C the thermostat closes so that the coolant flow is restricted through the air bleeder hole causing the engine to warm up more quickly When coolant temperature is more than 58 62 C the thermostat opens and the coolant flows When the coolant temperature goes up beyond 100 110 C the radiator fan switch conducts to operate the radiator fan The radiator fan draws air through the radiator core when there is not suffi cient air flow such as at low speeds This increases up the cooling action of the radiator When the temperature is below 97 103 C 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
264. ern on the valve seat with vernier calipers lf the outside diameter is too large or too small repair the seat see Seat Repair Valve Seat Surface Outside Diameter Seat O D Standard Exhaust 34 9 35 1 mm 1 374 1 382 in Inlet 38 9 39 1 mm 1 531 1 539 in OMeasure the seat width E of the portion where there is no build up carbon white portion of the valve seat with vernier calipers Good F lf the width is too wide G too narrow or uneven J repair the seat see Valve Seat Repair Valve Seat Surface Width or Seat Width Standard Exhaust 0 8 1 2 mm 0 031 0 047 in Inlet 0 8 1 2 mm 0 031 0 047 in Valve Seat Repair e Repair the valve seat with the valve seat cutters A Special Tools Valve Seat Cutter Holder 6 57001 1576 B Valve Seat Cutter Holder Bar 57001 1128 C For Exhaust Valve Seat Valve Seat Cutter 45 40 57001 1496 Valve Seat Cutter 32 038 5 57001 1122 Valve Seat Cutter 60 41 57001 1124 For Inlet Valve Seat Valve Seat Cutter 45 041 5 57001 1117 Valve Seat Cutter 32 44 57001 1515 Valve Seat Cutter 60 041 57001 1124 ge1400001 tif 8 15011752 C FC ENGINE TOP END 5 37 Cylinder Head OThe marks stamped on the back of the cutter A represent the following DBS cades tein Cutter Angle B svcd nr e i Outer Diameter of Cutt
265. ernary Catalyst GB06120B 5 1 14 GENERAL INFORMATION Technical Information Oxygen Sensor Figure 5 shows how the sensor operates the controlling factors There is a sharp voltage drop of about 1V in reality about 0 9 V the sensor uses for control a standard reference By utilizing this voltage and using 0 45 V as the reference line an output larger than the line indicates that exhaust gas is in the lean zone So when the system senses a rich condition through the sensor s output voltage it controls the fuel injection amount to make the fuel gradually leaner When it reaches a leaner point the sensor voltage signal drops sharply at the proximity A 1 and goes below 0 45V The system at this level senses that it has changed to lean and reverse the voltage signal to make the fuel richer It then controls the fuel injection amount to make the fuel gradually richer When it drops to a richer point the signal drops sharply at the proximity A 1 and goes over 0 45V The system at this level senses that it has changed to rich and reverse the signal to make the fuel leaner By having the signal repeat back and forth between the rich and lean sides it can constantly stay within the window of the good purification rates Thereby the oxygen sensor works as a combustion control sensor for the optimum air fuel ratio Rich Oxygen Sensor Output Lean trol Signal Lean Contre Signa Inc
266. ession Solenoid Inspection in the Fuel DFI and Electrical System chapter GE22010BS1 C GE22011BS1 C GE22012BS1 C 5 26 ENGINE TOP END Camshafts Camshaft Removal e Remove the engine see Engine Removal Installation chapter e Remove the rocker cases see this chapter e Remove Push Rods A Pipes B e Remove the outer camshaft cover and camshaft end cover see Compression Release Mechanism Removal in this chapter e Unscrew the push rod cover bolts and remove the push rod covers Front Push Rod Cover Bolts A Front Push Rod Cover B e Pull the tappets A out of the inner camshaft cover B e Remove Middle Camshaft Cover Bolts A Stopper Pin Plug B Middle Camshaft Cover C e Remove Spacer A Camshaft Chain Tensioner Bolts B Camshaft Chain Tensioner C Camshaft Chain D Decompression Shafts E Camshafts F GE11085BS1 C ENGINE TOP END 5 27 Camshafts Camshatt Installation e Push A the chain tensioner ratchet B and push down C the tensioner shoe D CAUTION Be careful the oil remaining in the tensioner body dashes out e Engage the first teeth A of the ratchet B with second groove C of the plunger D GE11078BS1 C e Insert the suitable stopper pin A into the chain tensioner body B through the link plate C e The rear camshaft A has a groove B and the front camshaft C has no gr
267. eterioration OThe hose and drain cap should not be hard and brittle nor should be soft or swollen Replace them if any cranks or swelling are noticed e Check that the hose is securely connected Breather Drain Cleaning e Refer to Air Cleaner Housing Installation in the Fuel DFI System chapter 6606012BN2 ENGINE LUBRICATION SYSTEM 7 15 Oil Pressure Oil Pressure Measurement Slide out the rubber boot A e Disconnect the oil pressure switch lead B from the ter minal screw C Unscrew the oil pressure switch D NOTE OMeasure the oil pressure after the engine is warmed up e Attach the oil pressure gauge B and adapter C to the switch hole Oil Pressure Switch A Special Tools Oil Pressure Gauge 5 kg cm 57001 125 Oil Pressure Gauge Adapter PT 1 8 57001 1033 GG12004BS1 C 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 oil pressure relief valve and or crankshaft bearing wear and con rod big end bearing insert wear im mediately x If the reading is much higher than the standard check the oil screen first and the oil passages for dirt or clogging Also replace the oil filter Oil Pressure Standard 127 167 kPa 1 3 1 7 kgf cm 18 24 psi 2000 r min rpm oil temp 90 C 194 F e Stop the engine e Remove t
268. ews securely e Install the seats see Frame chapter ELECTRICAL SYSTEM 16 29 Battery Battery Activation Electrolyte Filling e Make sure that the model name A of the electrolyte con tainer matches the model name B of the battery These names must be the same Battery Model Name for VN2000 A1 FTZ16 BS 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 battery type This is to prevent overfilling of the electrolyte shorting the battery life and deteriora tion of the battery performance CAUTION Do not remove the aluminum sealing sheet A from the filler ports B until just prior to use Be sure to use the dedicated electrolyte container for correct electrolyte volume e Place the battery on a level surface e Check to see that the sealing sheet has no peeling tears or holes in it e Remove the sealing sheet NOTE OThe battery is vacuum sealed If the sealing sheet has leaked air into the battery it may require a longer initial charge e Remove the electrolyte container from the vinyl bag e Detach the strip of caps A from the container and set aside these will be used later to seal the battery NOTE ODo not pierce or otherwise open the sealed cells B of the electrolyte container Do not attempt to separate individual cells e Place the electrolyte container upside d
269. f the screen is damaged replace it m NU n 6006010851 C ENGINE LUBRICATION SYSTEM 7 13 Oil Pan e Install the oil screen for crankcase room A Olnstall the holder B to the oil pan C noting holder direc tion OTorque the oil screen bolt Torque Oil Screen Bolt 9 8 N m 1 0 kgf m 87 in Ib e Put the O ring A to the oil screen for transmission room B e Instal the oil screen with the O ring to the left crankcase half C aligning the projection D on the left crankcase half with the recess E on the O ring e Apply silicone sealant A to the mating surfaces of the crankcase halves Sealant Three Bond TB1211F e Apply grease the O rings B and put them on the crankcases e Be sure the dowel pins C are in position e Install the oil pan A Olnstall a new gasket B OTorque the oil pan bolts following the specified sequence OTorque the No 1 bolt agin after tightening all the bolts Torque an Bolt 15 N m 1 5 kgf m 11 ft Ib 7 14 ENGINE LUBRICATION SYSTEM Oil Pan Blowby Gas System Inspection e Be certain that the hose is routed without being flattened or kinked and is connected correctly to the air cleaner base is not correct it e Inspect the breather hose A breather pipe B and the air cleaner drain cap for damage or signs of d
270. flames during charging since the battery gives off an explosive gas mixture of hydrogen and oxygen When using a battery charger connect the battery to the charger before turning on the charger This procedure prevents sparks at the battery terminals which could ignite any battery gases No fire should be drawn near the battery or no terminals should have the tightening loos ened The electrolyte contains sulfuric acid Be careful not to have it touch your skin or eyes If touched wash it off with liberal amount of water Get medial attention if severe Interchange A sealed battery can fully display its performance only when combined with a proper vehicle electric 16 32 ELECTRICAL SYSTEM Battery system Therefore replace a sealed battery only on a motorcycle which was originally equipped with a sealed battery Be careful if a sealed battery is installed on a motorcycle which had an ordinary battery as original equipment the sealed battery s life will be shortened Charging Condition Inspection OBattery charging condition can be checked by measuring battery terminal voltage with a digital voltmeter A e Remove Seats see Frame chapter Battery Cover Disconnect the battery terminals CAUTION sure to disconnect the negative cable first e Measure the battery terminal voltage NOTE OMeasure with a digital voltmeter which can be read one decimal place voltage the reading is 12 6 V
271. function on the first application of the pedal if this is not done Front Master Cylinder Disassembly e Refer to Master Cylinder Rubber Parts Replacement in Periodic Maintenance chapter Rear Master Cylinder Disassembly e Refer to Master Cylinder Rubber Parts Replacement in Periodic Maintenance chapter Master Cylinder Assembly Refer to Master Cylinder Rubber Parts Replacement in Periodic Maintenance chapter GLO7043BS1 C BRAKES 12 17 Master Cylinder Master Cylinder Inspection e Disassemble the front and rear master cylinders see Pe riodic Maintenance chapter Special Tool Inside Clrclip Pliers 57001 143 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 If a cup is worn damaged softened rotted or swollen the piston assy should be replaced to renew the cups xf fluid leakage is noted at the brake lever the piston assy should be replaced to renew the cups e Check the dust covers E for damage x If they are damaged replace them e Check the piston return spring 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
272. g California Model Starter Motor Lead Pipe Assembly 17 44 APPENDIX Cable Wire and Hose Routing Viewed from B B Viewed from cua IN APPENDIX 17 45 Cable Wire and Hose Routing California Model Red Tube Blue Tube To Red Fitting of Fuel Tank To Blue Fitting of Fuel Tank To Thermostat To Air Switching Valve To Throttle Body Green Tube 10 White Tube 11 Coolant Tube 12 Align the marks and install the tubes until the center of the paint mark and then tighten the clamps 13 Bolt 14 Pipe Assembly 15 Starter Motor 16 Bolts 17 Clamp 18 Starter Motor Lead 19 Clamps 20 Pipe Assembly 21 Clamps 22 Green Tape Tube 23 White Stripe Tube 24 Rear Tube 25 Clamp 26 Fitting 27 Clamp 28 Fitting of Throttle Body OMDNOOAWN 17 46 APPENDIX Cable Wire and Hose Routing 6809427BN5 APPENDIX 17 47 Cable Wire and Hose Routing OMNOOAWND Except California Model Pipe Assembly Starter Motor Lead Blue Stripe Clamp Blue Paint Mark Center Line of Paint Mark Clamp Brown Paint Mark 17 48 APPENDIX Cable Wire and Hose Routing d E CO x a De s PN y 0000 APPENDIX 17 49 Cable Wire and Hose Routing Coolant Reservoir Tube Bl
273. g the bearing otherwise the crankcase could be dam aged 6104020351 9 12 CRANKSHAFT TRANSMISSION Crankcase OFor the drive shaft bearing A press B the bearing on the left crankcase C so that its sealed side D faces downward e Press the needle bearing with manufacturer s mark facing out into hole on the left side of the left crankcase Push the needle bearing outer race until the face of the bearing is even with the end of the hole using a driver Special Tool Bearing Driver Set 57001 1129 e Press A the following oil seals into the crankcase halves with the bearing driver set so that spring side of the seal lips is toward the inside of the crankcase halves Oil Seal B at Pulley Shaft Spring C Left Crankcase Half D Oil Seal E at Shift Shaft Right Crankcase Half F Special Tool Bearing Driver Set 57001 1129 OFor the mechanical seal and oil seal installation at the water pump see Cooling System chapter G104118BS2 C 6104120851 C CRANKSHAFT TRANSMISSION 9 13 Crankcase e Install the bearing retainer Bearing Retainer A Bearing Retainer Bolts B Left Crankcase Half Inside C e Install the relief valve D e Apply a non permanent locking agent to the thread of the relief valve and torque it Torque Relief Valve 9 8 N m 1 0 kgf m 87 in Ib e Install the bearing retainers Bearing Retainers A
274. g 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 spark plug 17 58 APPENDIX Troubleshooting Guide except DFI 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 loose Throttle body assy O ring damage 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 Decompression mechanism sticks close Engine load faulty Clutch slipping Engine oil level too high Engine oil viscosity too high Drive train trouble Brake dragging Lubrication inadequate Engine oil level too low Engine oil poor quality or incorrect Water temperature warning system incorrect Water temperature warning light broken Water temperature switch 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 ECU trouble Fan motor broken Fan blade damaged Water pump not turning Wat
275. g end nuts to the specified torque to com press the plastigage and measure the plastigage width B to determine the bearing insert crankpin clearance see Camshaft Rocker Case Wear in the Engine Top End chapter Threads and Flanged Molybdenum Disulfide Oil Portion of Big End Bolts Torque Connecting Rod Big End Bolts 59 N m 6 0 kgf m 43 ft Ib ODo not move the connecting rod and crankshaft during clearance measurement Connecting Rod Big End Bearing Crankpin Clearance Standard 0 026 0 057 mm 0 001024 0 0022 in Service Limit 0 10 mm 0 0039 in xIf the clearance is within the standard no bearing insert replacement is required x If the clearance is between 0 057 mm 0 0022 in and the service limit 0 10 mm or 0 0039 in replace the bear ing inserts A with inserts painted blue B Check in sert crankpin clearance with plastigage The clearance may exceed the standard slightly but it must not be less than the minimum in order to avoid bearing seizure XlIf the clearance exceeds the service limit measure the diameter of the crankpin A Crankpin Diameter Standard 54 981 55 000 mm 2 1646 2 1654 in Service Limit 54 97 mm 2 1642 in lf the crankpin has worn past the service limit replace the crankshaft with a new one x If the measured crankpin diameter is not less than the ser vice limit but does not coincide with the original diameter marking on the crankshaft make a new mark on it C
276. ge see Input Voltage Inspection GC17159BS1 C FUEL SYSTEM DFI 3 91 Subthrottle Valve Actuator Service Code 62 Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Remove the fuel tank see this chapter e Connect the peak voltage adaper 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 e Temporarilly install the fuel tank OConnect the following Fuel Hose Meter Leads Connector Fuel Pump Leads Connector Fuel Level Sensor Leads Connector Subthrottle Valve Actuator Input Voltage Connections to Harness Connector I Meter BK lead 1 Meter P lead 2 II Meter G lead 3 Meter WI BL lead 4 ac e Measure the actuator input voltage with the engine stopped and with the connector joined e Turn the ignition switch ON BK Input Voltage at Sensor Standard about 8 5 10 5 V DC x lf the reading is out of the range check the wiring to ECU see wiring diagram in this section xIf the wiring is good replace the ECU e Install the fuel tank OBe sure the fuel tank dampers are in position 0017160852 C 3 92 FUEL SYSTEM Subthrottle Valve Actuator Service Code 62 O
277. gnal Canceling System Automobiles use a turn signal canceling system actuated by steering wheel turn But motorcycles turn with a bank additionally and so have a smaller steer angle This makes difficult to adopt an automobile type turn signal canceling system because of inaccurate operation in motorcycles So motorcycles adopt time amp distance counting system The canceling system consists of a battery turn signal control relay distance sensor and turn signal switch When the turn signal switch is pushed onto the right or left the turn signals start flashing and the control relay starts counting off 8 seconds At the end of this time the control relay starts calculating distance traveled using pulses from the distance sensor in the speedometer The control relay keeps working even after the tern signal switch was released and returned to the neutral position by spring force When the motorcycle has traveled an additional 65 meters 213 foots the control relay shuts off the current turns off the turn signal lights and resets itself lf the turn signal canceling system does not function properly first check all the wiring connections carefully Secondly inspect the distance sensor Thirdly inspect the turn signal switch in the left handlebar switch e Lastly check the turn signal control relay Wiring Inspection Refer to the Wiring Inspection Page 16 24 and note the following Make sure all connector terminals a
278. gs should also rise But they must be kept under the specified voltage e Turn off the ignition switch to stop the engine and discon nect the hand tester lf the charging voltage is kept between the values given in the table the charging system is considered to be working normally lf the output voltage is much higher than the values spec ified in the table the regulator rectifier is defective or the regulator rectifier leads are loose or open xIf the battery voltage does not rise as the engine speed increases then the regulator rectifier is defective or the alternator output is insufficient for the loads Check the alternator and regulator rectifier to determine which part is defective atr Pe 16 36 ELECTRICAL SYSTEM Charging System Alternator Inspection There are three types of alternator failures short open lead burned out or loss in rotor magnetism A short or open in one of the stator coil lead will result in either a low output or no output at all A loss in rotor magnetism which may be caused by dropping or hitting the alternator by leav ing it near an electromagnetic field or just by aging will re sult in low output e To check the alternator output voltage do the following procedures ORemove the regulator rectifier and disconnect the con nector A OConnect the hand tester to the connector as shown Special Tool Hand Tester 57001 1394 OStart the engine ORun it at 3000 rpm of t
279. h Lead Connector Insert the connector in the Cover Left Switch Housing Lead Connector Insert the connector in the Cover Headlight Lead Connectors City Light Lead Connector Europe Model Left Switch Housing Lead Connector Clutch Cable Left Switch Housing Lead Connector Insert the connector in the Cover 17 4 APPENDIX Cable Wire and Hose Routing APPENDIX 17 5 Cable Wire and Hose Routing Clamps Main Harness Regulator Rectifier Oil Filter Oil Pressure Warning Light Switch Insert the alternator lead conector in the bracket Main Harness Main Harness Alternator Lead Clamp Main Harness Rear Brake Light Switch Lead Connector Engine Bracket Rear Brake Light Switch Right Footboard Bracket Assembly 17 6 APPENDIX Cable Wire and Hose Routing 2 E a 2 a A 2 tan AU p 1 Bo pills 155 Xs OI Qo rn 2 3 A Sn Do i11 1 A D Ub rt e S 5 LZ in E 2 68809412845 APPENDIX 17 7 Cable Wire and Hose Routing Clutch Cable Run the clutch cable the front side of the steering stem head Clamp Bolt Clamps Clamp 015 Clamp 010 Install the rubber boot to the metal fitting Oil Pressure Warning Light Terminal Switch Lead Terminal Clamp
280. h flash point solvent wash the upper and lower tapered roller bearings A in the cages and wipe the upper and lower outer races which are press fitted into the frame head pipe clean of grease and dirt e Visually check the outer races and the rollers xf the rollers or races are worn or if either race is dented replace both races and all the roller bearings as a set see Steering chapter e Pack the upper and lower tapered roller 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 see Steering chapter Brake System Brake Fluid Leak Brake Hose and Pipe e Apply the brake lever or pedal and inspect the brake fluid leak from the brake hoses A and fitting xIf the brake fluid leaked from any position inspect or re place the problem part 2 16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Hose Damage and Installation Connection 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 bulges C or leakage are noticed Tighten any banjo bolts Torque Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 10 Inspect the brake hose routi
281. haft ae hel Sensor Joint Connector Kawasaki Diagnostic System Connector wak UD ser Y diagnosis La Terminal Joint Connector 3 Electronic Control Unit Rear Accessory Gonnectors HT ien License Plate Light 12V5W Tail Brake Lights 1221 50 Fuel Rear Right Turn Signal Reserve Light 12V21W Switch Fuel Rear Left Turn Signal Pump Light 12V21W Vehicle down Joint Connector Sensor 12V18Ah Starter finu Color Code Motor Ek f meet Main Fuse 84 304 CH Chocolate DG bark Green e creen Front Brake Light Switch Engine Stop Switch Starter Button BK BK R Y R Color R BK R Brake Lever OFF Free W2ROO011ENS C 16 16 ELECTRICAL SYSTEM Wiring Diagram California Air Radiator Switching Fan Regulator Valve Brace Atmospheric Inlet Pressure Air Right Handlebar Switches 1 Front Brake Light Switch GOO amp Fuel Sensor 2 Engine Stop Switch Level 3 Starter Button tus m Sensor Light T Switch gt BSS Ignition Boils MM Speedometer Unit gt 222 1 Qdometer Trip Meter Clock 25 zz Liquid Grystal Display ae ix 2 Speedometer Be 3 Fuel Meter 4 ll luminator LED 5
282. han sea level check the output voltage as follows ODetermine the local altitude elevation you know the local atmospheric pressure using barometer substitute the atmospheric pressure for throt tle vacuum pressure in the inlet air pressure sensor chart see intake Air Pressure Sensor section in this chapter And get the usable range of the atmospheric pressure sensor output voltage and check if output voltage is within the standard or not in the same way as Output Voltage Inspection of the inlet air pressure sensor If you know the local altitude use the following chart 3 60 FUEL SYSTEM DFI Atmospheric Pressure Sensor Service Code 15 Atmospheric Pressure Altitude Relationship Atomospheric Pressure mmHg abs 750 700 600 Atmospheric Pressure mmHg abs 7 Altitude km 1 X1 000 Altitude 2 4 2 6 2 8 X1 000m GC17A43584 C FUEL SYSTEM DFI 3 61 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
283. harge Standard Charge 1 8 x 5 10 hours using a recommended battery charger follow the charger s instructions for newly activated sealed battery Kawasaki recommended chargers Optimate Ill Yuasa 1 5 Amp Automatic Charger Battery Mate 150 9 x lf the above chargers are not available use equivalent one NOTE OCharging rates will vary depending on how long the battery has been stored temperature and the type of charger used Let battery sit 30 minutes after initial charge then check voltage using a voltmeter If it is not at least 12 6 volts repeat charging cycle 8 09000851 C 8 08019851 C ELECTRICAL SYSTEM 16 31 Battery e After charging is completed press down firmly with both hands to seat the strip of caps A into the battery don t pound or hammer When properly installed the strip of the caps will be level with the top of the battery CAUTION Once the strip of the caps A is installed onto the battery never remove the caps nor add water or electrolyte to the battery 8 09000951 C NOTE OTo ensure maximum battery life and customer satisfac tion it is recommended the battery be load tested at three times its amp hour rating for 15 seconds Re check voltage and if less than 12 6 volts repeat the charging cycle and load test If still below 12 6 volts the battery is defective Precautions 1 No need of topping up No topp
284. he 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 OWire 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 OElectrical Connectors Female Connectors A 8 07000251 C 16 26 ELECTRICAL SYSTEM Servicing Precautions Male Connectors B 8 07000351 C ELECTRICAL SYSTEM 16 27 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 xIf the connector is corroded or dirty clean it carefully If it is damaged replace it e Check that the connectors are not loose e Check the wiring for continuity OUse the wiring diagram to find the ends of the wire which is suspected of being a problem OConnect the hand tester between the ends of the wires Special Tool Hand Tester 57001 1394 OSet the tester to the x 1 O range and read the tester lf the tester does not read 0 the lead is defective Re place the wire or the wiring harness B if necessary GPO7008BS1 C 16 28 ELECTRICAL SYST
285. he engine speed ONote the voltage readings Alternator Output Voltage Tester Connections Reading Range Tester to Tester to 23000 rpm One black Another black lead lead x If the output voltage shows the value in the table the alter nator operates properly and the regulator rectifier is dam aged A much lower reading than the value in the table indicates that the alternator is defective ORepeat the test for the other black leads Hand Tester A 250 V AC 8 09020751 C ELECTRICAL SYSTEM 16 37 Charging System e Check the stator coil resistance as follows OTurn off the ignition switch OConnect the hand tester A to the connector as shown in the table ONote the resistance readings Stator Coil Resistance Tester Connections Reading Range Tester to Tester to One black Another black 0 18 0 220 lead lead lf there is more resistance than shown in the table or no hand tester reading infinity the stator has an open wire 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 x lf the stator coil has normal resistance but the voltage check showed the alternator to
286. he fuel tank from the vehicle and place it on a flat surface CAUTION For California model if gasoline solvent water or any other liquid enters the canister the canister s vapor absorbing capacity is greatly reduced If the canister does become contaminated replace it with a new one e For California model note the following OTo prevent the gasoline from flowing into or out of the canister hold the separator perpendicular to the ground For California model be careful not to spill the gasoline through the return hose Spilled fuel is hazardous x If liquid or gasoline flows into the breather hose remove the hose and blow it clean with compressed air California model careful of fuel spillage from the fuel tank since fuel still remains in the fuel tank and fuel pump Store the fuel tank in an area which is well ventilated and free from any source of flame or sparks Do not smoke in this area Place the fuel tank on a flat surface and plug the fuel pipes to prevent fuel leakage Fuel Tank Installation Read the above WARNING Route the hoses correctly see Appendix chapter e For California model note the following OTo prevent the gasoline from flowing into or out of the canister hold the separator perpendicular to the ground OConnect the hoses according to the diagram of the system see the last page of this chapter or Cable Wire and Hose Routing section in the Appendix
287. he gear position Switch starter lockout switch side stand switch and relay box lf their parts are normality replace the ECU IC Igniter Inspection OThe IC igniter is built in the ECU A ORefer to Fuel System chapter for ECU Inspection ELECTRICAL SYSTEM 16 49 Ignition System Ignition System Circuit GP10138BN4 C 1 Engine Stop Switch 9 Sub Throttle Sensor 16 Battery 2 Spark Plugs 10 Camshaft Position Sensor 17 Frame Ground 3 Ignition Coil 1 front cylinder 11 Crankshaft Sensor 18 Joint Connector 4 Ignition Coil 2 rear cylinder 12 Electronic Control Unit 19 Relay Box 5 Joint Connector 13 Ignition Fuse 10 A 20 Diode 6 Vehicle down Sensor 14 Ignition Switch 21 Side Stand Switch 7T Joint Connector 15 Main Fuse 30 22 Gear Position Switch 8 Main Throttle Sensor 16 50 ELECTRICAL SYSTEM Starter Motor Starter Motor Removal e Remove Rear Exhaust Pipe see Engine Top End chapter Starter Motor Terminal Nut A and Lead Starter Motor Bolts B e Pull the starter Motor C toward the right CAUTION Never drop the starter motor especially on a hard surface Such a shock to the motor can damage it Starter Motor Installation CAUTION Do not tap the starter motor 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 wher
288. he lips are misshapen discolored indicating that the rubber has deteriorated hardened or otherwise damaged WHEELS TIRES 10 1 Wheels Tires Table of Contents Exploded aude HR RR LR SPCCITICATONS PRI ET eere P M Puls W tenes Front Wheel 8 Front Wheel menm mener Rear Wheel Removal seriinin aaaeaii eaa aeaa Ea eannan E Rear W heel Installation Hois a ae ea a e a at Wheel INSPSCHON coo A A A A E RES A AAT Axle INSPSCUON er iret Dn SEA TRAY ER RR RR oe E ee Ra du YR Wheel Balance Balance ACU SUSI its cots sea ee a ra east a Balance Weight REMOVAL huie Tetas i tos Balance Weight Installation Air Pressure 10 14 THRE MAS DOCUON EE 10 14 MS Removals ae 10 14 Tre TSCA M ne 10 14 Tire Repar aes Ges Mate ae oth eee te nade dace ea 10 17 Hub Bearings Wheel Bearings teta eec poesie eu ee ee 10 18 Hub Bearings Rerrioval 1 Dp Ao Ret be lade b dee SLM Abe bete e 10 18 5 2
289. he oil filter e Apply molybdenum disulfide oil to the rocker shafts C e Install the rocker shafts so that their grooves D are placed vertically as shown Front Rocker Case E Rear Rocker Case F e Torque the rocker shaft bolts Torque Rocker Shaft Bolts 12 N m 1 2 kgf m 104 in Ib t t t ed GE20002BN2 ENGINE TOP END 5 19 Rocker Case e Replace the O rings A on each oil pipe B with new ones and grease them Torque the oil pipe bolts Torque Oil Pipe Bolts 9 8 N m 1 0 87 in Ib e Be sure the dowel pins A on each cylinder head are in position Replace each rocker case gasket B with a new one Front Rocker Case C Rear Rocker Case D GE20004BWi e Turn the crankshaft counterclockwise A and position the 1 or 2 piston at TDC observing piston movement through each spark plug hole Front Spark Plug Hole B Front C 5 20 ENGINE TOP END Rocker Case OAnother way to position each piston at TDC is as follows ORemove the outer camshaft cover and camshaft end cover see Decompression Mechanism Removal in this chapter OTurn the crankshaft couterclockwise and position 1 pis ton at TDC aligning A the projection B on the middle camshaft cover with the front decompression pin C OTurn the crankshaft counterclockwise and position 2 pis ton at T
290. he oil pressure gauge and adapter A WARNING Take care against burns from hot engine oil that will drain through the oil passage when the plug is re moved e When installing the oil pressure switch apply silicone sealant to the threads of the switch and tighten it to the specified torque Torque Oil Pressure Switch 15 N m 1 5 kgf m 11 ft Ib Sealant Silicone Sealant Kawasaki Bond 56019 120 7 16 ENGINE LUBRICATION SYSTEM Oil Pressure Relief Valve Inspection e Split the crankcase see Crankshaft Transmission chap ter Remove the relief valve A from the left crankcase half B e Check to see if the valve slides smoothly when pushing it in with a wooden or other soft rod and see if it comes back to its seat by spring 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 in a well ventilated area OTake care that there is no spark or flame anywhere near the working area Valve A Spring B cleaning does not solve the problem replace the relief valve as an assembly The relief valve is precision made with no allowance for replacement of individual parts 80130001 ENGINE REMOVAL INSTALLATION 8 1 Engine Remo
291. his 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 Water Hose Clamp Screws 2 0 0 20 kgf m 17 in Ib LS SSS 555 6010020151 C Hose Inspection e Whenever the radiator or water hoses are removed or in accordance with the Periodic Maintenance Chart check the radiator or water hoses and their connections Refer to Radiator Hose and Connection Check in the Periodic Maintenance Chapter ENGINE TOP END 5 1 Engine Top End Table of Contents Exploded View res 5 2 Ball Bearing and Outer Race Specifications 5 8 Replacement 5 29 Special Tools and Sealant 5 11 Ball Bearing Wear 5 29 Clean Air System 5 13 Cam NV CAL ass nece tdi m boe 5 30 Air Suction Valve Removal 5 13 Camshaft Chain Wear 5 30 Air Suction Valve Installation 5 13 Cylinder Head deseen 5 31 Air Suction Valve Inspection 5 13 Cylinder Compression Air Switching Valve Removal 5 13 Measurement 5 31 Air Switching Valve Installation 5 13 Cylinder Head Removal 5 32 Air Switching Valve Operation Cylinder Head Installation 5 33 oT 5 13 Cylinder Head Warp 5 3
292. hite California Model Air Tube Insert the clamp of harness in the frame Throttle Body Lead Connector Water Temperature Sensor Run the throttle cable between the thermostat and fuel tank bracket Coolant Reservoir Tube Black 10 Inlet Air Pressure Sensor 11 Inlet Air Pressure Sensor Tube 12 Clamp 13 Throttle Cables 14 Run the green tube upper side of the cylinder head and left side of the frame California Model 15 Air Switching Valve 16 Throttle Body Lead 17 Front 18 Run the throttle body lead on the inlet air pressure sensor tube 19 Throttle Body Lead 20 Water Hose 21 Water Hose 22 Coolant Reservoir Tube Black 23 Inlet Air Pressure Sensor Tube 24 Throttle Cables 25 Thermostat 26 Coolant Reservoir Tube Black 27 Inlet Air Pressure Sensor Tube 28 Water Hose 29 Throttle Cables 30 Fuel Tank Bracket 31 Frame 17 38 APPENDIX Cable Wire and Hose Routing APPENDIX 17 39 Cable Wire and Hose Routing Fuel Tank Meter Unit Meter Unit Lead Run the meter unit lead beside the fuel level sensor Fuel Pump Lead Fuel Pump Fuel Level Sensor Fuel Level Sensor Lead Fuel Tank Coolant Reservoir Tube Black Brown Pipe Thermostat Cap Green Tube Green Pipe Air Switching Valve California Model White Tube White Pipe Throttle Body California Model Frame Clamp
293. hot instantly it takes sometime before the sensor starts to work To 88061198 5 solve the problem of the slow temperature increase of ex haust gases which warms the electrolyte element a built in heater located inside the tubular element increases the temperature of the sensor so it can operate at a low ex haust gas temperature Furthermore this built in heater helps keep the sensor at a constant temperature Filter Air Fuel Ratio Control By Oxygen Sensor A21 indicates the optimum air fuel ratio point meaning the air fuel ratio at which optimum complete combustion can be obtained In the proximity of this mixture the purifi cation efficiency of the catalyst will be maximized The purification ratio of the three kinds of gas HC hy drocarbons CO carbon monoxide Nox nitrogen oxides using the ternary three catalyst is shown in Fig 4 The best purification rate is at the zone where the oxy gen sensor s signal shows the sharp changes This zone is called the window and if the oxygen sensor signal moves back and forth between the rich side fuel rich and lean side fuel lean from the oprimum mix ratio but still within the width of the window it indicates that the exhaust gas Excess Air Rate is in a good purification rate zone Window Purification Rate Oxygen Sensor Output Vs Theoretical Rich Mixing Ratio Lean Fig 4 Purification Rate by T
294. ht the belt could jump off the pulley or break Belt Handling Precautions CAUTION Do not adhere battery electrolyte thinner or other solvents to the belt Immediately wash away any solvent that spills on the belt ODrive belt is extremely durable and give long life in a prop erly designed drive However improper handling of the belt before or during installation can result in dramatically shortened service life OThe belt s tensile cords are designed to carry large loads in tension but not compression OCompression causes damage to the tensile cords of the belt and can also lead to adhesion problems OHandling situations that can cause compression in tensile cord include aggressive bending and twisting e When assembly handling and storage the forward bend ing A radius of the drive belt B shall not be smaller than 63 5 mm 2 5 in C e When assembly handling and storage the back bending A radius of the drive belt B shall not be smaller than 127 mm 5 0 in C GK10000BS1 C GK10001BS1 C FINAL DRIVE 11 7 Drive Belt e Do not twist A the drive belt B as shown OThis includes coiling the belt to make it smaller for pack aging e Do not use tools A to pry B the drive belt C onto the application OThe rear pulley D should be in the front position in the swingarm so that the belt can be easily put on by hand Drive Belt Wear Inspection e Refer to Belr Wea
295. ht Handlebar Switches F Meter Unit G Fuel Level Sensor H Spark Plug A Front Fuel Pump B Spark Plug C Rear Ignition Coil D Front Ignition Coil E Rear Radiator Fan A Horn B Alternator C Crankshaft Sensor D Oil Pressure Switch E Side Stand Switch F Atmospheric Pressure Sensor A ECU Fuse 30 A B Starter Relay and Main Fuse 30 A C Fuse Box D Battery E Vehicle down Sensor A Self diagnosis Terminal B Kawasaki Diagnostic System Connector C Battery D ELECTRICAL SYSTEM 16 23 Electrical Parts Location ECU Electronic Control Unit A Frame Ground Terminal A Turn Signal Control Relay B Starter Control Relay C Relay Box D Speed Sensor A Engine Ground Terminal B Starter Motor C Oxygen Sensor D Gear Position Switch E Frame Ground Terminal A Inlet Air Pressure Sensor B Water Temperature Sensor C Air Switching Valve D 2 Injector A Rear 1 Injector B Front Sub Throttle Sensor C Sub Throttle Sensor Actuator D 16 24 ELECTRICAL SYSTEM Electrical Parts Location Sub Throttle Sensor A Sub Throttle Sensor Actuator B Main Throttle Sensor C Inlet Air Temperature Sensor A Decompression Solenoid B Camshaft Position Sensor C Rear Brake Light Switch D Regulator Rectifier E une ELECTRICAL SYSTEM 16 25 Servicing Precautions There are a number of important prec
296. id burns do not remove the radiator cap or try to change the coolant when the engine is still hot Wait until it cools down Coolant on tires will make them slippery and can cause an accident and injury Since coolant is harmful to the human body do not use for drinking e Place a container under the radiator drain bolt A then remove the drain bolt PERIODIC MAINTENANCE 2 51 Periodic Maintenance Procedures e Remove the fuel tank see Fuel System chapter 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 Front B e Suck A the coolant with a hose B and pour the coolant into a suitable container e Install the reserve tank 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 see Specifications in this chapter in the cooling system If hard water is used in the system it causes scale accumulation in the water passages and consider ably reduces the efficiency of the cooling system Water and Coolant Mixture Ratio when shipping Soft Water 50 Coolant 50 Freezing Point 35 C 31 F Total Amount 2 6L 2 5 US gt e Tighten the drain bolts Tor
297. igniter in ECU trouble Carbon built up in combustion chamber Fuel poor quality or incorrect Be sure to use high octane gasoline recommended in Owner s Manual Spark plug incorrect Overheating Piston slap Cylinder piston clearance excessive Cylinder piston worn Connecting rod bent Piston pin piston pin hole worn Valve noise Engine not sufficiently warmed up after HLA installation HLA damaged worn seizure or spring bro ken APPENDIX 17 59 Troubleshooting Guide except DFI HLA aeration due to low oil level Air in HLA Metal chips or dust jammed in HLA Engine operated in red zone Valve spring broken or weak Camshaft bearing portion worn Other noise Connecting rod small end clearance exces sive Connecting rod big end clearance exces sive Piston ring worn broken or stuck Piston seizure damage Cylinder head gasket leaking Exhaust pipe leaking at cylinder head con nection Crankshaft runout excessive Engine mounts loose Crankshaft bearing worn Primary gear worn or chipped Camshaft chain tensioner trouble Camshaft chain sprocket guide worn Air suction valve damaged Air switching valve damaged Alternator rotor loose Catalytic converters melt down due to muf fler overheating KLEEN Balancer gear worn or chipped Balancer shaft position maladjusted Balancer bearing worn Water pump gear sprocket worn Abnormal Drive Train Noise Clutch noise Clutch housing friction plate clearance e
298. il Fork Oil Viscosity SAE10W 20 Fork Oil Capacity when changing oil Approx 515 mL 17 4 US oz e Wait for about five minutes so that any suspended air bub bles can surface e Measure the oil level using the fork oil level gauge A Special Tool Fork Oil Level Gauge 57001 1290 OSet the gauge stopper B so that its lower side shows the oil level distance specified C Olnsert the gauge tube into the inner tube D and position the stopper across the top of the inner tube E OPull the handle slowly to draw out the excess oil until no more oil comes up the tube no oil is drawn out from the beginning there is not enough oil in the fork Pour in some more oil then draw out the excess Front Fork Oil Level Fully compressed without fork spring Standard 203 2 mm 7 99 0 08 in e Install Cover Rubber Damper gm030008 1 8 04013552 C 13 10 SUSPENSION Front Fork e Install the fork spring with the smaller diameter end A facing down B e Install Washer e Install the front fork in the fork clamps and tighten the lower fork clamp bolt only Torque Lower Front Fork Clamp Bolt 34 N m 3 5 kgf m 25 ft lb NOTE OTighten the two clamp bolts alternately two times to en sure even tightening torque e Install Collar e Put the plug and new stopper ring in the inner tube e Push down the top plug A and install the stopper ring B into the gr
299. il see Engine Lubrication System in the Periodic Maintenance chapter Remove the outer clutch cover see this chapter e Remove Plate Bolts A Plate B Oil Pipe C e Remove Clutch Spring Bolts A Clutch Spring Plate B with Springs e Remove Washer A Thrust Bearing B Rod C Friction Plates and Steel Plates e Holding the clutch hub A remove the clutch hub nut B Special Tool Clutch Holder 57001 1243 C e Remove Washer A Spring Washer B Clutch Hub C 6 10 CLUTCH Clutch Remove the spacer A from the drive shaft B e Remove the outside and middle covers on the inside cover A see Final Drive chapter Remove the left downtube see Frame chapter e Remove Inner Clutch Cover Bolts B Inner Clutch Cover C e Remove Chain Guide Bolts A Chain Guides B Inside Pipe Bolt C e Pull Oil Pipe A Valve B with Spring C Holding the alternator rotor A remove the cam damper bolt B Special Tool Flywheel amp Pulley Holder 57001 1343 C Flywheel amp Pulley Holder Adapter 57001 1547 D CLUTCH 6 11 Clutch e Remove Spring Retainer A Holder B and Springs C as a set e Remove the damper cam A from the crankshaft e Pull A the clutch housing B and the sprocket C with the primary reduction chain D e Remove Starter Clutch Gear A Collor B Spacer C e Remove the washer A from the cr
300. 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 seats see Frame chapter e Connect a digital meter to the connector A using the needle adapter set E Special Tool Needle Adapter Set 57001 1457 Speed Sensor Input Voltage Connector to Sensor Meter O R lead C Meter gt BK W lead D e Measure the sensor input voltage with the engine stopped and with the connector joined e Turn the ignition switch ON Input Voltage at Sensor Standard About 9 11 V DC at Ignition SW ON 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 OBe sure the battery is fully charged e Turn the ignition switch OFF 6C17305BS1 C FUEL SYSTEM DFI 3 65 Speed Sensor Service Code 24 Connect a digital meter A to the connector A using the needle adapter set E Special Tool Needle Adapter Set 57001 1457 Throttle Sensor Output Voltage Connections to Sensor Meter P lead C Meter BK W lead D e Measure the sensor output voltage with the engine stopped and with the connector joined e
301. in the bracket Run the seat lock cable outside of the cable hook Hold the harness with the clamp and bend the clamp to bracket Bracket Frame Put the accessory terminals under the rear harness connector Fit the rear harness connector on the battery case cover Clamp Clamp Rear Harness Seat Lock Cable Clamp Seat Bracket 17 20 APPENDIX Cable Wire and Hose Routing Viewed from Upper Side AEB Viewed from Right Side d ee x em Oboe nf NP 6809416BN5 APPENDIX 17 21 Cable Wire and Hose Routing 10 After connection fit the oxygen sensor lead connector the bracket California Europe 12 13 14 15 16 17 18 Main Harness Left Side Damper Inside of Battery Cover Fit the Kawasaki Diagnostic System connector in the battery cover Put the accessory terminals under the rear harness connector To Frame Ground Main Harness Right Side Seat Lock Cable Fit the rear harness connector on the battery case cover Before connection fit the decompression solenoid camshaft sensor lead connector in the bracket After connection fit the gear position switch lead connector in the bracket models Speed Sensor Lead Connector Insert the clamp in the battery case Gear Position Switch Lead Decompression Sole noid Camshaft Sensor Lead and Oxygen Sensor Lead
302. in the housing so that the air bleeder hole B is on top e Install a new O ring into the housing e Apply a non permanent locking agent to the thermostat cap screws e Fill the radiator with coolant see Coolant Change in the Periodic Maintenance chapter e Align the projection A on the thermostat housing with the radiator hose clamp body B COOLING SYSTEM 4 17 Thermostat Thermostat Inspection Remove the thermostat and inspect the thermostat valve at room temperature lf the valve is open replace the valve with a new one e To check valve opening temperature suspend the ther mostat A and an accurate thermometer B in a container of water with the heat sensitive portions C in almost the same depth NOTE OThe thermostat must be completely submerged and the thermostat and thermometer must not touch the con tainer sides or bottom e Gradually raise the temperature of the water while stirring the water gently for even temperature lf the measurement is out of the range replace the ther mostat Thermostat Valve Opening Temperature 58 62 C 136 144 F 6009020252 C 4 18 COOLING SYSTEM Hoses and Pipes Hose Installation e Install the hoses and pipes being careful to follow bend ing direction Avoid sharp bending kinking flattening or twisting e Install the clamps A as near as possible to the hose end to clear the raised rib on the fitting T
303. ing OApply silicone sealant to the stepped parts A on the mat ing surfaces of the left and right crankcase halves Sealant Three Bond 1211 OGrease the new O rings B OBe sure to install the dowel pins C OReplace the cylinder base gaskets D OUsing the piston ring compressor assembly A with the chamfered side B upward install the cylinder block Special Tools Piston Ring Compressor Grip 57001 1095 Piston Ring Compressor Belt 095 0108 57001 1358 OThe front cylinder has the coolant drain plug and the rear cylinder has no coolant drain plug Be careful not to mix them up e Install the front cylinder in the same way OPosition the front piston at TDC OTorque the cylinder mounting bolts OApply a non permanent locking agent to the circumfer ence of bolt threads Torque Cylinder Bolts 25 N m 2 5 kgf m 18 ft lb GE16077BS2 C 5 44 ENGINE TOP END Cylinders Piston Cylinder Wear 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 three locations total of six measure ments shown in the figure xIf any of the cylinder inside diameter measurements ex ceeds the service limit replace the cylinder 10 mm A 70 mm B 20 mm C Cylinder Inside Diameter Standard 102 994 103 006 mm 4 054874 4 055346 in and less than 0 01 mm 0 0004 in difference betw
304. ing the front wheel or the motorcycle may fall over It could cause an accident and injury e Unscrew the axle to the right and drop the front wheel out of the fork CAUTION Do not lay the wheel directly 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 WHEELS TIRES 10 7 Wheels Rims Front Wheel Installation e Apply grease to the seal lips e Fit the collars A on the both side of the hub The collars are identical e Insert the axle from the right side of the wheel e Tighten the axle Torque Front Axle Nuts 127 N m 13 kgf m 94 ft Ib e Before tightening the clamp bolts on the right fork leg pump the forks down and up A 4 or 5 times to allow the right fork leg to find a neutral position on the front axle NOTE ODo not apply the front brake during this process to stop the motorcycle from rolling forward Put a block B in front of the wheel to stop it from moving e Tighten the axle clamp bolts A to the specified torque Torque Front Axle Clamp Bolts 25 N m 2 5 kgf m 18 ft Ib NOTE OTighten the two clamp bolts alternately two times to en sure even tightening torque e Check the clearance B between the front axle collar C and the right fork leg D The clearance between the front axle collar and the right fork leg should be between 1 05 3 19 mm 0 041 0 12
305. ing up is necessary in this battery until it ends its life under normal use Forcibly prying off the seal cap to add water is very dangerous Never do that 2 Refreshing charge If an engine will not start a horn sounds weak or lamps are dim it indicates the battery has been discharged Give refresh charge for 5 to 10 hours with charge current shown in the specification see this chapter When a fast charge is inevitably required do it following precisely the maximum charge current and time conditions indicated on the battery CAUTION This battery is designed to sustain no unusual deterioration if refresh charged according to the method specified above However the battery s performance may be reduced no ticeably if charged under conditions other than given above Never remove the seal cap during refresh charge If by chance an excessive amount of gas is generated due to overcharging the relief valve releases the gas to keep the battery normal 3 When you do not use the motorcycle for months Give a refresh charge before you store the motorcycle and store it with the negative cable re moved Give a refresh charge once a month during storage 4 Battery life If the battery will not start the engine even after several refresh charges the battery has ex ceeded its useful life Replace it Provided however the vehicle s starting system has no prob lem A WARNING Keep the battery away from sparks and open
306. ings A from the outside of each pis ton CAUTION Do not reuse snap rings as removal weakens and deforms them They could fall out and score the cylinder wall e Using the piston pin puller assembly remove the piston pins Special Tools Piston Pin Puller Assembly A 57001 1568 Remove the piston Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring A to remove it Remove the 3 piece oil ring with your thumbs the same manner 8 16020351 C ge160206 tif 5 42 ENGINE TOP END Cylinders Piston Cylinder Piston Installation NOTE OThe oil ring rails have no top or bottom e Install the oil ring expander A in the bottom piston ring groove so the ends B butt together e Install the oil ring steel rails one above the expander 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 e Do not mix up the top ring and second ring e Install the top ring A so that the R mark B faces up e Install the second ring C so that the RN mark D faces up 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 45 F of angle from the opening of the top ring Top Ring A Second Ring B Oil Ring Steel Rails
307. ions listed below 1 2 3 Never reuse old brake fluid Do not use fluid from a container that has been left unsealed or that has been open for a long time Do not mix two types and brands of fluid for use in the brake This lowers the brake fluid boiling point and could cause the brake to be ineffective It may also cause the rubber brake parts to deteriorate Don t leave the reservoir cap off for any length of time to avoid moisture contamination of the fluid Don t change the fluid in the rain or when a strong wind is blowing Except for the disc pads and disc use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning brake parts Do not use any other fluid for cleaning these parts Gasoline engine oil or any other petroleum distillate will cause deterioration of the rubber parts Oil spilled on any part will be diffi cult to wash off completely and will eventually dete riorate the rubber used in the disc brake When handing the disc pads or disc be careful that no disc brake fluid or any oil gets on them Clean off any fluid or oil that inadvertently gets on the pads or disc with a high flash point solvent Do not use one which will leave an oily residue Replace the pads with new ones if they cannot be cleaned satisfacto rily Brake fluid quickly ruins painted surfaces any spilled fluid should be completely washed away immediately If any of the brake line fittings or the bleed valve is opened at a
308. isplayed e Count the blinks of the LED light D to read the service code after entering the self diagnosis mode 1 or 2 e Any of the following procedures conditions ends self diagnosis OWhen pushing the RESET button more than 2 seconds and 2 seconds passed OWhen the ignition SW is turned to OFF OPushing the MODE button and the trip meter is displayed OWhen the ECU receives the speed sensor signal e To enter the self diagnosis dealer mode 1 ground A the self diagnosis terminal B to the ground 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 e To enter the self diagnosis dealer mode 2 repeat opening B and grounding A the lead more than five times E within 2 seconds C after the lead is first grounded and then keep it grounded continuously D for more than 2 seconds OCount the blinks of the LED light to read the service code Keep the auxiliary lead ground until you finish reading the service code NOTE Olf the self diagnosis mode is in dealer mode 1 then you need to enter the dealer mode 2 turn off the ignition switch once Service Code Clearing Procedures e Enter the self diagnosis dealer mode 2 see Self diagno sis Procedures NOTE OMake sure to keep the grounding until the following opening and grounding starts e Pull the clutch lever i
309. ke Hose H O ring I GS13063BS2 C GS13064BS2 C 2 42 PERIODIC MAINTENANCE Periodic Maintenance Procedures Master Cylinder Assembly e Before assembly clean all parts including the master cylinder with brake fluid or alcohol CAUTION Except for the disc pads and disc use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning brake parts Do not use any other fluid for cleaning these parts Gasoline engine oil or any other petroleum distillate will cause deterioration of the rubber parts Oil spilled on any part will be diffi cult to wash off completely and will eventually de teriorate the rubber used in the disc brake e Apply brake fluid to the new parts and to the inner wall of the cylinder Take care not to scratch the piston or the inner wall of the cylinder CAUTION Do not remove the secondary cup from the piston since removal will damage it e Tighten the brake lever pivot bolt and the locknut Silicone Grease Brake Lever Pivot Bolt Brake Lever Pivot Con tact Piston Rod Contact Dust Cover Torque Brake Lever Pivot Bolt 1 0 N m 0 10 kgf m 8 7 in Ib Brake Lever Pivot Locknut 5 9 N m 0 60 kgf m 52 in Ib Caliper Rubber Parts Replacement Front Caliper Disassembly e Loosen the front caliper assembly bolts A and banjo bolt B and tighten them loosely e Remove Front Caliper see Brakes chapter C Brake Pad Front Calipe
310. kgf m 15 ft Ib Clutch Drain Plug 20 N m 2 0 kgf m 15 ft Ib Remove the oil filler cap A and pour in the specified type and amount of oil Transmission Cover B Engine Oil Type API SE SF or SG class API SH or SJ class with JASO MA Viscosity SAE 10W 40 Amount 4 4L 4 7 US qt when filter is not removed 4 6 L 4 9 US qt when filter is removed 5 5 L 5 8 US qt when engine is completely disassembled and dry 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 e Check the oil level see Engine Lubrication System chap ter GSO9015BS1 C 40 C 1 104 F 1 509000851 C PERIODIC MAINTENANCE 2 49 Periodic Maintenance Procedures Oil Filter Replacement Drain the engine oil see Engine Oil Change in this sec tion Remove the oil filter A with the oil filter wrench B and discard the oil filter Special Tool Oil Filter Wrench 57001 1249 NOTE OThe filter has an oil filter bypass valve which can not be removed Replace the oil filter with the new one Apply oil to the gasket of the new filter before installation Tighten the filter with the oil filter wrench e Pour in the specified type and amount of oil Torque Oil Filter 18 N m 1 8 kgf m 13 ft Ib Fuel Hose Replacement e Remov
311. kgf m 43 ft Ib Upper Engine Mounting Bolts 9 44 N m 4 5 kgf m 33 ft Ib Lower Engine Bracket Bolts 10 59 N m 6 0 kgf m 43 ft Ib This bolts are not removed when removing the engine however torque them Front Engine Mounting Nut 11 44 N m 4 5 kgf m 33 16 Rear Downtube Bolts 12 108 N m 11 kgf m 80 ft lb 8 04020883 0 NOTE OFor the front downtube nuts 1 upper engine bracket nuts 8 and rear downtube bolts 12 tighten the fas teners alternately two times to ensure even tightening torque e For the adjusting bolt and locknut noting the following OTurn the adjusting bolt A upper and lower until the clearance between the bolt heads and crankcase B come to zero mm zero OTorque the adjusting bolt locknut C using the socket wrench D Special Tool Socket Wrench 57001 1347 e Run the leads cables and hoses correctly see Cable Wire and Hose Routing section in the Appendix chapter ENGINE REMOVAL INSTALLATION 8 11 Engine Removal Installation e Install the removed parts see appropriate chapters e Adjust the throttle cables see Fuel System chapter e Fill the engine with engine oil see Periodic Maintenance chapter e Fill the engine with coolant and bleed the air from the cooling system see Periodic Maintenance chapter e Adjust the idling see Periodic Maintenance chapter e Adjust the drive belt see Periodic Maintenance chapter e Check
312. l seals with manufacture and size marks facing out Make sure the seal is aligned properly when installing 65020198 5 Circlips Cotter Pins Replace circlips or cotter pins that were removed with new ones Install the circlip with its sharp edge facing outward and its chamfered side facing inward to prevent the clip from being pushed out of its groove when loaded Take care not to open the clip excessively when installing to prevent deformation 8020208 5 Lubrication It is important to lubricate rotating or sliding parts during PN P assembly to minimize wear during initial operation Lubri ot Y cation points called out throughout this manual apply Sa UA i the specific oil or grease as specified S A Sent bh 68020218 S 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 right 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 GENERAL INFORMATION 1 7 Model Identification VN2000 A1 US and Canada Left Side View 03814 VN2000 A1 US and Canada Right Side View 6
313. l spillage any spilled fuel must be completely wiped up immediately Turn both ignition switch and engine stop switch OFF e Wait until the engine cools down Open the fuel tank cap A to lower the pressure in the tank and draw the fuel out from the fuel tank with a com mercially available pump A WARNING The fuel cannot be removed completely from the fuel tank Be careful for remained fuel spillage e Disconnect the battery terminal Remove Rear Seat and Front Seat see Frame chapter Fuel Tank Bolt A e Disconnect the following from the fuel tank A Breather Hose Blue B Fuel Return Hose Red Californian Model C 3 118 FUEL SYSTEM DFI Fuel Tank e Unscrew the screw A and pull B out the cover C e Disconnect Fuel Level Sensor Connector A Meter Connector B Fuel Pump Connector C e Free the leads from the clamps D e Unscrew the bracket bolts A and pull down the bracket B e Place a cloth C around the fuel hose joint D e Pull down the fuel hose joint as follows OPush A the joint lock claws B in the photo the fuel hose joint has been removed for clarity A joint lock B as shown in the photo the fuel hose joint has been removed for clarity e Pull down the fuel hose joint WARNING Immediately wipe up fuel that spills FUEL SYSTEM DFI 3 119 Fuel Tank Close the fuel tank cap Remove t
314. laded screwdriver pry out the oil seal e Press out the mechanical seal A and ball bearing B from the inside of the right crankcase with the bearing driver set C Special Tool Bearing Driver Set 57001 1129 4 12 COOLING SYSTEM Water Pump OBe sure to replace the mechanical seal oil seal O ring and ball bearings with new ones because these parts will be damaged by removal e Apply plenty of high temperature grease to the oil seal lips e Apply oil to the outer circumference of the oil seal e Press the oil seal A into the hole from the inside of the right crankcase with the bearing driver set so that the spring side of the seal lips is toward the inside of the crankcase Special Tool Bearing Driver Set 57001 1129 e Press the oil seal in until the seal end is even with step B of the hole as shown OUse the bearing driver which has a larger diameter than the oil seal e Press in each ball bearing C with its manufacturer s mark facing out until it bottoms out e Press A the mechanical seal B by using a suitable 28 mm socket C and a bearing driver D until its flange touches the step E Gap F e Install the water pump shaft from the inside of the right crankcase Special Tool Bearing Driver Set 57001 1129 e Clean both sliding surfaces of a new mechanical seal with a high flash point solvent e g ethyl alcohol and apply a little coolant to
315. lay on the clip does discard it 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 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 OSlip the balance weight A on 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 blade A and clip B are fully seated on the rim C and that the clip is hooked over the rib D Left Side E Right Side F 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 condition 6J04074BS1 C 6J04075BS1 C 10 14 WHE
316. le x If the switch has an open circuit or a short it can be disas sembled for repair The contact surfaces may be cleaned but no internal parts are available for replacement any parts are not repairable the left handlebar switch must be replaced as a unit Turn Signal Switch Connections Color G GY BK Y Y R L left 9 e e OFF push R right 9 Signal Control Relay Inspection CAUTION Never drop the turn signal control relay especially on a hard surface Such a shock to the unit can damage it e Remove ECU see Fuel System chapter Turn Signal Control Relay A ELECTRICAL SYSTEM 16 63 Automatic Turn Signal Canceling System Connect one 12 V battery and turn signal lights as indi cated in the figure and count how many times the lights flash for one minute Turn Signal Control Relay Connector A Turn Signal Lights B 12 V Battery C x lf the lights do not flash as specified replace the turn sig nal control relay Testing Turn Signal Control Relay Inspection 8 14000351 C Load The Number of Turn Wattage W Flashing Times c m Signal Lights 21 23 140 250 2 42 46 75 95 Cycle s per minute corresponds to one light burned out and the other lights stay ON NOTE OEven if the foregoing checks show the turn signal con trol relay to be g
317. led or miss ing Air cleaner duct loose Air cleaner O ring damaged Water or foreign matter in fuel Throttle body assy loose Throttle body assy O ring damage 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 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 Decompression mechanism sticks open engine stalls when moving off HLA seizure Knocking Carbon built up in combustion chamber Fuel poor quality or incorrect Be sure to use high octane gasoline recommended by Owner s Manual Spark plug incorrect IC igniter in ECU trouble Miscellaneous Throttle valves 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 Air switching valve trouble Catalytic converters melt down due to muf fler 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 cylinder misfiring or poor runnin
318. left belt adjuster B aligns with the same swingarm mark C or position that the right belt adjuster notch aligns with xIf they do not adjust the belt deflection see Belt Deflec tion Adjustment and align the wheel alignment NOTE OWheel alignment can be also checked using the straightedge or string method A WARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition 1 07000851 PERIODIC MAINTENANCE 2 25 Periodic Maintenance Procedures Belt Wear and Damage Inspection e Using the jack and jack attachment under the frame pipe ribs lift the rear wheel off the ground see Rear Wheel Removal in the Wheels Tires chapter e Remove Bolts A and Washers Upper Belt Cover B e Visually inspect the belt A for wear and damage If the nylon fabric facing of any portion is worn off and the polyurethane compound is exposed or belt is damaged replace the belt immediately with a new one e Otherwise refer to the Drive Belt Tooth Wear Patterns and perform the according to the table of Drive Belt Wear Analysis Whenever the belt is replaced inspect the engine and rear pulleys see Pulley Wear Inspection in Final Drive chapter A WARNING A belt worn past the nylon fabric facing must be replaced Such a worn belt may cause a serious accident 2 26 PERIODIC MAINTENANCE Periodic Maintenance Procedures Drive Belt To
319. ls Steering Stem Bearing Driver B 57001 1344 Steering Stem Bearing Driver Adapter C 57001 1345 e Install the steering stem see Steering Stem Installation OCheck that there is no play and the steering stem turns smoothly without rattles If not the steering stem bearings may be damaged Stem Bearing Lubrication In accordance with the Periodic Maintenance Chart lubri cate the steering stem bearings Refer to the Stem Bearing Lubrication in Periodic Maintenance chapter 14 12 STEERING Steering Stem Bearing Stem Cap Deterioration Damage Replace the stem cap if its grease seal A shows dam age FRAME 15 1 Frame Table of Contents Exploded VieW T 15 2 serie DE 15 10 Vi MEA i MAI ELIO 15 11 Rear Seat Removal iter 15 11 Rear Seat Installation uii ita MA Sls 15 11 Front Seat Removal inniti het 15 11 5 DI E IN ERI 15 11 Side COVers sx fite elles tc tci oo ao s dore pA edie Lp ND Ru EUR Le Ref 15 12 Right Side Cover Removal i dette Eti ud 15 12 Right Side Cover Installations ric ent efecto s bed ge Ud ao cede 15 12 Left Side Cover 51 0 15 12 Left Side Cov
320. lug Torque Plug 2 5 N m 0 25 kgf m 22 in Ib Ball Bearing and Outer Race Replacement CAUTION Do not remove the ball bearing A on the middle cover B unless it is necessary Removal may damage them e Using a press or puller remove the ball bearing e Using a press and the bearing driver set A install the new bearing until it stops at the bottom of its housing Special Tool Bearing Driver Set 57001 1129 Ball Bearing Wear CAUTION Do not remove the ball bearings for inspection Re moval may damage them e Check the ball bearings OSince the ball bearings are made to extremely close toler ances the wear must be judged by feel rather than mea surement Clean each bearing in a high flash point sol vent dry it do not spin the bearing while it is dry and oil it with engine oil OSpin A the bearing by hand to check its condition x If the bearing is noisy does not spin smoothly or has any rough spots replace it gi140003 tif 5 30 ENGINE TOP END Camshafts Cam Wear Remove the camshaft see Camshaft Removal Measure the height A of each cam with a micrometer If the cams are worn down past the service limit replace the camshaft Cam Height Inlet Front Exhaust Front Standard 37 871 37 987 mm 37 351 37 467 mm 1 49098 1 49555 1 47051 1 47508 in in Service 37 77 mm 37 25 mm Limit 1 4870 in 1 4665 in Inlet Rear E
321. m ft lb 1 Muffler bracket bolts 25 2 5 18 2 Muffler cover clamp screws 6 9 0 7 61 R Replacement Parts CAL California Model EU Europian Models 5 8 ENGINE TOP END Specifications Item Standard Service Limit Push Rod Push rod length Push rod bend 295 18 mm 11 6212 in TIR 0 2 mm 0 008 in Camshafts Cam height Front Exhaust Inlet Rear Exhaust Inlet Camshaft journal diameter 928 Camshaft bearing inside diameter Camshaft journal diameter 22 Camshaft bearing inside diameter 922 Rocker arm inside diameter Rocker shaft diameter 37 351 37 467 mm 1 47051 1 47508 in 37 871 37 987 mm 1 49098 1 49555 in 39 571 39 687 mm 1 55791 1 56248 in 36 411 36 527 mm 1 43350 1 43807 in 27 967 27 980 mm 1 101061 1 101573 in 27 990 28 000 mm 1 101966 1 102360 in 21 975 21 990 mm 0 865156 0 865746 in 21 990 22 000 mm 0 865746 0 866140 in 16 000 16 018 mm 0 629921 0 630630 in 15 966 15 984 mm 0 628583 0 629291 in 37 25 mm 1 4665 in 37 77 mm 1 4870 in 39 47 mm 1 5539 in 36 31 mm 1 4295 in 27 94 mm 1 10000 in 28 06 mm 1 10472 in 21 95 mm 0 86417 in 22 06 mm 0 86850 in 16 05 mm 0 63189 in 15 94 mm 0 62756 in Cylinder Head Cylinder compression usable range 28 Cylinder head warp 284 500 kPa 2 9 5 1 kgf m 41 72 psi 8300 r min rpm
322. mbling the shifter with steel balls in place on the output shaft check the ball locking effect that the shifter gear does not come out of the output shaft when moving it up and down by hand e Replace any circlip A that were removed with new ones e Install the circlips so that the opening B is aligned with spline groove C Shift Fork Bending e Visually inspect the shift forks and replace any fork that is bend A bent fork could cause difficulty in shifting or allow the transmission to jump out of gear under load 90 A 6113040851 61128201 6111000351 9 38 CRANKSHAFT TRANSMISSION Transmission 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 lf the thickness of a shift fork ear is less than the service limit the shift fork must be replaced Shift Fork Ear Thickness Standard 6 9 7 0 mm 0 272 0 276 in Service Limit 6 8 mm 0 268 in xIf the gear groove is worn over the service limit the gear must be replaced Gear Groove Width Standard 7 05 7 15 mm 0 278 0 281 in Service Limit 7 3 mm 0 287 in Shift Fork Guide Pin Drum Groove Wear e Measure the diameter of each shift fork guide pin B and measure the width A of each shift drum groove xIf the guide pin on any shift fork is less than the service limit the fork must be replaced Shift F
323. moval Note the following e Fit the grooves inside the pulley onto the splines on the output shaft e Replace the washer with a new one e Apply molybdenum disulfide oil to the threads of the out put shaft and seating surface of the engine pulley mount ing nut e Tighten Engine Pulley Mounting Nut 177 N m 18 kgf m 130 ft Ib Special Tool Pulley Holder 57001 1572 Grip 57001 1591 Bend the one side of the washer over the nut e Adjust the drive belt deflection see Drive Belt Deflection Adjustment in the Periodic Maintenance chapter Rear Pulley Removal e Remove Rear Wheel see Wheels Tires chapter Rear Pulley Mounting Nuts A and Washers Rear Pulley B Rear Pulley Installation e Install Rear Pulley Washers and Rear Pulley Mounting Nuts e Tighten Torque Rear Pulley Mounting Nuts 69 N m 7 0 kgf m 51 ft Ib 11 12 FINAL DRIVE Pulley and Coupling Rear Pulley Coupling Removal e Remove Rear Wheel see Wheels Tires chapter Loosen lightly Rear Pulley Mounting Nuts A Remove the rear pulley B with the rear pulley coupling from the wheel e Remove Rear Pulley Mounting Nuts and Washers e Remove the rear pulley from the rear pulley coupling Rear Pulley Coupling Installation e Install the coupling dampers A so that the projections B face to the outside e Apply grease to the inside A of the coupling bushing e Install Sleeve B e Install the coupling on the c
324. must be KAWASAKI genuine or rec ommended by KAWASAKI Gaskets rings Oil seals t Grease seals 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 E ide A bly however if assembly order is provided in this Service a D Manual follow the procedures given E p 56 522 a ie b Vut 1 N T Es f 08020118 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 Oring Hardening shrinkage or damage of both gaskets and O rings after disassembly can r
325. n 5 25 Piston Ring Thickness 5 45 Spring Tension 5 25 Piston Ring End Gap 5 45 Decompression Solenoid oae e ete 5 46 5 25 Upper Muffler Removal 5 46 5 26 Lower Muffler Removal 5 46 Camshaft Removal 5 26 Exhaust Manifold Removal 5 46 Camshaft Installation 5 27 Muffler Exhaust Pipe Installation 5 47 5 2 ENGINE TOP END Exploded View US CA GAL S 5 S 00 GE02099BN5 ENGINE TOP END 5 3 Exploded View Torque No Fastener Nm kaim ftlb Remarks 1 Rocker case cover bolts 12 1 2 104 in Ib S AL 2 Rocker case bolts 15 1 5 11 S 3 Oil pipe banjo bolts 54 5 5 40 4jOlppetos 10 8Simb Upper cylinder head nuts 610 mm first 5 MO Upper cylinder head nuts 610 mm final 5 MO Upper cylinder head nuts 612 mm first 5 MO Upper cylinder head nuts 612 mm 88 90 65 final 5 MO Lower cylinder head nuts Water jacket plugs 9 Water jacket plugs 10 Air Switching Valve 11 Air Suction Valves 12 Oil Fitting MO Apply molybdenum disulfide oil L Apply a non permanent locking agent S Follow the specific tightening sequence G Apply grease R Replacement Parts CAL California Model US United
326. n discol oration or other damage xIf the sleeves needle bearing and ball bearing show sings of abnormal wear discoloration or damage re place them as a set Grease Seal and Needle Bearing Lubrication Refer to the Swingarm Pivot Lubrication in the Periodic Maintenance chapter 8 06029851 C 8 06030851 C 6 06031851 C 8 06032851 C STEERING 14 1 Steering Table of Contents Exploded casi etate ee es o ete Matt conte d e cde teet 14 2 Special tools Eee enn rete aene een e EG ed eder d DO D PER 14 4 PANGS i UH Cem 14 5 Handlebar Removal one Ed eer oec ence Erud 14 5 Handlebar Iristallatigriz zs ies tutte eed Deu E E et ad eoru eret ermita lem theca hasce 14 5 Steering re 14 7 Steering Check eian aniran Em 14 7 Steering AdjustMent siisii betes iea RS aantas 14 7 Steering Stellen eden oue O de astro pe ia a 14 8 Steering Stem Removal cde eae te ete n det aka Toe prono ta n RR RA RN SANE ok an cas Sas ep bug 14 8 Steering Stem InstallatiDpi o es Eder ete 14 9 terti VaL p s ei radit ice tales 14 10 Steering Stem Bearing sesta eb e ow Gardin
327. n at the factory Never drop the sensor especially on a hard surface Such a shock to the sensor can damage it Input Voltage Inspection NOTE 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 connectors e Connect a digital voltmeter A to the connector B using the needle adapter set C Special Tool Needle Adapter Set 57001 1457 Main Throttle Sensor Input Voltage Connections to ECU Connector Meter lead terminal 1 Meter gt lead terminal 25 e Measure the input voltage with the engine stopped and with the connectors joined e Turn the ignition switch ON Input Voltage at ECU Connector Standard 4 75 5 25 V DC e Turn the ignition switch OFF xIf the reading of input voltage is less than the standard check the ECU for its ground power supply and wiring shorted see ECU section xIf the input voltage is within the standard range remove the fuel tank and check wiring from ECU to the throttle sensor for continuity x If the wiring is good check the output voltage of the throt tle sensor OBO 6C17127BS1 6C17291BS1 C 3 46 FUEL SYSTEM DFI Main Throttle Sensor Service Code 11 Output Voltage Inspection e Measure the output voltage at the ECU in the same way as input voltage inspection Note the following
328. n more than 5 seconds and then release it 6C17278BS1 Gu s 51 200 D wae 6C17273BS1 m Ee 6C17274BS1 3 38 FUEL SYSTEM DFI Self Diagnosis e Repeat opening B and grounding A the lead self diagnosis terminal more than five times E within 2 seconds C after the lead is grounded and then keep it grounded continuously D for more than 2 seconds 6C17274BS1 FUEL SYSTEM DFI 3 39 Self Diagnosis Turn the ignition SW switch OFF E Connect the self diagnosis indicator terminal to the battery terminal using an auxiliary lead Y Turn the ignition SW ON and self diagnosis mode starts Na 5 5 5 Dealer Dealer pem sum e 1 CSa E NER Dealer Mode 2 Grounding the self diagnosis indicator terminal for more than 2 seconds than five times within 2 seconds after the terminal is first grounded and then keep it grounded Dealer Mode 1 Repeat opening and grounding the then keep it grounded i i I self diagnosis indicator terminal more i The LCD FI characters are displayed i 1 Locate the problem with the fault code table and check and repair DFI or ignition system according to inspection procedure on all fault code T
329. n the brake reservoirs e Bleed the brake line see Brake Line Bleeding e Check the brake for good braking power no brake drag and no fluid leakage A WARNING Do not attempt to ride the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against the disc The brakes will not function on the first appli cation of the lever or pedal if this is not done Front Caliper Disassembly e Refer to Caliper Rubber Parts Replacement in the Peri odic Maintenance chapter Front Caliper Assembly e Refer to Caliper Rubber Parts Replacement in the Peri odic Maintenance chapter 41058077 BRAKES 12 11 Calipers Rear Caliper Disassembly e Refer to Caliper Rubber Parts Replacement in the Peri odic Maintenance chapter Rear Caliper Assembly e Refer to Caliper Rubber Parts Replacement in Periodic Maintenance chapter Caliper Fluid Seal Damage The fluid seal piston seal A is placed around the pis ton to maintain clearance between the pad and the disc If the seal is in a poor condition it could lead the pad to wear excessively or the brake to drag which may cause the tem perature of the discs or the brake fluid to increase e Replace the fluid seal if it exhibits any of the conditions listed below OBrake fluid leakage around the pad OBrakes overheat OConsiderable difference in inner and outer pad wear OSeal and piston are stuck together lf
330. n 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 of highly flammable liquids do not use gasoline or low flash point solvent to clean the tank Remove the fuel tank see this chapter Remove the fuel pump from the fuel tank see Fuel Pump section in this chapter e Fill the fuel tank with some high flash point solvent and shake the tank to remove dirt and fuel deposits e Draw the solvent out of the tank e Dry the tank with compressed air e Install the fuel pump on the fuel tank see this chapter e Install the fuel tank see Fuel Tank Installation 3 122 FUEL SYSTEM Evaporative Emission Control System The Evaporative Emission Control System for California Model routes fuel vapors from the fuel system into the run ning engine or stores the vapors in a canister when the en gine is stopped Although no adjustments are required a thorough visual inspection must be made at the intervals specified by the Periodic Maintenance Chart Parts Removal Installation A WARNING Gasoline is extremely flammable and can be explo sive under certain conditions Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Turn the ignition switch OFF CAUTION If gasoline s
331. nance practices A WARNING This warning symbol identifies special instructions or procedures which if not correctly followed could result in per sonal injury or loss of life CAUTION This caution symbol identifies special instructions or procedures which if not strictly observed could result in dam age to or destruction of equipment This manual contains four more symbols in addition to WARNING and CAUTION which will help you distinguish different types of informa tion NOTE OThis note symbol indicates points of par ticular interest for more efficient and con venient operation e Indicates a procedural step or work to be done Olndicates a procedural sub step or how to do the work of the procedural step it follows It also precedes the text of a NOTE Indicates a conditional step or what action to take based on the results of the test or inspec tion in the procedural step or sub step it fol lows In most chapters an exploded view illustration of the system components follows the Table of Contents In these illustrations you will find the instructions indicating which parts require spec ified tightening torque oil grease or a locking agent during assembly GENERAL INFORMATION 1 1 General Information Table of Contents Before Servicing e old uua 1 2 Model Identification acces tr ta Ted ea eee de ERE ORARE ERE NL
332. ncy e Remove Radiator Fan Bolts A Radiator Fan B Radiator Installation e Torque the radiator fan bolts Torque Radiator Fan Bolts 8 3 N m 0 85 kgf m 74 e Fit the radiator stoppers A into the right and left grom mets e Torque Torque Water Hose Clamp Screws 2 0 N m 0 20 kgf m 17 in Ib Radiator Cover Bolts 11 1 1 kgf m 97 in Ib Radiator Inspection e Check the radiator core lf 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 B from the radiator core Hold the steam gun perpendicular C not oblique D to the core surface and run the steam gun fol lowing the core fin direction 6007020151 C COOLING SYSTEM 4 15 Radiator Radiator Cap Inspection Check the condition of the top and bottom valve seals of the radiator cap If any one of them shows visible damage replace the cap Bottom Valve Seal A Top Valve Seal B Valve Spring C e Install the cap A on a cooling system pressure tester B NOTE OWet the cap sealing surfaces
333. nd cut its needle to 2 1 2 3 mm 0 0827 0 0906 in long A Grind its cutting edge B smooth e Push in the check valve of the HLA D with the needle of the tack C and move the plunger up and down in the oil bath the plunger sinks into the HLA body repeat the air bleeding procedure and then push the plunger x After air bleeding if the plunger sinks into the HLA body again replace the HLA CAUTION Do not push the check valve in more than 2 1 2 3 mm Pushing too deep may cause the damage of the HLA S gt 52 XX GE20001BS2 C GE21060181 5 22 ENGINE TOP END Rocker Case HLA Installation Check that the HLA plunger is not damaged x lf the plunger does damage replace the HLA HLA Body A O ring B Plunger Spring C Pivot Plunger D SSS D Check Valve Spring F GE21060281 e Air bleed the HLA see HLA Air Bleeding e Soak a rocker arm A in engine oil and then insert the HLA B into the rocker arm careful not to tip the rocker arm having the HLA and not to allow engine oil to leak out of the HLA 218 P ENGINE TOP END 5 23 Decompression Mechanism Decompression Mechanism Removal Remove the right side cover see Frame chapter e Loosen the clamps A e Disconnect the decompression solenoid lead connector B e Unscrew the outer camshaft cove
334. nd license plate light should go on lf the light does not go on inspect or replace the following item Ignition Switch see Electrical System chapter PERIODIC MAINTENANCE 2 29 Periodic Maintenance Procedures Third Step Turn on the turn signal switch A left or right position The left or right turn signal lights B front and rear cording to the switch position should flash The turn signal indicator light C in the meter unit should flash xIf the each light does not flash inspect or replace the following item Turn Signal Light Bulb see Electrical System chapter Turn Signal Light Indicator Bulb see Electrical System chapter Turn Signal Control Relay Fuse 10 A see Electrical Sys tem chapter Turn Signal Switch see Electrical System chapter Turn Signal Control Relay see Electrical System chap ter Harness see Wiring Inspection in Electrical System chapter e Push the turn signal switch e The turn signal lights and indicator light should go off x If the light does not go off inspect or replace the following item Turn Signal Switch see Electrical System chapter Turn Signal Control Relay see Electrical System chap ter NOTE ORefer to Electrical system chapter for the automatic turn signal canceling system Fourth Step e Set the dimmer switch A to low beam position e Start the engine e The low beam headlight should go on xIf the low beam headlight does not
335. ness Connector C 8 6 ENGINE REMOVAL INSTALLATION Engine Removal Installation e Remove Spark Plug Caps A Clamp B Ignition Coil Bracket C Place it on the frame Engine Bracket Bolts D Engine Bracket E e Disconnect the horn lead connectors A e Disconnect Alternator Lead Connector A Crankshaft Sensor Lead Connector B Side Stand Switch Lead Connector C Oil Pressure Switch Terminal D Speed Sensor Lead Connector A Gear Position Sensor Lead Connector B Compression Release Solenoid Lead Connector C e Remove Hose Cover Screws A Both Sides Hose Cover B Engine Ground Terminal C ENGINE REMOVAL INSTALLATION 8 7 Engine Removal Installation e Unscrew the Allen bolt A and disconnect the starter mo tor lead terminal B e Disconnect Rear Brake Switch Connector A Regulator Rectifier Connectors B GHO4026BS2 C e Support the engine with a commercially available stand A e Remove Front Engine Mounting Bolt and Nut A Downtube Bolts and Nuts B Both Sides Downtubes C Both Sides NOTE ORemove the right downtube with the right footboard regulator rectifier and rear master cylinder installed 8 8 ENGINE REMOVAL INSTALLATION Engine Removal Installation e Remove Clamp A Radiator Hose Pipe Bolts B Radiator Hose Pipe C e Remove the bolts A holding the ower s tool box B and move it to left side e Remove Rear E
336. ng If any brake hose routing is incorrect route the brake hose according to Cable Wire and Hose Routing section in the Appendix chapter Brake Operation Inspection e Inspect the operation of the front and rear brake by run ning the vehicle on the dry road the brake operation is insufficiency inspect the brake system A WARNING When inspecting by running the vehicle note a surrounding traffic situation enough in the place of safety Brake Fluid Level Inspection 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 If the fluid level is lower than the lower level line fill the reservoir to the upper level line A in the reservoir B GL10020181 C PERIODIC MAINTENANCE 2 17 Periodic Maintenance Procedures e Check that the brake fluid level in the rear brake reservoir A is between the upper B and the lower C level lines If the fluid level is lower than the lower level line fill the reservoir to the upper level line OUse extra heavy duty brake fluid only from a container marked DOT4 OBrake fluid of DOT4 is installed in the brake system when shipped Torque Front Brake Reservoir Cap Screws 1 5 N m 0 15 kgf m 13 in Ib A WARNING Do not mix two brands of fluid Change the brake fluid in the brake line complet
337. ngine Mounting Bolts and Nuts A e Unscrew the upper and lower adjuster locknuts A Special Tool Socket Wrench 57001 1347 B e Unscrew the upper and lower adjusters A to make a space between the engine and frame ENGINE REMOVAL INSTALLATION 8 9 Engine Removal Installation e Move A the engine forward a little e Disconnect the following hoses Canister Purge Hose A Green California Model to Air Switching Valve Hose Reserve Tank Hose B Brown to Thermostat Housing Fuel Tank Breather Hose C Blue Fuel Tank Return Hose D Red California Model Vacuum Hose E White California Model to Throttle Body Assy e Remove the engine A from the motorcycle right side 8 10 ENGINE REMOVAL INSTALLATION Engine Removal Installation Engine Installation e Support the engine with a suitable stand e Set the collar A and insert the lower rear engine mount ing bolt e Torque the fasteners following the specified sequence Torque Front Downtube Nuts 1 88 N m 9 0 kgf m 65 ft Ib Upper Adjusting Bolt 2 9 8 N m 1 0 kgf m 87 in Ib Lower Adjusting Bolt 3 9 8 N m 1 0 kgf m 87 in Ib Upper Adjusting Bolt Locknut 4 49 N m 5 0 kgf m 36 ft Ib Lower Adjusting Bolt Locknut 5 49 N m 5 0 kgf m 36 ft Ib Upper Rear Engine Mounting Nut 6 59 N m 6 0 kgf m 43 ft Ib Lower Rear Engine Mounting Nut 7 59 N m 6 0 kgf m 43 ft Ib Upper Engine Bracket Nuts 8 59 N m 6 0
338. nnect the ECU con nectors ECU Installation e Connect the ECU connector e Fit the ECU A in the ribs B ECU Power Supply Inspection e Visually inspect the terminals of the ECU connector xIf the connector is clogged with mud or dust blow it off with compressed air Replace the main harness if the terminals A of the main harness connectors are cracked bent or otherwise dam aged Replace the ECU if the terminals of the ECU connector are cracked bent or otherwise damaged e With the ECU connector A joined check the following ground leads for continuity with the ignition SW ON or OFF using a digital voltmeter D ECU Grounding Inspection Meter Connections 26 27 51 BK Y Battery Terminal Terminal 25 BR BK Terminal Battery Terminal Engine Ground lt Battery Terminal Terminal B Readings 0 regardless of the ignition SW or OFF no continuity check the connector the engine ground lead or main harness and repair or replace them if nec essary Battery C in the Frame Special Tool Needle Adapter Set 57001 1457 FUEL SYSTEM DFI 3 103 ECU e Check the power source voltage of the ECU with a digital voltmeter ECU Power Source Inspection Meter Connection between 13 W Y Terminal and Battery Terminal Ignition SW OFF OV Ignition SW ON Battery Voltage 12 5 V or more x lf the voltmeter does not read as specified check th
339. nning Down Neutral no Starts leased running Down Neutral Pulled in Starts running Re Doesn t Down In Gear etait Stops Down In Gear Pulled in DOSE Stops start lf the side stand switch operation does not work inspect or replace the following item Battery see Electrical System chapter Main Fuse 30 A see Electrical System chapter Ignition Fuse 10 A see Electrical System chapter Ignition Switch see Electrical System chapter Side Stand Switch see Electrical System chapter Engine Stop Switch see Electrical System chapter Starter Button see Electrical System chapter Gear Position Switch see Electrical System chapter Starter Control Relay see Electrical System chapter Relay Box see Electrical System chapter Starter Control Relay see Electrical System chapter Harness see Wiring Inspection in Electrical System chapter xf the all parts are good condition replace the ECU 65178017 P 2 32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Engine Stop Switch Operation Inspection First Step e Turn on the ignition switch e Set the neutral position e Turn the engine stop switch to stop position e Push the start button e The engine does not start xIf the engine starts inspect or replace the following item Engine Stop Switch see Electrical System chapter Second Step e Turn on the ignition switch e Set the neutral position
340. nsistorized Electronically advanced digital From 13 BTDC 2900 r min rpm 51 BTDC 4 000 r min rpm From 15 BTDC 2900 r min rpm 51 BTDC 4 000 r min rpm NGK IZFR6F 11 Front to Rear 1 2 1 2 39 BTDC 69 ABDC 288 69 BBDC 39 ATDC 288 Forced lubrication semi dry sump API SE SF or SG class API SH or SJ class with JASO MA SAE10W 40 5 5 L 5 8 US qt when engine is completely disassembled and dry 1 10 GENERAL INFORMATION General Specifications VN2000 A1 Items Drive Train Primary reduction system Type Reduction ratio Clutch type Transmission Type Gear ratios ist 2nd 3rd Ath 5th Final drive system Type Reduction ratio Overall drive ratio Chain 1 500 48 32 Wet multi disc 5 speed constant mesh return shift 2 550 51 20 1 629 44 27 1 218 39 32 0 939 31 33 0 729 27 37 Belt 2 744 50 40 x 72 32 EU 2 455 48 44 x 72 32 3 003 Top gear EU 2 687 Top gear 12 V 55 W quartz halogen Frame Type Tubular double cradle Caster rake angel 32 Trail 182 mm 7 17 in Front tire Type Tubeless Size 150 80 16 71V Rear tire Type Tubeless Size 200 60 R16MC 79V Front suspension Type Telescopic fork Wheel travel 150 mm 5 91 in Rear suspension Type Swingarm with mono shock non link type Wheel travel 100 mm 3 94 in Brake Type Front Dual disc Rear Single disc Electrical Equipment Battery Capaci
341. nstall a cooling system pressure tester A on the radiator filler neck B NOTE OWet the cap sealing surfaces with water or coolant to prevent pressure leakage 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 93 kPa 0 95 kgf cm 13 5 psi or more the system is all right the pressure drops and no external source is found check for internal leakage Droplets in the engine oil indi cate internal leakage Check the cylinder head and oylin der gaskets and the water pump e Remove the pressure tester replenish the coolant and install the radiator cap COOLING SYSTEM 4 9 Coolant Cooling System Flushing Over a period of time the cooling system accumulates rust scale and lime in the water jacket and radiator When this accumulation is suspected or observed flush the cool ing system If this accumulation is not removed it will clog up the water passage and considerably reduce the effi ciency of the cooling system e Drain the cooling system see Coolant Change in the Pe riodic Maintenance chapter e Fill the cooling system with fresh water mixed with a flush ing compound CAUTION Do notuse a flushing compo
342. nt 50 Freezing point 35 C 31 F Total amount 2 5 L 2 6 US qt reserve tank full level including radiator and engine Radiator Cap Relief pressure 93 123 kPa 0 95 1 25 kgf cm 13 5 17 8 psi Thermostat Valve opening temperature 58 62 C 136 144 F Valve full opening lift 8 mm 0 3 in or more 75 C 167 F COOLING SYSTEM 4 7 Special Tools and Sealant Bearing Driver Set Bearing Remover Head 10 x 12 57001 1129 57001 1266 Ce Bearing Remover Shaft 57001 1265 he 4 8 COOLING SYSTEM Coolant Coolant Deterioration Inspection e Visually inspect the coolant A in the coolant level hose B In the photo the muffler have been removed for clar ity If whitish cotton like wafts are observed aluminum parts in the cooling system are corroded If the coolant is brown iron or steel parts are rusting In either case flash the cooling system the coolant gives off an abnormal smell check for cooling system leak It may be caused by exhaust gas leaking into the cooling system Coolant Level Inspection e Refer to Coolant Level Inspection in the Periodic Mainte nance chapter Coolant Draining Refer to Coolant Change in the Periodic Maintenance chapter Coolant Filling e Refer to Coolant Change in the Periodic Maintenance chapter Pressure Testing e Remove the fuel tank see Fuel System chapter e Remove the radiator cap and i
343. nts Exploded View ED 11 2 E A A PEE 11 4 Special a dc ev Sets den P e ect Mae Re 11 5 DIE 11 6 Belt Handling Precautions oer ete 11 6 Drive Belt Wear 11 7 Drive Belt Deflection 11 7 Drive Belt Deflection Adjustment sieis sista Laredo eee Raoul eh eae 11 7 Drive Belt ipa tects antes ta iet tenias 11 7 Drive Belt Instalati 11 8 Pilly a d COU DING 11 9 Engine Pulley Cover Removal sss tete vince 11 9 Engine Pulley Cover Installation 11 9 Engine Pulley Removal ito teret Engiri amp secs tute corrige dien ter ee see si Rear Pulley Removals react dcc aie Ae den Rear Pulley Install aun sip doe bett a tu oe e sco Seale aes dis Rear Pulley Coupling Removal nec nire he uin Db Rear Pulley Coupling IristallatiQn uui iit Pret to te t tut t ttd Pulley Wear Inspection pet Coupling Bearing Remov
344. ny brand ofthe specified oil to top off the level in preference to running the engine with the oil level low Then at your earliest convenience change the oil completely Engine Oil Change e Refer to Engine Oil Change in the Periodic Maintenance Chapter ENGINE LUBRICATION SYSTEM 7 9 Engine Oil and Oil Filter Oil Filter Replacement Refer to Oil Filter Replacement in the Periodic Mainte nance Chapter 7 10 ENGINE LUBRICATION SYSTEM Oil Pump and Oil Line Oil Pump Removal e Remove the engine see Engine Removal Installation chapter e Split the crankcase see Crankshaft Transmission chap ter e Remove Circlip A Oil Pump Sprocket B Pin C Washer D Oil Pump Cover Bolts E Oil Pump Cover F Clrclip G Oil Pump Gear H Pin J e Remove the rotor assembly with the pump shaft K from the left crankcase half L 8805015 52 C Oil Pump Installation e Install the oil pump shaft A to the inside of the left crankcase half B OApply molybdenum disulfide oil to the rubbing surfaces of the shaft and rotors e Install the scavenge oil pump for the crank room oil Olnstall the outer rotor A pin B and inner rotor C e Install the spacer A so that their pins B face downward ENGINE LUBRICATION SYSTEM 7 11 Oil Pump and Oil Line e Install the scavenge oil pump for the clutch room oil Olnstall the outer rotor A pin B and inner rotor C e Install the
345. ny time the AIR MUST BE BLED FROM THE BRAKE LINE 12 22 BRAKES Brake Hoses Brake Hose Removail installation CAUTION Brake fluid quickly ruins painted surfaces any spilled fluid should be completely washed away immediately e When removing the brake hose take care not to spill the brake fluid on the painted or plastic parts e When removing the brake hose A temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum e Immediately wash away any brake fluid that spills e There are washers B on each side of the brake hose fitting Replace them with new ones when installing e Tighten the banjo bolts C on the hose fittings Torque Brake Hose Banjo Bolts 25 2 5 kgf m 18 ft Ib e When installing the hoses A avoid sharp bending kink ing flattening or twisting and route the hoses according to Cable Wire and Hose Routing section in the General Information chapter e Fill the brake line after installing the brake hose see Brake Fluid Changing SUSPENSION 13 1 Suspension Table of Contents zue ni 13 2 SPECI CATIONS IE 13 6 Jerem 13 7 FONE FOr sS 13 8 Fork Oll Change AAEE ETAETA TAA EEn airi 13 8 Front Fork Removals d ati eere nee etta ee eT bI neds Te p ers 13 11 Front Fork 13 11 Fron
346. o faults Check the DFI electronic control system injectors sensors crankshaft sensors and ECU the fuel pressure is much higher than the specified check the following Delivery Pipe Clogging Injector Clogging lf the fuel pressure is much lower than specified check the following Fuel Pump for Operation check the sound of the pump Fuel Line Leakage or Clogging Amount of Fuel Flow see Fuel Flow Rate Inspection the fuel pressure is much lower than specified and if inspection above checks out good replace the fuel pump assy the fuel filter may be clogged and measure the fuel pressure again xIf the residual pressure 260 280 kPa drops at once the high pressure fuel line could be leaking e Remove the fuel pressure gauge and adapter e Pull A the joint lock B fully as shown e Insert the fuel hose joint A straight onto the delivery pipe e Push B the joint lock C until the hose joint clicks FUEL SYSTEM DFI 3 107 Fuel Line e Push and pull A the fuel hose joint B back and forth more than two times and make sure it is locked and doesn t come off A WARNING Make sure the fuel hose joint is installed correctly on the delivery pipe or the fuel could leak xIf it comes off reinstall the hose joint e Run the fuel hose in accordance with the Cable Wire and Hose Routing section in the Appendix chapter e Install the removed part Fuel Flow Rate Inspection NOTE OB
347. o times to ensure even tightening torque 13 12 SUSPENSION Front Fork e Install the removed parts and tighten Torque Front Axle Nut 127 N m 13 kgf m 94 ft Ib Front Axle Clamp Bolts 25 N m 2 5 kgf m 18 ft Ib Front Caliper Mounting Bolts 25 N m 2 5 kgf m 18 ft lb NOTE OTighten the two clamp bolts alternately two times to en sure even tightening torque Check the front brake effectiveness after installation A WARNING Do not attempt to ride the motorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against the disc The brake will not function on the first application of the lever if this is not done Front Fork Disassembly Drain the fork oil see Fork Oil Change OThe following parts are removed during draining the fork oil Cap A Stopper Ring B Top Plug C O ring D Collar E Washer F Spring G Hold the front fork horizontally in a vise A e Stop the cylinder unit B from turning by using the special tools e Unscrew the Allen bolt C and take the gasket out of the bottom of the outer tube Special Tools Fork Cylinder Holder Handle D 57001 183 Fork Cylinder Holder Adapter E 57001 1057 e Take the cylinder unit A out of the inner tube B SUSPENSION 13 13 Front Fork e Separate the inner tube from the outer tube as follows ORemove the spring band A and dust seal B fr
348. od and check insert crankpin clearance with the plastigage Crankshaft Runout e Measure the crankshaft runout If the measurement exceeds the service limit replace the crankshaft Crankshaft Runout Standard TIR 0 06 mm 0 0024 in or less Service Limit TIR 0 15 mm 0 0059 in 9 24 CRANKSHAFT TRANSMISSION Crankshaft Connecting Rods Crankshaft Main Bearing Journal Wear e Measure the diameter A of the crankshaft main journal Crankshaft Main Journal Diameter Standard 56 986 57 000 mm 2 2435 2 2441 in Service Limit 56 96 mm 2 2425 in If any journal has worn past the service limit replace the crankshaft with a new one Measure the main bearing bore diameter A in the crankcase halves Crankcase Main Bearing Bore Diameter Standard 57 030 57 049 mm 2 2559 2 2460 in Service Limit 57 08 mm 2 2472 in they are any signs of seizure damage or excessive wear replace the crankcase halves as a set 6105081851 C Crankshaft Side Clearance e Measure the crankshaft side clearance Crankshaft Side Clearance Standard 0 05 0 35 mm 0 00197 0 0138 in Service Limit 0 55 mm 0 0217 in Crankshaft A Crankcase B Clearance C gi040050 tif xIf the clearance is greater than the service limit measure the crankshaft web length A to see whether the crank shaft or the crankcase is f
349. of the ignition coil secondary cables 15 14 FRAME Fenders Front Fender Removal CAUTION Be careful not to scratch the painted surface during removal or installation e Remove Front Wheel see Wheels Tire chapter Front Fender Bolts A Front Fender B Rear Fender Removal CAUTION Be careful not to scratch the painted surface during removal or installation e Remove Seats Seats Removal Rear Fender Cover Bolts A and Washers e Pull B the rear fender cover C to clear the stopper and remove it Disconnect the rear turn signal and taillight lead connector A e Remove Seat Lock Cable B from bracket of latch side Rear Fender Front Bolts C Rear Fender Allen Bolts D both sides Remove the rear fender rearwards Rear Fender Installation e Install the grommets A into the rear fender cover B so that the wider side C faces to frame D e Put the stopper A into the grommet B Run the seat lock cable and rear turn signal and taillight lead in accordance with the Cable Wire and Hose Rout ing section in the Appendix chapter FRAME 15 15 Battery Case Tool Case Tool Case Removal e Remove Seats see Front Rear Seats Removal Connector A Battery Cover Screws B Battery Cover C e Remove Kawasaki Diagnostic System Connector A Partition Bolt B Partition C e Remove Seat Lock Cable Connectors A e Remove To
350. oil pump body A OBe sure the dowel pin B is in position e Install the pin C e Install the feed oil pump for the transmission room oil Olnstall the outer A and inner rotor B e Install Oil Pump Cover A Oil Pump Cover Bolts B Washer C Torque Oil Pump Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib e Install the following to the pump shaft Pin Oil Pump Sprocket Circlip e Check that the oil pump shaft turns smoothly in the left crankcase half 7 12 ENGINE LUBRICATION SYSTEM Oil Pan Oil Pan Removal e Drain the engine oil see Engine Lubrication System in the Periodic Maintenance chapter e Disconnect the oil pressure switch lead from the terminal screw see Oil Pressure Measurement e Remove Oil Pan Bolts A Oil Pan B Front C e Remove the oil screen A for transmission room with the O ring B e Remove Oil Screen Bolt A Oil Screen B for Crankcase Room Oil Pan Installation e Clean the oil screens A with high flash point solvent and remove any particles stuck to it A WARNING Clean the screen 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 solvents NOTE OWhile cleaning the screen check for any metal particles that might indicate internal engine damage OCheck the screen carefully for any damage hole and broken wire x l
351. ol Bag A Cable Lock Bracket Bolt B Cable Lock Bracket C e Remove Tool Case Bolts A 15 16 FRAME Battery Case Tool Case e Remove Connector Bracket A Remove Tool Case A Battery Case Removal e Remove Seats see Front Rear Seats Removal Battery see Electrical System chapter Battery Damper A e Disconnect Ground Lead Connector A White Lead Connector B Starter Relay Lead Connector C Atmospheric Pressure Sensor Lead Connector D e Remove Bracket Screw E Starter Relay F Fuse Box G e Remove Tool Case see Tool Case Removal Rear Shock Absorber see Suspension chapter ECU A FRAME 15 17 Battery Case Tool Case e Remove Relay Box A Turn Signal Control Relay B Starter Control Relay C e Remove Vehicle down Sensor Bolts A Vehicle down Sensor B e Remove Rear Fender see Rear Fender Removal Rear Wheel see Wheels Tires chapter Swingarm see Suspension chapter Battery Case Bolts A Move the battery case A to clear the bracket B of the frame e Remove the battery case A to rearward 15 18 FRAME Footboard and Sidestand Right Footboard Removal e Remove Footboard Bracket Bolts A Footboard B Right Footboard Installation Tighten Torque Footboard Bracket Bolts 34 3 5 kgf m 25 16 Right Footboard Disassembly e Remove Right Footboard see Right Footboard Removal Spring A Ci
352. ols satisfac tory results may be obtained by heating the case to ap proximately 93 C 200 F max and tapping the bearing in or out CAUTION Do not heat the case with a blowtorch This will warp the case Soak the case in oil and heat the oil e Using a press and the bearing driver set A install the new bearing or outer race until it stops at the bottom of its housing Special Tool Bearing Driver Set 57001 1129 Ball and Needle Bearing Wear CAUTION Do not remove the ball bearings for inspection Re moval may damage them e Check the ball bearings OSince the ball bearings are made to extremely close toler ances the wear must be judged by feel rather than mea surement Clean each bearing in a high flash point sol vent dry it do not spin the bearing while it is dry and oil it with engine oil OSpin A the bearing by hand to check its condition xIf the bearing is noisy does not spin smoothly or has any rough spots replace it e Check the needle bearings OThe 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 xf there is any doubt as to the condition of a needle bear ing replace it gi140003 tif CRANKSHAFT TRANSMISSION 9 41 Ball Bearing Needle Bearing and Oil Seal Oil Seal Inspection e Inspect the oil seal Replace it if t
353. oltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition SW OFF e Remove the relay box see Electrical System chapter Do not disconnect the relay box connector e Connect a digital voltmeter B to the ECU main relay con nector A using the needle adapter Battery C in the frame Special Tool Needle Adapter Set 57001 1457 OMeasure the power source voltage of the injector with the engine stopped and with the connectors joined e Turn the ignition SW ON e Start the engine Injector Power Source Voltage at ECU Main Relay Connections Meter W BK Lead Terminal D Meter gt Battery Terminal Standard Battery Voltage 12 5 V or more e Turn the ignition SW OFF x lf the power source voltage is incorrect check the ECU main relay see Electrical System chapter lf the power source voltage is normal check the output voltage of the injector 00113448 5 GC17345BS1 C FUEL SYSTEM DFI 3 79 Fuel Injectors 1 2 Service Code 41 42 Output Voltage Inspection Turn the ignition switch OFF Remove the ECU see ECU section in this chapter Do not disconnect the ECU connector Connect a digital voltmeter A to the connector B using the needle adapter set C Special Tool Needle Adapter Set 57001 1457 Injector Output Voltage at ECU Connections for Injector 1 Meter BL R lead terminal 38 Meter
354. olution or rubber lubricant to the rim flange and tire beads CAUTION Never lubricate with mineral oil engine oil or gaso line because they will cause deterioration of the tire 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 is at the tire balance mark B the chalk mark made during removal or the yellow paint mark on a new tire e Install the tire bead over the rim flange using a 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 core whenever inflating the tire and do not inflate the tire to more than 400 kPa 4 0 kg cm 57 psi Overinflation can explode the tire with possibility of injury and loss of life e Check to see that the rim lines A on both sides of the tire sidewalls are parallel with the rim flanges xf the rim flanges and tire sidewall bead lines are not par allel 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 tir
355. olvent water or any other liquid enters the canister the canister s vapor absorbing capac ity is greatly reduced If the canister does become contaminated replace it with a new one e To prevent the gasoline from flowing into or out of the canister hold the separator perpendicular to the ground e Be sure to plug the return hose to prevent fuel spilling before fuel tank removal A WARNING When removing the fuel tank be careful not to spill the gasoline through the return hose Spilled fuel is hazardous xIf liquid or gasoline flows into the breather hose remove the hose and blow it clean with compressed air Connect the hoses according to the diagram of the sys tem see Cable Wire and Hose Routing section in the Appendix chapter Make sure they do not get pinched or kinked Route hoses with a minimum of bending so that the air or vapor will not be obstructed Canister Installation Refer to Evaporative Emission Control System Check in the Periodic Maintenance chapter Canister Inspection Periodic Inspection e Refer to Evaporative Emission Control System Check the Periodic Maintenance Chapter chapter 2 Separator Inspection Periodic Inspection e Refer to Evaporative Emission Control System Check in the Periodic Maintenance chapter chapter 2 Hose Inspection Periodic Inspection e Refer to Evaporative Emission Control System Check in the Periodic Maintenance chapter chapter 2
356. om 6809414BN5 APPENDIX 17 11 Cable Wire and Hose Routing Front Main Harness Clamp 020 Clamp 015 Breather Tube Starter Relay Engine Ground Terminal Starter Motor Lead Run the starter motor lead and engine ground lead between the engine mount and frame bracket 10 Fuel Tank Bottom 11 Vacuum Tube White California Model 12 Main Harness 13 Frame 14 Damper 15 Breather Tube 16 Hold the harness with the damper and fit the damper on the hook of frame 17 Coolant Reservoir Tube 18 Tube Green California Model 17 12 APPENDIX Cable Wire and Hose Routing Aral PLY ML P WI aul clin va an pM 9 ON i We xU D APPENDIX 17 13 Cable Wire and Hose Routing Front Ignition Coil Secondary Lead Fuel Level Sensor Lead Connector Meter Unit Lead Connector Fuel Pump Lead Connector Run the leads outside of the clamp Insert the clamp in the bracket Rear Ignition Coil Secondary Lead Front Ignition Coil Primary Lead Red Green Front Ignition Coil Primary Lead Black Rear Ignition Coil Primary Lead Black Green Rear Ignition Coil Primary Lead Red Green Front Ignition Coil Direction of the Ignition Coil Primary Lead Rear Ignition Coil Clamp Red Green Ignition Coil Lead Clamp Re
357. om the outer tube ORemowve the retaining ring A from the outer tube OHolding the outer tube A by hand pull the inner tube B several times to pull out the inner tube OTake out the cylinder base out of the outer tube e Remove the guide bushings A washer B and oil seal C from the inner tube Front Fork Assembly e Replace the following parts with new ones after removal Dust Seal A Retaining Ring B Oil Seal C Inner Guide Bushing D Outer Guide Bushing E Bottom Allen Bolt Gasket F 6 04181851 C 13 14 SUSPENSION Front Fork e Put the cylinder unit A with the spring into the inner tube B protruding from the inner tube and install the cylinder base C onto the bottom end of the cylinder unit Olnstall the cylinder base with the tapered end D up e Install the inner tube cylinder unit and cylinder base as a set into the outer tube e Install the new guide bushing A with a used guide bush ing B on it by tapping the used guide bushing with fork oil seal driver C until it stops OThe split D of the bushing should face toward the side of the vehicle Special Tool Fork Oil Seal Driver 57001 1589 e Apply molybdenum disulfide grease to the oil seal lips and install the washer A and the oil seal B into the outer tube OFace the flat side C of the seal upward Special Tool Fork Oil Seal Driver D 57001 1589 e Install Retaining Ring e A
358. on chapter Clean the old grease out of the bearings e Apply grease to the inner surface of the needle bearings A e Apply a thin coat of grease to the lips B of the grease seals e Install the swingarm see Suspension chapter 65148104 PERIODIC MAINTENANCE 2 21 Periodic Maintenance Procedures Clutch and Drive Train Clutch Operation e Pull the clutch lever just enough to take up the free play A 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 or exhaust pipe during clutch adjustment e Loosen the locknut A at the clutch lever e Turn the adjuster B until the proper amount of clutch lever free play is obtained e Tighten the locknut securely lf it cannot be done use the adjuster at the middle of the cable e Loosen the locknut A at the middle of the clutch cable e Turn the adjusting nut B until the proper amount of clutch lever free play is obtained e Tighten the locknut securely A 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
359. onnecting the hose and applying compressed air to the hose joint open ing using the same wooden board But be careful not to put your fingers or palm inside the caliper opening during work A 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 pistons may crush your hand or fingers CAUTION Immediately wash away any brake fluid that spills e Remove the anti rattle spring A e Remove the dust seals B and fluid seals C e Remove the rubber friction boots D e Remove the bleed valves E and rubber caps F GLO5010BS1 C PERIODIC MAINTENANCE 2 45 Periodic Maintenance Procedures Rear Caliper Assembly Tighten the bleed valve Torque Caliper Bleed Valve 7 8 0 80 kgf m 69 in Ib Olt is recommended that the fluid seal piston seal which is removed be replaced with a new one Replace the dust seals A Replace the fluid seal B Either side of the seal may face outboard e Install the anti rattle spring A in the caliper as shown Apply brake fluid to the cylinders pistons and fluid seals piston seals and push the pistons into the cylinders by hand Take care that neither the cylinder nor the piston skirt gets scratched Replace the caliper holder shaft rubber friction boot A and dust boot B e Apply a thin coat of silicone or PBC grea
360. ood it may be defective in some man ner especially for automatic turn signal canceling op eration not readily detectable with above checks If all other checks are good replace the turn signal control relay Turn Signal Light Bulb Replacement e Remove the turn signal light lens screw A and take off the lens B e Push the bulb A in the socket and turn the bulb counter clockwise B e Replace the bulb 16 64 ELECTRICAL SYSTEM Automatic Turn Signal Canceling System e Insert the new bulb A by aligning the pins B with the groove in the walls of the socket C e Fit the projection A in the recess B of the lens Tighten Torque Turn Signal Light Lens Screws 1 0 N m 0 10 kgf m 8 7 in Ib ELECTRICAL SYSTEM 16 65 Automatic Turn Signal Canceling System Turn Signal Cancelling System Circuit SEIS 18 G BK Y BK Y 2 p Ignition Switch Fuse Box Turn Signal Control Relay Fuse 10 A Turn Signal Control Relay Meter Unit Distance Sensor Turn Signal Indicator Light Front Left Turn Signal Light GP24007BW3 9 Front Right Turn Signal Light 10 Rear Left Turn Signal Light 11 Rear Right Turn Signal Light 12 Turn Signal Switch 13 Joint Connector 14 Joint Connector 15 Main Fuse 30 A 16 Battery 16 66 ELECTRICAL SYSTEM Radiator Fan System Fan Motor Inspection e Disconnect th
361. oove 5 28 ENGINE TOP END Camshafts e Install the front A and rear B camshafts e Install the camshaft chain C OAlign the crankshaft timing mark D with the middle link of three blue colored links E and camshaft timing marks F with the blue colored links G e Install the camshaft tensioner H with the stopper pin I Torque Camshaft Tensioner Bolts 12 N m 1 2 kgf m 104 in Ib NOTE ODo not the pull the stopper pin out of the camshaft ten sioner Pull outthe stopper pin after installing the middle camshaft cover e Put the spacer J on the inner camshaft cover K GE11067BN2 e Apply molybdenum disulfide oil to the surface A shown with X marks of the decompression shafts B and install them to the camshafts GE11068BS1 C ENGINE TOP END 5 29 Camshafts e Be sure the dowel pins A are in position e Install the new gasket B NOTE OPull the stopper pin C after installing the middle camshaft cover see below e Install the middle camshaft cover A Torque Middle Camshaft Cover Bolts Length 95 mm 105mm 12 N m 1 2kgf m 104 in Ib Middle Camshaft Cover Bolts Length 35 mm 12 N m 1 2 kgf m 104in Ib e Pull the stopper pin B through the hole C of the middle camshaft cover e Gease the O ring D on the plug E e Install the stopper pin plug on the middle camshaft cover OApply a non permanent locking agent to the stopper pin p
362. oove in the inner tube e Install the cap and reinstall the front fork correctly see Front Fork Installation SUSPENSION 13 11 Front Fork Front Fork Removal YA gt e Using the jack A and jack attachment B under the frame pipes and a commercially available jack C under the engine lift the front wheel off the ground until the rear wheel touches the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1571 CAUTION Be sure to put the rear wheel on the ground when removing the front fork or the motorcycle may fall over The motorcycle could be damaged Be sure to put the rear wheel on the ground when removing the front fork or the motorcycle may fall over It could cause an accident and injury e Remove Front Wheel see Wheels Tires chapter Front Fender see Frame chapter Headlight Cover see Frame chapter NOTE Olf the front fork is to be disassembled or oil changed af ter removal remove the plug before the front is removed see Fork Oil Change e Loosen Front Fork Clamp Bolts A e Remove Front Fork B Front Fork Installation e Install the fork so that the top end of the inner tube is flush with the upper surface A of the steering stem head bracket e Tighten Torque Upper Front Fork Clamp Bolts 20 N m 2 0 kgf m 15 ft Ib Lower Front Fork Clamp Bolts 34 N m 3 5 kgf m 25 ft Ib NOTE OTighten the two lower clamp bolts alternately tw
363. open the rocker arm e Using the valve spring compressor assembly remove the valve Special Tools Valve Spring Compressor Assembly 57001 241 A Valve Spring Compressor Adapter 628 2 57001 243 B Valve Installation Replace the stem oil seal with a new one e Apply a thin coat of molybdenum disulfide grease to the valve stem before valve installation e Install the spring so that the closed coil end faces down wards Valve A and Stem Oil Seal B Spring Seat C Spring D Retainer E and Split Keepers F Valve Guide Removal Remove the valve stem oil seal and spring seats 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 Special Tool Valve Guide Arbor 5 7 57001 1564 CAUTION Do not heat the cylinder head with a blowtorch This will warp the head Soak the cylinder head in engine oil and heat the oil Valve Guide Installation e Apply engine oil to the valve guide outer surface before installation e Heat the area around the valve guide hole to about 120 150 C 248 302 F in the engine oil 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 5 7 57001 1564 e Wait until the cylinder head cools down and then ream the valve guide with the valve guide reamer
364. or Criteria The oxygen sensor is active and sensor must send signals output voltage continuously to the ECU Backups by ECU If the oxygen Sensor is not activated the ECU stops oxygen Sensor feedback mode Ignition Coil 1 The ignition coil primary winding must send signals output voltage continuously to the ECU If the ignition primary winding 1 has failures no signal wiring short or open the ECU shuts off the injector 1 to stop fuel to the cylinder 1 though the engine keeps running Ignition Coil 2 The ignition coil primary winding must send signals output voltage continuously to the ECU If the ignition primary winding 2 has failures no signal wiring short or open the ECU shuts off the injector 2 to stop fuel to the cylinder 2 though the engine keeps running Subthrottle Valve Actuator The actuator operates open and close of the subthrottle valve by the pulse signal from the ECU If the sub throttle actuator fails the signal is out to the usable range wiring short or open the ECU stops the current to the actuator Oxygen Sensor Heater The oxygen sensor heater raise temperature of the sensor for its earlier activation 12V 6 0W 0 5A If the oxygen sensor heater fails wiring short or open the ECU stops the current to the heater Note Subthrottle Stepping Driver The subthrottle stepping driver must send signals continuously to the EC
365. or if bubbles are found in the area the line is leaking Perform the following as necessary ORetighten the fuel hose clamps D Torque Fuel Hose Clamp Screws 1 5 0 15 kgf m 13 in Ib OReplace O ring of Injectors G ORepeat the leak test and check the fuel line for no leak age e Install the fuel outlet hose see Fuel Line section in this chapter e Run the hoses correctly see Cable Wire and Hose Rout ing section in the General Information chapter e Install the fuel tank see this chapter and connect the battery terminal 8017224852 C 3 78 FUEL SYSTEM Fuel Injectors 1 2 Service Code 41 42 Audible Inspection Start the engine e Insert a screwdriver from the engine right side between the fuel tank buttom end and the engine top end 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 not OA sound scope B can also be used e Do the same for the other injector Front D 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 x If either injector doesn t click the DFI circuit or the injector is suspect Perform Power Source Voltage Inspection first Power Source V
366. ork Guide Pin Diameter Standard 5 9 6 0 mm 0 232 0 236 in Service Limit 5 8 mm 0 228 in lf any shift drum groove is worn over the service limit the drum must be replaced Shift Drum Groove Width Standard 6 05 6 20 mm 0 238 0 244 in Service Limit 6 3 mm 0 248 in Gear Dog and Gear Dog Hole Damage 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 6113145851 C 6113146851 C 6113147851 C CRANKSHAFT TRANSMISSION 9 39 Transmission B did 19 05 81131298484 C 1 Drive Shaft 10 Five Circlips 2 Low 1st Gear 26 9 x 32 2 x t1 5 3 3rd Gear 11 Bushing Top Gear 4 4th Gear 12 Four Splined Washers 5 Top 5th Gear 30 3 x 40 x 11 5 6 2nd Gear 13 Output Shaft 7 Needle Bearing 14 Shifter 8 Circlip 23 2 x 27 9 x t1 2 15 Steel Balls 9 Three Thrust Washers 25 5 x 36 x t1 16 Bushing 3rd amp 4th Gears 17 Align bushing oil holes with the shaft holes 9 40 CRANKSHAFT TRANSMISSION Ball Bearing Needle Bearing and Oil Seal Ball Bearing and Outer Race Replacement CAUTION Do not remove the ball bearing or needle bearing outer race unless it is necessary Removal may damage them e Using a press or puller remove the ball bearing and or needle bearing outer race NOTE Oln the absence of the above mentioned to
367. oth Wear and Damage Patterns AJA LAJA Du AA QOO QUOC 8 A Belt Cross Section B Edge Bevel Wear C Rub Wear D Stone PERIODIC MAINTENANCE 2 27 Periodic Maintenance Procedures Drive Belt Wear and Damage Analysis Internal tooth cracks slight Condition Required Action O K for continued use but inspect the belt periodically Scuffing to side of teeth Fraying edge cord Beveled wear O K for continued use but inspect the belt periodically Also check the pulley flange O K for continued use but inspect the belt periodically replace the belt if excessive O K for continued use check the pulley alignment and flange condition External tooth cracks severe Replace the drive belt Severe fractured or missing teeth Replace the drive belt Tooth hook wear Replace the drive belt Inspect the pulley for wear 1 2 4 5 6 7 8 Stone damage Electrical System Spark Plug Condition Inspection e Visually inspect the spark plugs x lf the spark plug center electrode A and or side elec trode B are corroded or damaged or if the insulator C is cracked replace the plug If the spark plug is dirtied or the carbon is accumulated replace the spark plug e Measure the gap D with a wire type thickness gauge xIf the gap is incorrect replace the spark plug Spark Plug Gap 1 0 1 1 mm 0
368. oth ends the cable should move freely A within the cable housing If cable movement is not free after lubricating if the cable is frayed B or if the cable housing is kinked C replace the cable Bolts and Nuts 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 x lf 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 chapter For each fastener first loosen it by 1 2 turn then tighten it cotter pins are damaged replace them with new ones 6004020281 C 2 38 PERIODIC MAINTENANCE Periodic Maintenance Procedures Nut Bolt and Fastener to be checked Wheels Front Axle Front Axle Clamp Bolts 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 Steering Stem Head Nut Handlebar Clamp Bolts Engine
369. otor cycle s life without any maintenance if it is used under normal conditions Olnstall the canister and hoses the hoses according to Cable Wire and Hose Routing section in the Appendix chapter Refer to the di agram of the evaporative emission control system in the Fuel System 1 chapter too Olnstall the rear inner cover see Frame chapter e Check the liquid vapor separator as follows ORemove the rear inner cover see Frame chapter ORemove the band A and take out the separator B ODisconnect the hoses C from the separator OVisually inspect the separator for cracks and other dam age If the separator has any cracks or damage replace it with a new one OTo prevent the gasoline from flowing into or out of the canister hold the separator perpendicular to the ground e Check the hoses of the evaporative emission control sys tem as follows OCheck that the hoses are securely connected and clips are in position OReplace any kinked deteriorated or damaged hoses ORoute the hoses according to Cable Wire and Hose Routing section in the Appendix chapter Refer to the di agram of the evaporative emission control system in the Fuel System chapter too OWhen installing the hoses avoid sharp bending kinking flattening or twisting and route the hoses with a minimum of bending so that the emission flow will not be obstructed 2 36 PERIODIC MAINTENANCE Periodic Maintenance Proc
370. ound E Gear Position Switch Input Voltage at Other Gear Positions Connector to Sensor Meter BL Meter Frame Ground E e Measure the sensor input voltage with the engine stopped and with the connector joined e Turn the ignition switch ON Input Voltage at Neutral Position Standard About 0 V DC Input Voltage at Other Gear Positions Standard 1st About 5 V 2nd About 5 V 3rd About 5 V 4th About 5 V 5th About 5 V e Turn the ignition switch OFF the reading is out of the standard range check the wiring see wiring diagram in this section xIf the reading is good the input voltage is normal Check the gear position switch FUEL SYSTEM DFI 3 67 Gear Position Switch Service Code 25 NK lt OO TON lt OW N TON eo F dio SP N cou eoe WOM SST MEME MP ME XE CO C AINA ex ex ex ex ev e E a a 2 zi a G O4 7 1 ECU 2 Gear Position Switch 3 Frame Ground 6017385BN2 3 68 FUEL SYSTEM DFI Vehicle down Sensor Service Code 31 Vehicle down Sensor Removal e Remove the battery see Frame chapter e Unscrew the screws A and disconnect the connector B e Remove the vehicle down sensor C Installation e Install the vehicle down sensor A and washer in the orig inal po
371. ound the seat Ground Volum D lf the seat width is too narrow repeat the 45 grind until the seat is slightly too wide and then measure the seat O D lf the seat width is too wide make the 60 grind described below To make the 60 grind fit 60 cutter into the holder and slide it into the valve guide e Turn the holder while pressing down lightly Grind the seat at a 60 angle A until the seat width B is within the specified range x lf the seat width is within the specified range lap the valve to the seat as described below GE15020881 C GE15020781 GE15012381 C ENGINE TOP END 5 39 Cylinder Head 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 compound on the face of the valve 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 The seat 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 itis it may have been refaced too much replace it e Be sure to remove all grinding compound before assem bly 8 11000851 C
372. oupling dampers 00118007 P e When installing the stud bolt A in the coupling B note the following e Apply a non permanent locking agent to the threads C of the coupling side e Tighten Torque Rear Coupling Stud Bolts 44 N m 4 5 kgf m 33 ft Ib GK11006BS1 C FINAL DRIVE 11 13 Pulley and Coupling Pulley Wear Inspection e Visually inspect the engine and rear pulley teeth for wear and damage lf the teeth are worn damage or loss of the chrome plat ing exists replace the pulley and inspect the drive belt wear see Drive Belt Wear Inspection in Periodic Mainte nance chapter A Engine Pulley B Rear Pulley NOTE Olf the pulley requires replacement the belt is probably worn also Whenever replacing the pulley inspect the belt Coupling Bearing Removal e Remove Rear Pulley Coupling see Rear Pulley Coupling Re moval Sleeve A e Remove Collar A Grease Seal B e Remove Circlip A Special Tool Inside Circlip Pliers B 57001 143 e Remove Ball Bearing C Special Tool Oil Seal amp Bearing Remover 57001 1058 0118012 P 9118013 P Grip P 11 14 FINAL DRIVE Pulley and Coupling Coupling Bearing Installation e Apply grease to the new ball bearing e Press the ball bearing until it is bottomed Special Tool Bearing Driver Set 57001 1129 e Install Circlip Special Tool Inside Circlip Plier
373. own with the six sealed cells into the filler ports of the battery Hold the container level push down to break the seals of all six cells You will see air bubbles rising into each cell as the ports fill NOTE ODo not tilt the electrolyte container 8 08020451 C 8 08003851 C 8 09000851 C 8 09000751 C 16 30 ELECTRICAL SYSTEM Battery e Check the electrolyte flow lf no air bubbles A are coming up from the filler ports or if the container cells have not emptied completely tap the container B a few times e Keep the container in place for 20 minutes or more Don t remove the container from the battery until it s empty the battery requires all the electrolyte from the container for proper operation CAUTION Removal of the container before it is completely empty can shorten the service life of the battery Do not remove the electrolyte container until it is com pletely empty and 20 minutes have elapsed e Gently remove the container from the battery e Let the battery sit for 60 minutes prior to charging to allow the electrolyte to permeate into the plates for optimum performance NOTE OCharging the battery immediately after filling can shorten service life Let the battery sit for at least 60 minutes after filling Initial Charge e Place the strip A of caps loosely over the filler ports e Newly activated sealed batteries require an initial c
374. pliers Fuse Installation lf 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 Fuse Inspection e Remove the fuse see Fuse Removal e Inspect the fuse element is down 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 CAUTION Do not use a fuse rated for other amperage and volt age specified in the wiring diagram Installation of a fuse with a higher rating may cause damage to wiring and components and a fuse of a lower rat ing will soon blow again GP20000181 C APPENDIX 17 1 Appendix Table of Contents Cable Wire and Hose Routing a ipa eii e a dec aes 17 2 Troubleshooting Guide except DFI 17 56 17 2 APPENDIX Cable Wire and Hose Routing Ste Q WES 1D a vic N hs 1 ie LT OL hen gt m M 5 D 1 Ming ED 4 22 RS 4 09 e 0 29 iL BA A 6B09405BN5 C APPE
375. pply molybdenum disulfide grease to the dust seal lips and install it e Apply a non permanent locking agent to the threads of the Allen bolt and screw the Allen bolt into the bottom of the outer tube e Hold the front fork horizontally in a vise A e Hold the cylinder unit B with the special tools and tighten the Allen bolt C Special Tools Fork Cylinder Holder Handle D 57001 183 Fork Cylinder Holder Adapter E 57001 1057 Torque Bottom Allen Bolt 23 N m 2 3 kgf m 17 ft Ib e Install the cover stopper A as shown B Inner Tube C 252 3 0 3 mm 9 93 x 0 01 in e Tighten Torque Cover Stopper Bolt 4 2 N m 0 43 37 in Ib 89 1 O ze 8 04182851 C 6 04176851 C GM04177BS1 C 8 04013851 C GMO4188BS1 C SUSPENSION 13 15 Front Fork Inner Tube Outer Tube Inspection e Visually inspect the inner tube A and repair any damage Nick or rust damage can sometimes be repaired by using a wet stone to remove sharp edges or raised areas which cause seal damage the damage is not repairable replace the inner tube Since damage to the inner tube damages the oil seal replace the oil seal whenever the inner tube is repaired or replaced CAUTION If the inner tube is badly bent or creased replace it Excessive bending followed by subsequent straightening can weaken the inner
376. que Coolant Drain Bolt 9 8 N m 1 0 kgf m 87 in Ib e Pour the coolant into the radiator 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 2 52 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Loosen the air bleeder bolt A on the thermostat housing Front B e Replenish the coolant into the radiator until the coolant begins to flow out the air bleeder bolt hole that is all the remaining air is forced out e Tap the radiator hoses to force any air bubbles caught inside e Fill the radiator up to the filler neck A with coolant e Install the radiator cap e Tighten the air bleeder bolt B Torque Thermostat Air Bleeder Bolt 7 8 N m 0 80 kgf m 69 in Ib e Fill the reserve tank up to the F full level line A with coolant and install the cap in the photo the muffler has been removed for clarity e Install the fuel tank see Fuel System 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 xIf the coolant level is lower than the L level line B add coolant to the F level line CAUTION Do not add more coolant above the F level line PERIODIC MAINTENANCE 2 53 Periodic Maintenance Procedures
377. r Front Seat Installation e Slip the front seat hook A into the front seat bracket B on the frame e Tighten the front seat mounting bolts e Install the rear seat see Rear Seat Installation 15 12 FRAME Side Covers Right Side Cover Removal e Insert the ignition key C into the right side cover A and turn the key clockwise B until the key slot is vertical e Pull the right side cover forward D to clear the hook F and then remove the side cover pulling it outward to clear the projections E Right Side Cover Installation e Put the stoppers A into the grommets B e Turn the ignition switch key A counterclockwise B until the key slot is horizontal to secure the right side cover C Left Side Cover Removal e Remove the screw A e Pull B the left side cover evenly outward to clear the stoppers and remove the left side cover Left Side Cover Installation e Put the stoppers A into the grommets B e Tighten the screw Side Covers FRAME 15 13 Ignition Coil Bracket Cover Removal e Remove Ignition Coil Bracket Cover Screw A e Pull B the ignition coil bracket cover C evenly outward to clear the stoppers and remove the cover Ta MAL m P A gt Ignition Coil Bracket Cover Installation e Put the stoppers A into the grommets B Tighten the screw Refer to Ignition Coil Installation in Electrical System chapter for the position
378. r 12 1 2 104 in Ib 3 sensor 44 4 5 33 4 Gear position switch mounting bolts 6 9 0 7 61 in Ib 5 Gear position switch lead clamp bolts 6 9 0 7 61 in Ib 6 Camshaft position sensor bolt 9 8 1 0 87 in Ib L Exhaust pipe Inlet air pressure sensor Camshaft position sensor Atmospheric pressure sensor Vehicle down sensor ECU Electronic control unit Relay box Battery case Fuel pump Fuse 30A Gear position switch Canister Separater California Model European Model Replacement Parts Apply a non permanent locking agent Apply grease Apply cable lubricant Follow the specified tightening sequence Apply silicone sealant Three Bond TB1211F Apply adhesive cement Left hand Threads 3 6 FUEL SYSTEM DFI Exploded View FUEL SYSTEM DFI 3 7 Exploded View Torque No Fastener NS kgfm ilb Remarks 1 Fuel level sensor mounting bolts 6 9 0 70 61 in Ib L 2 Speed sensor mounting bolt 9 8 1 0 87 in lb L 3 Delivery joint bolts 9 8 1 0 87 in lb L 4 body assy holder bolts 9 8 1 0 87 in lb L 5 Inlet manifold bolts 9 8 1 0 87 in lb L 6 Air cleaner housing bolts 9 8 1 0 87 in lb 7 Air cleaner housing Allen bolts 9 8 1 0 87 in lb 8 Fuel level sensor 9 Speed sensor 10 Sub harness 11 O rings 12 1 Injector 13 Seals 14 Delivery pipe 15 Throttle body assy 16 Idle adjuster 17 2 Injector
379. r Assembly Bolts O rings e Using compressed air remove the pistons One way to remove the pistons is as follows Olnstall a rubber gasket A and a wooden board B more than 10 mm 0 4 in thick on the caliper half and fas ten them together with a suitable bolt and nut as shown Leave one of the oil passages C open OLightly apply compressed air D to the oil passage until the pistons hit the rubber gasket Block the hose joint opening E during this operation if the caliper half has the opening F Bolt and Nut G Cil Passage Sealed by Rubber Gasket H Push down PERIODIC MAINTENANCE 2 43 Periodic Maintenance Procedures A WARNING To avoid serious injury never place your fingers or palm in front of the piston If you apply compressed air into the caliper the piston may crush your hand or fingers OPull out the pistons by hand Remove the dust seals A and fluid seals B e Remove the bleed valve C and rubber D e Repeat the previous step to remove the pistons from the other side of the caliper body NOTE Olf compressed air is not available do as follows for both calipers coincidentally with the brake hose connected to the caliper OPrepare a container for brake fluid and perform the work above it ORemove the spring and pads see Brakes chapter OPump the brake lever until the pistons come out of the cylinders and then disassemble the caliper Front Caliper Assem
380. r Inspection in the Periodic Maintenance chapter Drive Belt Deflection Inspection e Refer to Belt Deflection Inspection in the Periodic Main tenance chapter Drive Belt Deflection Adjustment e Refer to Belt Deflection Adjustment in the Periodic Main tenance chapter Drive Belt Removal e Remove Rear Wheel see Wheels Tires chapter Engine Pulley see Engine Pulley Removal Swingarm see Suspension chapter NOTE OBefore removing observe the direction the belt s printed information A such as manufacture s name is facing so that it may be reinstalled on the pulleys to rotate in the same direction as originally installed e Remove the drive belt B GK10002BS1 C GK10003BS1 C 11 8 FINAL DRIVE Drive Belt Drive Belt Installation Installation is reverse of removal Note the following NOTE OBe sure the printed information faces the same direction so the belt rotates in the same direction as originally in stead When installing a new belt install it so the printed information can be read from left side of the motorcycle Tighten the swingarm pivot shaft nut to the specified torque see Exploded View in the Suspension chapter e Adjust the drive belt deflection see Drive Belt Deflection Adjustment in the Periodic Maintenance chapter FINAL DRIVE 11 9 Pulley and Coupling Engine Pulley Cover Removal e Remove Bolt A Outside Cover B e Remove Bolts A Washers an
381. r Stator Installation e Install the alternator stator coil so that the hole A faces rearward e Apply a non permanent locking agent to the alternator stator coil mounting bolts Tighten Torque Alternator Stator Coil Mounting Bolts 12 N m 1 2 kgf m 104 in Ib e Apply silicone sealant to the all sides of the grommets B and fit the grommets into the notches of the crankcase Sealant Three Bond TB1211F e Install the crankshaft sensor C and clamp D as shown e Tighten Torque Crankshaft Sensor Mounting Bolts 6 9 N m 0 70 kgf m 61 in Ib e Install the removed parts Charging Voltage Inspection e Remove the seats see Frame chapter e Check the battery condition e Warm up the engine to obtain actual alternator operating conditions e Check that the ignition switch is turned off and connect the hand tester to the battery as shown in the table Special Tool Hand Tester 57001 1394 Battery Charging Voltage Tester Connections Reading Range Tester to Tester to 23000 rpm 25 V DC Battery Battery 14 5 15 5 V e Turn on the ignition switch and 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 in the head light unit The readings should show nearly battery volt age when the engine speed is low and as the engine speed rises the readin
382. r bolts A and remove the outer camshaft cover B e Remove Camshaft Position Sensor Bolt A Decompression Solenoid Bolts B Camshaft Position Sensor Lead Connector C Camshaft Position Sensor D Decompression Solenoid E e Drain the engine oil see Engine Lubrication System chapter e Remove Decompression Push Rod A Camshaft End Cover Bolts B Camshaft End Cover C e Remove the holder A from the camshaft ends com pressing the spring B OPull up C the left end of the holder and pull the right end backwards D NOTE OTo remove the decompression shafts E remove the middle camshaft cover see Camshaft Removal in this chapter CAUTION Do not remove the middle camshaft cover without removing the rocker case or the engine internal prts damage will occur 5 24 ENGINE TOP END Decompression Mechanism Decompression Mechanism Installation e Be sure the dowel pins A are in position e Apply molybdenum disulfide oil to the rubbing surfaces A of the decompression shaft ends B Holder C Spring D Front Camshaft E Rear Camshaft F e Install the new gasket A e Position and bend the clamp B as shown e Torque the camshaft end cover bolts C Torque Camshaft End Cover Bolts 12 N m 1 2 kgf m 104 in Ib e Grease the O ring D on the camshaft position sensor E and torque the camshaft position sensor bolt F OApply a non permanent locking agent to the
383. r lead correctly see Cable Wire and Hose Routing section in Appendix chapter Oxygen Sensor Inspection California and Europe models e Refer to Fuel System DFI chapter for oxygen sensor inspection Front Brake Light Switch Inspection e Refer to the Front Brake Light Switch Inspection in the Periodic Maintenance chapter Rear Brake Light Switch Check Adjustment e Refer to the Rear Brake Light Switch Check Adjustment in the Periodic Maintenance chapter Water Temperature Sensor Removal CAUTION The water temperature sensor should never be al lowed to fall on a hard surface Such a shock to the part can damage it e Remove Fuel Tank see Fuel System chapter Radiator Cap e Pump out the coolant A in the thermostat using a sy ringe e Disconnect Water Temperature Sensor Connector B e Remove Water Temperature Sensor C L4 E ELECTRICAL SYSTEM 16 87 Switch and Sensors Water Temperature Sensor Installation Tighten Torque Water Temperature Sensor 12 N m 1 2 kgf m 104 in Ib e Fill the engine with coolant and bleed the air from the cooling system see Coolant Filling in the Cooling System chapter Water Temperature Sensor Inspection e Remove the water temperature sensor e Suspend the sensor A in a container of machine oil so that the heat sensitive portion and threaded portion are submerged e Suspend an accurate thermometer B with heat sensitive portions C
384. r short Injector 1 malfunction wiring open or short Injector 2 malfunction wiring open or short Fuel pump malfunction wiring open or short Ignition coil 1 primary winding malfunction wiring or short Ignition coil 2 primary winding malfunction wiring or short Starter relay malfunction wiring open or short Radiator fan relay malfunction wiring open or short Subthrottle valve actuator malfunction wiring open or short 3 42 FUEL SYSTEM DFI Self Diagnosis Service Code FI Indicator LED Light Problems 1 Air switching valve malfunction wiring open or short Decompression solenoid malfunction wiring open or short Oxygen sensor heater malfunction wiring open or short Subthrottle stepping driver malfunction wiring open or short 94 Oxygen sensor malfunction wiring open or short Footnotes 1 The ECU may be involved in these problems If all the parts and circuits checked out good be sure to check the ECU for ground and power supply If the ground and power supply are checked good replace the ECU California and European Models FUEL SYSTEM DFI 3 43 Self Diagnosis Backups OThe ECU takes the following measures to prevent engine damage when the DFI or the ignition
385. r the cylinder and or piston as necessary Replace the piston and or the piston rings Cylinder Head Removal e Remove Engine see Engine Removal Installation chapter Rocker Cases see this chapter e Remove the oil pipe bolts A and pull up the oil pipes B Front Cylinder C e Remove the push rods and pipes e Remove the cylinder head nuts A ENGINE TOP END 5 33 Cylinder Head Remove the lower cylinder head nuts A e Take the cylinder heads B off the cylinders C Cylinder Head Installation CAUTION The cylinder head and rocker case are machined in the assembled state so they must be used as a set e Apply molybdenum disulfide oil A to both sides of the washers B and the cylinder head nut C threads e For the washers A under M12 cylinder head nuts put them so that their chamber side B faces upwards A SY NA W N NN SS d S Y N NN N NN N N fe NW GE14030BS1 C GE14031BS1 C GE14045BS1 C 5 34 ENGINE TOP END Cylinder Head e Be sure the dowel pins A are in position e Replace the cylinder head gaskets B OThe front gasket has an F mark C while the rear gasket has an R mark D Olnstall the gasket so that their can be read and be sure that the projections E are in position e Temporarily torque th
386. r the throttle cables are removed or accor dance with the Periodic Maintenance Chart lubricate the these cables Refer to General Lubrication in the Periodic Maintenance Chapter OUse a commercially available pressure cable lubricator to lubricate these cables OWith the cable disconnected at both ends the cable should move freely in the cable housing 3 110 FUEL SYSTEM DFI Throttle Body Assy Idle Speed Check e Refer to Idle Speed Check in the Periodic Maintenance Chapter Idle Speed Adjustment e Refer to Idle Speed Check in the Periodic Maintenance Chapter Throttle Bore Cleaning e Check the throttle bore for cleanliness as follows ORemowve the air cleaner housing see this chapter OCheck the throttle bores A at the throttle valves B and around them for carbon deposits by opening the valves If any carbon accumulates wipe the carbon off the throttle bores around the throttle valves using a lint free cloth C penetrated with a high flash point solvent Front D High Altitude Performance Adjustment OAny modification is not necessary in this model since the atmospheric pressure sensor senses pressure change due to high altitude and the ECU compensates the change Throttle Body Assy and Intake Manifold Removal e Remove the fuel tank see this chapter A WARNING Gasoline is extremely flammable and can be explo sive under certain conditions Make sure the area is well ventilated and fre
387. r wheel on the ground when removing the steering or the motorcycle may fall over It could cause an accident and injury e Remove Headlight Unit see Electrical System chapter Headlight Cover see Frame chapter Front Turn Signal Light see Electrical System chapter Brake Hose Clamp Bolt A Brake Lever Master Cylinder and Hose Assembly Connectors B disconnect Stem Cover Bolts C Stem Cover Remove Handlebar Clamp Bolts and Clamp Handlebar Assembly Steering Stem Head Nut A and Washer Front Fork see Suspension chapter e Remove O ring A Steering Stem Head B STEERING 14 9 Steering Stem e Remove Claw Washer A Remove Steering Stem Nut A Special Tool Steering Stem Nut Wrench B 57001 1100 Remove Oil Seal C Remove O ring A NOTE OBe sure to remove the O ring for removal of the steering stem e Pull out the steering stem B from the bottom Steering Stem Installation e Apply grease to the needle bearings e Install Steering Stem A Bearing B New O ring C 1 0 34 5 x 2 mm Stem Cap D Stem Nut E e Settle the bearings in place as follows OTighten the stem nut to 39 N m 4 kgf m 29 ft lb of torque To tighten the steering stem nut to the speci fied torque hook the wrench on the stem nut and pull the wrench at the hole by 218 N 22 2 kgf 49 Ib force in the direction shown Special Tool Steering Stem Nut Wrench A 57
388. rame may fail in use possibly causing an accident If the frame is bent dented cracked or warped replace it G009010BS1 C ELECTRICAL SYSTEM 16 1 Electrical System Table of Contents Exploded 16 4 Specifications 16 12 Special Tools 16 13 Wiring Diagram United States and afines 16 14 Wiring Diagram California 16 16 Wiring Diagram Australia and Malaysia it e et eruta 16 18 Wiring Diagram Other than United States Canada Australia and Malaysia ce Cete bet dotes 16 20 Electrical Parts Location 16 22 Servicing Precautions 16 25 Electrical Wiring 16 27 Wiring Inspection 16 27 T 16 28 Battery Removal 16 28 Battery Installation 16 28 Battery Activation 16 29 Precautions 16 31 16 31 Charging Condition Inspection 16 32 Refreshing 16 32 Charging System 16 34 Alternator Rotor Removal 16 34 Alternator Rotor Installation 16 34 Alternator Stator Removal 16 34 Alternator
389. rankpin Diameter Marks None 54 981 54 991 mm 2 1646 2 16500 in 54 992 55 000 2 16504 2 1654 Crankpin Diameter Mark O mark or no mark B CRANKSHAFT TRANSMISSION 9 23 Crankshaft Connecting Rods Temporarily install the big end and tighten the big end bolts to the specified torque Molybdenum Disulfide Oil Threads and Flanged Portion of Big End Bolts Torque Connecting Rod Big End Bolts 59 N m 6 0 kgf m 43 ft lb Measure the connecting rod big end bore diameter and mark each connecting rod big end in accordance with the inside diameter OThe mark already on the big end should almost coincide with the measurement because of little wear Connecting Rod Big End Bore Diameter Marks None 58 000 58 010 mm 2 2835 2 28386 in 58 011 58 019 mm 2 28390 2 2842 in Big End Cap A Connecting Rod B OUT Mark C Diameter Mark D or no mark e Select the proper bearing insert A identified by the size color B in accordance with the combination of the con necting rod and crankshaft coding Big End Bearing Insert Selection gi040051 tif Con rod Big End Crankpin Bearing Insert Bore Diameter Diameter Marking Mark Size Color Part Number None 92028 1476 Nong None Black 92028 1475 e O O None Blue 92028 1474 e Install the new inserts the connecting r
390. rclip B Pin C Right Footboard Assembly e Replace the circlip A with a new one e Install Footboard Damper B Footboard C Bank Sensor D Bank Sensor Bolts E Pin F Circlip e Install the spring G as shown e Install Footboard Bracket H Footboard Bracket Bolts I Washers J e Apply oil to the bushings K and install them GO14000BS2 C FRAME 15 19 Footboard and Sidestand Left Footboard Removal Remove Footboard Bracket Bolts A Footboard B Left Footboard Installation e Instal the shift pedal Tighten Torque Footboard Bracket Bolts 34 3 5 kgf m 25 ft Ib Left Footboard Disassembly e Remove Left Footboard see Left Footboard Removal Spring A Circlip B Pin C Left Footboard Assembly e Replace the circlip A with a new one e Apply grease to the contact positions of the footboard footboard bracket and pin e Install Footboard Damper B Footboard C Bank Sensor D Bank Sensor Bolts E Pin F Circlip e Install the spring G as shown e Install Footboard Bracket H Footboard Bracket Bolts I Washers J e Apply oil to the bushings K and install them YAT p ERO 6014001852 C 15 20 FRAME Footboard and Sidestand Side Stand Installation e Apply grease to the contact surface of the frame and side stand e Install Side Stand A Side Stand Mounting Bolt B and Nut C Tight
391. re Sensor or Inlet Air Pressure Sensor Input voltage Output voltage Inlet Air Temperature Sensor Resistance Water Temperature Sensor Resistance Vehicle down Sensor Detection angle Detection time Fuel Injectors Type Static injection quantity Nozzle type x diameter Resistance Fuel Pump Type Discharge Speed Sensor Input voltage at sensor Output voltage at sensor Subthrottle Sensor Input Voltage Output Voltage Resistance DFI System Make Denso Idle Speed 900 x 50 r min rpm Throttle Body Assy Type x Bore Two barrel type x 46 mm 1 81 in Digital memory type with built in IC igniter sealed with resin 304 kPa 3 1 kgf cm 44 psi with fuel pump running 280 kPa 2 9 kgf cm 41 psi with fuel pump stopped 304 kPa 3 1 kgf cm 44 psi with fuel pump running Non adjustable and non removable 4 75 5 25 V DC between BL W and BR BK leads 1 02 4 62 V DC between Y W and BR BK leads at idle throttle opening to full throttle opening 4 6 4 75 5 25 V DC 3 80 4 20 V DC at standard atmospheric pressure 1 6 3 7 at 20 C 68 F 0 24 0 43 kQ at 80 C 176 F 1 055 1 199 at 40 C 104 F 0 151 0 162 kQ at 100 C 212 F More than 45 5 for each bank Within 0 5 1 0 sec 284 379 9 403 5 mL min One spray type with 12 holes 11 7 12 3 at 20 68 F Friction pump 67 mL or more for 3 seconds about 9 11 V DC at Ignition
392. re clean and tight and none of them have been bent Clean the dirty terminals and straighten slightly bent ter minals Distance Sensor Inspection Remove Ignition Coil Bracket Cover see Frame chapter e Remove the meter lead connector A from the bracket B ODo not disconnect the connector e Using a jack and attachment raise the rear wheel off the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1571 e Set the hand tester A to the DC25 V range and connect it to the LB lead terminal B in the connector C and ground D as shown Connections Hand Tester Needle Adapter E LB Lead Terminal Hand Tester Ground Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 e Turn the ignition switch ON e Turn the rear wheel slowly to see that the tester s pointer fluctuates repeated by reading 0 5 V and 12 V the tester s pointer fluctuates distance sensor is nor mal lf the tester s pointer does not fluctuate inspect the speed sensor and turn signal control relay If the speed sensor and control relay are good replace the digital meter as sembly GP24008BS1 C 16 62 ELECTRICAL SYSTEM Automatic Turn Signal Canceling System Turn Signal Switch Inspection Open the headlight housing e Unplug the 9 pin connectors A that leads to the left han dlebar switch e Check the turn signal switch connections according to the tab
393. re sen sor 5 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 C Special Tool Needle Adapter Set 57001 1457 Inlet Air Pressure Sensor Input Voltage Connections to ECU Meter BL W lead terminal 1 Meter gt BR BK lead terminal 25 e Measure the input voltage with the engine stopped and with the connectors joined e Turn the ignition switch ON Input Voltage at ECU Standard 4 75 5 25 V DC the reading is less than the standard range check the ECU for its ground and power supply and wiring shorted see this chapter If the ground and power supply are good replace the ECU GC17291BS1 C FUEL SYSTEM DFI 3 49 Inlet Air Pressure Sensor Service Code 12 the reading is within the standard range remove the fuel tank and check wiring from ECU to the inlet pressure sensor for continuity wiring is good check the output voltage of the inlet air pressure sensor Output Voltage Inspection e Measure the output voltage at the ECU in the same way as input voltage inspection Note the following Inlet Air Pressure Sensor Output Voltage Connections to ECU Meter Y BL lead terminal 19 Meter gt lead terminal 25 Output Voltage at ECU Usable Range 3 80 4 20 V D
394. rease Results of Feedback Decrease Fuel Injection Fig 5 A 1 Feedback Control Method by Oxygen Sensor GB06121B 5 GENERAL INFORMATION 1 15 Technical Information Oxygen Sensor Maintenance 1 Periodic Inspections Periodic inspections or special maintenance is not re quired for the sensor 2 Oxygen Sensor Removal and Installation Handle the oxygen sensor with care Be careful not to damage sensor wires Do not service the oxygen sensor while it is hot and not use an inpact wrench while removing or installing the oxygen sensor Avoid the fouling damaging of the sensing part of the sensor with foreign substances such as coolant battery fluid anti corrosion fluid and brake fluid Stop using the sensor if it is fouled with these sub stances Also stop using the sensor if the head part of the sensor exposed to the atmosphere is fouled Since the sen sor has a filter that allows air to escape but stop water fouling of the sensor head may clog this filter Being subjected to a flame is also unacceptable for the sensor with the same reason as above 3 Condition of the Sensor Perform resistance measurements and visually check for scars bends and clogging of the sensor filter 4 If trouble with the sensor occurs one of the following service codes will be displayed Accordingly follow the related procedures in the Service Manual for necessary maintenance Service Code Outline of t
395. ree length of the clutch springs A any spring is shorter than the service limit it must be replaced Clutch Spring Free Length Standard 81 7 mm 3 196 in Service Limit 77 5 mm 3 05 in 8 060680851 C GFO6062BS1 C GF06060381 C ENGINE LUBRICATION SYSTEM 7 1 Engine Lubrication System Table of Contents Engine Oil Flow Chants eee dena eoi iR pee Ms tese dedi dis 7 2 Exploded dE E 7 4 A 7 6 Special Tools 7 7 ERiQine Oil rid Fite n 7 8 Oil Level 7 8 Engine Ol Charge reden Lec 7 8 Oil Filter 7 9 Gil Pump HE XL RE ET 7 10 Oil Pump 7 10 Oil Pump Installatior e Leet heec e eh eee t etre de eee cade 7 10 OA e IM IUE 7 12 elu 7 12 Oil PamlInstallatioty eet bees ore etie ete ime mE ee EHE hrs o tes 7 12 Blowby Gas System Inspection eret teer nt adt n Aeon 7 14 Breather Drain stories Re MR 7 14 ecce
396. ring for Gear Position Sensor If above parts are installed on the shift drum holder Shift Drum Cam Bolt A Shift Drum Holder B Rollers C Shift Drum Cam D Dowel Pin E Shift Drum Assembly Align A the recess B on the holder with the longest roller C on the cam e Apply a non permanent locking agent to the shift drum cam bolt Transmission Disassembly e Remove the transmission shafts see this chapter Using the circlip pliers special tool remove the circlips and disassemble the transmission shaft Special Tool Outside Circlip Pliers 57001 144 The shiffer A on the output shaft has three steel balls for the positive neutral finder mechanism Remove the shiffer gear as follows ORemove 1st gear B OSet the output shaft in a vertical position holding the 3rd gear C OSpin the shifter quickly C and pull it off upward 8113126 52 C mT o CRANKSHAFT TRANSMISSION 9 37 Transmission Transmission Assembly e Install the gear bushing A on the shafts with their oil holes B aligned CAUTION Do not apply grease to the steel balls to hold them in place This will cause the positive neutral finder mechanism to malfunction e Fit the three steel balls A into the holes B of the shiffer and then install the gear on the output shaft so that the steel balls align with the recesses D in the shaft OAfter asse
397. rk Plug Wrench Hex16 57001 1262 Torque Spark Plugs 18 N m 1 8 kgf m 13 ft Ib e Install the spark plug caps securely OBe sure the spark plug caps are installed by pulling up it lightly Spark Plug Cleaning Inspection e Refer to Spark Plug Condition Inspection in the Periodic Maintenance chapter Ignition Coil Primary Peak Voltage NOTE OBe sure the battery is fully charged e Remove the fuel tank see Fuel System chapter e Remove all the spark plug caps but do not remove the spark plugs e Install new spark plugs into all the spark plug caps and ground them onto the engine e Install a commercially available peak voltage adapter A into the hand tester B e Connect the adapter between the ignition coil primary lead terminal and the engine ground with the primary lead left connected Recommended Tool Peak Voltage Adapter Type KEK 54 9 B Brand KOWA SEIKI Olnsert the adapter probe into the terminal of the primary lead C ECU D Battery E Ignition Coil F New Spark Plug G Special Tool Hand Tester 57001 1394 Hand Tester Range DC 1000 V Primary Lead Connections Adapter R Adapter BK Front Ignition Coil BK Ground Rear Ignition Coil BK G Ground ELECTRICAL SYSTEM 16 45 Ignition System A WARNING To avoid extremely high voltage shocks do not touch the spark plugs or tester connections Turn the ignition switch and
398. rod B is for the front cylinder Olnstall the connecting rods so that their OUT marks C face outward Engine Left Side D Engine Right Side E e Remove debris and clean the surface of inserts e Apply molybdenum disulfide oil MO to the threads and flanged portions of the connecting rod big end bolts e Tighten the big end bolts to the specified torque Torque Connecting Rod Big End Bolts 59 N m 6 0 kgf m 43 ft lb 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 6105065851 C 6105067BS1 C CRANKSHAFT TRANSMISSION 9 21 Crankshaft Connecting Rods Connecting Rod Bend Remove the connecting rod big end bearing inserts and reinstall the connecting rod big end cap Select an arbor A of the same diameter as the connect ing rod big end and insert the arbor through the connect ing rod big end Select an arbor of the same diameter as the piston pin and more than 105 mm long and insert the arbor B through the connecting rod small end On a surface plate set the big end arbor on a 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 leng
399. rod big end bore diameter Bearing Insert Size Color Parts Number Marking None Brown 92028 1476 Black 92028 1475 Blue 92028 1474 Crankshaft side clearance 0 05 0 35 mm 0 55 mm 0 00197 0 0138 in 0 0217 in Crankshaft web length 103 85 103 95 mm 103 6 mm 4 0886 4 0925 in 4 0787 in Crankshaft runout TIR 0 06 mm TIR 0 15 mm 0 0024 in or less 0 0059 in Crankshaft main bearing journal clearance 0 025 0 052 mm 0 10 mm 0 00098 0 00205 in 0 00394 in Crankshaft main journal diameter 56 986 57 000 mm 56 96 mm 2 2435 2 2441 in 2 2425 in Crankcase main bearing bore diameter 57 030 57 049 mm 57 08 mm 2 2559 2 2460 in 2 2472 in CRANKSHAFT TRANSMISSION 9 7 Specifications Item Standard Service Limit Transmission Shift fork ear thickness 6 9 7 0 mm 6 8 mm 0 272 0 276 in 0 268 in Gear shift fork groove width 7 05 7 15 mm 7 3 0 278 0 281 in 0 287 in Shift fork guide pin diameter 5 9 6 0 mm 5 8 mm 0 232 0 236 in 0 228 in Shift drum groove width 6 05 6 20 mm 6 3 mm 0 238 0 244 in 0 248 in 9 8 CRANKSHAFT TRANSMISSION Special Tools and Sealants Outside Circlip Pliers Flywheel amp Pulley Holder 57001 144 57001 1343 Gear Holder Kawasaki Bond Liquid Gasket Black 57001 1574 92104 1064 ST5715748T C Bearing Driver Set Flywheel amp Pulley Holder Adapt
400. ront Rear Standard 2 3mm 0 08 0 12 in 900 50 r min rpm Viscous paper element Permanent type antifreeze Green Soft water 50 Coolant 50 35 31 F 2 5 L 2 6 US qt Non adjustable hydraulic lash adjusters 2 3 mm 0 08 0 12 in SE SF or SG API SH or SJ with JASO MA SAE 10W 40 4 4 L 4 7 US qt when filter is not removed 4 6 L 4 9 US qt when filter is removed 5 5 L 5 8 US qt when engine is completely disassembled and dry Between upper and lower level lines Wait 2 3 minutes after idling or running BRIDGESTONE BATTLAX 20 4 3 mm 0 17 in BRIDGESTONE BATTLAX BTO20R 7 0 mm 0 28 in Up to 186 kg 410 Ib load 250 kPa 2 5 kgf cm 36 psi Up to 186 kg 410 Ib load 290 kPa 3 0 kgf cm 42 psi Service Limit 1 mm 0 04 in DE AT CH 1 6 mm 0 063 in Up to 130 km h 80 mph 2 mm 0 08 in Over 130km h 80mph 3 mm 0 1 in 2 12 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Final Drive Drive belt deflection RECON 44 1 4 5 kgf 10 Ib force 2 5 4 0 mm 0 10 0 16 in when installing new belt or engine remounted 2E FAT Ont INS Ld Brakes Brake fluid Grade DOT4 Brake pad lining thickness Front 4 0 mm 0 16 in 1 mm 0 04 in Rear 7 5 mm 0 30 in 1 mm 0 04 in Brake light timing Front Pulled ON ON after about 10 mm 0 39 of pedal EE travel
401. rouble 33 Oxygen sensor is not activated 67 Heater trouble due to wiring short or open 94 Oxygen sensor output voltage is incorrect 1 16 GENERAL INFORMATION Technical Information Electric Solenoid Operated Decompressor An automatic decompressor Automatic Compression Reliese system is installed to the right side of the engine This decompressor is activated by an electric solenoid to make starting engine easy When the ignition is switched on and the starter button depressed the solenoid pulls a fulcrum mounted link that depresses push rods in each camshaft The push rods activate the decompression mechanism to partially open the exhaust valves as the piston nears top dead center releasing some of compression that can cause resistance during starting Releasing the starter button de activates the solenoid and a spring returns the push rods to their normal operating po sition oo IRR Ya 6806124BN2 1 Decompression Solenoid 5 Decompression Shaft 2 Decompression Lever 6 Spring 3 Decompression Push Rod 7 Exhaust Cam 4 Holder 8 Push Rod GENERAL INFORMATION 1 17 Technical Information Dual Balancer Shaft System Dual balancers harmonize primary balance and reduce vibration The VN2000 A1 engine applied two balancer shafts one 1 is located in front of the front cylinder and another one 2 is behind the rear cylinder Each balancer shaft is driven by the chain which
402. rouble Inspect and replace see chapter 11 Camshaft cam worn Inspect and replace see chapter 5 Inspect and replace see chapter 5 Air suction valve trouble Inspect and replace see chapter 5 Catalytic converters melt down due to muffler Replace muffler see chapter 5 overheating White smokes Piston oil ring worn Inspect and replace see chapter 5 Cylinder worn Inspect and 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 FUEL SYSTEM DFI 3 35 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions detailed reference Too high fuel pressure Inspect see chapter 3 Injection stuck open Inspect see chapter 3 Water temperature sensor trouble Inspect and replace see chapter 3 Inlet air temperature sensor trouble Inspect and replace see chapter 3 Air cleaner duct loose Reinstall see chapter 3 Air cleaner O ring damaged Replace see chapter 3 Too low fuel pressure Inspect see chapter 3 Water temperature sensor trouble Inspect and replace see chapter 3 Inlet air temperature sensor trouble Inspect and replace see chapter 3 3 36 FUEL SYSTEM DFI Self Diagnosis Self diagnosis Outline 4 V The self diagnosis system has three modes and can be switched to another mode by grounding
403. ry 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 C Special Tool Needle Adapter Set 57001 1457 Atmospheric Pressure Sensor Input Voltage Connections to ECU Meter BL W lead terminal 1 Meter gt lead terminal 25 e Measure the input voltage with the engine stopped and with the connectors joined e Turn the ignition switch ON Input Voltage at ECU Standard 4 75 5 25 V DC the reading of input voltage is less than the standard range check the ECU for its ground and power supply see this chapter If the ground and power supply are good replace the ECU the reading is within the standard range check the wiring between the ECU and atmospheric pressure sen sor for continuity xIf the wiring is good check the output voltage 6C17291BS1 C 3 58 FUEL SYSTEM DFI 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
404. s 57001 143 e Replace the grease seal with a new one e Press the seal in until the face of the seal is level with the end of the grease seal hole Special Tool Bearing Driver Set 57001 1129 e Apply grease to the grease seal lip e Install Collar Coupling Bearing Inspection and Lubrication Since the coupling bearing A is made to extremely close tolerances the clearance cannot normally be measured e Wash the bearing with a high flash point solvent dry it do not spin it while it is dry and oil it e Spin it by hand to check its condition x lf it is noisy does not spin smoothly or has any rough spots it must be replaced xf the same bearing is to be sued again re wash it with a high flash point solvent dry it and pack it with good quality bearing grease before installation e Turn the bearing by hand a few times to make sure the grease is distributed uniformly inside the bearing Rubber Damper Inspection e Remove the rear wheel see Rear Wheel Removal in the Wheels Tires chapter e Remove the rear wheel coupling and inspect the rubber dampers A e Replace the damper if it appears damaged or deterio rated BRAKES 12 1 Brakes Table of Contents Exploded Specifications Special Brake Lever Brake Pedal Brake Lever Position Adjustment Brake
405. s Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts Solvent Use a high flush point solvent when cleaning parts High flush point solvent should be used according to directions of the solvent manufacturer Cleaning vehicle before disassembly Clean the vehicle thoroughly before disassembly Dirt or other foreign materials entering into sealed areas during 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 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 8020088 5 Inspection Reuse of worn or damaged parts may lead to serious ac cident Visually inspect removed parts for corrosion discol N oration or other damage Refer to the appropriate sections IN of this manual for service limits on individual parts Replace Y J N the parts if any damage has been found or if the part is be We yond its service limit 6020098 S Replacement Parts Replacement Parts
406. s in the stream of exhaust gases has a coated layer of porous ceramic Voltage is generated and can be mea sured because of the difference in oxygen density positive and negative ions Pa gt gt Pb Electromotive Force Chamber A Oxygen Partial Pressure in Chamber A Chamber B Oxygen Partial Pressure in Chamber B Pt Electrode Pt Electrode Solid Electrolyte Fig 1 Operation Principle of Zirconia Solid Electrolyte Element GB06117BS2 C Zirconia Element Sensor Cover Exhaust Gas Platinum Electrode 20 20 4 0244e2207 Atmospheric side Electrode Porous platinum Ceramic coating Exhaust side Zirconia Solid Electrolyte Porous platinum Electrode Fig 2 Sectional View Conceptual of Oxygen Sensor Element GBO6118BS2 C GENERAL INFORMATION 1 13 Technical Information Oxygen Sensor and consists of a passageway to lead the fresh air inside Rubber the tubular element Installed in this passageway is a air Filter permeable filter that allows the fresh air to pass through f e The sensor uses the fresh air as the oxygen reference but won t allow moisture through This keeps the sensor in touch with the atmosphere At a normal temperature Zirconia solid electrolyte is Heater Y an insulator and not able to sense the gases Since the Zirconia Elenent F exhaust gas temperature does not become
407. se x lf it is loose unscrew it apply a non permanent locking agent to the threads and tighten it Torque Shift Shaft Return Spring Pin 39 4 0 kgf m 30 416 Check the gear set lever and its spring for breaks or dis tortion x lf the lever or spring is damaged way replace it e Visually inspect the shift drum pins pin holder and cam lf they are badly worn or if they show any damage replace them Transmission Removal e Remove the engine see Engine Removal Installation chapter e Split the crankcase see this chapter e Take out the transmission shafts A and shift drum B as a set e Separate the drive and output shafts shift drum and shift forks Transmission Installation e Install the drive A and output B shaft assy into the right crankcase half C e Install the shift drum D and shift forks E with the rod F e Apply molybdenum disulfide oil to the sliding surfaces of the gears and bearings 9 36 CRANKSHAFT TRANSMISSION Transmission Olnstal the shift forks as shown OPosition the one with larger rib A on the drive shaft and place the pin in the center groove in the shift drum B OThe two forks C on the output shaft are identical Olnstall the shift rods D noting the groove position The rods are identical E Engine Left Side Engine Right Side Shift Drum Disassembly e Remove the shift drum assy see this chapter e Remove Pin and Sp
408. se to the caliper holder shaft C and holder holes Silicone or PBC grease is a special high temperature water resistance grease e Install the pads see Brake Pad Installation Spark Plug Replacement e Remove Fuel Tank for Rear Spark Plug see Fuel System chap ter Spark Plug Caps A e Remove the spark plug using the 16 mm 0 63 in plug wrench vertically Special Tool Spark Plug Wrench Hex16 57001 1262 CAUTION The insulator A of the spark plug may break if when the wrench is inclined during loosening B Inclined Spark Plug Wrench C Contact Spark Plug and Plug Wrench D Bad E Vertically Spark Plug Wrench F Good GP10132BS1 C 2 46 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Insert new spark plug in the plug hole and finger tighten it first e Using the plug wrench A vertically tighten the plug CAUTION The insulator of the spark plug may break if when the wrench is inclined during tightening Special Tool Spark Plug Wrench Hex16 57001 1262 Torque Spark Plugs 18 N m 1 8 kgf m 13 ft Ib e Install the spark plug caps securely OBe sure the spark plug caps are installed by pulling up it lightly Air Cleaner Element Replacement A WARNING If dirt or dust is allowed to pass through into the throttle body assy the throttle may become stuck possibly causing accident CAUTION If dirt gets through into the engine e
409. sembly Standard 51 32 52 32 mm 2 02 2 06 in xIf the length is not within the specified range adjust the length see Clutch Plate Assembly Adjustment GF06046BS2 C CLUTCH 6 19 Clutch Clutch Plate Assembly Adjustment e Inspect the clutch plate assembly length and then re place the steel plate s which brings the length within the specified range ORemove Spring Bolts Spring Holders Springs Spring Plate OReplace the following steel plate s Part No Thickness 13089 1080 1 6 mm 0 063 in 13089 1081 2 3 mm 0 091 in e Install the removed parts and inspect the clutch plate as sembly length Torque Clutch Spring Bolts 9 8 N m 1 0 kgf m 87 in Ib Friction and Steel Plate Wear and Damage Inspection e Visually inspect the friction and steel plates for signs of seizure overheating discoloration or uneven wear xf any plates show signs of damage replace the plates e Measure the thickness of the friction plates A at several points If they have worn past the service limit replace the friction plate and measure the spring plate gap and adjust it if necessary Friction Plate Thickness Standard 3 3 3 5 mm 0 130 0 138 in Service Limit 3 1 mm 0 122 in Friction or Steel Plate Warp 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 Th
410. sert the exhaust pipe joint gaskets A direction as shown Front B Rear C Chamfer Side D GE18005BS1 C 5 48 ENGINE TOP END Mufflers e Be sure that the tabs on the muffler are fitted A into the slots on the clamps e Install the claws A on the exhaust pipe cover ends B into the slots C on the clamps D First tighten all the bolts and nuts to a snug fit Secondary tighten the exhaust pipe holder nuts evenly Finaly tighten the rest of the mounting bolts and clamp bolts securely Torque Upper and Lower Muffler Bracket Bolts 25 N m 2 5 kgf m 18 ft lb Torque Exhaust Pipe Cover Clamp Screws 6 9 N m 0 70 kgf m 61 in Ib e Route the O sensor lead correctly California Europe and UK model see Cable Wire and Harness Routing in the Appendix chapter e Thoroughly warm up the engine wait until the engine cools down and retighten all clamp bolts GE18016BS1 C CLUTCH 6 1 Clutch Table Exploded Specifications 4 22 Special Tools and Sealant Clutch Lever and Cable Lever Free Play Inspection Clutch Cable Removal Clutch Cable Installation Clutch Cable Lubrication Clutch Lever Installation
411. sh rod locknut has been loosened Olf the push rod length cannot be adjusted by turning the clevis the brake pedal may be deformed or incorrectly installed e Loosen the locknut A and turn the push rod with the hex head B to achieve the correct pedal position x lf the length C is 370 1 5 mm 14 6 0 06 in the pedal position will be within the standard range Tighten Torque Rear Master Cylinder Push Rod Locknut 17 N m 1 7 kgf m 12 ft lb Brake Pedal Removal Remove Right Footboard see Frame chapter e Disconnect the brake switch lead connector A F BRAKES 12 9 Brake Lever Brake Pedal e Remove Right Footboard Bracket Front Bolt A Right Footboard Bracket Rear Bolt B Right Footboard Bracket Assembly C e Remove Brake Lever Bolt A Brake Lever B Brake Pedal Return Spring C Brake Switch Return Spring D e Pull out the brake pedal A from the right footboard bracket B Brake Pedal Installation e Apply grease to the brake pedal shaft e Install the pedal shaft A so that the punched mark on the shaft is aligned B with the punched mark on the brake lever C e Install Brake Pedal Return Spring D Brake Switch Return Spring E e Tighten Torque Brake Pedal Clamp Bolt 25 N m 2 5 kgf m 18 ft lb Footboard Bracket Bolts 34 3 5 kgf m 25 ft lb Check the brake for proper braking power no brake drag and no fluid leakage
412. sioner B Torque Upper and Lower Balancer Chain Guide Bolts C 12 N m 1 2 kgf m 8 7 ft lb Balancer Chain Tensioner Bolts D 12 N m 1 2 kgf m 8 7 ft lb e Pull the stopper pin E out of the chain tensioner body e Apply molybdenum disulfide oil to the threads and flange portion of balancer chain sprocket nut e Torque Torque Balancer Chain Sprocket Nut F 125 N m 13 0 kgf m 92 2 ft lb Special Tool Flywheel amp Pulley Holder 57001 1343 Flywheel amp Pulley Holder Adapter 57001 1547 Torque Front G and Rear H Balancer Sprocket Bolts 83 N m 8 5 kgf m 61 ft lb Special Tool Flywheel amp Pulley Holder 57001 1343 ff Ww 20 1 Lo 7 Sq 5 9 5 i GI06013BN2 C e Be sure the roller A is on the camshaft chain sprocket B and torque the camshaft chain sprocket bolt Torque Camshaft Chain Sprocket Bolt 29 N m 3 0 kgf m 22 ft lb Special Tool Flywheel amp Pulley Holder 57001 1343 Flywheel amp Pulley Holder Adapter 57001 1547 A 610608012 CRANKSHAFT TRANSMISSION 9 29 Balancer Mechanism Torque the camshaft oil pipe bolt A Torque Camshaft Oil Pipe Bolt 9 8 N m 1 0 kgf m 87 in Ib e Be sure the following are in position Spacer B O ring C Dowel Pins D e Install the inner camshaft cover and torque the inner camshaft cover bolts Torque Inner Camshaft Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib 9 30 CRANKSHAF
413. sition The arrow mark B on the sensor must be on the rear and point upward e Do not install the sensor upside down e Tighten the sensor bolts C securely Front D e Install the seats see Frame chapter A WARNING Incorrect installation of the vehicle down sensor could cause sudden loss of engine power The rider could lose balance during certain riding situ ations like leaning over in a turn with the potential for an accident resulting in injury or death Ensure that the down sensor is held in place by its bolt as shown Vehicle down Sensor Inspection NOTE OBe sure the battery is fully charged e Take out the vehicle down sensor A see this section Do not disconnect the connector B e Connect a digital volt meter C to the connector using two needle adapters D Special Tool Needle Adapter Set 57001 1457 e Turn the ignition SW ON and measure the power source voltage with the connector joined Vehicle down Sensor Power Source Voltage Connections to Sensor Meter BL W lead E Meter BR BK lead F Standard 4 75 5 25 V DC e Turn the ignition SW OFF xIf the reading of input voltage is less than the standard check the ECU for its ground power supply and wiring shorted 8017381 52 C 80173128 52 C FUEL SYSTEM DFI 3 69 Vehicle down Sensor Service Code 31 x If the power source is normal check the output voltage of the sensor e Conn
414. sition Light 12 21 5 Joint Connector BK Y BK Y BK Y BK Y Front Accessory Connectors KY 1 v a BL Y Y R D e AKZ Y BR BK Torn Signal PT Control Relay 11 eil D Pressure Switch 0 Side Stand Switch Frame Fuse Box Relay Box Ground 1 up Fuse 1 Starter Circuit Relay Left Handlebar Switches 2 Accessory Fuse 10 2 ECU Relay 1 Starter Lockout Switch 3 Radiator Fan Fuse 20 3 Fuel Pump Relay 2 Horn Button 4 Decompression Solenoid Fuse 10A 4 Headlight Relay 3 Dimmer Switch Feu EUM na vi 5 Relay Turn Signal Fuse fee T Headlight Fuse 8 Taillight Fuse 104 9 Ignition Fuse 10 LEFT HANDLEBAR SWITCH CONNECTIONS 10 Horn Fuse 10 Starter Lookout Switch Horn Button Button Dimmer Switch Jurn Signal Switch Color G G Color Color R eK Dm amp Y hutch Push Lo Released Pulled in W2L0O011EN5 6 ELECTRICAL SYSTEM 16 15 Wiring Diagram United States and Canada Sub Sub Fuel Fuel Camshaft Decompression throttle InjectorInjector Position solenoid Water Valve Temperature Sensor s 1 Actuator Sear Speed Inlet Position i Senso Wain Air nitch Throttle Temperature Sensor Sensor Cranks
415. spect operating source voltage see in this section the reading is incorrect check the following Battery Main Fuse 30 A in Starter Relay see Electrical System chapter Ignition Fuse 10 A in Fuse Box see Electrical System chapter Fuel Pump Relay see Electrical System chapter Wiring for Fuel Pump Power Source see next diagram Vehicle down Sensor see this chapter Battery Voltage 12 5 V or more Operating Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition SW OFF e Remove the ignition coil bracket cover see Frame chap ter e Measure the operating voltage of the fuel pump at the fuel pump connector A with the connector joined Hand Tester B Needle Adapters C Pump Operating Voltage at Pump Connector Connections to Pump Connector Tester gt Y R lead D Tester BK W lead E Reading Battery Voltage 12 5 V or more for 3 seconds and then 0 V lf the measurement is normal replace the fuel pump e After inspection remove the needle adapter and apply silicone sealant to the seal of the connector for water proofing Silicone Sealant Kawasaki Bond 56019 120 Sealing of Fuel Pump Connector W R BK Y GC10020BS1 6C10021BS1 C 3 86 FUEL SYSTEM DFI Fuel Pump Service Code 45 c BATTERY JQ IG GNITIONCOTT Jet Jj 6610022 2
416. ssary Tire Tread Wear Inspection As the tire tread wears down the tire becomes more sus ceptible to puncture and failure An accepted estimate is that 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 GS11000BS1 C PERIODIC MAINTENANCE 2 19 Periodic Maintenance Procedures 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 any measurement is less than the service limit replace the tire see Wheels Tires chapter Tread Depth Front Standard 4 3 mm 0 17 in Service Limit 1 mm 0 04 in DE AT CH 1 6 mm 0 063 in Rear Standard 7 0 mm 0 28 in Service Limit 2 mm 0 08 in Up to 130 km h 80 mph 3 mm 0 1 in Over to 130 km h 80 mph Wheel Bearing Damage Inspection e Using a jack and attachment raise the front wheel off the ground see Wheels Tires chapter e Turn the handlebar all the way to the right or left e Inspect the roughness of the front wheel bearing by push ing and pulling A the wheel e Spin B the front wheel lightly and check for smoothly turn roughness binding or noise x If roughness binding or noise is found remove the front wheel and inspect the wheel bearing see Wheels Tires chapter e Using a jack and attachment raise the rear wheel off the gro
417. static and dynamic conditions Crankshaft Sensor Removal Installation e See the Ignition System section in the Electrical System chapter Crankshaft Sensor Inspection OThe crankshaft have no power source and when the en gine stops the crankshaft generates no signals 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 C OM C 00 b ODA E 60 NL COP 00 t OA xb xb bob b CO CO CO CO CO CO CO CO CN ee GC17303BW2 1 ECU 2 Crankshaft Sensor 3 62 FUEL SYSTEM DFI Camshaft Position Sensor Service Code 23 Camshaft Position Sensor Removal Installation e See the Ignition System section in the Electrical System chapter Camshaft Position Sensor Inspection e See the Ignition System section in the Electrical System chapter NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Remove the outer camshaft cover see Compression Re lease Mechanism Removal in the Engine Top End chap ter e Disconnect the camshaft position sensor connector A and conne
418. sur face A shock to the sensor can damage it NOTE OThe standard voltage marked with an asterisk refers to the value when the voltage reading at the Input Voltage Inspection shows 5V exactly OWhen the input voltage reading shows other than 5V derive a voltage range as follows Example In the case of a input voltage of 4 75 V 1 08 x 4 75 5 00 1 03 V 4 60 x 4 75 5 00 4 37 V Thus the valid range is 1 03 4 37 V lf the output voltage is within the standard range check the wiring for continuity see next diagram lf the output voltage is far out of the standard range e g when the wiring is open the reading is O V check the throttle sensor resistance 3 72 FUEL SYSTEM DFI Subthrottle Sensor Service Code 32 Resistance Inspection e Turn the ignition switch OFF Disconnect the subthrottle sensor connector Connect a digital meter A to the subthrottle sensor con nector B Measure the subthrottle sensor resistance Throttle Sensor Resistance Connections BL lead C BK lead D Standard 4 6kQ 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 6C17293BS1 C gt 10 TON E r STON e co r
419. system parts have troubles Service Codes Parts Main Throttle Sensor Inlet Air Pressure Sensor Inlet Air Tempera ture Sensor Output Signal Usable Range or Criteria Main Throttle Sensor Output Voltage 0 2 4 8V Inlet Air Pressure absolute Pv 100 mmHg 900 mmHg Inlet Air Temperature 47 178 C Backups by ECU If the main throttle sensor system fails the signal is out of the usable range wiring short or open the ECU locks ignition timing into the ignition timing at closed throttle position and sets the DFI in the D J method Also the main throttle sensor system and inlet air pressure fails the ECU locks ignition timing into the ignition timing at closed throttle position and sets the DFI the a N method If the inlet air pressure sensor system fails the signal Pv is out of the usable range wiring short or open the ECU sets the DFI in the a N method 1 If the inlet air temperature sensor fails the signal is out of the usable range wiring short or open the ECU sets Ta at 40 C Water Tem perature Sensor Atmo spheric Pressure Sensor Crankshaft Sensor Camshaft Position Sensor Water Temperature Tw 30C 120 C Absolute Atmospheric Pressure Pa 100 mmHg 900 mmHg Crankshaft sensor must send 23 signals output signal to the ECU at the one cranking Cam sensor must send one signal output signal to the ECU at
420. t 6 mm bolts Torque 8 mm Crankcase Bolts 29 N m 3 0 kgf m 22 ft Ib 6 mm Crankcase Bolts 12 N m 1 2 kgf m 8 8 ft lb Check the following turn freely Crankshaft C First D and Rear E Balancer Shafts Water Pump Shaft F Drive Shaft G and Output Shaft H Pulley Shaft J After tightening all the crankcase bolts check the follow ing items OWipe up the liquid gasket that seeps out around the crankcase mating surface e Install the transfer gears Olnstall the transfer gear A which has shorter diameter to the output shaft B Olnstall the transfer gear C which has larger diameter to the pulley shaft D OPut the washer E which has shorter diameter to the out put shaft OPut the washer F which has larger diameter to the pulley shaft OPut the washer G so that their OUT SIDE marks H face outward to the output shaft OReplace the transfer gear nuts with new ones OApply molybdenum disulfide oil to the nut J thread and seating surfaces of the washers and nuts OTemporarily tighten the transfer gear nuts Special Tool Gear Holder 57001 1574 NOTE OThe transfer gear nut A on the output shaft has left hand threads It is silver color and has L B mark Turn the nut counterclockwise and tighten it esa 489 7 6104126851 8 6104127851 61048212 CRANKSHAFT TRANSMISSION 9 17 Crankcase OCheck
421. t Fork DisSassermbly cuoi haeo ED Ceo pe o Doo df Ue ete 13 12 Front IPOPRASSOMO EE 13 13 Inner Tube Outer Tube Inspection 2 0 000010001 13 15 Dust Seal InspectiOr unice SOR ARE 13 15 Spring PM 13 15 Rear Shock Absorber ed e d eie a Ua Pt 13 16 Rebound Damping Force 13 16 Spring Prelosd ti eot oet o eoi tas Qiu eee 13 16 Rear Shock Absorber Removal iei e Mees etg o e Lebe Fox E ER Re 13 17 Rear Shock Absorber InstallatlOris eoe pfe ero diced b tetro d quls abut Qnae 13 18 Rear Shock Absorber 13 18 T a Ec SWING ALIN Installation rmm Swingarm Bearing Removal Swingarm Bearing Installation uoi ere ic ai aden pe cx Sete bee deae druide 13 21 Swingarm Bearing Sleeve Inspection eene 13 22 Grease Seal and Needle Bearing 13 22 13 2 SUSPENSION Exploded View Cm 9900 000 aie 08 gt 4 DO 00 A 00000 99 56 ce Q9 29 20 P 000 aw eO SUSPENSION 13 3 Exploded View Torque No Fast
422. tall each injector B into the delivery joint C Check that there is no dirt or dust on the injector seating surface A of the inlet manifold B Check that the two dowel pins C are in place in the inlet manifold e Fit the end of the injector into the delivery joint D and install them into the inlet manifold B e Apply a non permanent locking agent to the delivery joint bolts and torque them Torque Delivery Joint Bolts 9 8 N m 1 0 kgf m 87 in Ib e Fit A the connectors B of the injector into the bracket recesses C FUEL SYSTEM DFI 3 77 Fuel Injectors 1 2 Service Code 41 42 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 clamps D as shown Torque Fuel Hose Clamp Screws 1 5 N m 0 15 kgf m 13 in Ib OApply a soap and water solution to the areas E shown OWatching the pressure gauge squeeze the pump lever F and build up the pressure until the pressure reaches the maximum pressure Injector Fuel Line Maximum Pressure Standard 300 kPa 3 06 kgf cm 43 psi CAUTION During pressure testing do not exceed the maxi mum pressure for which the system is designed e Watch the gauge for at least 6 seconds If the pressure holds steady the system is good xIf the pressure drops at once
423. tance with a commercially avail able coil tester A to check the condition of the ignition coil B e Connect the ignition coil with the spark plug cap left at tached at the end of the spark plug terminal to the tester in the manner prescribed by the manufacturer and mea sure the arcing distance 3 Needle Arcing Distance Standard 6mm 0 24 in or more A WARNING To avoid extremely high voltage shocks do not touch the coil body or leads x If the distance reading is less than the specified value the ignition coil or spark plug caps are defective GP10148BS2 C GP10141BS1 C 7 GP10128BS1 C ELECTRICAL SYSTEM 16 43 Ignition System To determine which part is defective measure the arcing distance again with the spark plug caps removed from the ignition coil Remove the caps by turning them counter clockwise xIf the arcing distance is subnormal as before the trouble is with the ignition coil itself If the arcing distance is now normal the trouble is with the spark plug cap xf the coil tester is not available the coil can be checked for a broken or badly shorted winding with the hand tester Special Tool Hand Tester 57001 1394 NOTE OThe hand tester cannot detect layer shorts and shorts resulting from insulation breakdown under high voltage e Measure the primary winding resistance as follows OConnect the hand tester between the coil terminals OSet
424. tarter Circuit Relay 6 3 Battery Voltage Apply positive lead Apply negative lead Diode Circuit Inspection e Remove the relay box e Check conductivity of the following pairs of terminals see Relay Box Internal Circuit Diode Circuit Inspection 2 3 2 4 3 4 3 6 4 8 9 15 9 16 Tester Connection The resistance should be low in one direction and more than ten times as much in the other direction If any diode shows low or high in both directions the diode is defective and the relay box must be replaced NOTE OThe actual meter reading varies with the meter or tester used and the individual diodes but generally speaking the lower reading should be from zero to one half the scale 16 92 ELECTRICAL SYSTEM Relay Box Relay Box Internal Circuit GP19009BN2 C A Headlight Relay B ECU Main Relay C Fuel Pump Relay D Starter Circuit Relay E Fan Relay ELECTRICAL SYSTEM 16 93 Fuse Main Fuse Removal Remove the left side cover see Frame chapter e Disconnect the starter relay connector A e Pull out the main fuse B from the starter relay with needle nose pliers ECU Fuse Removal e Remove the left side cover see Frame chapter e Open the cap A and pull out the ECU fuse B Fuse Box Fuse Removal e Remove the left side cover see Frame chapter e Unlock the hook to lift up the lids A e Pull the fuses B straight out of the fuse box with needle nose
425. tch Inspection NOTE OBe sure the transmission mechanism is good condition e Remove Seats see Frame chapter Battery Cover see Battery Removal e Disconnect the gear position switch lead connector A 0 108215 PON e Set the hand tester A to the x1 kO or x100 O range and connect it to the terminals in the gear position switch lead connector B and ground 3 ol C Internal Circuit 2 1 Green Lead 2 Blue Lead 1 3 Black Lead Special Tool Hand Tester 57001 1394 8 18063 52 C ELECTRICAL SYSTEM 16 89 Switch and Sensors Gear Position Switch Resistance Connections Gear T 2 Ground 3 Ground Position Ground about 11 63 12 87 kQ 10 33 11 44 kO 3 00 3 32 1 70 1 89 kQ 1 07 1 19 9 70 10 74 0 695 0 769 9 32 10 32 0 430 0 476 9 06 10 03 If the tester reading is not as specified replace the gear position switch with a new one 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 lf 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
426. tching valve see Engine Top End chapter e Set the hand tester A to the x O range and connect it to the air switching valve terminals as shown Special Tool Hand Tester 57001 1394 Air Switching Valve Resistance Standard 18 22 O at 20 C 68 F x lf the resistance reading is except the specified value re place it with a new one e Connect the 12 V battery A to the air switching valve terminals as shown e Blow the air to the inlet air duct A and make sure does not flow the blown air from the outlet air ducts B GE04030BS1 8 04033 81 GE04031BS1 o o ELECTRICAL SYSTEM 16 81 Air Switching Valve e Disconnect the 12 V battery Blow the air to the inlet air duct A again and make sure flow the blown air from the outlet air ducts B xIf the air switching valve dose not operate as described replace it with a new one NOTE OTo check air flow through the air switching valve just blow through the air cleaner hose C AS gt 8 04032851 C 16 82 ELECTRICAL SYSTEM Decompression Solenoid Decompression Solenoid Inspection e Remove Seats see Frame chapter Right Cover see Frame chapter e Disconnect the decompression solenoid lead connector A e Set the hand tester A to the x1 O range and connect it to the terminals in the decompression solenoid lead con nector B Black C Black D Special Tool H
427. th 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 0 2 100 mm 0 08 3 94 Connecting Rod Twist e With the big end arbor A still on the V block C hold the connecting rod horizontally and measure the amount that the arbor B varies from being parallel with the surface plate over a 100 mm length of the arbor to determine the amount of connecting rod twist If connecting rod twist exceeds the service limit the con necting rod must be replaced Connecting Rod Twist Service Limit 0 2 100 mm 0 08 3 94 in Connecting Rod Big End Side Clearance e Measure the side clearance B of the connecting rod big end A Olnsert a thickness gauge between the big end and either crank web to determine clearance Connecting Rod Big End Side Clearance Standard 0 08 0 30 mm 0 0031 0 0118 in Service Limit 0 5 mm 0 0197 in xIfthe 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 9 22 CRANKSHAFT TRANSMISSION Crankshaft Connecting Rods Connecting Rod Big End Bearing Wear Remove the big end cap and place a strip of plastigage on the crankpin A Tighten the bi
428. that the positive neutral finder operates propely While spinning A the output shaft B using an air impact wrench gears shift smoothly from the 1st 2nd 5th gear and 5th 4th e 1st When the output shaft stays still the gear can be shifted to only the 1st gear or neutral It shoud not be shifted to the 2 nd gear or other higher gear positions Shift Drum C e f the positive neutral finder operates propely torque the transfer gear nuts Torque Transfer Gear Nut Output Shaft 196 N m 20 0 kgf m 145 ft Ib Transfer Gear Nut Pulley Shaft 78 N m 8 0 kgf m 58 ft Ib Special Tool Gear Holder 57001 1574 e Install the sprocket A and oil pump chain B e Tighten the sprocket bolt C OTemporarily install the balancer gear to the rear balancer shaft OHolding the rear balancer gear with the flywheel amp pulley holder torque the sprocket bolt Torque Rear Balancer Sprocket Nut 29 N m 3 0 kgf m 22 ft lb Special Tool Flywheel amp Pulley Holder 57001 1343 e Install the tensioner D with the spring E OPosition the spring so that its end is applied to the crankcase wall F e Torque the tensioner bolt G Torque Oil Pump Chain Tensioner Bolt 12 N m 1 2 kgf m 8 8ft Ib e Apply grease to the O ring A and put it on the pulley shaft B e Install the color C so that its chamfer side D faces in ward 6104128851 C 6104129851 C 9 18 CRANKSHA
429. 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 Repeat the measurements 5 or more times for one ignition coil Ignition Coil Primary Peak Voltage Standard 210 V or more Repeat the test for the other ignition coil xIf the reading is less than the specified value check the following Ignition Coils see Ignition Coil Inspection Crankshaft Sensors see Crankshaft Sensor Inspection the ignition coils and crankshaft sensors are normal check the ECU see Fuel System chapter Crankshaft Sensor Removal e Remove Clutch and Damper Cam see Clutch chapter Alternator Rotor see Alternator Rotor Removal Oil Pressure Switch Lead Terminal Crankshaft Sensor Mounting Bolts A Crankshaft Sensor B and Clamp Crankshaft Sensor Installation e Refer to Alternator Stator Installation in this chapter Crankshaft Sensor Inspection e Remove all the spark plug caps but do not remove the spark plugs e Disconnect the crankshaft sensor lead connector A 16 46 ELECTRICAL SYSTEM Ignition System Connect a commercially available peak voltage adapter A to the hand tester B Recommended Tool Peak Voltage Adapter Type KEK 54 9 B Brand KOWA SEIKI Special Tool Hand Tester 57001 1394 e Insert the adapter probes into the connector C of the crankshaft sensor D as shown Connections Adapter
430. the fluid seal is replaced replace the dust seal B as well Also replace all seals every other time the pads are changed Caliper Dust Boot and Friction Boot Damage e Check that the dust boot A and friction boot B are not cracked worn swollen or otherwise damaged xIf they show any damage replace it Caliper Piston and Cylinder Damage e Visually inspect the pistons C and cylinder surfaces Replace the caliper if the cylinder and piston are badly scored or rusty Caliper Holder Shaft Wear The caliper body must slide smoothly on the caliper holder shafts If the body does not slide smoothly one pad will wear more than the other and constant drag on the disc may cause the temperature of the discs or the brake fluid to increase e Visually inspect that the caliper holder shafts A are not badly worn or bent xIf the caliper holder shafts are damaged replace the en tire caliper assembly 6L05077BS1 C GLO5078BS1 C GLO5079BS1 C 12 12 BRAKES Brake Pads Front Brake Pad Removal e Loosen the front brake pad pin A lightly e Remove the caliper mounting bolts B with the hose in stalled e Remove Caliper C with the hose installed e Remove Pad Spring Bolts A Pad Spring B e Remove Front Brake Pad Pin A Brake Pads B Front Brake Pad Installation e Push the caliper pistons in by hand as far as they will go e Install Brake Pads Front Brake Pad Pin e
431. the self diagnosis terminal A 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 ECU stops the injec tion 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 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 OWhen a problem occurs with the FI system the FI indica tor LED light A and Fl symbol B go on e Remove the seats and the battery cover see Frame and Electrical System chapter e Pull the self diagnosis terminal A and connect an auxil iary lead B for grounding to the self diagnosis terminal NOTE OUse a fully 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 a auxiliary lead 6C17277BS1 6C17272BS1 FUEL SYSTEM DFI 3 37 Self Diagnosis e Turn the ignition SW ON e Push the MODE button A and display the odometer e Push the RESET button B for more than two seconds The LCD FI characters C are d
432. the sliding surface to give the mechanical seal initial lubrication e Apply coolant to the surface of the rubber seal A and sealing seat B and press the rubber seal and sealing seat into the impeller by hand until the seat bottoms out e Tighten the water pump impeller bolt by turning the bolt counterclockwise Torque Water Pump Impeller Bolt 12 N m 1 2 kgf m 104 in Ib 8006020451 C COOLING SYSTEM 4 13 Radiator A WARNING 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 Radiator Removal Drain the coolant see this chapter e Pull up the radiator fan motor connector A out of the bracket B pushing the thin plate C to the front side Remove the radiator fan motor connector A e Remove Radiator Cover Bolts A Radiator Cover B Remove Hose Clamp A Loosen Radiator Hose B e Remove Hose Clamp A Loosen Radiator Hose B Radiator Bolt C 4 14 COOLING SYSTEM Radiator e Lift up the radiator to clear the stoppers Remove the radiator CAUTION Do not touch the radiator core This could damage the radiator fins resulting in loss of cooling effi cie
433. the two cranking If the water temperature sensor system fails the signal is out of the usable range wiring short or op en the ECU sets Tw at 80 C If the atmospheric pressure sensor system fails the signal is out of the usable range wiring short or open the ECU sets Pa at 760 mmHg the standard atmospheric pressure If crankshaft sensor generates less than 23 or more signals the engine stops by itself If the camshaft position sensor system fails the signal is missing wiring short or open the ECU continues to ignite cylinders in the same sequence following the last good signal Gear The gear position is If the speed sensor system fails no signal wiring 25 Position decided by the signal of short or open the ECU set the top 5 gear Switch speed sensor position Vende If the vehicle down sensor system has failures the output voltage Vd is more than usable range 31 down Output Voltage signal wiring open ECU shuts off the fuel pump Sensor VWd 0 4V 4 4V ie the fuel injectors and the ignition system If the subthrottle sensor system fails the signal Subthrottle is out of the usable range wiring short or open 32 Output Voltage sensor 45 4 85 V the actuator locks sub throttle valve at full open position 3 44 FUEL SYSTEM DFI Self Diagnosis Service Codes Parts Oxygen Sensor Output Signal Usable Range
434. ts Exploded VIeWs Aiea 4 2 Coolant Flow Chart eni on t Po ed de cien 4 4 3 2 4 T DEM 4 6 Special Tools and 4 7 Coolant m 4 8 Coolant Deterioration Inspection useeeesseussessssssssesseseeeeene nennen nnne nnn nnns 4 8 Coolant Level 4 0 00 0 0 000000 000000000000 4 8 Coolant Draining 2555 4 8 rus 4 8 Pressure 4 8 Cooling System Flushing oerte terae 4 9 Water ETa EEEE AE AE E A AA ATE AE 4 10 Water Pump Removal nreti oiea p ovr ope aan a avid ae Pepe dy 4 10 Water 1 5 4 10 Water Pump lIrispection neci teet nre ere Y ae E Tr EE os 4 10 Mechanical Seal 4 11 dures ban dares tues 4 13 Radiator Removal Tm 4 13 Radiator EEEE EEEE 4 14
435. ts B and kick the wheel forward until the belt is too loose e Turn in the left and right belt adjuster nuts evenly until the drive belt has the correct amount of deflection OTo keep the belt and wheel aligned the notch on the left belt adjuster should align with the same swingarm mark C that the right belt adjuster notch aligns with 2 24 PERIODIC MAINTENANCE Periodic Maintenance Procedures Tighten both belt adjuster locknuts A WARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition Tighten both belt adjuster locknuts and make sure the axle stays aligned Tighten the axle nut Torque Rear Axle Nut 108 N m 11 kgf m 80 ft Ib e Inspect the drive belt deflection see Drive Belt Deflection Inspection 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 within 30 degree OLoosen once and tighten again when the slot goes past the nearest hole e Bend the cotter pin A over the nut A WARNING If the rear axle nut is not securely tightened or the cotter pin is not installed an unsafe riding condi tion may result e Check the rear brake for weak braking power and brake drag Wheel Alignment Inspection Adjustment Check that the notch A on the
436. ts see Frame chapter e Connect a digital voltmeter A to the oxygen sensor con nector B main harness side using the needle adapter set C Special Tool Needle Adapter Set 57001 1457 Oxygen Sensor Output Voltage Connections to Oxygen Sensor Connector Meter BL Y lead Meter gt BR BK lead e Remove the air switching valve hoses A both sides from the fittings B e Install C the suitable plugs D both sides on the fittings and shut off the secondary air e Turn the ignition SW ON e Start the engine and let it idle e Measure the output voltage of the sensor with the con nector joined Oxygen Sensor Output Voltage with Plugs Standard 0 7 0 8 V Next remove the plugs A both sides from the fittings B with idring e Measure the output voltage of the sensor with the con nector joined Oxygen Sensor Output Voltage without Plugs Standard approx 0 1 V the reading is within range with plugs 0 7 0 8 V without plugs approx 0 1 V the oxygen sensor is good x If the reading is without range inspect the engine and fuel supply system xIf the engine and fuel supply system good replace the Oxygen sensor FUEL SYSTEM DFI 3 99 Oxygen Sensor Incorrect Output Voltage Service Code 94 lt gt T lt io p co e 9 ko r co UD LO uU MEC MEM
437. ts 12 1 2 104 in Ib S see text Outside plate bolt 9 8 1 0 87 in Ib Clutch hub nut 135 14 0 101 Clutch spring bolts 98 1 0 87 in lb Outer clutch cover bolts 12 1 2 104 in Ib S see text Plug on outer clutch cover 20 2 0 14 Clutch cover oil drain plug 21 2 1 15 Clutch release lever bolt 5 9 0 60 52 in lb Starter lockout switch screw Inside plate bolt 9 8 1 0 87 in Ib a PERIODIC MAINTENANCE 2 7 Torque and Locking Agent Fastener Tordue Remarks Engine Lubrication System Rocker shaft oil pipe bolts 98 1 0 87 in lb Cylinder head oil pipe banjo bolts 54 5 4 40 Oil filter 17 5 1 75 12 5 Oil passage bolt 29 3 0 21 Oil passage adapter drain plug 9 8 1 0 87 Relief valve 15 1 5 11 Camshaft oil pipe bolt 9 8 1 0 87 in lb Oil pipe bolt L16 9 8 1 0 87 in lb Oil pipe bolt L30 12 1 2 104 in Ib Oil pump drive sprocket bolt 29 3 0 21 Oil pump chain tensioner bolt 12 1 2 104 in Ib Oil pump cover bolts 9 8 1 0 87 Inside plate bolt 9 8 1 0 87 Outside plate bolt 9 8 1 0 87 Clutch cover drain plug 21 2 1 15 Oil pressure switch 15 1 5 11 55 Oil passage adapter 20 2 0 14 L Oil pan plug 20 2 0 14 L Oil pipe stopper bolt 6 9 0 7 61 in Ib Oil screen bolt for crank room 9 8 1 0 87 in lb Oil pan bolts 15 1 5 11 5 Left pan drain plug 20 2 0 14 Right oil pan drain plug 15 1 5 11 Engine Removal Installation Front downtube nuts 88 9 0 65 S AL Upper adjusting bolt 9 8 1 0 87 in lb 5 Lower
438. ty 12 V 18 Ah Headlight Type Semi sealed beam Bulb 12 V 65 W quartz halogen Tail brake light Alternator Type Rated output 12 V 5 21 W Three phase AC 38A x 14 V 5 000 r min rpm Specifications are subject to change without notice and may not apply to every country AU Australia CAL California CA Canada US United States of America EU Europe GENERAL INFORMATION 1 11 Technical Information Oxygen Sensor Overview Kawasaki has adopted an oxygen sensor A for the Euro pean and California models in addition to the secondary air injection system and honeycomb catalyst This helps Ka sawaki keep the motorcycle with cleaner exhaust gas and cope with the emission regulations The oxygen sensor A is mounted above the exhaust manifold B whereas the honeycomb catalyst is located inside the silencer in the downstream of the exhaust gas The oxygen sensor uses the substance called zirconia 7 The electromotive force varies depending on the density of the oxygen The sensor measures the oxygen density of the exhaust gas to detect whether the air fuel mixture is lean or rich in relation to the optimum air fuel mixture When the ECU is in the oxygen sensor feedback mode it controls combustion by making the fuel injection amount of the injector rich or lean through the signal from the sensor 1 12 GENERAL INFORMATION Technical Information Oxygen Sensor Construction and Operation The o
439. ubber 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 e Bleed the brake line and the caliper as follows ORepeat this operation until no more air can be seen com ing out into the plastic hose Pump the brake lever until it becomes hard and apply the brake lever and hold it A Quickly open and close B the bleed valve while holding the brake lever applied Release the brake lever 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 e Remove the clear plastic hose e Tighten Torque Caliper Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib Front Brake Reservoir Cap Screws 1 5 N m 0 15 kgf m 13 in Ib e Repeat the above steps for other caliper NOTE OFor the rear brake caliper A bleed the brake line for two bleed valves B e Check the fluid level e After bleeding is done check the brake for good braking power no brake drag and no fluid leakage GL09017BS2 C BRAKES 12 21 Brake Fluid A WARNING When working with the disc brake observe the pre caut
440. ube Clamps 17 56 APPENDIX Troubleshooting Guide except DFI NOTE ORefer to Fuel System chapter for most of DFI troubleshooting 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 Difficulty Starter motor not rotating Starter lockout switch or gear position switch trouble Starter motor trouble Battery voltage low Starter relays not contacting or operating Starter button not contacting Wiring open or shorted Ignition switch trouble Engine stop switch trouble Fuse blown Starter motor rotating but engine doesn t turn over Starter clutch trouble Vehicle down sensor DFI coming off Engine won t turn over Valve seizure Rocker arm seizure Cylinder piston seizure Crankshaft seizure Connecting rod small end seizure Connecting rod big end seizure Transmission gear or bearing seizure Camshaft seizure Balancer bearing seizure No fuel flow No fuel in tank Fuel pump trouble Fuel tank air vent obstructed Fuel filter clogged Fuel line clogged Engine flooded Clean spark plugs and adjust plug gaps Starting technique faulty When flooded do not crank the engine with the throttle fully opened This promotes engine flood be cause more fuel is supplied automatically DFI No spark spark weak Vehicle down sensor DFI coming off Ignition switch not ON
441. und Special Tools Jack 57001 1238 Jack Attachment 57001 1571 GP10131BS1 C GP18070481 5 DC25V GP18070181 C 16 48 ELECTRICAL SYSTEM Ignition System 1st Check Start the engine to the following conditions Condition Transmission Gear 1st position Clutch Lever Release Side Stand Down or Up OTurn the ignition switch on and push the starter button OThen the starter motor should not turn when the starter system circuit is normality the engine is start inspect the starter lockout switch gear position switch and relay box lf their parts are normality replace the ECU 2nd Check Start the engine to the following conditions Condition Transmission Gear 1st position Clutch Lever Pulled in Side Stand gt Up OTurn the ignition switch on and push the starter button OThen the starter motor should turn when the starter sys tem circuit is normality If the starter motor is not turn inspect the starter lockout switch gear position switch and relay box lf their parts are normality replace the ECU 3rd Check e Inspect the engine for its secure stop after the following operations are completed e Run the engine to the following conditions Condition Transmission Gear 1st Position Clutch Lever Release Side Stand Up e Set the side stand on the ground then the engine will stop x If whichever may not be stopped inspect t
442. und see Wheels Tires chapter e Inspect the roughness of the rear wheel bearing by push ing and pulling A the wheel e Spin B the rear wheel lightly and check for smoothly turn roughness binding or noise roughness binding or noise is found remove the rear wheel and inspect the wheel bearing see Wheels Tires chapter and coupling see Final Drive chapter Suspensions Front Forks Rear Shock Absorber Operation Inspection e Pump the forks down and up A 4 or 5 times and inspect the smooth stroke xf the forks do not smoothly or noise is found inspect the fork oil level or fork clamps see Suspension chapter 6J03001181 C 65115020 2 20 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Pump the seat down and up A 4 or 5 times and inspect the smooth stroke x If the shock absorber does not smoothly or noise is found inspect the oil leak see Rear Shock Absorber Oil Leak Inspection or shock absorber clamps see Suspension chapter 1 65148110 Front Fork Oil Leak Inspection e Visually inspect the front forks A for oil leakage Replace or repair any defective parts if necessary Rear Shock Absorber Oil Leak Inspection e Remove Seats see Frame chapter Battery Cover e Visually inspect the shock absorber A for oil leakage If it is oil leaked replace the shock absorber Swingarm Pivot Lubrication Remove the swingarm see Suspensi
443. und 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 Coolant Change in the Peri odic Maintenance chapter 4 10 COOLING SYSTEM Water Pump Water Pump Removal e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Remove Muffler see Engine Top End chapter Exhaust Pipe see Engine Top End chapter Outer Transmission Cover see Crankshaft Transmis sion chapter Inner Transmission Cover see Crankshaft Transmis sion chapter e Remove Impeller Bolt A Impeller B NOTE OThe impeller bolt has left hand threads Turn the bolt clockwise and remove it Water Pump Installation e Put the washer on the water pump impeller bolt and tighten the bolt by turning the bolt counter clockwise Torque Water Pump Impeller Bolt 12 N m 1 2 kgf m 104 in Ib Water Pump Inspection e Visually inspect the mechanical seal lf any one of the parts is damaged replace the mechani cal seal as a unit OThe sealing seat and rubber seal may be removed easily by hand
444. up OLook parallel to the belt during inspection An inaccu rate reading will occur if looking from any other angle e Inspect the belt deflection at two positions by rotating the rear wheel Special Tools Drive Belt Tension Gauge 57001 1585 e Inspect the drive belt deflection at arbitrary position and record the value A e Turn the rear wheel 90 degrees 4 45N 103002BS1 C 6512015851 C 6512016851 PERIODIC MAINTENANCE 2 23 Periodic Maintenance Procedures e Inspect the drive belt deflection and record the value B 6512017851 e Decide the belt deflection at the position C of one where deflection is large 6512018851 C Drive Belt Deflection with 45 N 4 5 kgf 10 Ib force Standard 2 5 4 0 mm 0 10 0 16 in Drive Belt Deflection with 45 N 4 5 kgf 10 Ib force when installing new belt or engine remounted Standard 2 5 mm 0 10 in x lf the deflection is out of the specification adjust it Belt Deflection Adjustment e Remove Muffler Body see Engine Top End chapter Upper Belt Cover e Remove the axle cotter pin and loosen the axle nut e Using the jack and jack attachment under the frame pipe ribs lift the rear wheel off the ground see Rear Wheel Removal in the Wheels Tires chapter e Loosen the left and right belt adjuster locknuts A the belt is too tight back out the left and right belt ad juster nu
445. upply ports see chapter 12 Engine overheating see Overheating of Troubleshooting Guide in chapter 17 Air switching valve trouble Inspect and replace see chapter 16 Air suction valve trouble Inspect and replace see chapter 5 Intermittent any DFI fault and its recovery Check that DFI connectors are clean and tight and examine wires for signs of burning or fraying see chapter 3 FUEL SYSTEM DFI 3 33 DFI System Troubleshooting Guide Poor Running or No Power at High Speed Symptoms or Possible Causes Actions detailed reference Firing incorrect Spark plug dirty broken or maladjusted Spark plug cap or high tension wiring trouble Clean spark plug and adjust plug gap see chapter 2 Inspect plug cap and ignition coil see chapter 16 Spark plug cap shorted or not in good contact Reinstall or inspect the cap see chapter 16 Spark plug incorrect 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 Ignition coil trouble Fuel mixture incorrect Air cleaner clogged poorly sealed or missing Inspect see chapter 16 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 Change fuel Inspect and clean fuel system
446. urface Valve seat cutting angle Outside diameter Width Valve spring free length Exhaust Inlet Exhaust Inlet Outer EX IN 45 32 60 34 9 35 1 mm 1 374 1 382 in 38 9 39 1 mm 1 531 1 539 in 0 8 1 2 mm 0 031 0 047 in 0 8 1 2 mm 0 031 0 047 in 44 76 mm orange 43 2 mm 1 700 in 1 7622 in Inner EX IN 39 82 mm orange 38 3 mm 1 508 in 1 5677 in Cylinder Piston Cylinder inside diameter 102 994 103 006 mm 103 10 mm 4 054874 4 055346 in 4 05905 in Piston diameter 102 965 102 980 mm 102 82 mm 4 053732 4 04802 in 4 04802 in Piston cylinder clearance 0 043 0 070 mm 0 00169 0 00276 Piston ring groove clearance Top 0 035 0 070 mm 0 17 mm 0 00138 0 00276 in 0 00669 in Second 0 02 0 06 mm 0 16 mm 0 00079 0 00236 in 0 00630 in Piston ring groove width Top 1 225 1 240 mm 1 32 mm 0 048228 0 048819 in 0 05197 in Second 1 21 mm 1 23 mm 1 31 mm 0 04764 0 04843 in 0 05157 in Piston ring thickness Top 1 17 mm 1 19 mm 1 10 mm 0 04606 0 04685 in 0 0433 in Second 1 17 mm 1 19 mm 1 10 mm 0 04606 0 04685 in 0 0433 in Piston ring end gap Top 0 25 0 35 mm 0 7 mm 0 0098 0 0138 in 0 028 in Second 0 40 0 55 mm 0 8 mm 0 0157 0 0217 in 0 031 in Oil 0 3 0 9 mm 1 2 mm 0 012 0 035 in 0 0472 in ENGINE TOP END 5 11 Special Tools and Sealant
447. ut switch screw inside 190 ormo 14 Check Valve 15 Starter Lockout Switch EO Apply engine oil L Apply a non permanent locking agent G Apply grease MO Apply molybdenum disulfide oil R Replacement Parts S Follow the specific tightening sequence Si Apply silicone grease or PBC grease LG Apply liquid gasket Kawasaki Bond 56019 120 CL Apply cable lubricant 6 4 CLUTCH Specifications Item Standard Service Limit Clutch Lever Free Play 2 3 mm 0 08 0 12 in Clutch Clutch spring free length 81 17 mm 3 20 in 77 5 mm 3 05 in Clutch plate assembly length 51 32 52 32 mm 2 02 2 06 in Friction plate thickness 3 3 3 5 mm 0 130 0 138 in 3 1 mm 0 122 in Friction or steel plate warp 0 2 mm 0 0079 in or less 0 3 mm 0 012 in CLUTCH 6 5 Special Tools and Sealant Clutch Holder Flywheel amp Pulley Holder Adapter 57001 1243 57001 1547 ST5715478T C Flywheel amp Pulley Holder Kawasaki Bond Liquid Gasket Black 57001 1343 92104 1064 6 6 CLUTCH Clutch Lever and Cable Lever Free Play Inspection e Refer to Clutch in the Periodic Maintenance chapter Clutch Cable Removal e Free the clutch cable A from the clamps B e Loosen the locknut A at the middle of the clutch cable e Turn the adjusting nut B to give the cable plenty of play e Loosen the locknut at
448. val Installation Table of Contents Exploded Views asi mate Gt du ES Tie leat 8 2 Specifications io veges deere es Ses dc m rete ec inci eem ee EG ed de i E e E 8 4 Engine 5 8 5 Engine RemoVal s tbv eae orn to Roten qa 8 5 Installation er m 8 10 8 2 ENGINE REMOVAL INSTALLATION Exploded View 6H02041BN5 ENGINE REMOVAL INSTALLATION 8 3 Exploded View No Fastener Fondue Remarks N m kgf m ft Ib 1 Front downtube nuts 88 9 0 65 S AL 2 Upper adjusting bolt 9 8 1 0 87 5 3 Lower adjusting bolt 9 8 1 0 87 in lb 5 n 5 Lower adjusting boltlocknt 49 so s 6 Upperrear engine mounting nut 59 80 49 s 7 towerrear engine mounting nut se 80 49 s 8 Upper engine bracketnuts 9 80 4 SA 9 Upper engine mounting bois 44 as 39 s 10 Lower engine bracketbots se 80 49 s Front engine mounting nut 44 45 39 s 42 12 Rear downtube bots 6 Mo S WL Apply a soap and water solution or rubber lubricant AL Tighten the two bolts or nuts alternately two times to ensure even tightening torque S Tighten the fasteners following the specified sequence from this table No 1 to No 12 2 L 8
449. variable resistor that change output voltage according to throttle operating The ECU senses this voltage change and determines fuel injec tion quantity and ignition timing according to engine rpm and throttle opening Input Terminal A Output Terminal B Ground Terminal C Subthrottle Sensor Removal Adjustment CAUTION Do not remove or adjust the subthrottle sensor A since it has been adjusted and set with precision at the factory Never drop the sensor especially on a hard surface Such a shock to the sensor can damage it Subthrottle Sensor Connector B Input Voltage Inspection NOTE OBe sure the battery is fully charged OThe inspection is the same as Input Voltage Inspection of the inlet air pressure sensor and the atmospheric pressure sensor Turn the ignition switch OFF Remove the ECU see this chapter Do not disconnect the ECU connectors Connect a digital voltmeter A to the connector B using the needle adapter set C Special Tool Needle Adapter Set 57001 1457 Subthrottle Sensor Input Voltage Connections to ECU Connector Meter BL W lead terminal 1 Meter gt BR BK lead terminal 25 e Measure the input voltage with the engine stopped and with the connectors joined e Turn the ignition switch ON Input Voltage at ECU Connector Standard 4 75 5 25 V DC e Turn the ignition switch OFF xIf the reading of input voltage is less than the standard
450. ve Fuel Tank see this chapter Air Switching Valve with Hoses see Engine Top End chapter Vacuum Hoses on Throttle Body Assy e Remove connectors for injector A e Connect each test light set B to the injector main harness connector C e Connect the battery lead terminal 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 en gine with the starter motor and check to see if the needle oscillates at regular intervals Special Tool Hand Tester 57001 1394 xf the test light doesn t flicker or the tester needle doesn t oscillates check the wiring and connectors again If the wiring is good the ECU is suspect Replace the ECU Injector Resistance Inspection e Remove Fuel Tank see this chapter Air Switching Valve with Hoses see Engine Top End chapter Vacuum Hoses on Throttle Body Assy e Disconnect the connector from the injector A see Injec tor Removal e Measure the injector resistance with a digital voltmeter B Front C Injector Resistance Connections to Injector Meter Meter 1 WIR BL R Terminal 2 WIR Terminal Standard
451. ve and discard it CAUTION Replace the air valve whenever the tire is replaced Do not reuse the air valve 6J05006BS1 C WHEELS TIRES 10 15 Tires e Install a new valve in the front wheel rim ORemove the valve cap lubrication the stem seal A with a soap and water solution or rubber lubricant and pull the valve stem B through the rim C 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 OThe air valve is shown in the figure A Valve Cap B Valve Core C Stem Seal D Valve Stem E Valve Seat F Valve Opened e Check the fire rotation mark on the front and rear tires and install them on the rim accordingly OPosition the air valve to the left side for front tire Tire Rotation Mark A Rotation Direction B e Install a new air valve in the rear wheel rim Valve Cap A Valve Body B Valve Nuts C Valve Washer D Rim E Valve Grommet F Coupling Damper Side ORemove the valve cap valve nuts valve washer and in sert the valve stem through the rim from the inside out Torque Tire Air Valve Nuts 1 5 N m 0 15 kgf m 13 in Ib Tire Air Valve Cap 0 15 N m 0 015 kgf m 1 3 in Ib 6J05028BS1 C 6J05030781 6J05003BS1 C 6J04017BS1 C 10 16 WHEELS TIRES Tires e Apply a soap and water s
452. wenden aeons ebd Pe DEC 14 11 Stem Bearing Ftemoyval 2 puto erue eniin d sque istae eed ee abs Ae ace 14 11 Stem Bearing Irnstallatlopiz eroi repro e terr deridet ne ees 14 11 Stem Bearing EUbFIOStiOris eR cu iaeia 14 11 Stem Cap Deterioration 2 00 0 422000000000000004 9 lt 14 12 14 2 STEERING Exploded View GNO2042BW5 C STEERING 14 3 Exploded View No Fastener Handlebar clamp bolts Remarks 1 2 Handlebar holder nuts 3 Steering stem head nut O S 108 43 in lb 5 Steering stem nut 6 Lower front fork clamp bolts 25 G Apply grease O Apply 2 stroke oil S Follow the specific tightening sequence AD Apply adhesive AL Tighten the two clamp bolts alternately two times to ensure even tightening torque Lh Left hand Threads 14 4 STEERING Special tools Head Pipe Outer Race Press Shaft Steering Stem Nut Wrench 57001 1075 57001 1100 Head Pipe Outer Race Driver Steering Stem Bearing Driver 57001 1077 57001 1344 Head Pipe Outer Race Remover Steering Stem Bearing Driver Adapter 57001 1107 57001 1345 STEERING 14 5 Handlebar Handlebar Removal Remove Headlight Upper Cover Bolts A Headlight Upper Cover B e Remove Clutch Lever Assembly A Left Han
453. with water or coolant to prevent pressure leakage 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 nee dle must remain within the same range at least 6 seconds Radiator Cap Relief Pressure Standard 93 123 kPa 0 95 1 25 kgf cm 13 5 17 8 psi for 6 seconds the cap holds too much pressure or cannot hold the specified pressure replace it with a new one Radiator Filler Neck Inspection 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 Front B 4 16 COOLING SYSTEM Thermostat Thermostat Removal e Remove Coolant Drain about 200 mL Fuel Tank see Fuel System chapter e Pull back throttle body harness connector A out of the bracket B pushing the thin plate C to right side Water Hoses D Bracket Bolts E Water Temperature Sensor Connector F Reserve Tank Hose G e Remove the thermostat housing H along with the bracket e Remove the screws A take off the cap B and take out the thermostat 60008013 P Thermostat Installation e Install the thermostat A
454. x cessive Clutch housing gear worn Wrong installation of outside friction plate Transmission noise Bearings worn Transmission gears worn or chipped Metal chips jammed in gear teeth Engine oil insufficient Drive line noise Drive belt adjusted improperly Drive belt worn Rear and or engine sprocket worn Rear wheel coupling damaged 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 Master cylinder damaged Other noise Bracket nut bolt etc not properly mounted or tightened 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 portion worn Crankshaft bearings worn Oil pressure switch damaged Oil pressure switch lead damaged Relief valve stuck open O ring at the oil pipe in the crankcase dam aged 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
455. x chap ter Torque Clamp Bolt E 9 8 N m 1 0 kgf m 87 in Ib e Install the plate F as shown x lf the oil pipe filter G is clogged clean the filter e Apply grease the O ring H e Install the oil pipe J with the O ring and torque the out side plate bolts K OApply a non permanent locking agent to the outside plate bolts Torque Outside Plate Bolts 9 8 1 0 kgf m 87 in Ib gt GF06053BW2 0 CLUTCH 6 17 Clutch Starter Clutch Disassembly Remove the clutch housing with the one way clutch see this chapter Remove the following from the clutch housing A Plate B One way Clutch C Washer D Needle Bearing E Starter Clutch Assembly e Install the one way clutch A so that its arrow B faces outward Starter Clutch Inspection e Remove the starter clutch gear A and torque limiter then reinstall the starter clutch gear into the starter clutch e Turn the starter clutch to both side OWhen viewed from the right side of the engine the clutch should turn clockwise B freely but should not turn coun terclockwise C If the starter clutch does not operate as it should or if it makes noise disassemble the starter clutch If one way clutch A installation is wrong reinstall it Visually inspect the one way clutch coupling and starter clutch gear for damage there is any worn or damaged surface in the following parts replace it Sliding Surfac
456. xamination 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 10 18 WHEELS TIRES Hub Bearings Wheel Bearings Hub Bearings Removal Remove the wheel and take out the following Collars Grease Seals A Circlips B Coupling C Out of Rear Hub Front Hub D Rear Hub E Special Tool Inside Circlip Pliers 57001 143 e Use the bearing remover to remove the hub bearings A CAUTION Do not lay the wheel directly on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground Special Tools Bearing Remover Shaft 13 B 57001 1377 Bearing Remover Head 25 x 28 C 57001 1346 for Front Hub Bearing Remover Head 20 x 22 57001 1293 for Rear Hub Hub Bearings Installation e Before installing the hub bearings blow any dirt or foreign particles out of the hub with compressed air to prevent contamination of the bearings e Replace the bearings with new ones NOTE Olnstall the bearings so that the marked side faces out e Install the bearings by using a bearing driver
457. xcessive en gine wear and possibly engine damage will occur Remove Air Cleaner Cover Screws A Air Cleaner Cover B e Unscrew the air cleaner element screw A and remove the air cleaner element B e Discard Air Cleaner Element PERIODIC MAINTENANCE 2 47 Periodic Maintenance Procedures e Install a new element A with the mesh side facing up ward CAUTION Use only the recommended air cleaner element Kawasaki part number 11013 0002 Using an other air cleaner element will wear the engine prematurely or lower the engine performance Engine Oil Change e Situate the motorcycle so that it is vertical after warning up the engine e Remove the oil filler cap A on the transmission cover B e Remove the left A and right B oil pan drain plugs and drain the oil e Remove the clutch drain plug A on the outside clutch cover B OThe oil in the oil filter can be drained by removing the filter see Oil Filter Change Replace the gasket A for left drain plug B with a new one if it is damaged Replace the O ring C for right drain plug D with a new one 6509014851 C 2 48 PERIODIC MAINTENANCE Periodic Maintenance Procedures Replace the O ring A for drain plug B on the outside clutch cover C Tighten the drain plugs Torque Left Oil Pan Drain Plug 15 N m 1 5 kgf m 11 ft Ib Right Oil Pan Drain Plug 20 N m 2 0
458. xhaust Rear Standard 36 411 36 527 39 571 39 687 mm 1 43350 1 43807 1 55791 1 56248 in in Service 36 31 mm 39 47 mm Limit 1 4295 in 1 5539 in Camshaft Chain Wear Hold the chain taut with a force of about 49 N 5 kg 11 Ib in some manner and measure a 20 link length Since the chain may wear unevenly take measurement at several places any measurement exceeds the service limit replace the chain Also replace the camshafts and the crankshaft when the chain is replaced Camshaft Chain 20 link Length Standard 127 00 127 36 mm 5 0000 5 0412 in Service Limit 128 9 mm 5 075 in GE11012281 20 link Length GE11070581 ENGINE TOP END 5 31 Cylinder Head Cylinder Compression Measurement NOTE OBe sure the battery is fully charged e Warm up the engine thoroughly Stop the engine e Remove the fuel tank see Fuel System DFI chapter e Remove one spark plug and attach the compression gauge and adapter firmly into the spark plug hole Do not remove the other spark plug only the plug lead e For the other cylinder remove both spark plugs Special Tool Spark Plug Wrench Hex 16 57001 1262 e Using 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 A Compression Gauge Ad
459. xygen sensor uses a solid electrolyte called zirco nia An electrolyte is a substance that has positive and negative ions and can move freely in a liquid For explanation purposes picture a solid electrolyte plate as a wall and chambers A and B are divided by this wall If both sides of the wall have platinum electrodes with holes the difference in oxygen density weight between cham bers A and B will move the oxygen from the chamber of higher oxygen density to the chamber of lower oxygen den sity until the two chambers are about equal in density What actually moves are the oxygen ions through the wall of the solid electrolyte The higher density side chamber will receive the Pt electrode surface with holes on the solid electrolyte wall and will become minus the oxygen ions O At this point the O2 ions reach the Pt electrode of the opposite side Since the result of this Oz move also brings movement of e just like cells work a battery voltage will be built within the sensor The conceptual sectional view of the actual element in the oxygen sensor is shown The sensor is exposed to ex haust gas The shape of the sensor is tubular since the at mospheric side and exhaust gas side are parted by the wall That means that the inside of this tubular solid electrolyte is the atmosphere side higher oxygen density and the out side of the tube faces the exhaust gas The outside surface which i
460. y OWhen the input voltage reading shows other than 5V derive a voltage range as follows Example In the case of a input voltage of 4 75 V 1 02 x 4 75 5 00 0 97 V 4 62 x 4 75 5 00 4 39 V Thus the valid range is 0 97 4 39 V 6C17292BS1 C FUEL SYSTEM DFI 3 47 Main Throttle Sensor Service Code 11 lf the output voltage is within the standard range check the wiring for continuity see next diagram lf the output voltage is far out of the standard range e g when the wiring is open the reading is 0 V check the throttle sensor resistance Resistance Inspection 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 BK lead D Standard 4 6 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 6C17293BS1 D 10 ton 10 E C lt C 160 SYN C gt lt o 10 xr co LO LE LO SPSS SST rot
461. y a thin coat of grease to the oil seal A in the right end cover B Apply a thin coat of grease to the left bearing A e Fit shims onto the right end cover OThe line on the yoke should align A with the line on the m left cover Torque Starter Motor Assembly Bolts 4 9 N m 0 50 kgf m 43 16 ege Brush Inspection Measure the length A of each brush If any is worn down to the service limit replace the carbon brush holder assy B and the terminal bolt assy C Starter Motor Brush Length Standard 12 5 mm 0 49 in Service Limit 5 mm 0 20 in CALUL Commutator Cleaning and Inspection e Smooth the commutator surface if necessary with fine emery cloth A and clean out the grooves CAA LUU ELECTRICAL SYSTEM 16 53 Starter Motor e Measure the diameter A of the commutator B Replace the starter motor with a new one if the commu tator diameter is less than the service limit 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 lf there is a high resistance or no reading between two segments a winding is open and the starter motor must be replaced e Using the highest hand tester range measure the resis tance between the segments and the shaft B x If there is any reading at all the
462. ycle c Addition of components or accessories that result in the vehicle exceeding the stan dards d Permanently removing disconnecting or rendering inoperative any component or element of design of the emission control systems WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING 10 000 PER VIOLATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below Replacement of the original exhaust system or muffler with a component not in compliance with Federal regulations Removal of the muffler s or any internal portion of the muffler s Removal of the air box or air box cover e Modifications to the muffler s or air inlet system by cutting drilling or other means if such modifications result in increased noise levels Foreword This manual is designed primarily for use by trained mech

Kawasaki VN2000 A1 Vulcan 03 Service Manual ENG

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