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Kawasaki Ninja 250R service manual (eng)

1. 3 17 Special Tools and Sealant 3 19 DFI Servicing Precautions 3 21 DFI Servicing Precautions 3 21 Troubleshooting the DFI System 3 23 Outline 3 23 Inquiries to Rider 3 26 DFI System Troubleshooting Guide 3 29 Self Diagnosis 3 34 Self diagnosis Outline 3 34 Self diagnosis Procedures 3 34 Service Code Clearing Procedure
2. 11 6 Drive Chain Slack Inspection 11 6 Drive Chain Slack Adjustment 11 6 Wheel Alignment Inspection Adjustment 11 6 Drive Chain Wear Inspection 11 6 Drive Chain Lubrication 11 6 Drive Chain Guide Wear Inspection 11 6 Drive Chain Removal 11 6 Drive Chain Installation 11 6 Drive Chain Replacement 11 7 Sprocket Coupling 11 10 Engine Sprocket Removal
3. 16 11 Parts Location 16 12 Wiring Diagram 16 14 Precautions 16 16 Electrical Wiring 16 17 Wiring Inspection 16 17 Battery 16 18 Battery Removal 16 18 Battery Installation 16 18 Battery Activation 16 19 Precautions
4. 2 45 Radiator Hose and O ring Replacement 2 48 Engine Oil Change 2 48 Oil Filter Replacement 2 49 Brake Hose and Pipe Replacement 2 50 Brake Fluid Change 2 50 Master Cylinder Rubber Parts Replacement 2 51 Caliper Rubber Parts Replacement 2 53 Spark Plug Replacement 2 54 http mototh com PERIODIC MAINTENANCE 2 3 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition The initial maintenance is vitally important and must not be neglected Periodic Inspection FREQUENCY Whichever comes first ODOMETER READING 1 000 km 1 000 mile 1 6
5. 3 91 Fuel Pump Installation 3 92 Fuel Pump Operation Inspection 3 92 Fuel Pump Operating Voltage Inspection 3 93 Pressure Regulator Removal 3 94 Fuel Filter Cleaning 3 94 Fuel Pump Relay Removal Installation 3 94 Fuel Pump Relay Inspection 3 94 Fuel Injectors 3 96 http mototh com FUEL SYSTEM DFI 3 3 Fuel Injector Removal Installation 3 96 Fuel Injector Audible Inspection 3 96 Fuel Injector Resistance Inspection
6. 16 69 Fuse Box Fuse Removal 16 69 15 A ECU Fuse Removal 16 69 Fuse Installation 16 70 Fuse Inspection 16 70 http mototh com ELECTRICAL SYSTEM 16 3 Dummy Page http mototh com 16 4 ELECTRICAL SYSTEM Exploded View http mototh com ELECTRICAL SYSTEM 16 5 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Front Brake Light Switch Screw 1 2 0 12 11 in lb 2 License Plate Light Cover Screws 0 90 0 092 8 0 in lb 3 License Plate Light Mounting Screws 1 2 0 12 11 in lb 4 Switch Housing Screws 3 5 0 36 31 in lb 5 Tail Brake Light Mounting Bolts 5 9 0 60 52 in lb http mototh com 16 6 ELECTRICAL SYSTEM Exploded View http mototh com ELECTRICAL SYSTEM 16 7 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Alternator Cover Bolts 9 8 1 0 87 in lb 2 Alternator Rotor Bolt 88 2 9 0 65 S 3 Crankshaft Sensor Screws 3 0 0 31 27 in lb 4
7. 6 9 Clutch Removal 6 9 Clutch Installation 6 9 Clutch Plate Wear and Damage Inspection 6 11 Clutch Plate Warp Inspection 6 11 Clutch Spring Free Length Inspection 6 11 http mototh com 6 2 CLUTCH Exploded View http mototh com CLUTCH 6 3 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Clutch Cover Bolts 9 8 1 0 87 in lb 2 Clutch Hub Nut 132 13 5 97 4 3 Clutch Lever Clamp Bolt 8 8 0 90 78 in lb 4 Clutch Spring Bolts 8 8 0 90 78 in lb 5 Oil Filler Plug Hand Tighten CL Apply cable lubricant EO Apply engine oil G Apply grease M Apply molybdenum disulfide grease R Replacement Parts Si Apply silicone grease W Apply water http mototh com 6 4 CLUTCH Specifications Item Standard Service Limit Clutch Lever Free Play 2 3 mm 0 08 0 12 in Clutch Friction Plate Thickness 2 92 3
8. 4 16 Hose Inspection 4 16 Water Temperature Sensor 4 17 Water Temperature Sensor Removal Installation 4 17 Water Temperature Sensor Inspection 4 17 http mototh com 4 2 COOLING SYSTEM Exploded View http mototh com COOLING SYSTEM 4 3 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Coolant Drain Bolt Cylinder 5 9 0 60 52 in lb 2 Coolant Drain Bolt Water Pump 9 8 1 0 87 in lb 3 Radiator Bolts 9 8 1 0 87 in lb 4 Radiator Cap Bracket Bolt 9 8 1 0 87 in lb 5 Radiator Water Hose Clamp Screws 1 5 0 15 13 in lb 6 Reserve Tank Bolts 9 8 1 0 87 in lb 7 Reserve Tank Bracket Bolts 9 8 1 0 87 in lb 8 Reserve Tank Cap Hand Tighten 9 Resistor Bolt 7 8 0 80 69 in lb 10 Thermostat Cover Bolts 9 8 1 0 87 in lb 11 Thermostat Housing Mounting Bolts 9 8 1 0 87 in lb 12 Water Hose Fitting Bolts 9 8 1 0 87 in lb 13 Water Pipe Bolts 9 8 1 0 87 in lb 14 Water Pump Bolts 9 8 1 0 87 in lb 15 Water Pu
9. 12 17 Brake Fluid Level Inspection 12 17 Brake Fluid Change 12 17 Brake Line Bleeding 12 17 Brake Hose 12 20 Brake Hose Removal Installation 12 20 Brake Hose Inspection 12 20 http mototh com 12 2 BRAKES Exploded View http mototh com BRAKES 12 3 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Bleed Valve 5 5 0 56 49 in lb L 2 Brake Hose Banjo Bolts 25 2 5 18 3 Brake Lever Pivot Bolt 5 9 0 60 52 in lb Si 4 Brake Lever Pivot Bolt Locknut 5 9 0 60 52 in lb 5 Front Brake Disc Mounting Bolts 27 2 8 20 L 6 Front Brake Light Switch Screw 1 2 0 12 11 in lb 7 Front Brake Pad Pins 17 2 1 8 13 8 Front Brake Reservoir Cap Screws 1 5 0 15 13 in lb 9 Front Caliper Holder Pin Bolt 17 2 1 8
10. 4 7 Cooling System Flushing 4 8 Coolant Reserve Tank Removal 4 8 Coolant Reserve Tank Installation 4 8 Water Pump 4 9 Water Pump Cover Removal 4 9 Water Pump Cover Installation 4 9 Water Pump Removal 4 9 Water Pump Installation 4 9 Water Pump Impeller Inspection 4 10 Radiator 4 11 Radiator and Radiator Fan Removal 4 11 Radiat
11. 16 58 Meter Unit Removal Installation 16 58 Meter Unit Disassembly 16 58 Meter Indicator Light Bulb Replacement 16 59 Tachometer Inspection 16 59 Water Temperature Gauge Inspection 16 60 Switches and Sensors 16 62 Brake Light Timing Inspection 16 62 Brake Light Timing Adjustment 16 62 Switch Inspection 16 62 Water Temperature Sensor Inspection 16 63 Speed Sensor Removal 16 63 Speed Senso
12. 16 36 Spark Plug Installation 16 36 Spark Plug Condition Inspection 16 37 Interlock Operation Inspection 16 37 IC Igniter Inspection 16 38 Electric Starter System 16 41 Starter Motor Removal 16 41 Starter Motor Installation 16 41 Starter Motor Disassembly 16 42 Starter Motor Assembly 16 42 Brush Inspection 16 43 Commutator Cleaning and Inspection
13. 1 11 http mototh com 1 2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera tion on a motorcycle read the precautions given below To facilitate actual operations notes illustra tions photographs cautions and detailed descriptions have been included in each chapter wherever necessary This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts Especially note the following Battery Ground Before completing any service on the motorcycle discon nect the battery cables from the battery to prevent the en gine from accidentally turning over Disconnect the ground cable first and then the positive When completed with the service first connect the positive cable to the positive terminal of the battery then the negative ca ble to the negative terminal Edges of Parts Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts Solvent Use a high flush point solvent when cleaning parts High flush point solvent should be used according to directions of the solvent manufacturer Cleaning Vehicle before Disassembly Clean the vehicle thoroughly before disassembly Dirt or other foreign materials entering into sealed areas during ve hicle disas
14. 15 10 Inner Fairing Installation 15 10 Side Cover 15 11 Side Cover Removal 15 11 Side Cover Installation 15 11 Seat Covers 15 12 Seat Cover Removal 15 12 Seat Cover Installation 15 12 Fenders 15 14 Front Fender Removal 15 14 Front Fender Installation 15 14 Flap and Rear Fender Removal
15. 2 35 Electrical System 2 36 Lights and Switches Operation Inspection 2 36 Headlight Aiming Inspection 2 38 Sidestand Switch Operation Inspection 2 39 Engine Stop Switch Operation Inspection 2 40 Others 2 40 Chassis Parts Lubrication 2 40 Bolts Nuts and Fasteners Tightness Inspection 2 42 Replacement Parts 2 43 Air Cleaner Element Replacement 2 43 Fuel Hose Replacement 2 44 Coolant Change
16. 7 9 Oil Pump 7 10 Oil Pump Removal 7 10 Oil Pump Installation 7 10 Oil Pump Inspection 7 10 Oil Pressure Measurement 7 11 Oil Pressure Measurement 7 11 Oil Pressure Switch 7 12 Oil Pressure Switch Removal 7 12 Oil Pressure Switch Installation 7 12 http mototh com 7 2 ENGINE LUBRICATION SYSTEM Exploded View http mototh com ENGINE LUBRICATION SYSTEM 7 3 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Crankcase Oil Passage Plug 15 1 5 11
17. 15 14 Flap and Rear Fender Installation 15 15 Frame 15 16 Frame Inspection 15 16 Sidestand 15 17 Sidestand Removal 15 17 Sidestand Installation 15 17 http mototh com 15 2 FRAME Exploded View http mototh com FRAME 15 3 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Front Footpeg Bracket Bolts 25 2 5 18 2 Rear Footpeg Bracket Bolts 25 2 5 18 3 Sidestand Nut 39 4 0 29 4 Sidestand Switch Bolt 8 8 0 90 78 in lb L G Apply grease L Apply a non permanent locking agent R Replacement Parts http mototh com 15 4 FRAME Exploded View http mototh com FRAME 15 5 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Windshield Mounting Bolts 0 42 0
18. 3 96 Fuel Injector Power Source Voltage Inspection 3 97 Fuel Injector Output Voltage Inspection 3 98 Fuel Injector Fuel Line Inspection 3 99 Throttle Grip and Cables 3 101 Free Play Inspection 3 101 Free Play Adjustment 3 101 Cable Installation 3 101 Cable Lubrication 3 101 Throttle Body Assy 3 102 Idle Speed Inspection Adjustment 3 102 Synchronization Inspection Adjustment 3 102 Throttle Bod
19. 10 2 Specifications 10 4 Special Tools 10 5 Wheels Rims 10 6 Front Wheel Removal 10 6 Front Wheel Installation 10 6 Rear Wheel Removal 10 8 Rear Wheel Installation 10 8 Wheel Inspection 10 10 Axle Inspection 10 10 Balance Inspection 10 11 Balance Adjustment
20. 9 23 Balancer Removal 9 23 Balancer Installation 9 23 Balancer Shaft Bearing Insert Journal Wear Inspection 9 23 Transmission 9 25 Shift Pedal Removal 9 25 Shift Pedal Installation 9 25 External Shift Mechanism Removal 9 26 External Shift Mechanism Installation 9 26 External Shift Mechanism Inspection 9 26 Transmission Shaft Removal 9 27 Transmission Shaft Installation 9 27 Transmission Shaft Disassembly 9 28 Transmission Shaft Assembly 9 28 Shift Drum and Fork Removal 9 31 Shift Drum and Fork Installation 9 31 Shift Drum Disassembly 9 32 Shift Drum Assembly 9 32 Shift Fork Bending Inspection 9 32 Shift Fork Gear Groove Wear Inspection 9 33 Shift Fork Guide Pin Drum Groove Wear Inspection 9 33 Gear Dog and Gear Dog Hole Damage Inspection 9 33 http mototh com 9 2 CRANKSHAFT TRANSMISSION Exploded View http mototh com CRANKSHAFT TRANSMISSION 9 3 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Connecting Rod Big End Nuts 27 5 2 8 20 MO 2 Crankcase Bolts M8 L 90 mm 24 2 4 18
21. 10 17 Hub Bearing Inspection 10 18 Hub Bearing Lubrication 10 18 Speedometer Gear Housing 10 19 Speedometer Gear Housing Disassembly 10 19 Speedometer Gear Housing Assembly 10 19 Speedometer Gear Housing Lubrication 10 20 http mototh com 10 2 WHEELS TIRES Exploded View http mototh com WHEELS TIRES 10 3 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Front Axle Nut 88 9 0 65 2 Rear Axle Nut 98 10 0 72 3 HG Apply high temperature grease R Replacement Parts WL Apply soap and water solution or rubber lubricant http mototh com 10 4 WHEELS TIRES Specifications Item Standard Service Limit Wheels Rims Rim Runout Axial TIR 0 5 mm 0 02 in or less TIR 1 0 mm 0 04 in Radial TIR 0 8 mm 0 03 in or less TIR 1 0 mm 0 04 in Axle Runout 100 mm 3 94 in TIR 0 1 mm 0 004 in or less TIR 0 2 mm 0 008 in W
22. 10 11 Balance Weight Removal 10 11 Balance Weight Installation 10 11 Tires 10 13 Air Pressure Inspection Adjustment 10 13 Tire Inspection 10 13 Tire Removal 10 13 Tire Installation 10 14 Tire Repair 10 16 Hub Bearing 10 17 Hub Bearing Removal 10 17 Hub Bearing Installation
23. 13 17 Swingarm Bearing Removal 13 17 Swingarm Bearing Installation 13 17 Swingarm Bearing Sleeve Inspection 13 17 Swingarm Bearing Lubrication 13 17 Tie Rod Rocker Arm 13 18 Tie Rod Removal 13 18 Tie Rod Installation 13 18 Rocker Arm Removal 13 18 Rocker Arm Installation 13 18 Tie Rod Rocker Arm Bushing Inspection 13 18 Tie Rod Rocker Arm Sleeve Inspection 13 19 http mototh com 13 2 SUSPENSION
24. 3 109 Fuel Tank 3 110 Fuel Tank Removal 3 110 Fuel Tank Installation 3 112 Fuel Tank Inspection 3 113 Fuel Tank Cleaning 3 113 http mototh com 3 4 FUEL SYSTEM DFI Exploded View http mototh com FUEL SYSTEM DFI 3 5 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Crankshaft Sensor Screws 3 0 0 31 27 in lb 2 Delivery Pipe Assy Mounting Screws 3 4 0 35 30 in lb 3 Inlet Air Temperature Sensor Screw 1 2 0 12 11 in lb 4 Oxygen Sensor 44 1 4 50 32 5 5 Speed Sensor Bolt 7 8 0 80 69 in lb L 6 Throttle Body Assy Holder Clamp Screws 2 0 0 20 18 in lb 7 Water Temperature Sensor 25 2 5 18 8 Throttle Cable Accelerator 9 Throttle Cable Decelerator CL Apply cable lubricant EO Apply engine oil G Apply grease L Apply a non permanent locking agent R Replacement Parts SS Apply silicone
25. 2 20 Valve Clearance Inspection 2 20 Valve Clearance Adjustment 2 21 Air Suction System Damage Inspection 2 23 Clutch 2 23 Clutch Operation Inspection 2 23 Wheels Tires 2 24 Air Pressure Inspection 2 24 Wheel Tire Damage Inspection 2 25 Tire Tread Wear Inspection 2 25 Wheel Bearing Damage Inspection 2 26 Final Drive 2 26 Drive Chain Lubrication Co
26. 14 9 Handlebar 14 10 Handlebar Removal 14 10 Handlebar Installation 14 10 http mototh com 14 2 STEERING Exploded View http mototh com STEERING 14 3 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Handlebar Mounting Bolts 25 2 5 18 2 Lower Front Fork Clamp Bolts 30 3 1 22 3 Steering Stem Head Bolt 44 4 5 32 4 Steering Stem Nut 4 9 0 50 43 in lb 5 Switch Housing Screws 3 5 0 36 31 in lb 6 Upper Front Fork Clamp Bolts 20 2 0 15 AD Apply adhesive G Apply grease L Apply a non permanent locking agent http mototh com 14 4 STEERING Special Tools Steering Stem Bearing Driver 57001 137 Bearing Puller 57001 158 Bearing Puller Adapter 57001 317 Oil Seal amp Bearing Remover 57001 1058 Steering Stem Bearing Driver Adapter 34 5 57001 1074 Head Pipe Outer Race Press Shaft 57001 1075 Head Pipe Outer Race Driver 51 5 57001 1076 Steering Stem Nut Wrench 57001 1100 Head Pipe Outer Race Driver 47 57001 1447 http mototh com STEERING 14 5 Steering Steering Insp
27. 11 10 Engine Sprocket Installation 11 10 Rear Sprocket Removal 11 11 Rear Sprocket Installation 11 11 Coupling Installation 11 11 Coupling Bearing Removal 11 12 Coupling Bearing Installation 11 12 Coupling Bearing Inspection 11 12 Coupling Bearing Lubrication 11 13 Coupling Damper Inspection 11 13 Sprocket Wear Inspection 11 13 Rear Sprocket Warp Inspection 11 13 http mototh com 11 2 FINAL DRIVE
28. 2 13 Periodic Maintenance Procedures 2 14 Fuel System DFI 2 14 Air Cleaner Element Cleaning 2 14 Throttle Control System Inspection 2 14 Engine Vacuum Synchronization Inspection 2 15 Idle Speed Inspection 2 18 Idle Speed Adjustment 2 18 Fuel Hose Inspection fuel leak damage installation condition 2 18 Cooling System 2 19 Coolant Level Inspection 2 19 Water Hose and Pipe Inspection coolant leak damage installation condition 2 20 Engine Top End
29. 16 22 Interchange 16 22 Charging Condition Inspection 16 22 Refreshing Charge 16 23 Charging System 16 24 Alternator Cover Removal 16 24 Alternator Cover Installation 16 24 Stator Coil Removal 16 25 Stator Coil Installation 16 25 Alternator Rotor Removal 16 25 Alternator Rotor Installation 16 26 Charging Voltage Inspection 16 28 Alternator Inspec
30. 16 43 Armature Inspection 16 44 Brush Lead Inspection 16 44 Brush Plate and Terminal Bolt Inspection 16 44 http mototh com 16 2 ELECTRICAL SYSTEM Starter Relay Inspection 16 44 Lighting System 16 47 Headlight Beam Horizontal Adjustment 16 47 Headlight Beam Vertical Adjustment 16 47 Headlight Bulb Replacement 16 47 Headlight Removal Installation 16 48 City Light Bulb Replacement 16 48 Tail Brake Light Bulb Replacement 16 49 Tail Brake L
31. 7 6 Engine Oil and Oil Filter 7 7 Oil Level Inspection 7 7 Engine Oil Change 7 7 Oil Filter Replacement 7 7 Bypass Valve Disassembly 7 8 Bypass Valve Assembly 7 8 Bypass Valve Cleaning and Inspection 7 8 Oil Screen Cleaning and Inspection 7 8 Oil Pressure Relief Valve 7 9 Oil Pressure Relief Valve Removal 7 9 Oil Pressure Relief Valve Installation 7 9 Oil Pressure Relief Valve Inspection
32. TIR 0 2 100 mm 0 008 3 94 in Connecting Rod Big End Side Clearance 0 13 0 38 mm 0 0051 0 0150 in 0 58 mm 0 023 in Connecting Rod Big End Bearing Insert Crankpin Clearance 0 031 0 059 mm 0 0012 0 0023 in 0 10 mm 0 004 in Crankpin Diameter 29 984 30 000 mm 1 1805 1 1811 in 29 97 mm 1 1799 in Marking None 29 984 29 994 mm 1 1805 1 1809 in 29 995 30 000 mm 1 1809 1 1811 in Connecting Rod Big End Inside Diameter 33 000 33 016 mm 1 2992 1 2998 in Marking None 33 000 33 008 mm 1 2992 1 2995 in 33 009 33 016 mm 1 2996 1 2998 in Connecting Rod Big End Bearing Insert Thickness Brown 1 480 1 485 mm 0 05827 0 05846 in Black 1 485 1 490 mm 0 05846 0 05866 in Blue 1 489 1 494 mm 0 05862 0 05882 in Crankshaft Side Clearance 0 05 0 20 mm 0 0020 0 0079 in 0 40 mm 0 0157 in Crankshaft Runout TIR 0 02 mm 0 0008 in or less TIR 0 05 mm 0 0020 in Crankshaft Main Bearing Insert Journal Clearance 0 014 0 038 mm 0 0006 0 0015 in 0 07 mm 0 0028 in Crankshaft Main Journal Diameter 27 984 28 000 mm 1 1017 1 1024 in 27 96 mm 1 101 in Marking None 27 984 27 99
33. Use a soft plastic hose B as a pump inlet hose in order to insert the hose smoothly Put the hose through the fill opening C into the tank and draw the fuel out Front D WARNING The fuel could not be removed completely from the fuel tank Be careful for remained fuel spillage Disconnect the fuel pump lead connector A Be sure to place a piece of cloth A around the fuel hose joint B Push the joint lock claws C Pull the joint lock A as shown in the figure Pull B the fuel hose joint C out of the fuel supply pipe WARNING Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is disconnected fuel spills out from the hose and the pipe because of residual pressure Cover the hose connection with a piece of clean cloth to prevent fuel spillage Close the fuel tank cap Remove the fuel tank and place a it on a flat surface http mototh com 3 112 FUEL SYSTEM DFI Fuel Tank Fuel Tank Installation Note the above WARNING see Fuel Tank Removal Run the hoses correctly see Cable Wire and Hose Rout ing section in the Appendix chapter Check that the dampers A are in place on the frame and the fuel tank If the dampers are damaged or deteriorated replace them Pull the joint lock A as shown in the figure Insert the fuel hose joint A straight onto the fuel supply pipe until the hos
34. 12 8 Brake Pedal Position Adjustment 12 8 Brake Pedal Removal 12 8 Brake Pedal Installation 12 8 Calipers 12 9 Front Caliper Removal 12 9 Rear Caliper Removal 12 9 Caliper Installation 12 9 Front Caliper Disassembly 12 10 Front Caliper Assembly 12 10 Rear Caliper Disassembly 12 10 Rear Caliper Assembly 12 10 Caliper Fluid Seal Damage Ins
35. Install the removed parts see appropriate chapters Meter Unit Disassembly Remove Meter Unit Meter Unit Removal Installation Screws A Meter Cover B http mototh com ELECTRICAL SYSTEM 16 59 Meter Gauge Indicator Unit Remove the speedometer A tachometer B and water temperature gauge C by removing screws D CAUTION Do not remove a meter pointer unless the meter is to be replace The pointers cannot be reinstalled The pointer mounting is different from replacement meters Meter Indicator Light Bulb Replacement Remove the meter unit Meter Unit Removal Installation Pull out the socket A together with the bulb Pull the bulb B out of the socket CAUTION Do not turn the bulb Pull the bulb out to prevent damage to the bulb Do not use bulb rated for greater wattage then the specified value Replace the bulb with a new one Repeat the same procedure for other bulbs Tachometer Inspection Remove the meter unit see Meter Unit Removal Installa tion Using the insulated auxiliary leads connect the 12 V bat tery to the meter unit connector 9 pins connector as fol lows Connect the battery positive terminal to the BR lead ter minal A Connect the battery negative terminal to the BK Y lead terminal B CAUTION Do not short each terminals Using the insulated auxiliary leads open and connect the BK lead terminal A to the battery positi
36. Swingarm Bearing Removal Remove Swingarm see Swingarm Removal Oil Seals A Sleeve B Remove the needle bearings Special Tool Oil Seal amp Bearing Remover A 57001 1058 Swingarm Bearing Installation Apply plenty of grease to the needle bearings Install the needle bearings so that the manufacturer s marks face out Special Tool Bearing Driver Set A 57001 1129 Swingarm Bearing Sleeve Inspection CAUTION Do not remove the bearings for inspection Re moval may damage them Inspect the needle bearings A installed in the swingarm The rollers in a needle bearing normally wear very little and wear is difficult to measure Instead of measuring visually inspect the bearing for abrasion discoloration or other damage If the needle bearing and sleeve B show any signs of abnormal wear discoloration or damage replace them as a set Swingarm Bearing Lubrication Refer to the Swingarm Pivot Lubrication in the Periodic Maintenance chapter http mototh com 13 18 SUSPENSION Tie Rod Rocker Arm Tie Rod Removal Squeeze the brake lever slowly and hold it with a band A Remove the lower fairings see Lower Fairing Removal in the Frame chapter Raise the rear wheel off the ground with the jack Special Tools Jack 57001 1238 Jack Attachment 57001 1608 Remove Upper Tie Rod Nut and Bolt A Lower Tie Rod Nut and Bolt B Tie Rods C Tie Rod
37. 6 6 k at 0 C 32 F 0 29 0 39 k at 80 C 176 F Water Temperature Sensor Output Voltage About DC 2 80 2 97 V at 20 C 68 F Speed Sensor Input Voltage DC 4 75 5 25 V Output Voltage About DC 0 05 0 09 V or DC 4 5 4 9 V at ignition switch ON and 0 km h Vehicle down Sensor Input Voltage DC 4 75 5 25 V Output Voltage With sensor tilted 55 75 or more right or left DC 3 7 4 4 V With sensor arrow mark pointed up DC 0 4 1 4 V http mototh com 3 18 FUEL SYSTEM DFI Specifications Item Standard Subthrottle Sensor Input Voltage DC 4 75 5 25 V Output Voltage DC 0 78 0 82 V at subthrottle valve full close position DC 3 9 4 1 V at subthrottle valve full open position for reference Resistance 4 6 k Subthrottle Valve Actuator Resistance About 5 2 7 8 Input Voltage About DC 11 5 13 5 V Oxygen Sensor Output Voltage Rich DC 0 7 V or more Output Voltage Lean DC 0 2 V or less Heater Resistance 11 7 15 5 at 20 C 68 F Throttle Grip and Cables Throttle Grip Free Play 2 3 mm 0 08 0 12 in Air Cleaner Element Polyurethane foam http mototh com FUEL SYSTEM DFI 3 19 Special Tools and Sealant Oil Pressure Gauge 5 kgf cm 57001 125 Fork Oil Level Gauge 57001 1290 Vacuum Gauge 57001 1369 Hand Tester 57001 1394 Throttle Sensor Setting Adapter 1
38. Install the removed parts see appropriate chapters http mototh com COOLING SYSTEM 4 15 Thermostat Thermostat Inspection Remove the thermostat see Thermostat Removal and inspect the thermostat valve A at room temperature If the valve is open replace the thermostat with a new one To check valve opening temperature suspend the ther mostat A in a container of water and raise the tempera ture of the water The thermostat must be completely submerged and must not touch the container sides or bottom Suspend an ac curate thermometer B in the water so that the heat sen sitive portions C are located in almost the same depth It must not touch the container either If the measurement is out of the specified range replace the thermostat with a new one Thermostat Valve Opening Temperature 63 5 66 5 C 146 152 F http mototh com 4 16 COOLING SYSTEM Hoses and Pipes Hose Installation Install the hoses and pipes being careful to follow bend ing direction Avoid sharp bending kinking flattening or twisting Run the hoses correctly see Cable Wire and Hose Rout ing section in the Appendix chapter Install the clamp A as near as possible to the hose end to clear the raised rib of the fitting This will prevent the hoses from working loose The clamp screws should be positioned correctly to pre vent the clamps from contacting the other parts Torque Radiator
39. None None Black 92028 1423 None None Blue 92028 1422 Crankshaft Selection when Replacing Crankshaft Clutch Housing Crankshaft Gear Marking Color Primary Gear Marking Color Part Number A White A White 13031 0111 A White B Red 13031 0112 B Red A White 13031 0111 B Red B Red 13031 0112 B Red C None 13031 0113 C None A White 13031 0111 C None B Red 13031 0112 C None C None 13031 0113 C None D Yellow 13031 0114 D Yellow A White 13031 0111 D Yellow B Red 13031 0112 D Yellow C None 13031 0113 D Yellow D Yellow 13031 0114 http mototh com CRANKSHAFT TRANSMISSION 9 9 Special Tools and Sealant Bearing Puller 57001 135 Outside Circlip Pliers 57001 144 Bearing Puller Adapter 57001 317 Kawasaki Bond Liquid Gasket Black 92104 1064 http mototh com 9 10 CRANKSHAFT TRANSMISSION Crankcase Crankcase Splitting Remove the engine see Engine Removal in the Engine Removal Installation chapter Set the engine on a clean surface and hold the engine steady while parts are being removed Remove Clutch see Clutch Removal in the Clutch chapter External Shift Mechanism see External Shift Mecha nism Removal Oil Pump see Oil Pump Removal in the Engine Lubri cation System chapter Starter Motor see Starter Motor Removal in the Electri cal System chapter Alternator Rotor see Alternator Rotor Removal
40. This manual contains four more symbols in addition to WARNING and CAUTION which will help you distinguish different types of informa tion NOTE This note symbol indicates points of par ticular interest for more efficient and con venient operation Indicates a procedural step or work to be done Indicates a procedural sub step or how to do the work of the procedural step it follows It also precedes the text of a NOTE Indicates a conditional step or what action to take based on the results of the test or 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 http mototh com http mototh com GENERAL INFORMATION 1 1 1 General Information Table of Contents Before Servicing 1 2 Model Identification 1 7 General Specifications 1 8 Unit Conversion Table
41. 3 64 FUEL SYSTEM DFI Subthrottle Sensor Service Code 32 Subthrottle Sensor Output Voltage Inspection Measure the output voltage at the subthrottle sensor in the same way as input voltage inspection note the fol lowing Disconnect the subthrottle sensor connector and connect the harness adapter A between these connectors Special Tool Throttle Sensor Setting Adapter 57001 1538 Subthrottle Sensor Output Voltage Connections to Adapter Digital Meter R sensor BL W lead Digital Meter W sensor BR BK lead Remove the fuel tank see Fuel Tank Removal Disconnect the subthrottle valve actuator harness con nector A Measure the output voltage with the engine stopped with the connector joined Turn the ignition switch ON Measure the output voltage when the subthrottle valve is completely closed by turning the lever A fully clockwise B Output Voltage Standard DC 0 78 0 82 V at subthrottle valve full close position DC 3 9 4 1 V at subthrottle valve full open position for reference NOTE Turn the lever counterclockwise confirm the output volt age will be raise The standard voltage refers to the value when the volt age reading at the Input Voltage Inspection shows 5 V exactly When the input voltage reading shows other than 5 V derive a voltage range as follows Example In the case of a input voltage of 4 75 V 0 78 4 75 5 00
42. Cable Wire and Hose Routing http mototh com APPENDIX 17 29 Cable Wire and Hose Routing 1 Vehicle down Sensor 2 Clamps 3 Air Switching Valve 4 Install the hose so that its white mark side faces the air switching valve 5 Damper 6 Inlet Air Pressure Sensor 7 Vacuum Hose 8 Air Switching Valve Hose 9 Clamp http mototh com 17 30 APPENDIX Cable Wire and Hose Routing http mototh com APPENDIX 17 31 Cable Wire and Hose Routing 1 Front Master Cylinder 2 Front Brake Hose 3 Bracket 4 Guide 5 Front Brake Caliper 6 Rear Brake Reservoir Tank 7 Rear Brake Caliper 8 Clamp 9 Rear Master Cylinder http mototh com 17 32 APPENDIX Troubleshooting Guide NOTE Refer to the Fuel System chapter for most of DFI trouble shooting guide This is not an exhaustive list giving every possible cause for each problem listed It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties Engine Doesn t Start Starting Difficulty Starter motor not rotating Ignition and engine stop switch not ON Starter lockout switch or neutral switch trou ble Starter motor trouble Battery voltage low Starter relay not contacting or operating Starter button not contacting Starter system wiring shorted or open Ignition switch trouble Engine stop switch trouble Main 30 A or ignition fuse blown Starter motor rotating but engine doesn t turn over Vehicle
43. Exploded View http mototh com SUSPENSION 13 3 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Front Fork Bottom Allen Bolts 20 2 0 15 L 2 Lower Front Fork Clamp Bolts 30 3 1 22 3 Upper Front Fork Clamp Bolts 20 2 0 15 G Apply grease L Apply a non permanent locking agent R Replacement Parts http mototh com 13 4 SUSPENSION Exploded View http mototh com SUSPENSION 13 5 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Rear Shock Absorber Nuts 59 6 0 44 2 Swingarm Pivot Shaft Nut 98 10 0 72 3 3 Tie Rod Nuts 59 6 0 44 4 Uni Trak Rocker Arm Nut 59 6 0 44 G Apply grease R Replacement Parts http mototh com 13 6 SUSPENSION Specifications Item Standard Front Fork Per One Unit Fork Inner Tube Diameter 37 mm 1 5 in Air Pressure Atmospheric pressure Non adjustable Rebound Damper Setting Non adjustable Fork Spring Preload Setting Non adjustable Fork Oil Viscosity SHOWA SS08 or equivalent SAE 10W Amount Approx 310 mL 10 5 US oz when changing oil 360 2 5 mL 12 2 0 085 US oz after disassembly and completely dry Fork Oil Level 108 2 mm 4 25 0 08 in fully compressed without fork spring below from the top of the inner tube Fork Spring Free Length 420 5 mm 16 56 in Service Limit 412 mm 16 22 in Rear Shock Absorber Rebound Damper Setting Non adju
44. The sensor and thermometer must not touch the con tainer side or bottom Place the container over a source of heat and gradually raise the temperature of the oil while stirring the oil gently for even temperature Using a digital meter measure the internal resistance of the sensor across the terminals at the temperatures shown in the following Inlet Air Temperature Sensor Resistance Standard 5 4 6 6 k at 0 C 32 F 0 29 0 39 k at 80 C 176 F If the reading is out of the standard replace the sensor If the reading is within the standard but the problem still exists replace the ECU see ECU Removal Installation http mototh com 3 52 FUEL SYSTEM DFI Inlet Air Temperature Sensor Service Code 13 Inlet Air Temperature Sensor Circuit 1 ECU 2 Water proof Joint 1 3 Inlet Air Temperature Sensor http mototh com FUEL SYSTEM DFI 3 53 Water Temperature Sensor Service Code 14 Water Temperature Sensor Removal Installation CAUTION Never drop the water temperature sensor especially on a hard surface Such a shock to the sensor can damage it Remove Coolant Drain see Coolant Change in the Periodic Maintenance chapter Connector A Disconnect Water Temperature Sensor B Replace the gasket with a new one and tighten the water temperature sensor Torque Water Temperature Sensor 25 N m 2 5 kgf m 18 ft lb Fill the engine with coolant and bleed the ai
45. 2 Engine Oil Drain Bolt Crankcase 19 6 2 0 14 5 3 Engine Oil Drain Bolt Oil Screen Cover 19 6 2 0 14 5 4 Oil Breather Mounting Bolts 9 8 1 0 87 in lb L 5 Oil Filter Mounting Bolt 19 6 2 0 14 5 6 Oil Hose Banjo Bolts 19 6 2 0 14 5 7 Oil Passage Plugs 20 2 0 15 L 8 Oil Pipe Banjo Bolt 12 1 2 106 in lb 9 Oil Pressure Relief Valve 15 1 5 11 L 10 Oil Pressure Switch 15 1 5 11 SS 11 Oil Pressure Switch Terminal Bolt 1 5 0 15 13 in lb G 12 Oil Pump Mounting Bolts 9 8 1 0 87 in lb L 13 Oil Screen Cover Bolts 9 8 1 0 87 in lb EO Apply engine oil G Apply grease L Apply a non permanent locking agent R Replacement Parts SS Apply silicone sealant http mototh com 7 4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart http mototh com ENGINE LUBRICATION SYSTEM 7 5 Specifications Item Standard Engine Oil Type API SE SF or SG API SH SJ or SL with JASO MA Viscosity SAE 10W 40 Capacity 1 3 L 1 4 US qt when filter is not removed 1 6 L 1 7 US qt when filter is removed 1 7 L 1 8 US qt when engine is completely dry Level Between upper and lower level lines Wait 2 3 minutes after idling or running Oil Pressure Measurement Oil Pressure 98 147 kPa 1 0 1 5 kgf cm 14 21 psi at 4 000 r min rpm Oil Temperature 90 C 194 F http mototh com 7 6 ENGINE LUBRICATION SYSTEM Special Tools and Se
46. 2 35 Electrical System Lights and switches operation inspect year 2 36 Headlight aiming inspect year 2 38 Sidestand switch operation inspect year 2 39 Engine stop switch operation inspect year 2 40 Others Chassis parts lubricate year 2 40 Bolts and nuts tightness inspect 2 42 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 http mototh com PERIODIC MAINTENANCE 2 5 Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY Whichever comes first ODOMETER READING 1 000 km 1 000 mile 1 12 24 36 48 ITEM Every 0 6 7 5 15 24 30 See Page Air cleaner element replace 2 years 2 43 Fuel hose replace 4 years 2 44 Coolant change 3 years 2 45 Radiator hose and O ring replace 3 years 2 48 Engine oil change year 2 48 Oil filter replace year 2 49 Brake hose and pipe replace 4 years 2 50 Brake fluid change 2 years 2 50 Rubber parts of master cylinder and caliper replace 4 years 2 51 2 53 Spark plug replace 2 54 Service more frequently wh
47. Digital Meter Y actuator G lead Measure the actuator input voltage with the engine stopped and with the connector joined Turn the ignition switch ON Input Voltage Standard About DC 11 5 13 5 V Turn the ignition switch OFF If the reading is in specification but the actuator does not operate replace the throttle body assy see Throttle Body Assy Removal Installation If the reading is out of the specification remove the ECU and check the wiring for continuity between main harness connectors Special Tool Hand Tester 57001 1394 Disconnect the ECU and actuator connectors Wiring Continuity Inspection ECU Connector A Subthrottle Valve Actuator Connector B W BL lead ECU terminal 1 C P lead ECU terminal 2 D G Y lead ECU terminal 14 E BK BL lead ECU terminal 15 F If the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see ECU Removal Installation http mototh com FUEL SYSTEM DFI 3 75 Subthrottle Valve Actuator Service Code 62 Subthrottle Valve Actuator Circuit 1 ECU 2 Subthrottle Valve Actuator http mototh com 3 76 FUEL SYSTEM DFI Air Switching Valve Service Code 64 Air Switching Valve Removal Installation Refer to the Air Switching Valve Removal Installation in the Engine Top End chapter Air Switching Valve I
48. ELECTRICAL SYSTEM 16 65 Switches and Sensors Oxygen Sensor Installation 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 contami nation from hands can reduce sensor performance Tighten Torque Oxygen Sensor 44 1 N m 4 50 kgf m 32 5 ft lb Run the oxygen sensor lead correctly see Cable Wire and Hose Routing section in the Appendix chapter Oxygen Sensor Inspection Refer to the Oxygen Sensor Inspection in the Fuel System DFI chapter Fuel Reserve Switch Inspection Remove the fuel tank see Fuel Tank Removal in the Fuel System DFI chapter Fill the fuel tank with fuel Close the fuel tank cap surely Connect the test light A 12 V 3 4 W bulb in a socket with leads and the 12 V battery B to the fuel pump connector Connections Battery 12 V 3 4 W Bulb One Side 12 V 3 4 W Bulb Other Side BL Lead Terminal Battery BK Lead Terminal If the test light turn on the reserve switch is defective Replace the fuel pump Remove the fuel pump see Fuel Pump Removal in the Fuel System DFI chapter Connect the test light 12 V 3 4 W bulb in a socket with leads and the 12 V battery to the fuel pump connector as shown in the figure 12 V Battery A Test Light B Fuel Pump Connector C Fue
49. FUEL SYSTEM DFI 3 39 Self Diagnosis Backups The ECU takes the following measures to prevent engine damage when the DFI or the ignition system parts have troubles Service Codes Parts Output Signal Usable Range or Criteria Backups by ECU 11 Main Throttle Sensor Output Voltage 0 2 4 8 V If the main throttle sensor system fails the output voltage is out of the usable range wiring short or open the ECU locks ignition timing into the ignition timing at closed throttle position and sets the DFI in the D J method Also the main throttle sensor system and inlet air pressure fails the ECU locks ignition timing into the ignition timing at closed throttle position and sets the DFI in the N method 12 Inlet Air Pressure Sensor Inlet Air Pressure Absolute Pv 150 800 mmHg If the inlet air pressure sensor system fails the signal is out of the usable range wiring short or open the ECU sets the DFI in the N method 13 Inlet Air Temperature Sensor Inlet Air Temperature Ta 30 120 C 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 14 Water Temperature Sensor Water Temperature Tw 30 120 C If the water temperature sensor system fails the signal is out of the usable range wiring short or open the ECU sets Tw at 80 C 21 Crankshaft Sensor Crankshaft sensor must
50. Stator Coil Bolts 12 N m 1 2 kgf m 106 in lb Install the alternator B and crankshaft sensor C leads into the alternator cover as shown in the figure Crankshaft Sensor D Damper E Clamp F Grommets G Silicone Sealant Applied Areas H Apply silicone sealant to the grommets and fit them into the notch of the cover securely Sealant Kawasaki Bond Silicone Sealant 92104 0004 Install the crankshaft sensor and clamp Tighten Torque Crankshaft Sensor Screws 3 0 N m 0 31 kgf m 27 in lb Install the alternator cover see Alternator Cover Installa tion Alternator Rotor Removal Remove Alternator Cover see Alternator Cover Removal Shaft A Starter Idle Gear B Hold the alternator rotor steady with the flywheel holder A Remove the rotor bolt B and washer C Special Tool Flywheel Holder 57001 1313 CAUTION Do not hold the projections D http mototh com 16 26 ELECTRICAL SYSTEM Charging System Using the flywheel puller A remove the alternator rotor B from the crankshaft Special Tool Flywheel Puller Assembly M38 1 5 M35 1 5 57001 1405 CAUTION Do not attempt to strike the alternator rotor itself Striking the rotor can cause the magnets to lose their magnetism Alternator Rotor Installation Using a cleaning fluid clean off any oil or dirt on the fol lowing portions and dry them with a clean cloth Crankshaft Tape
51. Stick coil shorted or not in good contact Inspect or Reinstall see chapter 16 Stick coil trouble Inspect see chapter 16 Spark plug dirty broken or gap maladjusted Inspect and replace see chapter 2 Spark plug incorrect Replace it with the correct plug see chapter 2 ECU ground and power supply trouble Inspect see chapter 3 ECU trouble Inspect see chapter 3 No or little fuel in tank Supply fuel see Owner s Manual Fuel injector trouble Inspect and replace see chapter 3 Fuel pump not operating Inspect see chapter 3 Fuel pump relay trouble Inspect and replace see chapter 3 Fuel filter or pump screen clogged Inspect and replace fuel pump see chapter 3 Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump see chapter 3 Fuel line clogged Inspect and repair see chapter 3 Poor Running at Low Speed Symptoms or Possible Causes Actions Spark weak Stick coil shorted or not in good contact Inspect or Reinstall see chapter 16 Stick coil trouble Inspect see chapter 16 Spark plug dirty broken or gap maladjusted Inspect and replace see chapter 2 Spark plug incorrect Replace it with the correct plug see chapter 2 ECU trouble Inspect see chapter 3 Fuel air mixture incorrect Little fuel in tank Supply fuel see Owner s Manual Air cleaner clogged poorly sealed or missing Clean element or inspect sealing see chapter 2 A
52. The 32 cutter removes material very quickly Check the seat outside diameter frequently to pre vent overgrinding After making the 32 grind return to the seat outside di ameter measurement step above To measure the seat width use a vernier caliper to mea sure the width of the 45 angle portion of the seat at sev eral places around the seat If the seat width is too narrow repeat the 45 grind until the seat is slightly too wide and then return to the seat outside diameter measurement step above http mototh com ENGINE TOP END 5 31 Valves If the seat width is too wide make the 67 5 A grind described below If the seat width is within the specified range lap the valve to the seat as described below Grind the seat at a 67 5 angle until the seat width is within the specified range To make the 67 5 grind fit 67 5 cutter into the holder and slide it into the valve guide Turn the holder while pressing down lightly After making the 67 5 grind return to the seat width mea surement step above Correct Width B Lap the valve to the seat once the seat width and outside diameter are within the ranges specified above Put a little coarse grinding compound on the face of the valve in a number of places around the valve head Spin the valve against the seat until the grinding com pound produces a smooth matched surface on both the seat and the valve Repeat the process
53. 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 The procedure to bleed the front brake line is as follows Bleeding the rear brake line is the same as for the front brake Remove the reservoir cap A and diaphragm Fill the reservoir with fresh brake fluid to the upper level line in the reservoir Slowly pump the brake lever several times until no air bubbles can be seen rising up through the fluid from the holes at the bottom of the reservoir Bleed the air completely from the master cylinder by this operation Remove the rubber cap A from the bleed valve on the caliper Attach a clear plastic hose B to the bleed valve and run the other end of the hose into a container http mototh com 12 18 BRAKES Brake Fluid Bleed the brake line and the caliper Repeat this operation until no more air can be seen com ing out into the plastic hose 1 Pump the brake lever until it becomes hard and apply the brake and hold it A 2 Quickly open and close B the bleed valve while hold ing the brake applied 3 Release the brake C NOTE The 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 duri
54. http mototh com ELECTRICAL SYSTEM 16 43 Electric Starter System Align the end covers A with the marks C of the yoke B Replace the O rings on the through bolts with new ones and tighten them Torque Starter Motor Through Bolts 3 4 N m 0 35 kgf m 30 in lb Brush Inspection Measure the length of each brush A If any is worn down to the service limit replace the brush plate assembly B Starter Motor Brush Length C Standard 10 mm 0 39 in Service Limit 5 0 mm 0 20 in Commutator Cleaning and Inspection Smooth the commutator surface A if necessary with fine emery cloth B and clean out the grooves Measure the diameter A of the commutator B If the commutator diameter is less than the service limit replace the starter motor with a new one Commutator Diameter Standard 28 mm 1 10 in Service Limit 27 mm 1 06 in http mototh com 16 44 ELECTRICAL SYSTEM Electric Starter System Armature Inspection Using the 1 hand tester range measure the resis tance between any two commutator segments A Special Tool Hand Tester 57001 1394 If there is a high resistance or no reading between any two segments a winding is open and the starter motor must be replaced Using the highest hand tester range measure the resis tance between the segments and the shaft B If there is any reading at all the armature has a short and the
55. with Flange http mototh com WHEELS TIRES 10 9 Wheels Rims Engage the drive chain with the rear sprocket Install the caliper bracket A onto the swingarm stop B Insert the axle from the left side of the wheel and tighten the axle nut Torque Rear Axle Nut 98 N m 10 0 kgf m 72 3 ft lb Insert a new cotter pin A NOTE When inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle tighten the nut clockwise B up to next alignment It should be within 30 Loosen once and tighten again when the slot goes past the nearest hole Bend the cotter pin A over the nut WARNING If the rear axle nut is not securely tightened or the cotter pin is not installed an unsafe riding condi tion may result Adjust the drive chain slack after installation see Drive Chain Slack Inspection in the Periodic Maintenance chap ter Install the rear caliper see Caliper Installation in the Brakes chapter Check the rear brake effectiveness see Brake Operation Inspection in the Periodic Maintenance chapter WARNING Do not attempt to drive the motorcycle until a full brake pedal is obtained by pumping the brake pedal until the pads are against the disc The brake will not function on the first application of the pedal if this is not done http mototh com 10 10 WHEELS TIRES Wheels Rims Wheel Inspection Raise the fr
56. 0 741 V 0 82 4 75 5 00 0 779 V Thus the valid range is 0 741 0 779 V Turn the ignition switch OFF If the reading is out of the standard check the subthrot tle sensor resistance see Subthrottle Sensor Resistance Inspection http mototh com FUEL SYSTEM DFI 3 65 Subthrottle Sensor Service Code 32 If the reading is within the standard remove the ECU and check the wiring for continuity between main harness con nectors Special Tool Hand Tester 57001 1394 Disconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Subthrottle Sensor Connector B BL W lead ECU terminal 19 C BR BK lead ECU terminal 22 D If the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see ECU Removal Installation Subthrottle Sensor Resistance Inspection 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 Subthrottle Sensor Resistance Connections BL lead C BR BK lead D Standard 4 6 k If the reading is out of the standard replace the throttle body assy see Throttle Body Assy Removal Installation If the reading is within the standard but the problem still exists replace the ECU see E
57. 1 499 1 503 mm 0 05902 0 05917 in Blue 1 503 1 507 mm 0 05917 0 05933 in Transmission Shift Fork Ear Thickness 4 9 5 0 mm 0 193 0 197 in 4 8 mm 0 189 in Gear Groove Width 5 05 5 15 mm 0 199 0 203 in 5 3 mm 0 209 in Shift Fork Guide Pin Diameter 5 9 6 0 mm 0 232 0 236 in 5 8 mm 0 228 in Shift Drum Groove Width 6 05 6 20 mm 0 238 0 244 in 6 3 mm 0 248 in http mototh com 9 8 CRANKSHAFT TRANSMISSION Specifications Connecting Rod Big End Bearing Insert Selection Bearing Insert Con rod Big End Inside Diameter Marking Crankpin Diameter Marking Size Color Part Number None Brown 92028 1494 None None Black 92028 1493 None Blue 92028 1492 Crankshaft Main Bearing Insert Selection Bearing Insert Crankcase Main Bearing Inside Diameter Marking Crankpin Main Journal Diameter Marking Size Color Part Number Journal Nos 92028 1487 1 3 1 Black 92028 1490 2 None 92028 1486 1 3 None 1 Blue 92028 1489 2 92028 1582 1 3 None None Yellow 92028 1586 2 The bearing insert for Nos 2 journal have an oil groove Balancer Shaft Bearing Insert Selection Bearing Insert Crankcase Main Bearing Inside Diameter Marking Balancer Shaft Journal Diameter Marking Size Color Part Number Brown 92028 1424
58. 106 in lb Exhaust Pipe Mounting Bolt 9 8 1 0 87 in lb Muffler Body Clamp Bolt 17 1 7 13 Muffler Body Mounting Bolt 30 3 1 22 Muffler Body Rear Cover Bolts 9 8 1 0 87 in lb L Muffler Cover Bolts 9 8 1 0 87 in lb Muffler Cover Clamp Bolt 9 8 1 0 87 in lb Muffler Cover Clamp Screw 6 9 0 70 61 in lb Rear Camshaft Chain Guide Bolt 17 1 7 13 Spark Plugs 13 1 3 115 in lb Throttle Body Assy Holder Clamp Screws 2 0 0 20 18 in lb Clutch Clutch Cover Bolts 9 8 1 0 87 in lb Clutch Hub Nut 132 13 5 97 4 Clutch Lever Clamp Bolt 8 8 0 90 78 in lb Clutch Spring Bolts 8 8 0 90 78 in lb Oil Filler Plug Hand Tighten Engine Lubrication System Crankcase Oil Passage Plug 15 1 5 11 Engine Oil Drain Bolt Crankcase 19 6 2 0 14 5 Engine Oil Drain Bolt Oil Screen Cover 19 6 2 0 14 5 Oil Breather Mounting Bolts 9 8 1 0 87 in lb L Oil Filter Mounting Bolt 19 6 2 0 14 5 Oil Hose Banjo Bolts 19 6 2 0 14 5 Oil Passage Plugs 20 2 0 15 L Oil Pipe Banjo Bolt 12 1 2 106 in lb Oil Pressure Relief Valve 15 1 5 11 L Oil Pressure Switch 15 1 5 11 SS Oil Pressure Switch Terminal Bolt 1 5 0 15 13 in lb G Oil Pump Mounting Bolts 9 8 1 0 87 in lb L Oil Screen Cover Bolts 9 8 1 0 87 in lb http mototh com 2 8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener N m kgf m ft lb
59. 12 18 24 30 36 ITEM Every 0 6 4 7 5 12 15 20 24 See Page Fuel System Air cleaner element clean 2 14 Throttle control system play smooth return no drag inspect year 2 14 Engine vacuum synchronization inspect 2 15 Idle speed inspect 2 18 Fuel leak fuel hose and pipe inspect year 2 18 Fuel hose and pipe damage inspect year 2 18 Fuel hose and pipe installation condition inspect year 2 18 Cooling System Coolant level inspect 2 19 Coolant leak water hose and pipe inspect year 2 20 Water hose damage inspect year 2 20 Water hose installation condition inspect year 2 20 Engine Top End Valve clearance inspect 2 20 Air suction system damage inspect 2 23 Clutch Clutch operation play disengagement engagement inspect 2 23 Wheels and Tires Tire air pressure inspect year 2 24 Wheel tire damage inspect 2 25 Tire tread wear abnormal wear inspect 2 25 Wheel bearing damage inspect year 2 26 Final Drive Drive chain lubrication condition inspect Every 600 km 400 mile 2 26 Drive chain slack inspe
60. A for any signs of deterioration or damage Replace it if necessary Spring Tension Inspection Since a spring becomes shorter as it weakens check its free length A to determine its condition If the spring of either fork leg is shorter than the service limit it must be replaced If the length of a replacement spring and that of the remaining spring vary greatly the remaining spring should also be replaced in order to keep the fork legs balanced for motorcycle stability Spring Free Length Standard 420 5 mm 16 56 in Service Limit 412 mm 16 22 in http mototh com 13 14 SUSPENSION Rear Shock Absorber Spring Preload Adjustment Remove the bolts A chain cover B and left front footpeg bracket C for turning the wrench easily Using the steering stem nut wrench A turn the adjusting nut to adjust the spring preload Special Tool Steering Stem Nut Wrench 57001 1100 The standard adjuster setting for average build rider of 68 kg 150 Ib with no passenger and no accessories is 2nd position Spring Preload Setting Standard Position 2nd position Adjustable Range 1st 5th position If the compression of the spring is not suited to the op erating conditions adjust it to an appropriate position by referring to the table below Spring Preload Adjustment Adjuster Position Damping Force Shock Absorber Hardness Load Road Conditions Driving Speed 1st Weak Sof
61. A is in position http mototh com FRAME 15 13 Seat Covers Put the projections A into the holes B Install the removed parts see appropriate chapters http mototh com 15 14 FRAME Fenders Front Fender Removal Remove Bolts A with Collar Both Sides Front Fender B Front Fender Installation Installation is the reverse of removal Flap and Rear Fender Removal Remove Seat Covers see Seat Cover Removal Bolts A Both Sides Rear Footpeg Brackets B Both Sides Remove Relay Box A see Relay Box Removal in the Electrical System chapter Battery Case B see Battery Removal in the Electrical System chapter ECU C see ECU Removal in the Fuel System DFI chapter Remove Fuse Box A Clamp B Connectors C http mototh com FRAME 15 15 Fenders Remove Tail Brake Light see Tail Brake Light Removal in the Electrical System chapter Owner s Tool A Connector B Bolts C Flap with Turn Signal and License Plate Lights Remove the screws A both sides Pull out the rear fender backward Flap and Rear Fender Installation Installation is the reverse of removal Install the removed parts see appropriate chapters Torque Rear Footpeg Bracket Bolts 25 N m 2 5 kgf m 18 ft lb Run the cable leads and harness correctly see Cable Wire and Hose Routing section in the Appendix chapter http mototh com 15
62. A over the nut WARNING If the rear axle nut is not securely tightened or the cotter pin is not installed an unsafe riding condi tion may result Install the speedometer cable so that the drive notch A of it fits into the projection B of the speedometer pinion in the housing Install the removed parts see appropriate chapters Check the front brake effectiveness see Brake Operation Inspection in the Periodic Maintenance chapter 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 http mototh com 10 8 WHEELS TIRES Wheels Rims Rear Wheel Removal Raise the rear wheel off the ground with the stand A Remove Rear Caliper Mounting Bolts A Rear Caliper B Remove Cotter Pin A Axle Nut B Washer C Axle D from Left Side Remove the drive chain A from the rear sprocket toward the left Move the rear wheel back and remove it CAUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground Rear Wheel Installation Apply high temperature grease to the grease seal lips Fit the collars on the both sides of the hub Left Side Collar A Right Side Collar B
63. Apply a adhesive cement to the slash portion A of the air cleaner housing Install the right cover Tighten Torque Air Cleaner Housing Screws 1 15 N m 0 12 kgf m 10 in lb http mototh com 3 110 FUEL SYSTEM DFI Fuel Tank Fuel Tank Removal WARNING Gasoline is extremely flammable and can be explo sive under certain conditions Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Turn the ignition switch OFF and disconnect the battery terminal To avoid fire do not remove the fuel tank when the engine is still hot Wait until it cools down To make fuel spillage minimum draw the fuel out from the fuel tank when the engine is cold Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately Turn the ignition switch OFF Wait until the engine cools down Disconnect the battery terminal see Battery Removal in the Electrical System chapter Remove Lower Fairings see Lower Fairing Removal in the Frame chapter Front Seat see Front Seat Removal in the Frame chap ter Fuel Tank Bolts A Pull off the fuel tank drain hose A from the fuel tank Open the fuel tank cap A to lower the pressure in the tank http mototh com FUEL SYSTEM DFI 3 111 Fuel Tank Draw the fuel out from the fuel tank with a commercially available pump A
64. FUEL SYSTEM DFI 3 31 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions Water temperature sensor trouble Inspect see chapter 3 Inlet air temperature sensor trouble Inspect see chapter 3 Spark plug dirty broken or gap maladjusted Inspect and replace see chapter 2 Stick coil trouble Inspect see chapter 16 Stumble Fuel pressure too low Inspect see chapter 3 Fuel injector trouble Inspect see chapter 3 Main throttle sensor trouble Inspect see chapter 3 Subthrottle sensor trouble Inspect see chapter 3 Subthrottle valve actuator trouble Inspect see chapter 3 Inlet air pressure sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Inlet air temperature sensor trouble Inspect see chapter 3 Surge Unstable fuel pressure Fuel pressure regulator trouble Inspect and replace fuel pump or kinked fuel line Inspect and replace fuel pump see chapter 3 Fuel injector trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Backfiring when deceleration Spark plug dirty broken or gap maladjusted Inspect and replace see chapter 2 Fuel pressure too low Inspect see chapter 3 Fuel pump trouble Inspect see chapter 3 Main throttle sensor trouble Inspect see chapter 3 Subthrottle sensor trouble Inspect see chapter 3 Subthrottle valve actuator trouble Inspec
65. If dirt gets through into the engine excessive en gine wear and possibly engine damage will occur Remove Right Side Cover see Side Cover Removal in the Frame chapter Air Cleaner Housing Cap Bolts A Air Cleaner Housing Cap B Pull out the air cleaner element A Separate the plastic holders A Install a new element and air cleaner housing cap Tighten Torque Air Cleaner Housing Cap Bolts 2 5 N m 0 25 kgf m 22 in lb http mototh com 2 44 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel Hose Replacement WARNING Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is disconnected fuel spills out from the hose and the pipe because of residual pressure Cover the hose connection with a piece of clean cloth to prevent fuel spillage Remove the fuel tank see Fuel Tank Removal in the Fuel System DFI chapter Be sure to place a piece of cloth A around the fuel hose joint Push the joint lock claws B Pull the joint lock A as shown in the figure Pull the fuel hose joint B out of the fuel supply pipe Replace the fuel hose with a new one Pull A the joint lock B fully as shown in the figure Install a new fuel hose so that the white mark side faces fuel supply pipe of the fuel pump Insert the fuel hose joint A straight onto the fuel supply pipe until the hose
66. MO S 3 Crankcase Bolts M8 L 73 mm 19 1 9 14 MO S 4 Crankcase Bolts M6 12 1 2 106 in lb 5 Oil Breather Mounting Bolts 9 8 1 0 87 in lb L 6 Shift Drum Bearing Holder Bolts 12 1 2 106 in lb L 7 Starter Motor Clutch Bolts 34 3 3 5 25 L G Apply grease L Apply a non permanent locking agent LG Apply liquid gasket M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts S Follow the specified tightening sequence SS Apply silicone sealant http mototh com 9 4 CRANKSHAFT TRANSMISSION Exploded View http mototh com CRANKSHAFT TRANSMISSION 9 5 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Neutral Switch 15 1 5 11 2 Shift Drum Pin Plate Bolt 9 0 0 92 80 in lb L 3 Shift Drum Positioning Bolt 24 5 2 5 18 4 Shift Lever Bolt 12 1 2 106 in lb 5 Shift Pedal Mounting Bolt 25 2 5 18 6 Shift Shaft Return Spring Pin 19 6 2 0 14 5 L 7 Tie Rod Locknuts 7 0 0 71 62 in lb EO Apply engine oil G Apply grease L Apply a non permanent locking agent R Replacement Parts http mototh com 9 6 CRANKSHAFT TRANSMISSION Specifications Item Standard Service Limit Crankshaft Connecting Rods Connecting Rod Bend TIR 0 2 100 mm 0 008 3 94 in Connecting Rod Twist
67. Peak Voltage Adapter 57001 1449 Kawasaki Bond Silicone Sealant 92104 0004 http mototh com 16 12 ELECTRICAL SYSTEM Parts Location http mototh com ELECTRICAL SYSTEM 16 13 Parts Location 1 Meter Unit 2 Ignition Switch 3 Starter Lockout Switch 4 Air Switching Valve 5 Stick Coils 6 Spark Plugs 7 Starter Relay 8 Relay Box 9 ECU 10 Turn Signal Relay 11 Fuse Box 12 Battery 12 V 8 Ah 13 Speed Sensor 14 Sidestand Switch 15 Neutral Switch 16 Starter Motor 17 Alternator 18 Crankshaft Sensor 19 Oil Pressure Switch 20 Regulator Rectifier 21 Front Brake Light Switch 22 Resistor 23 Fan Motor 24 Water Temperature Sensor 25 Oxygen Sensor 26 Engine Ground 27 Rear Brake Light Switch http mototh com 16 14 ELECTRICAL SYSTEM Wiring Diagram http mototh com ELECTRICAL SYSTEM 16 15 Wiring Diagram http mototh com 16 16 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems Learn and ob serve all the rules below Do not reverse the battery cable connections This will burn out the diodes on the electrical parts Always check battery condition before condemning other parts of an electrical system A fully charged battery is a must for conducting accurate electrical system tests The electrical parts should never be struck sharply as with a hammer or allowed to fall on a hard surface Such a s
68. Refer to the Fuse Installation in the Electrical System chapter ECU Fuse Inspection Refer to the Fuse Inspection in the Electrical System chapter ECU Main Relay Removal Installation The ECU main relay is built in the relay box A Refer to the Relay Box Removal in the Electrical System chapter ECU Main Relay Inspection Refer to the Relay Circuit Inspection in the Electrical Sys tem chapter http mototh com 3 88 FUEL SYSTEM DFI Fuel Line Fuel Pressure Inspection NOTE Be sure the battery is fully charged Remove Fuel Tank see Fuel Tank Removal Fuel Hose see Fuel Hose Replacement in the Periodic Maintenance chapter Be sure to place a piece of cloth around the fuel supply pipes of the fuel pump and the throttle body assy WARNING Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is disconnected fuel spills out from the hose and the pipe because of residual pressure Cover the hose connection with a piece of clean cloth to prevent fuel spillage Install the fuel pressure gauge adapter A and fuel hoses Special Tool 57001 1607 B between the fuel supply pipes of the fuel pump and throttle body assy Secure the fuel hoses with the clamps Connect the pressure gauge C to the fuel pressure gauge adapter Special Tools Oil Pressure Gauge 5 kgf cm 57001 125 Fuel Pressure Gauge Adapter 57001 1593 Fuel
69. Secure the fuel hose with a clamp Insert the fuel hose into the measuring cylinder B WARNING Wipe off spilled out fuel immediately Be sure to hold the measuring cylinder vertical Close the fuel tank cap Turn the engine stop switch to run position Turn the ignition switch ON The fuel pump should operate for 3 seconds and then should stop CAUTION Do not drive the fuel pump 3 seconds or more with out the fuel in the fuel tank If the fuel pump is driven without the fuel it may be damaged Measure the discharge for 3 seconds Repeat this operation several times Amount of Fuel Flow Standard 17 mL 0 57 US oz or more for 3 seconds Turn the ignition switch OFF If the fuel flow is much less than the specified replace the fuel pump see Fuel Pump Removal Installation Install the fuel tank see Fuel Tank Installation Start the engine and check for fuel leakage http mototh com FUEL SYSTEM DFI 3 91 Fuel Pump Fuel Pump Removal WARNING Gasoline is extremely flammable and can be explo sive under certain conditions Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Turn the ignition switch OFF and disconnect the battery terminal To make fuel spillage minimum draw the fuel out from the fuel tank when the engine is cold Be prepared for fuel spillage any spilled
70. Self Diagnosis http mototh com FUEL SYSTEM DFI 3 37 Self Diagnosis How to Read Service Codes Service codes are shown by a series of long and short blinks of the FI indicator light as shown below Read 10th digit and unit digit as the FI indicator light blinks When there are a number of problems all the service codes can be stored and the display will begin starting from the lowest number service code in the numerical order Then after completing all codes the display is repeated until the self diagnosis indicator terminal is open If there is no problem no code and unlight For example if two problems occurred in the order of 21 12 the service codes are displayed from the lowest number in the order listed 12 21 12 21 repeated If the problem is with the following parts the ECU cannot memorize these problems the FI indicator light doesn t go on and no service codes can be displayed FI Indicator Light Fuel Pump Fuel Pump Relay ECU Main Relay ECU Power Source Wiring and Ground Wiring see ECU Power Supply Inspection Fuel Injectors How to Erase Service Codes Even if the ignition switch is turned OFF the battery or the ECU are disconnected or the problem is solved all service codes remain in the ECU Refer to the Service Code Clearing Procedure for the service code erasure http mototh com 3 38 FUEL SYSTEM DFI Self Diagnosis Service Code Table Service
71. Swingarm pivot shaft runout excessive Steering maladjusted Front fork bent Right and left front fork oil level uneven Shock absorption unsatisfactory Too hard Front fork oil excessive Front fork oil viscosity too high Rear shock absorber adjustment too hard Tire air pressure too high Front fork bent Too soft Tire air pressure too low Front fork oil insufficient and or leaking Front fork oil viscosity too low Rear shock adjustment too soft Front fork rear shock absorber spring weak Rear shock absorber oil leaking http mototh com 17 36 APPENDIX Troubleshooting Guide Brake Doesn t Hold Air in the brake line Pad or disc worn Brake fluid leakage Disc warped Contaminated pad Brake fluid deteriorated Primary or secondary cup damaged in master cylinder Master cylinder scratched inside Battery Trouble Battery discharged Charge insufficient Battery faulty too low terminal voltage Battery cable making poor contact Load excessive e g bulb of excessive wattage Ignition switch trouble Alternator trouble Wiring faulty Regulator rectifier trouble Battery overcharged Alternator trouble Regulator rectifier trouble Battery faulty http mototh com MODEL APPLICATION Year Model Beginning Frame No 2008 EX250K8F JKAEX250KKDA00052 This digit in the frame number changes from one machine to another Part No 99924 1399 01 Printed in Japan http mototh com
72. Water Hose Clamp Screws 1 5 N m 0 15 kgf m 13 in lb Hose Inspection Refer to the Water Hose and Pipe Inspection in the Peri odic Maintenance chapter http mototh com COOLING SYSTEM 4 17 Water Temperature Sensor CAUTION The water temperature sensor should never be al lowed to fall on a hard surface Such a shock to the water temperature sensor can damage it Water Temperature Sensor Removal Installation Refer to the Water Temperature Sensor Removal Instal lation in the Fuel System DFI chapter Water Temperature Sensor Inspection Refer to the Water Temperature Sensor Inspection in the Electrical System chapter http mototh com http mototh com ENGINE TOP END 5 1 5 Engine Top End Table of Contents Exploded View 5 2 Exhaust System 5 6 Specifications 5 7 Special Tools and Sealant 5 9 Clean Air System 5 11 Air Suction Valve Removal 5 11 Air Suction Valve Installation 5 11 Air Suction Valve Inspection 5 11 Air Switching Valve Removal 5 12 Air Switching Valve Installation 5 12 Air Switching Valve Operation Test 5 12 Air Switching Valve Unit Test 5 12 Clean Air System Hose Inspection 5 12 Cylinde
73. brake fluid on the painted or plastic parts When removing the brake hoses B temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum Immediately wash away any brake fluid that spills There are washers on each side of the brake hose fitting Replace them with new ones when installing Tighten Torque Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft lb When installing the hoses avoid sharp bending kinking flatting or twisting and run the hoses according to Cable Wire and Hose Routing section in the Appendix chapter Fill the brake line after installing the brake hose see Brake Fluid Change Brake Fluid Change NOTE The procedure to change the front brake fluid is as fol lows Changing the rear brake fluid is the same as for the front brake Level the brake fluid reservoir Remove the reservoir cap and diaphragm Remove the rubber cap A from the bleed valve on the caliper Attach a clear plastic hose B to the bleed valve and run the other end of the hose into a container Fill the reservoir with fresh specified brake fluid http mototh com PERIODIC MAINTENANCE 2 51 Periodic Maintenance Procedures Change the brake fluid Repeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes 1 Open the bleed valve A 2 Apply the brake and hold it B 3 Close the bleed
74. lb Pour in the specified type and amount of oil http mototh com PERIODIC MAINTENANCE 2 49 Periodic Maintenance Procedures Recommended Engine Oil Type API SE SF or SG API SH SJ or SL with JASO MA Viscosity SAE 10W 40 Capacity 1 3 L 1 4 US qt when filter is not removed 1 6 L 1 7 US qt when filter is removed 1 7 L 1 8 US qt when engine is completely dry NOTE Although 10W 40 engine oil is the recommended oil for most conditions the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area Check the oil level see Oil Level Inspection in the Engine Lubrication System chapter Oil Filter Replacement Drain the engine oil see Engine Oil Change Remove the oil filter mounting bolt A Replace the oil filter with a new one Apply engine oil to a new O rings A before installation Install the oil filter and tighten the mounting bolt B Torque Oil Filter Mounting Bolt 19 6 N m 2 0 kgf m 14 5 ft lb Pour in the specified type and amount of oil see Engine Oil Change http mototh com 2 50 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Hose and Pipe Replacement CAUTION Brake fluid quickly ruins painted plastic surfaces any spilled fluid should be completely washed away immediately Remove the brake hose banjo bolts A When removing the brake hose take care not to spill the
75. m 2 5 kgf m 18 ft lb Align the mark A on the shift shaft with the mark B on the shift lever Tighten Torque Shift Lever Bolt 12 N m 1 2 kgf m 106 in lb Install the shift pedal C as shown in the figure About 16 D To adjust the pedal position loosen the front locknut E left hand threads and rear locknut F and then turn the tie rod G Tighten Torque Tie Rod Locknuts 7 0 N m 0 71 kgf m 62 in lb http mototh com 9 26 CRANKSHAFT TRANSMISSION Transmission Be sure the sealing lip of the rubber boots A fits into the groove of the ball joint after installing the shift lever link Correctly Boot Fitting Position B Incorrectly Boot Fitting Position C External Shift Mechanism Removal Remove Engine Oil Drain see Engine Oil Change in the Periodic Maintenance chapter Shift Lever see Shift Pedal Removal Clutch see Clutch Removal in the Clutch chapter Spread the shift mechanism arm A and over shift limiter B out of the shift drum C and pull out the shift shaft assembly D External Shift Mechanism Installation Check that the return spring A and pawl spring B are properly fitted on the mechanism Install the shift shaft assembly Place the shift mechanism arm C and over shift limiter D on the shift drum pins Install the removed parts see appropriate chapters External Shift Mechanism Inspection Examine the shif
76. see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Inlet air temperature sensor trouble Inspect see chapter 3 Miscellaneous Subthrottle sensor trouble Inspect see chapter 3 Subthrottle valve actuator trouble Inspect see chapter 3 Speed sensor trouble Inspect see chapter 3 Throttle valves will not fully open Inspect throttle cables and lever linkage see chapter 3 http mototh com FUEL SYSTEM DFI 3 33 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions Engine overheating Water temperature sensor crankshaft sensor or speed sensor trouble see Overheating of Troubleshooting Guide in chapter 17 Air switching valve trouble Inspect and replace see chapter 16 Air suction valve trouble Inspect and replace see chapter 5 Exhaust Smokes Excessively Black smoke Air cleaner element clogged Clean element see chapter 2 Fuel pressure too high Inspect see chapter 3 Fuel injector trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Inlet air temperature sensor trouble Inspect see chapter 3 Brown smoke Air duct loose Reinstall see chapter 3 Fuel pressure too low Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Inlet air temperature sensor trouble Inspect see chapter 3 http mototh com 3 34 FUEL SYSTEM DFI Self Diagnosis Self dia
77. sensor BK lead Measure the output voltage with the engine stopped and with the connector joined Turn the ignition switch ON Output Voltage Standard About DC 0 05 0 09 V or DC 4 5 4 9 V at ignition switch ON and 0 km h NOTE Rotate the rear wheel by hand confirm the output volt age will be raise or lower Turn the ignition switch OFF If the reading is out of the standard replace the sensor If the reading is within the standard remove the ECU and check the wiring for continuity between main harness con nectors Special Tool Hand Tester 57001 1394 Disconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Speed Sensor Connector B LG R lead ECU terminal 5 C BR BK lead ECU terminal 22 D If the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see ECU Removal Installation http mototh com 3 58 FUEL SYSTEM DFI Speed Sensor Service Code 24 25 Speed Sensor Circuit 1 ECU 2 Speed Sensor 3 Water proof Joint 2 4 Water proof Joint 1 http mototh com FUEL SYSTEM DFI 3 59 Vehicle down Sensor Service Code 31 Vehicle down Sensor Removal CAUTION Never drop the vehicle down sensor especially on a hard surface Such a shock to the sensor can damage it Remove Fuel Tank see Fuel Tank Removal Connecto
78. 0 kgf m 87 in lb Take out the holder plate B Install the O ring and tighten the cap bolt Torque Camshaft Chain Tensioner Cap Bolt 5 0 N m 0 51 kgf m 44 in lb http mototh com ENGINE TOP END 5 17 Camshaft Camshaft Chain Camshaft Removal Remove Cylinder Head Cover see Cylinder Head Cover Re moval Plugs Position the crankshaft at 2 piston TDC Using a wrench on the alternator rotor bolt turn the crank shaft counterclockwise until the 2T mark A on the al ternator rotor is aligned with the projection B in the in spection window on the alternator cover Remove Camshaft Chain Tensioner see Camshaft Chain Ten sioner Removal Camshaft Cap Bolts A Plates Upper Chain Guide B Camshaft Caps C Camshafts D Loosen the camshaft cap bolts as shown sequence 1 12 in the figure Stuff a clean cloth into the chain tunnel to keep any parts from dropping into the crankcase Remove Camshaft Sprocket Bolts A Camshaft Sprockets B CAUTION The crankshaft may be turned while the camshafts are removed Always pull the chain taut while turn ing the crankshaft This avoids kinking the chain on the lower crankshaft sprocket A kinked chain could damage both the chain and the sprocket http mototh com 5 18 ENGINE TOP END Camshaft Camshaft Chain Camshaft Installation Install the camshaft sprockets as shown in the figure Inlet Camshaft Sprocket
79. 000 mm 1 0234 1 0236 in Balancer Shaft Journal Diameter Marks or no mark Measure the main bearing inside diameter and mark the upper crankcase half in accordance with the inside diam eter A Crankcase Main Bearing Inside Diameter Marks or no mark NOTE Tighten the crankcase bolts to the specified torque see Crankcase Assembly The mark already on the upper crankcase half should almost coincide with the measurement Crankcase Main Bearing Inside Diameter Marks 29 000 29 008 mm 1 1417 1 1420 in None 29 009 29 016 mm 1 1421 1 1424 in Select the proper bearing insert A in accordance with the combination of the crankcase and balancer shaft coding Size Color B Bearing Insert Crankcase Main Bearing Inside Diameter Marking Balancer Shaft Journal Diameter Marking Size Color Part Number Brown 92028 1424 None None Black 92028 1423 None None Blue 92028 1422 Install the new inserts in the crankcase and check in sert journal clearance with the plastigage http mototh com CRANKSHAFT TRANSMISSION 9 25 Transmission Shift Pedal Removal Remove Shift Pedal Mounting Bolt A Shift Lever Bolt B Shift Pedal C with Shift Lever Shift Pedal Installation Apply grease to the shift pedal A Install the washers B and shift pedal Tighten Torque Shift Pedal Mounting Bolt C 25 N
80. 03381 oz US mL 0 02816 oz imp mL 0 06102 cu in Units of Force N 0 1020 kg N 0 2248 lb kg 9 807 N kg 2 205 lb Units of Length km 0 6214 mile m 3 281 ft mm 0 03937 in Units of Torque N m 0 1020 kgf m N m 0 7376 ft lb N m 8 851 in lb kgf m 9 807 N m kgf m 7 233 ft lb kgf m 86 80 in lb Units of Pressure kPa 0 01020 kgf cm kPa 0 1450 psi kPa 0 7501 cmHg kgf cm 98 07 kPa kgf cm 14 22 psi cmHg 1 333 kPa Units of Speed km h 0 6214 mph Units of Power kW 1 360 PS kW 1 341 HP PS 0 7355 kW PS 0 9863 HP Units of Temperature http mototh com http mototh com PERIODIC MAINTENANCE 2 1 2 Periodic Maintenance Table of Contents Periodic Maintenance Chart 2 3 Torque and Locking Agent 2 6 Specifications 2 11 Special Tools
81. 07 mm 0 0012 0 0028 in 0 17 mm 0 0067 in Second 0 02 0 06 mm 0 0008 0 0024 in 0 16 mm 0 0063 in Piston Ring Groove Width Top 0 82 0 84 mm 0 0323 0 0331 in 0 92 mm 0 0362 in Second 0 81 0 83 mm 0 0319 0 0327 in 0 91 mm 0 0358 in Piston Ring Thickness Top 0 77 0 79 mm 0 0303 0 0311 in 0 70 mm 0 028 in Second 0 77 0 79 mm 0 0303 0 0311 in 0 70 mm 0 028 in Piston Ring End Gap Top 0 15 0 30 mm 0 0059 0 0118 in 0 6 mm 0 024 in Second 0 40 0 55 mm 0 0157 0 0217 in 0 9 mm 0 035 in Oil 0 20 0 80 mm 0 0079 0 0315 in 1 1 mm 0 043 in http mototh com ENGINE TOP END 5 9 Special Tools and Sealant Compression Gauge 20 kgf cm 57001 221 Valve Spring Compressor Assembly 57001 241 Piston Pin Puller Assembly 57001 910 Valve Seat Cutter 45 24 5 57001 1113 Valve Seat Cutter 32 25 57001 1118 Valve Seat Cutter Holder Bar 57001 1128 Valve Seat Cutter 32 22 57001 1206 Valve Seat Cutter 67 5 22 57001 1207 Valve Spring Compressor Adapter 16 57001 1305 Compression Gauge Adapter M10 1 0 57001 1317 http mototh com 5 10 ENGINE TOP END Special Tools and Sealant Valve Seat Cutter Holder 4 5 57001 1330 Valve Guide Arbor 4 5 57001 1331 Valve Guide Reamer 4 5 57001 1333 Piston Base 2 3 57001 1336 Valve Guid
82. 08 mm 0 115 0 121 in 2 6 mm 0 10 in Friction and Steel Plate Warp 0 15 mm 0 0059 in or less 0 3 mm 0 012 in Clutch Spring Free Length 39 4 mm 1 55 in 37 6 mm 1 48 in Clutch Housing Gear Selection when Replacing Clutch Housing Gear Crankshaft Clutch Housing Primary Gear Marking Color Gear Marking Color Part Number A White A White 13095 0095 A White B Red 13095 0096 A White C None 13095 0097 A White D Yellow 13095 0098 B Red A White 13095 0095 B Red B Red 13095 0096 B Red C None 13095 0097 B Red D Yellow 13095 0098 C None B Red 13095 0096 C None C None 13095 0097 C None D Yellow 13095 0098 D Yellow C None 13095 0097 D Yellow D Yellow 13095 0098 http mototh com CLUTCH 6 5 Special Tool and Sealant Clutch Holder 57001 1243 Kawasaki Bond Silicone Sealant 92104 0004 http mototh com 6 6 CLUTCH Clutch Lever and Cable Clutch Lever Free Play Inspection Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter Clutch Lever Free Play Adjustment Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter Clutch Cable Removal Remove the right lower fairing see Lower Fairing Re moval in the Frame chapter Loosen the locknut A at the clutch lever and screw in the adjuster B Line up the slots C in the clutch lever locknut and ad juste
83. 13 Si 10 Front Caliper Mounting Bolts 25 2 5 18 11 Front Master Cylinder Clamp Bolts 8 8 0 90 78 in lb S B Apply brake fluid L Apply a non permanent locking agent R Replacement Parts S Follow the specified tightening sequence Si Apply silicone grease ex PBC grease http mototh com 12 4 BRAKES Exploded View http mototh com BRAKES 12 5 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Bleed Valve 5 5 0 56 49 in lb L 2 Brake Hose Banjo Bolts 25 2 5 18 3 Brake Pedal Bolt 8 8 0 90 78 in lb 4 Rear Brake Disc Mounting Bolts 27 2 8 20 L 5 Rear Brake Pad Pins 17 2 1 8 13 6 Rear Caliper Holder Pin Bolt 17 2 1 8 13 Si 7 Rear Caliper Mounting Bolts 25 2 5 18 8 Rear Master Cylinder Mounting Bolts 25 2 5 18 9 Rear Master Cylinder Push Rod Locknut 17 2 1 8 13 B Apply brake fluid G Apply grease L Apply a non permanent locking agent R Replacement Parts Si Apply silicone grease ex PBC grease http mototh com 12 6 BRAKES Specifications Item Standard Service Limit Brake Lever Brake Pedal Brake Lever Position Non adjustable Brake Lever Free Play Non adjustable Pedal Free Play Non adjustable Pedal Position About 40 mm 1 57 in below top of footpeg Brake Pads Lining Thickness Front 4 5 mm 0 18 in 1 mm 0 04 in Rear 4 5 mm 0 1
84. 1494 None None Black 92028 1493 None Blue 92028 1492 Install the new inserts in the connecting rod and check insert crankpin clearance with the plastigage Crankshaft Side Clearance Inspection Insert a thickness gauge A between the crankcase main bearing and the crank web at the No 2 journal B to determine clearance If the clearance exceeds the service limit replace the crankcase halves as a set NOTE The upper and lower crankcase halves are machined at the factory in the assembled state so the crankcase halves must be replaced as a set Crankshaft Side Clearance Standard 0 05 0 20 mm 0 0020 0 0079 in Service Limit 0 40 mm 0 0157 in http mototh com 9 20 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods Crankshaft Runout Inspection Measure the crankshaft runout If the measurement exceeds the service limit replace the crankshaft Crankshaft Runout Standard TIR 0 02 mm 0 0008 in or less Service Limit TIR 0 05 mm 0 0020 in Crankshaft Main Bearing Insert Journal Wear Inspection Using a plastigage press gauge measure the bearing insert journal B clearance A NOTE Tighten the crankcase bolts to the specified torque see Crankcase Assembly Do not turn the crankshaft during clearance measure ment Journal clearance less than 0 025 mm 0 00098 in can not be measured by plastigage however using genuine parts
85. 15 1 5 11 L 7 Coolant Drain Bolt Cylinder 5 9 0 60 52 in lb 8 Cylinder Head Bolts M8 31 4 3 2 23 2 MO S 9 Cylinder Head Bolt M6 12 1 2 106 in lb S 10 Cylinder Head Cover Bolts 9 8 1 0 87 in lb 11 Cylinder Head Jacket Plugs 20 2 0 15 L 12 Rear Camshaft Chain Guide Bolt 17 1 7 13 13 Spark Plugs 13 1 3 115 in lb 14 Throttle Body Assy Holder Clamp Screws 2 0 0 20 18 in lb EO Apply engine oil L Apply a non permanent locking agent M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts S Follow the specified tightening sequence SS Apply silicone sealant http mototh com 5 4 ENGINE TOP END Exploded View http mototh com ENGINE TOP END 5 5 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Exhaust Pipe Holder Nuts 12 1 2 106 in lb 2 Exhaust Pipe Mounting Bolt 9 8 1 0 87 in lb 3 Muffler Body Clamp Bolt 17 1 7 13 4 Muffler Body Mounting Bolt 30 3 1 22 5 Muffler Body Rear Cover Bolts 9 8 1 0 87 in lb L 6 Muffler Cover Bolts 9 8 1 0 87 in lb 7 Muffler Cover Clamp Bolt 9 8 1 0 87 in lb 8 Muffler Cover Clamp Screw 6 9 0 70 61 in lb L Apply a non permanent locking agent R Replacement Parts http mototh com 5 6 ENGINE TOP END Exhaust System Exhaust S
86. 19 3 19 5 mm 0 7598 0 7677 in Inlet 21 9 22 1 mm 0 8622 0 8701 in Measure the seat width E of the portion where there is no build up carbon white portion of the valve seat with a vernier caliper Good F If the width is too wide G too narrow H or uneven J repair the seat see Valve Seat Repair Valve Seating Surface Width Standard Exhaust 0 5 1 0 mm 0 0197 0 0394 in Inlet 0 5 1 0 mm 0 0197 0 0394 in Valve Seat Repair Repair the valve seat with the valve seat cutters A Special Tools Valve Seat Cutter Holder Bar B 57001 1128 Valve Seat Cutter Holder 4 5 C 57001 1330 For Exhaust Valve Seat Valve Seat Cutter 45 24 5 57001 1113 Valve Seat Cutter 32 22 57001 1206 Valve Seat Cutter 67 5 22 57001 1207 For Inlet Valve Seat Valve Seat Cutter 45 24 5 57001 1113 Valve Seat Cutter 32 25 57001 1118 Valve Seat Cutter 67 5 22 57001 1207 If the manufacturer s instructions are not available use the following procedure http mototh com ENGINE TOP END 5 29 Valves Seat Cutter Operation Care 1 This valve seat cutter is developed to grind the valve for repair Therefore the cutter must not be used for other purposes than seat repair 2 Do not drop or shock the valve seat cutter or the dia mond particles may fall off 3 Do not fail to apply engine oil to the valve seat cutter before g
87. 3 60 Subthrottle Sensor Service Code 32 3 63 Subthrottle Sensor Removal Adjustment 3 63 Subthrottle Sensor Input Voltage Inspection 3 63 Subthrottle Sensor Output Voltage Inspection 3 64 Subthrottle Sensor Resistance Inspection 3 65 Oxygen Sensor not activated Service Code 33 3 66 Oxygen Sensor Removal Installation 3 66 Oxygen Sensor Inspection 3 66 Stick Coils 1 2 Service Code 51 52 3 69 Stick Coil Removal Installation 3 69 Stick Coil Primary Winding Resistance Inspection 3 69 Stick Coil Input Voltage Inspection 3 69 Radiator Fan Rela
88. 57001 1400 Peak Voltage Adapter 57001 1415 Needle Adapter Set 57001 1457 Throttle Sensor Setting Adapter 57001 1538 Sensor Harness Adapter 57001 1561 Fuel Pressure Gauge Adapter 57001 1593 http mototh com 3 20 FUEL SYSTEM DFI Special Tools and Sealant Fuel Hose 57001 1607 Oxygen Sensor Measuring Adapter 57001 1682 Measuring Adapter 57001 1700 Kawasaki Bond Silicone Sealant 56019 120 http mototh com FUEL SYSTEM DFI 3 21 DFI Servicing Precautions DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system This DFI system is designed to be used with a 12 V sealed battery as its power source Do not use any other battery except for a 12 V sealed battery as a power source Do not reverse the battery cable connections This will damage the ECU To prevent damage to the DFI parts do not disconnect the battery cables or any other electrical connections when the ignition switch is ON or while the engine is running Take care not to short the leads that are directly con nected to the battery positive terminal to the chassis ground When charging remove the battery from the motorcycle This is to prevent ECU damage by excessive voltage Whenever the DFI electrical connections are to be dis connected first turn off the ignition switch and disconnect the battery terminal Do not pull the lead only t
89. 92180 1054 50 http mototh com PERIODIC MAINTENANCE 2 23 Periodic Maintenance Procedures CAUTION Be sure to remeasure the clearance after selecting a shim If the clearance is out of the specified range use the additional shim If there is no valve clearance use a shim that is a few sizes smaller and remeasure the valve clearance When installing the shim face the marked side toward the valve lifter At this time apply engine oil to the shim or the valve lifter to keep the shim in place during camshaft installation CAUTION Do not put shim stock under the shim This may cause the shim to pop out at high rpm causing ex tensive engine damage Do not grind the shim This may cause it to fracture causing extensive engine damage Apply molybdenum disulfide oil solution to the valve lifter surface and install the lifter Install the camshaft see Camshaft Installation in the En gine Top End chapter Recheck the valve clearance and readjust if necessary Install the removed parts see appropriate chapters Air Suction System Damage Inspection Remove Lower Fairings see Lower Fairing Removal in the Frame chapter Fuel Tank Bolts see Fuel Tank Removal in the Fuel Sys tem DFI chapter Pull the air switching valve hose A out of the air cleaner housing Start the engine and run it at idle speed Plug the air switching valve hose end with your finger and feel vacuum pulsing in
90. A Exhaust Camshaft Sprocket B The exhaust camshaft has the groove C Apply a non permanent locking agent to the threads of the camshaft sprocket bolts and tighten them Torque Camshaft Sprocket Bolts 15 N m 1 5 kgf m 11 ft lb Apply molybdenum disulfide oil solution to all cam parts and journals If a new camshaft is to be used apply a thin coat of molyb denum disulfide grease to the cam surfaces NOTE Be sure to operate from the engine left side Position the crankshaft at 2 piston TDC see Camshaft Removal CAUTION The crankshaft may be turned while the camshafts are removed Always pull the chain taut while turn ing the crankshaft This avoids kinking the chain on the lower crankshaft sprocket A kinked chain could damage both the chain and the sprocket Engage the camshaft chain A with the camshaft sprock ets Pull the tension side exhaust side of the chain taut to install the chain on the sprockets Timing marks B align with the cylinder head upper sur face Exhaust Camshaft Sprocket C Inlet Camshaft Sprocket D Count the camshaft chain link pins as shown to verify that the sprocket are positioned correctly http mototh com ENGINE TOP END 5 19 Camshaft Camshaft Chain Install the six dowel pins on the marks A Install the camshaft caps as shown in the figure noting the EX B and IN C marks CAUTION The camshaft caps are machined w
91. Assy Removal 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 CAUTION Never drop the throttle body assy especially on a hard surface Such a shock to the body assy can damage it Remove Fuel Tank see Fuel Tank Removal Vacuum Hose A Fuel Injector Connectors B Subthrottle Valve Actuator Connector C Disconnect Main Throttle Sensor Connector A Subthrottle Sensor Connector B http mototh com FUEL SYSTEM DFI 3 103 Throttle Body Assy Loosen the nuts A and remove the throttle cable lower ends B Remove Bolts A Idle Adjusting Cable B from Bracket Remove Air Switching Valve Hose A Bracket Bolts B Right Air Cleaner Housing Mounting Bolt C Remove the left air cleaner housing mounting bolt A Loosen the air duct clamp screws B Move C the air cleaner housing D backward and pull out the air ducts from the throttle body assy Loosen the throttle body assy holder clamp screws A and pull out the throttle body assy B backward Remove the throttle body assy to left side of motorcycle After removing the throttle body assy stuff pieces of
92. Clamp Bolt A and Clamp Muffler Cover Clamp Screw B Muffler Cover Bolts C Muffler Cover D Remove Clamp Bolt A Loosen Mounting Nut and Bolt B Muffler Body C Muffler Body Installation Replace the muffler body gasket A with a new one Install the muffler body gasket so that its chamfer side B faces front C Rear D Install the muffler body and mounting bolt Install the muffler body clamp bolt A as shown in the figure 74 84 B More than 15 mm 0 59 in C Swingarm D Tighten Torque Muffler Body Mounting Bolt 30 N m 3 1 kgf m 22 ft lb Muffler Body Clamp Bolt 17 N m 1 7 kgf m 13 ft lb http mototh com 5 40 ENGINE TOP END Muffler If the pad A was removed install it as shown in the figure Muffler Cover B 1 5 mm 0 04 0 20 in C Insert the claw A into the cover clamp B and tighten the clamp screw C as shown in the figure About 15 D Torque Muffler Cover Clamp Screw 6 9 N m 0 70 kgf m 61 in lb Tighten Torque Muffler Cover Bolts 9 8 N m 1 0 kgf m 87 in lb Fit the hole A of the clamp B to the hook C of the muffler cover D Tighten Torque Muffler Cover Clamp Bolt E 9 8 N m 1 0 kgf m 87 in lb Thoroughly warm up the engine wait until the engine cools down retighten all the bolts and screw Install the removed parts see appropriate chapters Exhaust
93. Code FI Indicator Light Problems 11 Main throttle sensor malfunction wiring open or short 12 Inlet air pressure sensor malfunction wiring open or short 13 Inlet air temperature sensor malfunction wiring open or short 14 Water temperature sensor malfunction wiring open or short 21 Crankshaft sensor malfunction wiring open or short 24 and 25 Speed sensor malfunction wiring open or short First 24 is displayed and then 25 repeatedly 31 Vehicle down sensor malfunction wiring open or short 32 Subthrottle sensor malfunction wiring open or short 33 Oxygen sensor inactivation wiring open or short 51 Stick coil 1 malfunction wiring open or short 52 Stick coil 2 malfunction wiring open or short 56 Radiator fan relay malfunction wiring open or short 62 Subthrottle valve actuator malfunction wiring open or short 64 Air switching valve malfunction wiring open or short 67 Oxygen sensor heater malfunction wiring open or short 94 Oxygen sensor malfunction wiring open or short Notes The ECU may be involved in these problems If all the parts and circuits checked out good be sure to check the ECU for ground and power supply If the ground and power supply are checked good replace the ECU When no service code is displayed the electrical parts of the DFI system has no fault and the mechanical parts of the DFI system and the engine are suspect http mototh com
94. DFI 3 69 Stick Coils 1 2 Service Code 51 52 Stick Coil 1 Service Code 51 Stick Coil 2 Service Code 52 Stick Coil Removal Installation Refer to the Stick Coil Removal Installation in the Electri cal System chapter Stick Coil Primary Winding Resistance Inspection Refer to the Stick Coil Inspection in the Electrical System chapter If the reading is within the standard check the input volt age see Stick Coil Input Voltage Inspection Stick Coil Input Voltage Inspection NOTE Be sure the battery is fully charged Turn the ignition switch OFF Remove the ECU see ECU Removal Do not disconnect the ECU connectors Connect a digital meter A to the connector B with the needle adapter set Special Tool Needle Adapter Set 57001 1457 Stick Coil Input Voltage Connections to ECU Connector For Stick Coil 1 Digital Meter BK lead terminal 35 Digital Meter BK Y lead terminal 43 For Stick Coil 2 Digital Meter BK G lead terminal 44 Digital Meter BK Y lead terminal 43 Measure the input voltage to each primary winding of the stick coils with the engine stopped and with the connec tors joined Turn the engine stop switch to run position Turn the ignition switch ON Input Voltage Standard Battery Voltage Turn the ignition switch OFF If the input voltage is out of the standard check the wiring for continuity s
95. ECU Removal Installation If there is still no battery voltage check the ECU main relay and pump relay see Relay Circuit Inspection in the Electrical System chapter If the main relay and pump relay are normal check the power source wiring see wiring diagram in this section If the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see ECU Removal Installation If the reading is in specification check the output voltage see Fuel Injector Output Voltage Inspection http mototh com 3 98 FUEL SYSTEM DFI Fuel Injectors Fuel Injector Output Voltage Inspection NOTE Be sure the battery is fully charged Turn the ignition switch OFF Remove the ECU see ECU Removal Do not disconnect the ECU connector Connect a digital meter A to the connector B with the needle adapter set Special Tool Needle Adapter Set 57001 1457 Fuel Injector Output Voltage Connections to ECU Connector For Fuel Injector 1 Digital Meter BL R lead ECU terminal 34 Digital Meter Battery terminal For Fuel Injector 2 Digital Meter BL G lead ECU terminal 33 Digital Meter Battery terminal Measure the output voltage with the engine stopped and with the connector joined Turn the engine stop switch to run position Turn the ignition switch ON Output
96. Exhaust Pipe see Exhaust Pipe Removal in the Engine Top End chapter Air Switching Valve see Air Switching Valve Removal in the Engine Top End chapter Throttle Body Assy see Throttle Body Assy Removal in the Fuel System DFI chapter Shift Lever see Shift Pedal Removal in the Crank shaft Transmission chapter Engine Sprocket see Engine Sprocket Removal in the Final Drive chapter Regulator Rectifier see Regulator Rectifier Inspection in the Electrical System chapter Remove Oil Pressure Switch Lead A Neutral Switch Lead Connector B Breather Hose End C http mototh com ENGINE REMOVAL INSTALLATION 8 5 Engine Removal Installation Remove Starter Motor Cable A Engine Ground Cable Terminal Bolt B Alternator and Crankshaft Sensor Lead Connectors see Alternator Cover Removal in the Electrical System chap ter Stick Coil Lead Connectors see Stick Coil Removal in the Electrical System chapter Support the engine with a suitable stand A Put a plank B onto the suitable stand for engine balance Remove Engine Mounting Bracket Nuts and Bolts A Both Sides Engine Mounting Nut B and Bolt Engine Mounting Brackets C Both Sides Remove Engine Mounting Nuts A and Bolts Engine B Engine Installation Support the engine with a suitable stand Put a plank onto the suitable stand for engine balance http mototh com 8 6 ENGINE REMOVAL INSTALLATION Engine Removal In
97. Exploded View http mototh com FINAL DRIVE 11 3 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Engine Sprocket Cover Bolts 9 8 1 0 87 in lb 2 Engine Sprocket Nut 127 13 0 93 7 MO 3 Rear Axle Nut 98 10 0 72 3 4 Rear Sprocket Nuts 59 6 0 44 5 Speed Sensor Mounting Bracket Bolts 9 8 1 0 87 in lb L HG Apply high temperature grease HO Apply heavy oil L Apply a non permanent locking agent MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts SS Apply silicone sealant http mototh com 11 4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain Drive Chain Slack 20 30 mm 0 8 1 2 in Drive Chain Wear 20 link Length 317 5 318 2 mm 12 50 12 53 in 323 mm 12 7 in Standard Chain Make ENUMA Type EK520SR O2 Link 106 links Sprockets Rear Sprocket Warp TIR 0 4 mm 0 016 in or less TIR 0 5 mm 0 020 in http mototh com FINAL DRIVE 11 5 Special Tool and Sealant Bearing Driver Set 57001 1129 Kawasaki Bond Silicone Sealant 92104 0004 http mototh com 11 6 FINAL DRIVE Drive Chain Drive Chain Slack Inspection Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter Drive Chain Slack Adjustment Refer to th
98. Fairing see Lower Fairing Removal in the Frame chapter Engine Oil Drain see Engine Oil Change in the Periodic Maintenance chapter Coolant Drain see Coolant Change in the Periodic Maintenance chapter Water Pipes see Water Pump Cover Removal in the Cooling System chapter Disconnect the alternator and crankshaft sensor lead con nectors A Place a suitable container under the alternator cover A Take out the leads from the clamps B Remove Alternator Cover Bolts C Alternator Cover Alternator Cover Installation Apply silicone sealant to the crankshaft sensor lead grom met and crankcase halves mating surface A on the front and rear sides of the cover mount Sealant Kawasaki Bond Silicone Sealant 92104 0004 Check that dowel pins B are in place on the crankcase Install a new gasket C and the alternator cover Tighten Torque Alternator Cover Bolts 9 8 N m 1 0 kgf m 87 in lb Run the leads correctly see Cable Wire and Hose Rout ing section in the Appendix chapter Install the removed parts see appropriate chapters http mototh com ELECTRICAL SYSTEM 16 25 Charging System Stator Coil Removal Remove Alternator Cover see Alternator Cover Removal Screws A and Clamp B Crankshaft Sensor C Lead Grommets D Stator Coil Bolts E Stator Coil F Stator Coil Installation Install the stator coil A and tighten the bolts Torque
99. H on the output shaft are identical http mototh com 9 32 CRANKSHAFT TRANSMISSION Transmission Install the shift drum bearing holder A Apply a non permanent locking agent to the threads of the shift drum bearing holder bolts B and tighten them Torque Shift Drum Bearing Holder Bolts 12 N m 1 2 kgf m 106 in lb Install the pin spring washer and tighten the shift drum positioning bolt to the upper crankcase Torque Shift Drum Positioning Bolt 24 5 N m 2 5 kgf m 18 ft lb Shift Drum Disassembly Remove the shift drum see Shift Drum and Fork Re moval While holding the shift drum with a vise remove the shift drum pin plate bolt Shift Drum Assembly Be sure to install the dowel pin A The shift drum pins B are identical Apply a non permanent locking agent to the threads of the shift drum pin plate bolt C and tighten it Torque Shift Drum Pin Plate Bolt 9 0 N m 0 92 kgf m 80 in lb Shift Drum Pin Plate D Shift Drum Pin Holder E Shift Drum Bearing F Shift Drum G Operating Plate Pin H Operating Plate I Circlip J Shift Fork Bending Inspection Visually inspect the shift forks and replace any fork that is bent A bent fork could cause difficulty in shifting or allow the transmission to jump out of gear when under power 90 A http mototh com CRANKSHAFT TRANSMISSION 9 33 Transmission Shift Fork Gear Groove Wear Inspe
100. Inlet Air Pressure Sensor Circuit 1 ECU 2 Water proof Joint 2 3 Inlet Air Pressure Sensor 4 Water proof Joint 1 http mototh com 3 50 FUEL SYSTEM DFI Inlet Air Temperature Sensor Service Code 13 Inlet Air Temperature Sensor Removal Installation CAUTION Never drop the inlet air temperature sensor espe cially on a hard surface Such a shock to the sensor can damage it Remove Fuel Tank see Fuel Tank Removal Inlet Air Temperature Sensor Connector A Disconnect Inlet Air Temperature Sensor Screw B Inlet Air Temperature Sensor C Put the inlet air temperature sensor A into the air cleaner housing B Tighten Torque Inlet Air Temperature Sensor Screw 1 2 N m 0 12 kgf m 11 in lb Inlet Air Temperature Sensor Output Voltage Inspection NOTE Be sure the battery is fully charged Turn the ignition switch OFF Remove the fuel tank see Fuel Tank Removal Disconnect the inlet air temperature sensor connector and connect the harness adapter A between these connectors as shown in the figure Main Harness B Inlet Air Temperature Sensor C Special Tool Measuring Adapter 57001 1700 Connect a digital meter D to the harness adapter leads Inlet Air Temperature Sensor Output Voltage Connections to Adapter Digital Meter R sensor Y lead Digital Meter BK sensor BR BK lead Measure the output voltage with the engine stopped and the
101. Overall Drive Ratio 8 466 Top gear Frame Type Tubular diamond Caster Rake Angle 26 Trail 82 mm 3 23 in Front Tire Type Tubeless Size 110 70 17 M C 54S Rim Size 17 2 75 Rear Tire Type Tubeless Size 130 70 17 M C 62S Rim Size 17 3 50 Front Suspension Type Telescopic fork Wheel Travel 120 mm 4 72 in Rear Suspension Type Swingarm uni trak Wheel Travel 130 mm 5 12 in http mototh com 1 10 GENERAL INFORMATION General Specifications Items EX250K8F Brake Type Front Single disc Rear Single disc Electrical Equipment Battery 12 V 8 Ah Headlight Type Semi sealed beam Bulb High 12 V 55 W quartz halogen 2 Low 12 V 55 W quartz halogen Tail Brake Light 12 V 5 21 W Alternator Type Three phase AC Rated Output 23 0 A 14 0 V 5 000 r min rpm Specifications are subject to change without notice and may not apply to every country http mototh com GENERAL INFORMATION 1 11 Unit Conversion Table Prefixes for Units Prefix Symbol Power mega M 1 000 000 kilo k 1 000 centi c 0 01 milli m 0 001 micro 0 000001 Units of Mass kg 2 205 lb g 0 03527 oz Units of Volume L 0 2642 gal US L 0 2200 gal imp L 1 057 qt US L 0 8799 qt imp L 2 113 pint US L 1 816 pint imp mL 0
102. Pipe Removal Remove Muffler Body see Muffler Body Removal Oxygen Sensor see Oxygen Sensor Removal in the Electrical System chapter Mounting Bolt A http mototh com ENGINE TOP END 5 41 Muffler Remove Exhaust Pipe Holder Nuts A Exhaust Pipe B Exhaust Pipe Installation Replace the exhaust pipe gaskets with new ones Install the exhaust pipe Tighten Torque Exhaust Pipe Holder Nuts 12 N m 1 2 kgf m 106 in lb Exhaust Pipe Mounting Bolt 9 8 N m 1 0 kgf m 87 in lb Install the removed parts see appropriate chapters http mototh com http mototh com CLUTCH 6 1 6 Clutch Table of Contents Exploded View 6 2 Specifications 6 4 Special Tool and Sealant 6 5 Clutch Lever and Cable 6 6 Clutch Lever Free Play Inspection 6 6 Clutch Lever Free Play Adjustment 6 6 Clut
103. Relay Box Relay Circuit Inspection with the battery connected Battery Connection Tester Connection Tester Reading 2 11 1 3 0 ECU Main Relay 4 5 7 6 0 Fuel Pump Relay 9 10 7 8 0 Fan Relay 18 19 17 20 0 Battery Connection Tester Connection DC 25 V Range Tester Reading V Starter Circuit Relay 16 12 11 12 Battery Voltage Apply positive lead Apply negative lead Diode Circuit Inspection Remove the relay box see Relay Box Removal Check conductivity of the following pairs of terminals see Relay Box Internal Circuit in this section Diode Circuit Inspection Tester Connection 1 11 2 11 12 13 12 15 12 16 13 14 13 15 The resistance should be low in one direction and more than ten times as much in the other direction If any diode shows low or high in both directions the diode is defective and the relay box must be replaced NOTE The actual meter reading varies with the meter or tester used and the individual diodes but generally speaking the lower reading should be from zero to one half the scale http mototh com 16 68 ELECTRICAL SYSTEM Relay Box Relay Box Internal Circuit A Headlight Circuit Relay B ECU Main Relay C Fuel Pump Relay D Starter Circuit Relay E Fan Relay http mototh com ELECTRICAL SYSTEM 16 69 Fuse 30 A Main Fuse Removal Remove Front Seat see Front Seat Rem
104. Remarks Engine Removal Installation Engine Mounting Bracket Bolts and Nuts 69 7 0 51 Engine Mounting Nuts 69 7 0 51 Crankshaft Transmission Connecting Rod Big End Nuts 27 5 2 8 20 MO Crankcase Bolts M8 L 90 mm 24 2 4 18 MO S Crankcase Bolts M8 L 73 mm 19 1 9 14 MO S Crankcase Bolts M6 12 1 2 106 in lb Neutral Switch 15 1 5 11 Oil Breather Mounting Bolts 9 8 1 0 87 in lb L Shift Drum Bearing Holder Bolts 12 1 2 106 in lb L Shift Drum Pin Plate Bolt 9 0 0 92 80 in lb L Shift Drum Positioning Bolt 24 5 2 5 18 Shift Lever Bolt 12 1 2 106 in lb Shift Pedal Mounting Bolt 25 2 5 18 Shift Shaft Return Spring Pin 19 6 2 0 14 5 L Starter Motor Clutch Bolts 34 3 3 5 25 L Tie Rod Locknuts 7 0 0 71 62 in lb Wheels Tires Front Axle Nut 88 9 0 65 Rear Axle Nut 98 10 0 72 3 Final Drive Engine Sprocket Cover Bolts 9 8 1 0 87 in lb Engine Sprocket Nut 127 13 0 93 7 MO Rear Axle Nut 98 10 0 72 3 Rear Sprocket Nuts 59 6 0 44 Speed Sensor Mounting Bracket Bolts 9 8 1 0 87 in lb L Brakes Bleed Valves 5 5 0 56 49 in lb L Brake Hose Banjo Bolts 25 2 5 18 Brake Lever Pivot Bolt 5 9 0 60 52 in lb Si Brake Lever Pivot Bolt Locknut 5 9 0 60 52 in lb Brake Pedal Bolt 8 8 0 90 78 in lb Front Brake Disc Mounting Bolts 27 2 8 20 L Front Brake Light Switch Screw 1 2 0 12 11 in
105. Right Air Cleaner Housing Mounting Bolt C Rear Fender see Flap and Rear Fender Removal in the Frame chapter Remove Left Air Cleaner Housing Mounting Bolt A Breather Hose B http mototh com 3 108 FUEL SYSTEM DFI Air Cleaner Loosen the air duct clamp screws A Remove the air cleaner housing B pulling out the duct portion C from the grommet After removing the air cleaner housing stuff pieces of lint free clean cloth into the throttle body assy CAUTION If dirt gets into the engine excessive engine wear and possible engine damage will occur Air Cleaner Housing Installation Install is the reverse of removal Install the air duct clamp screws in the direction as shown in the figure Screw Heads A About 21 B Insert the duct portion A into the grommet B Tighten Torque Air Duct Clamp Screws 2 0 N m 0 20 kgf m 18 in lb Air Cleaner Housing Mounting Bolts 9 8 N m 1 0 kgf m 87 in lb Install the removed parts see appropriate chapters Air Cleaner Housing Disassembly Remove Air Cleaner Housing see Air Cleaner Housing Removal Air Cleaner Element see Air Cleaner Element Replace ment in the Periodic Maintenance chapter Screws A Right Cover B Flame Arrester http mototh com FUEL SYSTEM DFI 3 109 Air Cleaner Air Cleaner Housing Assembly Install the flame arrester A Be sure the O ring B is in position
106. Sensor 5 Neutral Switch 6 Oil Pressure Switch 7 ECU 8 Fuel Reserve Switch 9 Battery 12 V 8 Ah 10 Frame Ground 11 Main Fuse 30 A 12 Fuse Box 13 Ignition Fuse 10 A 14 Joint Connector 1 15 FI Indicator Light 12 V 3 4 W 16 Oil Pressure Warning Indicator Light 12 V 3 4 W 17 Neutral Indicator Light 12 V 3 4 W 18 Turn Signal Indicator Light 12 V 3 4 W 19 High Beam Indicator Light 12 V 3 4 W 20 Tachometer 21 Speedometer 22 Water Temperature Gauge 23 Meter Lights 12 V 3 4 W http mototh com 16 62 ELECTRICAL SYSTEM Switches and Sensors Brake Light Timing Inspection Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance chapter Brake Light Timing Adjustment Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance chapter Switch Inspection Using a hand tester check to see that only the connec tions shown in the table have continuity For the switch housings and the ignition switch refer to the tables in the Wiring Diagram If the switch has an open or short repair it or replace it with a new one Special Tool Hand Tester 57001 1394 Rear Brake Light Switch Connections Sidestand Switch Connections Neutral Switch Connections Oil Pressure Switch Connections Engine lubrication system is in good condition http mototh com ELECTRICAL SYSTEM 16 63 Switches and Sensors Water Temperature Sensor Inspection Remove th
107. Subthrottle Valve Actuator G Y 15 Subthrottle Valve Actuator BK BL 16 Unused 17 Water Temperature Sensor O 18 Self diagnosis Terminal Y BK 19 Subthrottle Sensor BL W 20 Inlet Air Temperature Sensor Y 21 Unused 22 Ground for Sensors BR BK 23 Oxygen Sensor Heater P BK 24 Crankshaft Sensor Y BK 25 Unused 26 Ground for ECU BK Y 27 Power Supply to ECU from Battery W BK 28 Engine Stop Switch R 29 Starter Lockout Switch R G 30 Starter Button BK R 31 Fuel Pump Relay BR Y 32 Air Switching Valve R BL 33 Injector 2 BL G 34 Injector 1 BL R http mototh com FUEL SYSTEM DFI 3 13 DFI System 35 Stick Coil 1 BK 36 Sidestand Switch G BK 37 Fan Relay P W 38 Unused 39 Meter Unit Tachometer LB 40 FI Indicator Light R Y 41 Unused 42 Ground for Fuel System BK Y 43 Ground for Ignition System BK Y 44 Stick Coil 2 BK G http mototh com 3 14 FUEL SYSTEM DFI DFI Parts Location Main Throttle Sensor A Subthrottle Sensor B Fuel Injectors 1 2 A Crankshaft Sensor A Oxygen Sensor A Ignition Switch A FI Indicator Light B http mototh com FUEL SYSTEM DFI 3 15 DFI Parts Location Stick Coils 1 2 A Air Switching Valve B Inlet Air Pressure Sensor C Subthrottle Valve Actuator A Speed Sensor A Water Temperature Sensor A Vehicle down Sensor B Inlet Air Temperature Sensor A http mototh com 3 16 FUEL SYSTE
108. This manual is designed primarily for use by trained mechanics in a properly equipped shop However it contains enough detail and basic in formation to make it useful to the owner who de sires to perform his own basic maintenance and repair work A basic knowledge of mechanics the proper use of tools and workshop proce dures must be understood in order to carry out maintenance and repair satisfactorily When ever the owner has insufficient experience or doubts his ability to do the work all adjust ments maintenance and repair should be car ried out only by qualified mechanics In order to perform the work efficiently and to avoid costly mistakes read the text thor oughly familiarize yourself with the procedures before starting work and then do the work care fully in a clean area Whenever special tools or equipment are specified do not use makeshift tools or equipment Precision measurements can only be made if the proper 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 Be alert for problems and non scheduled main
109. Turn Signal Relay Inspection in the Electrical System chapter Harness see Wiring Inspection in the Electrical System chapter Push the turn signal switch The turn signal lights and indicator light should go off If the light does not go off inspect or replace the following item Turn Signal Switch see Switch Inspection in the Electri cal System chapter Turn Signal Relay see Turn Signal Relay Inspection in the Electrical System chapter Third Step Set the dimmer switch A to low beam position Start the engine The low beam headlight should go on If the low beam headlight does not go on inspect or re place the following item Headlight Low Beam Bulb see Headlight Bulb Replace ment in the Electrical System chapter Headlight Fuse 10 A see Fuse Inspection in the Electri cal System chapter Dimmer Switch see Switch Inspection in the Electrical System chapter Headlight Relay in Relay Box see Relay Circuit Inspec tion in the Electrical System chapter Harness see Wiring Inspection in the Electrical System chapter http mototh com 2 38 PERIODIC MAINTENANCE Periodic Maintenance Procedures Set the dimmer switch to high beam position 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 s
110. Voltage Standard Battery Voltage for 3 seconds and then 0 V Turn the ignition switch OFF If the reading is in specification check the ECU for its ground and power supply see ECU Power Supply In spection If the ground and power supply are good replace the ECU see ECU Removal Installation If the reading is out of the specification remove the ECU and check the wiring for continuity between main harness connector Special Tool Hand Tster 57001 1394 Disconnect the ECU and injector connector Wiring Continuity Inspection ECU Connector A Fuel Injector Connector B For Fuel Injector 1 C BL R lead ECU terminal 34 D For Fuel Injector 2 BL G lead ECU terminal 33 If the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see ECU Removal Installation http mototh com FUEL SYSTEM DFI 3 99 Fuel Injectors Fuel Injector Fuel Line Inspection Remove Fuel Tank see Fuel Tank Removal Fuel Hose see Fuel Hose Replacement in the Periodic Maintenance chapter Be sure to place a piece of cloth around the fuel supply pipes of the fuel pump and the throttle body assy WARNING Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is disconnected fuel spills out from the hose and the pipe because of residual pressure Cover
111. 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 http mototh com 2 20 PERIODIC MAINTENANCE Periodic Maintenance Procedures Water Hose and Pipe Inspection coolant leak damage installation condition The high pressure inside the radiator hose can cause coolant to leak A or the hose to burst if the line is not properly maintained Visually inspect the hoses for signs of deterioration Squeeze the hoses A hose should not be hard and brittle nor should it be soft or swollen Replace the hose if any fraying cracks B or bulges C are noticed Check that the hoses are securely connected and clamps are tightened correctly Torque Radiator Water Hose Clamp Screws 1 5 N m 0 15 kgf m 13 in lb Engine Top End Valve Clearance Inspection NOTE Valve clearance must be checked and adjusted when the engine is cold at room temperature Remove Cylinder Head Cover see Cylinder Head Cover Re moval in the Engine Top End chapter Plugs A B Special Tool Filler Cap Driver 57001 1454 Check the valve clearance when the pistons are at TDC The pistons are numbered beginning with the engine left side Using a wrench on the alternator rotor bolt t
112. again Measure coil winding resistance when the DFI part is cold at room temperature Make sure all connectors in the circuit are clean and tight and examine leads for signs of burning fraying short etc Deteriorated leads and bad connections can cause reappearance of problems and unstable operation of the DFI system If any wiring is deteriorated replace the wiring http mototh com FUEL SYSTEM DFI 3 25 Troubleshooting the DFI System Pull each connector A apart and inspect it for corrosion dirt and damage If the connector is corroded or dirty clean it carefully If it is damaged replace it Connect the connectors securely Check the wiring for continuity Use the wiring diagram to find the ends of the lead which is suspected of being a problem Connect the hand tester between the ends of the leads Special Tool Hand Tester 57001 1394 Set the tester to the 1 range and read the tester If the tester does not read 0 the lead is defective Re place the lead or the main harness or the subharness If both ends of a harness A are far apart ground B the one end C using a jumper lead D and check the con tinuity between the end E and the ground F This en ables to check a long harness for continuity If the harness is open repair or replace the harness When checking a harness A for short circuit open one end B and check the continuity between the other e
113. and let it idle Measure the output voltage with the connector joined Output Voltage with Plug Standard DC 0 7 V or more Next remove the plug from the fitting A with idling Measure the output voltage with the connector joined Output Voltage without Plug Standard DC 0 2 V or less Turn the ignition switch OFF If the reading is out of the standard with plug DC 0 7 V or more without plug DC 0 2 V or less remove the ECU and check the wiring for continuity between main harness connectors Special Tool Hand Tester 57001 1394 Disconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Oxygen Sensor Connector B BL Y lead ECU terminal 4 C BR BK lead ECU terminal 22 D If the wiring is good replace the sensor If the reading is within the standard with plug DC 0 7 V or more without plugs DC 0 2 V or less check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see ECU Removal Installation http mototh com 3 68 FUEL SYSTEM DFI Oxygen Sensor not activated Service Code 33 Oxygen Sensor Circuit 1 Ignition Switch 2 Water proof Joint 3 3 Water proof Joint 1 4 Oxygen Sensor 5 ECU 6 Joint Connector 2 7 Battery 12 V 8 Ah 8 Frame Ground 9 Main Fuse 30 A 10 Oxygen Sensor Heater Fuse 10 A 11 Fuse Box http mototh com FUEL SYSTEM
114. as a set Pad Lining Thickness Standard Front 4 5 mm 0 18 in Rear 4 5 mm 0 18 in Service Limit 1 mm 0 04 in Brake Operation Inspection Inspect the operation of the front and rear brake by run ning the vehicle on the dry road If the brake operation is insufficiency inspect the brake system WARNING When inspecting by running the vehicle note a surrounding traffic situation enough in the place of safety http mototh com 2 32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Light Switch Operation Inspection Turn on the ignition switch The brake light A should go on when the brake lever is applied or after the brake pedal is depressed about 10 mm 0 39 in If it does not adjust the brake light switch While holding the switch body turn the adjusting nut 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 If it does not go on inspect or replace the following items Battery see Charging Condition Inspection in the Elec trical System chapter Brake Light see Tail Brake Light Removal in the Electri cal System chapter Main Fuse 30 A and Taillight Fuse 10 A see Fuse In spection in the Electrical System chapter Front Brake Light Switch A see Swit
115. brake This lowers the brake fluid boiling point and could cause the brake to be ineffective It may also cause the rubber brake parts to deteriorate 4 Don t leave the reservoir cap off for any length of time to avoid moisture contamination of the fluid 5 Don t change the fluid in the rain or when a strong wind is blowing 6 Except for the disc pads and disc use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning of the brake parts Do not use any other fluid for cleaning these parts Gasoline engine oil or any other petroleum distillate will cause deterio ration of the rubber parts Oil spilled on any part will be difficult to wash off completely and will eventually deteriorate the rubber used in the disc brake 7 When handling the disc pads or disc be careful that no disc brake fluid or any oil gets on them Clean off any fluid or oil that inadvertently gets on the pads or disc with a high flash point solvent Do not use one which will leave an oily residue Replace the pads with new ones if they cannot be cleaned satisfacto rily 8 Brake fluid quickly ruins painted surfaces any spilled fluid should be completely wiped up imme diately 9 If any of the brake line fittings or the bleed valve is opened at any time the AIR MUST BE BLED FROM THE BRAKE LINE http mototh com 12 20 BRAKES Brake Hose Brake Hose Removal Installation Refer to the Brake Hose and Pipe Replacement in the Periodic Ma
116. button Then the starter motor should not turn when the starter system circuit is normality If the engine is start inspect the starter lockout switch neutral switch and relay box If 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 Sidestand Up Turn the ignition switch ON and push the starter button Then 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 neutral switch sidestand switch and relay box If their parts are normality replace the ECU http mototh com 16 38 ELECTRICAL SYSTEM Ignition System 3rd Check Inspect the engine for its secure stop after the following operations are completed Run the engine to the following conditions Condition Transmission Gear 1st Position Clutch Lever Pulled in Sidestand Up Set the sidestand on the ground then the engine will stop If the engine does not stop inspect the neutral switch sidestand switch and relay box If their parts are normality replace the ECU IC Igniter Inspection The IC igniter is built in the ECU A Refer to the following items Interlock Operation Inspection see Interlock Operation Inspection Ignition System Troubleshooting see Ignition System section ECU Power Suppl
117. chapter Engine Sprocket Cover see Engine Sprocket Removal in the Final Drive chapter Connector A Disconnect http mototh com 16 64 ELECTRICAL SYSTEM Switches and Sensors Remove Speed Sensor Bolt A Speed Sensor B Speed Sensor Installation Installation is the reverse of removal Run the lead correctly see Cable Wire and Hose Rout ing section in the Appendix chapter Apply a non permanent locking agent to the threads of the speed sensor bolt and tighten it Torque Speed Sensor Bolt 7 8 N m 0 80 kgf m 69 in lb Install the removed parts see appropriate chapters Speed Sensor Inspection Remove the speed sensor see Speed Sensor Removal Connect the speed sensor connector A with the battery B 10 k resistor C and hand tester D as shown in the figure Set the tester to the DC 25 V range Special Tool Hand Tester 57001 1394 Trace A each side of the speed sensor surface with the screwdriver Then the tester indicator should flick B If the tester indicator does not flick replace the speed sensor Oxygen Sensor Removal CAUTION Never drop the sensor especially on a hard surface Such a shock to the sensor can damage it Remove Right Lower Fairing see Lower Fairing Removal in the Frame chapter Oxygen Sensor Lead Connector A Disconnect Free the lead from the clamps B Remove the oxygen sensor C http mototh com
118. conditions or especially after using a high pressure water spray perform the general lubri cation Pivots Lubricate with Grease Brake Lever Brake Pedal Clutch Lever Rear Brake Joint Pin Sidestand Points Lubricate with Grease Clutch Inner Cable Upper and Lower Ends A Throttle Inner Cable Upper and Lower Ends http mototh com PERIODIC MAINTENANCE 2 41 Periodic Maintenance Procedures Cables Lubricate with Rust Inhibitor Clutch Cable Throttle Cables Lubricate the cables by seeping the oil between the cable and housing The cable may be lubricated by using a commercially available pressure cable lubricator with an aerosol cable lubricant With the cable disconnected at both ends the 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 http mototh com 2 42 PERIODIC MAINTENANCE Periodic Maintenance Procedures Bolts Nuts and Fasteners Tightness Inspection Check the tightness of the bolts and nuts listed here Also check to see that each cotter pin is in place and in good condition NOTE For the engine fasteners check the tightness of them when the engine is cold at room temperature If there are loose fasteners retighten them to the spec ified torque following the specified tightening sequence Refer to the appropriate chapter for torque specif
119. diagnosis indicator terminal to the battery terminal for more than 2 seconds D and then keep it grounded continuously E Count the blinks of the FI indicator light to read the ser vice code Keep the auxiliary lead ground until you finish reading the service code http mototh com FUEL SYSTEM DFI 3 35 Self Diagnosis To enter the self diagnosis dealer mode 2 open A and ground B the lead more than five times C within 2 sec onds D after the lead is first grounded and then keep it grounded continuously E for more than 2 seconds Count the blinks of the FI indicator light to read the ser vice code Keep the auxiliary lead ground until you finish reading the service code Auxiliary Lead F Self diagnosis Terminal G NOTE To enter the dealer mode 2 from the dealer mode 1 turn off the ignition switch once Service Code Clearing Procedures Enter the self diagnosis dealer mode 2 see Self diagnosis Procedures NOTE Make sure to keep the grounding until the following opening and grounding starts Pull the clutch lever in more than 5 seconds and then release it Repeat opening A and grounding B the lead self diagnosis terminal more than five times C within 2 seconds D after the lead is grounded and then keep it grounded continuously E for more than 2 seconds Auxiliary Lead F Self diagnosis Terminal G http mototh com 3 36 FUEL SYSTEM DFI
120. gear D Apply molybdenum disulfide oil solution to the crankshaft main bearing inserts Connecting Rod Removal Split the crankcase see Crankcase Splitting Remove Connecting Rod Big End Nuts A Crankshaft NOTE Mark and record the locations of the connecting rods and their big end caps so that they can be reassembled in their original positions Remove the connecting rods from the crankshaft CAUTION Discard the connecting rod bolts To prevent dam age to the crankpin surfaces do not allow the con necting rod bolts to bump against the crankpins Connecting Rod Installation CAUTION To minimize vibration the connecting rods should have the same weight mark Big End Cap A Connecting Rod B Weight Mark Alphabet C Diameter Mark Around Weight Mark D or no mark http mototh com 9 16 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods CAUTION If the connecting rods big end bearing inserts or crankshaft are replaced with new ones select the bearing insert and check clearance with a plasti gage press gauge before assembling engine to be sure the correct bearing inserts are installed CAUTION The connecting rod bolts are designed to stretch when tightened Never reuse them Replace the connecting rod big end bolts and nuts with new ones Apply molybdenum disulfide oil solution to the inner sur faces of upper and lower bearing inserts A Do not ap
121. http mototh com APPENDIX 17 13 Cable Wire and Hose Routing 1 Subthrottle Sensor Lead Connector 2 Main Throttle Sensor Lead Connector 3 Front Right Turn Signal Light Lead Connector 4 Oxygen Sensor 5 Clutch Cable 6 Subthrottle Sensor 7 Main Throttle Sensor 8 Fuel Injector 2 9 Subthrottle Valve Actuator Lead Connector 10 Fuel Injector 1 11 Throttle Body Assy 12 Fuel Injector 2 Lead Connector 13 Fuel Injector 1 Lead Connector http mototh com 17 14 APPENDIX Cable Wire and Hose Routing http mototh com APPENDIX 17 15 Cable Wire and Hose Routing 1 Stick Coil 1 Lead Connector 2 Front Left Turn Signal Light Lead Connector 3 Throttle Cable Decelerator 4 Throttle Cable Accelerator 5 Guide Run the oil pressure switch lead through into the guide 6 Oil Pressure Switch Lead Connector 7 Stick Coil 2 Lead Connector 8 Inlet Air Temperature Sensor Lead Connector 9 To Fuel Tank 10 Fuel Pump Lead Connector http mototh com 17 16 APPENDIX Cable Wire and Hose Routing http mototh com APPENDIX 17 17 Cable Wire and Hose Routing 1 Clamp Hold the neutral switch and speed sensor leads 2 Speed Sensor Lead 3 Neutral Switch Lead Connector 4 Insert the speed sensor lead into the groove of the speed sensor mounting bracket 5 Clutch Cable 6 Clamps Hold the oxygen sensor lead 7 Oxygen Sensor Lead Connector http mototh com 17 18 APPENDIX Cable Wire and Ho
122. in the Electrical System chapter Water Pump see Water Pump Removal in the Cooling System chapter Oil Filter see Oil Filter Replacement in the Periodic Maintenance chapter Oil Screen see Oil Screen Cleaning and Inspection in the Engine Lubrication System chapter Cylinder Head see Cylinder Head Removal in the En gine Top End chapter Cylinder see Cylinder Removal in the Engine Top End chapter If the crankshaft is to be removed remove the pistons see Piston Removal in the Engine Top End chapter Remove the upper crankcase bolts A Remove the lower crankcase bolts First loosen the M6 bolts A M8 Bolts B Tap lightly around the crankcase mating surface with a plastic mallet and split the crankcase Take care not to damage the crankcase http mototh com CRANKSHAFT TRANSMISSION 9 11 Crankcase Crankcase Assembly CAUTION The upper and lower crankcase halves are ma chined at the factory in the assembled state so the crankcase halves must be replaced as a set With a high flash point solvent clean off the mating sur faces of the crankcase halves and wipe dry Using compressed air blow out the oil passages in the crankcase halves Apply engine oil to the new O ring A Apply a non permanent locking agent to the threads of the oil breather mounting bolts B and tighten them Torque Oil Breather Mounting Bolts 9 8 N m 1 0 kgf m 87 in lb Install the breather hos
123. install the balance weight 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 http mototh com WHEELS TIRES 10 13 Tires Air Pressure Inspection Adjustment Refer to the Air Pressure Inspection in the Periodic Main tenance chapter Tire Inspection Refer to the Wheel Tire Damage Inspection in the Peri odic Maintenance chapter Tire Removal Remove Wheels see Front Rear Wheel Removal 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 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 Break the beads away from both sides of the rim with the bead breaker A Special Tool Bead Breaker Assembly 57001 1072 Step on the side of the tire opposite the valve stem and start prying the tire off the rim near the air valve with tire irons A Special Tools Rim Protector B 57001 1063 Bead Breaker Assembly 57001 1072 http mototh com 10 14 WHEELS TIRES Tires NOTE For easier removal always position t
124. is fully seated in the adjuster at the clutch lever or it could slip into place later creating enough cable play to prevent clutch disengagement After the adjustment start the engine and check that the clutch does not slip and that it releases properly Wheels Tires Air Pressure Inspection Remove the air valve cap 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 Install the air valve cap Adjust the tire air pressure according to the specifications if necessary Air Pressure when Cold Front Up to 170 kg 375 lb load 200 kPa 2 00 kgf cm 28 psi Rear Up to 170 kg 375 lb load 225 kPa 2 25 kgf cm 32 psi http mototh com PERIODIC MAINTENANCE 2 25 Periodic Maintenance Procedures Wheel Tire Damage Inspection Remove any imbedded stones A or other foreign parti cles B from tread Visually inspect the tire for cracks and cuts and replace the tire if necessary Swelling or high spots indicate inter nal damage requiring tire replacement Visually inspect the wheel for cracks cuts and dents dam age If any damage is found replace the wheel if necessary Tire Tread Wear Inspection As the tire tread wears down the tire becomes more sus ceptible to puncture and failure An accepted estimate is that 90 of all tire failures occur during the last 1
125. joint clicks Push B the joint lock C until the hose joint clicks http mototh com PERIODIC MAINTENANCE 2 45 Periodic Maintenance Procedures Push and pull A the fuel hose joint B back and forth more than two times and make sure it is locked and does not come off WARNING Make sure the fuel hose joint is installed correctly on the fuel supply pipe or the fuel could leak If it comes off reinstall the hose joint Run the fuel hose correctly see Cable Wire and Hose Routing section in the Appendix chapter Install the fuel tank see Fuel Tank Installation in the Fuel System DFI chapter Start the engine and check the fuel hose for leaks Coolant Change WARNING To avoid burns do not remove the radiator cap or try to change the coolant when the engine is still hot Wait until it cools down Coolant on tires will make them slippery and can cause an accident and injury Immediately wipe up or wash away any coolant that spills on the frame engine or other painted parts Since coolant is harmful to the human body do not use for drinking Remove the lower fairings see Lower Fairing Removal in the Frame 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 http mototh com 2 46 PERIODIC MAINTENANCE Periodic Maintenance Procedures Place a container
126. lb Front Brake Pad Pins 17 2 1 8 13 Front Brake Reservoir Cap Screws 1 5 0 15 13 in lb Front Caliper Holder Pin Bolt 17 2 1 8 13 Si Front Caliper Mounting Bolts 25 2 5 18 Front Master Cylinder Clamp Bolts 8 8 0 90 78 in lb S Rear Brake Disc Mounting Bolts 27 2 8 20 L Rear Brake Pad Pins 17 2 1 8 13 Rear Caliper Holder Pin Bolt 17 2 1 8 13 Si http mototh com PERIODIC MAINTENANCE 2 9 Torque and Locking Agent Torque Fastener N m kgf m ft lb Remarks Rear Caliper Mounting Bolts 25 2 5 18 Rear Master Cylinder Mounting Bolts 25 2 5 18 Rear Master Cylinder Push Rod Locknut 17 2 1 8 13 Suspension Front Fork Bottom Allen Bolts 20 2 0 15 L Lower Front Fork Clamp Bolts 30 3 1 22 Rear Shock Absorber Nuts 59 6 0 44 Swingarm Pivot Shaft Nut 98 10 0 72 3 Tie Rod Nuts 59 6 0 44 Uni Trak Rocker Arm Nut 59 6 0 44 Upper Front Fork Clamp Bolts 20 2 0 15 Steering Handlebar Mounting Bolts 25 2 5 18 Lower Front Fork Clamp Bolts 30 3 1 22 Steering Stem Head Bolt 44 4 5 32 Steering Stem Nut 4 9 0 50 43 in lb Switch Housing Screws 3 5 0 36 31 in lb Upper Front Fork Clamp Bolts 20 2 0 15 Frame Front Footpeg Bracket Bolts 25 2 5 18 Rear Footpeg Bracket Bolts 25 2 5 18 Sidestand Nut 39 4 0 29 Sidestand Switch Bolt 8 8 0 90 78 in lb L Windshield Mounting Bolts 0 42 0 043 3 7 in lb Electric
127. less than the service limit on either of the rings replace all the rings NOTE When using new rings in a used piston check for un even groove wear The rings should fit perfectly parallel to the groove sides If not replace the piston http mototh com ENGINE TOP END 5 37 Cylinder Pistons Piston Ring End Gap Inspection 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 Measure the gap B between the ends of the ring with a thickness gauge Piston Ring End Gap Standard Top 0 15 0 30 mm 0 0059 0 0118 in Second 0 40 0 55 mm 0 0157 0 0217 in Oil 0 20 0 80 mm 0 0079 0 0315 in Service Limit Top 0 6 mm 0 024 in Second 0 9 mm 0 035 in Oil 1 1 mm 0 043 in If the end gap of either ring is greater than the service limit replace all the rings Boring Honing Performance When boring and honing a cylinder note the following There is one size of oversize piston available Oversize piston require oversize rings Oversize Pistons and Rings 0 5 mm 0 020 in Before boring a cylinder first measure the exact diameter of the oversize piston and then according to the stan dard clearance in the Specifications section determine the rebore diameter However if the amount of boring necessary would make the inside diameter grea
128. lint free clean cloth into the throttle body assy holders CAUTION If dirt gets into the engine excessive engine wear and possible engine damage will occur http mototh com 3 104 FUEL SYSTEM DFI Throttle Body Assy Throttle Body Assy Installation Install the throttle body assy holder clamp screws in the direction as shown in the figure Screw Heads A Install the throttle body assy to the throttle body assy hold ers Tighten Torque Throttle Body Assy Holder Clamp Screws 2 0 N m 0 20 kgf m 18 in lb Install the air duct clamp screws in the direction as shown in the figure Screw Heads A About 21 B Install the air ducts to the throttle body assy Tighten Torque Air Duct Clamp Screws 2 0 N m 0 20 kgf m 18 in lb Air Cleaner Housing Mounting Bolts 9 8 N m 1 0 kgf m 87 in lb Apply a thin coating of grease to the throttle cable lower ends Fit the accelerator cable end and the decelerator cable end into the throttle pulley Turn the throttle grip and make sure that the throttle valves move smoothly and return by spring force Run the leads and hoses correctly see Cable Wire and Hose Routing section in the Appendix chapter Adjust Throttle Grip Free Play see Throttle Control System In spection in the Periodic Maintenance chapter Idle Speed see Idle Speed Adjustment in the Periodic Maintenance chapter http mototh com FUEL SY
129. loose Reinstall see chapter 3 Throttle body assy holder loose Reinstall see chapter 3 Throttle body assy dust seal damage Replace see chapter 3 Water or foreign matter in fuel Change fuel Inspect and clean fuel system see chapter 3 Fuel injector O ring damage Replace see chapter 3 Fuel injector clogged Inspect and repair see chapter 3 Fuel line clogged Inspect and repair see chapter 3 Fuel pump operates intermittently and often DFI fuse blows Fuel pump bearings may wear Replace the fuel pump see chapter 3 Fuel pump trouble Inspect see chapter 3 Inlet air pressure sensor trouble Inspect see chapter 3 Cracked or obstructed inlet air pressure sensor vacuum hose Inspect and repair or replace see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Inlet air temperature sensor trouble Inspect see chapter 3 Main throttle sensor trouble Inspect see chapter 3 Subthrottle sensor trouble Inspect see chapter 3 Subthrottle valve actuator trouble Inspect see chapter 3 Knocking Fuel poor quality or incorrect Fuel change Use the gasoline recommended in the Owner s Manual Spark plug incorrect Replace it with the correct plug see chapter 2 Stick coil trouble Inspect see chapter 16 ECU trouble Inspect see chapter 3 Engine vacuum not synchronizing Inspect and adjust see chapter 2 Inlet air pressure sensor trouble Inspect
130. mm 0 807 in 6 Needle Bearing 7 Bearing Outer Race 8 2nd Gear 9 Bushing 10 6th Top Gear 11 3rd Gear 12 4th Gear 13 5th Gear 14 1st Gear 15 Ball Bearing 16 Drive Shaft 17 Nut 18 Washer 19 Collar 20 Oil Seal 21 Bushing 22 2nd Gear 23 6th Top Gear 24 3rd Gear 25 Bushing 26 4th Gear 27 5th Gear 28 1st Gear 29 Output Shaft http mototh com CRANKSHAFT TRANSMISSION 9 31 Transmission Shift Drum and Fork Removal Remove Lower Crankcase Half see Crankcase Splitting Transmission Shafts see Transmission Shaft Removal Shift Drum Positioning Bolt A Washer B Spring C Pin D Remove Shift Drum Bearing Holder Bolts A Shift Drum Bearing Holder B Shift Rods C Shift Forks Pull out the shift drum A about half of it and remove the circlip B and the operating plate C Pull out the shift drum fully from the upper crankcase Shift Drum and Fork Installation Apply engine oil to the shift drum forks and rods Insert the shift drum into the upper crankcase half and install the operating plate pin A operating plate B and new circlip C NOTE When installing the operating plate the projection D of the operating plate faces toward the outside Install the shift rods E noting the groove position Position the one with shorter ears F on the drive shaft and place the pin in the center groove in the shift drum G The two forks
131. no fluid leakage Rear Master Cylinder Removal Remove Brake Hose Banjo Bolt A Brake Hose B Cotter Pin C Joint Pin D Bolts E Rear Master Cylinder F Slide out the clamp G Pull off the reservoir hose lower end and drain the brake fluid into a container Rear Master Cylinder Installation Replace the cotter pin with a new one Replace the washers that are on each side of hose fitting with new ones Tighten Torque Rear Master Cylinder Mounting Bolts 25 N m 2 5 kgf m 18 ft lb Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft lb Bleed the brake line see Brake Line Bleeding Check the brake for good braking power no brake drag and no fluid leakage http mototh com BRAKES 12 15 Master Cylinder Front Master Cylinder Disassembly Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter Rear Master Cylinder Disassembly Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter Master Cylinder Assembly Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter Master Cylinder Inspection Visual Inspection Remove the master cylinders see Front Rear Master Cylinder Removal Disassemble the front and rear master cylinders see Master Cylinder Rubber Parts Replacement in the Peri odic Maintenance chapter Check that there are no scratches r
132. of the pipe is the standard oil level distance A correct measurement can not be obtained unless the level gauge pipe is placed in the center of the inner tube Oil Level fully compressed without spring Standard 108 2 mm 4 25 0 08 in Place the stopper of the level gauge at the top D of the inner tube E and pull the handle slowly to draw out the excess oil from fork into the gauge thus attaining the stan dard level If not oil is drawn out there is not enough oil in the fork Pour in some more oil and measure again Install Fork Spring A Fork Spring Seat B Collar C Replace the top plug O ring and snap ring with new ones Install Top Plug Snap Ring Front Fork see Front Fork Installation Front Fork Disassembly Drain the fork oil see Front Fork Oil Change Hold the fork leg horizontally in a vise A Stop the cylinder unit B from turning by using the special tools Special Tools Fork Cylinder Holder Handle C 57001 183 Fork Cylinder Holder Adapter D 57001 1057 Unscrew the Allen bolt E then take the bolt and gasket out of the bottom of the outer tube Take the cylinder unit out of the inner tube http mototh com SUSPENSION 13 11 Front Fork Remove the following from the top of the outer tube Dust Seal A Retaining Ring B Use the fork outer tube weight A to separate the inner tube from the outer tube Holding the inner tube by han
133. one select the proper crankshaft in accordance with the combination of the crankshaft primary gear and clutch housing gear markings with colors Crankshaft Primary Gear A Clutch Housing Gear B Be sure to confirm the marking and color on the crank shaft primary gear Crankshaft Selection when Replacing Crankshaft Clutch Housing Crankshaft Gear Marking E Color F Primary Gear Marking C Color D Part Number A White A White 13031 0111 A White B Red 13031 0112 B Red A White 13031 0111 B Red B Red 13031 0112 B Red C None 13031 0113 C None A White 13031 0111 C None B Red 13031 0112 C None C None 13031 0113 C None D Yellow 13031 0114 D Yellow A White 13031 0111 D Yellow B Red 13031 0112 D Yellow C None 13031 0113 D Yellow D Yellow 13031 0114 http mototh com CRANKSHAFT TRANSMISSION 9 15 Crankshaft and Connecting Rods NOTE If the crankshaft is replaced with a new one refer to the Connecting Rod Big End Bearing Insert Selection in the Specifications CAUTION If the crankshaft bearing inserts or crankcase halves are replaced with new ones select the bear ing inserts and check clearance with a plastigage press gauge before assembling engine to be sure the correct bearing inserts are installed Install the crankshaft Align the timing mark A on the balancer drive gear B with the timing mark C on the balancer
134. output voltage with the connector joined use the needle adapter set C Insert the needle adapter inside the seal until the needle adapter reaches the terminal Special Tool Needle Adapter Set 57001 1457 CAUTION Insert the needle adapter straight along the terminal in the connector to prevent short circuit between terminals Make sure that measuring points are correct in the con nector noting the position of the lock D and the lead color before measurement Do not reverse connections of a digital meter Be careful not to short circuit the leads of the DFI or elec trical system parts by contact between adapters Turn the ignition switch ON and measure the voltage with the connector joined CAUTION Incorrect reverse connection or short circuit by needle adapters could damage the DFI or electrical system parts After measurement remove the needle adapters and ap ply silicone sealant to the seals A of the connector B for waterproofing Sealant Kawasaki Bond Silicone Sealant 56019 120 Always check battery condition before replacing the DFI parts A fully charged battery is a must for conducting accurate tests of the DFI system Trouble may involve one or in some cases all items Never replace a defective part without determining what CAUSED the problem If the problem was caused by some other item or items they too must be repaired or replaced or the new replacement part will soon fail
135. rod does not return to its original position once it moves out to take up camshaft chain slack Observe all the rules listed below When removing the tensioner do not take out the mounting bolts only halfway Retightening the mounting bolts from this position could damage the tensioner and the camshaft chain Once the bolts are loosened the tensioner must be removed and reset as described in Camshaft Chain Ten sioner Installation Do not turn over the crankshaft while the tensioner is removed This could upset the camshaft chain timing and damage the valves Remove Right Lower Fairing see Lower Fairing Removal in the Frame chapter Cap Bolt A Loosen Mounting Bolts B Chain Tensioner C Camshaft Chain Tensioner Installation Remove the tensioner cap bolt and O ring While compressing the push rod A turn it clockwise with a suitable screwdriver until the rod stopped CAUTION Do not turn the rod counterclockwise at installation This could detach the rod and the tensioner cannot be reinstalled Replace the chain tensioner gasket with a new one While holding the rod in position with a suitable push rod holder plate A install the tensioner on the cylinder block 3 5 mm 0 14 in B 7 mm 0 28 in C 12 mm 0 47 in D 8 5 mm 0 33 in E http mototh com 5 16 ENGINE TOP END Camshaft Chain Tensioner Tighten Torque Camshaft Chain Tensioner Mounting Bolts A 9 8 N m 1
136. sealant http mototh com 3 6 FUEL SYSTEM DFI Exploded View http mototh com FUEL SYSTEM DFI 3 7 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Air Cleaner Housing Cap Bolts 2 5 0 25 22 in lb 2 Air Cleaner Housing Mounting Bolts 9 8 1 0 87 in lb 3 Air Cleaner Housing Screws 1 15 0 12 10 in lb 4 Air Duct Clamp Screws 2 0 0 20 18 in lb 5 Fuel Pump Bolts 9 8 1 0 87 in lb L AD Apply adhesive AO Apply high quality form air filter oil L Apply a non permanent locking agent R Replacement Parts http mototh com 3 8 FUEL SYSTEM DFI DFI System DFI System http mototh com FUEL SYSTEM DFI 3 9 DFI System 1 ECU 2 Battery 12 V 8 Ah 3 Neutral Switch 4 Inlet Air Pressure Sensor 5 Air Switching Valve 6 Water Temperature Sensor 7 Speed Sensor 8 Vehicle down Sensor 9 Oxygen Sensor 10 Crankshaft Sensor 11 Main Throttle Sensor 12 Fuel Injectors 13 Subthrottle Valve Actuator 14 Subthrottle Sensor 15 Inlet Air Temperature Sensor 16 Fuel Pump http mototh com 3 10 FUEL SYSTEM DFI DFI System DFI System Wiring Diagram http mototh com FUEL SYSTEM DFI 3 11 DFI System Part Names 1 Oxygen Sensor 2 ECU 3 Joint Connector 2 4 Kawasaki Diagnostic System Connector 5 Self diagnosis Terminal 6 Fuel Pump 7 Battery 12 V 8 Ah 8 Frame Ground 9 Starter Relay 10 Main Fuse 30 A 11 Relay Box 12 Fuel Pump R
137. send 22 signals to the ECU at the one cranking If the crankshaft sensor generates other than 22 signals the engine stops by itself 24 and 25 Speed Sensor Speed sensor must send 4 signals to the ECU at the one rotation of the engine sprocket The gear position is decided by the signal of the speed sensor If the speed sensor system fails no signal wiring short or open the speedometer shows 0 and the ECU sets the top 6 gear position 31 Vehicle down Sensor Output Voltage 0 4 4 4 V If the vehicle down sensor system has failures the output voltage is more than usable range wiring open the ECU shuts off the fuel pump relay the fuel injectors and the ignition system 32 Subthrottle Sensor Output Voltage 0 15 4 85 V If the subthrottle sensor system fails the output voltage is out of the usable range wiring short or open the ECU drive the subthrottle valve to the full closed position and it stops the current to the subthrottle valve actuator 33 Oxygen Sensor The oxygen sensor is active and sensor must send signals output voltage continuously to the ECU If the oxygen sensor is not activated the ECU stops the feedback mode of the oxygen sensor 51 Stick Coil 1 The stick coil primary winding must send signals continuously to the ECU If the stick coil 1 primary winding has failures no signal wiring short or open the ECU shuts off the injector 1 to stop fuel
138. sensor trouble Inspect see chapter 3 Engine stalls easily Spark plug dirty broken or gap maladjusted Inspect and replace see chapter 2 Stick coil trouble Inspect see chapter 16 Main throttle sensor trouble Inspect see chapter 3 Subthrottle sensor trouble Inspect see chapter 3 Subthrottle valve actuator trouble Inspect see chapter 3 Inlet air pressure sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Inlet air temperature sensor trouble Inspect see chapter 3 Fuel pump trouble Inspect see chapter 3 Fuel injector trouble Inspect see chapter 3 Fuel pressure too low or too high Inspect see chapter 3 Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump see chapter 3 Fuel line clogged Inspect and repair see chapter 3 Poor acceleration Fuel pressure too low Inspect see chapter 3 Water or foreign matter in fuel Change fuel Inspect and clean fuel system see chapter 3 Fuel filter or pump screen clogged Inspect and replace fuel pump see chapter 3 Fuel pump trouble Inspect see chapter 3 Fuel injector trouble Inspect see chapter 3 Main throttle sensor trouble Inspect see chapter 3 Subthrottle sensor trouble Inspect see chapter 3 Subthrottle valve actuator trouble Inspect see chapter 3 Inlet air pressure sensor trouble Inspect see chapter 3 http mototh com
139. steps Following the sequence numbers on the lower crankcase half tighten the M8 bolts 1 7 L 90 mm 3 54 in Torque Crankcase Bolts M8 24 N m 2 4 kgf m 18 ft lb Tighten the M8 bolts 8 9 L 73 mm 2 87 in Torque Crankcase Bolts M8 19 N m 1 9 kgf m 14 ft lb Tighten the M6 bolts Torque Crankcase Bolts M6 12 N m 1 2 kgf m 106 in lb L 135 mm 5 31 in A L 85 mm 3 35 in B with New Copper Washer L 60 mm 2 36 in C L 38 mm 1 50 in D Tighten the upper crankcase bolts in the order listed Torque Crankcase Bolts M6 12 N m 1 2 kgf m 106 in lb L 85 mm 3 35 in A L 60 mm 2 36 in B with New Copper Washer After tightening all crankcase bolts check the following items Wipe up the liquid gasket that seeps out around the crankcase mating surface Crankshaft and transmission shafts turn freely While spinning the output shaft gears shift smoothly from the 1st to 6th gear and 6th to 1st When the output shaft stays still the gear can not be shifted to 2nd gear or other higher gear positions Install the removed parts see appropriate chapters http mototh com 9 14 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods Crankshaft Removal Split the crankcase see Crankcase Splitting Removal the crankshaft A Crankshaft Installation If the crankshaft is replaced with a new
140. surface of the cylinder head at several positions Use a thickness gauge A to measure the space between the straightedge B and the head Cylinder Head Warp Standard Service Limit 0 05 mm 0 002 in If the cylinder head is warped more than the service limit replace it If the cylinder head is warped less than the service limit repair the head by rubbing the lower surface on emery paper secured to a surface plate first No 200 then No 400 http mototh com 5 26 ENGINE TOP END Valves Valve Clearance Inspection Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter Valve Clearance Adjustment Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter Valve Removal Remove Cylinder Head see Cylinder Head Removal Valve Lifter and Shim Mark and record the valve lifter and shim locations so they can be installed in their original positions Using the valve spring compressor assembly remove the valve Special Tools Valve Spring Compressor Assembly A 57001 241 Valve Spring Compressor Adapter 16 B 57001 1305 Valve Installation Replace the oil seal with a new one Apply engine oil to the lip of the oil seal Apply a thin coat of molybdenum disulfide grease to the valve stem before valve installation Install the spring so that the closed coil end faces down wards Valve Stem A Spring Seat B Valve Sprin
141. the hose If there is no vacuum pulsation check the hose line for leak If there is no leak check the air switching valve see Air Switching Valve Unit Test in the Electrical Sys tem chapter or air suction valve see Air Suction Valve Inspection in the Engine Top End chapter Clutch Clutch Operation Inspection Pull the clutch lever just enough to take up the free play A Measure the gap between the lever and the lever holder If the gap is too wide the clutch may not release fully If the gap is too narrow the clutch may not engage fully In either case adjust it Clutch Lever Free Play Standard 2 3 mm 0 08 0 12 in http mototh com 2 24 PERIODIC MAINTENANCE Periodic Maintenance Procedures WARNING To avoid a serious burn never touch the engine or exhaust pipe during clutch adjustment Turn the adjuster A so that 5 6 mm 0 20 0 24 in B of threads are visible Remove the right lower fairing see Lower Fairing Re moval in the Frame chapter Slide the dust cover A at the clutch cable lower end out of place Loosen both adjusting nuts B at the clutch cover as far as they will go Pull the clutch outer cable C tight and tighten the adjust ing nuts against the cable holder D Slip the dust cover back onto place Turn the adjuster at the clutch lever until the free play is correct WARNING Be sure that the outer cable end at the clutch lever
142. the steering stem A is removed or if the steering can not be adjusted for smooth action check the steering stem for straightness If the steering stem is bent replace the steering stem Oil Seal Deterioration Damage Inspection Inspect the oil seal for any sign of deterioration or dam age If the oil seal is deterioration or damage replace it with a new one http mototh com 14 10 STEERING Handlebar Handlebar Removal Remove Left Switch Housing A Handlebar Weight B Left Handlebar Grip C Clutch Lever Clamp Bolt D Clutch Lever Assembly E Bolts F Left Handlebar G Remove Front Master Cylinder A see Front Master Cylinder Re moval in the Brakes chapter Right Switch Housing B Handlebar Weight C Throttle Grip D Bolts E Right Handlebar F Handlebar Installation Tighten Torque Handlebar Mounting Bolts 25 N m 2 5 kgf m 18 ft lb Install the clutch lever see Clutch Lever Installation in the Clutch chapter Apply adhesive cement to the inside of the left handlebar grip and install it Apply a non permanent locking agent to the left handlebar weight screw and tighten it Install the left switch housing Fit the projection A into a hole B in the handlebar Tighten Torque Switch Housing Screws 3 5 N m 0 36 kgf m 31 in lb Install Throttle Grip Throttle Cable Tips A Right Switch Housing Fit the projection B into
143. to the cylinder 1 though the engine keeps running http mototh com 3 40 FUEL SYSTEM DFI Self Diagnosis Service Codes Parts Output Signal Usable Range or Criteria Backups by ECU 52 Stick Coil 2 The stick coil primary winding must send signals continuously to the ECU If the stick coil 2 primary winding 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 56 Radiator Fan Relay When the relay OFF condition the fan relay is open 62 Subthrottle Valve Actuator The actuator operates open and close of the subthrottle valve by the pulse signal from the ECU If the subthrottle valve actuator fails the signal is out of the usable range wiring short or open the ECU stops the current to the actuator 64 Air Switching Valve The air switching valve controls the flow of the secondary air by opening and shutting the solenoid valve 67 Oxygen Sensor Heater The oxygen sensor heater raise temperature of the sensor for its earlier activation 12 V 6 6 W 0 55 A If the oxygen sensor heater fails wiring short or open the ECU stops the current to the heater 94 Oxygen Sensor The oxygen sensor must send signals continuously to the ECU If the oxygen sensor output voltage is incorrect the ECU stops the feedback mode of the oxygen sensor Note 1 N Method the
144. 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 Torque Threads Diameter mm N m kgf m ft lb 5 3 4 4 9 0 35 0 50 30 43 in lb 6 5 9 7 8 0 60 0 80 52 69 in lb 8 14 19 1 4 1 9 10 0 13 5 10 25 34 2 6 3 5 19 0 25 12 44 61 4 5 6 2 33 45 14 73 98 7 4 10 0 54 72 16 115 155 11 5 16 0 83 115 18 165 225 17 0 23 0 125 165 20 225 325 23 0 33 0 165 240 http mototh com PERIODIC MAINTENANCE 2 11 Specifications Item Standard Service Limit Fuel System DFI Throttle Grip Free Play 2 3 mm 0 08 0 12 in Idle Speed 1 300 50 r min rpm Throttle Body Vacuum 24 0 1 33 kPa 180 10 mmHg at idle speed Bypass Screws Turn Out 0 2 1 2 for reference Air Cleaner Element Polyurethane foam Cooling System Coolant Type Recommended Permanent type of antifreeze Color Green Mixed Ratio Soft water 50 Coolant 50 Freezing Point 35 C 31 F Total Amount 1 5 L 1 6 US qt Engine Top End Valve Cle
145. under the coolant drain bolts A then remove the drain bolts The coolant will drain from the radiator and engine Remove the hose A Pour the coolant into a suitable container Install the hose Tighten the drain bolts with the gasket Replace the drain bolt gaskets with new ones Torque Coolant Drain Bolt Water Pump 9 8 N m 1 0 kgf m 87 in lb Coolant Drain Bolt Cylinder 5 9 N m 0 60 kgf m 52 in lb When filling the coolant choose a suitable mixture ratio by referring to the coolant manufacturer s directions CAUTION Soft or distilled water must be used with the an tifreeze in the cooling system If hard water is used in the system it causes scales accumulation in the water passages and consider ably reduces the efficiency of the cooling system Water and Coolant Mixture Ratio Recommended Soft Water 50 Coolant 50 Freezing Point 35 C 31 F Total Amount 1 5 L 1 6 US qt http mototh com PERIODIC MAINTENANCE 2 47 Periodic Maintenance Procedures Fill the radiator up to the filler neck A with coolant NOTE Pour in the coolant slowly so that it can expel the air from the engine and radiator Check the cooling system for leaks Tap the radiator hoses to force any air bubbles caught inside Fill the radiator up to the filler neck with coolant Fill the reserve tank up to the F full level line A with coolant an
146. valve C 4 Release the brake D NOTE The fluid level must be checked often during the chang ing operation and replenished with fresh brake fluid If the fluid in the reservoir runs out any time during the changing operation the brakes will need to be bled since air will have entered the brake line Remove the clear plastic hose Install the diaphragm and reservoir cap Tighten Torque Front Brake Reservoir Cap Screws 1 5 N m 0 15 kgf m 13 in lb Follow the procedure below to install the rear brake fluid reservoir cap correctly First 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 Apply a non permanent locking agent to the threads of the bleed valve Tighten the bleed valve and install the rubber cap Torque Bleed Valve 5 5 N m 0 56 kgf m 49 in lb After changing the fluid check the brake for good braking power no brake drag and no fluid leakage If necessary bleed the air from the lines Master Cylinder Rubber Parts Replacement Front Master Cylinder Disassembly Remove the front master cylinder see Front Master Cylin der Removal in the Brakes chapter Remove the reservoir cap and diaphragm and pour the brake fluid into a container Unscrew the loc
147. with a fine grinding compound Lapper A Valve Seat B Valve C The seating area should be marked about in the middle of the valve face If the seat area is not in the right place on the valve check to be sure the valve is the correct part If it is it may have been refaced too much replace it Be sure to remove all grinding compound before assem bly When the engine is assembled be sure to adjust the valve clearance see Valve Clearance Inspection in the Periodic Maintenance chapter http mototh com 5 32 ENGINE TOP END Valves http mototh com ENGINE TOP END 5 33 Cylinder Pistons Cylinder Removal Remove Cylinder Head see Cylinder Head Removal Bolt A Water Pipe B Water Hose Fitting C Cylinder D Cylinder Installation NOTE If a new cylinder is used use a new piston ring Install the dowel pins A and new cylinder gasket B Apply molybdenum disulfide oil solution to the cylinder bore The piston ring openings must be positioned as shown in the figure The openings of the oil ring steel rails must be about 30 40 of angle from the opening of the top ring Top Ring A Second Ring B Upper Oil Ring Steel Rail C Lower Oil Ring Steel Rail D Oil Ring Expander E Hollow F 30 40 G Slip the piston base A to hold piston level as shown in the figure and install the cylinder Special Tool Piston Base 2 3 57001 1336 Piston Remova
148. 0 of tread life 90 worn So it is false economy and unsafe to use the tires until they are bald Measure the tread depth at the center of the tread with a depth gauge A Since the tire may wear unevenly take measurement at several places If any measurement is less than the service limit replace the tire see Tire Removal Installation in the Wheels Tires chapter Tread Depth Standard Front IRC 4 2 mm 0 17 in BRIDGESTONE 4 6 mm 0 18 in DUNLOP 4 5 mm 0 18 in Rear IRC 6 5 mm 0 26 in BRIDGESTONE 7 0 mm 0 28 in DUNLOP 7 4 mm 0 29 in Service Limit Front 1 mm 0 04 in AT CH DE 1 6 mm 0 06 in Rear 2 mm 0 08 in Up to 130 km h 80 mph 3 mm 0 12 in Over 130 km h 80 mph WARNING To ensure safe handling and stability use only the recommended standard tires for replacement in flated to the standard pressure NOTE Most countries may have their own regulations a mini mum tire tread depth be sure to follow them Check and balance the wheel when a tire is replaced with a new one http mototh com 2 26 PERIODIC MAINTENANCE Periodic Maintenance Procedures Wheel Bearing Damage Inspection Raise the front wheel off the ground with the jack see Front Wheel Removal in the Wheels Tires chapter Turn the handlebar all the way to the right or left Inspect the roughness of the front wheel bearing by push ing and pulling A the wh
149. 043 3 7 in lb http mototh com 15 6 FRAME Exploded View http mototh com FRAME 15 7 Seats Rear Seat Removal Insert the ignition switch key A into the seat lock turning the key clockwise pulling the front part of the seat B up and pull the seat forward Rear Seat Installation Insert the rear seat slot A to the bracket B of the frame Insert the seat hook C into the latch hole D Push down the front part of the seat until the lock clicks Front Seat Removal Remove Side Covers see Side Cover Removal Bolts A Both Sides Pull the front seat B backward Front Seat Installation Insert the front seat hooks A into the braces B of the bracket Tighten the bolts Install the side covers see Side Cover Installation http mototh com 15 8 FRAME Fairings Lower Fairing Removal Remove Side Covers see Side Cover Removal Rivets A Bolts B Front Turn Signal Light Lead Connectors Disconnect Lower Fairings C Lower Fairing Installation Installation is the reverse of removal Run the front turn signal light lead A to the hooks B Fit A the front portion of the lower fairing in the rear por tion of the upper fairing Install the tabs B of the lower fairing into the slots C of the inner cover Windshield Removal Remove Bolts A with Washer Windshield B http mototh com FRAME 15 9 Fairings Windshi
150. 12 14 Rear Master Cylinder Removal 12 14 Rear Master Cylinder Installation 12 14 Front Master Cylinder Disassembly 12 15 Rear Master Cylinder Disassembly 12 15 Master Cylinder Assembly 12 15 Master Cylinder Inspection Visual Inspection 12 15 Brake Disc 12 16 Brake Disc Removal 12 16 Brake Disc Installation 12 16 Brake Disc Wear Inspection 12 16 Brake Disc Warp Inspection 12 16 Brake Fluid
151. 16 2 k If the tester does not read as specified replace the coil http mototh com 16 36 ELECTRICAL SYSTEM Ignition System Stick Coil Primary Peak Voltage NOTE Be sure the battery is fully charged Remove the stick coils see Stick Coil Removal but do not remove the spark plugs Measure the primary peak voltage as follows Install the new spark plug A into each stick coil B and ground them onto the engine Connect the peak voltage adapter C into the hand tester D which is set to the DC 250 V range Connect the adapter to the lead wire peak voltage adapter E which is connected between the stick coil connector and stick coil ECU F Battery G Special Tools Hand Tester 57001 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Lead Wire Peak Voltage Adapter 57001 1449 Primary Lead Connection Adapter R to lead wire peak voltage adapter R Adapter BK to lead wire peak voltage adapter W WARNING To avoid extremely high voltage shocks do not touch the spark plugs or tester connections Turn the ignition switch and the engine stop switch ON 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 times for one stick coil Stick Coil Primary Peak Voltage Standard 90 V or more Repeat the test for the other stick coil If the reading is less t
152. 16 FRAME Frame Frame Inspection Visually inspect the frame for cracks dents bending or warp If there is any damage to the frame replace it WARNING A repaired frame may fail in use possibly causing an accident If the frame is bent dented cracked or warped replace it http mototh com FRAME 15 17 Sidestand Sidestand Removal Raise the rear wheel off the ground with the stand Remove Sidestand Switch Bolt A Sidestand Switch B Spring C Sidestand Bolt D Sidestand E Sidestand Installation Apply grease to the sliding area A of the sidestand B Tighten the bolt and lock them with the nut Torque Sidestand Nut 39 N m 4 0 kgf m 29 ft lb Hook the spring C so that face the long spring end up ward Install the spring hook direction as shown in the figure Install the sidestand switch Apply a non permanent locking agent to the threads of the switch bolt and tighten it Torque Sidestand Switch Bolt 8 8 N m 0 90 kgf m 78 in lb http mototh com http mototh com ELECTRICAL SYSTEM 16 1 16 Electrical System Table of Contents Exploded View 16 4 Specifications 16 10 Special Tools and Sealant
153. 1754 0 1760 in 4 44 mm 0 175 in Inlet 4 475 4 490 mm 0 1762 0 1768 in 4 46 mm 0 176 in Valve Guide Inside Diameter Exhaust 4 500 4 512 mm 0 1772 0 1776 in 4 58 mm 0 180 in Inlet 4 500 4 512 mm 0 1772 0 1776 in 4 58 mm 0 180 in Valve Valve Guide Clearance Wobble Method Exhaust 0 07 0 12 mm 0 0028 0 0047 in 0 27 mm 0 011 in Inlet 0 02 0 08 mm 0 0008 0 0032 in 0 23 mm 0 010 in Valve Seat Cutting Angle 32 45 67 5 Valve Seating Surface Width Exhaust 0 5 1 0 mm 0 0197 0 0394 in Inlet 0 5 1 0 mm 0 0197 0 0394 in Outside Diameter Exhaust 19 3 19 5 mm 0 7598 0 7677 in Inlet 21 9 22 1 mm 0 8622 0 8701 in Valve Spring Free Length Exhaust 39 5 mm 1 555 in 38 0 mm 1 50 in Inlet 39 5 mm 1 555 in 38 0 mm 1 50 in http mototh com 5 8 ENGINE TOP END Specifications Item Standard Service Limit Cylinder Pistons Cylinder Inside Diameter 62 000 62 012 mm 2 4409 2 4414 in 62 10 mm 2 4449 in Piston Diameter 61 942 61 957 mm 2 4387 2 4392 in 61 79 mm 2 4327 in Piston Cylinder Clearance 0 043 0 070 mm 0 0017 0 0028 in Oversize Pistons and Rings 0 5 mm 0 020 in Piston Ring Groove Clearance Top 0 03 0
154. 2 If the reading is within the usable range remove the ECU and check the wiring for continuity between main harness connector Special Tool Hand Tester 57001 1394 Disconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Inlet Air Pressure Sensor Connector B Y BL lead ECU terminal 7 C BR BK lead ECU terminal 22 D If the wiring is good check the sensor for various vacuum Remove the inlet air pressure sensor A and disconnect the vacuum hose from the sensor Connect an auxiliary hose B to the inlet air pressure sen sor Temporarily install the inlet air pressure sensor Connect a digital meter C vacuum gauge D the fork oil level gauge E and the harness adapter to the inlet air pressure sensor Special Tools Fork Oil Level Gauge 57001 1290 Vacuum Gauge 57001 1369 Sensor Harness Adapter 57001 1561 Inlet Air Pressure Sensor Output Voltage Connections to Adapter Digital Meter G W sensor Y BL lead Digital Meter BK sensor BR BK lead Turn the ignition switch ON Measure the inlet air pressure sensor output voltage from various vacuum readings while pulling the handle of the fork oil level gauge Check the inlet air pressure sensor output voltage using the following formula and chart Suppose Pg Vacuum Pressure Gauge of Throttle Body Pl Local Atmospheric Pressure Absolute measured by a barometer Pv V
155. 2 50 12 53 in 323 mm 12 7 in Standard Chain Make ENUMA Type EK520SR O2 Link 106 links Brakes Brake Fluid Grade DOT4 Brake Pad Lining Thickness Front 4 5 mm 0 18 in 1 mm 0 04 in Rear 4 5 mm 0 18 in 1 mm 0 04 in Brake Light Timing Front Pulled ON Rear ON after about 10 mm 0 39 in of pedal travel Electrical System Spark Plug Type NGK CR8E Gap 0 7 0 8 mm 0 028 0 031 in http mototh com PERIODIC MAINTENANCE 2 13 Special Tools Inside Circlip Pliers 57001 143 Steering Stem Nut Wrench 57001 1100 Jack 57001 1238 Vacuum Gauge 57001 1369 Filler Cap Driver 57001 1454 Throttle Sensor Setting Adapter 57001 1538 Extension Tube 57001 1578 Jack Attachment 57001 1608 http mototh com 2 14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System DFI Air Cleaner Element Cleaning NOTE In dusty areas the element should be cleaned more frequently than the recommended interval After riding through rain or on muddily roads the ele ment should be cleaned immediately WARNING If dirt or dust is allowed to pass through into the throttle body assy the throttle may become stuck possibly causing accident CAUTION If dirt gets through into the engine excessive en gine wear and possibly engin
156. 2 mm 1 1017 1 1020 in 1 27 993 28 000 mm 1 1021 1 1024 in Crankcase Main Bearing Inside Diameter 31 000 31 016 mm 1 2205 1 2211 in http mototh com CRANKSHAFT TRANSMISSION 9 7 Specifications Item Standard Service Limit Marking 31 000 31 008 mm 1 2205 1 2208 in None 31 009 31 016 mm 1 2208 1 2211 in Crankshaft Main Bearing Insert Thickness Black 1 495 1 499 mm 0 05885 0 05902 in Blue 1 499 1 503 mm 0 05902 0 05917 in Yellow 1 503 1 507 mm 0 05917 0 05933 in Balancer Balancer Shaft Bearing Insert Journal Clearance 0 020 0 044 mm 0 0008 0 0017 in 0 07 mm 0 0028 in Balancer Shaft Journal Diameter 25 984 26 000 mm 1 0230 1 0236 in 25 96 mm 1 022 in Marking None 25 984 25 994 mm 1 0230 1 0234 in 25 995 26 000 mm 1 0234 1 0236 in Crankcase Main Bearing Inside Diameter 29 000 29 016 mm 1 1417 1 1424 in Marking 29 000 29 008 mm 1 1417 1 1420 in None 29 009 29 016 mm 1 1421 1 1424 in Balancer Shaft Bearing Insert Thickness Brown 1 495 1 499 mm 0 05885 0 05902 in Black
157. 3 ECU Power Supply Inspection 3 84 DFI Power Source 3 87 ECU Fuse Removal 3 87 ECU Fuse Installation 3 87 ECU Fuse Inspection 3 87 ECU Main Relay Removal Installation 3 87 ECU Main Relay Inspection 3 87 Fuel Line 3 88 Fuel Pressure Inspection 3 88 Fuel Flow Rate Inspection 3 89 Fuel Pump 3 91 Fuel Pump Removal
158. 30 000 mm 1 1805 1 1811 in Service Limit 29 97 mm 1 1799 in If any crankpin has worn past the service limit replace the crankshaft with a new one If the measured crankpin diameters are not less than the service limit but do not coincide with the original diameter markings on the crankshaft make new marks on it Crankpin Diameter Marks None 29 984 29 994 mm 1 1805 1 1809 in 29 995 30 000 mm 1 1809 1 1811 in Crankpin Diameter Marks or no mark http mototh com CRANKSHAFT TRANSMISSION 9 19 Crankshaft and Connecting Rods Measure the connecting rod big end inside diameter and mark each connecting rod big end in accordance with the inside diameter Tighten the connecting rod big end nuts to the specified torque see Connecting Rod Installation NOTE The mark already on the big end should almost coincide with the measurement Connecting Rod Big End Inside Diameter Marks None 33 000 33 008 mm 1 2992 1 2995 in 33 009 33 016 mm 1 2996 1 2998 in Big End Cap A Connecting Rod B Weight Mark Alphabet C Diameter Mark Around Weight Mark D or no mark Select the proper bearing insert A in accordance with the combination of the connecting rod and crankshaft coding Size Color B Bearing Insert Con rod Big End Inside Diameter Marking Crankpin Diameter Marking Size Color Part Number None Brown 92028
159. 4 Air Switching Valve Resistance Standard 20 24 at 20 C 68 F If the tester does not read as specified value replace it with a new one Connect the 12 V battery A to the air switching valve terminals as shown in the figure Blow the air to the inlet air duct A and make sure does not flow the blown air from the outlet air duct B 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 duct B If the air switching valve does not operate as described replace it with a new one NOTE To check air flow through the air switching valve just blow through the air switching valve hose inlet side http mototh com ELECTRICAL SYSTEM 16 55 Air Switching Valve Air Switching Valve Circuit 1 ECU 2 Joint Connector 2 3 Battery 12 V 8 Ah 4 Frame Ground 5 Main Fuse 30 A 6 Relay Box 7 ECU Main Relay 8 ECU Fuse 15 A 9 Fuse Box 10 Ignition Switch 11 Water proof Joint 3 12 Air Switching Valve http mototh com 16 56 ELECTRICAL SYSTEM Radiator Fan System Fan Motor Inspection Remove the fuel tank see Fuel Tank Removal in the Fuel System DFI chapter Disconnect the connector A Using an auxiliary leads supply battery power to the fan motor If the fan does not rotate the fan motor is defective and must be replaced Resistor Inspection Remove Right Lower Fairing see Lower Fai
160. 6 Fuel Pump 7 Battery 12 V 8 Ah 8 Frame Ground 9 Main Fuse 30 A 10 Fuel Pump Relay 11 Relay Box 12 ECU Main Relay 13 Ignition Fuse 10 A 14 ECU Fuse 15 A 15 Fuse Box http mototh com 3 96 FUEL SYSTEM DFI Fuel Injectors Fuel Injector Removal Installation Refer to the Throttle Body Assy Disassembly Assembly Fuel Injector Audible Inspection NOTE Be sure the battery is fully charged Remove the lower fairings see Lower Fairing Removal in the Frame chapter Start the engine and let it idle Apply the tip of a screwdriver A to the fuel injector B Put the grip end onto your ear and listen whether the fuel injector is clicking or not A sound scope can also be used The click interval becomes shorter as the engine speed rises Do the same for the other fuel injector If all the fuel injectors click at a regular intervals the fuel injectors are normal Turn the ignition switch OFF If any fuel injector does not click check the fuel injector resistance see Fuel Injector Resistance Inspection Fuel Injector Resistance Inspection Remove the fuel tank see Fuel Tank Removal Disconnect the injector connector A Connect a digital meter to the terminals of the injector B Measure the fuel injector resistance Fuel Injector Resistance Connections For Fuel Injector 1 W R BL R terminal For Fuel Injector 2 W R BL G terminal St
161. 8 Main Throttle Sensor Output Voltage Connections to Adapter Digital Meter R sensor Y W lead Digital Meter W sensor BR BK lead Start the engine and warm it up thoroughly Check idle speed to ensure the throttle opening is correct Idle Speed Standard 1 300 50 r min rpm If the idle speed is out of the specified range adjust it see Idle Speed Adjustment in the Periodic Maintenance chapter Turn the ignition switch OFF Measure the output voltage with the engine stopped and with the connector joined Turn the ignition switch ON Output Voltage Standard DC 1 020 1 050 V at idle throttle opening DC 4 185 4 385 V at full throttle opening for reference NOTE Open the throttle confirm the output voltage will be raise The standard voltage refers to the value when the volt age reading at the Input Voltage Inspection shows 5 V exactly When the input voltage reading shows other than 5 V derive a voltage range as follows Example In the case of a input voltage of 4 75 V 1 020 4 75 5 00 0 969 V 1 050 4 75 5 00 0 998 V Thus the valid range is 0 969 0 998 V Turn the ignition switch OFF If the reading is out of the standard check the main throt tle sensor resistance see Main Throttle Sensor Resis tance Inspection http mototh com FUEL SYSTEM DFI 3 43 Main Throttle Sensor Service Code 11 If the reading is within th
162. 8 in 1 mm 0 04 in Brake Discs Thickness Front 4 3 4 7 mm 0 17 0 19 in 4 0 mm 0 16 in Rear 4 8 5 2 mm 0 19 0 20 in 4 5 mm 0 18 in Runout TIR 0 15 mm 0 006 in or less TIR 0 3 mm 0 01 in Brake Fluid Grade DOT4 http mototh com BRAKES 12 7 Special Tools Inside Circlip Pliers 57001 143 Jack 57001 1238 Jack Attachment 57001 1608 http mototh com 12 8 BRAKES Brake Lever Brake Pedal Brake Pedal Position Inspection Check that the brake pedal A is in the correct position Footpeg B Pedal Position Standard About 40 mm 1 57 in C below top of footpeg If it is incorrect adjust the brake pedal position Brake Pedal Position Adjustment NOTE Usually it is not necessary to adjust the pedal position but always adjust it when push rod locknut has been loosened Loosen the locknut A and turn the push rod with the hex head B to achieve the correct pedal position If the length C shown is 80 1 mm 3 15 0 04 in the pedal position will be within the standard range Tighten Torque Rear Master Cylinder Push Rod Locknut 17 2 N m 1 8 kgf m 13 ft lb Check the brake light switch operation see Brake Light Switch Operation Inspection in the Periodic Maintenance chapter Brake Pedal Removal Remove Right Front Footpeg Bracket Bolts A Cotter Pin B Joint Pin C Rear Brake Light Switch Spri
163. 9 If the above chargers are not available use equivalent one NOTE Charging rates will vary depending on how long the battery has been stored temperature and the type of charger used Let battery sit 30 minutes after initial charge then check voltage using a voltmeter If it is not at least 12 8 V repeat charging cycle http mototh com ELECTRICAL SYSTEM 16 21 Battery After charging is completed press down firmly with both hands to seat the strip of caps A into the battery don t pound or hammer When properly installed the strip of the caps will be level with the top of the battery CAUTION Once the strip of the caps is installed onto the bat tery never remove the caps nor add water or elec trolyte to the battery NOTE To 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 8 V repeat the charging cycle and load test If still below 12 8 V the battery is defective http mototh com 16 22 ELECTRICAL SYSTEM Battery Precautions 1 No need of topping up No topping up is necessary in this battery until it ends its life under normal use Forcibly prying off the seal cap to add water is very dangerous Never do that 2 Refreshing charge If an engine will not start a horn sounds weak or lamps are dim it indicates the battery has been discharged Give re
164. Aiming Inspection in the Periodic Maintenance chapter Headlight Bulb Replacement Remove Upper Fairing see Upper Fairing Removal in the Frame chapter Headlight Bulb Dust Cover A Remove Hook A Headlight Bulb B CAUTION When handling the quartz halogen bulb never touch the glass portion with bare hands Always use a clean cloth Oil contamination from hands or dirty rags can reduce bulb life or cause the bulb to explode NOTE Clean off any contamination that inadvertently gets on the bulb with alcohol or soap and water solution Replace the headlight bulb Fit the projection A of the bulb in the hollow B of the headlight http mototh com 16 48 ELECTRICAL SYSTEM Lighting System Install the hook A Fit the dust cover A onto the bulb B firmly as shown in the figure Good C Bad D After installation adjust the headlight aim see Headlight Aiming Inspection in the Periodic Maintenance chapter Headlight Removal Installation Refer to the Upper Fairing Disassembly Assembly in the Frame chapter After installing confirm the damper A between the head light B and upper fairing C as shown in the figure City Light Bulb Replacement Remove the upper fairing see Upper Fairing Removal in the Frame chapter Pull out the socket A together with the bulb http mototh com ELECTRICAL SYSTEM 16 49 Lighting System Pull out the bulb A s
165. CU Removal Installation Subthrottle Sensor Circuit 1 ECU 2 Subthrottle Sensor 3 Water proof Joint 2 4 Water proof Joint 1 http mototh com 3 66 FUEL SYSTEM DFI Oxygen Sensor not activated Service Code 33 Oxygen Sensor Removal Installation Refer to the Oxygen Sensor Removal Installation in the Electrical System chapter Oxygen Sensor Inspection Warm up the engine thoroughly until the radiator fan starts Turn the ignition switch OFF Remove the right lower fairing see Lower Fairing Re moval in the Frame chapter Disconnect the oxygen sensor lead connector and con nect the harness adapter A between these connectors Special Tool Oxygen Sensor Measuring Adapter 57001 1682 Connect a digital meter to the harness adapter leads Oxygen Sensor Output Voltage Connections to Adapter Digital Meter BL W sensor BL lead Digital Meter BR BK sensor W lead Remove the fuel tank see Fuel Tank Removal Separate the hose A from the air cleaner housing Separate the hose A from the air suction valve cover Do not disconnect the air switching valve connector A http mototh com FUEL SYSTEM DFI 3 67 Oxygen Sensor not activated Service Code 33 Install the suitable plug A on the fitting of the air suction valve cover and shut off the secondary air Install the fuel tank see Fuel Tank Installation Start the engine
166. DFI control method from medium to heavy engine load When the engine load is light like at idling or low speed the ECU determines the injection quantity by calculating from the throttle vacuum inlet air pressure sensor output voltage and engine speed crankshaft sensor output voltage This method is called D J method As the engine speed increases and the engine load turns middle to heavy the ECU determines the injection quantity by calculating from the throttle opening main throttle sensor output voltage and the engine speed This method is called N method This depends on the number of stopped cylinders http mototh com FUEL SYSTEM DFI 3 41 Main Throttle Sensor Service Code 11 Main Throttle Sensor Removal Adjustment CAUTION Do not remove or adjust the main throttle sensor A since it has been adjusted and set with precision at the factory Never drop the throttle body assy especially on a hard surface Such a shock to the main throttle sen sor can damage it Main Throttle Sensor Input Voltage Inspection NOTE Be sure the battery is fully charged Turn the ignition switch OFF Remove the right lower fairing see Lower Fairing Re moval in the Frame chapter Disconnect the main throttle sensor connector and con nect the harness adapter A between these connectors Special Tool Throttle Sensor Setting Adapter 57001 1538 Connect a digital meter to the harness adapter leads Main Thr
167. Hose 57001 1607 WARNING Do not try to start the engine with the fuel hoses disconnected Connect the fuel pump lead connector Turn the engine stop switch run position Turn the ignition switch ON The fuel pump should operate for 3 seconds and then should stop NOTE After turning on the engine stop switch and ignition switch inspect the fuel leakage from the connected portion of the special tools CAUTION Do not drive the fuel pump 3 seconds or more with out the fuel in the fuel tank If the fuel pump is driven without the fuel it may be damaged Start the engine and let it idle Measure the fuel pressure with the engine idling Fuel Pressure with Engine Idling Standard 294 kPa 3 0 kgf cm 43 psi http mototh com FUEL SYSTEM DFI 3 89 Fuel Line NOTE The gauge needle will fluctuate Read the pressure at the average of the maximum and minimum indications Turn the ignition switch OFF If the fuel pressure is much higher than specified replace the fuel pump because the fuel pressure regulator in the fuel pump have been clogged or stuck If the fuel pressure is much lower than specified check the following Fuel Line Leakage see Fuel Injector Fuel Line Inspec tion Amount of Fuel Flow see Fuel Flow Rate Inspection After above checks measure the fuel pressure again Remove the fuel pressure gauge hoses and adapter Install Fuel Hose see Fuel Hose R
168. Installation Apply grease to the inside of the oil seals and O rings Tighten Torque Tie Rod Nuts 59 N m 6 0 kgf m 44 ft lb Install the removed parts see appropriate chapters Rocker Arm Removal Squeeze the brake lever slowly and hold it with a band Remove the lower fairings see Lower Fairing Removal in the Frame chapter Raise the rear wheel off the ground with the jack Special Tools Jack 57001 1238 Jack Attachment 57001 1608 Remove Lower Rear Shock Absorber Nut and Bolt A Lower Tie Rod Nut and Bolt B Rocker Arm Nut and Bolt C Rocker Arm D Rocker Arm Installation Apply grease to the inside of the oil seals and O rings Tighten Torque Uni Trak Rocker Arm Nut 59 N m 6 0 kgf m 44 ft lb Tie Rod Nuts 59 N m 6 0 kgf m 44 ft lb Rear Shock Absorber Nuts 59 N m 6 0 kgf m 44 ft lb Install the removed parts see appropriate chapters Tie Rod Rocker Arm Bushing Inspection The bushings wear so little that the wear is difficult to mea sure Instead inspect the bushings for abrasion color change or other damage If there is any doubt as to the condition of either bushings replace the bushing with a new one http mototh com SUSPENSION 13 19 Tie Rod Rocker Arm Tie Rod Rocker Arm Sleeve Inspection Visually inspect the sleeves If there is visible damage replace the sleeve with a new one http mototh com http moto
169. M DFI DFI Parts Location Fuse Box Oxygen Sensor Heater Fuse 10 A ECU Fuse 15 A Ignition Fuse 10 A Fan Fuse 10 A A Battery 12 V 8 Ah B Relay Box ECU Main Relay Fan Relay Fuel Pump Re lay C ECU D Kawasaki Diagnostic System Connector E Self diagnosis Terminal F Fuel Pump A http mototh com FUEL SYSTEM DFI 3 17 Specifications Item Standard Digital Fuel Injection System Idle Speed 1 300 50 r min rpm Throttle Body Assy Type Two barrel type Bore 28 mm 1 10 in Throttle Body Vacuum 24 0 1 33 kPa 180 10 mmHg Bypass Screws Turn Out 0 2 1 2 for reference ECU Make DENSO Fuel Pressure High Pressure Line 294 kPa 3 0 kgf cm 43 psi with engine idling Fuel Pump Discharge 17 mL 0 57 US oz or more for 3 seconds Fuel Injectors Type INP 288 Nozzle Type Fine atomizing type with 8 holes Resistance About 11 7 12 3 at 20 C 68 F Main Throttle Sensor Input Voltage DC 4 75 5 25 V Output Voltage DC 1 020 1 050 V at idle throttle opening DC 4 185 4 385 V at full throttle opening for reference Resistance 4 6 k Inlet Air Pressure Sensor Input Voltage DC 4 75 5 25 V Output Voltage DC 3 80 4 20 V at standard atmospheric pressure see this text for details Inlet Air Temperature Sensor Output Voltage About DC 2 25 2 50 V at inlet air temperature 20 C 68 F Resistance 5 4
170. M DFI Radiator Fan Relay Service Code 56 Radiator Fan Relay Circuit 1 ECU 2 Joint Connector 2 3 Battery 12 V 8 Ah 4 Frame Ground 5 Main Fuse 30 A 6 Joint Connector 1 7 Relay Box 8 Fan Relay 9 ECU Fuse 15 A 10 Fan Fuse 10 A 11 Fuse Box 12 Resistor 13 Fan Motor 14 Water proof Joint 3 15 Water proof Joint 1 16 Water Temperature Sensor http mototh com FUEL SYSTEM DFI 3 73 Subthrottle Valve Actuator Service Code 62 Subthrottle Valve Actuator Removal CAUTION Do not remove the subthrottle valve actuator A since it has been adjusted and set with precision at the factory Never drop the throttle body assy especially on a hard surface Such a shock to the subthrottle valve actuator can damage it Subthrottle Valve Actuator Inspection NOTE Be sure the battery is fully charged Remove the throttle body assy see Throttle Body Assy Removal Connect the following parts temporary Main Throttle Sensor Connector A Subthrottle Sensor Connector B Subthrottle Valve Actuator Connector C Turn the ignition switch ON Check to see that all the subthrottle valves D open and close smoothly Turn the ignition switch OFF If the subthrottle valves do not operate check the sub throttle valve actuator resistance see Subthrottle Valve Actuator Resistance Inspection Subthrottle Valve Actuator Resistance Inspection Turn the ignition switch OFF Remove the fuel ta
171. Ninja 250R Motorcycle Service Manual http mototh com http mototh com 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 1 j Periodic Maintenance 2 j Fuel System DFI 3 j Cooling System 4 j Engine Top End 5 j Clutch 6 j Engine Lubrication System 7 j Engine Removal Installation 8 j Crankshaft Transmission 9 j Wheels Tires 10 j Final Drive 11 j Brakes 12 j Suspension 13 j Steering 14 j Frame 15 j Electrical System 16 j Appendix 17 j http mototh com http mototh com Ninja 250R Motorcycle Service Manual All rights reserved No parts of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Quality Assurance Division Consumer Products amp Machinery Company Kawasaki Heavy Industries Ltd Japan No liability can be accepted for any inaccuracies or omissions in this publication although every possible care has been taken to make it as complete and accurate as possible Th
172. Plate Light Lead Connector 2 Tail Brake Light Lead Connector 3 ECU Lead Connectors 4 Rear Brake Light Switch Lead Connector 5 Rear Right Turn Signal Light Lead Connector 6 Rear Left Turn Signal Light Lead Connector 7 Kawasaki Diagnostic System Connector 8 Bands 9 Battery Negative Cable 10 Alternator Lead Connector 11 Crankshaft Sensor Lead Connector 12 Fuel Injector 2 Lead Connector 13 Front Right Turn Signal Light Lead Connector 14 Subthrottle Sensor Lead Connector 15 Main Throttle Sensor Lead Connector 16 Oxygen Sensor Lead Connector 17 Stick Coil 1 Lead Connector 18 Ignition Switch Lead Connector 19 Air Switching Valve Lead Connector 20 Frame Ground Terminal 21 Vehicle down Sensor Lead Connector 22 Right Switch Housing Lead Connector 23 Resistor Lead Connector http mototh com 17 6 APPENDIX Cable Wire and Hose Routing http mototh com APPENDIX 17 7 Cable Wire and Hose Routing 1 Right Switch Housing Lead 2 Guide Run the left switch housing lead through into the guide 3 Guide Run the right switch housing lead through into the guide 4 Clutch Cable 5 Left Switch Housing Lead 6 Guide Run the clutch cable and left switch housing lead through into the guide 7 Guide Run the throttle cables right switch housing and ignition switch leads through into the guide 8 Brake Hose 9 Throttle Cable Accelerator 10 Throttle Cable Decelerator 11 Ignition Switch Lead 12 Speedometer C
173. Plugs Alternator Cover Hand Tighten 5 Regulator Rectifier Bolts 9 8 1 0 87 in lb 6 Spark Plugs 13 1 3 115 in lb 7 Speed Sensor Bolt 7 8 0 80 69 in lb L 8 Starter Motor Cable Terminal Nut 9 8 1 0 87 in lb 9 Starter Motor Clutch Bolts 34 3 3 5 25 L 10 Starter Motor Mounting Bolts 9 8 1 0 87 in lb 11 Starter Motor Terminal Locknut 6 9 0 70 61 in lb 12 Starter Motor Through Bolts 3 4 0 35 30 in lb 13 Starter Relay Cable Terminal Nuts 5 0 0 51 44 in lb 14 Stator Coil Bolts 12 1 2 106 in lb G Apply grease L Apply a non permanent locking agent M Apply molybdenum disulfide grease R Replacement Parts S Follow the specified tightening sequence SS Apply silicone sealant http mototh com 16 8 ELECTRICAL SYSTEM Exploded View http mototh com ELECTRICAL SYSTEM 16 9 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Fuel Pump Bolts 9 8 1 0 87 in lb L 2 Neutral Switch 15 1 5 11 3 Oil Pressure Switch 15 1 5 11 SS 4 Oil Pressure Switch Terminal Bolt 1 5 0 15 13 in lb G 5 Oxygen Sensor 44 1 4 50 32 5 6 Resistor Bolt 7 8 0 80 69 in lb 7 Sidestand Switch Bolt 8 8 0 90 78 in lb L 8 Water Temperature Sensor 25 2 5 18 G Apply grease L Apply a non permanent locking agent R Replacement Parts SS Apply silicone sealant http mototh com 16 10 ELECTRICAL SYSTEM
174. STEM DFI 3 105 Throttle Body Assy Throttle Body Assy Disassembly 1 Subthrottle Valve Actuator 2 Subthrottle Sensor 3 Main Throttle Sensor 4 Throttle Body Assy 5 Fuel Injectors 6 Delivery Pipe Assy CAUTION Do not remove disassemble or adjust the main throttle sensor subthrottle sensor subthrottle valve actuator throttle link mechanism and throttle body assy because they are adjust or set surely at the manufacturer Adjustment of these parts could result in poor performance requiring replacement of the throttle body assy Remove the throttle body assy see Throttle Body Assy Removal Cut the band A Remove the screws B to pull out the injectors from the throttle body assy together with the delivery pipe assy C NOTE Do not damage the insertion portions of the injectors when they are pulled out from the throttle body http mototh com 3 106 FUEL SYSTEM DFI Throttle Body Assy Pull out the injectors A from the delivery pipe assy B NOTE Do not damage the insertion portions of the injectors when they are pulled out from the delivery pipe assy CAUTION Never drop the fuel injector especially on a hard surface Such a shock to the injector can damage it Throttle Body Assy Assembly Before assembling blow away dirt or dust from the throttle body and delivery pipe by applying compressed air Replace the O rings A of each injector B with new ones Appl
175. Specifications Item Standard Battery Type Sealed Battery Model Name YTX9 BS Capacity 12 V 8 Ah Voltage 12 8 V or more Charging System Type Three phase AC Alternator Output Voltage 40 V or more at 4 000 r min rpm Stator Coil Resistance 0 05 0 6 at 20 C 68 F Charging Voltage 13 9 14 9 V Regulator Rectifier Output Voltage Ignition System Crankshaft Sensor Resistance 100 150 Crankshaft Sensor Peak Voltage 4 5 V or more Stick Coil Primary Winding Resistance 1 0 1 6 Secondary Winding Resistance 10 8 16 2 k Primary Peak Voltage 90 V or more Spark Plug Type NGK CR8E Gap 0 7 0 8 mm 0 028 0 031 in Electric Starter System Starter Motor Brush Length 10 mm 0 39 in Service Limit 5 0 mm 0 20 in Commutator Diameter 28 mm 1 10 in Service Limit 27 mm 1 06 in Air Switching Valve Resistance 20 24 at 20 C 68 F Switches and Sensors Rear Brake Light Switch Timing ON after about 10 mm 0 39 in of pedal travel Engine Oil Pressure Switch Connections When engine is stopped ON When engine is running OFF Water Temperature Sensor Resistance In the text http mototh com ELECTRICAL SYSTEM 16 11 Special Tools and Sealant Flywheel Holder 57001 1313 Hand Tester 57001 1394 Flywheel Puller Assembly M38 1 5 M35 1 5 57001 1405 Peak Voltage Adapter 57001 1415 Lead Wire
176. Voltage Service Code 94 Oxygen Sensor Circuit 1 Ignition Switch 2 Water proof Joint 3 3 Water proof Joint 1 4 Oxygen Sensor 5 ECU 6 Joint Connector 2 7 Battery 12 V 8 Ah 8 Frame Ground 9 Main Fuse 30 A 10 Oxygen Sensor Heater Fuse 10 A 11 Fuse Box http mototh com 3 82 FUEL SYSTEM DFI FI Indicator Light Light Inspection Refer to the Lights and Switches Operation Inspection in the Periodic Maintenance chapter FI Indicator Light Circuit 1 Ignition Switch 2 Water proof Joint 3 3 ECU 4 Joint Connector 2 5 Battery 12 V 8 Ah 6 Frame Ground 7 Main Fuse 30 A 8 Ignition Fuse 10 A 9 Fuse Box 10 FI Indicator Light http mototh com FUEL SYSTEM DFI 3 83 ECU ECU Identification Most countries have their own regulations so each ECU has different characteristic So do not confuse ECU with each other and use only the ECU for your model Other wise the motorcycle cannot clear the regulation ECU Identification Part Number A Specification 21175 0199 WVTA FULL N GB WVTA FULL N ECU Removal CAUTION Never drop the ECU especially on a hard surface Such a shock to the ECU can damage it Remove Seat Covers see Seat Cover Removal in the Frame chapter Bolts A Brackets B Lift up the ECU A with rubber protector B Remove ECU Connectors A Disconnect ECU B ECU Installation Install ECU A In Rubber Protector B ECU Connecto
177. WARNING This battery is sealed type Never remove sealing cap B even at charging Never add water Charge with current and time as stated below Terminal Voltage 11 5 less than 12 8 V Standard Charge 0 9 A 5 10 h see following chart Quick Charge 4 A 1 h 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 0 9 A 20 h NOTE Increase the charging voltage to a maximum voltage of 25 V if the battery will not accept current initially Charge for no more than 5 minutes at the increased voltage then check if the battery is drawing current If the battery will accept current decrease the voltage and charge by the standard charging method described on the battery case If the battery will not accept current after 5 min utes replace the battery Battery A Battery Charger B Standard Value C Current starts to flow D Determine the battery condition after refresh charge Determine the condition of the battery left for 30 minutes after completion of the charge by measuring the terminal voltage according to the table below Criteria Judgement 12 8 V or higher Good 12 0 lower than 12 8 V Charge insufficient Recharge lower than 12 0 V Unserviceable Replace http mototh com 16 24 ELECTRICAL SYSTEM Charging System Alternator Cover Removal Remove Left Lower
178. a hole C in the handlebar Tighten Torque Switch Housing Screws 3 5 N m 0 36 kgf m 31 in lb Apply a non permanent locking agent to the right handle bar weight screw and tighten it Install the front brake master cylinder see Front Master Cylinder Installation in the Brakes chapter http mototh com FRAME 15 1 15 Frame Table of Contents Exploded View 15 2 Seats 15 7 Rear Seat Removal 15 7 Rear Seat Installation 15 7 Front Seat Removal 15 7 Front Seat Installation 15 7 Fairings 15 8 Lower Fairing Removal 15 8 Lower Fa
179. able 13 Guide Run the speedometer cable through into the guide 14 Guide Run the speedometer cable through into the guide 15 Guides Run the main harness through into the guides 16 Regulator Rectifier Lead Connector 17 Left Switch Housing Lead Connector 18 Guide Run the throttle cables and inlet air pressure sensor lead through into the guide 19 Guides Run the main harness through inside the guides 20 Inlet Air Pressure Sensor Lead Connector 21 Guide Run the horn lead through into the guide 22 Horn Lead Connectors 23 Guide Run the main harness through inside the guide 24 Band Hold the main harness together with the frame pipe 25 Clamp Hold the main harness and insert the clamp into the frame http mototh com 17 8 APPENDIX Cable Wire and Hose Routing http mototh com APPENDIX 17 9 Cable Wire and Hose Routing 1 Speedometer Cable 2 Guide Run the headlight high lead through into the guide 3 Headlight High Connector 4 Band Hold the headlight high lead and insert the band into the upper fairing bracket 5 Guide Run the meter unit harness and main harness through into the guide 6 Band Hold the meter unit harness and main harness and insert the band into the upper fairing bracket 7 Starter Lockout Switch Lead 8 Meter Connectors 9 Left Switch Housing Lead 10 Headlight Low Connector 11 Fuel Tank Breather Hose 12 Guide Run the fuel tank breather hose through into th
180. ace Such a shock to the subthrottle sen sor can damage it Subthrottle Sensor Input Voltage Inspection NOTE Be sure the battery is fully charged Turn the ignition switch OFF Disconnect the subthrottle sensor and connect the har ness adapter A between these connectors Special Tool Throttle Sensor Setting Adapter 57001 1538 Connect a digital meter to the harness adapter leads Subthrottle Sensor Input Voltage Connections to Adapter Digital Meter BK sensor BL lead Digital Meter W sensor BR BK lead Measure the input voltage with the engine stopped and with the connector joined Turn the ignition switch ON Input Voltage Standard DC 4 75 5 25 V Turn the ignition switch OFF If the reading is within the standard check the output volt age see Subthrottle Sensor Output Voltage Inspection If the reading is out of the standard remove the ECU and check the wiring for continuity between main harness connectors Special Tool Hand Tester 57001 1394 Disconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Subthrottle Sensor Connector B BL lead ECU terminal 8 C BR BK lead ECU terminal 22 D If the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see ECU Removal Installation http mototh com
181. acuum Pressure Absolute of Throttle Body Vv Sensor Output Voltage V http mototh com FUEL SYSTEM DFI 3 47 Inlet Air Pressure Sensor Service Code 12 then Pv Pl Pg For example suppose the following data is obtained Pg 8 cmHg Vacuum Gauge Reading Pl 70 cmHg Barometer Reading Vv 3 2 V Digital Meter Reading then Pv 70 8 62 cmHg Absolute Plot this Pv 62 cmHg at a point 1 on the chart and draw a vertical line through the point Then you can get the usable range 2 of the sensor output voltage Usable range 3 08 3 48 V Plot Vv 3 2 V on the vertical line Point 3 Results In the chart Vv is within the usable range and the sensor is normal If the reading is out of the usable range replace the sen sor If the reading is within the usable range check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see ECU Removal Installation http mototh com 3 48 FUEL SYSTEM DFI Inlet Air Pressure Sensor Service Code 12 ID Idling Ps Standard Atmospheric Pressure Absolute Pv Throttle Vacuum Pressure Absolute ST Standard of Sensor Output Voltage V TO Throttle Full Open UR Usable Range of Sensor Output Voltage V Vv Inlet Air Pressure Sensor Output Voltage V Digital Meter Reading http mototh com FUEL SYSTEM DFI 3 49 Inlet Air Pressure Sensor Service Code 12
182. ake sure that the fuel pump operates make light sounds for 3 seconds and then stops Turn the ignition switch OFF If the pump does not operate as described above check the operating voltage see Fuel Pump Operating Voltage Inspection http mototh com FUEL SYSTEM DFI 3 93 Fuel Pump Fuel Pump Operating Voltage Inspection NOTE Be sure the battery is fully charged Turn the ignition switch OFF Remove the fuel tank bolts see Fuel Tank Removal Disconnect the fuel pump lead connector and connect the harness adapter A between these connectors as shown in the figure Main Harness B Fuel Pump C Special Tool Measuring Adapter 57001 1700 Connect a digital meter D to the harness adapter leads Fuel Pump Operating Voltage Connections to Adapter Digital Meter R pump R lead Digital Meter BK pump BK lead Measure the operating voltage with engine stopped and with the connector joined Turn the engine stop switch run position Turn the ignition switch ON Operating Voltage Standard Battery Voltage for 3 seconds and then 0 V Turn the ignition switch OFF If the reading stays on battery voltage and never shows 0 V check the fuel pump relay see Relay Circuit Inspection in the Electrical System chapter If the pump relay is normal check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are g
183. al System Alternator Cover Bolts 9 8 1 0 87 in lb Alternator Rotor Bolt 88 2 9 0 65 S Crankshaft Sensor Screws 3 0 0 31 27 in lb Front Brake Light Switch Screw 1 2 0 12 11 in lb Fuel Pump Bolts 9 8 1 0 87 in lb L License Plate Light Cover Screws 0 90 0 092 8 0 in lb License Plate Light Mounting Screws 1 2 0 12 11 in lb Neutral Switch 15 1 5 11 Oil Pressure Switch 15 1 5 11 SS Oil Pressure Switch Terminal Bolt 1 5 0 15 13 in lb G Oxygen Sensor 44 1 4 50 32 5 Plugs Alternator Cover Hand Tighten Regulator Rectifier Bolts 9 8 1 0 87 in lb Resistor Bolt 7 8 0 80 69 in lb Sidestand Switch Bolt 8 8 0 90 78 in lb L Spark Plugs 13 1 3 115 in lb Speed Sensor Bolt 7 8 0 80 69 in lb L http mototh com 2 10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener N m kgf m ft lb Remarks Starter Motor Cable Terminal Nut 9 8 1 0 87 in lb Starter Motor Clutch Bolts 34 3 3 5 25 L Starter Motor Mounting Bolts 9 8 1 0 87 in lb Starter Motor Terminal Locknut 6 9 0 70 61 in lb Starter Motor Through Bolts 3 4 0 35 30 in lb Starter Relay Cable Terminal Nuts 5 0 0 51 44 in lb Stator Coil Bolts 12 1 2 106 in lb Switch Housing Screws 3 5 0 36 31 in lb Tail Brake Light Mounting Bolts 5 9 0 60 52 in lb Water Temperature Sensor 25 2 5 18 The table below relating tightening
184. alant Outside Circlip Pliers 57001 144 Oil Pressure Gauge 10 kgf cm 57001 164 Oil Pressure Gauge Adapter M18 1 5 57001 1278 Kawasaki Bond Silicone Sealant 56019 120 http mototh com ENGINE LUBRICATION SYSTEM 7 7 Engine Oil and Oil Filter 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 Check that the engine oil level is between the upper A and lower B levels in the gauge NOTE Situate the motorcycle so that it is perpendicular to the ground If the motorcycle has just been used wait several min utes for all the oil to drain down If the oil has just been changed start the engine and run it for several minutes at idle speed This fills the oil filter with oil Stop the engine then wait several minutes until the oil settles CAUTION Racing the engine before the oil reaches every part can cause engine seizure If the engine oil gets extremely low or if the oil pump or oil passages clog up or otherwise do not function properly the oil pressure warning indicator light will light If this light stays on when the engine is running above idle speed stop the engine immedi ately and find the cause If the oil level is too high remove the excess oil using a syringe or some other suitable device If the oil level i
185. alve stem oil seal and or damaged piston oil rings This may be indicated by white exhaust smoke Remove the carbon deposits and replace damaged parts if necessary Cylinder compression is higher than usable range Incorrect cylinder head gasket thickness Replace the gasket with a standard part Gas leakage around cylinder head Replace damaged check gasket and cylinder head warp Bad condition of valve seating Repair if necessary Incorrect valve clearance Adjust the valve clearance Incorrect piston cylinder clearance Replace the piston and or cylinder Piston seizure Inspect the cylinder and replace repair the cylinder and or piston as necessary Cylinder compression is lower than usable range Bad condition of piston ring and or piston ring grooves Replace the piston and or the piston rings http mototh com ENGINE TOP END 5 23 Cylinder Head Cylinder Head Removal Remove Coolant Drain see Coolant Change in the Periodic Maintenance chapter Cylinder Head Cover see Cylinder Head Cover Re moval Camshafts see Camshaft Removal Radiator see Radiator and Radiator Fan Removal in the Cooling System chapter Throttle Body Assy see Throttle Body Assy Removal in the Fuel System DFI chapter Exhaust Pipe see Exhaust Pipe Removal Remove the water pipe A Remove Front Camshaft Chain Guide A Rear Camshaft Chain Guide Bolt B Rear Camshaft Chain Guide C Remove En
186. andard About 11 7 12 3 at 20 C 68 F If the reading is out of the standard replace the injector If the reading is within the standard check the power source voltage see Fuel Injector Power Source Voltage Inspection http mototh com FUEL SYSTEM DFI 3 97 Fuel Injectors Fuel Injector Power Source Voltage Inspection NOTE Be sure the battery is fully charged Turn the ignition switch OFF Disconnect the injector connector and connect the har ness adapter A between these connectors as shown in the figure Main Harness B Fuel Injector 1 C Special Tool Measuring Adapter 57001 1700 Connect a digital meter D to the harness adapter leads Fuel Injector Power Source Voltage Connections to Adapter For Fuel Injector 1 2 Digital Meter R injector W R lead Digital Meter Battery terminal Measure the power source voltage with the engine stopped Turn the engine stop switch to run position Turn the ignition switch ON Power Source Voltage Standard Battery Voltage for 3 seconds and then 0 V Turn the ignition switch OFF If the reading stays on battery voltage and never shows 0 V check the fuel pump relay see Relay Circuit Inspection in the Electrical System chapter If the pump relay is normal check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see
187. approximate 12 mm 0 47 in C Tighten Torque Lower Front Fork Clamp Bolts 30 N m 3 1 kgf m 22 ft lb Upper Front Fork Clamp Bolts 20 N m 2 0 kgf m 15 ft lb Install the removed parts see appropriate chapters http mototh com SUSPENSION 13 9 Front Fork Front Fork Oil Change Remove Front Fork see Front Fork Removal Snap Ring A see Front Fork Removal Top Plug B with O ring C Collar D Fork Spring Seat E Fork Spring F Compress A the fork B upside down to draw out the oil into the suitable container C Hold the fork tube upright pour in the type and amount of fork oil specified Fork Oil Viscosity SHOWA SS08 or equivalent SAE 10W Amount Per Side When changing oil Approx 310 mL 10 5 US oz After disassembly and completely dry 360 2 5 mL 12 2 0 085 US oz NOTE Move the outer tube up and down a few times to remove the air that is trapped in the fork oil in order to stabilize the oil level http mototh com 13 10 SUSPENSION Front Fork Hold the outer tube vertically in a vise and compress the fork completely Wait until the oil level stabilizes Use the fork oil level gauge A to measure the distance between the top of the inner tube to the oil level Special Tool Fork Oil Level Gauge 57001 1290 Set the oil level gauge stopper B so that the distance C from the bottom of the stopper to the lower end
188. ar 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 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 Battery charging condition can be checked by measuring battery terminal voltage with a digital voltmeter A Remove the battery see Battery Removal Measure the battery terminal voltage NOTE Measure with a digital voltmeter which can be read one decimal place voltage http mototh com ELECTRICAL SYSTEM 16 23 Battery If the reading is 12 8 V or more no refresh charge is re quired however if the read is below the specified refresh charge is required Battery Terminal Voltage Standard 12 8 V or more Terminal Voltage V A Battery Charge Rate B Good C Refresh charge is required D Refreshing Charge Remove the battery A see Battery Removal Do refresh charge by following method according to the battery terminal voltage
189. arance Exhaust 0 22 0 29 mm 0 0087 0 0114 in Inlet 0 15 0 24 mm 0 0059 0 0094 in Clutch Clutch Lever Free Play 2 3 mm 0 08 0 12 in Engine Lubrication System Engine Oil Type API SE SF or SG API SH SJ or SL with JASO MA Viscosity SAE 10W 40 Capacity 1 3 L 1 4 US qt when filter is not removed 1 6 L 1 7 US qt when filter is removed 1 7 L 1 8 US qt when engine is completely dry Level Between upper and lower level lines Wait 2 3 minutes after idling or running Wheels Tires Tread Depth Front IRC 4 2 mm 0 17 in BRIDGESTONE 4 6 mm 0 18 in DUNLOP 4 5 mm 0 18 in 1 mm 0 04 in AT CH DE 1 6 mm 0 06 in Rear IRC 6 5 mm 0 26 in BRIDGESTONE 7 0 mm 0 28 in DUNLOP 7 4 mm 0 29 in Up to 130 km h 80 mph 2 mm 0 08 in Over 130 km h 80 mph 3 mm 0 12 in http mototh com 2 12 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Air Pressure when Cold Front Up to 170 kg 375 lb load 200 kPa 2 00 kgf cm 28 psi Rear Up to 170 kg 375 lb load 225 kPa 2 25 kgf cm 32 psi Final Drive Drive Chain Slack 20 30 mm 0 8 1 2 in Drive Chain Wear 20 link Length 317 5 318 2 mm 1
190. ation 3 77 Oxygen Sensor Heater Resistance Inspection 3 77 Oxygen Sensor Heater Power Source Voltage Inspection 3 77 Oxygen Sensor Incorrect Output Voltage Service Code 94 3 79 Oxygen Sensor Removal Installation 3 79 Oxygen Sensor Inspection 3 79 FI Indicator Light 3 82 Light Inspection 3 82 ECU 3 83 ECU Identification 3 83 ECU Removal 3 83 ECU Installation 3 8
191. ation Inspection 2 32 Suspension 2 32 Front Forks Rear Shock Absorber Operation Inspection 2 32 Front Fork Oil Leak Inspection 2 33 Rear Shock Absorber Oil Leak Inspection 2 33 Rocker Arm Operation Inspection 2 33 Tie Rod Operation Inspection 2 33 Swingarm Pivot Lubrication 2 34 Steering 2 34 Steering Play Inspection 2 34 Steering Play Adjustment 2 35 http mototh com 2 2 PERIODIC MAINTENANCE Steering Stem Bearing Lubrication
192. ation points are called out throughout this manual apply the specific oil or grease as specified Direction of Engine Rotation When rotating the crankshaft by hand the free play amount of rotating direction will affect the adjustment Ro tate the crankshaft to positive direction clockwise viewed from output side Electrical Wires A two color wire is identified first by the primary color and then the stripe color Unless instructed otherwise electrical wires must be connected to those of the same color Instrument Use a meter that has enough accuracy for an accurate measurement Read the manufacture s instructions thor oughly before using the meter Incorrect values may lead to improper adjustments http mototh com GENERAL INFORMATION 1 7 Model Identification EX250K8F Left Side View EX250K8F Right Side View Frame Number Engine Number http mototh com 1 8 GENERAL INFORMATION General Specifications Items EX250K8F Dimensions Overall Length 2 085 mm 82 09 in Overall Width 715 mm 28 15 in Overall Height 1 115 mm 43 90 in Wheelbase 1 400 mm 55 12 in Road Clearance 130 mm 5 12 in Seat Height 775 mm 30 51 in Dry Mass 152 kg 335 2 lb Curb Mass Front 82 kg 180 8 lb Rear 87 kg 191 8 lb Fuel Tank Capacity 17 8 L 4 7 US gal Performance Minimum Turning Radius 2 7 m 8 9 ft Engine Type 4 stroke DOHC 2 cylinder Cooling System Liquid co
193. ble Sidestand Switch Operation Sidestand Gear Position Clutch Lever Engine Start Engine Run Up Neutral Released Starts Continue running Up Neutral Pulled in Starts Continue running Up In Gear Released Doesn t start Stops Up In Gear Pulled in Starts Continue running Down Neutral Released Starts Continue running Down Neutral Pulled in Starts Continue running Down In Gear Released Doesn t start Stops Down In Gear Pulled in Doesn t start Stops If the sidestand switch operation does not work inspect or replace the following item Battery see Charging Condition Inspection in the Elec trical System chapter Main Fuse 30 A see Fuse Inspection in the Electrical System chapter Ignition Fuse 10 A see Fuse Inspection in the Electrical System chapter Ignition Switch see Switch Inspection in the Electrical System chapter Sidestand Switch see Switch Inspection in the Electrical System chapter Engine Stop Switch see Switch Inspection in the Elec trical System chapter Starter Button see Switch Inspection in the Electrical System chapter Neutral Switch see Switch Inspection in the Electrical System chapter Starter Relay see Starter Relay Inspection in the Elec trical System chapter Relay Box see Relay Circuit Inspection in the Electrical System chapter Starter Circuit Relay see Relay Circuit Inspection in the Electrical System chapter Harness see Wirin
194. ble 1 Alternator Output Voltage at 4 000 r min rpm Connections Tester Range Tester to Tester to Reading 250 V AC One Yellow Lead Another Yellow Lead 40 V or more If the output voltage shows the value in the table the al ternator operates properly The regulator rectifier is dam aged If the output voltage shows a much lower reading than that given in the table stop the engine and inspect the stator coil resistance Check the stator coil resistance as follows Stop the engine Connect the hand tester as shown in the table 2 Special Tool Hand Tester 57001 1394 Note the readings total 3 measurements Table 2 Stator Coil Resistance at 20 C 68 F Connections Tester Range Tester to Tester to Reading 1 One Yellow Lead Another Yellow Lead 0 05 0 6 If there is more resistance than shown in the table or no hand tester reading infinity for any two leads the stator has an open lead and must be replaced Much less than this resistance means the stator is shorted and must be replaced Using the highest resistance range of the hand tester measure the resistance between each of the yellow leads and chassis ground Any hand tester reading less than infinity indicates a short necessitating stator replacement If the stator coils have normal resistance but the voltage check showed the alternator to be defective then the rotor magnets have probably
195. c Unscrew the banjo bolt and remove the brake hose D from the caliper see Brake Hose Removal Installation CAUTION Immediately wash away any brake fluid that spills NOTE If the caliper is to be disassembled after removal and if compressed air is not available disassemble the caliper before the brake hose is removed see Rear Caliper Disassembly Caliper Installation Install the caliper and brake hose lower end Replace the washers on each side of hose fitting with new ones Tighten Torque Caliper Mounting Bolts Front 25 N m 2 5 kgf m 18 ft lb Rear 25 N m 2 5 kgf m 18 ft lb Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft lb Check the fluid level in the brake reservoirs Bleed the brake line see Brake Line Bleeding Check the brake for good braking power no brake drag and no fluid leakage WARNING Do not attempt to drive the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal and 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 http mototh com 12 10 BRAKES Calipers Front Caliper Disassembly Refer to the Caliper Rubber Parts Replacement in the Pe riodic Maintenance chapter Front Caliper Assembly Refer to the Caliper Rubber Parts Replacement in the Pe riodic Maintenance chapter Rear Caliper Disassembly Refer to th
196. case Assembly Do not turn the balancer shaft during clearance mea surement Journal clearance less than 0 025 mm 0 00098 in can not be measured by plastigage however using genuine parts maintains the minimum standard clearance Balancer Shaft Bearing Insert Journal Clearance Standard 0 020 0 044 mm 0 0008 0 0017 in Service Limit 0 07 mm 0 0028 in If the clearance is within the standard no bearing replace ment is required If the clearance is between 0 044 mm 0 0017 in and the service limit 0 07 mm 0 0028 in replace the bearing in serts A with inserts painted blue B Check insert journal clearance with the plastigage The clearance may exceed the standard slightly but it must not be less than the min imum in order to avoid bearing seizure If the clearance exceeds the service limit measure the diameter of the balancer shaft journal Balancer Shaft Journal Diameter Standard 25 984 26 000 mm 1 0230 1 0236 in Service Limit 25 96 mm 1 022 in http mototh com 9 24 CRANKSHAFT TRANSMISSION Balancer If any journal has worn past the service limit replace the balancer shaft with a new one If the measured journal diameters are not less than the service limit but do not coincide with the original diameter markings A on the balancer shaft make new marks on it Balancer Shaft Journal Diameter Marks None 25 984 25 994 mm 1 0230 1 0234 in 25 995 26
197. ce with a vernier caliper If the outside diameter of the seating surface is too small repeat the 45 grind until the diameter is within the spec ified range Widened Width A of engagement by machining with 45 cutter Ground Volume B by 32 cutter 32 C Correct Width D Ground Volume E by 67 5 cutter 67 5 F Measure the outside diameter of the seating surface with a vernier caliper If the outside diameter of the seating surface is too small repeat the 45 grind A until the diameter is within the specified range Original Seating Surface B NOTE Remove all pittings of flaws from 45 ground surface After grinding with 45 cutter apply thin coat of machin ist s dye to seating surface This makes seating surface distinct and 32 and 67 5 grinding operation easier When the valve guide is replaced be sure to grind with 45 cutter for centering and good contact If the outside diameter A of the seating surface is too large make the 32 grind described below If the outside diameter of the seating surface is within the specified range measure the seat width as described be low Grind the seat at a 32 angle B until the seat outside diameter is within the specified range To make the 32 grind fit a 32 cutter into the holder and slide it into the valve guide Turn the holder one turn at a time while pressing down very lightly Check the seat after each turn CAUTION
198. ch Cable Removal 6 6 Clutch Cable Installation 6 6 Clutch Cable Lubrication 6 6 Clutch Lever Installation 6 6 Clutch Cover 6 7 Clutch Cover Removal 6 7 Clutch Cover Installation 6 7 Release Shaft Removal 6 7 Release Shaft Installation 6 7 Clutch Cover Disassembly 6 8 Clutch Cover Assembly 6 8 Clutch
199. ch Inspection in the Electrical System chapter Rear Brake Light Switch see Switch Inspection in the Electrical System chapter Harness see Wiring Inspection in the Electrical System chapter Suspension Front Forks Rear Shock Absorber Operation Inspection Pump the forks down and up A 4 or 5 times and inspect the smooth stroke If the forks do not smoothly or noise is found inspect the fork oil level or fork clamps see Front Fork Oil Change in the Suspension chapter http mototh com PERIODIC MAINTENANCE 2 33 Periodic Maintenance Procedures Pump the seat down and up A 4 or 5 times and inspect the smooth stroke If the shock absorber does not smoothly stroke or noise is found inspect the oil leak see Rear Shock Absorber Oil Leak Inspection Front Fork Oil Leak Inspection Visually inspect the front forks A for oil leakage Replace or repair any defective parts if necessary Rear Shock Absorber Oil Leak Inspection Visually inspect the shock absorber A for oil leakage If the oil leakage is found on it replace the shock absorber with a new one Rocker Arm Operation Inspection Pump the seat down and up 4 or 5 times and inspect the smooth stroke If the rocker arm A does not smoothly stroke or noise is found inspect the fasteners and bearings see Rocker Arm Tie Rod Bearing Sleeve Inspection in the Suspen sion chapter Tie Rod Operation Inspection Pump the seat down and up 4
200. ckness Standard 2 92 3 08 mm 0 115 0 121 in Service Limit 2 6 mm 0 10 in Clutch Plate Warp Inspection Place each friction plate or steel plate on a surface plate and measure the gap between the surface plate A and each friction plate or steel plate B with a thickness gauge C The gap is the amount of friction or steel plate warp If any plate is warped over the service limit replace it with a new one Friction and Steel Plate Warp Standard 0 15 mm 0 0059 in or less Service Limit 0 3 mm 0 012 in Clutch Spring Free Length Inspection Measure the free length of the clutch springs A If any spring is shorter than the service limit it must be replaced Clutch Spring Free Length Standard 39 4 mm 1 55 in Service Limit 37 6 mm 1 48 in http mototh com http mototh com ENGINE LUBRICATION SYSTEM 7 1 7 Engine Lubrication System Table of Contents Exploded View 7 2 Engine Oil Flow Chart 7 4 Specifications 7 5 Special Tools and Sealant
201. clearance Connecting Rod Big End Side Clearance Standard 0 13 0 38 mm 0 0051 0 0150 in Service Limit 0 58 mm 0 023 in If the clearance exceeds the service limit replace the con necting rod with new one and then check the clearance again If the clearance is too large after connecting rod replacement the crankshaft also must be replaced http mototh com 9 18 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Big End Bearing Insert Crankpin Wear Inspection Measure the bearing insert crankpin A clearance with plastigage B Tighten the big end nuts to the specified torque see Con necting Rod Installation NOTE Do not move the connecting rod and crankshaft during clearance measurement Connecting Rod Big End Bearing Insert Crankpin Clearance Standard 0 031 0 059 mm 0 0012 0 0023 in Service Limit 0 10 mm 0 004 in If the clearance is within the standard no bearing replace ment is required If the clearance is between 0 059 mm 0 0023 in and the service limit 0 10 mm 0 004 in replace the bear ing inserts A with inserts painted blue B Check the in sert crankpin clearance with the plastigage The clear ance may exceed the standard slightly but it must not be less than the minimum in order to avoid bearing seizure If the clearance exceeds the service limit measure the diameter of the crankpins Crankpin Diameter Standard 29 984
202. connector joined Turn the ignition switch ON Output Voltage Standard About DC 2 25 2 50 V at inlet air temperature 20 C 68 F NOTE The output voltage changes according to the inlet air temperature http mototh com FUEL SYSTEM DFI 3 51 Inlet Air Temperature Sensor Service Code 13 Turn the ignition switch OFF If the reading is within the standard check the ECU for its ground and power supply see ECU Power Supply In spection If the ground and power supply are good replace the ECU see ECU Removal Installation If the reading is out of the standard remove the ECU and check the wiring for continuity between main harness side connectors Special Tool Hand Tester 57001 1394 Disconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Inlet Air Temperature Sensor Connector B Y lead ECU terminal 20 C BR BK lead ECU terminal 22 D If the wiring is good check the inlet air temperature sensor resistance see Inlet Air Temperature Sensor Resistance Inspection Inlet Air Temperature Sensor Resistance Inspection Remove the inlet air temperature sensor see Inlet Air Temperature Sensor Removal Installation Suspend the sensor A in a container of machine oil so that the heat sensitive portion is submerged Suspend a thermometer B with the heat sensitive por tion C located in almost the same depth with the sensor NOTE
203. contains nitrogen gas do not incinerate the rear shock absorber with out first releasing the gas or it may explode Before a rear shock absorber is scrapped drill a hole at the point A shown to release the nitrogen gas completely Wear safety glasses when drilling the hole as the gas may below out bits of drilled metal when the hole opens Remove the rear shock absorber see Rear Shock Ab sorber Removal Drill the cylinder of the shock absorber using about 2 mm 0 08 in drillbit http mototh com 13 16 SUSPENSION Swingarm Swingarm Removal Remove Lower Fairings see Lower Fairing Removal in the Frame chapter Chain Cover see Drive Chain Removal in the Final Drive chapter Rear Wheel see Rear Wheel Removal in the Wheels Tires chapter Caps A Both Sides Remove Bolt A Clamp B Raise the rear wheel off the ground with jack Special Tools Jack 57001 1238 Jack Attachment 57001 1608 Remove Lower Rear Shock Absorber Nut and Bolt A Upper Tie Rod Nut and Bolt B Unscrew the swingarm pivot shaft nut A Pull out the pivot shaft A and remove the swingarm B http mototh com SUSPENSION 13 17 Swingarm Swingarm Installation Installation is the reverse of removal Apply grease to the lips of the oil seals Tighten Torque Swingarm Pivot Shaft Nut 98 N m 10 0 kgf m 72 3 ft lb Install the removed parts see appropriate chapters
204. continuity Use the wiring diagram to find the ends of the lead which is suspected of being a problem Connect the hand tester between the ends of the leads Special Tool Hand Tester 57001 1394 Set the tester to the 1 range and read the tester If the tester does not read 0 the lead is defective Re place the lead or the wiring harness B if necessary http mototh com 16 18 ELECTRICAL SYSTEM Battery Battery Removal Turn off the ignition switch Remove Front Seat see Front Seat Removal in the Frame chap ter Relay Box see Relay Box Removal Screw A and Battery Cover B Disconnect the negative cable A CAUTION Be sure to disconnect the negative cable first Slide out the positive terminal cap B and disconnect the positive cable Remove the battery C Remove the screws A and battery case B as necessary Battery Installation Turn off the ignition switch Put the battery into the battery case Connect the positive cable A first Connect the negative cable B Apply a light coat of grease on the terminals to prevent corrosion Cover the terminal with red cap C Insert the projections A into the holes B Install the removed parts see appropriate chapters http mototh com ELECTRICAL SYSTEM 16 19 Battery Battery Activation Electrolyte Filling Make sure that the mo
205. crankcase B where the starter motor is grounded Replace the O ring A with a new one Apply grease to the O ring Tighten Torque Starter Motor Mounting Bolts 9 8 N m 1 0 kgf m 87 in lb Install the starter motor cable and tighten the nut Torque Starter Motor Cable Terminal Nut 9 8 N m 1 0 kgf m 87 in lb Slide the rubber cap to the original position Install the removed parts see appropriate chapters http mototh com 16 42 ELECTRICAL SYSTEM Electric Starter System Starter Motor Disassembly Remove the starter motor see Starter Motor Removal Take off the starter motor through bolts A and remove the both end covers B and pull the armature out of the yoke Remove the terminal locknut A washer and insulators and then remove the brushes and terminal bolt B with the brush plate C from the end cover Starter Motor Assembly Replace the O rings with new ones Apply a thin coat of high temperature grease to the oil seal A and needle bearing B Fit the toothed washer C into the end cover Install Brush Plate A New O ring Insulators Washer Tighten Torque Starter Motor Terminal Locknut B 6 9 N m 0 70 kgf m 61 in lb Fit the tongue C of the brush plate into the groove of the end cover Install the steel washer A and resin washer B on the armature shaft Install the armature C among the brushes
206. ct Every 1 000 km 600 mile 2 27 Drive chain wear inspect 2 29 Chain guide wear inspect 2 29 Brakes Brake fluid leak brake hose and pipe inspect year 2 30 Brake hose and pipe damage inspect year 2 30 Brake hose installation condition inspect year 2 30 http mototh com 2 4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY Whichever comes first ODOMETER READING 1 000 km 1 000 mile 1 6 12 18 24 30 36 ITEM Every 0 6 4 7 5 12 15 20 24 See Page Brake fluid level inspect 6 months 2 30 Brake pad wear inspect 2 31 Brake operation effectiveness play no drag inspect year 2 31 Brake light switch operation inspect 2 32 Suspension Front forks rear shock absorber operation damping and smooth stroke inspect 2 32 Front forks rear shock absorber oil leak inspect year 2 33 Rocker arm operation inspect 2 33 Tie rods operation inspect 2 33 Swingarm pivot lubricate 2 34 Steering Steering play inspect year 2 34 Steering stem bearings lubricate 2 years
207. ct sequence and all circlips and washers are properly in place Install the 6th gear bushing onto the drive shaft with their oil holes aligned The output shaft gears can be recognized by size the gear with the largest diameter is 1st gear and the small est one is 6th gear Be sure that all parts are put back in the correct sequence and all circlips and washers are properly in place Install the 5th and 6th gears onto the output shaft with their oil holes aligned Install the 2nd and 3rd 4th gear bushings onto the output shaft with their oil holes aligned Fit the steel balls into the 5th gear holes in the output shaft aligning three oil holes A 5th Gear B Output Shaft C Steel Balls D CAUTION Do not apply grease to the balls to hold them in place This will cause the positive neutral finder mechanism to malfunction After assembling the 5th gear with steel balls in place on the output shaft check the ball locking effect that the 5th gear doesn t come out of the output shaft when moving it up and down by hand Check that each gear spins or slides freely on the trans mission shafts without binding after assembly http mototh com 9 30 CRANKSHAFT TRANSMISSION Transmission 1 Circlip 29 mm 1 14 in 2 Circlip 3 Thrust Washer 30 mm 1 18 in Inside Diameter 25 3 mm 0 996 in 4 Toothed Washer 30 mm 1 18 in 5 Thrust Washer 30 mm 1 18 in Inside Diameter 20 5
208. ction Measure the thickness of the shift fork ears A and mea sure the width B of the gear grooves If the thickness of a shift fork ear is less than the service limit the shift fork must be replaced Shift Fork Ear Thickness Standard 4 9 5 0 mm 0 193 0 197 in Service Limit 4 8 mm 0 189 in If the gear groove is worn over the service limit the gear must be replaced Gear Groove Width Standard 5 05 5 15 mm 0 199 0 203 in Service Limit 5 3 mm 0 209 in Shift Fork Guide Pin Drum Groove Wear Inspection Measure the diameter of each shift fork guide pin A and measure the width B of each shift drum groove If the guide pin on any shift fork is less than the service limit the fork must be replaced Shift Fork Guide Pin Diameter Standard 5 9 6 0 mm 0 232 0 236 in Service Limit 5 8 mm 0 228 in If any shift drum groove is worn over the service limit the drum must be replaced Shift Drum Groove Width Standard 6 05 6 20 mm 0 238 0 244 in Service Limit 6 3 mm 0 248 in Gear Dog and Gear Dog Hole Damage Inspection Visually inspect the gear dogs A and gear dog holes B Replace any damaged gears or gears with excessively worn dogs or dog holes http mototh com http mototh com WHEELS TIRES 10 1 10 Wheels Tires Table of Contents Exploded View
209. d in a vertical position pull down the outer tube several times to pull out the inner tube Special Tool Fork Outer Tube Weight 57001 1218 Take out the cylinder base from the outer tube bottom Remove the inner guide bushing from the inner tube Front Fork Assembly Replace the following parts with a new one Inner Guide Bushing A Oil Seal B Outer Guide Bushing C Bottom Allen Bolt Gasket D 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 Install the cylinder base with the tapered end D facing upward Install the inner tube cylinder unit and cylinder base as a set into the outer tube http mototh com 13 12 SUSPENSION Front Fork Install the new guide bushing A with a use one B on it by tapping the use one with the fork oil seal driver C The split D of the bushing should face toward the side of the motorcycle Special Tool Front Fork Oil Seal Driver 57001 1219 Apply molybdenum disulfide grease to the oil seal lips and install the washer and the oil seal A into the outer tube Special Tool Front Fork Oil Seal Driver B 57001 1219 Install the retaining ring on the outer tube Install a new bottom Allen bolt gasket Apply a non permanent locking agent to the threads of the bottom Allen bolt and tighten it Hold the ou
210. d install the cap B Install the radiator cap Start the engine warm it up thoroughly until the radiator fan turns on and then stop the engine Check the coolant level in the reserve tank after the en gine cools down If the coolant level is lower than the L low level line C add coolant to the F level line CAUTION Do not add more coolant above the F level line http mototh com 2 48 PERIODIC MAINTENANCE Periodic Maintenance Procedures Radiator Hose and O ring Replacement Drain the coolant see Coolant Change Remove Thermostat Housing A see Thermostat Housing Re moval in the Cooling System chapter Water Pump Cover B see Water Pump Cover Removal in the Cooling System chapter O rings C Hoses D Apply grease to the new O rings and install them Install the new hoses and tighten the clamps securely Torque Radiator Water Hose Clamp Screws 1 5 N m 0 15 kgf m 13 in lb Fill the coolant see Coolant Change Check the cooling system for leaks Engine Oil Change Situate the motorcycle so that it is vertical after warming up the engine Remove the engine oil drain bolt A to drain the oil The oil in the oil filter can be drained by removing the filter see Oil Filter Replacement Replace the drain bolt gasket B with a new one Tighten the drain bolt Torque Engine Oil Drain Bolt Oil Screen Cover 19 6 N m 2 0 kgf m 14 5 ft
211. dard replace the sensor If the reading is within the standard check the power source voltage see Oxygen Sensor Heater Power Source Voltage Inspection Oxygen Sensor Heater Power Source Voltage Inspection NOTE Be sure the battery is fully charged Turn the ignition switch OFF Disconnect the oxygen sensor lead connector and con nect the harness adapter A between these connectors Special Tool Oxygen Sensor Measuring Adapter 57001 1682 Connect a digital meter to the harness adapter lead Oxygen Sensor Power Source Voltage Connections to Adapter Digital Meter P Y sensor BK lead Digital Meter Battery terminal Measure the power source voltage with the engine stopped and with the connector joined Turn the ignition switch ON Power Source Voltage Standard Battery Voltage Turn the ignition switch OFF If the reading is in specification but the problem still ex ists replace the ECU see ECU Removal Installation If the reading is out of the standard check the following Oxygen Sensor Heater Fuse 10 A see Fuse Inspection in the Electrical System chapter Power Source Wiring see wiring diagram in this section http mototh com 3 78 FUEL SYSTEM DFI Oxygen Sensor Heater Service Code 67 If the fuse and wiring are good remove the ECU and check the wiring for continuity between main harness con nectors Special Tool Hand Tester 57001 1394 Disc
212. del 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 EX250K YTX9 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 Place the battery on a level surface Check to see that the sealing sheet has no peeling tears or holes in it Remove the sealing sheet NOTE The battery is vacuum sealed If the sealing sheet has leaked air into the battery it may require a longer initial charge Remove the electrolyte container from the vinyl bag Detach the strip of caps A from the container and set aside these will be used later to seal the battery NOTE Do not pierce or otherwise open the sealed cells B of the electrolyte container Do not attempt to separate individual cells Place the electrolyte container upside down with the six sealed cells into the filler ports of the battery Hold the container level push down to break the seals of all six cells You will see air bubbles rising int
213. der 5 9 0 60 52 in lb Coolant Drain Bolt Water Pump 9 8 1 0 87 in lb Radiator Bolts 9 8 1 0 87 in lb Radiator Cap Bracket Bolt 9 8 1 0 87 in lb Radiator Water Hose Clamp Screws 1 5 0 15 13 in lb Reserve Tank Bolts 9 8 1 0 87 in lb Reserve Tank Bracket Bolts 9 8 1 0 87 in lb Reserve Tank Cap Hand Tighten Resistor Bolt 7 8 0 80 69 in lb Thermostat Cover Bolts 9 8 1 0 87 in lb Thermostat Housing Mounting Bolts 9 8 1 0 87 in lb Water Hose Fitting Bolts 9 8 1 0 87 in lb Water Pipe Bolts 9 8 1 0 87 in lb Water Pump Bolts 9 8 1 0 87 in lb Water Pump Cover Bolts 9 8 1 0 87 in lb Water Temperature Sensor 25 2 5 18 Engine Top End Air Suction Valve Cover Bolts 9 8 1 0 87 in lb http mototh com PERIODIC MAINTENANCE 2 7 Torque and Locking Agent Torque Fastener N m kgf m ft lb Remarks Air Switching Valve Bracket Bolts 9 8 1 0 87 in lb Camshaft Cap Bolts 12 1 2 106 in lb S Camshaft Chain Tensioner Cap Bolt 5 0 0 51 44 in lb Camshaft Chain Tensioner Mounting Bolts 9 8 1 0 87 in lb Camshaft Sprocket Bolts 15 1 5 11 L Coolant Drain Bolt Cylinder 5 9 0 60 52 in lb Cylinder Head Bolts M8 31 4 3 2 23 2 MO S Cylinder Head Bolt M6 12 1 2 106 in lb S Cylinder Head Cover Bolts 9 8 1 0 87 in lb Cylinder Head Jacket Plugs 20 2 0 15 L Exhaust Pipe Holder Nuts 12 1 2
214. der A Take off the plate holder http mototh com FINAL DRIVE 11 9 Drive Chain Set the plate holder B A and cutting and riveting pin B as shown in the figure Turn the pin holder until the riveting pin touches the link pin Turn the wrench clockwise until the tip of riveting pin hits of the link pin Rivet it Same work for the other link pin After staking check the staked area of the link pin for cracks Measure the outside diameter A of the link pin and link plates width B Link Pin Outside Diameter Standard 5 3 5 7 mm 0 21 0 22 in Link Plates Outside Width Standard 17 35 17 50 mm 0 683 0 689 in If the reading exceeds the specified length cut and rejoin the chain again Check Movement of the Rollers Adjust the drive chain slack after installing the chain see Drive Chain Slack Adjustment in the Periodic Mainte nance chapter Install the removed parts see appropriate chapters http mototh com 11 10 FINAL DRIVE Sprocket Coupling Engine Sprocket Removal Remove Shift Lever A see Shift Pedal Removal in the Crank shaft Transmission chapter Engine Sprocket Cover Bolts B Engine Sprocket Cover C Remove the bolts A Flatten out the bended washer A Remove the engine sprocket nut B and washer NOTE When loosening the engine sprocket nut hold the rear brake on Raise the rear
215. der Dust Seals Fluid Seals Bleed Valve Rubber Cap NOTE If compressed air is not available do as follows with the brake hose connected to the caliper Prepare a container for brake fluid and perform the work above it Remove the pads see Brake Pad Removal in the Brakes chapter Pump the brake lever until the pistons come out of the cylinders and then disassemble the caliper http mototh com 2 54 PERIODIC MAINTENANCE Periodic Maintenance Procedures Caliper Assembly Clean the caliper parts except for the pads CAUTION For cleaning the parts use only disc brake fluid isopropyl alcohol or ethyl alcohol Apply a non permanent locking agent to the threads of the bleed valve Install the bleed valve and rubber cap Torque Bleed Valve 5 5 N m 0 56 kgf m 49 in lb Apply brake fluid to the cylinder bores Replace the fluid seals A with new ones Apply silicone grease to the fluid seals and install them into the cylinders by hand Replace the dust seals B with new ones Apply brake fluid to the outside of the pistons and push them into each cylinder by hand Check the dust cover A and the friction boot B replace them with new ones if they are damaged Apply a thin coat of PBC Poly Butyl Cuprysil grease to the caliper holder shaft C and pin bolt D PBC is a spe cial high temperature water resistance grease Install the caliper holder and pad s
216. down sensor DFI coming off Starter clutch trouble Starter idle gear trouble Engine won t turn over Valve seizure Valve lifter seizure Cylinder piston seizure Crankshaft seizure Connecting rod small end seizure Connecting rod big end seizure Transmission gear or bearing seizure Camshaft seizure Starter idle gear seizure No fuel flow No fuel in tank Fuel pump trouble Fuel tank air vent obstructed Fuel filter clogged Fuel line clogged No spark spark weak Vehicle down sensor DFI coming off Ignition switch not ON Engine stop switch turned OFF Clutch lever not pulled in or gear not in neu tral Battery voltage low Spark plug dirty broken or gap malad justed Spark plug incorrect Stick coil shorted or not in good contact Stick coil trouble ECU trouble Neutral starter lockout or sidestand switch trouble Crankshaft sensor trouble Ignition switch or engine stop switch shorted Starter system wiring shorted or open Main 30 A or ignition fuse blown Fuel air mixture incorrect Bypass screw and or idle adjusting screw maladjusted Air passage clogged Air cleaner clogged poorly sealed or miss ing Leak from oil filler cap crankcase breather hose or air cleaner drain cap Compression Low Spark plug loose Cylinder head not sufficiently tightened down Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valv
217. e C as shown in the figure About 34 5 mm 1 36 in D Replace the O rings A with new ones Apply grease to the new O rings Install the oil passage pipe B as shown in the figure Slit Horizontal C 70 D 1 mm 0 04 in Hole direction Lower Crankcase E http mototh com 9 12 CRANKSHAFT TRANSMISSION Crankcase Install Shift Drum see Shift Drum and Fork Installation Shift Forks and Shift Rods see Shift Drum and Fork In stallation Crankshaft see Crankshaft Installation Balancer Shaft see Balancer Installation Connecting Rods see Connecting Rod Installation Camshaft Chain Transmission Shafts and Gears see Transmission Shaft Installation Dowel Pins A Before fitting the lower case on the upper case check the following Be sure to hang the camshaft chain on the crankshaft Check to see that the shift drum and transmission gears are in the neutral position Apply liquid gasket A to the mating surface of the lower crankcase half Sealant Kawasaki Bond Liquid Gasket Black 92104 1064 CAUTION Do not apply liquid gasket around the crankshaft main bearing inserts and oil passage holes Fit the lower crankcase to the upper crankcase Apply molybdenum disulfide oil solution to the seating sur face A and threads B of the M8 bolts http mototh com CRANKSHAFT TRANSMISSION 9 13 Crankcase Tighten the lower crankcase bolts using the following
218. e damage to wiring and components http mototh com APPENDIX 17 1 17 Appendix Table of Contents Cable Wire and Hose Routing 17 2 Troubleshooting Guide 17 32 http mototh com 17 2 APPENDIX Cable Wire and Hose Routing http mototh com APPENDIX 17 3 Cable Wire and Hose Routing 1 Headlight High Connector 2 Headlight Low Connector 3 Bands 4 Meter Lead Connectors 5 City Light Lead Connector 6 Horn Lead Connectors 7 Regulator Rectifier Lead Connector 8 Oil Pressure Switch Lead Connector 9 Left Switch Housing Lead Connectors 10 Inlet Air Pressure Sensor Lead Connector 11 Stick Coil 1 Lead Connector 12 Front Left Turn Signal Light Lead Connector 13 Fuel Injector 1 Lead Connector 14 Subthrottle Valve Actuator Lead Connector 15 Neutral Switch Lead Connector 16 Sidestand Switch Lead Connector 17 Speed Sensor Lead Connector 18 Inlet Air Temperature Sensor Lead Connector 19 Fuel Pump Lead Connector 20 Starter Relay Lead Connector 21 Relay Box Lead Connectors 22 Turn Signal Relay Lead Connector 23 Clamp 24 Fuse Box 25 Clamp 26 Band http mototh com 17 4 APPENDIX Cable Wire and Hose Routing http mototh com APPENDIX 17 5 Cable Wire and Hose Routing 1 License
219. e sprocket see Drive Chain Slack Adjustment in the Pe riodic Maintenance chapter Install the removed parts see appropriate chapters Rear Sprocket Removal Remove the rear wheel see Rear Wheel Removal in the Wheels Tires chapter CAUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground Remove Rear Sprocket Nuts A Rear Sprocket B Rear Sprocket Installation Install the sprocket facing the tooth number marking A outward Tighten Torque Rear Sprocket Nuts 59 N m 6 0 kgf m 44 ft lb Install the rear wheel see Rear Wheel Installation in the Wheels Tires chapter Coupling Installation Apply high temperature grease to the following Coupling Grease Seal Lips A Coupling Internal Surface A Ball Bearing A http mototh com 11 12 FINAL DRIVE Sprocket Coupling Apply high temperature grease to the following Wheel Flange Portion A O ring B Install the collar C Coupling Bearing Removal Remove Coupling Grease Seal Remove the bearing A by tapping from the wheel side Special Tool Bearing Driver Set B 57001 1129 Coupling Bearing Installation Replace the bearing with a new one Press in the bearing A until it is bottomed Special Tool Bearing Driver Set B 57001 1129 Pack the bearing with high temperat
220. e Caliper Rubber Parts Replacement in the Pe riodic Maintenance chapter Rear Caliper Assembly Refer to the Caliper Rubber Parts Replacement in the Pe riodic Maintenance chapter Caliper Fluid Seal Damage Inspection The fluid seal piston seal A is placed around the pis ton to maintain clearance between the pad and the disc If the 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 Replace the fluid seal if it exhibits any of the conditions listed below Brake fluid leakage around the pad Brakes overheat Considerable difference in inner and outer pad wear Seal and piston are stuck together If the fluid seal is replaced replace the dust seal B as well Also replace all seals every other time the pads are changed http mototh com BRAKES 12 11 Calipers Caliper Dust Seal Damage Inspection Check that the dust seals A are not cracked worn swollen or otherwise damaged If they show any damage replace the dust seals with new ones Pistons B Fluid Seals C Caliper Dust Boot and Friction Boot Damage Inspection Check that the dust boot A and friction boot B are not cracked worn swollen or otherwise damaged If they show any damage replace it http mototh com 12 12 BRAKES Calipers Caliper Piston and Cylinder Damage Inspection Visually inspec
221. e Drive Chain Slack Adjustment in the Periodic Maintenance chapter Wheel Alignment Inspection Adjustment Refer to the Wheel Alignment Inspection in the Periodic Maintenance chapter Drive Chain Wear Inspection Refer to the Drive Chain Wear Inspection in the Periodic Maintenance chapter Drive Chain Lubrication Refer to the Drive Chain Lubrication Condition in the Pe riodic Maintenance chapter Drive Chain Guide Wear Inspection Refer to the Chain Guide Wear Inspection in the Periodic Maintenance chapter Drive Chain Removal Remove Chain Cover Bolts A and Chain Cover B Engine Sprocket see Engine Sprocket Removal Rear Wheel see Rear Wheel Removal in the Wheels Tires chapter Swingarm see Swingarm Removal in the Suspension chapter Remove the drive chain A from the output shaft B and take it off the chassis Drive Chain Installation Install the drive chain to the output shaft Install Swingarm see Swingarm Installation in the Suspension chapter Rear Wheel see Rear Wheel Installation in the Wheels Tires chapter Engine Sprocket see Engine Sprocket Installation Chain Cover Adjust the drive chain slack after installing the chain see Drive Chain Slack Adjustment in the Periodic Mainte nance chapter http mototh com FINAL DRIVE 11 7 Drive Chain Drive Chain Replacement Remove Chain Cover see Drive Chain Removal Engine Sprocket Cover see Engin
222. e Driver 57001 1564 Washer 57001 1720 Kawasaki Bond Silicone Sealant 92104 0004 http mototh com ENGINE TOP END 5 11 Clean Air System Air Suction Valve Removal Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Air Switching Valve see Air Switching Valve Removal Free the heat insulation rubber plate A from the air suc tion valve cover B Remove Air Suction Valve Cover Bolts A Air Suction Valve Cover B Air Suction Valve Air Suction Valve Installation Install the air suction valve A so that its wider side B of the reed valve case faces the front Tighten Torque Air Suction Valve Cover Bolts 9 8 N m 1 0 kgf m 87 in lb Install the removed parts see appropriate chapters Air Suction Valve Inspection Remove the air suction valve see Air Suction Valve Re moval Visually inspect the reeds for cracks folds warps heat damage or other damage If there is any doubt as to the condition of the reeds A replace the air suction valve as an assembly Check the reed contact areas B of the valve holder for grooves scratches any signs of separation from the holder or heat damage If there is any doubt as to the condition of the reed contact areas replace the air suction valve as an assembly If any carbon or other foreign particles have accumulated between the reed and the reed contact area wash the valve assembly clean
223. e Sprocket Removal CAUTION For safety if the drive chain shall be replaced re place it using a recommended tool Recommended Tool Type EK Joint Tool 50 Brand ENUMA Body A Handlebar B Cutting and Riveting Pin C For Cutting D For Riveting E Plate Holder A F Plate Holder B G Gauge H Grind A the pin head to make it flat Set the cutting and riveting pin B as shown in the figure Screw the pin holder until it touches the link pin Be sure that the cutting pin hits center of the link pin http mototh com 11 8 FINAL DRIVE Drive Chain Screw the handlebar A into the body Turn the pin holder with the wrench B clockwise to ex tract the link pin Replace the link pin link plate and grease seals Apply grease to the link pins A and grease seals B C Engage the drive chain on the engine and rear sprockets Insert the link pins in the drive chain ends Install the grease seals Install the link plate so that the mark D faces out Push the link plate by hand or plier to fix it Be sure to set the grease seals correctly Set the plate holder A A and plate holder B B on the body Fit the plate holder A to the link plate Turn the pin holder by hand until the plate holder B touches the other link plate Turn the pin holder by a wrench clockwise until two pins of link come into groove of the plate hol
224. e bottom E Install the oil level gauge until the bottom http mototh com CLUTCH 6 9 Clutch Clutch Removal Remove Clutch Cover see Clutch Cover Removal Clutch Spring Bolts A Clutch Springs Clutch Spring Plate B with Bearing and Pusher C Remove Friction Plates and Steel Plates Clutch Hub Nut A Holding the clutch hub B remove the nut and washer Special Tool Clutch Holder C 57001 1243 Remove Clutch Hub Spacer Needle Bearing Bushing Clutch Housing Thrust Spacer Clutch Installation Install the thrust spacer A so that the chamfer side B faces inward Install the bushing A and needle bearing B Install the snap ring C on the bushing so that it faces inward Install the clutch housing spacer clutch hub washer and clutch hub nut Holding the clutch hub tighten the clutch hub nut Special Tool Clutch Holder 57001 1243 Torque Clutch Hub Nut 132 N m 13 5 kgf m 97 4 ft lb http mototh com 6 10 CLUTCH Clutch If the clutch housing is replaced with a new one select the proper clutch housing in accordance with the combination of the clutch housing gear and crankshaft primary gear markings with colors Crankshaft Primary Gear A Clutch Housing Gear B Be sure to confirm the marking and color on the clutch housing gear Clutch Housing Gear Selection when Replacing Clutch Housing Gear Crankshaft Clutch Housing Pri
225. e damage will occur Remove the element A see Air Cleaner Element Re placement WARNING Clean the element in a well ventilated area and make sure that there are no sparks or flame any where near the working area Because of the danger of highly flammable liquids do not use gasoline or a low flash point solvent to clean the element Clean the element in a bath of high flash point solvent and then dry it with compressed air or by shaking it After cleaning saturate a clean lint free towel with SE SF or SG class SAE 30 oil and apply the oil to the element by tapping the element outside with the towel Visually check the element for tears or breaks If the element has any tears or breaks replace the ele ment Throttle Control System Inspection Check that the throttle grip A moves smoothly from full open to close and the throttle closes quickly and com pletely by the return spring in all steering positions If the throttle grip does not return properly check the throt tle cable routing grip free play and cable damage Then lubricate the throttle cable Check the throttle grip free play B Throttle Grip Free Play Standard 2 3 mm 0 08 0 12 in http mototh com PERIODIC MAINTENANCE 2 15 Periodic Maintenance Procedures If the free play is incorrect adjust the throttle cable as follows Loosen the locknut A Turn the adjuster B until the proper amount of fr
226. e guide 13 Guide Run the fuel tank breather hose through into the guide 14 Guide Run the fuel tank breather and reserve tank overflow hoses through into the guide 15 Guide Run the fuel tank breather and reserve tank overflow hoses through into the guide 16 Run the fuel tank breather and reserve tank overflow hoses through the inside of the swingarm 17 Reserve Tank Overflow Hose 18 Sidestand Switch Lead Connector 19 Clamp Run the sidestand switch lead through the inside of the clamp 20 Sidestand Switch http mototh com 17 10 APPENDIX Cable Wire and Hose Routing http mototh com APPENDIX 17 11 Cable Wire and Hose Routing 1 Ignition Switch Lead Connector 2 Vehicle down Sensor Lead Connector 3 Throttle Cable Accelerator 4 Throttle Cable Decelerator 5 Guide Run the throttle cables right switch housing and ignition switch leads through into the guide 6 Right Switch Housing Lead 7 Brake Hose 8 Clamp 9 Clutch Cable 10 Air Switching Valve Lead Connector 11 Band Hold the main harness and insert the band into the frame 12 Resistor Lead Connector Main Harness Side 13 Right Switch Housing Lead Connector 14 Clamp Hold the right switch housing and resistor leads and insert the clamp into the frame 15 Resistor Lead Connector Radiator Fan Side 16 Water Temperature Sensor Lead Connector 17 Resistor 18 Bracket http mototh com 17 12 APPENDIX Cable Wire and Hose Routing
227. e joint clicks Push the joint lock B until the hose joint clicks Push and pull A the hose joint B back and forth more than two times and make sure it is locked and does not come off WARNING Make sure the hose joint is installed correctly on the supply pipe or the fuel could leak If it comes off reinstall the hose joint Connect the fuel pump lead connector and the battery terminal see Battery Installation in the Electrical System chapter http mototh com FUEL SYSTEM DFI 3 113 Fuel Tank Fuel Tank Inspection Open the tank cap Visually inspect the gasket A on the tank cap for any damage Replace the gasket if it is damaged Check to see if the water drain pipe B in the tank are not clogged Check the tank cap breather also If they are clogged remove the tank and drain it and then blow the breather free with compressed air CAUTION Do not apply compressed air to the air vent holes C in the tank cap This could cause damage and clogging of the labyrinth in the cap Fuel Tank Cleaning WARNING Clean the tank in a well ventilated area and take care that there are no sparks or flame anywhere near the working area Because of the danger or highly flammable liquids do not use gasoline or low flash point solvents to clean the tank Remove Fuel Tank see Fuel Tank Removal Fuel Pump see Fuel Pump Removal Pour some high flash point solvent into the fuel tan
228. e right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously See your Motorcycle dealer for the latest information on product improvements incorporated after this publication All information contained in this publication is based on the latest product information available at the time of publication Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts 2008 Kawasaki Heavy Industries Ltd First Edition 1 Feb 20 2008 K http mototh com LIST OF ABBREVIATIONS A ampere s lb pound s ABDC after bottom dead center m meter s AC alternating current min minute s ATDC after top dead center N newton s BBDC before bottom dead center Pa pascal s BDC bottom dead center PS horsepower BTDC before top dead center psi pound s per square inch C degree s Celsius r revolution DC direct current rpm revolution s per minute F farad s TDC top dead center F degree s Fahrenheit TIR total indicator reading ft foot feet V volt s g gram s W watt s h hour s ohm s L liter s COUNTRY AND AREA CODES AT Austria WVTA FULL N WVTA Model Full Power CH Switzerland GB WVTA FULL N WVTA Model Left Side Traffic Full Power DE Germany http mototh com Foreword
229. e spring broken or weak No valve clearance Valve not seating properly valve bent worn or carbon accumulation on the seating surface Poor Running at Low Speed Spark weak Battery voltage low Stick coil trouble Stick coil shorted or not in good contact Spark plug dirty broken or maladjusted Spark plug incorrect ECU trouble Crankshaft sensor trouble Fuel air mixture incorrect Bypass screw maladjusted Air passage clogged Air bleed pipe bleed holes clogged Pilot passage clogged Air cleaner clogged poorly sealed or miss ing Fuel tank air vent obstructed Fuel pump trouble Throttle body assy holder loose Air cleaner duct loose Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn http mototh com APPENDIX 17 33 Troubleshooting Guide Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Camshaft cam worn Run on dieseling Ignition switch trouble Engine stop switch trouble Fuel injector trouble Loosen terminal of battery cable or ECU ground lead Carbon accumulating on valve seating sur face Engine overheating Other ECU trouble Throttle body assy not synchronizing Engine oil viscosity too high Drive train trouble Brake dragging C
230. e standard remove the ECU and check the wiring for continuity between main harness con nectors Special Tool Hand Tester 57001 1394 Disconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Main Throttle Sensor Connector B Y W lead ECU terminal 6 C BR BK lead ECU terminal 22 D If the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see ECU Removal Installation Main Throttle Sensor Resistance Inspection Turn the ignition switch OFF Disconnect the main throttle sensor connector Connect a digital meter A to the main throttle sensor connector B Measure the main throttle sensor resistance Main Throttle Sensor Resistance Connections BL lead C BR BK lead D Standard 4 6 k If the reading is out of the standard replace the throttle body assy see Throttle Body Assy Removal Installation If the reading is within the standard but the problem still exists replace the ECU see ECU Removal Installation Main Throttle Sensor Circuit 1 ECU 2 Main Throttle Sensor 3 Water proof Joint 2 4 Water proof Joint 1 http mototh com 3 44 FUEL SYSTEM DFI Inlet Air Pressure Sensor Service Code 12 Inlet Air Pressure Sensor Removal CAUTION Never drop the inlet air pressure sensor especially on a hard surface Such a
231. e water temperature sensor see Water Tem perature Sensor Removal Installation in the Fuel System DFI chapter Suspend the sensor A in a container of coolant so that the threaded portion is submerged Suspend an accurate thermometer B with temperature sensing portions C located in almost the same depth NOTE The sensor and thermometer must not touch the con tainer side or bottom Place the container over a source of heat and gradu ally raise the temperature of the coolant while stirring the coolant gently Using the hand tester measure the internal resistance of the sensor The sensor sends electric signals to the ECU and water temperature gauge in the meter unit Measure the resistance across the terminals and the body for the gauge at the temperatures shown in the table If the hand tester does not show the specified values re place the sensor Water Temperature Sensor Resistance for ECU D Resistance k Temperature Terminal 1 3 0 155 20 C 68 F 2 46 0 143 80 C 176 F 0 32 0 011 110 C 230 F 0 1426 0 0041 Resistance for Water Temperature Gauge E Resistance Temperature Terminal 2 Body 50 C 122 F 210 40 120 C 248 F 21 2 1 5 Speed Sensor Removal CAUTION Never drop the sensor especially on a hard surface Such a shock to the sensor can damage it Remove Left Side Cover see Side Cover Removal in the Frame
232. ealing surfaces with water or coolant to prevent pressure leaks Build up pressure in the system carefully until the pres sure reaches 123 kPa 1 25 kgf cm 18 psi CAUTION During pressure testing do not exceed the pres sure for which the system is designed The maxi mum pressure is 123 kPa 1 25 kgf cm 18 psi Watch the gauge for at least 6 seconds If the pressure holds steady the system is all right If the pressure drops and no external source is found check for internal leaks Droplets in the engine oil indicate internal leakage Check the cylinder head gasket and the water pump Remove the pressure tester replenish the coolant and install the radiator cap http mototh com 4 8 COOLING SYSTEM Coolant Cooling System Flushing Over a period of time the cooling system accumulates rust scale and lime in the water jacket and radiator When this accumulation is suspected or observed flush the cool ing system If this accumulation is not removed it will clog up the water passage and considerable reduce the effi ciency of the cooling system Drain the cooling system see Coolant Change in the Pe riodic Maintenance chapter Fill the cooling system with fresh water mixed with a flush ing compound CAUTION Do not use a flushing compound which is harmful to the aluminum engine and radiator Carefully follow the instructions supplied by the manufacturer of the cleaning product Warm
233. eather fine cloudy rain snow always other Temperature hot warm cold very cold always other Problem frequency chronic often once Road street highway mountain road uphill downhill bumpy pebble Altitude normal high about 1 000 m or more Motorcycle conditions when problem occurred lights up immediately after ignition switch ON and goes off after 1 2 seconds normal lights up immediately after ignition switch ON and stays on DFI problem unlights light ECU or its wiring fault FI indicator light sometimes lights up probably wiring fault starter motor not rotating starter motor rotating but engine do not turn over starter motor and engine do not turn over no fuel flow no fuel in tank no fuel pump sound no spark Starting difficulty other right after starting when opening throttle grip when closing throttle grip when moving off when stopping the motorcycle when cruising Engine stalls other very low idle speed very high idle speed rough idle speed battery voltage is low charge the battery spark plug loose tighten it spark plug dirty broken or gap maladjusted remedy it backfiring afterfiring hesitation when acceleration engine oil viscos
234. ection Refer to the Steering Play Inspection in the Periodic Main tenance chapter Steering Adjustment Refer to the Steering Play Adjustment in the Periodic Maintenance chapter http mototh com 14 6 STEERING Steering Stem Stem Stem Bearing Removal Remove Lower Fairings see Lower Fairing Removal in the Frame chapter Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Front Wheel see Front Wheel Removal in the Wheels Tires chapter Handlebars see Handlebar Removal Front Forks see Front Fork Removal in the Suspension chapter Steering Stem Head Bolt A Steering Stem Head B Remove the bolts A Pushing up the stem base and remove the steering stem nut A and stem cap B Special Tool Steering Stem Nut Wrench C 57001 1100 Remove Steering Stem D Upper Ball Bearing Inner Race and Ball Bearings NOTE Be aware of removing the steering stem so that the stem bearing steel balls are not lost Remove the upper and lower outer races using the re mover A Special Tool Oil Seal amp Bearing Remover 57001 1058 NOTE If either steering stem bearing is damaged it is recom mended that both the upper and lower bearings includ ing outer races should be replaced with new ones http mototh com STEERING 14 7 Steering Stem Remove the lower ball bearing inner race with its oil seal A which is pressed onto the steering stem using t
235. ee Crankshaft Sensor Inspection Stick Coil Removal CAUTION Never drop the stick coils especially on a hard sur face Such a shock to the stick coils can damage it Remove the fuel tank see Fuel Tank Removal in the Fuel System DFI chapter Disconnect the stick coil connectors A Pull the stick coils B off the spark plugs CAUTION Do not pry the connector part of the coil while re moving the coil http mototh com ELECTRICAL SYSTEM 16 35 Ignition System Stick Coil Installation Insert the coil as shown being careful of the coil heads A direction Be sure the stick coils are installed by pulling up it lightly Connect the connectors CAUTION Do not tap the coil head while installing the coil Run the leads correctly see Cable Wire and Hose Rout ing section in the Appendix chapter Install the removed parts see appropriate chapters Stick Coil Inspection Remove the stick coils see Stick Coil Removal Measure the primary winding resistance A as follows Connect the hand tester between the coil terminals Set the tester to the 1 range and read the tester Measure the secondary winding resistance B as follows Connect the tester between the plug terminal and coil terminal Set the tester to the 1 k range and read the tester Stick Coil Winding Resistance Primary Windings 1 0 1 6 Secondary Windings 10 8
236. ee Headlight Bulb Replace ment in the Electrical System chapter Dimmer Switch see Switch Inspection in the Electrical System chapter Turn off the engine stop switch The low beam and high beam headlights should stay go ing on If the headlights and high beam indicator light does go off inspect or replace the following item Headlight Relay in Relay Box see Relay Circuit Inspec tion in the Electrical System chapter Turn off the ignition switch The headlights and high beam indicator light should go off Headlight Aiming Inspection Inspect the headlight beam for aiming If the headlight beam points to one side rather than straight ahead adjust the horizontal beam Headlight Beam Horizontal Adjustment Turn the horizontal adjuster A on the headlight in or out until the beam points straight ahead If the headlight beam points too low or high adjust the vertical beam Headlight Beam Vertical Adjustment Turn the vertical adjuster A on the headlight in or out to adjust the headlight vertically NOTE ON high beam the brightest points should be slightly below horizontal with the motorcycle on its wheels and the rider seated Adjust the headlight to the proper an gle according to local regulations http mototh com PERIODIC MAINTENANCE 2 39 Periodic Maintenance Procedures Sidestand Switch Operation Inspection Inspect the sidestand switch A operation accordance to the following ta
237. ee Lower Fairing Removal in the Frame chapter Radiator Cap Check the radiator filler neck for signs of damage Check the condition of the top and bottom sealing seats A in the filler neck They must be smooth and clean for the radiator cap to function properly http mototh com 4 14 COOLING SYSTEM Thermostat Thermostat Removal Remove Coolant Drain see Coolant Change in the Periodic Maintenance chapter Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Thermostat Cover Bolts A Move the thermostat cover A outwards and remove the thermostat B Thermostat Installation Install the thermostat A in the housing so that the air bleeder hole B as shown in the figure Tighten Torque Thermostat Cover Bolts 9 8 N m 1 0 kgf m 87 in lb Install the removed parts see appropriate chapters Thermostat Housing Removal Remove Coolant Drain see Coolant Change in the Periodic Maintenance chapter Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Water Temperature Sensor Connector A Disconnect Hose Clamp Screws B Loosen Hoses C Bolts D Thermostat Housing E Thermostat Housing Installation Be sure to install the ground lead on the thermostat hous ing mounting bolt Tighten Torque Thermostat Housing Mounting Bolts 9 8 N m 1 0 kgf m 87 in lb Radiator Water Hose Clamp Screws 1 5 N m 0 15 kgf m 13 in lb
238. ee play can be obtained Tighten the locknut against the adjuster securely If the throttle grip free play can not be adjusted with the adjuster use the adjusters in the lower ends of the throttle cables Remove Left Side Cover see Side Cover Removal in the Frame chapter Left Lower Fairing see Lower Fairing Removal in the Frame chapter Turn out both upper nuts A and turn in both lower nuts B as far as they will go so as to give the throttle grip plenty of play With the throttle grip completely closed turn out the lower nut and turn in the upper nut of the decelerator cable C until the inner cable just becomes tight Turn out the lower nut and turn in the upper nut of the accelerator cable D until the correct free play is obtained Check that the throttle linkage lever A stops against the adjusting screw B with the throttle grip closed Engine Vacuum Synchronization Inspection NOTE These procedures are explained on the assumption that the inlet and exhaust systems of the engine are in good condition Situate the motorcycle so that it is vertical Remove the fuel tank see Fuel Tank Removal in the Fuel System DFI chapter Pull off the rubber caps A from the fittings of each throttle body http mototh com 2 16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Pull off the air switching valve hose A from the air cleaner housing Plug the air switching val
239. ee wiring diagram in this section If the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see ECU Removal Installation If the input voltage is within the standard check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see ECU Removal Installation http mototh com 3 70 FUEL SYSTEM DFI Stick Coils 1 2 Service Code 51 52 Stick Coil Circuit 1 Engine Stop Switch 2 Stick Coil 1 2 3 Water proof Joint 3 4 ECU 5 Joint Connector 2 6 Battery 12 V 8 Ah 7 Frame Ground 8 Main Fuse 30 A 9 Ignition Fuse 10 A 10 Fuse Box 11 Ignition Switch http mototh com FUEL SYSTEM DFI 3 71 Radiator Fan Relay Service Code 56 Radiator Fan Relay Removal Installation The radiator fan relay is built in the relay box A Refer to the Relay Box Removal in the Electrical System chapter Radiator Fan Relay Inspection Refer to the Relay Circuit Inspection in the Electrical Sys tem chapter If the radiator fan relay is normal check the wiring for continuity see wiring diagram in this section If the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see ECU Removal Installation http mototh com 3 72 FUEL SYSTE
240. eel Spin B the front wheel lightly and check for smoothly turn roughness binding or noise If roughness binding or noise is found remove the front wheel and inspect the wheel bearing see Front Wheel Removal Hub Bearing Inspection in the Wheels Tires chapter Raise the rear wheel off the ground with the stand see Rear Wheel Removal in the Wheels Tires chapter Inspect the roughness of the rear wheel bearing by push ing and pulling A the wheel Spin B the rear wheel lightly and check for smoothly turn roughness binding or noise If roughness binding or noise is found remove the rear wheel and inspect the wheel bearing see Rear Wheel Re moval Hub Bearing Inspection in the Wheels Tires chap ter and coupling see Coupling Bearing Inspection in the Final Drive chapter Final Drive Drive Chain Lubrication Condition Inspection If a special lubricant is not available a heavy oil such as SAE 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication If the chain appears especially dirty clean it before lubri cation CAUTION The O rings between the side plates seal in the lu bricant between the pin and the bushing To avoid damaging the O rings and resultant loss of lubri cant observe the following rules Use only kerosene or diesel oil for cleaning of the O ring of the drive chain Any other cleaning solution such as gasoline or trichloroethyl
241. elay 13 ECU Main Relay 14 Fan Relay 15 Ignition Fuse 10 A 16 ECU Fuse 15 A 17 Fan Fuse 10 A 18 Oxygen Sensor Heater Fuse 10 A 19 Fuse Box 20 Joint Connector 1 21 FI Indicator Light 22 Tachometer 23 Water Temperature Gauge 24 Ignition Switch 25 Engine Stop Switch 26 Starter Button 27 Fan Motor 28 Resistor 29 Stick Coil 1 2 30 Water proof Joint 3 31 Air Switching Valve 32 Speed Sensor 33 Subthrottle Valve Actuator 34 Subthrottle Sensor 35 Main Throttle Sensor 36 Inlet Air Pressure Sensor 37 Water proof Joint 2 38 Vehicle down Sensor 39 Fuel Injector 1 2 40 Water proof Joint 1 41 Water Temperature Sensor 42 Inlet Air Temperature Sensor 43 Crankshaft Sensor Color Codes BK Black BL Blue BR Brown CH Chocolate DG Dark Green G Green GY Gray LB Light Blue LG Light Green O Orange P Pink PU Purple R Red V Violet W White Y Yellow http mototh com 3 12 FUEL SYSTEM DFI DFI System Terminal Numbers of ECU Connectors Terminal Names 1 Subthrottle Valve Actuator W BL 2 Subthrottle Valve Actuator P 3 Fuel Level Warning Indicator Light GY 4 Oxygen Sensor BL Y 5 Speed Sensor LG R 6 Main Throttle Sensor Y W 7 Inlet Air Pressure Sensor Y BL 8 Power Supply to Sensors BL 9 Vehicle down Sensor Y G 10 Neutral Switch LG 11 Crankshaft Sensor R BK 12 Power Supply to ECU from ECU Main Relay BR W 13 External Communication Line LG BK 14
242. eld Installation Put the bottom end A to the projection B Tighten Torque Windshield Mounting Bolts 0 42 N m 0 043 kgf m 3 7 in lb Upper Fairing Removal Remove Windshield see Windshield Removal Lower Fairings see Lower Fairing Removal Inner Fairing see Inner Fairing Removal Bolts A Both Sides Pull out the upper fairing B forward Disconnect Headlight Lead Connectors A City Light Lead Connector B Remove the upper fairing C Upper Fairing Disassembly Remove Upper Fairing see Upper Fairing Removal Bolts A Headlight B Brackets C Nuts D and Rear View Mirrors Upper Fairing Assembly Assembly is the reverse of disassembly Upper Fairing Installation Installation is the reverse of removal Inner Cover Removal Refer to the Meter Unit Removal Installation in the Elec trical System chapter Inner Cover Installation Refer to the Meter Unit Removal Installation in the Elec trical System chapter http mototh com 15 10 FRAME Fairings Upper Fairing Bracket Removal Remove Upper Fairing see Upper Fairing Removal Meter Unit see Meter Unit Removal Installation in the Electrical System chapter Fuel Tank A see Fuel Tank Removal in the Fuel Sys tem DFI chapter Clutch Cable B Throttle Cables C Left and Right Switch Housing Lead Connectors Ignition Switch Lead Connector Bands D Bolt E Nuts F and Bolts Upper Fai
243. emoval Separate the hose A from the air cleaner housing Separate the hose A from the air suction valve cover Do not disconnect the air switching valve connector A http mototh com 3 80 FUEL SYSTEM DFI Oxygen Sensor Incorrect Output Voltage Service Code 94 Install the suitable plug A on the fitting of the air suction valve cover and shut off the secondary air Install the fuel tank see Fuel Tank Installation Start the engine and let it idle Measure the output voltage with the connector joined Output Voltage with Plug Standard DC 0 7 V or more Next remove the plug from the fitting A with idling Measure the output voltage with the connector joined Output Voltage without Plug Standard DC 0 2 V or less Turn the ignition switch OFF If the reading is out of the standard with plug DC 0 7 V or more without plug DC 0 2 V or less check the following Fuel Pressure see Fuel Pressure Inspection Fuel Injector see Fuel Injectors section If the fuel pressure and fuel injectors are good replace the sensor If the reading is within the standard with plug DC 0 7 V or more without plug DC 0 2 V or less check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see ECU Removal Installation http mototh com FUEL SYSTEM DFI 3 81 Oxygen Sensor Incorrect Output
244. en operating in severe conditions dusty wet muddy high speed or frequent starting stopping For higher odometer readings repeat at the frequency interval established here http mototh com 2 6 PERIODIC MAINTENANCE Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non permanent locking agent or silicone sealant etc Letters used in the Remarks column mean G Apply grease L Apply a non permanent locking agent MO Apply molybdenum disulfide grease oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 S Follow the specified tightening sequence Si Apply silicone grease ex PBC grease SS Apply silicone sealant Torque Fastener N m kgf m ft lb Remarks Fuel System DFI Air Cleaner Housing Cap Bolts 2 5 0 25 22 in lb Air Cleaner Housing Mounting Bolts 9 8 1 0 87 in lb Air Cleaner Housing Screws 1 15 0 12 10 in lb Air Duct Clamp Screws 2 0 0 20 18 in lb Crankshaft Sensor Screws 3 0 0 31 27 in lb Delivery Pipe Assy Mounting Screws 3 4 0 35 30 in lb Fuel Pump Bolts 9 8 1 0 87 in lb L Inlet Air Temperature Sensor Screw 1 2 0 12 11 in lb Oxygen Sensor 44 1 4 50 32 5 Speed Sensor Bolt 7 8 0 80 69 in lb L Throttle Body Assy Holder Clamp Screws 2 0 0 20 18 in lb Water Temperature Sensor 25 2 5 18 Cooling System Coolant Drain Bolt Cylin
245. ene will cause de terioration and swelling of the O ring Immediately blow the chain dry with compressed air after clean ing Complete cleaning and drying the chain within 10 minutes http mototh com PERIODIC MAINTENANCE 2 27 Periodic Maintenance Procedures Apply oil to the sides of the rollers so that oil will penetrate to the rollers and bushings Apply the oil to the O rings so that the O rings will be coated with oil Wipe off any excess oil Oil Applied Areas A O rings B Drive Chain Slack Inspection NOTE Check the slack with the motorcycle setting on its side stand Clean the chain if it is dirty and lubricate it if it appears dry Check the wheel alignment see Wheel Alignment Inspec tion Rotate the rear wheel to find the position where the chain is tightest Measure the vertical movement chain slack A midway between the sprockets If the chain slack exceeds the standard adjust it Chain Slack Standard 20 30 mm 0 8 1 2 in Drive Chain Slack Adjustment Remove the cotter pin A and loosen the axle nut B Loosen the both chain adjuster locknuts C If the chain is too loose turn out the left and right chain adjusters D evenly If the chain is too tight turn in the left and right chain adjusters evenly and kick the wheel forward Turn both chain adjusters evenly until the drive chain has the correct amount of slack To keep the chain and wheel
246. eplacement in the Periodic Maintenance chapter Fuel Tank see Fuel Tank Installation Start the engine and check for fuel leakage Fuel Flow Rate Inspection WARNING Gasoline is extremely flammable and can be explo sive under certain conditions Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Turn the ignition switch OFF Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately NOTE Be sure the battery is fully charged Turn the ignition switch OFF Wait until the engine cools down Prepare a fuel hose Special Tool 57001 1607 and a measuring cylinder Special Tool Fuel Hose 57001 1607 Remove the fuel tank bolts see Fuel Tank Removal Open the fuel tank cap A to lower the pressure in the tank Remove the fuel hose from the fuel pump see Fuel Tank Removal Be sure to place a piece of cloth around the fuel supply pipe of the fuel pump WARNING Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is disconnected fuel spills out from the hose and the pipe because of residual pressure Cover the hose connection with a piece of clean cloth to prevent fuel spillage http mototh com 3 90 FUEL SYSTEM DFI Fuel Line Connect the prepared fuel hose A to the fuel supply pipe of the fuel pump
247. er set Special Tool Needle Adapter Set 57001 1457 ECU Power Supply Inspection Connections I Digital Meter Terminal 12 BR W Digital Meter Battery terminal II Digital Meter Terminal 27 W BK Digital Meter Battery terminal Ignition Switch OFF Terminal 12 BR W 0 V Terminal 27 W BK Battery Voltage Ignition Switch ON Both Battery Voltage If the reading is out of the specification check the follow ing Main Fuse 30 A see Fuse Inspection in the Electrical System chapter ECU Fuse 15 A see Fuse Inspection in the Electrical System chapter ECU Main Relay see Relay Circuit Inspection in the Electrical System chapter Power Source Wiring see wiring diagram in this sec tion If the fuse wiring and relay are good replace the ECU see ECU Removal Installation http mototh com 3 86 FUEL SYSTEM DFI ECU ECU Power Source Circuit 1 Ignition Switch 2 Water proof Joint 3 3 ECU 4 Joint Connector 2 5 Battery 12 V 8 Ah 6 Frame Ground 7 Main Fuse 30 A 8 Relay Box 9 ECU Main Relay 10 ECU Fuse 15 A 11 Fuse Box http mototh com FUEL SYSTEM DFI 3 87 DFI Power Source ECU Fuse Removal Refer to the 15 A ECU Fuse Removal in the Electrical System chapter ECU Fuse Installation If a fuse fails during operation inspect the DFI system to determine the cause and then replace it with a new fuse of proper amperage
248. ery 12 V 8 Ah 9 Frame Ground 10 Main Fuse 30 A 11 Fuel Pump Relay 12 Relay Box 13 ECU Main Relay 14 Ignition Fuse 10 A 15 ECU Fuse 15 A 16 Fuse Box http mototh com FUEL SYSTEM DFI 3 101 Throttle Grip and Cables Free Play Inspection Refer to the Throttle Control System Inspection in the Pe riodic Maintenance chapter Free Play Adjustment Refer to the Throttle Control System Inspection in the Pe riodic Maintenance chapter Cable Installation Install the throttle cables in accordance with the Cable Wire and Hose Routing section in the Appendix chapter Install the lower ends of the throttle cables in the throttle pulley on the throttle body assy after installing the upper ends of the throttle cables in the grip After installation adjust each cable properly see Throttle Control System Inspection in the Periodic Maintenance chapter WARNING Operation with incorrectly routed or improperly ad justed cables could result in an unsafe riding con dition Cable Lubrication Refer to the Chassis Parts Lubrication in the Periodic Maintenance chapter http mototh com 3 102 FUEL SYSTEM DFI Throttle Body Assy Idle Speed Inspection Adjustment Refer to the Idle Speed Inspection Adjustment in the Pe riodic Maintenance chapter Synchronization Inspection Adjustment Refer to the Engine Vacuum Synchronization Inspection in the Periodic Maintenance chapter Throttle Body
249. es are reamed they must be cleaned thor oughly Special Tool Valve Guide Reamer 4 5 57001 1333 Valve to Guide Clearance Measurement Wobble Method If a small bore gauge is not available inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below Insert a new valve A into the guide B and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface Move the stem back and forth C to measure valve valve guide clearance Repeat the measurement in a direction at a right angle to the first If the reading exceeds the service limit replace the guide http mototh com 5 28 ENGINE TOP END Valves NOTE The reading is not actual valve valve guide clearance because the measuring point is above the guide Valve Valve Guide Clearance Wobble Method Standard Exhaust 0 07 0 12 mm 0 0028 0 0047 in Inlet 0 02 0 08 mm 0 0008 0 0032 in Service Limit Exhaust 0 27 mm 0 011 in Inlet 0 23 mm 0 010 in Valve Seat Inspection Remove the valve see Valve Removal Check the valve seating surface A between the valve B and valve seat C Measure the outside diameter D of the seating pattern on the valve seat If the outside diameter is too large or too small repair the seat see Seat Repair Valve Seating Surface Outside Diameter Standard Exhaust
250. essary Inspect the vacuums as before If both vacuums are within the specification finish the en gine vacuum synchronization If any vacuum can not be adjusted within the specification remove the bypass screws 1 2 and clean them Remove Bypass Screw A Spring B Washer C O ring D Check the bypass screw and its hole for carbon deposits If any carbons accumulate wipe the carbons off from the bypass screw and the hole using a cotton pad penetrated with a high flash point solvent Replace the O ring with a new one Check the tapered portion E of the bypass screw for wear or damage If the bypass screw is worn or damaged replace it Turn in the bypass screw until it seats fully but not tightly Repeat the same procedure for other bypass screw Repeat the synchronization If the vacuums are correct check the output voltage of the main throttle sensor see Main Throttle Sensor Output Voltage Inspection in the Fuel System DFI chapter Special Tool Throttle Sensor Setting Adapter 57001 1538 Main Throttle Sensor Output Voltage Connections to Adapter Digital Meter R sensor Y W lead Digital Meter W sensor BR BK lead Standard DC 1 020 1 050 V at idle throttle opening If the output voltage is out of the standard check the in put voltage of the main throttle sensor see Main Throttle Sensor Input Voltage Inspection in the Fuel System DFI chapte
251. f any fraying cracks B or bulges C are noticed Check that the hose is routed according to Cable Wire and Hose Routing section in the Appendix chapter Replace the hose if it has been sharply bent or kinked Hose Joints A Fuel Hose B http mototh com PERIODIC MAINTENANCE 2 19 Periodic Maintenance Procedures Check that the hose joints are securely connected Push and pull A the hose joint B back and forth more than two times and make sure it is locked and does not come off Fuel Pump Side C Throttle Body Assy Side D WARNING Make sure the hose joint is installed correctly on the fuel supply pipe or the fuel could leak If it comes off reinstall the hose joint Cooling System Coolant Level Inspection NOTE Check the level when the engine is cold room or ambi ent temperature Check the coolant level in the reserve tank A with the motorcycle held perpendicular Do not use the side stand If the coolant level is lower than the L level line B un screw the reserve tank cap and add coolant to the F level line C L low F full CAUTION For refilling add the specified mixture of coolant and soft water Adding water alone dilutes the coolant and degrades its anticorrosion properties The diluted coolant can attack the aluminum en gine parts In an emergency soft water alone can be added But the diluted coolant must be returned to the correct mixture ratio within
252. ferent thickness NOTE Mark and record the locations of the valve lifters and shims so that they can be reinstalled in their original positions Clean the shim to remove any dust or oil Measure the thickness of the removed shim A Select a new shim thickness calculation as follows a b c d a Present Shim Thickness b Measured Valve Clearance c Specified Valve Clearance Mean Value 0 255 mm Exhaust 0 195 mm Inlet d Replace Shim Thickness Example Inlet 2 90 0 45 0 195 3 155 mm Exchange the shim for the 3 175 size shim http mototh com 2 22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Adjustment Shims Thickness Part Number Mark 2 50 92180 1014 50 2 55 92180 1016 55 2 60 92180 1018 60 2 65 92180 1020 65 2 675 92180 1174 68 2 70 92180 1022 70 2 725 92180 1175 73 2 75 92180 1024 75 2 775 92180 1176 78 2 80 92180 1026 80 2 825 92180 1177 83 2 85 92180 1028 85 2 875 92180 1178 88 2 90 92180 1030 90 2 925 92180 1179 93 2 95 92180 1032 95 2 975 92180 1180 98 3 00 92180 1034 00 3 025 92180 1181 03 3 05 92180 1036 05 3 075 92180 1182 08 3 10 92180 1038 10 3 125 92180 1183 13 3 15 92180 1040 15 3 175 92180 1184 18 3 20 92180 1042 20 3 25 92180 1044 25 3 30 92180 1046 30 3 35 92180 1048 35 3 40 92180 1050 40 3 45 92180 1052 45 3 50
253. fresh charge for 5 to 10 hours with charge current shown in the specification see Refreshing Charge When a fast charge is inevitably required do it following precisely the maximum charge current and time conditions indicated on the battery CAUTION This battery is designed to sustain no unusual deterioration if refresh charged according to the method specified above However the battery s performance may be reduced 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 WARNING Keep the battery away from sparks and open flames during charging since the battery gives off an explosive gas mixture of hydrogen and oxygen When using a battery charger connect the battery to the charger before turning on the charger This procedure prevents sparks at the battery terminals which could ignite any battery gases No fire should be drawn ne
254. ft Cap Clearance Standard 0 028 0 071 mm 0 0011 0 0028 in Service Limit 0 16 mm 0 0063 in If any clearance exceeds the service limit measure the diameter of each camshaft journal with a micrometer Camshaft Journal Diameter Standard 23 950 23 972 mm 0 9429 0 9438 in Service Limit 23 92 mm 0 942 in If the camshaft journal diameter is less than the service limit replace the camshaft with a new one and measure the clearance again If the clearance still remains out of the service limit re place the cylinder head unit Camshaft Runout Inspection Remove the camshafts see Camshaft Removal Set the camshaft in a camshaft alignment jig or on V blocks Measure the runout with a dial gauge at the specified place as shown in the figure If the runout exceeds the service limit replace the camshaft Camshaft Runout Standard TIR 0 02 mm 0 0008 in or less Service Limit TIR 0 1 mm 0 004 in http mototh com ENGINE TOP END 5 21 Camshaft Camshaft Chain Cam Wear Inspection Remove the camshafts see Camshaft Removal Measure the height A of each cam with a micrometer If the cams are worn down past the service limit replace the camshaft Cam Height Standard Exhaust 32 843 32 957 mm 1 2930 1 2975 in Inlet 33 843 33 957 mm 1 3324 1 3369 in Service Limit Exhaust 32 74 mm 1 289 in Inlet 33 74 mm 1 328 in Camshaft C
255. fuel must be completely wiped up immediately CAUTION Never drop the fuel pump especially on a hard sur face Such a shock to the pump can damage it Draw the fuel out from the fuel tank with a commercially available electric pump Remove the fuel tank see Fuel Tank Removal Be careful of fuel spillage from the fuel tank since fuel still remains in the fuel tank and fuel pump Plug the fuel supply pipe of the fuel pump Turn the fuel tank upside down Free the lead from the clamp A Unscrew the fuel pump bolts B and take out the fuel pump C CAUTION Do not pull the lead of the fuel pump If they are pulled the lead terminals may be damaged Discard the fuel pump gasket A http mototh com 3 92 FUEL SYSTEM DFI Fuel Pump Fuel Pump Installation Remove dirt or dust from the fuel pump A by lightly ap plying compressed air Replace the fuel pump gasket with a new one Apply a non permanent locking agent to the threads of the fuel pump bolts Tighten the fuel pump bolts to a snug fit tighten them alternating diagonally Torque Fuel Pump Bolts 9 8 N m 1 0 kgf m 87 in lb Tighten the pump bolts again alternating diagonally to check the tightness Hold the lead A with the clamp B Fuel Pump Operation Inspection NOTE Be sure the battery is fully charged Turn the engine stop switch to run position Turn the ignition switch ON and m
256. g White C Oil Seal D Retainer E Split Keepers F Closed Coil End G Valve Guide Removal Remove Valve see Valve Removal Oil Seal Spring Seat Heat the area around the valve guide to 120 150 C 248 302 F and hammer lightly on the valve guide arbor A to remove the guide from the top of the head CAUTION Do not heat the cylinder head with a torch This will warp the cylinder head Soak the cylinder head in oil and heat the oil Special Tool Valve Guide Arbor 4 5 57001 1331 http mototh com ENGINE TOP END 5 27 Valves Valve Guide Installation Apply engine oil to the valve guide outer surface before installation Heat the area around the valve guide hole to about 120 150 C 248 302 F CAUTION Do not heat the cylinder head with a torch This will warp the cylinder head Soak the cylinder head and heat the oil Using the valve guide driver A and washer B press and insert the valve guide in until the washer surface C touches the head surface D 15 3 15 5 mm 0 60 0 61 in E Special Tools Valve Guide Driver 57001 1564 Washer 57001 1720 Wait until the cylinder head cools down and then ream the valve guide with the valve guide reamer A even if the old guide is reused Turn 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 Once the guid
257. g a 3 0 3 5 mm 0 12 0 14 in drill bit B Using a 3 mm 0 12 in rod A tap out the pin B and then pull out the speedometer cable bushing and speedometer pinion NOTE It is recommended that the assembly be replaced rather than attempting to repair the components Speedometer Gear Housing Assembly When assembling the speedometer gear housing be careful of the following items After inserting a new pin stake the housing hole to secure the pin in place Apply high temperature grease to the speedometer gear Replace the grease seal with a new one Apply a little high temperature grease to the seal Install it using a press or a suitable driver so that the face of the seal is level with the surface of the housing http mototh com 10 20 WHEELS TIRES Speedometer Gear Housing Speedometer Gear Housing Lubrication Clean and grease A the speedometer gear housing B http mototh com FINAL DRIVE 11 1 11 Final Drive Table of Contents Exploded View 11 2 Specifications 11 4 Special Tool and Sealant 11 5 Drive Chain
258. g Inspection in the Electrical System chapter If the all parts are good condition replace the ECU see ECU Removal Installation in the Fuel System DFI chap ter http mototh com 2 40 PERIODIC MAINTENANCE Periodic Maintenance Procedures Engine Stop Switch Operation Inspection First Step Turn on the ignition switch Set the neutral position Turn the engine stop switch to stop position A Push the starter button The engine does not start If the engine starts inspect or replace the following item Engine Stop Switch see Switch Inspection in the Elec trical System chapter Second Step Turn on the ignition switch Set the neutral position Turn the engine stop switch to run position A Push the starter button and run the engine Turn the engine stop switch to stop position Immediately the engine should be stop If the engine does not stop inspect or replace the follow ing item Engine Stop Switch see Switch Inspection in the Elec trical System chapter If the engine stop switch is good condition replace the ECU see ECU Removal Installation in the Fuel System DFI chapter Others Chassis Parts Lubrication Before lubricating each part clean off any rusty spots with rust remover and wipe off any grease oil dirt or grime Lubricate the points listed below with indicated lubricant NOTE Whenever the vehicle has been operated under wet or rainy
259. g incorrect ECU trouble Muffler overheating For KLEEN do not run the engine even if with only one cylinder misfiring or poor running Request the nearest service fa cility to correct it For KLEEN do not push start with a dead battery Connect another full charged battery with jumper cables and start the engine using the electric starter For KLEEN do not start the engine under misfire due to spark plug fouling or poor connection of the stick coil For KLEEN do not coast the motorcycle with the ignition switch off Turn the igni tion switch ON and run the engine ECU trouble Fuel air mixture incorrect Throttle body assy holder loose Air cleaner duct loose Air cleaner clogged poorly sealed or miss ing Compression high Carbon built up in combustion chamber Engine load faulty Clutch slipping Engine oil level too high http mototh com 17 34 APPENDIX Troubleshooting Guide Engine oil viscosity too high Drive train trouble Brake dragging Lubrication inadequate Engine oil level too low Engine oil poor quality or incorrect Gauge incorrect Water temperature gauge broken Water temperature sensor broken Coolant incorrect Coolant level too low Coolant deteriorated Wrong coolant mixed ratio Cooling system component incorrect Radiator fin damaged Radiator clogged Thermostat trouble Radiator cap trouble Radiator fan relay trouble Fan motor broken Fan blade damaged Water pump not turning Water pump impeller dama
260. g weak or broken Rear shock absorber noise Shock absorber damaged Disc brake noise Pad installed incorrectly Pad surface glazed Disc warped Caliper trouble Other noise Bracket nut bolt etc not properly mounted or tightened Oil Pressure Warning Indicator Light Goes On Engine oil pump damaged Engine oil screen clogged Engine oil filter clogged Engine oil level too low Engine oil viscosity too low Camshaft bearing worn Crankshaft bearing worn Oil pressure switch damaged Wiring faulty Relief valve stuck open O ring at the oil passage in the crankcase damaged Exhaust Smokes Excessively White smoke Piston oil ring worn Cylinder worn Valve oil seal damaged Valve guide worn Engine oil level too high Black smoke Air cleaner clogged Brown smoke Air cleaner duct loose Air cleaner poorly sealed or missing Handling and or Stability Unsatisfactory Handlebar hard to turn Cable routing incorrect Hose routing incorrect Wiring routing incorrect Steering stem nut too tight Steering stem bearing damaged Steering stem bearing lubrication inade quate Steering stem bent Tire air pressure too low Handlebar shakes or excessively vibrates Tire worn Swingarm pivot bearing worn Rim warped or not balanced Wheel bearing worn Handlebar mounting bolt loose Steering stem nut loose Front rear axle runout excessive Engine mounting nut loose Handlebar pulls to one side Frame bent Wheel misalignment Swingarm bent or twisted
261. ged Over Cooling Gauge incorrect Water temperature gauge broken Water temperature sensor broken Cooling system component incorrect Thermostat trouble Clutch Operation Faulty Clutch slipping Friction plate worn or warped Steel plate worn or warped Clutch spring broken or weak Clutch hub or housing unevenly worn No clutch lever play Clutch inner cable trouble Clutch release mechanism trouble Clutch not disengaging properly Clutch plate warped or too rough Clutch spring compression uneven Engine oil deteriorated Engine oil viscosity too high Engine oil level too high Clutch housing frozen on drive shaft Clutch hub nut loose Clutch hub spline damaged Clutch friction plate installed wrong Clutch lever play excessive Clutch release mechanism trouble Gear Shifting Faulty Doesn t go into gear shift pedal doesn t return Clutch not disengaging Shift fork bent or seized Gear stuck on the shaft Shift return spring weak or broken Shift return spring pin loose Shift mechanism arm broken Shift pawl broken Pawl spring broken Jumps out of gear Shift fork ear worn bent Gear groove worn Gear dogs and or dog holes worn Shift drum groove worn Shift fork guide pin worn Drive shaft output shaft and or gear splines worn Overshifts Neutral positioning pin spring weak or bro ken Pawl spring broken Abnormal Engine Noise Knocking ECU trouble Carbon built up in combustion chamber Fuel poor quality or incorrect Spark pl
262. gine Mounting Bracket Nuts and Bolts A Both Sides Engine Mounting Nut B and Bolt Engine Mounting Brackets C Both Sides Oil Hose Banjo Bolt D http mototh com 5 24 ENGINE TOP END Cylinder Head Remove M6 Cylinder Head Bolt A M8 Cylinder Head Bolts B Cylinder Head Cylinder Head Installation NOTE The camshaft cap is machined with the cylinder head so if a new cylinder head is installed use the cap that is supplied with the new head Install a new cylinder head gasket and dowel pins Replace the cylinder head bolt washers with new ones Apply molybdenum disulfide oil solution to both sides A of the cylinder head bolt washers B and the threads of the head bolts C Tighten the M8 cylinder head bolts following the tightening sequence 1 7 146 mm 5 75 in 1 6 115 mm 4 53 in 7 Torque Cylinder Head Bolts M8 31 4 N m 3 2 kgf m 23 2 ft lb Tighten the M6 cylinder head bolt following the tightening sequence 8 Torque Cylinder Head Bolt M6 12 N m 1 2 kgf m 106 in lb http mototh com ENGINE TOP END 5 25 Cylinder Head Install Front Camshaft Chain Guide A Rear Camshaft Chain Guide B Tighten Torque Rear Camshaft Chain Guide Bolt C 17 N m 1 7 kgf m 13 ft lb Install the removed parts see appropriate chapters Cylinder Head Warp Inspection Clean the cylinder head Lay a straightedge across the lower
263. gnosis Outline The self diagnosis system has three modes and can be switched to another mode by grounding the self diagnosis terminal User Mode The ECU notifies the rider of troubles in DFI system and ignition system by lighting the FI indicator light when DFI system and ignition system parts are faulty and initiates fail safe function In case of serious troubles the ECU stops the injection ignition starter motor operation Dealer Mode 1 The FI indicator light 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 emits service code s to show the problem s which the DFI system and ignition system had in the past Self diagnosis Procedures When a problem occurs with the DFI system and ignition system the FI indicator light A goes on NOTE Use a fully charged battery when conducting self diagnosis Otherwise the FI indicator light blinks very slowly or doesn t blink Keep the self diagnosis terminal grounded during self diagnosis with an auxiliary lead Remove the front seat see Front Seat Removal in the Frame chapter Ground the self diagnosis terminal A Yellow lead to the battery terminal using a wire Turn on the ignition switch Connect an auxiliary lead A to the self diagnosis terminal B for grounding To enter the self diagnosis dealer mode 1 ground C the self
264. hain Removal Split the crankcase see Crankcase Splitting in the Crank shaft Transmission chapter Remove the camshaft chain A from the crankshaft sprocket http mototh com 5 22 ENGINE TOP END Cylinder Head Cylinder Compression Measurement NOTE Use the battery which is fully charged Warm up the engine thoroughly Stop the engine Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Stick Coils see Stick Coil Removal in the Electrical Sys tem chapter Spark Plugs see Spark Plug Replacement in the Peri odic Maintenance chapter Attach the compression gauge A and adapter B firmly into the spark plug hole 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 20 kgf cm 57001 221 Compression Gauge Adapter M10 1 0 57001 1317 Cylinder Compression Usable Range 1 050 1 500 kPa 10 7 15 3 kgf cm 152 218 psi at 500 r min rpm Repeat the measurement for the other cylinder Install the spark plugs Torque Spark Plugs 13 N m 1 3 kgf m 115 in lb The following table should be consulted if the obtainable compression reading is not within the us able range Problem Diagnosis Remedy Action Carbon accumulation on piston and in combustion chamber possibly due to damaged v
265. han the specified value check the following Stick Coils see Stick Coil Inspection Crankshaft Sensor see Crankshaft Sensor Inspection ECU see ECU Power Supply Inspection in the Fuel Sys tem DFI chapter Spark Plug Removal Refer to the Spark Plug Replacement in the Periodic Maintenance chapter Spark Plug Installation Refer to the Spark Plug Replacement in the Periodic Maintenance chapter http mototh com ELECTRICAL SYSTEM 16 37 Ignition System Spark Plug Condition Inspection Remove the spark plugs see Spark Plug Replacement in the Periodic Maintenance chapter Visually inspect the spark plugs If 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 Measure the gap D with a wire type thickness gauge If the gap is incorrect replace the spark plug Spark Plug Gap 0 7 0 8 mm 0 028 0 031 in Use the standard spark plug or its equivalent Spark Plug NGK CR8E Interlock Operation Inspection Raise the rear wheel off the ground with stand Turn the engine stop switch ON run position 1st Check Start the engine to the following conditions Condition Transmission Gear 1st Position Clutch Lever Release Sidestand Down or Up Turn the ignition switch ON and push the starter
266. hapter Coolant Drain see Coolant Change in the Periodic Maintenance chapter Resistor see Resistor Inspection in the Electrical Sys tem chapter Radiator Hose Clamp Screw A Loosen Radiator Bolts B Remove Radiator Hose Clamp Screw A Loosen Radiator Bolts B Remove Radiator Fan Motor Lead Connector A Disconnect Radiator B CAUTION Do not touch the radiator core This could damage the radiator fins resulting in loss of cooling effi ciency Remove Radiator Fan Mounting Bolts A Radiator Fan B http mototh com 4 12 COOLING SYSTEM Radiator Radiator and Radiator Fan Installation Installation is the reverse of removal Run the leads correctly see Cable Wire and Hose Rout ing section in the Appendix chapter Cover the heat insulation rubber plate on the radiator see Engine Installation in the Engine Removal Installa tion chapter Install the removed parts see appropriate chapters Torque Radiator Bolts 9 8 N m 1 0 kgf m 87 in lb Radiator Water Hose Clamp Screws 1 5 N m 0 15 kgf m 13 in lb Resistor Bolt 7 8 N m 0 80 kgf m 69 in lb Radiator Inspection Check the radiator core If there are obstructions to air flow remove them If the corrugated fins A are deformed carefully straighten them If the air passages of the radiator core are blocked more than 20 by unremovable obstructions or irreparably de formed fins
267. he bearing puller B and adapter C Special Tools Bearing Puller 57001 158 Bearing Puller Adapter 57001 317 Stem Stem Bearing Installation Replace the bearing outer races with new ones 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 51 5 B 57001 1076 Head Pipe Outer Race Driver 47 C 57001 1447 Apply grease to the outer races Replace the bearing inner races and oil seal with new ones Apply grease to the oil seal Install the washer A and oil seal B on the steering stem and drive the ball bearing inner race C applied grease onto the stem Special Tools Steering Stem Bearing Driver D 57001 137 Steering Stem Bearing Driver Adapter 34 5 E 57001 1074 Apply grease to the lower ball bearings 20 A and inner race B and install the ball bearings onto the inner race Apply grease to the upper ball bearings 19 A and outer race B and install the ball bearings onto the outer race http mototh com 14 8 STEERING Steering Stem Install the steering stem A carefully through the head pipe so that the steel balls on the steering stem does not fall Install the stem cap B and steering stem nut C and tighten it by hand Install the stem head A Tighten the stem head bolt B lightly Settle the bearings in place as follows T
268. he con nector Conversely make sure that all the DFI electrical connections are firmly reconnected before starting the en gine Connect these connectors until they click A Do not turn the ignition switch ON while any of the DFI electrical connectors are disconnected The ECU memo rizes service codes Do not spray water on the electrical parts DFI parts con nectors leads and wiring If a transceiver is installed on the motorcycle make sure that the operation of the DFI system is not influenced by electric wave radiated from the antenna Check operation of the system with the engine at idle Locate the antenna as far as possible away from the ECU When any fuel hose is disconnected do not turn on the ignition switch Otherwise the fuel pump will operate and fuel will spout from the fuel hose Do not operate the fuel pump if the pump is completely dry This is to prevent pump seizure Before removing the fuel system parts blow the outer sur faces of these parts clean with compressed air When any fuel hose is disconnected fuel may spout out by residual pressure in the fuel line Cover the hose joint with a piece of clean cloth to prevent fuel spillage When installing the fuel hoses avoid sharp bending kink ing flattening or twisting and run the fuel hoses with a minimum of bending so that the fuel flow will not be ob structed Run the hoses according to Cable Wire and Hose Rout ing section i
269. he tire bead oppo site the valve stem in the rim well and pry the tire bead a little at a time CAUTION Be careful not to scratch the inner liner A and air sealing surfaces B of the rim and tire with the tire irons A scratched inner liner or sealing surface may allow air to leak After removing the bead on one side remove the other bead from the same manner Remove the tire from the rim Tire Installation WARNING Use the same manufacturer s tires on both front and rear wheels Inspect the rim and tire and replace them if necessary Clean the sealing surfaces of the rim and tire and smooth the sealing surfaces of the rim with a fine emery cloth if necessary Remove the air valve and discard it CAUTION Replace the air valve whenever the tire is replaced Do not reuse the air valve Install a new valve in the rim Remove the valve cap lubricate the stem seal A with a soap and water solution or rubber lubricant and pull B the valve stem through the rim from the inside out until it snaps into place CAUTION Do not use engine oil or petroleum distillates to lu bricate the stem because they will deteriorate the rubber The air valve is shown in the figure Valve Cap A Valve Core B Stem Seal C Valve Stem D Valve Seat E Valve Opened F http mototh com WHEELS TIRES 10 15 Tires Check the tire rotation mark on the front and rear tires and install them o
270. heel Balance 10 g 0 35 oz or less Balance Weights 10 g 0 35 oz 20 g 0 71 oz 30 g 1 06 oz Rim Size Front 17 2 75 Rear 17 3 50 Tires Air Pressure when Cold Front Up to 170 kg 375 lb load 200 kPa 2 00 kgf cm 28 psi Rear Up to 170 kg 375 lb load 225 kPa 2 25 kgf cm 32 psi Tread Depth Front IRC 4 2 mm 0 17 in BRIDGESTONE 4 6 mm 0 18 in DUNLOP 4 5 mm 0 18 in 1 mm 0 04 in AT CH DE 1 6 mm 0 06 in Rear IRC 6 5 mm 0 26 in BRIDGESTONE 7 0 mm 0 28 in DUNLOP 7 4 mm 0 29 in Up to 130 km h 80 mph 2 mm 0 08 in Over 130 km h 80 mph 3 mm 0 12 in Standard Tires Make Type Size Front IRC RX 01F BRIDGESTONE BATTLAX BT45F DUNLOP GT501F 110 70 17 M C 54S 110 70 17 M C 54H Rear IRC RX 01R BRIDGESTONE BATTLAX BT45R DUNLOP GT501 130 70 17 M C 62S 130 70 17 M C 62H WARNING Use the same manufacturer s tires on both front and rear wheels http mototh com WHEELS TIRES 10 5 Special Tools Inside Circlip Pliers 57001 143 Rim Protector 57001 1063 Bead Breaker Assembly 57001 1072 Bearing Driver Set 57001 1129 Jack 57001 1238 Bearing Remover Shaft 9 57001 1265 Bearing Remover Head 15 17 57001 1267 Jack Attachment 57001 1608 http mototh com 10 6 WHEELS TIRES Whee
271. her 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 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 Apply silicone grease to the brake lever pivot bolt and push rod Tighten Torque Brake Lever Pivot Bolt 5 9 N m 0 60 kgf m 52 in lb Brake Lever Pivot Bolt Locknut 5 9 N m 0 60 kgf m 52 in lb http mototh com PERIODIC MAINTENANCE 2 53 Periodic Maintenance Procedures Caliper Rubber Parts Replacement NOTE The procedure to assembly disassembly the front caliper is as follows Assembling disassembling the rear caliper is the same as for the front caliper Caliper Disassembly Remove Front Rear Caliper see Front Rear Caliper Removal in the Brakes chapter Brake Pads see Brake Pad Removal in the Brakes chapter Pad Spring Using compressed air remove the pistons Cover the piston area with a clean thick cloth A Blow compressed air B into the hole for the banjo bolt to remove the piston 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 Pull out the pistons by hand Remove Caliper Hol
272. hock to the parts can damage them To prevent damage to electrical parts do not disconnect the battery cables or any other electrical connections when the ignition switch is ON or while the engine is running Because of the large amount of current never keep the starter button pushed when the starter motor will not turn over or the current may burn out the starter motor wind ings Take care not to short the cables that are directly con nected to the battery positive terminal to the chassis ground Troubles may involve one or in some cases all items Never replace a defective part without determining what CAUSED the failure If the failure was caused by some other item or items they must be repaired or replaced or the new replacement will soon fail again Make sure all connectors in the circuit are clean and tight and examine wires for signs of burning fraying etc Poor wires and bad connections will affect electrical system op eration Measure coil and winding resistance when the part is cold at room temperature http mototh com ELECTRICAL SYSTEM 16 17 Electrical Wiring Wiring Inspection Visually inspect the wiring for signs of burning fraying etc If any wiring is poor replace the damaged wiring Pull each connector A apart and inspect it for corrosion dirt and damage If the connector is corroded or dirty clean it carefully If it is damaged replace it Check the wiring for
273. ications If torque specifications are not in the appropriate chapter see the Standard Torque Table For each fastener first loosen it by 1 2 turn then tighten it If cotter pins are damaged replace them with new ones Bolt Nut and Fastener to be checked Engine Clutch Lever Pivot Bolt Locknut Engine Mounting Bracket Bolts and Nuts Engine Mounting Nuts Exhaust Pipe Holder Nuts Exhaust Pipe Mounting Bolt Muffler Body Clamp Bolt Muffler Body Mounting Bolt Radiator Bolts Wheels Front Axle Nut Rear Axle Nut Rear Axle Nut Cotter Pin Brakes Brake Lever Pivot Bolt Locknut Brake Pedal Bolt Caliper Mounting Bolts Front Master Cylinder Clamp Bolts Rear Master Cylinder Mounting Bolts Rear Master Cylinder Push Rod Joint Cotter Pin Suspension Front Fork Clamp Bolts Rear Shock Absorber Nuts Swingarm Pivot Shaft Nut Tie Rod Nuts Uni Trak Rocker Arm Nut Steering Handlebar Mounting Bolts Steering Stem Head Bolt Others Footpeg Bracket Bolts Sidestand Nut http mototh com PERIODIC MAINTENANCE 2 43 Periodic Maintenance Procedures Replacement Parts Air Cleaner Element Replacement NOTE In dusty areas the element should be replaced more frequently than the recommended interval After riding through rain or on muddily roads the ele ment should be replaced immediately WARNING If dirt or dust is allowed to pass through into the throttle body assy the throttle may become stuck possibly causing accident CAUTION
274. icense plate light and tail brake light leads 5 Rear Right Turn Signal Light Lead 6 Rear Left Turn Signal Light Lead 7 License Plate Light Lead 8 Clamp 9 Kawasaki Diagnostic System Connector 10 Self diagnosis Terminal http mototh com 17 24 APPENDIX Cable Wire and Hose Routing http mototh com APPENDIX 17 25 Cable Wire and Hose Routing 1 Thermostat 2 Radiator Cap 3 Install the hose so that its white paint mark side faces the radiator 4 Radiator 5 Clamp Screw 6 45 7 Cylinder Head 8 45 55 9 Align the white paint mark on the hose with the projection mark on the fitting 10 Install the hose so that its end covers the white paint mark on the pipe 11 Cylinder 12 Install the hose so that its white paint mark side faces the pipe 13 Align the white paint mark on the hose with the projection mark on the fitting 14 Upper 15 Viewed A 16 Section B B 17 Viewed C 18 Viewed D http mototh com 17 26 APPENDIX Cable Wire and Hose Routing http mototh com APPENDIX 17 27 Cable Wire and Hose Routing 1 Run the reserve tank overflow hose into the guides 2 Reserve Tank Overflow Hose 3 Bracket 4 Run the clutch cable and reserve tank hose into the hole of the reserve tank 5 Clutch Cable 6 Reserve Tank Hose 7 Radiator Cap 8 Reserve Tank 9 Clamps 10 Hose Curve Side 11 Run the only reserve tank overflow hose into the bracket guide http mototh com 17 28 APPENDIX
275. icle down Sensor Service Code 31 If the reading is out of the standard remove the ECU and check the wiring for continuity between main harness connectors Special Tool Hand Tester 57001 1394 Disconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Vehicle down Sensor Connector B BL lead ECU terminal 8 C BR BK lead ECU terminal 22 D If the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see ECU Removal Installation Vehicle down Sensor Output Voltage Inspection Remove the vehicle down sensor see Vehicle down Sensor Removal Connect the harness adapter A to the vehicle down sen sor connectors as shown in the figure Special Tool Measuring Adapter 57001 1700 Main Harness B Vehicle down Sensor C Connect a digital meter D to the harness adapter leads Vehicle down Sensor Output Voltage Connections to Adapter Digital Meter W sensor Y G lead Digital Meter BK sensor BR BK lead http mototh com FUEL SYSTEM DFI 3 61 Vehicle down Sensor Service Code 31 Hold the sensor vertically Measure the output voltage with the engine stopped and with the connector joined Turn the ignition switch ON Tilt the sensor 55 75 or more A right or left then hold the sensor almost vertical with the ar
276. ight Removal 16 50 Tail Brake Light Installation 16 50 License Plate Light Bulb Replacement 16 50 Turn Signal Light Bulb Replacement 16 51 Turn Signal Relay Inspection 16 52 Air Switching Valve 16 54 Air Switching Valve Operation Test 16 54 Air Switching Valve Unit Test 16 54 Radiator Fan System 16 56 Fan Motor Inspection 16 56 Resistor Inspection 16 56 Meter Gauge Indicator Unit
277. ighten the steering stem nut with 15 N m 1 5 kgf m 11 ft lb of torque first and loosen it a fraction of a turn until it turns lightly To tighten the stem nut to the specified torque hook the wrench on the stem nut and pull the wrench at the hole by 84 N 8 6 kgf 19 lb A force in the direction shown Afterward tighten it again with specified torque using a steering stem nut wrench B Special Tool Steering Stem Nut Wrench 57001 1100 Torque Steering Stem Nut 4 9 N m 0 50 kgf m 43 in lb Adjust the steering see Steering Play Inspection in the Periodic Maintenance chapter Install the front forks see Front Fork Installation in the Suspension chapter NOTE Tighten the upper front fork clamp bolts first next the stem head bolt last the lower front fork clamp bolts Torque Upper Front Fork Clamp Bolts 20 N m 2 0 kgf m 15 ft lb Steering Stem Head Bolt 44 N m 4 5 kgf m 32 ft lb Lower Front Fork Clamp Bolts 30 N m 3 1 kgf m 22 ft lb WARNING Do not impede the handlebar turning by routing the cables harnesses and hoses improperly see Ca ble Wire and Hose Routing section in the Appendix chapter Install the removed parts see appropriate chapters http mototh com STEERING 14 9 Steering Stem Steering Stem Bearing Lubrication Refer to the Steering Stem Bearing Lubrication in the Pe riodic Maintenance chapter Steering Stem Warp Inspection Whenever
278. in the Periodic Maintenance chapter http mototh com http mototh com CRANKSHAFT TRANSMISSION 9 1 9 Crankshaft Transmission Table of Contents Exploded View 9 2 Specifications 9 6 Special Tools and Sealant 9 9 Crankcase 9 10 Crankcase Splitting 9 10 Crankcase Assembly 9 11 Crankshaft and Connecting Rods 9 14 Crankshaft Removal 9 14 Crankshaft Installation 9 14 Connecting Rod Removal 9 15 Connecting Rod Installation 9 15 Crankshaft Connecting Rod Cleaning 9 16 Connecting Rod Bend Inspection 9 17 Connecting Rod Twist Inspection 9 17 Connecting Rod Big End Side Clearance Inspection 9 17 Connecting Rod Big End Bearing Insert Crankpin Wear Inspection 9 18 Crankshaft Side Clearance Inspection 9 19 Crankshaft Runout Inspection 9 20 Crankshaft Main Bearing Insert Journal Wear Inspection 9 20 Starter Motor Clutch 9 22 Starter Motor Clutch Removal Installation 9 22 Starter Motor Clutch Inspection 9 22 Starter Motor Clutch Disassembly 9 22 Starter Motor Clutch Assembly 9 22 Balancer
279. inal respectively If the test light turns on the regulator rectifier is defective Replace it If the test light does not turn on continue the test http mototh com ELECTRICAL SYSTEM 16 31 Charging System Do the 2nd step regulator circuit test Connect the test light and the 12 V battery in the same manner as specified in the Regulator Circuit Test 1st Step Apply 12 V to the BR terminal Check the Y1 Y2 and Y3 terminal respectively If the test light turns on the regulator rectifier is defective Replace it If the test light does not turn on continue the test Do the 3rd step regulator circuit test Connect the test light and the 12 V battery in the same manner as specified in the Regulator Circuit Test 1st Step Momentarily apply 24 V to the BR terminal by adding a 12 V battery Check the Y1 Y2 and Y3 terminals respectively CAUTION Do not apply more than 24 V If more than 24 V is ap plied the regulator rectifier may be damaged Do not apply 24 V more than a few seconds If 24 V is applied for more than a few seconds the regula tor rectifier may be damaged If the test light did not light when the 24 V was applied momentarily to the voltage monitoring terminal the regu lator rectifier is defective Replace it If the regulator rectifier passes all of the tests described it may still be defective If the charging system still does not work properly after checking all of the co
280. ine load varies The system is pressurized by the radiator cap to suppress boiling and the resultant air bubbles which can cause engine overheating As the engine warms up the coolant in the radiator and the water jacket expands The excess coolant flows through the radiator cap and hose to the reserve tank to be stored there temporarily Conversely as the engine cools down the coolant in the radiator and the water jacket contracts and the stored coolant flows back to the radiator from the reserve tank The radiator cap has two valves One is a pressure valve which holds the pressure in the system when the engine is running When the pressure exceeds 93 123 kPa 0 95 1 25 kgf cm 13 18 psi the pressure valve opens and releases the pressure to the reserve tank As soon as pressure escapes the valve closes and keeps the pressure at 93 123 kPa 0 95 1 25 kgf cm 13 18 psi When the engine cools down another small valve vacuum valve in the cap opens As the coolant cools the coolant contracts to form a vacuum in the system The vacuum valve opens and allows the coolant from the reserve tank to enter the radiator http mototh com 4 6 COOLING SYSTEM Specifications Item Standard Coolant Provided when Shipping Type Recommended Permanent type of antifreeze soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators Color Green Mixed Ratio Soft wate
281. intenance chapter Brake Hose Inspection Refer to the Brake Hose and Pipe Damage and Instal lation Condition Inspection in the Periodic Maintenance chapter http mototh com SUSPENSION 13 1 13 Suspension Table of Contents Exploded View 13 2 Specifications 13 6 Special Tools 13 7 Front Fork 13 8 Front Fork Removal Each Fork Leg 13 8 Front Fork Installation Each Fork Leg 13 8 Front Fork Oil Change 13 9 Front Fork Disassembly 13 10 Front Fork Assembly 13 11 Inner Tube Outer Tube Inspectio
282. ir duct loose Reinstall see chapter 3 Throttle body assy holder loose Reinstall see chapter 3 Throttle body assy dust seal damage Replace see chapter 3 Fuel injector O ring damage Replace see chapter 3 Fuel filter or pump screen clogged Inspect and replace fuel pump see chapter 3 http mototh com 3 30 FUEL SYSTEM DFI DFI System Troubleshooting Guide Symptoms or Possible Causes Actions Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump see chapter 3 Fuel line clogged Inspect and repair see chapter 3 Inlet air pressure sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Inlet air temperature sensor trouble Inspect see chapter 3 Main throttle sensor trouble Inspect see chapter 3 Subthrottle sensor trouble Inspect see chapter 3 Subthrottle valve actuator trouble Inspect see chapter 3 Unstable rough idling Fuel pressure too low or too high Inspect see chapter 3 Fuel injector trouble Inspect see chapter 3 Main throttle sensor trouble Inspect see chapter 3 Subthrottle sensor trouble Inspect see chapter 3 Subthrottle valve actuator trouble Inspect see chapter 3 Engine vacuum not synchronizing Inspect and adjust see chapter 2 Inlet air pressure sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Inlet air temperature
283. iring Installation 15 8 Windshield Removal 15 8 Windshield Installation 15 9 Upper Fairing Removal 15 9 Upper Fairing Disassembly 15 9 Upper Fairing Assembly 15 9 Upper Fairing Installation 15 9 Inner Cover Removal 15 9 Inner Cover Installation 15 9 Upper Fairing Bracket Removal 15 10 Upper Fairing Bracket Installation 15 10 Inner Fairing Removal
284. istons 5 33 Cylinder Removal 5 33 Cylinder Installation 5 33 Piston Removal 5 33 Piston Installation 5 34 Cylinder Wear Inspection 5 35 Piston Wear Inspection 5 35 Piston Ring Piston Ring Groove Wear Inspection 5 36 Piston Ring Groove Width Inspection 5 36 Piston Ring Thickness Inspection 5 36 Piston Ring End Gap Inspection 5 37 Boring Honing Performance 5 37 Throttle Body Assy Holder 5 38 Throttle Body Assy Holder Installation 5 38 Muffler 5 39 Muffler Body Removal 5 39 Muffler Body Installation 5 39 Exhaust Pipe Removal 5 40 Exhaust Pipe Installation 5 41 http mototh com 5 2 ENGINE TOP END Exploded View http mototh com ENGINE TOP END 5 3 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Air Suction Valve Cover Bolts 9 8 1 0 87 in lb 2 Air Switching Valve Bracket Bolts 9 8 1 0 87 in lb 3 Camshaft Cap Bolts 12 1 2 106 in lb S 4 Camshaft Chain Tensioner Cap Bolt 5 0 0 51 44 in lb 5 Camshaft Chain Tensioner Mounting Bolts 9 8 1 0 87 in lb 6 Camshaft Sprocket Bolts
285. ith the cylinder head So if a cap is installed in a wrong location the camshaft may seize because of improper oil clearance in the bearings Install the plates on the camshaft caps The exhaust side plates A is longer the inlet side plates B Install the upper chain guide A First tighten the all camshaft cap bolts evenly to seat the camshaft in place then tighten all bolts following the spec ified tightening sequence Torque Camshaft Cap Bolts 12 N m 1 2 kgf m 106 in lb Plates EX B Plates IN C Install the camshaft chain tensioner see Camshaft Chain Tensioner Installation Finally inject A the engine oil into 8 places on the cylin der head as shown in the figure Install the cylinder head cover see Cylinder Head Cover Installation http mototh com 5 20 ENGINE TOP END Camshaft Camshaft Chain Camshaft Camshaft Cap Wear Inspection Remove Upper Chain Guide see Camshaft Removal Camshaft Caps see Camshaft Removal Cut the strips of plastigauge to journal width Place a strip on each journal parallel to the camshaft installed in the correct position Measure each clearance between the camshaft journal and the camshaft cap using the plastigauge press gauge A Tighten the camshaft cap bolts see Camshaft Installa tion NOTE Do not turn the camshaft when the plastigauge is be tween the journal and camshaft cap Camshaft Journal Camsha
286. ith the inside diam eter A Crankcase Main Bearing Inside Diameter Marks or no mark NOTE Tighten the crankcase bolts to the specified torque see Crankcase Assembly The mark already on the upper crankcase half should almost coincide with the measurement Crankcase Main Bearing Inside Diameter Marks 31 000 31 008 mm 1 2205 1 2208 in None 31 009 31 016 mm 1 2208 1 2211 in Select the proper bearing insert A in accordance with the combination of the crankcase and crankshaft coding Size Color B Bearing Insert Crankcase Main Bearing Inside Diameter Marking Crankpin Main Journal Diameter Marking Size Color Part Number Journal Nos 92028 1487 1 3 1 Black 92028 1490 2 None 92028 1486 1 3 None 1 Blue 92028 1489 2 92028 1582 1 3 None None Yellow 92028 1586 2 The bearing insert for Nos 2 journal have an oil groove Install the new inserts in the crankcase halves and check insert journal clearance with the plastigage http mototh com 9 22 CRANKSHAFT TRANSMISSION Starter Motor Clutch Starter Motor Clutch Removal Installation Refer to the Alternator Rotor Removal Installation in the Electrical System chapter Starter Motor Clutch Inspection Remove Alternator Cover see Alternator Cover Removal in the Electrical System chapter Starter Idle Gear and shaft Turn the starter motor clutch gear A by hand The sta
287. its upper and lower pins B with the upper and lower grooves C in the socket and turn the bulb clockwise Turn the bulb about 15 Tighten Torque License Plate Light Cover Screws 0 90 N m 0 092 kgf m 8 0 in lb http mototh com ELECTRICAL SYSTEM 16 51 Lighting System Headlight Tail Light Circuit 1 High Beam Indicator Light 12 V 3 4 W 2 Ignition Switch 3 Alternator 4 Water proof Joint 3 5 Joint Connector 2 6 License Plate Light 12 V 5 W 7 Tail Brake Light 12 V 21 5 W 8 Battery 12 V 8 Ah 9 Frame Ground 10 Starter Relay 11 Main Fuse 30 A 12 Headlight Circuit Relay 13 Relay Box 14 Taillight Fuse 10 A 15 Headlight Fuse 10 A 16 Fuse Box 17 Dimmer Switch 18 Headlight Low 12 V 55 W 19 Headlight High 12 V 55 W 20 City Light 12 V 5 W 21 Joint Connector 1 Turn Signal Light Bulb Replacement Unscrew the screw A and remove the lens B http mototh com 16 52 ELECTRICAL SYSTEM Lighting System Push and turn the bulb A counterclockwise and remove it Insert the new bulb A by aligning its upper and lower pins B with the upper and lower grooves C in the socket and turn the bulb clockwise Turn the bulb about 15 Turn Signal Relay Inspection Remove Left Seat Cover see Seat Cover Removal in the Frame chapter Turn Signal Relay A Connector B Disconnect Connect one 12 V battery and turn signal lights as indi cated in the fig
288. ity too high brake dragging engine overheating clutch slipping Poor running at low speed other http mototh com 3 28 FUEL SYSTEM DFI Troubleshooting the DFI System spark plug loose tighten it spark plug dirty broken or gap maladjusted remedy it spark plug incorrect replace it knocking fuel poor quality or incorrect brake dragging clutch slipping engine overheating engine oil level too high engine oil viscosity too high Poor running or no power at high speed other http mototh com FUEL SYSTEM DFI 3 29 DFI System Troubleshooting Guide NOTE This is not an exhaustive list giving every possible cause for each problem listed It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties in DFI system The ECU may be involved in the DFI electrical and ignition system troubles If these parts and circuits are checked out good be sure to check the ECU for ground and power supply If the ground and power supply are checked good replace the ECU Engine Won t Turn Over Symptoms or Possible Causes Actions Neutral starter lockout or sidestand switch trouble Inspect each switch see chapter 16 Vehicle down sensor operated Turn ignition switch OFF see chapter 3 Vehicle down sensor trouble Inspect see chapter 3 Crankshaft sensor trouble Inspect see chapter 16
289. k and shake the tank to remove dirt and fuel deposits Draw the solvent out of the fuel tank Dry the tank with compressed air Install Fuel Pump see Fuel Pump Installation Fuel Tank see Fuel Tank Installation http mototh com http mototh com COOLING SYSTEM 4 1 4 Cooling System Table of Contents Exploded View 4 2 Coolant Flow Chart 4 4 Specifications 4 6 Coolant 4 7 Coolant Deterioration Inspection 4 7 Coolant Level Inspection 4 7 Coolant Draining 4 7 Coolant Filling 4 7 Pressure Testing
290. knut and pivot bolt and remove the brake lever Pull the dust cover out of place and remove the circlip Special Tool Inside Circlip Pliers 57001 143 Pull out the piston A secondary cup B primary cup C and return spring D CAUTION Do not remove the secondary cup from the piston since removal will damage it http mototh com 2 52 PERIODIC MAINTENANCE Periodic Maintenance Procedures Rear Master Cylinder Disassembly NOTE Do not remove the push rod clevis for master cylinder disassembly since removal requires brake position ad justment Remove the rear master cylinder see Rear Master Cylin der Removal in the Brakes chapter Remove the circlip A Special Tool Inside Circlip Pliers 57001 143 Pull out the push rod with the piston stop Take off the piston B secondary cup C primary cup D and return spring E Remove the circlip F and pull out the brake hose con nector G and O ring H Special Tool Inside Circlip Pliers 57001 143 CAUTION Do not remove the secondary cup from the piston since removal will damage it Master Cylinder Assembly Before assembly clean all parts including the master cylinder with brake fluid or alcohol CAUTION Except for the disc pads and disc use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning brake parts Do not use any other fluid for cleaning these parts Gasoline engine oil or any ot
291. kshaft Sensor Resistance Inspection 3 55 Crankshaft Sensor Peak Voltage Inspection 3 55 Speed Sensor Service Code 24 25 3 56 Speed Sensor Removal Installation 3 56 Speed Sensor Inspection 3 56 Speed Sensor Input Voltage Inspection 3 56 Speed Sensor Output Voltage Inspection 3 57 Vehicle down Sensor Service Code 31 3 59 Vehicle down Sensor Removal 3 59 Vehicle down Sensor Installation 3 59 Vehicle down Sensor Input Voltage Inspection 3 59 http mototh com 3 2 FUEL SYSTEM DFI Vehicle down Sensor Output Voltage Inspection
292. l Remove the cylinder see Cylinder Removal Place a clean cloth under the pistons and remove the pis ton pin snap ring A from the outside of each piston http mototh com 5 34 ENGINE TOP END Cylinder Pistons Remove the piston pins Special Tool Piston Pin Puller Assembly A 57001 910 Remove the pistons Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring A to remove it Remove the 3 piece oil ring with your thumbs in the same manner Piston Installation Apply molybdenum disulfide oil solution to the oil ring ex pander and install the oil ring expander A in the bottom piston ring groove so the ends B not butt together Apply molybdenum disulfide oil solution to the oil ring steel rails and install the oil ring steel rails one above the ex pander and one below it Spread the rail with your thumbs but only enough to fit the rail over the piston Release the rail into the bottom piston ring groove NOTE The oil ring rails have no top or bottom Do not mix up the top and second ring Install the top ring A so that the R mark B faces up Install the second ring C so that the RN mark D faces up Apply molybdenum disulfide oil solution to the piston rings http mototh com ENGINE TOP END 5 35 Cylinder Pistons NOTE If a new piston is used use new piston ring Install the pis
293. l A onto collar B so that the surface of the oil seal is flush with the counterbore bottom surface C of the crankcase Apply grease to the oil seal lips Transmission Shaft Disassembly Remove the transmission shafts see Transmission Shaft Removal Remove the circlips disassemble the transmission shafts Special Tool Outside Circlip Pliers 57001 144 The 5th gear A on the output shaft has three steel balls assembled into it for the positive neutral finder mecha nism Remove the 5th gear Set the output shaft in a vertical position holding the 3rd gear B Spin the 5th gear quickly C and pull it off upward Remove the ball bearing A from each shafts Special Tools Bearing Puller B 57001 135 Bearing Puller Adapter C 57001 317 Discard the bearing Transmission Shaft Assembly Apply engine oil to the bushings ball bearings and shafts Install the ball bearings on the shafts with the groove to ward the clutch side Install the gear bushings A on the shaft with their holes B aligned http mototh com CRANKSHAFT TRANSMISSION 9 29 Transmission Replace any circlips removed with new ones Install the circlips A so that the opening B is aligned with a spline groove C The drive shaft gears can be recognized by size the gear with the smallest diameter is 1st gear and the largest one is 6th gear Be sure that all parts are put back in the cor re
294. l Reserve Switch D If the test light doesn t light replace the fuel pump NOTE It may take a long time to turn on the test light in case that the fuel reserve switch is inspected just after the fuel pump is removed Leave the fuel reserve switch with leads for inspection connected for few minutes http mototh com 16 66 ELECTRICAL SYSTEM Relay Box The relay box A has relays and diodes The relays and diodes can not be removed Relay Box Removal CAUTION Never drop the relay box especially on a hard sur face Such a shock to the relay box can damage it Remove Front Seat see Front Seat Removal in the Frame chap ter Connectors A Disconnect Relay Box B Relay Circuit Inspection Remove the relay box see Relay Box Removal Check conductivity of the following numbered terminals by connecting the hand tester and one 12 V battery to the relay box as shown in the figure see Relay Box Internal Circuit in this section If the tester does not read as specified replace the relay box Relay Circuit Inspection with the battery disconnected Tester Connection Tester Reading Headlight Circuit Relay 1 3 7 6 ECU Main Relay 4 5 Not 7 8 Fuel Pump Relay 9 10 Not 11 16 Starter Circuit Relay 11 12 17 20 Fan Relay 18 19 Not The actual reading varies with the hand tester used http mototh com ELECTRICAL SYSTEM 16 67
295. l line B NOTE Hold the reservoir horizontal by turning the handlebar when checking brake fluid level If the fluid level is lower than the lower level line fill the reservoir to the upper level line C in the reservoir http mototh com PERIODIC MAINTENANCE 2 31 Periodic Maintenance Procedures Check that the brake fluid level in the rear brake reservoir A is above the lower level line B If the fluid level is lower than the lower level line fill the reservoir to the upper level line C WARNING Change the brake fluid in the brake line completely if the brake fluid must be refilled but the type and brand of the brake fluid that is already in the reser voir are unidentified After changing the fluid use only the same type and brand of fluid thereafter Recommended Disc Brake Fluid Grade DOT4 Follow procedure below to install the rear brake fluid reservoir cap correctly First tighten the rear brake fluid reservoir cap B clock wise C by hand until slight resistance is felt indicating that the cap is seated on the reservoir body then tighten the cap an additional 1 6 turn D while holding the brake fluid reservoir body A Brake Pad Wear Inspection Remove the brake pads see Brake Pad Removal in the Brakes chapter Check the lining thickness A of the pads in each caliper If the lining thickness of either pad is less than the service limit B replace both pads in the caliper
296. lead Measure the input voltage with the engine stopped and with the connector joined Turn the ignition switch ON Input Voltage Standard DC 4 75 5 25 V Turn the ignition switch OFF If the reading is within the standard check the output volt age see Speed Sensor Output Voltage Inspection If the reading is out of the standard remove the ECU and check the wiring for continuity between main harness connectors Special Tool Hand Tester 57001 1394 Disconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Speed Sensor Connector B BL lead ECU terminal 8 C BR BK lead ECU terminal 22 D If the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see ECU Removal Installation http mototh com FUEL SYSTEM DFI 3 57 Speed Sensor Service Code 24 25 Speed Sensor Output Voltage Inspection Raise the rear wheel off the ground with the stand Measure the output voltage at the speed sensor in the same way as input voltage inspection note the following Disconnect the speed sensor connector and connect the harness adapter A between these connectors Special Tool Throttle Sensor Setting Adapter 1 57001 1400 Speed Sensor Output Voltage Connections to Adapter Digital Meter Y W sensor Y lead Digital Meter BK W
297. linder Pistons Piston Ring Piston Ring Groove Wear Inspection 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 With the piston rings in their grooves make several mea surements with a thickness gauge A to determine piston ring groove clearance Piston Ring Groove Clearance Standard Top 0 03 0 07 mm 0 0012 0 0028 in Second 0 02 0 06 mm 0 0008 0 0024 in Service Limit Top 0 17 mm 0 0067 in Second 0 16 mm 0 0063 in Piston Ring Groove Width Inspection Measure the piston ring groove width Use a vernier caliper at several points around the piston Piston Ring Groove Width Standard Top A 0 82 0 84 mm 0 0323 0 0331 in Second B 0 81 0 83 mm 0 0319 0 0327 in Service Limit Top 0 92 mm 0 0362 in Second 0 91 mm 0 0358 in If the width of any of the two grooves is wider than the service limit at any point replace the piston Piston Ring Thickness Inspection Measure the piston ring thickness Use the micrometer to measure at several points around the ring Piston Ring Thickness Standard Top A 0 77 0 79 mm 0 0303 0 0311 in Second B 0 77 0 79 mm 0 0303 0 0311 in Service Limit Top 0 70 mm 0 028 in Second 0 70 mm 0 028 in If any of the measurements is
298. llow the repair methods indicated by the manufacturer of the repair tools and materials so that safe results can be obtained http mototh com WHEELS TIRES 10 17 Hub Bearing Hub Bearing Removal Remove the wheels see Front Rear Wheel Removal and take out the following Collars Speedometer Gear Out of front hub Coupling Out of rear hub Grease Seals Circlips A Special Tool Inside Circlip Pliers 57001 143 Use the bearing remover to remove the hub bearings A CAUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground Special Tools Bearing Remover Shaft 9 B 57001 1265 Bearing Remover Head 15 17 C 57001 1267 Hub Bearing Installation Before installing the hub bearings blow any dirt or foreign particles out of the hub with compressed air to prevent contamination of the bearings Replace the bearings with new ones Install the bearings by using the bearing driver set which does not contact the bearing inner race NOTE Install the bearings so that the marked side faces out Press in each bearing A right until they are bottomed Special Tool Bearing Driver Set B 57001 1129 Replace 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
299. 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 1 mm 0 004 in or less Service Limit TIR 0 2 mm 0 008 in http mototh com WHEELS TIRES 10 11 Wheels Rims Balance Inspection Remove the front and rear wheels see Front Rear Wheel Removal Support the wheel so that it can be spun freely Spin the wheel lightly and mark A the wheel at the top when the wheel stops Repeat this procedure several times If the wheel stops of its own accord in various positions it is well balanced If the wheel always stops in one position adjust the wheel balance see Balance Adjustment Balance Adjustment If the wheel always stops in one position provisionally attach a balance weight A on the rim at the marking using adhesive tape Rotate the wheel 1 4 turn B and see whether or not the wheel stops in this position If it does the correct balance weight is being used If the wheel rotates and the weight goes up replace the weight with the next heavier size If the wheel rotates and the weight goes down replace the weight with the next lighter size Repeat these steps until the wheel remains at rest after being rotated 1 4 turn Rotate the wheel another 1 4 turn and then another 1 4 turn to see if the wheel is correctly balanced Repeat the entire procedure as many times as necessary to achieve c
300. ls Rims Front Wheel Removal Remove Speedometer Cable Lower End A Cotter Pin B Axle Nut C and Washer Front Caliper Mounting Bolts D Front Caliper E Remove the lower fairings see Lower Fairing Removal in the Frame chapter Raise the front wheel off the ground with the jack Special Tools Jack 57001 1238 Jack Attachment 57001 1608 Pull out the axle to the left and drop the front wheel out of the forks CAUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground Front Wheel Installation Apply high temperature grease to the grease seal lips Fit the collar on the right of the hub Fit the speedometer gear projections A to the wheel hub projections B http mototh com WHEELS TIRES 10 7 Wheels Rims Install the front wheel so that the speedometer gear hous ing stop A fit into the fork leg projection B Insert the front axle and install the washer Tighten Torque Front Axle Nut 88 N m 9 0 kgf m 65 ft lb Insert a new cotter pin A NOTE When inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle tighten the nut clockwise B up to next alignment It should be within 30 Loosen once and tighten again when the slot goes past the nearest hole Bend the cotter pin
301. lutch slipping Engine overheating Air suction valve trouble Air switching valve trouble Poor Running or No Power at High Speed Firing incorrect Spark plug dirty broken or maladjusted Spark plug incorrect Stick coil shorted or not in good contact trouble Stick coil trouble ECU trouble Fuel air mixture incorrect Air cleaner clogged poorly sealed or miss ing Air cleaner duct loose Water or foreign matter in fuel Throttle body assy holder loose Fuel to injector insufficient Fuel tank air vent obstructed Fuel line clogged Fuel pump trouble Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Knocking Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect ECU trouble Miscellaneous Throttle valve won t fully open Brake dragging Clutch slipping Engine overheating Engine oil level too high Engine oil viscosity too high Drive train trouble Camshaft cam worn Air suction valve trouble Air switching valve trouble Catalytic converter melt down due to muffler overheating KLEEN Overheating Firing incorrect Spark plug dirty broken or maladjusted Spark plu
302. ly Excessive application can clog oil passages and cause serious damage http mototh com 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 absolutely necessary Replace with new ones whenever removed Press bearings with the manufacturer and size marks facing out Press the bearing into place by putting pressure on the correct bearing race as shown Pressing the incorrect race can cause pressure between the inner and outer race and result in bearing damage Oil Seal Grease Seal Do not remove pressed oil or grease seals unless removal is necessary Replace with new ones whenever removed Press new oil seals with manufacture and size marks facing out Make sure the seal is aligned properly when installing Apply specified grease to the lip of seal before installing the seal Circlips Cotter Pins Replace the circlips or cotter pins that were removed with new ones Take care not to open the clip excessively when installing to prevent deformation http mototh com 1 6 GENERAL INFORMATION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation Lubri c
303. maintains the minimum standard clearance Crankshaft Main Bearing Insert Journal Clearance Standard 0 014 0 038 mm 0 0006 0 0015 in Service Limit 0 07 mm 0 0028 in If the clearance is within the standard no bearing replace ment is required If the clearance is between 0 038 mm 0 0015 in and the service limit 0 07 mm 0 0028 in replace the bearing in serts A with inserts painted blue B Check insert journal clearance with the plastigage The clearance may exceed the standard slightly but it must not be less than the min imum in order to avoid bearing seizure If the clearance exceeds the service limit measure the diameter of the crankshaft main journal Crankshaft Main Journal Diameter Standard 27 984 28 000 mm 1 1017 1 1024 in Service Limit 27 96 mm 1 101 in If any journal has worn past the service limit replace the crankshaft with a new one If the measured journal diameters are not less than the service limit but do not coincide with the original diameter markings on the crankshaft make new marks on it Crankshaft Main Journal Diameter Marks None 27 984 27 992 mm 1 1017 1 1020 in 1 27 993 28 000 mm 1 1021 1 1024 in Crankshaft Main Journal Diameter Marks 1 or no mark http mototh com CRANKSHAFT TRANSMISSION 9 21 Crankshaft and Connecting Rods Measure the main bearing inside diameter and mark the upper crankcase half in accordance w
304. mary Gear Marking C Color D Gear Marking E Color F Part Number A White A White 13095 0095 A White B Red 13095 0096 A White C None 13095 0097 A White D Yellow 13095 0098 B Red A White 13095 0095 B Red B Red 13095 0096 B Red C None 13095 0097 B Red D Yellow 13095 0098 C None B Red 13095 0096 C None C None 13095 0097 C None D Yellow 13095 0098 D Yellow C None 13095 0097 D Yellow D Yellow 13095 0098 Install the friction plate first and steel plate and afterward install them alternately The inner end A and outer end B friction plate blocks are wider than the others Wider C Narrower D http mototh com CLUTCH 6 11 Clutch Apply engine oil to the bearing and install it Apply molybdenum disulfide grease to the pusher ends Install the clutch spring plate A with the pusher B Install the springs and tighten the clutch spring bolts Torque Clutch Spring Bolts 8 8 N m 0 90 kgf m 78 in lb Install the clutch cover see Clutch Cover Installation Clutch Plate Wear and Damage Inspection Visually inspect the friction and steel plates for signs of seizure overheating discoloration or uneven wear Measure the thickness of each friction plate A at several points If any plates show signs of damage or if they have worn past the service limit replace them with new ones Friction Plate Thi
305. mp Cover Bolts 9 8 1 0 87 in lb 16 Water Temperature Sensor 25 2 5 18 G Apply grease R Replacement Parts http mototh com 4 4 COOLING SYSTEM Coolant Flow Chart http mototh com COOLING SYSTEM 4 5 Coolant Flow Chart Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion When the engine starts the water pump turns and the coolant circulates The thermostat is a wax pellet type which opens or closes with coolant temperature changes The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level When coolant temperature is less than 63 5 66 5 C 146 152 F the thermostat closes so that the coolant flow is restricted through the air bleeder hole causing the engine to warm up more quickly When coolant temperature is more than 63 5 66 5 C 146 152 F the thermostat opens and the coolant flows When the coolant temperature goes up beyond 103 C 217 F the radiator fan relay 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 coolant temperature is below 98 C 208 F the fan relay opens and the radiator fan stops In this way this system controls the engine temperature within narrow limits where the engine op erates most efficiently even if the eng
306. mponents and the battery test the regulator rectifier by replacing it with a known good unit http mototh com 16 32 ELECTRICAL SYSTEM Charging System Charging System Circuit 1 Alternator 2 Battery 12 V 8 Ah 3 Frame Ground 4 Main Fuse 30 A 5 Joint Connector 1 6 Load 7 Water proof Joint 3 8 Ignition Switch 9 Regulator Rectifier http mototh com ELECTRICAL SYSTEM 16 33 Ignition System WARNING The ignition system produces extremely high volt age Do not touch the spark plugs or stick coils while the engine is running or you could receive a severe electrical shock CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition switch is ON or while the engine is running This is to pre vent ECU damage Do not install the battery backwards The negative side is grounded This is to prevent damage to the ECU Crankshaft Sensor Removal Refer to the Stator Coil Removal Crankshaft Sensor Installation Refer to the Stator Coil Installation Crankshaft Sensor Inspection Remove Right Side Cover see Side Cover Removal in the Frame chapter Crankshaft Sensor Lead Connector A Disconnect Set the hand tester B to the 1 range and connect lead to the yellow lead and lead to the black lead in the connector Special Tool Hand Tester 57001 1394 Crankshaft Sensor Resistance 100 150 If there is more resistance than
307. n 13 13 Dust Seal Inspection 13 13 Spring Tension Inspection 13 13 Rear Shock Absorber 13 14 Spring Preload Adjustment 13 14 Rear Shock Absorber Removal 13 14 Rear Shock Absorber Installation 13 15 Rear Shock Absorber Inspection 13 15 Rear Shock Absorber Scrapping 13 15 Swingarm 13 16 Swingarm Removal 13 16 Swingarm Installation
308. n the Appendix chapter To prevent corrosion and deposits in the fuel system do not add to fuel any fuel antifreeze chemicals http mototh com 3 22 FUEL SYSTEM DFI DFI Servicing Precautions If the motorcycle is not properly handled the high pres sure inside the fuel line can cause fuel to leak or the hose to burst Remove the fuel tank see Fuel Tank Removal and check the fuel hose A Replace the fuel hose if any fraying cracks or bulges are noticed To maintain the correct fuel air mixture F A there must be no inlet air leaks in the DFI system Be sure to install the oil filler plug A after filling the engine oil Torque Oil Filler Plug Hand Tighten http mototh com FUEL SYSTEM DFI 3 23 Troubleshooting the DFI System Outline When an abnormality in the system occurs the FI indi cator light goes on to alert the rider on the meter panel In addition the condition of the problem is stored in the mem ory of the ECU Electronic Control Unit With the engine stopped and turned in the self diagnosis mode the service code A is indicated by the number of times the FI indicator light blinks When due to a malfunction the FI indicator light remains lit ask the rider about the conditions B under which the problem occurred and try to determine the cause C Don t rely solely on the DFI self diagnosis function use common sense Even when the DFI system is operating normally the FI indicat
309. n the gauge adapter is removed Tighten Torque Crankcase Oil Passage Plug 15 N m 1 5 kgf m 11 ft lb http mototh com 7 12 ENGINE LUBRICATION SYSTEM Oil Pressure Switch Oil Pressure Switch Removal Remove Left Lower Fairing see Lower Fairing Removal in the Frame chapter Switch Cover A Switch Terminal Bolt B Oil Pressure Switch C Oil Pressure Switch Installation Apply silicone sealant to the threads of the oil pressure switch and tighten it Sealant Kawasaki Bond Silicone Sealant 56019 120 Torque Oil Pressure Switch 15 N m 1 5 kgf m 11 ft lb Install the switch lead A as shown in the figure 45 B Front C Apply grease to the terminal Tighten the terminal bolt Torque Oil Pressure Switch Terminal Bolt 1 5 N m 0 15 kgf m 13 in lb Cover the switch Install the left lower fairing see Lower Fairing Installation in the Frame chapter http mototh com ENGINE REMOVAL INSTALLATION 8 1 8 Engine Removal Installation Table of Contents Exploded View 8 2 Engine Removal Installation 8 4 Engine Removal 8 4 Engine In
310. n the rim accordingly Tire Rotation Mark A Rotating Direction B Position the tire on the rim so that the air valve A align with the tire balance mark B the chalk mark made during removal or the yellow paint mark on a new tire By hand slide as much as possible of the lower side of the tire bead over the rim flange starting at the side opposite the valve stem Fit the rim protectors and tire irons to install the remaining part of the tire bead which cannot be installed by hand For easy tire installation position the parts of the bead which is already over the rim flange in the rim well NOTE To prevent rim damage be sure to place the rim protec tors at any place the tire irons are applied Install the other side of the tire bead onto the rim in the same manner Lubricate the tire beads and rim flanges with a soap and water solution or rubber lubricant to help seat the tire beads in the sealing surfaces of the rim while inflating the tire Center the rim in the tire beads and inflate the tire with compressed air until the tire beads seat in the sealing surfaces WARNING Be sure to install the valve core whenever inflating the tire and do not inflate the tire to more than 400 kPa 4 0 kgf cm 57 psi Overinflation can explode the tire with possibility of injury and loss of life http mototh com 10 16 WHEELS TIRES Tires Check to see that the rim lines A on both sides of the
311. nd C and ground D If there is continuity the harness has a short circuit to ground and it must be repaired or re placed Narrow down suspicious locations by repeating the con tinuity tests from the ECU connectors If no abnormality is found in the wiring or connectors the DFI parts are the next likely suspects Check the part starting with input and output voltages However there is no way to check the ECU itself If an abnormality is found replace the affected DFI part If no abnormality is found in the wiring connectors and DFI parts replace the ECU http mototh com 3 26 FUEL SYSTEM DFI Troubleshooting the DFI System DFI Diagnosis Flow Chart Inquiries to Rider Each rider reacts to problems in different ways so it is important to confirm what kind of symptoms the rider has encountered Try to find out exactly what problem occurred under exactly what conditions by asking the rider knowing this information may help you reproduce the problem The following sample diagnosis sheet will help prevent you from overlooking any areas and will help you decide if it is a DFI system problem or a general engine problem http mototh com FUEL SYSTEM DFI 3 27 Troubleshooting the DFI System Sample Diagnosis Sheet Rider name Registration No license plate No Year of initial registration Model Engine No Frame No Date problem occurred Mileage Environment when problem occurred W
312. ndard remove the ECU and check the wiring for continuity between main harness con nectors Special Tool Hand Tester 57001 1394 Disconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Crankshaft Sensor Connector B R BK lead ECU terminal 11 C Y BK lead ECU terminal 24 D If the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see ECU Removal Installation Crankshaft Sensor Circuit 1 ECU 2 Crankshaft Sensor http mototh com 3 56 FUEL SYSTEM DFI Speed Sensor Service Code 24 25 Speed Sensor Removal Installation Refer to the Speed Sensor Removal Installation in the Electrical System chapter Speed Sensor Inspection Refer to the Speed Sensor Inspection in the Electrical System chapter Speed Sensor Input Voltage Inspection NOTE Be sure the battery is fully charged Turn the ignition switch OFF Remove the left side cover see Side Cover Removal in the Frame chapter Disconnect the speed sensor connector and connect the harness adapter A between these connectors Special Tool Throttle Sensor Setting Adapter 1 57001 1400 Connect a digital meter to the harness adapter leads Speed Sensor Input Voltage Connections to Adapter Digital Meter BL sensor P lead Digital Meter BK W sensor BK
313. nder Head Cover Cylinder Head Cover Removal Remove Air Switching Valve see Air Switching Valve Removal Stick Coils see Stick Coil Removal in the Electrical Sys tem chapter Coolant Reserve Tank Bolts see Coolant Reserve Tank Removal in the Cooling System chapter Thermostat Housing see Thermostat Housing Removal in the Cooling System chapter Water Hose A Bolt B and Bracket C Free the heat insulation rubber plate A from the cylinder head cover Remove Air Suction Valve Cover A see Air Suction Valve Re moval Cylinder Head Cover Bolts B Cylinder Head Cover C Cylinder Head Cover Installation Replace the head cover gasket with a new one Apply silicone sealant A to the head cover gasket as shown in the figure Sealant Kawasaki Bond Silicone Sealant 92104 0004 Install the new head cover gasket Install Dowel Pins A Plug Hole Gaskets B http mototh com 5 14 ENGINE TOP END Cylinder Head Cover Insert the hook A of the water pipe B in the groove of the damper C as shown in the figure Damper D Install the head cover E and tighten the bolts Torque Cylinder Head Cover Bolts 9 8 N m 1 0 kgf m 87 in lb Install the removed parts see appropriate chapters http mototh com ENGINE TOP END 5 15 Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION This is a non return type camshaft chain tensioner The push
314. ndition Inspection 2 26 Drive Chain Slack Inspection 2 27 Drive Chain Slack Adjustment 2 27 Wheel Alignment Inspection 2 28 Drive Chain Wear Inspection 2 29 Chain Guide Wear Inspection 2 29 Brakes 2 30 Brake Fluid Leak Brake Hose and Pipe Inspection 2 30 Brake Hose and Pipe Damage and Installation Condition Inspection 2 30 Brake Fluid Level Inspection 2 30 Brake Pad Wear Inspection 2 31 Brake Operation Inspection 2 31 Brake Light Switch Oper
315. ng Return Spring Remove the brake pedal bolt and take out the brake pedal D Brake Pedal Installation Apply grease to the pivot shaft A and install the washer B Install Brake Pedal C Washer D Tighten Torque Brake Pedal Bolt E 8 8 N m 0 90 kgf m 78 in lb Hook Rear Brake Light Switch Spring Return Spring F Replace the cotter pin with a new one Insert the cotter pin and bend the pin ends Install the right front footpeg bracket and tighten the bolts Torque Front Footpeg Bracket Bolts 25 N m 2 5 kgf m 18 ft lb Check the brake pedal position see Brake Pedal Position Inspection http mototh com BRAKES 12 9 Calipers Front Caliper Removal Loosen the banjo bolt A at the brake hose lower end and tighten it loosely Unscrew the caliper mounting bolts B and detach the caliper C from the disc Unscrew the banjo bolt and remove the brake hose D from the caliper see Brake Hose Removal Installation CAUTION Immediately wash away any brake fluid that spills NOTE If the caliper is to be disassembled after removal and if compressed air is not available disassemble the caliper before the brake hose is removed see Front Caliper Disassembly Rear Caliper Removal Loosen the banjo bolt A at the brake hose lower end and tighten it loosely Unscrew the caliper mounting bolts B and detach the caliper C from the dis
316. ng bleeding the bleeding operation must be done over again from the beginning since air will have entered the line Tap the brake hose lightly from the caliper to the reser voir for more complete bleeding Remove the clear plastic hose Install the diaphragm and reservoir cap Tighten Torque Front Brake Reservoir Cap Screws 1 5 N m 0 15 kgf m 13 in lb Follow the procedure below to install the rear brake fluid reservoir cap correctly First 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 Apply a non permanent locking agent to the threads of the bleed valve Tighten the bleed valve and install the rubber cap Torque Bleed Valve 5 5 N m 0 56 kgf m 49 in lb Check the fluid level see Brake Fluid Level Inspection in the Periodic Maintenance chapter After bleeding is done check the brake for good braking power no brake drag and no fluid leakage http mototh com BRAKES 12 19 Brake Fluid WARNING When working with the disc brake observe the pre cautions listed below 1 Never reuse old brake fluid 2 Do not use fluid from a container that has been left unsealed or that has been open for a long time 3 Do not mix two types and brands of fluid for use in the
317. nk see Fuel Tank Removal 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 G lead 3 W BL lead 4 Standard About 5 2 7 8 If the reading is out of the standard replace the throttle body assy see Throttle Body Assy Removal Installation If the reading is within the standard check the input volt age see Subthrottle Valve Actuator Input Voltage Inspec tion http mototh com 3 74 FUEL SYSTEM DFI Subthrottle Valve Actuator Service Code 62 Subthrottle Valve Actuator Input Voltage Inspection NOTE Be sure the battery is fully charged Turn the ignition switch OFF Disconnect the subthrottle valve actuator connector and connect the harness adapter A between these connec tors as shown in the figure Main Harness B Subthrottle Valve Actuator C Special Tool Measuring Adapter 57001 1700 Connect the peak voltage adapter D and a digital meter E to the harness adapter leads Special Tool Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Subthrottle Valve Actuator Input Voltage Connections to Adapter I Digital Meter R actuator P lead Digital Meter BK actuator BK lead II Digital Meter W actuator W BL lead
318. nspection Refer to the Air Switching Valve Unit Test in the Electrical System chapter If the air switching valve is normal check the wiring for continuity see wiring diagram in this section If the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see ECU Removal Installation Air Switching Valve Circuit 1 ECU 2 Joint Connector 2 3 Battery 12 V 8 Ah 4 Frame Ground 5 Main Fuse 30 A 6 Relay Box 7 ECU Main Relay 8 ECU Fuse 15 A 9 Fuse Box 10 Ignition Switch 11 Water proof Joint 3 12 Air Switching Valve http mototh com FUEL SYSTEM DFI 3 77 Oxygen Sensor Heater Service Code 67 Oxygen Sensor Heater Removal Installation The oxygen sensor heater is built in the oxygen sensor So the heater itself can not be removed Remove the oxy gen sensor see Oxygen Sensor Removal in the Electrical System chapter Oxygen Sensor Heater Resistance Inspection Turn the ignition switch OFF Remove the right lower fairing see Lower Fairing Re moval in the Frame chapter Disconnect the oxygen sensor lead connector A Connect a digital meter A to the oxygen sensor lead con nector B Measure the oxygen sensor heater resistance Oxygen Sensor Heater Resistance Connections BK lead C BK lead D Standard 11 7 15 5 at 20 C 68 F If the reading is out of the stan
319. o each cell as the ports fill NOTE Do not tilt the electrolyte container http mototh com 16 20 ELECTRICAL SYSTEM Battery Check the electrolyte flow If no air bubbles A are coming up from the filler ports or if the container cells have not emptied completely tap the container B a few times Keep the container in place for 20 minutes or more Don t remove the container from the battery until it s empty the battery requires all the electrolyte from the container for proper operation CAUTION Removal of the container before it is completely empty can shorten the service life of the battery Do not remove the electrolyte container until it is com pletely empty and 20 minutes have elapsed Gently remove the container from the battery Let the battery sit for 30 minutes prior to charging to allow the electrolyte to permeate into the plates for optimum performance NOTE Charging the battery immediately after filling can shorten service life Let the battery sit for at least 30 minutes after filling Initial Charge Place the strip A of caps loosely over the filler ports Newly activated sealed batteries require an initial charge Standard Charge 0 9 A 5 10 hours If using a recommended battery charger follow the charger s instructions for newly activated sealed battery Kawasaki recommended chargers Optimate III Yuasa 1 5 Amp Automatic Charger Battery Mate 150
320. o not attempt to drive the motorcycle until a full brake lever is obtained by pumping the brake lever and the pads are against the disc The brake will not function on the first application of the lever if this is not done Brake Pad Wear Inspection Refer to the Brake Pad Wear Inspection in the Periodic Maintenance chapter http mototh com 12 14 BRAKES Master Cylinder Front Master Cylinder Removal Remove the banjo bolt A to disconnect the brake hose from the master cylinder see Brake Hose Removal In stallation Unscrew the clamp bolts B and take off the master cylin der C as an assembly with the reservoir brake lever and brake switch installed Disconnect the front brake light switch connector D CAUTION Immediately wash away any brake fluid that spills Front Master Cylinder Installation Set the front master cylinder to match its mating surface A to the punch mark B of the handlebar The master cylinder clamp must be installed with the ar row mark C upward Tighten the upper clamp bolt first and then the lower clamp bolt Torque Front Master Cylinder Clamp Bolts 8 8 N m 0 90 kgf m 78 in lb Replace the washers that are on each side of the hose fitting with new ones Tighten Torque Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft lb Bleed the brake line see Brake Line Bleeding Check the brake for good braking power no brake drag and
321. oled Bore and Stroke 62 0 41 2 mm 2 44 1 62 in Displacement 249 cm 15 19 cu in Compression Ratio 11 6 1 Maximum Horsepower 24 kW 33 PS 11 000 r min rpm Maximum Torque 22 N m 2 2 kgf m 16 ft lb 8 200 r min rpm Carburetion System FI Fuel Injection KEIHIN TTK28 2 Starting System Electric starter Ignition System Battery and coil transistorized Timing Advance Electronically advanced digital igniter in ECU Ignition Timing From 10 BTDC 1 300 r min rpm 38 BTDC 6 000 r min rpm Spark Plug NGK CR8E Cylinder Numbering Method Left to right 1 2 Firing Order 1 2 Valve Timing Inlet Open 36 BTDC Close 56 ABDC Duration 272 Exhaust Open 61 BBDC Close 31 ATDC Duration 272 http mototh com GENERAL INFORMATION 1 9 General Specifications Items EX250K8F Lubrication System Forced lubrication wet sump Engine Oil Type API SE SF or SG API SH SJ or SL with JASO MA Viscosity SAE 10W 40 Capacity 1 7 L 1 8 US qt Drive Train Primary Reduction System Type Gear Reduction Ratio 3 087 71 23 Clutch Type Wet multi disc Transmission Type 6 speed constant mesh return shift Gear Ratios 1st 2 600 39 15 2nd 1 789 34 19 3rd 1 409 31 22 4th 1 160 29 25 5th 1 000 27 27 6th 0 893 25 28 Final Drive System Type Chain drive Reduction Ratio 3 071 43 14
322. one Sealant 92104 0004 Replace the clutch cover gasket with a new one Tighten the clutch cover bolts Torque Clutch Cover Bolts 9 8 N m 1 0 kgf m 87 in lb Release Shaft Removal CAUTION Do not remove the clutch release lever and shaft assembly unless it is absolutely necessary If re moved the oil seal replacement may be required Remove the clutch cover see Clutch Cover Removal Pull the lever and shaft assembly straight out of the clutch cover Release Shaft Installation Apply grease to the oil seal lips on the upper ridge of the clutch cover Apply engine oil to the needle bearing in the hole of the clutch cover Apply molybdenum disulfide grease to the pusher holding portion on the release shaft Insert the release shaft straight into the upper hole of the clutch cover CAUTION When inserting the release shaft be careful not to remove the spring of the oil seal http mototh com 6 8 CLUTCH Clutch Cover Clutch Cover Disassembly Remove Oil Seal A Needle Bearing B Oil Level Gauge Clutch Cover Assembly Replace the needle bearing and oil seal with new ones NOTE Install the needle bearing so that the manufacture s mark face out Install the needle bearing A and oil seal B position as shown in the figure Press the needle bearing so that the bearing surface C is flush with the housing end of clutch cover D Press the oil seal until th
323. onnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Oxygen Sensor Connector B P BK lead ECU terminal 23 C If the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see ECU Removal Installation Oxygen Sensor Circuit 1 Ignition Switch 2 Water proof Joint 3 3 Water proof Joint 1 4 Oxygen Sensor 5 ECU 6 Joint Connector 2 7 Battery 12 V 8 Ah 8 Frame Ground 9 Main Fuse 30 A 10 Oxygen Sensor Heater Fuse 10 A 11 Fuse Box http mototh com FUEL SYSTEM DFI 3 79 Oxygen Sensor Incorrect Output Voltage Service Code 94 Oxygen Sensor Removal Installation Refer to the Oxygen Sensor Removal Installation in the Electrical System chapter Oxygen Sensor Inspection Warm up the engine thoroughly until the radiator fan starts Turn the ignition switch OFF Remove the right lower fairing see Lower Fairing Re moval in the Frame chapter Disconnect the oxygen sensor lead connector and con nect the harness adapter A between these connectors Special Tool Oxygen Sensor Measuring Adapter 57001 1682 Connect a digital meter to the harness adapter leads Oxygen Sensor Output Voltage Connections to Adapter Digital Meter BL W sensor BL lead Digital Meter BR BK sensor W lead Remove the fuel tank see Fuel Tank R
324. ont rear wheel off the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1608 Spin the wheel lightly and check for roughness or binding If roughness or binding is found replace the hub bearings see Hub Bearing Removal Installation Inspect the wheel for small cracks dents bending or warp If there is any damage to the wheel replace the wheel Remove the wheel and support it with the tire by the axle Measure the rim runout axial A and radial B with a dial gauge If rim runout exceeds the service limit check the hub bear ings see Hub Bearing Inspection If the problem is not due to the bearings replace the wheel Rim Runout with tire installed Standard Axial TIR 0 5 mm 0 02 in or less Radial TIR 0 8 mm 0 03 in or less Service Limit Axial TIR 1 0 mm 0 04 in Radial TIR 1 0 mm 0 04 in WARNING Never attempt to repair a damaged wheel If there is any damage besides wheel bearings the wheel must be replaced to insure safe operational condi tion Axle Inspection Remove the front and rear axles see Front Rear Wheel Removal Visually inspect the front and rear axle for damages If the axle is damaged or bent replace it 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
325. ood replace the ECU see ECU Removal Installation If there is still no battery voltage check the ECU main relay and fuel pump relay see Relay Circuit Inspection in the Electrical System chapter If the main relay and pump relay are normal check the wiring for continuity see wiring diagram in this section If the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see ECU Removal Installation If the reading is in specification but the pump does not op erate replace the fuel pump see Fuel Pump Removal In stallation http mototh com 3 94 FUEL SYSTEM DFI Fuel Pump Pressure Regulator Removal The pressure regulator A is built into the fuel pump B and can not be removed Fuel Filter Cleaning The fuel filter A are built into the pump and can not be cleaned or checked If the fuel filter is suspected of clogging or being damaged replace it with the fuel pump as a set Fuel Pump Relay Removal Installation The fuel pump relay is built in the relay box A Refer to the Relay Box Removal in the Electrical System chapter Fuel Pump Relay Inspection Refer to the Relay Circuit Inspection in the Electrical Sys tem chapter http mototh com FUEL SYSTEM DFI 3 95 Fuel Pump Fuel Pump Circuit 1 Ignition Switch 2 Engine Stop Switch 3 Water proof Joint 3 4 ECU 5 Joint Connector 2
326. or 5 times and inspect the smooth stroke If the tie rods A do not smoothly stroke or noise is found inspect the fasteners and tie rod bearings see Rocker Arm Tie Rod Bearing Sleeve Inspection in the Suspen sion chapter http mototh com 2 34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Swingarm Pivot Lubrication Remove Swingarm see Swingarm Removal in the Suspension chapter Sleeve A Using a high flash point solvent clean the old grease out of the needle bearings B Apply plenty of grease to the inner surface of the needle bearings Apply thin coat of grease to the lips of the oil seals Install the swingarm see Swingarm Installation in the Suspension chapter Steering Steering Play Inspection Remove the lower fairings see Lower Fairing Removal in the Frame chapter Raise the front wheel off the ground with the jack Special Tools Jack 57001 1238 Jack Attachment 57001 1608 With the front wheel pointing straight ahead alternately tap each end of the handlebar The front wheel should swing fully left and right from the force of gravity until the fork hits the stop If the wheel binds or catches before the stop the steering is too tight Feel for steering looseness by pushing and pulling the forks If you feel looseness the steering is too loose NOTE The cables and wiring will have some effect on the mo tion of the fork which must be taken into accoun
327. or and Radiator Fan Installation 4 12 Radiator Inspection 4 12 Radiator Cap Inspection 4 12 Radiator Filler Neck Inspection 4 13 Thermostat 4 14 Thermostat Removal 4 14 Thermostat Installation 4 14 Thermostat Housing Removal 4 14 Thermostat Housing Installation 4 14 Thermostat Inspection 4 15 Hoses and Pipes 4 16 Hose Installation
328. or light A may light up under strong electrical inter ference No remedy needed Turn the ignition switch OFF to stop the indicator light When the FI indicator light goes on and the motorcycle is brought in for repair check the service codes When the repair has been done the light doesn t go on But the service codes stored in memory are not erased to preserve the problem history and the light can display the codes in the self diagnosis mode The problem history is referred when solving unstable problems When the motorcycle is down the vehicle down sensor operates and the ECU shuts off the fuel pump relay fuel in jectors and ignition system The ignition switch is left ON If the starter button is pushed the electric starter turns but the engine does not start When the starter button is pushed the FI indicator light blinks but the service code is not dis played To start the engine again raise the motorcycle turn the ignition switch OFF and then ON Much of the DFI system troubleshooting work consists of confirming continuity of the wiring The DFI parts are assembled and adjusted with precision and it is impossible to disassemble or repair them http mototh com 3 24 FUEL SYSTEM DFI Troubleshooting the DFI System When checking the DFI parts use a digital meter which can be read two decimal place voltage or resistance The DFI part connectors A have seals B including the ECU When measuring the input or
329. orn the most If the disc has worn past the service limit replace it Measuring Area B Brake Discs Thickness Standard Front 4 3 4 7 mm 0 17 0 19 in Rear 4 8 5 2 mm 0 19 0 20 in Service Limit Front 4 0 mm 0 16 in Rear 4 5 mm 0 18 in Brake Disc Warp Inspection Raise the front rear wheel off the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1608 For front disc inspection turn the handlebar fully to one side Set up a dial gauge against the disc A as shown in the figure and measure disc runout while turning B the wheel by hand If runout exceeds the service limit replace the disc Disc Runout Standard TIR 0 15 mm 0 006 in or less Service Limit TIR 0 3 mm 0 01 in http mototh com BRAKES 12 17 Brake Fluid Brake Fluid Level Inspection Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter Brake Fluid Change Refer to the Brake Fluid Change in the Periodic Mainte nance chapter Brake Line Bleeding The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action Air however is easily compressed When air enters the brake lines brake lever or pedal movement will be partially used in compressing the air This will make the lever or pedal feel spongy and there will be a loss in braking power
330. orrect wheel balance Permanently install the balance weight Balance Weight Removal Insert a regular tip screwdrivers A B between the rib C and the weight D as shown in the figure Pry the balance weight with two screwdrivers and remove the balance weight Discard the used balance weight CAUTION Do not tap the screwdrivers The rim could be dam aged Balance Weight Installation Check if the weight portion has any play on the blade A and clip B If it does discard it WARNING If the balance weight has any play on the rib of the rim the blade and or clip have been stretched Re place the loose balance weight Do not reuse used balance weight Unbalanced wheels can create an unsafe riding condition http mototh com 10 12 WHEELS TIRES Wheels Rims 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 Balance 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 Do 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 Slip the balance weight A onto the rib B by pushing or lightly hammering C the clip D Left Side E Right Side F Be sure to
331. ors Special Tool Hand Tester 57001 1394 Disconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Water Temperature Sensor Connector B O lead ECU terminal 17 C BR BK lead ECU terminal 22 D If the wiring is good check the water temperature sensor resistance see Water Temperature Sensor Resistance Inspection Water Temperature Sensor Resistance Inspection Refer to the Water Temperature Sensor Inspection in the Electrical System chapter If the reading is within the standard but the problem still exists replace the ECU see ECU Removal Installation Water Temperature Sensor Circuit 1 ECU 2 Water proof Joint 1 3 Water Temperature Sensor http mototh com FUEL SYSTEM DFI 3 55 Crankshaft Sensor Service Code 21 The crankshaft sensor has no power source and when the engine stops the crankshaft sensor generates no sig nals Crankshaft Sensor Removal Installation Refer to the Crankshaft Sensor Removal Installation in the Electrical System chapter Crankshaft Sensor Resistance Inspection Refer to the Crankshaft Sensor Inspection in the Electrical System chapter If the reading is within the standard check the peak volt age see Crankshaft Sensor Peak Voltage Inspection Crankshaft Sensor Peak Voltage Inspection Refer to the Crankshaft Sensor Peak Voltage Inspection in the Electrical System chapter If the reading is within the sta
332. ors Special Tool Hand Tester 57001 1394 Disconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Inlet Air Pressure Sensor Connector B BL lead ECU terminal 8 C BR BK lead ECU terminal 22 D If the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see ECU Removal Installation Inlet Air Pressure Sensor Output Voltage Inspection Measure the output voltage at the inlet air pressure sen sor in the same way as input voltage inspection note the following Disconnect the inlet air pressure sensor connector and connect the harness adapter A between these connec tors Special Tool Sensor Harness Adapter 57001 1561 Inlet Air Pressure Sensor Output Voltage Connections to Adapter Digital Meter G W sensor Y BL lead Digital Meter BK sensor BR BK lead Measure the output voltage with the engine stopped and with the connector joined Turn the ignition switch ON Output Voltage Usable Range DC 3 80 4 20 V at standard atmospheric pressure 101 32 kPa 76 cmHg NOTE The output voltage changes according to local atmo spheric pressure Turn the ignition switch OFF If the reading is out of the usable range replace the sen sor http mototh com 3 46 FUEL SYSTEM DFI Inlet Air Pressure Sensor Service Code 1
333. ottle Sensor Input Voltage Connections to Adapter Digital Meter BK sensor BL lead Digital Meter W sensor BR BK lead Measure the input voltage with the engine stopped and with the connector joined Turn the ignition switch ON Input Voltage Standard DC 4 75 5 25 V Turn the ignition switch OFF If the reading is within the standard check the output volt age see Main Throttle Sensor Output Voltage Inspec tion If the reading is out of the standard remove the ECU and check the wiring for continuity between main harness connectors Special Tool Hand Tester 57001 1394 Disconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Main Throttle Sensor Connector B BL lead ECU terminal 8 C BR BK lead ECU terminal 22 D If the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see ECU Removal Installation http mototh com 3 42 FUEL SYSTEM DFI Main Throttle Sensor Service Code 11 Main Throttle Sensor Output Voltage Inspection Measure the output voltage at the main throttle sensor in the same way as input voltage inspection note the follow ing Disconnect the main throttle sensor connector and con nect the harness adapter A between these connectors Special Tool Throttle Sensor Setting Adapter 57001 153
334. oval in the Frame chap ter 30 A Main Fuse Connector A Disconnect Pull out the main fuse A from the starter relay with a needle nose pliers Fuse Box Fuse Removal Remove the front seat see Front Seat Removal in the Frame chapter Unlock the hook A to lift up the lid B Pull the fuses A straight out of the fuse box with needle nose pliers 15 A ECU Fuse Removal Remove the front seat see Front Seat Removal in the Frame chapter Unlock the hook A to lift up the lid B http mototh com 16 70 ELECTRICAL SYSTEM Fuse Pull out the ECU fuse A from the fuse box Fuse Installation If a fuse fails during operation inspect the electrical sys tem to determine the cause and then replace it with a new fuse of proper amperage Install the fuse box fuses on the original position as spec ified on the lid Fuse Inspection Remove the fuse see 30 A Main Fuse Box 15 A ECU Fuse Removal Inspect the fuse element If it is blown out replace the fuse Before replacing a blown fuse always check the amperage in the affected circuit If the amperage is equal to or greater than the fuse rating check the wiring and related components for a short circuit Housing A Fuse Element B Terminals C Blown Element D CAUTION When replacing a fuse be sure the new fuse matches the specified fuse rating for that circuit Installation of a fuse with a higher rating may caus
335. pection 12 10 Caliper Dust Seal Damage Inspection 12 11 Caliper Dust Boot and Friction Boot Damage Inspection 12 11 Caliper Piston and Cylinder Damage Inspection 12 12 Caliper Holder Shaft Wear Inspection 12 12 Brake Pads 12 13 Brake Pad Removal 12 13 Brake Pad Installation 12 13 Brake Pad Wear Inspection 12 13 Master Cylinder 12 14 Front Master Cylinder Removal 12 14 Front Master Cylinder Installation
336. ply any grease or oil to the cap inside and cap insert outside B Install the inserts so that their nails C are on the same side and fit them into the recess of the connecting rod and cap CAUTION Wrong application of oil and grease could cause bearing damage When installing the inserts A be careful not to damage the insert surface with the edge of the connecting rod B or the cap C One way to install inserts is as follows Installation D to Cap Installation E to Connecting Rod Push F Spare Dowel Pin G Connecting Rod Bolts H Install the cap on the connecting rod aligning the weight and diameter marks Remove debris and clean the surface of inserts Apply molybdenum disulfide oil solution MO to the threads and seating surfaces of the big end nuts and bolts Install the crankshaft see Crankshaft Installation Install each connecting rod on its original crankpin Tighten Torque Connecting Rod Big End Nuts 27 5 N m 2 8 kgf m 20 ft lb Crankshaft Connecting Rod Cleaning After removing the connecting rods from the crankshaft clean them with a high flash point solvent Blow the crankshaft oil passages with compressed air to remove any foreign particles or residue that may have accumulated in the passages http mototh com CRANKSHAFT TRANSMISSION 9 17 Crankshaft and Connecting Rods Connecting Rod Bend Inspection Remove the connecting rod big end bea
337. pring Install the pads see Brake Pad Installation in the Brakes chapter Wipe up any spilled brake fluid on the caliper with wet cloth Spark Plug Replacement Remove the stick coils see Stick Coil Removal in the Electrical System chapter Remove the spark plugs using the 16 mm 0 63 in plug wrench A vertically http mototh com PERIODIC MAINTENANCE 2 55 Periodic Maintenance Procedures Replace the spark plug with a new one Standard Spark Plug Type NGK CR8E Insert the new spark plug in the plug hole and finger tighten it first Using the plug wrench A vertically tighten the plug CAUTION The insulator of the spark plug may break if when the wrench is inclined during tightening Torque Spark Plugs 13 N m 1 3 kgf m 115 in lb Install the stick coils securely Be sure the stick coils are installed by pulling up it lightly http mototh com http mototh com FUEL SYSTEM DFI 3 1 3 Fuel System DFI Table of Contents Exploded View 3 4 DFI System 3 8 DFI Parts Location 3 14 Specifications
338. projection A in its shaft fits into the slot B of the water pump shaft Apply a non permanent locking agent to the threads of the oil pump mounting bolts and tighten them Torque Oil Pump Mounting Bolts 9 8 N m 1 0 kgf m 87 in lb Oil Pump Inspection Visually inspect the oil pump body inner and outer rotors and cover If there is any damage or uneven wear replace the oil pump as an assembly http mototh com ENGINE LUBRICATION SYSTEM 7 11 Oil Pressure Measurement Oil Pressure Measurement Remove the right lower fairing see Lower Fairing Re moval in the Frame chapter Remove the oil passage plug and attach the adapter A and gauge B to the plug hole Special Tools Oil Pressure Gauge 10 kgf cm 57001 164 Oil Pressure Gauge Adapter M18 1 5 57001 1278 Start the engine and warm up the engine Run the engine at the specified speed and read the oil pressure gauge If the reading is much lower than the standard check the oil pump relief valve and or crankshaft bearing in sert wear immediately If the reading is much higher than the standard check the oil passages for clogging Oil Pressure Standard 98 147 kPa 1 0 1 5 kgf cm 14 21 psi at 4 000 r min rpm Oil Temperature 90 C 194 F Stop the engine Remove the oil pressure gauge and adapter WARNING Take care against burns form hot engine oil that will drain through the oil passage whe
339. properly aligned the notch E on the right wheel align ment indicator F should align with the same swingarm mark or position G that the left indicator notch aligns with WARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition Tighten both chain adjuster locknuts securely Tighten Torque Rear Axle Nut 98 N m 10 0 kgf m 72 3 ft lb Turn the wheel measure the chain slack again at the tight est position and readjust if necessary http mototh com 2 28 PERIODIC MAINTENANCE Periodic Maintenance Procedures Insert a new cotter pin A NOTE When inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle tighten the nut clockwise B up to next alignment It should be within 30 Loosen once and tighten again when the slot goes past the nearest hole Bend the cotter pin A over the nut WARNING If the rear axle nut is not securely tightened or the cotter pin is not installed an unsafe riding condi tion may result Wheel Alignment Inspection Check that the notch A on the left alignment indicator B aligns with the same swingarm mark or position C that the right alignment indicator notch aligns with If they do not adjust the chain slack and align the wheel alignment see Drive Chain Slack Adjustment NOTE Wheel alignment can be also checked using the straightedge or s
340. r Remove the vacuum gauge hoses and install the rubber caps on the original position http mototh com 2 18 PERIODIC MAINTENANCE Periodic Maintenance Procedures Idle Speed Inspection Start the engine and warm it up thoroughly With the engine idling turn the handlebar to both sides A If handlebar movement changes the idle speed the throttle cables may be improperly adjusted or incorrectly routed or damaged Be sure to correct any of these conditions before riding see Throttle Control System Inspection and Cable Wire and Hose Routing section in the Appendix chapter WARNING Operation with improperly adjusted incorrectly routed or damaged cables could result in an unsafe riding condition Check the idle speed Idle Speed Standard 1 300 50 r min rpm If the idle speed is out of the specified range adjust it Idle Speed Adjustment Start the engine and warm it up thoroughly Turn the adjusting screw A until the idle speed is correct Open and close the throttle a few times to make sure that the idle speed is within the specified range Readjust if necessary Fuel Hose Inspection fuel leak damage installation condition If the motorcycle is not properly handled the high pres sure inside the fuel line can cause fuel to leak A or the hose to burst Remove the fuel tank see Fuel Tank Re moval in the Fuel System DFI chapter and check the fuel hose Replace the hose i
341. r A Disconnect Vehicle down Sensor B Vehicle down Sensor Installation The UPPER mark A of the sensor should face upward WARNING Incorrect installation of the vehicle down sensor could cause sudden loss of engine power The rider could lose balance during certain riding situ ations like leaning over in a turn with the potential for an accident resulting in injury or death Ensure that the vehicle down sensor is held in place by the sensor bracket Vehicle down Sensor Input Voltage Inspection NOTE Be sure the battery is fully charged Turn the ignition switch OFF Remove the fuel tank see Fuel Tank Removal Disconnect the vehicle down sensor connector and con nect the harness adapter A between these connectors as shown in the figure Main Harness B Vehicle down Sensor C Special Tool Measuring Adapter 57001 1700 Connect a digital meter D to the harness adapter leads Vehicle down Sensor Input Voltage Connections to Adapter Digital Meter R sensor BL lead Digital Meter BK sensor BR BK lead Measure the input voltage with the engine stopped and with the connector joined Turn the ignition switch ON Input Voltage Standard DC 4 75 5 25 V Turn the ignition switch OFF If the reading is within the standard check the output volt age see Vehicle down Sensor Output Voltage Inspec tion http mototh com 3 60 FUEL SYSTEM DFI Veh
342. r A and 12 V battery B to the starter relay C as shown in the figure Special Tool Hand Tester 57001 1394 If the relay does not work as specified the relay is defec tive Replace the relay Testing Relay Tester Range 1 range Criteria When battery is connected 0 When battery is disconnected http mototh com 16 46 ELECTRICAL SYSTEM Electric Starter System Electric Starter Circuit 1 Ignition Switch 2 Engine Stop Switch 3 Starter Button 4 Water proof Joint 3 5 Neutral Switch 6 Joint Connector 2 7 Sidestand Switch 8 Battery 12 V 8 Ah 9 Frame Ground 10 Starter Relay 11 Main Fuse 30 A 12 Starter Motor 13 Relay Box 14 Starter Circuit Relay 15 Starter Lockout Switch 16 Fuse Box 17 Ignition Fuse 10 A http mototh com ELECTRICAL SYSTEM 16 47 Lighting System This motorcycle adopt the daylight system and have a headlight relay in the relay box The headlight does not go on when the ignition switch and the engine stop switch are first turned on The headlight comes on after the starter button is released and stays on until the ignition switch is turned off The headlight will go out momentarily whenever the starter button is pressed and come back on when the button is released Headlight Beam Horizontal Adjustment Refer to the Headlight Aiming Inspection in the Periodic Maintenance chapter Headlight Beam Vertical Adjustment Refer to the Headlight
343. r Indicator Light Replace ment in the Electrical System chapter City Light Bulb see City Light Bulb Replacement in the Electrical System chapter Oil Pressure Switch see Switch Inspection in the Elec trical System chapter ECU see ECU Power Supply Inspection in the Fuel Sys tem DFI chapter Ignition Switch see Switch Inspection in the Electrical System chapter Neutral Switch see Switch Inspection in the Electrical System chapter Harness see Wiring Inspection in the Electrical System chapter Turn off the ignition switch The all lights should go off If the light does not go off replace the ignition switch http mototh com PERIODIC MAINTENANCE 2 37 Periodic Maintenance Procedures Second Step Turn on the turn signal switch A left or right position The left or right turn signal lights B front and rear ac cording to the switch position should flash The turn signal indicator light C in the meter unit should flash If the each light does not flash inspect or replace the following item Turn Signal Light Bulb see Turn Signal Light Bulb Re placement in the Electrical System chapter Meter Unit for Turn Signal Indicator Light see Meter In dicator Light Replacement in the Electrical System chap ter Turn Signal Relay Fuse 10 A see Fuse Inspection in the Electrical System chapter Turn Signal Switch see Switch Inspection in the Electri cal System chapter Turn Signal Relay see
344. r and then free the cable from the lever Slide the dust cover A at the clutch cable lower end out of place Remove the clutch cable lower from the cable holder B loosening the locknuts C Free the clutch inner cable tip from the clutch release lever Pull the clutch cable out of the frame Clutch Cable Installation Run the clutch cable correctly see Cable Wire and Hose Routing section in the Appendix chapter Adjust the clutch cable see Clutch Operation Inspection in the Periodic Maintenance chapter Clutch Cable Lubrication Refer to the Chassis Parts Lubrication in the Periodic Maintenance chapter Clutch Lever Installation Install the clutch lever so that the mating surface A of the clutch lever is aligned with the punch mark B Tighten Torque Clutch Lever Clamp Bolt 8 8 N m 0 90 kgf m 78 in lb http mototh com CLUTCH 6 7 Clutch Cover Clutch Cover Removal Remove Engine Oil Drain see Engine Oil Change in the Periodic Maintenance chapter Right Lower Fairing see Lower Fairing Removal in the Frame chapter Clutch Cable Lower End A Clutch Cover Bolts B Turn the release lever A toward the rear as shown in the figure and remove the clutch cover B About 90 C Clutch Cover Installation Apply silicone sealant to the area A where the mating surface of the crankcase touches the clutch cover gasket Sealant Kawasaki Bond Silic
345. r 50 coolant 50 Freezing Point 35 C 31 F Total Amount 1 5 L 1 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 18 psi Thermostat Valve Opening Temperature 63 5 66 5 C 146 152 F Valve Full Opening Lift 6 mm 0 24 in or more at 80 C 176 F http mototh com COOLING SYSTEM 4 7 Coolant Coolant Deterioration Inspection Remove the right lower fairing see Lower Fairing Re moval in the Frame chapter Visually inspect the coolant A in the reserve tank If whitish cotton like wafts are observed aluminum parts in the cooling system are corroded If the coolant is brown iron or steel parts are rusting In either case flush the cooling system If the coolant gives off an abnormal smell check for a cooling system leak It may be caused by exhaust gas leaking into the cooling system Coolant Level Inspection Refer to the Coolant Level Inspection in the Periodic Main tenance chapter Coolant Draining Refer to the Coolant Change in the Periodic Maintenance chapter Coolant Filling Refer to the Coolant Change in the Periodic Maintenance chapter Pressure Testing Remove the right lower fairing see Lower Fairing Re moval in the Frame chapter Remove the radiator cap and install a cooling system pressure tester A on the filler neck NOTE Wet the cap s
346. r Head Cover 5 13 Cylinder Head Cover Removal 5 13 Cylinder Head Cover Installation 5 13 Camshaft Chain Tensioner 5 15 Camshaft Chain Tensioner Removal 5 15 Camshaft Chain Tensioner Installation 5 15 Camshaft Camshaft Chain 5 17 Camshaft Removal 5 17 Camshaft Installation 5 18 Camshaft Camshaft Cap Wear Inspection 5 20 Camshaft Runout Inspection 5 20 Cam Wear Inspection 5 21 Camshaft Chain Removal 5 21 Cylinder Head 5 22 Cylinder Compression Measurement 5 22 Cylinder Head Removal 5 23 Cylinder Head Installation 5 24 Cylinder Head Warp Inspection 5 25 Valves 5 26 Valve Clearance Inspection 5 26 Valve Clearance Adjustment 5 26 Valve Removal 5 26 Valve Installation 5 26 Valve Guide Removal 5 26 Valve Guide Installation 5 27 Valve to Guide Clearance Measurement Wobble Method 5 27 Valve Seat Inspection 5 28 Valve Seat Repair 5 28 Cylinder P
347. r Installation 16 64 Speed Sensor Inspection 16 64 Oxygen Sensor Removal 16 64 Oxygen Sensor Installation 16 65 Oxygen Sensor Inspection 16 65 Fuel Reserve Switch Inspection 16 65 Relay Box 16 66 Relay Box Removal 16 66 Relay Circuit Inspection 16 66 Diode Circuit Inspection 16 67 Fuse 16 69 30 A Main Fuse Removal
348. r from the cool ing system see Coolant Change in the Periodic Mainte nance chapter Water Temperature Sensor Output Voltage Inspection NOTE Be sure the battery is fully charged Turn the ignition switch OFF Remove the fuel tank see Fuel Tank Removal Disconnect the water temperature sensor connector and connect the harness adapter A between these connec tors as shown in the figure Main Harness B Water Temperature Sensor C Special Tool Measuring Adapter 57001 1700 Connect a digital meter D to the harness adapter leads Water Temperature Sensor Output Voltage Connections to Adapter Digital Meter R sensor O lead Digital Meter BK sensor BR BK lead Measure the output voltage with the engine stopped and with the connector joined Turn the ignition switch ON Output Voltage Standard About DC 2 80 2 97 V at 20 C 68 F NOTE The output voltage changes according to the coolant temperature in the engine Turn the ignition switch OFF If the reading is within the standard check the ECU for its ground and power supply see ECU Power Supply In spection If the ground and power supply are good replace the ECU see ECU Removal Installation http mototh com 3 54 FUEL SYSTEM DFI Water Temperature Sensor Service Code 14 If the reading is out of the standard remove the ECU and check the wiring for continuity between main harness connect
349. red Portion A Alternator Rotor Tapered Portion B Apply a thin coat of molybdenum disulfide grease to the crankshaft C Install the starter clutch gear A and washer B Again clean the crankshaft tapered portion C and dry there Fit the woodruff key D securely in the slot in the crank shaft before installing the alternator rotor Install the alternator rotor A while turning B the starter clutch gear C http mototh com ELECTRICAL SYSTEM 16 27 Charging System Install the washer and alternator rotor bolt A NOTE Confirm the alternator rotor fit or not to the crankshaft before tightening it with specified torque Install the rotor bolt and tighten it with 55 N m 5 6 kgf m 41 ft lb of torque Special Tool Flywheel Holder B 57001 1313 CAUTION Do not hold the projections C Remove the rotor bolt and washer Check the tightening torque with flywheel puller Special Tool Flywheel Puller Assembly M38 1 5 M35 1 5 57001 1405 If the rotor is not pulled out with 20 N m 2 0 kgf m 15 ft lb of drawing torque it is installed correctly If the rotor is pulled out with under 20 N m 2 0 kgf m 15 ft lb of drawing torque clean off any oil dirt or flaw of the crankshaft and rotor tapered portion and dry them with a clean cloth Then confirm that it is not pulled out with above torque Tighten the alternator rotor bolt while holding the alte
350. replace the radiator with a new one CAUTION When cleaning the radiator with steam cleaner be careful of the following to prevent radiator damage Keep the steam gun A away more than 0 5 m 1 6 ft B from the radiator core Hold the steam gun perpendicular C not oblique D to the core surface Run the steam gun following the core fin direction Radiator Cap Inspection Remove Right Lower Fairing see Lower Fairing Removal in the Frame chapter Radiator Cap Check the condition of the bottom A and top B valve seals and valve spring C If any one of them shows visible damage replace the cap with a new one http mototh com COOLING SYSTEM 4 13 Radiator Install the cap A on a cooling system pressure tester B NOTE Wet the cap sealing surfaces with water or coolant to prevent pressure leaks Watching the pressure gauge pump the pressure tester to build up the pressure until the relief valve opens the gauge needle flicks downward Stop pumping and mea sure leak time at once The relief valve must open within the specified range in the table below and the gauge hand must remain within the same range at least 6 seconds Radiator Cap Relief Pressure Standard 93 123 kPa 0 95 1 25 kgf cm 13 18 psi If the cap can not hold the specified pressure or if it holds too much pressure replace it with a new one Radiator Filler Neck Inspection Remove Right Lower Fairing s
351. rews start them all in their holes and tighten them to a snug fit Then tighten them according to the specified se quence to prevent case warpage or deformation which can lead to malfunction Conversely when loosening the bolts nuts or screws first loosen all of them by about a quar ter turn and then remove them If the specified tightening sequence is not indicated tighten the fasteners alternating diagonally Tightening Torque Incorrect torque applied to a bolt nut or screw may lead to serious damage Tighten fasteners to the specified torque using a good quality torque wrench Force Use common sense during disassembly and assembly excessive force can cause expensive or hard to repair dam age When necessary remove screws that have a non permanent locking agent applied using an impact driver Use a plastic faced mallet whenever tapping is necessary Gasket O ring Hardening shrinkage or damage of both gaskets and O rings after disassembly can reduce sealing performance Remove old gaskets and clean the sealing surfaces thor oughly so that no gasket material or other material remains Install the new gaskets and replace the used O rings when re assembling Liquid Gasket Non permanent Locking Agent For applications that require Liquid Gasket or a Non permanent Locking Agent clean the surfaces so that no oil residue remains before applying liquid gasket or non permanent locking agent Do not apply them exces sive
352. rinding the seat surface Also wash off ground particles sticking to the cutter with washing oil NOTE Do not use a wire brush to remove the metal particles from the cutter It will take off the diamond particles 4 Setting the valve seat cutter holder in position operate the cutter in one hand Do not apply too much force to the diamond portion NOTE Prior to grinding apply engine oil to the cutter and dur ing the operation wash off any ground particles sticking to the cutter with washing oil 5 After use wash it with washing oil and apply thin layer of engine oil before storing Marks Stamped on the Cutter The marks stamped on the back of the cutter A represent the following 60 Cutter angle B 37 5 Outer diameter of cutter C Operating Procedures Clean the seat area carefully Coat the seat with machinist s dye Fit a 45 cutter into the holder and slide it into the valve guide Press down lightly on the handle and turn it right or left Grind the seating surface only until it is smooth CAUTION Do not grind the seat too much Overgrinding will reduce valve clearance by sinking the valve into the head If the valve sinks too far into the head it will be impossible to adjust the clearance and the cylin der head must be replaced http mototh com 5 30 ENGINE TOP END Valves Measure the outside diameter of the seating surfa
353. ring Bracket G Upper Fairing Bracket Installation Installation is the reverse of removal Run the cables and leads correctly see Cable Wire and Hose Routing section in the Appendix chapter Inner Fairing Removal Remove Lower Fairings see Lower Fairing Removal Rivets A Both Sides Screws B Both Sides Inner Fairing C Inner Fairing Installation Fit the front portions A of the inner fairing into the lower portions B of the upper fairing http mototh com FRAME 15 11 Side Cover Side Cover Removal Remove the screw A Pull the side cover B evenly outward to clear the stop pers C Side Cover Installation Fit the groove A to the projection B Insert the projections C into the holes D Tighten the screw http mototh com 15 12 FRAME Seat Covers Seat Cover Removal Remove Side Covers see Side Cover Removal Seats see Rear Front Seat Removal Bolts A Pull the left and right seat covers B to clear the stoppers C Remove the projections A from the holes B and pull out the center seat cover C forward Seat Cover Installation Installation is the reverse of removal Install the damper to the center seat cover so that its flat ten side A faces downward Put the projection A into the hole B of the tail brake light Put the holes C to the projections D of the rear fender Be sure that the damper
354. ring Removal in the Frame chapter Bolt A Clamp B Connectors C Resistor D Set the hand tester to the 1 range and check the continuity as shown in the figure Special Tools Hand Tester 57001 1394 Connections BL lead A BL lead B BK lead C BK lead D Standard About 0 If the resistor has an open or short replace it with a new one http mototh com ELECTRICAL SYSTEM 16 57 Radiator Fan System Radiator Fan Circuit 1 ECU 2 Joint Connector 2 3 Battery 12 V 8 Ah 4 Frame Ground 5 Main Fuse 30 A 6 Joint Connector 1 7 Relay Box 8 Fan Relay 9 ECU Fuse 15 A 10 Fan Fuse 10 A 11 Fuse Box 12 Resistor 13 Fan Motor 14 Water proof Joint 3 15 Water proof Joint 1 16 Water Temperature Sensor http mototh com 16 58 ELECTRICAL SYSTEM Meter Gauge Indicator Unit Meter Unit Removal Installation Remove Upper Fairing see Upper Fairing Removal in the Frame chapter Speedometer Cable Upper End A Connectors B Remove the inner cover A with meter unit B Remove Bolts A Meter Unit B CAUTION Place the meter unit so that the face is up If a meter unit is left upside down or sideways for any length of time it will malfunction Installation is the reverse of removal Fit the projections A into the grommets B Run the leads and cable correctly see Cable Wire and Hose Routing section in the Appendix chapter
355. ring 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 at least 100 mm 3 94 in long and insert the arbor B through the connecting rod small end On a surface plate set the big end arbor on V block C With the connecting rod held vertically use a height gauge to measure the difference in the height of the arbor above the surface plate over a 100 mm 3 94 in length to determine the amount of connecting rod bend If the connecting rod bend exceeds the service limit the connecting rod must be replaced Connecting Rod Bend Service Limit TIR 0 2 100 mm 0 008 3 94 in Connecting Rod Twist Inspection With the big end arbor A still on V block C hold the connecting rod horizontally and measure the amount that the arbor B varies from being paralleled with the surface plate over a 100 mm 3 94 in length of the arbor to de termine the amount of connecting rod twist If the connecting rod twist exceeds the service limit the connecting rod must be replaced Connecting Rod Twist Service Limit TIR 0 2 100 mm 0 008 3 94 in Connecting Rod Big End Side Clearance Inspection Measure the connecting rod big end side clearance Insert a thickness gauge A between the big end and ei ther crank web to determine
356. rna tor rotor steady with the flywheel holder Special Tool Flywheel Holder 57001 1313 CAUTION Do not hold the projections Torque Alternator Rotor Bolt 88 2 N m 9 0 kgf m 65 ft lb Apply a thin coat of molybdenum disulfide grease to the shaft A and install it and starter idle gear B Install the alternator cover see Alternator Cover Installa tion http mototh com 16 28 ELECTRICAL SYSTEM Charging System Charging Voltage Inspection Check the battery condition see Charging Condition In spection Warm up the engine to obtain actual alternator operating conditions Remove the battery cover see Battery Removal Check that the ignition switch is turned off and connect the hand tester A to the battery terminals B Special Tool Hand Tester 57001 1394 Start the engine and note the voltage readings at var ious engine speeds with the headlight turned on and then turned off To turn off the headlight disconnect the headlight connector on the headlight unit The readings should show nearly battery voltage when the engine speed is low and as the engine speed rises the readings should also rise But they must be kept under the specified voltage Charging Voltage Connections Tester Range Tester to Tester to Reading 25 V DC Battery Battery 13 9 14 9 V Turn off the ignition switch to stop the engine and discon nect the hand tes
357. row mark pointed up B and measure the output voltage Output Voltage Standard With sensor tilted 55 75 or more right or left DC 3 7 4 4 V With sensor arrow mark pointed up DC 0 4 1 4 V NOTE If you need to test again turn the ignition switch OFF and then ON Turn the ignition switch OFF If the reading is out of the standard replace the sensor If the reading is within the standard remove the ECU and check the wiring for continuity between main harness con nectors Special Tool Hand Tester 57001 1394 Disconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Vehicle down Sensor Connector B Y G lead ECU terminal 9 C BR BK lead ECU terminal 22 D If the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see ECU Removal Installation http mototh com 3 62 FUEL SYSTEM DFI Vehicle down Sensor Service Code 31 Vehicle down Sensor Circuit 1 ECU 2 Water proof Joint 2 3 Vehicle down Sensor 4 Water proof Joint 1 http mototh com FUEL SYSTEM DFI 3 63 Subthrottle Sensor Service Code 32 Subthrottle Sensor Removal Adjustment CAUTION Do not remove or adjust the subthrottle sensor A since it has been adjusted and set with precision at the factory Never drop the throttle body assy especially on a hard surf
358. rs C Connect http mototh com 3 84 FUEL SYSTEM DFI ECU Insert the slits of the rubber protector to the projections A of the rear fender ECU Power Supply Inspection Remove the front seat see Front Seat Removal in the Frame chapter Visually inspect the ECU connectors If the connector is clogged with mud or dust blow it off with compressed air Remove the ECU see ECU Removal Visually inspect the terminals A of the ECU connectors If the terminals of the main harness connectors are dam aged replace the main harness If the terminals of the ECU connectors are damaged re place the ECU Turn the ignition switch OFF Disconnect the ECU connectors A Set the hand tester B to the 1 range and check the following wiring for continuity Special Tool Hand Tester 57001 1394 ECU Grounding Continuity Inspection Connections I BK Y leads ECU terminal 26 42 or 43 Battery Terminal II Engine Ground Battery Terminal Criteria Both 0 If no continuity check the connectors the engine ground lead or main harness and repair or replace them if nec essary http mototh com FUEL SYSTEM DFI 3 85 ECU If the wiring is good check the power source voltage of the ECU NOTE Be sure the battery is fully charged Connect the ECU connectors Connect a digital meter A to the connector B with the needle adapt
359. rter motor clutch gear should turn clockwise B freely but should not turn counterclockwise C If the starter motor clutch does not operate as it should or if it makes noise go to the next step Disassemble the starter motor clutch and visually inspect the clutch parts If there is any worn or damaged part replace it NOTE Examine the starter motor clutch gear as well Replace it if it worn or damaged Starter Motor Clutch Disassembly Remove Alternator Rotor see Alternator Rotor Removal in the Electrical System chapter Starter Motor Clutch Bolts A Starter Motor Clutch B Starter Motor Clutch Assembly Apply a non permanent locking agent to the threads of the starter motor clutch bolts and tighten them Torque Starter Motor Clutch Bolts 34 3 N m 3 5 kgf m 25 ft lb http mototh com CRANKSHAFT TRANSMISSION 9 23 Balancer Balancer Removal Split the crankcase see Crankcase Splitting Remove the balancer shaft A with the balancer gear Balancer Installation Install the balancer shaft Align the timing mark A on the balancer gear B with the timing mark C on the balancer drive gear D Apply molybdenum disulfide oil solution to the balancer shaft bearing inserts Balancer Shaft Bearing Insert Journal Wear Inspection Measure the bearing insert journal A clearance with plastigage B NOTE Tighten the crankcase bolts to the specified torque see Crank
360. s 3 35 How to Read Service Codes 3 37 How to Erase Service Codes 3 37 Service Code Table 3 38 Backups 3 39 Main Throttle Sensor Service Code 11 3 41 Main Throttle Sensor Removal Adjustment 3 41 Main Throttle Sensor Input Voltage Inspection 3 41 Main Throttle Sensor Output Voltage Inspection 3 42 Main Throttle Sensor Resistance Inspection 3 43 Inlet Air Pressure Sensor Service Code 12 3 44 Inlet Air Pressure Sensor Removal 3 44 Inlet Air Pressure Sensor Installa
361. s too low add the correct amount of oil through the oil filler opening Use the same type and make of oil that is already in the engine NOTE If the engine oil type and make are unknown use any brand of the specified oil to top off the level in preference to running the engine with the oil level low Then at your earliest convenience change the oil completely Engine Oil Change Refer to the Engine Oil Change in the Periodic Mainte nance chapter Oil Filter Replacement Refer to the Oil Filter Replacement in the Periodic Main tenance chapter http mototh com 7 8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter Bypass Valve Disassembly Remove the oil filter see Oil Filter Replacement in the Periodic Maintenance chapter NOTE Oil draining is not necessary but place the oil pan un der the oil filter because oil drain a little at the oil filter removal Drive the retaining pin A out of the oil filter mounting bolt B Drop out the spring C and the bypass valve steel ball D Bypass Valve Assembly Drop the bypass valve steel ball into the oil filter mounting bolt Put the spring into the oil filter mounting bolt and com press it beyond the small hole Drive the retaining pin into the small hole to hold the spring Install the oil filter see Oil Filter Replacement in the Pe riodic Maintenance chapter Bypass Valve Cleaning and Inspection Disassemble the bypa
362. se Routing http mototh com APPENDIX 17 19 Cable Wire and Hose Routing 1 Alternator Lead Connector 2 Crankshaft Sensor Lead Connector 3 Alternator Lead 4 Crankshaft Sensor Lead 5 Brackets 6 Clutch Cable 7 Run the clutch cable and reserve tank hose into the hole of the reserve tank 8 Reserve Tank Overflow Hose 9 Reserve Tank Hose 10 Battery Negative Cable Set the direction of the cable as shown in the figure http mototh com 17 20 APPENDIX Cable Wire and Hose Routing http mototh com APPENDIX 17 21 Cable Wire and Hose Routing 1 Starter Relay 2 Relay Box Lead Connectors 3 Clamp Hold the main harness and insert the clamp into the frame 4 ECU Lead Connectors 5 Battery Positive Cable 6 Clamp Hold the main harness and insert the clamp into the frame 7 Turn Signal Relay Lead Connector 8 Clamp Hold the rear turn signal light and turn signal relay leads and insert the clamp into the rear fender 9 Rear Turn Signal Light Lead Connectors 10 Rear Brake Light Switch 11 Clamp Hold the rear brake light switch lead 12 Rear Brake Light Switch Lead Connector 13 Battery Negative Cable 14 Starter Motor Cable http mototh com 17 22 APPENDIX Cable Wire and Hose Routing http mototh com APPENDIX 17 23 Cable Wire and Hose Routing 1 Tail Brake Light Lead Connector 2 License Plate Light Lead Connector 3 Clamp Hold the license plate light lead 4 Clamp Hold the l
363. sembly can cause excessive wear and decrease performance of the vehicle http mototh com GENERAL INFORMATION 1 3 Before Servicing Arrangement and Cleaning of Removed Parts Disassembled parts are easy to confuse Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly Storage of Removed Parts After all the parts including subassembly parts have been cleaned store the parts in a clean area Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re assembly Inspection Reuse of worn or damaged parts may lead to serious ac cident Visually inspect removed parts for corrosion discol oration or other damage Refer to the appropriate sections of this manual for service limits on individual parts Replace the parts if any damage has been found or if the part is be yond its service limit Replacement Parts Replacement parts must be KAWASAKI genuine or recommended by KAWASAKI Gaskets O rings oil seals grease seals circlips or cotter pins must be replaced with new ones whenever disassembled Assembly Order In most cases assembly order is the reverse of disassem bly however if assembly order is provided in this Service Manual follow the procedures given http mototh com 1 4 GENERAL INFORMATION Before Servicing Tightening Sequence Generally when installing a part with several bolts nuts or sc
364. shock to the sensor can damage it Remove Fuel Tank see Fuel Tank Removal Inlet Air Pressure Sensor Connector A Disconnect Remove the inlet air pressure sensor A from the rubber damper of the air switching valve and separate the vac uum hose B Inlet Air Pressure Sensor Installation Installation is the reverse of removal Inlet Air Pressure Sensor Input Voltage Inspection NOTE Be sure the battery is fully charged Turn the ignition switch OFF Remove the fuel tank see Fuel Tank Removal Disconnect the inlet air pressure sensor connector and connect the harness adapter A between these connec tors Special Tool Sensor Harness Adapter 57001 1561 Connect a digital meter to the harness adapter leads Inlet Air Pressure Sensor Input Voltage Connections to Adapter Digital Meter G sensor BL lead Digital Meter BK sensor BR BK lead Measure the input voltage with the engine stopped and with the connector joined Turn the ignition switch ON Input Voltage Standard DC 4 75 5 25 V Turn the ignition switch OFF If the reading is within the standard check the output volt age see Inlet Air Pressure Sensor Output Voltage Inspec tion http mototh com FUEL SYSTEM DFI 3 45 Inlet Air Pressure Sensor Service Code 12 If the reading is out of the standard remove the ECU and check the wiring for continuity between main harness connect
365. ss valve see Bypass Valve Disas sembly Clean the bypass valve parts in a high flash point solvent WARNING Clean the parts in a well ventilated area and take care that there is no spark or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline or low flash point solvent Visually inspect the bypass valve parts If there is any damaged part replace it Oil Screen Cleaning and Inspection Remove the bolts A and oil screen cover B Clean the oil screen C with high flash point solvent and remove any particles stuck to it 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 solvent NOTE While cleaning the screen check for any metal particles that might indicate internal engine damage Check the screen carefully for any damage holes and broken wires If the screen is damaged replace the oil screen http mototh com ENGINE LUBRICATION SYSTEM 7 9 Oil Pressure Relief Valve Oil Pressure Relief Valve Removal Remove the clutch cover see Clutch Cover Removal in the Clutch chapter Unscrew the oil pressure relief valve A from the crankcase Oil Pressure Relief Valve Installation Apply a non permanent locking agent to the threads of the relief valve and tigh
366. stable Spring Preload Setting 2nd position Adjustable range 1st 5th position Gas Pressure 980 kPa 10 kgf cm 142 psi Non adjustable http mototh com SUSPENSION 13 7 Special Tools Fork Cylinder Holder Handle 57001 183 Fork Cylinder Holder Adapter 57001 1057 Oil Seal amp Bearing Remover 57001 1058 Steering Stem Nut Wrench 57001 1100 Bearing Driver Set 57001 1129 Fork Outer Tube Weight 57001 1218 Front Fork Oil Seal Driver 57001 1219 Jack 57001 1238 Fork Oil Level Gauge 57001 1290 Jack Attachment 57001 1608 http mototh com 13 8 SUSPENSION Front Fork Front Fork Removal Each Fork Leg Remove Lower Fairings see Lower Fairing Removal in the Frame chapter Front Wheel see Front Wheel Removal in the Wheels Tires chapter Front Fender see Front Fender Removal in the Frame chapter Bolts A Both Sides Bracket B Remove the handlebar and remove the fork top plug A beforehand if the fork leg is to be disassembled NOTE To remove the top plug remove the snap ring B push ing down the top plug with the screwdriver Loosen the upper A and lower B front fork clamp bolts With a twisting motion remove the fork leg down and out Front Fork Installation Each Fork Leg Insert the fork leg until the inner tube top hit the handlebar lightly that is the distance between the inner tube top A and steering stem head surface B is
367. stallation 8 5 http mototh com 8 2 ENGINE REMOVAL INSTALLATION Exploded View http mototh com ENGINE REMOVAL INSTALLATION 8 3 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Engine Mounting Bracket Bolts and Nuts 69 7 0 51 2 Engine Mounting Nuts 69 7 0 51 http mototh com 8 4 ENGINE REMOVAL INSTALLATION Engine Removal Installation Engine Removal Support the rear part of the swingarm with a stand Squeeze the brake lever slowly and hold it with a band 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 Remove Engine Oil Drain see Engine Oil Change in the Periodic Maintenance chapter Coolant Drain see Coolant Change in the Periodic Maintenance chapter Lower Fairings see Lower Fairing Removal in the Frame chapter Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Clutch Cable Lower End see Clutch Cable Removal in the Clutch chapter Coolant Reserve Tank see Coolant Reserve Tank Re moval in the Cooling System chapter Radiator see Radiator and Radiator Fan Removal in the Cooling System chapter
368. stallation Apply grease to a new O ring A Fit the O ring into the groove of the water pump cover B Install the water pump cover and water pipes and tighten the bolts Torque Water Pump Cover Bolts 9 8 N m 1 0 kgf m 87 in lb Water Pipe Bolts 9 8 N m 1 0 kgf m 87 in lb Install the removed parts see appropriate chapters Water Pump Removal Remove Water Pump Cover see Water Pump Cover Removal Water Pump Bolts A Water Pump B Water Pump Installation Apply grease to a new O ring A Install the water pump aligning the slot B of the water pump shaft with the oil pump shaft Tighten Torque Water Pump Bolts 9 8 N m 1 0 kgf m 87 in lb http mototh com 4 10 COOLING SYSTEM Water Pump Water Pump Impeller Inspection Remove the water pump see Water Pump Removal Visually inspect the impeller A If the surface is corroded or if the blades are damaged replace the water pump unit http mototh com COOLING SYSTEM 4 11 Radiator Radiator and Radiator Fan Removal 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 MOTOR LEAD CON NECTOR IS DISCONNECTED TOUCHING THE FAN BEFORE THE CONNECTOR IS DISCONNECTED COULD CAUSE INJURY FROM THE FAN BLADES Remove Inner Fairing see Inner Fairing Removal in the Frame c
369. stallation Install the heat insulation rubber plate as shown in the figure A After installation set the projection in the hole B To Radiator C To Fan Motor Lead D To Air Suction Valve Cover E To Stick Coils F To Water Pipe G To Throttle Body Assy Holders H To Breather Hose Insert the lower engine mounting bolt A first while sup porting the engine Then insert the upper engine mount ing bolt B and tighten the nuts lightly http mototh com ENGINE REMOVAL INSTALLATION 8 7 Engine Removal Installation Before tightening the mounting nuts install the engine mounting brackets When inserting the front engine mounting bolt use the suitable stand under the engine to lift it Tighten Torque Engine Mounting Bracket Bolts and Nuts 69 N m 7 0 kgf m 51 ft lb Engine Mounting Nuts 69 N m 7 0 kgf m 51 ft lb Run the leads cables and hoses correctly see Cable Wire and Hose Routing section in the Appendix chapter Install the removed parts see appropriate chapters Adjust Throttle Cables see Throttle Control System Inspection in the Periodic Maintenance chapter Clutch Cable see Clutch Operation Inspection in the Pe riodic Maintenance chapter Drive Chain see Drive Chain Slack Inspection in the Periodic Maintenance chapter Fill the engine with engine oil see Engine Oil Change in the Periodic Maintenance chapter Fill the engine with coolant see Coolant Change
370. starter motor must be replaced NOTE Even if the foregoing checks show the armature to be good it may be defective in some manner not readily detectable with the hand tester If all other starter motor and starter motor circuit components check good but the starter motor still does not turn over or only turns over weakly replace the starter motor with a new one Brush Lead Inspection Using the 1 hand tester range measure the resis tance as shown in the figure Terminal Bolt and Positive Brush A Brush Plate and Negative Brush B Special Tool Hand Tester 57001 1394 If there is not close to zero ohms the brush lead has an open Replace the brush plate assembly Brush Plate and Terminal Bolt Inspection Using the highest hand tester range measure the resis tance as shown in the figure Terminal Bolt and Brush Plate A Terminal Bolt and Negative Brush Holder B Terminal Bolt and End Cover C Special Tool Hand Tester 57001 1394 If there is any reading the brush holder and or terminal bolt have a short Replace the brush plate assembly Starter Relay Inspection Remove Battery Negative Cable see Battery Removal Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Bracket Bolts A Bracket B http mototh com ELECTRICAL SYSTEM 16 45 Electric Starter System Remove Cable Terminals A and Connector B Disconnect Starter Relay C Connect the hand teste
371. t Be sure the leads and cables are properly routed The bearings must be in good condition and properly lubricated in order for any test to be valid http mototh com PERIODIC MAINTENANCE 2 35 Periodic Maintenance Procedures Steering Play Adjustment Loosen Lower Front Fork Clamp Bolts Both Sides Stem Head Bolt A Adjust the steering Special Tool Steering Stem Nut Wrench B 57001 1100 If the steering is too tight loosen the stem nut a fraction of a turn If the steering is too loose tighten the stem nut a fraction of a turn NOTE Turn the stem nut 1 8 turn at time maximum Tighten Torque Steering Stem Head Bolt 44 N m 4 5 kgf m 32 ft lb Lower Front Fork Clamp Bolts 30 N m 3 1 kgf m 22 ft lb Check the steering again If the steering is still too tight or too loose repeat the ad justment Steering Stem Bearing Lubrication Remove the steering stem see Stem Stem Bearing Re moval in the Steering chapter Using a high flash point solvent wash the upper and lower A ball bearings and wipe the upper and lower outer races which are press fitted into the frame head pipe clean off grease and dirt Visually check the outer races and the ball bearings Replace them if they show wear or damage Apply a light coat of grease to the upper and lower ball bearings and outer races Install the steering stem see Stem Stem Bearing Instal lation in the S
372. t B Direction of Rotation C NOTE If a sprocket requires replacement the chain is proba bly worn also When replacing a sprocket inspect the chain Rear Sprocket Warp Inspection Raise the rear wheel off the ground with the stand so that it will turn freely Set a dial gauge A against the rear sprocket B near the teeth as shown in the figure and rotate C the rear wheel to measure the sprocket runout warp The difference between the highest and lowest dial gauge readings is the amount of runout warp If the runout exceeds the service limit replace the rear sprocket Rear Sprocket Warp Standard TIR 0 4 mm 0 016 in or less Service Limit TIR 0 5 mm 0 020 in http mototh com http mototh com BRAKES 12 1 12 Brakes Table of Contents Exploded View 12 2 Specifications 12 6 Special Tools 12 7 Brake Lever Brake Pedal 12 8 Brake Pedal Position Inspection
373. t Light Good Low 5th Strong Hard Heavy Bad Highway Rear Shock Absorber Removal Squeeze the brake lever slowly and hold it with a band A WARNING Be sure to hold the front brake when removing the shock absorber or the motorcycle may fall over It could cause an accident and injury Remove the lower fairings see Lower Fairing in the Frame chapter Raise the rear wheel off the ground with jack Special Tools Jack 57001 1238 Jack Attachment 57001 1608 http mototh com SUSPENSION 13 15 Rear Shock Absorber Remove the caps A both sides Remove Lower Tie Rod Nut and Bolt A Rear Shock Absorber Nuts and Bolts B Remove the shock absorber C from downside Rear Shock Absorber Installation Install the rear shock absorber Tighten Torque Rear Shock Absorber Nuts 59 N m 6 0 kgf m 44 ft lb Tie Rod Nuts 59 N m 6 0 kgf m 44 ft lb Install the removed parts see appropriate chapters Rear Shock Absorber Inspection Remove the rear shock absorber see Rear Shock Ab sorber Removal Visually inspect the following items Smooth Stroke Oil Leakage Crack or Dent If there is any damage to the rear shock absorber replace it Visually inspect the rubber bushing If it show any signs of damage replace it Rear Shock Absorber Scrapping WARNING Since the rear shock absorber
374. t see chapter 3 Inlet air pressure sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Inlet air temperature sensor trouble Inspect see chapter 3 Air switching valve trouble Inspect and replace see chapter 16 Air suction valve trouble Inspect and replace see chapter 5 After fire Spark plug burned or gap maladjusted Replace see chapter 2 Fuel injector trouble Inspect see chapter 3 Inlet air pressure sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Inlet air temperature sensor trouble Inspect see chapter 3 Other Intermittent any DFI fault and its recovery Check that DFI connectors are clean and tight and examine leads for signs of burning or fraying see chapter 3 http mototh com 3 32 FUEL SYSTEM DFI DFI System Troubleshooting Guide Poor Running or No Power at High Speed Symptoms or Possible Causes Actions Firing incorrect Stick coil shorted or not in good contact Inspect or Reinstall see chapter 16 Stick coil trouble Inspect see chapter 16 Spark plug dirty broken or gap maladjusted Inspect and replace see chapter 2 Spark plug incorrect Replace it with the correct plug see chapter 2 ECU trouble Inspect see chapter 3 Fuel air mixture incorrect Air cleaner clogged poorly sealed or missing Clean element or inspect sealing see chapter 2 Air duct
375. t be cut for installation Standard Chain Make ENUMA Type EK520SR O2 Link 106 links Chain Guide Wear Inspection Remove the swingarm see Swingarm Removal in the Suspension chapter Visually inspect the chain guide A Replace the chain guide if it shows any signs of abnormal wear or damage http mototh com 2 30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brakes Brake Fluid Leak Brake Hose and Pipe Inspection Apply the brake lever or pedal and inspect the brake fluid leak from the brake hoses A and fittings B If the brake fluid leaked from any position inspect or re place the problem part Brake Hose and Pipe Damage and Installation Condition Inspection Inspect the brake hoses and fittings for deterioration cracks and signs of leakage The high pressure inside the brake line can cause fluid to leak A or the hose to burst if the line is not properly main tained Bend and twist the rubber hose while examining it Replace the hose if any crack B bulge C or leakage is noticed Tighten any brake hose banjo bolts Torque Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft lb Inspect the brake hose routing If any brake hose routing is incorrect run the brake hose according to Cable Wire and Hose Routing section in the Appendix chapter Brake Fluid Level Inspection Check that the brake fluid level in the front brake reservoir A is above the lower leve
376. t shaft A for any damage If the shaft is bent straighten or replace it If the splines B are damaged replace the shaft If the return spring C or pawl spring D is damaged in any way replace them If the shift mechanism arm E or over shift limiter F is damaged in any way replace the shaft http mototh com CRANKSHAFT TRANSMISSION 9 27 Transmission Check the return spring pin A is not loose If it is loose unscrew it apply a non permanent locking agent to the threads and tighten it Torque Shift Shaft Return Spring Pin 19 6 N m 2 0 kgf m 14 5 ft lb Visually inspect the shift drum pins A pin holder B and pin plate C If they are badly worn or if they show any damage replace them Transmission Shaft Removal Split the crankcase see Crankcase Splitting Remove the drive shaft A and output shaft B Transmission Shaft Installation Check to see that the set pins A and set rings B are in place Install the drive shaft and output shaft into the upper crankcase half Apply engine oil to the bearings The bearing set pins and rings must match properly with the holes or grooves in the bearing outer races When they are properly matched there is no clearance A be tween the crankcase and the bearing outer races http mototh com 9 28 CRANKSHAFT TRANSMISSION Transmission Assemble the crankcase see Crankcase Assembly Press in the oil sea
377. t the pistons A and cylinder surfaces B Replace the caliper if the cylinder and piston are badly scores or rusty Caliper Holder Shaft Wear Inspection The caliper body must slide smoothly on the caliper holder shafts A If the body does not slide smoothly one pad will wear more than the other pad wear will increase and con stant drag on the disc will raise brake and brake fluid tem perature Check to see that the caliper holder shafts are not badly worn or stepped and that the friction boots B are not damaged If the friction boot is damaged replace the friction boot To replace the friction boot remove the pads and the caliper holder If the caliper holder shaft is damage replace the caliper holder http mototh com BRAKES 12 13 Brake Pads Brake Pad Removal NOTE The procedure to remove the front brake pad is as fol lows Removing the rear brake pad is the same as for the front brake pad Loosen the pad pins A Unscrew the bolts B Remove the caliper with the hose installed Remove Pad Pins Brake Pads A Brake Pad Installation Push the caliper pistons in by hand as far as they will go Install the pad spring A in its correct position Install the outside pad first then install the inside pad Insert the pad pins Install the caliper see Caliper Installation Tighten Torque Brake Pad Pins 17 2 N m 1 8 kgf m 13 ft lb WARNING D
378. teering chapter Adjust the steering see Steering Play Adjustment http mototh com 2 36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Electrical System Lights and Switches Operation Inspection First Step Turn on the ignition switch The following lights should go on according to below table Taillight A goes on License Plate Light B goes on Meter Panel Lights C go on Neutral Indicator Light D goes on Oil Pressure Warning Indicator Light E goes on FI Indicator Light F goes on about 2 seconds City Light G goes on If the light does not go on inspect or replace the following item Battery see Charging Condition Inspection in the Elec trical System chapter Main Fuse 30 A and Taillight Fuse 10 A see Fuse In spection in the Electrical System chapter Applicable Bulb see Wiring Diagram in the Electrical System chapter Taillight Bulb see Tail Brake Light Bulb Replacement in the Electrical System chapter License Plate Light Bulb see License Plate Light Bulb Replacement in the Electrical System chapter Meter Unit for Meter Lights see Meter Indicator Light Replacement in the Electrical System chapter Meter Unit for Neutral Indicator Light see Meter Indica tor Light Replacement in the Electrical System chapter Meter Unit for Oil Pressure Warning Indicator Light see Meter Indicator Light Replacement in the Electrical Sys tem chapter FI Indicator Light see Mete
379. ten it CAUTION Do not apply too much non permanent locking agent to the threads This may block the oil pas sage Torque Oil Pressure Relief Valve 15 N m 1 5 kgf m 11 ft lb Oil Pressure Relief Valve Inspection Check to see if the valve A slides smoothly when push ing it in with a wooden or other soft rod and see if it comes back to its seat by spring B pressure NOTE Inspect the valve in its assembled state Disassembly and assembly may change the valve performance If any rough spots are found during above inspection wash the valve clean with a high flash point solvent and blow out any foreign particles that may be in the valve with compressed air WARNING Clean the oil pressure relief valve in a well ventilated area and take care that there is no spark or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline or low flash point solvent If cleaning does not solve the problem replace the oil pressure relief valve as an assembly The oil pressure relief valve is precision made with no allowance for re placement of individual parts http mototh com 7 10 ENGINE LUBRICATION SYSTEM Oil Pump Oil Pump Removal Remove Clutch see Clutch Removal in the Clutch chapter Oil Pump Mounting Bolts A Oil Pump B Oil Pump Installation Fill the oil pump with engine oil for initial lubrication Turn the oil pump shaft so that the
380. tenance Use proper tools and genuine Kawasaki Mo torcycle parts Special tools gauges and testers that are necessary when servicing Kawasaki motorcycles are introduced by the Service Manual Genuine parts provided as spare parts are listed in the Parts Catalog 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 this manual the product is divided into its major systems and these systems make up the manual s chapters The Quick Reference Guide shows you all of the product s system and assists in locating their chapters Each chapter in turn has its own comprehensive Ta ble of Contents For example if you want ignition coil informa tion use the Quick Reference Guide to locate the Electrical System chapter Then use the Table of Contents on the first page of the chap ter to find the Ignition Coil section Whenever you see these WARNING and CAUTION symbols heed their instructions Always follow safe operating and maintenance practices 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
381. ter If the charging voltage is kept between the values given in the table the charging system is considered to be working normally If the charging voltage is much higher than the values specified in the table the regulator rectifier is defective or the regulator rectifier leads are loose or open If the charging voltage does not rise as the engine speed increases then the regulator rectifier is defective or the alternator output is insufficient for the loads Check the alternator and regulator rectifier to determine which part is defective Alternator Inspection There are three types of alternator failures short open wire burned out or loss in rotor magnetism A short or open in one of the coil wires will result in either a low output or no output at all A loss in rotor magnetism which may be caused by dropping or hitting the alternator by leaving it near an electromagnetic field or just by aging will result in low output http mototh com ELECTRICAL SYSTEM 16 29 Charging System To check the alternator output voltage do the following procedures Turn off the ignition switch Remove the right side cover see Side Cover Removal in the Frame chapter Disconnect the alternator lead connector A Connect the hand tester as shown in the table 1 Special Tool Hand Tester 57001 1394 Start the engine Run it at the rpm given in the table 1 Note the voltage readings total 3 measurements Ta
382. ter than 0 5 mm 0 020 in oversize the cylinder block must be replaced Cylinder inside diameter must not vary more than 0 01 mm 0 0004 in at any point Be wary of measurements taken immediately after boring since the heat affects cylinder diameter In the case of a rebored cylinder and oversize piston the service limit for the cylinder is the diameter that the cylin der was bored to plus 0 1 mm 0 004 in and the service limit for the piston is the oversize piston original diameter minus 0 15 mm 0 0059 in If the exact figure for the re bored diameter is unknown it can be roughly determined by measuring the diameter at the base of the cylinder Never separate the liner from the cylinder because the top surface of cylinder and liner is machined at the factory as an assembly http mototh com 5 38 ENGINE TOP END Throttle Body Assy Holder Throttle Body Assy Holder Installation Fit the groove A of the throttle body holder to the projec tion B of the cylinder head Install the clamps C as shown in the figure Tighten Torque Throttle Body Assy Holder Clamp Screws 2 0 N m 0 20 kgf m 18 in lb http mototh com ENGINE TOP END 5 39 Muffler WARNING To avoid a serious burn do not remove the muffler when the engine is still hot Wait until the muffler cool down Muffler Body Removal Remove Lower Fairings see Lower Fairing Removal in the Frame chapter Muffler Cover
383. ter tube in a vise A stop the cylinder unit B with the special tools then tighten the Allen bolt C Special Tools Fork Cylinder Holder Handle D 57001 183 Fork Cylinder Holder Adapter E 57001 1057 Torque Front Fork Bottom Allen Bolts 20 N m 2 0 kgf m 15 ft lb Install the dust seal Pour in the specified type of oil see Front Fork Oil Change http mototh com SUSPENSION 13 13 Front Fork Inner Tube Outer Tube Inspection Visually inspect the inner tube A and repair any dam age Nicks or rust damage can sometimes be repaired by using a wet stone to remove sharp edges or raised areas which cause seal damage If the damage is not repairable replace the inner tube Since damage to the inner tube damages the oil seal replace the oil seal whenever the inner tube is repaired or replaced CAUTION If the inner tube is badly bent or creased replace it Excessive bending followed by subsequent straightening can weaken the inner tube Temporarily assemble the inner and outer B tubes and pump them back and forth manually to check for smooth operation If you feel binding or catching the inner and outer tubes must be replaced WARNING A straightened inner or outer fork tube may fail in use possibly causing an accident Replace a badly bent or damaged inner or outer tube and inspect the other tube carefully before reusing it Dust Seal Inspection Inspect the dust seal
384. th com STEERING 14 1 14 Steering Table of Contents Exploded View 14 2 Special Tools 14 4 Steering 14 5 Steering Inspection 14 5 Steering Adjustment 14 5 Steering Stem 14 6 Stem Stem Bearing Removal 14 6 Stem Stem Bearing Installation 14 7 Steering Stem Bearing Lubrication 14 9 Steering Stem Warp Inspection 14 9 Oil Seal Deterioration Damage Inspection
385. the hose connection with a piece of clean cloth to prevent fuel spillage Check the injector fuel line for leakage as follows Connect a commercially available vacuum pressure pump A to the nipple of the fuel supply pipe B with the fuel hose C both ends with the clamps D as shown in the figure Right Side View E Apply soap and water solution to the areas F as shown in the figure Watching the pressure gauge squeeze the pump lever G 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 Watch the gauge for at least 6 seconds If the pressure holds steady the fuel line is good If the pressure drops at once or if bubbles are found in the area the fuel line is leaking Replace the fuel supply pipe assy injectors and related parts Repeat the leak test and check the fuel line for no leak age Install Fuel Hose see Fuel Hose Replacement in the Periodic Maintenance chapter Fuel Tank see Fuel Tank Installation Start the engine and check for fuel leakage http mototh com 3 100 FUEL SYSTEM DFI Fuel Injectors Fuel Injector Circuit 1 Ignition Switch 2 Engine Stop Switch 3 Water proof Joint 3 4 Fuel Injector 1 2 5 ECU 6 Joint Connector 2 7 Fuel Pump 8 Batt
386. the seal surface is flush B with the end of the hole Apply high temperature grease to the grease seal lips Special Tool Bearing Driver Set C 57001 1129 http mototh com 10 18 WHEELS TIRES Hub Bearing Hub Bearing Inspection Since the hub bearings are made to extremely close tol erances the clearance can not normally be measured NOTE Do not remove any bearings for inspection If any bear ings are removed they will need to be replaced with new ones Turn each bearing in the hub back and forth A while checking for plays roughness or binding If bearing play roughness or binding is found replace the bearing Examine the bearing seal B for tears or leakage If the seal is torn or is leaking replace the bearing Hub Bearing Lubrication NOTE Since the hub bearings are packed with grease and sealed lubrication is not required http mototh com WHEELS TIRES 10 19 Speedometer Gear Housing Speedometer Gear Housing Disassembly Pull the speedometer gear housing A off the front wheel Remove the grease seal B and snap ring C Pull out the speedometer gear D If the speedometer cable bushing E or speedometer pin ion F needs to be removed work in accordance with fol lowing procedures First drill the housing A through the pin B using a 1 0 1 5 mm 0 04 0 06 in drill bit C Drill the housing from the outside to the pin end A usin
387. the specified value the coil has an open lead and must be replaced Much less than this resistance means the coil is shorted and must be replaced Using the highest resistance range of the tester measure the resistance between the crankshaft sensor leads and chassis ground Any tester reading less than infinity indicates a short necessitating replacement of the crankshaft sensor as sembly http mototh com 16 34 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Peak Voltage Inspection NOTE Be sure the battery is fully charged Remove Right Side Cover see Side Cover Removal in the Frame chapter Crankshaft Sensor Lead Connector A Disconnect Set the hand tester B to the DC 25 V range Connect the peak voltage adapter C to the hand tester and crankshaft sensor leads in the connector Special Tools Hand Tester 57001 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Connections Crankshaft Sensor Lead Peak Voltage Adapter Hand Tester Yellow Red Black Black Turn the ignition switch and engine stop switch ON Pushing the starter button turn the engine 4 5 sec onds with the transmission gear in neutral to measure the crankshaft sensor peak voltage Repeat the measurement 5 or more times Crankshaft Sensor Peak Voltage Standard 4 5 V or more If the tester reading is not specified one inspect the crank shaft sensor s
388. tion 16 28 Regulator Rectifier Inspection 16 30 Ignition System 16 33 Crankshaft Sensor Removal 16 33 Crankshaft Sensor Installation 16 33 Crankshaft Sensor Inspection 16 33 Crankshaft Sensor Peak Voltage Inspection 16 34 Stick Coil Removal 16 34 Stick Coil Installation 16 35 Stick Coil Inspection 16 35 Stick Coil Primary Peak Voltage 16 36 Spark Plug Removal
389. tion 3 44 Inlet Air Pressure Sensor Input Voltage Inspection 3 44 Inlet Air Pressure Sensor Output Voltage Inspection 3 45 Inlet Air Temperature Sensor Service Code 13 3 50 Inlet Air Temperature Sensor Removal Installation 3 50 Inlet Air Temperature Sensor Output Voltage Inspection 3 50 Inlet Air Temperature Sensor Resistance Inspection 3 51 Water Temperature Sensor Service Code 14 3 53 Water Temperature Sensor Removal Installation 3 53 Water Temperature Sensor Output Voltage Inspection 3 53 Water Temperature Sensor Resistance Inspection 3 54 Crankshaft Sensor Service Code 21 3 55 Crankshaft Sensor Removal Installation 3 55 Cran
390. tire sidewalls are parallel with the rim flanges If the rim flanges and tire sidewall rim lines are not parallel remove the valve core Lubricate the rim flanges and tire beads Install the valve core and inflate the tire again After the tire beads seat in the rim flanges check for air leakage Inflate the tire slightly above standard inflation Use a soap and water solution or submerge the tire and check for bubbles that would indicate leakage Adjust the air pressure to the specified pressure see Air Pressure Inspection in the Periodic Maintenance chap ter Install the air valve cap Adjust the wheel balance see Balance Adjustment Tire Repair Currently two types of repair for tubeless tires have come into wide use One type is called a temporary external re pair which can be carried out without removing the tire from the rim and the other type is called permanent internal repair which requires tire removal It is generally under stood that higher running durability is obtained by perma nent internal repairs than by temporary external ones Also permanent internal repairs have the advantage of permitting a thorough examination for secondary damage not visible from external inspection of the tire For these reasons Kawasaki does not recommend temporary exter nal repair Only appropriate permanent internal repairs are recommended Repair methods may vary slightly from make to make Fo
391. ton with its marking hollow facing forward Fit a new piston pin snap ring into the side of the piston so that the ring opening A does not coincide with the slit B of the piston pin hole Apply molybdenum disulfide oil solution to the piston pins and piston journals When installing the piston pin snap ring compress it only enough to install it and no more CAUTION Do not reuse snap rings as removal weakens and deforms them They could fall out and score the cylinder wall Install the cylinder see Cylinder Installation Cylinder Wear Inspection Since there is a difference in cylinder wear in different di rections take a side to side and a front to back measure ment at each of the two locations total of four measure ments shown in the figure If any of the cylinder inside diameter measurements ex ceeds the service limit replace the cylinder 10 mm 0 39 in A 60 mm 2 36 in B Cylinder Inside Diameter Standard 62 000 62 012 mm 2 4409 2 4414 in Service Limit 62 10 mm 2 4449 in Piston Wear Inspection Measure the outside diameter A of each piston 5 mm 0 20 in B up from the bottom of the piston at a right angle to the direction of the piston pin If the measurement is under service limit replace the pis ton Piston Diameter Standard 61 942 61 957 mm 2 4387 2 4392 in Service Limit 61 79 mm 2 4327 in http mototh com 5 36 ENGINE TOP END Cy
392. traight from the socket CAUTION Do not turn the bulb Pull the bulb out to prevent damage to the bulb Do not use bulb rated for greater wattage then the specified value Replace the bulb with a new one Tail Brake Light Bulb Replacement Remove the rear seat see Rear Seat Removal in the Frame chapter Turn the socket A counterclockwise B Push the bulb A in the socket turn it counterclockwise B and pull it out Insert the new bulb A by aligning its upper and lower pins B with the upper and lower grooves C in the socket and turn the bulb clockwise Turn the bulb about 15 Fit the projections A of the socket into the grooves B of the tail brake light Turn the socket clockwise http mototh com 16 50 ELECTRICAL SYSTEM Lighting System Tail Brake Light Removal Remove Seat Covers see Seat Cover Removal in the Frame chapter Connector A Disconnect Tail Brake Light Mounting Bolts B Tail Brake Light C Tail Brake Light Installation Tighten Torque Tail Brake Light Mounting Bolts 5 9 N m 0 60 kgf m 52 in lb Run the lead correctly see Cable Wire and Hose Rout ing section in the Appendix chapter License Plate Light Bulb Replacement Remove Screws A License Plate Light Cover B Push and turn the bulb A counterclockwise and remove it Replace the bulb with a new one Insert the new bulb A by aligning
393. tring method WARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition http mototh com PERIODIC MAINTENANCE 2 29 Periodic Maintenance Procedures Drive Chain Wear Inspection Remove the chain cover see Drive Chain Removal in the Final Drive chapter Rotate the rear wheel to inspect the drive chain for dam aged rollers and loose pins and links If there is any irregularity replace the drive chain Lubricate the drive chain if it appears dry Stretch the chain taut by hanging a 98 N 10 kg 20 lb weight A on the chain Measure the length of 20 links B on the straight part C of the chain from the pin center of the 1st pin to the pin center of the 21st pin Since the chain may wear unevenly take measurements at several places If any measurements exceed the service limit replace the chain Also replace the front and rear sprockets when the drive chain is replaced Drive Chain 20 link Length Standard 317 5 318 2 mm 12 50 12 53 in Service Limit 323 mm 12 7 in WARNING If the drive chain wear exceeds the service limit re place the chain or an unsafe riding condition may result A chain that breaks or jumps off the sprock ets could snag on the engine sprocket or lock the rear wheel severely damaging the motorcycle and causing it to go out of control For safely use only the standard chain It is an end less type and should no
394. ug incorrect Overheating Piston slap Cylinder piston clearance excessive Cylinder piston worn Connecting rod bent Piston pin piston pin hole worn Valve noise Valve clearance incorrect Valve spring broken or weak Camshaft bearing worn Valve lifter worn Other noise Connecting rod small end clearance exces sive Connecting rod big end clearance exces sive Piston ring groove clearance excessive Piston ring worn broken or stuck Piston ring groove worn Piston seizure damage Cylinder head gasket leaking Exhaust pipe leaking at cylinder head con nection Crankshaft runout excessive Engine mount loose Crankshaft bearing worn Primary gear worn or chipped http mototh com APPENDIX 17 35 Troubleshooting Guide Camshaft chain tensioner trouble Camshaft chain sprocket guide worn Air suction valve damaged Air switching valve damaged Alternator rotor loose Catalytic converter melt down due to muffler overheating KLEEN Abnormal Drive Train Noise Clutch noise Clutch damper weak or damaged Clutch housing friction plate clearance ex cessive Clutch housing gear worn Transmission noise Bearings worn Transmission gear worn or chipped Metal chips jammed in gear teeth Engine oil insufficient Drive line noise Drive chain adjusted improperly Drive chain worn Rear and or engine sprocket worn Chain lubrication insufficient Rear wheel misaligned Abnormal Frame Noise Front fork noise Oil insufficient or too thin Sprin
395. up the engine and run it at normal operating tem perature for about ten minutes Stop the engine and drain the cooling system Fill the system with fresh water Warm up the engine and drain the system Repeat the previous two steps once more Fill the system with a permanent type coolant and bleed the air from the system see Coolant Change in the Peri odic Maintenance chapter Coolant Reserve Tank Removal Remove Right Lower Fairing see Lower Fairing Removal in the Frame chapter Coolant A from Reserve Tank Drain see Coolant Change in the Periodic Maintenance chapter Bolts B Hoses C Clutch Cable D see Clutch Cable Removal in the Clutch chapter Coolant Reserve Tank E Coolant Reserve Tank Installation Installation is the reverse of removal Run the cable and hoses correctly see Cable Wire and Hose Routing section in the Appendix chapter Install the removed parts see appropriate chapters Torque Reserve Tank Bolts 9 8 N m 1 0 kgf m 87 in lb http mototh com COOLING SYSTEM 4 9 Water Pump Water Pump Cover Removal Remove Coolant Drain see Coolant Change in the Periodic Maintenance chapter Left Lower Fairing see Lower Fairing Removal in the Frame chapter Engine Sprocket Cover see Engine Sprocket Removal in the Final Drive chapter Bolts A and Water Pipes B Remove Water Pump Cover Bolts A Water Pump Cover B Water Pump Cover In
396. ure and count how may times the lights flash for one minute Turn Signal Relay A Turn Signal Lights B 12 V Battery C If the lights do not flash as specified replace the turn sig nal relay Testing Turn Signal Relay Load The Number of Turn Signal Lights Wattage W Flashing Times c m 1 10 Lights stays on 2 20 75 95 Cycle s per minute Corrected to one light burned out http mototh com ELECTRICAL SYSTEM 16 53 Lighting System Turn Signal Light Circuit 1 Ignition Switch 2 Water proof Joint 3 3 Joint Connector 2 4 Rear Right Turn Signal Light 12 V 10 W 5 Rear Left Turn Signal Light 12 V 10 W 6 Battery 12 V 8 Ah 7 Frame Ground 8 Main Fuse 30 A 9 Turn Signal Relay Fuse 10 A 10 Fuse Box 11 Turn Signal Switch 12 Turn Signal Relay 13 Front Left Turn Signal Light 12 V 10 W 14 Front Right Turn Signal Light 12 V 10 W 15 Joint Connector 1 16 Turn Signal Indicator Light 12 V 3 4 W http mototh com 16 54 ELECTRICAL SYSTEM Air Switching Valve Air Switching Valve Operation Test Refer to the Air Suction System Damage Inspection in the Periodic Maintenance chapter Air Switching Valve Unit Test Remove the air switching valve see Air Switching Valve Removal in the Engine Top End chapter Set the hand tester A to the 1 range and connect it to the air switching valve terminals as shown in the figure Special Tool Hand Tester 57001 139
397. ure grease Replace the grease seal with a new one Press in the grease seal so that the seal surface is flush with the end of the hole Apply high temperature grease to the grease seal lips Special Tool Bearing Driver Set 57001 1129 Coupling Bearing Inspection Since the coupling bearing is made to extremely close tolerances the clearance can not normally be measured NOTE It is not necessary to remove the coupling bearing for inspection If the bearing is removed it will need to be replaced with a new one Turn the bearing in the coupling back and forth A while checking for plays roughness or binding If the bearing play roughness or binding is found replace the bearing http mototh com FINAL DRIVE 11 13 Sprocket Coupling Coupling Bearing Lubrication Pack the bearing with high temperature grease Turn the bearing around by hand a few times to make sure the grease is distributed uniformly inside the bearing Coupling Damper Inspection Remove the rear wheel coupling and inspect the rubber dampers A Replace the damper if it appears damaged or deterio rated Sprocket Wear Inspection Visually inspect the engine and rear sprocket teeth for wear and damage If the teeth are worn as illustrated replace the sprocket and inspect the drive chain wear see Drive Chain Wear Inspection in the Periodic Maintenance chapter Worn Tooth Engine Sprocket A Worn Tooth Rear Sprocke
398. urn the crank shaft counterclockwise until the 2T mark A on the al ternator rotor is aligned with the projection B in the in spection window on the alternator cover Measure the valve clearance of the valves for which the cam A are turned away from each other http mototh com PERIODIC MAINTENANCE 2 21 Periodic Maintenance Procedures Using the thickness gauge A measure the valve clear ance between the cam and the valve lifter Valve Clearance Standard Exhaust 0 22 0 29 mm 0 0087 0 0114 in Inlet 0 15 0 24 mm 0 0059 0 0094 in Each piston has two inlet and two exhaust valves Mea sure these two inlet or exhaust valves at the same crank shaft position Valve Clearance Measuring Position 1 Piston TDC at End of Compression Stroke Inlet Valve Clearances of 1 Piston Exhaust Valve Clearances of 1 Piston NOTE Check the valve clearance using this method only Checking the clearance at any other cam position may result in improper valve clearance Valve Clearance Measuring Position 2 Piston TDC at End of Compression Stroke Inlet Valve Clearances of 2 Piston Exhaust Valve Clearances of 2 Piston If the valve clearance is not within the specified range first record the clearance and then adjust it Valve Clearance Adjustment To change the valve clearance remove the camshaft chain tensioner camshafts and valve lifters Replace the shim with one of a dif
399. ust or pitting on the inner wall A of each master cylinder and on the outside of each piston B If a master cylinder or piston shows any damage replace them Inspect the primary cup C and secondary cup D If a cup is worn damaged softened rotted or swollen the piston assembly should be replaced to renew the cups If fluid leakage is noted at the brake lever the piston as sembly should be replaced to renew the cups Check the dust covers E for damage If they are damaged replace them Check the piston return springs F for any damage If the springs are damaged replace them Check that relief port G and supply port H are not plugged If the relief port becomes plugged the brake pads will drag on the disc Blow the ports clean with compressed air Front Master Cylinder J Rear Master Cylinder K http mototh com 12 16 BRAKES Brake Disc Brake Disc Removal Remove the wheels see Front Rear Wheel Removal in the Wheels Tires chapter Unscrew the mounting bolts and take off the disc Brake Disc Installation Install the brake disc on the wheel so that the marked side A faces out Apply a non permanent locking agent to the threads of the front and rear brake disc mounting bolts B and tighten them Torque Brake Disc Mounting Bolts 27 N m 2 8 kgf m 20 ft lb Brake Disc Wear Inspection Measure the thickness of each disc A at the point where it has w
400. ve hose end and air cleaner housing fitting Connect a vacuum gauge special tool and hoses A to the fittings on the throttle body Special Tool Vacuum Gauge 57001 1369 Connect a highly accurate tachometer B to one of the stick coil primary leads Remove the fuel hose see Fuel Hose Replacement Connect the following parts temporary Fuel Pump Lead Connector A Extension Tube B Special Tool Extension Tube 57001 1578 Start the engine and warm it up thoroughly Check the idle speed using a highly accurate tachometer A Idle Speed Standard 1 300 50 r min rpm If the idle speed is out of the specified range adjust it with the adjusting screw see Idle Speed Adjustment CAUTION Do not measure the idle speed by the tachometer of the meter unit While idling the engine inspect the throttle body vacuum using the vacuum gauge B Throttle Body Vacuum Standard 24 0 1 33 kPa 180 10 mmHg at idle speed If any one vacuum is not within the specification turn in the bypass screws until it seats fully but not tightly CAUTION Do not over tighten them They could be damaged requiring replacement http mototh com PERIODIC MAINTENANCE 2 17 Periodic Maintenance Procedures Turn out the bypass screw of the higher vacuum between 1 A and 2 B to the lower vacuum Open and close the throttle valves after each measure ment and adjust the idle speed as nec
401. ve terminal re peatedly http mototh com 16 60 ELECTRICAL SYSTEM Meter Gauge Indicator Unit Then the tachometer needle A should flick B If the needle does not flick check the meter unit harness for continuity see wiring diagram in this section Special Tool Hand Tester 57001 1394 If the harness is normal replace the tachometer Water Temperature Gauge Inspection Remove the meter unit see Meter Unit Removal Installa tion Using the insulated auxiliary leads connect the 12 V bat tery to the meter unit connector 9 pins connector as fol lows Connect the battery positive terminal to the BR lead ter minal A Connect the battery negative terminal to the BK Y lead terminal B CAUTION Do not short each terminals Connect the variable rheostat A to the W Y lead terminal B as shown in the figure Adjust the resistance value to the approximately 20 The water temperature gauge A indicate the position B of the about 125 C If the water temperature gauge does not work check the meter unit harness for continuity see wiring diagram in this section Special Tool Hand Tester 57001 1394 If the harness is normal replace the water temperature gauge http mototh com ELECTRICAL SYSTEM 16 61 Meter Gauge Indicator Unit Meter Unit Circuit 1 Fuel Level Warning Indicator Light 12 V 3 4 W 2 Ignition Switch 3 Water proof Joint 3 4 Water Temperature
402. weakened and the rotor must be replaced http mototh com 16 30 ELECTRICAL SYSTEM Charging System Regulator Rectifier Inspection Remove Left Lower Fairing see Lower Fairing Removal in the Frame chapter Bolts A Connector B Disconnect Regulator Rectifier C Rectifier Circuit Check Check conductivity of the following pair of terminals Rectifier Circuit Inspection W Y1 W Y2 W Y3 Tester connection BK Y Y1 BK Y Y2 BK Y Y3 The resistance should be low in one direction and more than ten times as much in the other direction If any two terminals are low or high in both directions the rectifier is defective and the regulator rectifier must be replaced NOTE The actual meter reading varies with the meter used and the individual rectifier but generally speaking the lower reading should be from zero to one half the scale Regulator Circuit Check To test the regulator out of circuit use three 12 V batteries and a test light 12 V 3 6 W bulb in a socket with leads CAUTION The test light works as an indicator and also a cur rent limiter to protect the regulator rectifier from ex cessive current Do not use an ammeter instead of a test light Check to be sure the rectifier circuit is normal before con tinuing Do the 1st step regulator circuit test Connect the test light and the 12 V battery to the regula tor rectifier as shown in the figure Check the Y1 Y2 and Y3 term
403. wheel off the ground with the stand Loosen the drive chain see Drive Chain Slack Adjust ment in the Periodic Maintenance chapter Remove the drive chain from the rear sprocket toward the right Pull the engine sprocket A with drive chain B off the output shaft C Disengage the drive chain from the engine sprocket Engine Sprocket Installation Replace the sprocket washer and axle cotter pin Install the engine sprocket so that protruding side A faces inside Apply molybdenum disulfide oil solution to the threads and the seating surface of the engine sprocket nut Tighten Torque Engine Sprocket Nut 127 N m 13 0 kgf m 93 7 ft lb NOTE Tighten the nut while applying the rear brake After torquing the engine sprocket nut bend the one side of the washer over the nut http mototh com FINAL DRIVE 11 11 Sprocket Coupling Apply silicone sealant A to the crankcase as shown in the figure Sealant Kawasaki Bond Silicone Sealant 92104 0004 Install the speed sensor mounting bracket Tighten Torque Speed Sensor Mounting Bracket Bolts 9 8 N m 1 0 kgf m 87 in lb Run the speed sensor lead correctly see Cable Wire and Hose Routing section in the Appendix chapter Install the engine sprocket cover Tighten Torque Engine Sprocket Cover Bolts 9 8 N m 1 0 kgf m 87 in lb Adjust the drive chain slack after installing the engin
404. with a high flash point solvent CAUTION Do not scrape off the deposits with a scraper as this could damage the rubber requiring replacement of the suction valve assembly http mototh com 5 12 ENGINE TOP END Clean Air System Air Switching Valve Removal Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Connector A Disconnect Separate the hoses B from the air suction valve cover and air cleaner housing fitting and remove the air switch ing valve C CAUTION Never drop the air switching valve especially on a hardsurface Such a shock to the air switching valve can damaged it Air Switching Valve Installation Installation is the reverse of removal Run the lead and hoses correctly see Cable Wire and Hose Routing section in the Appendix chapter Install the removed parts see appropriate chapters Air Switching Valve Operation Test Refer to the Air Suction System Damage Inspection in the Periodic Maintenance chapter Air Switching Valve Unit Test Refer to the Air Switching Valve Unit Test in the Electrical System chapter Clean Air System Hose Inspection Be certain that all the hoses are routed without being flat tened or kinked and are connected correctly to the air cleaner housing air switching valve and air suction valve cover If they are not correct them Replace them if they are damaged http mototh com ENGINE TOP END 5 13 Cyli
405. y Service Code 56 3 71 Radiator Fan Relay Removal Installation 3 71 Radiator Fan Relay Inspection 3 71 Subthrottle Valve Actuator Service Code 62 3 73 Subthrottle Valve Actuator Removal 3 73 Subthrottle Valve Actuator Inspection 3 73 Subthrottle Valve Actuator Resistance Inspection 3 73 Subthrottle Valve Actuator Input Voltage Inspection 3 74 Air Switching Valve Service Code 64 3 76 Air Switching Valve Removal Installation 3 76 Air Switching Valve Inspection 3 76 Oxygen Sensor Heater Service Code 67 3 77 Oxygen Sensor Heater Removal Install
406. y Assy Removal 3 102 Throttle Body Assy Installation 3 104 Throttle Body Assy Disassembly 3 105 Throttle Body Assy Assembly 3 106 Air Cleaner 3 107 Air Cleaner Element Removal Installation 3 107 Air Cleaner Element Inspection 3 107 Air Cleaner Oil Draining 3 107 Air Cleaner Housing Removal 3 107 Air Cleaner Housing Installation 3 108 Air Cleaner Housing Disassembly 3 108 Air Cleaner Housing Assembly
407. y Inspection see ECU Power Supply Inspection in the Fuel System DFI chapter http mototh com ELECTRICAL SYSTEM 16 39 Ignition System http mototh com 16 40 ELECTRICAL SYSTEM Ignition System Ignition System Circuit 1 ECU 2 Joint Connector 2 3 Sidestand Switch 4 Battery 12 V 8 Ah 5 Frame Ground 6 Main Fuse 30 A 7 ECU Main Relay 8 Relay Box 9 Starter Lockout Switch 10 Ignition Fuse 10 A 11 ECU Fuse 15 A 12 Oxygen Sensor Heater Fuse 10 A 13 Fuse Box 14 Ignition Switch 15 Engine Stop Switch 16 Spark Plugs 17 Stick Coils 18 Water proof Joint 3 19 Speed Sensor 20 Subthrottle Sensor 21 Main Throttle Sensor 22 Water proof Joint 2 23 Vehicle down Sensor 24 Water proof Joint 1 25 Neutral Switch 26 Crankshaft Sensor 27 Oxygen Sensor http mototh com ELECTRICAL SYSTEM 16 41 Electric Starter System Starter Motor Removal CAUTION Do not tap the starter motor shaft or body Tapping the shaft or body could damage the motor Remove the lower fairings see Lower Fairings Removal in the Frame chapter Slide back the rubber cap A Remove Starter Motor Cable Terminal Nut B Mounting Bolts C Pull out the starter motor A toward the left side Starter Motor Installation CAUTION Do not tap the starter motor shaft or body Tapping the shaft or body could damage the motor When installing the starter motor clean the starter mo tor legs A and
408. y engine oil to the new O rings insert them to the delivery pipe assy C and confirm whether the injectors turn smoothly or not Replace the dust seals A with new ones Apply engine oil to the new dust seals Install the injectors along with the delivery pipe assy to the throttle body Tighten Torque Delivery Pipe Assy Mounting Screws 3 4 N m 0 35 kgf m 30 in lb Bind the lead with band Install the throttle body assy see Throttle Body Assy In stallation http mototh com FUEL SYSTEM DFI 3 107 Air Cleaner Air Cleaner Element Removal Installation Refer to the Air Cleaner Element Replacement in the Pe riodic Maintenance chapter Air Cleaner Element Inspection Remove the air cleaner element see Air Cleaner Element Replacement in the Periodic Maintenance chapter Visually check the element A for tears or breaks If the element has any tears or breaks replace the ele ment Air Cleaner Oil Draining Visually check the drain cap A if the water or oil accu mulates If any water or oil accumulates in the cap remove the cap and drain it WARNING Be sure to reinstall the cap after draining Oil on tires will make them slippery and can cause an ac cident and injury Air Cleaner Housing Removal Remove Rear Wheel see Rear Wheel Removal in the Wheels Tires chapter Fuel Tank see Fuel Tank Removal Air Switching Valve Hose A Bracket Bolts B
409. ystem Manifold Mark Position A Muffler Body Mark Position B Honeycomb Type Catalyst Position C Honeycomb Type Catalyst Position D Manifold with Hole E for Oxygen Sensor F http mototh com ENGINE TOP END 5 7 Specifications Item Standard Service Limit Camshafts Cam Height Exhaust 32 843 32 957 mm 1 2930 1 2975 in 32 74 mm 1 289 in Inlet 33 843 33 957 mm 1 3324 1 3369 in 33 74 mm 1 328 in Camshaft Journal Camshaft Cap Clearance 0 028 0 071 mm 0 0011 0 0028 in 0 16 mm 0 0063 in Camshaft Journal Diameter 23 950 23 972 mm 0 9429 0 9438 in 23 92 mm 0 942 in Camshaft Bearing Inside Diameter 24 000 24 021 mm 0 9449 0 9457 in 24 08 mm 0 948 in Camshaft Runout TIR 0 02 mm 0 0008 in or less TIR 0 1 mm 0 004 in Cylinder Head Cylinder Compression Usable Range 1 050 1 500 kPa 10 7 15 3 kgf cm 152 218 psi at 500 r min rpm Cylinder Head Warp 0 05 mm 0 002 in Valves Valve Clearance Exhaust 0 22 0 29 mm 0 0087 0 0114 in Inlet 0 15 0 24 mm 0 0059 0 0094 in Valve Head Thickness Exhaust 0 8 mm 0 032 in 0 5 mm 0 020 in Inlet 0 5 mm 0 020 in 0 3 mm 0 012 in Valve Stem Bend TIR 0 01 mm 0 0004 in or less TIR 0 05 mm 0 002 in Valve Stem Diameter Exhaust 4 455 4 470 mm 0

Kawasaki Ninja 250R service manual (eng)

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