Home

"service manual"

1. Periodic Maintenance Procedures e Wrap the threads A of the piston rod with tape e Remove the oil seal assembly B e Remove the O ring A and spring B e Remove the rebound rubber A out of its groove B e Remove Collar C Spring Holder D Oil Seal E e Remove Oil Seal A NOTICE To avoid damage to the surfaces of the oil seal as sembly body B cover the screwdriver C with the cloth D e Replace the following with new ones Oil Seals Rebound Rubber if damaged O ring e Install each parts direction as shown Oil Seal A Oil Seal B Spring Holder C Collar D Rebound Rubber E Spring F O ring G PERIODIC MAINTENANCE 2 73 2 74 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Remove Stopper A Damper B Damper Holder C e Inspect the piston rod sliding surface A x If the sliding surface is scratches or distortion replace it e Hold the lower of the piston rod assembly in a vise with soft jaws or heavy cloth e Make the threads of the piston rod end using the die A Die 12 x 1 25 mm e Clean all parts with solvent and dry them with compressed p air e Install Damper Holder A Damper B Stopper C e Wrap the threads of the piston rod with tape A e Apply thin coat of rear shock oil to the sliding surface of the piston rod e Insert the oil seal assembly B
2. 13 26 SUSPENSION Tie Rod Rocker Arm Tie Rod Removal e Place the jack under the frame so that the rear wheel is raised off the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Remove Nut A Lower Chain Guide Roller B e Remove Rear Tie Rod Mounting Bolt and Nut A Front Tie Rod Mounting Bolt and Nut B Tie Rod C When pulling out the mounting bolts lift the rear wheel slightly Forcing or tapping on a bolt could damage the bolt sleeve and bearing Tie Rod Installation e Replace with new ones Tie Rod Mounting Nuts Lower Chain Guide Roller Nut e Apply plenty of grease to the oil seals e Install Collars Tie Rod e Apply 2 stroke oil to the threads of the tie rod mounting bolts e Tighten Torque Tie Rod Mounting Nuts 59 N m 6 0 kgf m 44 ft lb e Install the lower chain guide roller and tighten the nut Rocker Arm Removal e Using the jack under the frame raise the rear wheel off the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Remove the rear tie rod mounting bolt and nut A When pulling out the mounting bolts lift the rear wheel slightly Forcing or tapping on a bolt could damage the bolt sleeve and bearing SUSPENSION 13 27 Tie Rod Rocker Arm e Remove Rear Shock Absorber Bolt and Nut Lower A Rocker Arm Pivot Bolt and Nut B Rocker Arm C Rocker Arm Installation e Repl
3. FUEL SYSTEM DFI 3 87 Fuel Tank Fuel Tank Removal A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Always stop the engine and do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Remove Seat see Seat Removal in the Frame chapter Radiator Shrouds see Radiator Shroud Removal in the Frame chapter Fuel Tank Bolt A Band B e Draw the fuel out from the fuel tank with a commercially available pump A OUse a soft plastic hose B as a pump intake hose in order to insert the hose smoothly OPut the hose through the fill opening C into the tank and draw the fuel out A WARNING Spilled fuel is flammable and can be explosive un der certain conditions The fuel can not be removed completely from the fuel tank Be careful for re mained fuel spillage e Lift up the fuel tank and disconnect the fuel pump lead connector A e Be sure to place a piece of cloth around the fuel hose joint e Wipe off the dirt of the surface A around the connection using a cloth or a soft brush 6C09095BS1 C JC16153BS1 3 88 FUEL SYSTEM DFI Fuel Tank When removing with standard tip screwdriver e Insert the standard tip screwdriver A into the slit B on the joint lock C e Turn the driver to disconnect the jo
4. Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop However it contains enough detail and basic in formation to make it useful to the owner who de sires to perform his own basic maintenance and repair work A basic knowledge of mechanics the proper use of tools and workshop proce dures must be understood in order to carry out maintenance and repair satisfactorily When ever the owner has insufficient experience or doubts his ability to do the work all adjust ments maintenance and repair should be car ried out only by qualified mechanics In order to perform the work efficiently and to avoid costly mistakes read the text thor oughly familiarize yourself with the procedures before starting work and then do the work care fully in a clean area Whenever special tools or equipment are specified do not use makeshift tools or equipment Precision measurements can only be made if the proper instruments are used and the use of substitute tools may ad versely affect safe operation To get the longest life out of your vehicle e Follow the Periodic Maintenance Chart in the Service Manual eBe alert for problems and non scheduled maintenance e Use proper tools and genuine Kawasaki Mo 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 part
5. Cylinder Head Removal Cylinder Head Installation Cylinder Head Cleaning Cylinder Head Warp Inspection VIE Valve Clearance Inspection Valve Clearance Adjustmert Valve Hemoval Valve Installation Valve Guide Removal ssnnsn 5 14 5 14 5 15 5 15 5 16 5 19 5 19 5 19 5 20 5 20 5 21 5 21 5 22 5 23 5 23 5 24 5 25 5 25 5 25 5 25 5 26 5 27 Valve Guide Installation Valve Valve Guide Clearance Measurement Wobble Method Valve Seat Inspection 00 11 Valve Seat Repair Cylinder and Piston sssssseeeeeeeeen Cylinder Removal essseeeeseeeen Piston Hemova Cylinder and Piston Installation Cylinder Wear Inspection Piston Wear Inspection Piston Cylinder Clearance IISPOCUO EE Piston Ring Ring Groove Clearance Inspection Piston Ring Groove Width ele EE Piston Ring Thickness Inspection Piston Ring End Gap Measurement Piston Piston Pin Connecting Rod Wear Inspection Throttle Body Assy Holder Throttle Body Assy Holder Hemoval Throttle Body Assy Holder Installation Muffler Body Removal Exhaust Pipe Removal Muffler Installation 0000000aaaaea Silencer Wool Replacement 5 27 5 28 5 29 5 29 5 34 5 34 5 34 5 34 5 36 5 36 5 36 5 36 5 37 5 37 5 37
6. GP10571BS1 C 16 24 ELECTRICAL SYSTEM Ignition System Spark Plug Cleaning and Inspection e Refer to the Spark Plug Cleaning and Inspection in the Periodic Maintenance chapter Spark Plug Gap Inspection e Refer to the Spark Plug Cleaning and Inspection in the Periodic Maintenance chapter Ignition Coil Primary Peak Voltage Check e Remove the spark plug cap from the spark plug but do not remove the spark plug e Install the good spark plug A to the spark plug cap then touch the frame with it NOTE OMeasure the voltage with each lead connected cor rectly The correct value may not be obtained if disconnected OMaintain the correct value of compression pressure for the cylinder Be sure to measure the voltage with the spark plug installed to the cylinder head e Connect the peak voltage adapter B to the hand tester Special Tools Hand Tester 57001 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Needle Adapter Set 57001 1457 Hand Tester Range DC 250 V e Connect the peak voltage adapter to the ignition coil ter minal and ground Connections Peak Voltage Hand Adapter Tester Ground C R lead gt Terminal O Lead D BK lead Ignition Coil E ECU F Needle Adapter G e Shift the gear to the neutral position e Crank the engine by kicking the pedal several times to measure the peak voltage of the ignition coil Ignition Coil Primary Peak Voltage
7. Release Shaft Lever Position and Adjusting Washer Selection Washers Thickness Position Distance Judgment 49 2 56 5 mm 1 94 Standard 1 5mm 0 06in 2 22 in More than 56 5 mm 2 22 in Too big 1 0 mm 0 04 in Less than 49 2 mm 1 94 in Too small 1 0 mm 0 04 in Remove the push rod holder assembly as necessary and reinstall the clutch CLUTCH 6 13 GF06193BS1 C GF06177BS1 C 6 14 CLUTCH Clutch Release Shaft Removal e Remove Clutch see Clutch Removal Clutch Cable Upper End see Clutch Cable Removal e Remove the tip A of the clutch cable e Pull out the release shaft assembly B Release Shaft Installation e Apply engine oil to the needle bearings A e Replace the oil seal B with a new one see Crankcase Assembly in the Crankshaft Transmission chapter e Apply grease to the release shaft lower end C and oil seal lips e Insert the release shaft straight into the upper hole of the crankcase NOTICE When inserting the release shaft be careful not to remove the spring of the oil seal e Install the removed parts see appropriate chapters Clutch Plates Wear Damage Inspection e Refer to the Clutch Plates Inspection in the Periodic Main tenance chapter Clutch Plates Warp Inspection e Refer to the Clutch Plates Inspection in the Periodic Main tenance chapter Clutch Spring Free Length Inspection e M
8. 6113014981 9 32 CRANKSHAFT TRANSMISSION Bearings Oil Seals e Inspect the needle bearings OThe rollers in a needle bearing normally wear very little and wear is difficult to measure Instead of measuring inspect the bearing for abrasion color change or other damage x lf there is any doubt as to the condition of a needle bear ing replace it Oil Seal Inspection e Inspect the oil seals x Replace the oil seal if the lips are deformed discolored indicating that the rubber has deteriorated hardened or otherwise damaged WHEELS TIRES 10 1 Wheels Tires Table of Contents EXDIOHRANIEN Lt Sd Sd ne r dE uen 10 2 SDC CIIC AU OMS a en RSA ar na nied Sante AS R MR men nr Min ne 10 4 SD LIAL EE 10 5 Wheels RIMS aaora a a a a a E Ea 10 6 Front Wheel Removal EE EE 10 6 Front Wheel Installation EE 10 6 Rear Wheel Removal esse 10 7 Rear Wheel Installations evi vas ch EE ren head einen 10 8 Wheels TIS SCLIN EE 10 9 Spoke Tightness Inspection nina sew caaaialands nace 10 9 Rim Runout INSPEC ONT EE 10 9 Rim Installation ROT ere gert 10 10 AXIS INSPEC O EE 10 10 RR EE 10 11 Air Pressure Inspection Adjustment nnne 10 11 MIS FROM VUE Tirelnstallatio EE Hub E lee GE Front Hub Bearing Removal Rear Hub Bearing Removal Hub Bearing Installation
9. GJ050103S1 When the track is pebbly or hard increase the tire pressure to prevent damage or punctures through the tires will skid more easily l 100 kPa 1 0 kgf cm 14 psi 2 34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Tires Inspection e Remove any imbedded stones or other foreign particles from the tread x Repair or replace with a new one if necessary e Visually inspect the tire for cracks and cuts x Replace the tire if any damage are noticed OSwelling or high spots indicate internal damage requiring tire replacement A WARNING Some replacement tires may adversely affect han dling and cause an accident resulting in serious in jury or death To ensure proper handling and sta bility use only the recommended standard tires for replacement inflated to the standard pressure NOTE OCheck and balance the wheel when a tire is replaced with a new one Standard Tire Front Size 80 100 21 51M Make DUNLOP Type MX51F Tube Rear Size 100 90 19 57M Make DUNLOP Type MX51 Tube Spoke Tightness Inspection e Check that all the spokes are tightened evenly lf spoke tightness is uneven or loose tighten the spoke nipples evenly Torque Spoke Nipples 2 2 N m 0 22 kgf m 19 in Ib e Check the rim runout see Rim Runout Inspection A WARNING A missing spoke places an additional load on the other spokes which will eventually cause other spokes to break creating th
10. ST5701438ST Steering Stem Nut Wrench 57001 1100 ST5711008ST Jack 57001 1238 ST5712388ST C Fork Piston Rod Puller M12 x 1 25 57001 1289 N ST571289ST C Fork Oil Level Gauge 57001 1290 ST5712908ST C Filler Cap Driver 57001 1454 ST5714548T Fork Spring Compressor 57001 1587 eee eee Jack Attachment 57001 1608 WS ST571587ST F H ST571608ST C Top Plug Wrench 50 mm 57001 1645 Ze a 8757164597 C Top Plug Wrench 36 mm 57001 1705 8757170597 C PERIODIC MAINTENANCE 2 13 Special Tools Fork Spring Compressor 57001 1771 8757177197 2 14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System DFI Fuel Hose and Connections Inspection Olf the motorcycle is not properly handled the high pres sure inside the fuel line can cause fuel to leak A or the hose burst Remove the fuel tank see Fuel Tank Re moval in the Fuel System DFI chapter and check the fuel hose x Replace the fuel hose if any fraying cracks B or bulges C are noticed e Check that the fuel hose is routed according to Cable Wire and Hose Routing section in the Appendix chapter e When installing the fuel hose avoid sharp bending kink ing flattening or twist and run the fuel hose with a mini mum of bending so that fuel flow
11. CRANKSHAFT TRANSMISSION 9 19 Transmission Transmission Shaft Removal e Split the crankcase see Crankcase Disassembly e Pull out the shift rods A and remove the shift forks B e Remove the shift drum C e Pull out the drive shaft D and output shaft E together Transmission Shaft Installation e Apply engine oil to the following parts Transmission Shafts Transmission Gears Ball Bearings Shift Drum Shift Forks e Install the drive shaft A and output shaft B in the right crankcase with their gears meshed e Install the shift drum A e Fit the output shaft shift forks B into the proper gear grooves OUpturn the 057 mark of shift forks e Insert the shift rod C temporary e Fit the shift fork guide pin into the proper shift drum grooves e Install the shift rod securely e Fit the drive shaft shift fork D into the proper position OUpturn the 056 mark of shift fork e Install the shift rod E securely e Check that each shaft moves smoothly e Assembly the crankcase see Crankcase Assembly Transmission Shaft Disassembly e Remove the transmission shafts see Transmission Shaft Removal e Remove the circlips washers then gears Special Tool Outside Circlip Pliers 57001 144 NOTE ODo not reuse the removed circlips 9 20 CRANKSHAFT TRANSMISSION Transmission Transmission Shaft Assembly e Apply engine oil liberally to the transmission shaft
12. E Aa aAa ETA EE H b Bearing INspectioN BEE Hub Bearing Eubrication e a sees rearea e r a aE A aE A E aae a EER EEN 10 2 WHEELS TIRES Exploded View GJO2202BH5 C Exploded View WHEELS TIRES 10 3 No Fastener sone Remarks N m kgf m ft Ib 1 Spoke Nipples Not less Not less Not less than 2 2 than 0 22 than 19 in lb 2 Front Axle Nut 78 8 0 58 3 Front Axle Clamp Bolts 20 2 0 15 AL S 4 Rear Axle Nut 108 11 0 79 7 AL Tighten the two clamp bolts alternately two times to ensure even tightening torque HG Apply high temperature grease R Replacement Parts S Follow the specified tightening sequence WL Apply soap and water solution or rubber lubricant 10 4 WHEELS TIRES Specifications Item Wheels Rims Rim Size Front Rear Rim Runout Axial Radial Axle Runout 100 mm 3 94 in Tires Air Pressure when cold Front Rear Standard Tire Front Size Make Type Rear Size Make Type Standard 21 x 1 60 19 x 1 85 TIR 1 0 mm 0 04 in or less TIR 1 0 mm 0 04 in or less TIR 0 03 mm 0 001 in or less 100 kPa 1 00 kgf cm2 14 psi 80 100 21 51M DUNLOP MX51F Tube 100 90 19 57M DUNLOP MX51 Tube Service Limit TIR 2 0 mm 0 08 in TIR 2 0 mm 0 08 in TIR 0 2 mm 0 008 in Special Tools WHEELS TIRES 10 5 Inside Circlip Pliers 57001 143 ST5701438ST Rim Protector 57001 1063
13. ST571063ST C Bead Breaker Assembly 57001 1072 Bearing Driver Set 57001 1129 ST5711298ST Jack 57001 1238 ST5712388ST C Bearing Remover Head 420 x 22 57001 1293 ST571293ST Bearing Remover Head 25 x 28 57001 1346 ST5718468T C Bearing Remover Shaft 13 57001 1377 ST5713778T Jack Attachment ES Jl ST571608ST C 10 6 WHEELS TIRES Wheels Rims Front Wheel Removal e Remove the axle nut A e Loosen the axle clamp bolts B on both sides e Raise the front wheel off the ground with jack Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Pull out the axle and remove the wheel e Remove the collars A with caps B on both sides 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 the disc does not touch the ground e Insert a wood wedge between the brake pads OThis prevents them from being moved out of their proper position should the brake lever be squeezed accidentally Front Wheel Installation e Apply high temperature grease to the grease seal lips e Install the caps and collars to the hub on both sides OFit the projection A and groove B e Install the front wheel e Insert the axle A from right side e Screw the front axle clamp bolts right B temporarily e Tighten Torque Front Axle Nut C 78 N m
14. ST5714548T Valve Guide Driver 57001 1564 ST5715648T C Piston Pin Puller 57001 1568 ST571568ST C Valve Spring Compressor Adapter D24 57001 1586 ST571586ST C ENGINE TOP END 5 11 Special Tools and Sealant Valve Guide Driver Attachment F Liquid Gasket TB1216B 57001 1722 92104 1064 ke ST5717228ST C ST9210648T C 5 12 ENGINE TOP END Cylinder Head Cover Cylinder Head Cover Removal e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Fuel Hose see Fuel Hose Replacement in the Periodic Maintenance chapter Spark Plug Cap A Cylinder Head Cover Bolts B and Washers Cylinder Head Cover C e Remove the cylinder head cover gasket A Cylinder Head Cover Installation e Using a high flash point solvent clean off any oil or dirt that may be on the liquid gasket coating area Dry them with a clean cloth e Apply liquid gasket A to the cylinder head Sealant Liquid Gasket TB1216B 92104 1064 NOTE OMake the application finish within 20 minutes when the liquid gasket TB1216B to the mating surface of the cylinder head cover is applied e Replace the spark plug hole gasket A with a new one and install it e Make sure that the upper chain guide A is bottomed NOTICE Unless the upper chain guide is bottomed the camshaft chain could push the cylinder head cover upward leading to an
15. Valve Stem Diameter GE15049BS1 Valve Stem Diameter A 45 B Valve Stem Bend GE15011281 Dial Gauge A Special Tools and Sealant ENGINE TOP END 5 9 Compression Gauge 20 kgf cm 57001 221 T5702218T C Valve Spring Compressor Assembly 57001 241 T5702418T Piston Ring Compressor Grip 57001 1095 ST571095ST C Piston Ring Compressor Belt 667 79 57001 1097 ST571097ST Valve Seat Cutter 45 627 5 57001 1114 ST5711148T Valve Seat Cutter 45 632 57001 1115 Valve Seat Cutter 32 628 57001 1119 ST571115ST ST5711198T Valve Seat Cutter Holder Bar 57001 1128 ST5711288ST C Valve Seat Cutter 32 633 57001 1199 ST5711998ST Valve Spring Compressor Adapter 22 57001 1202 T5712028T C 5 10 ENGINE TOP END Special Tools and Sealant Compression Gauge Adapter M10 x 1 0 57001 1317 SN ST5713178T C Valve Seat Cutter 60 25 57001 1328 ST5713288ST Valve Seat Cutter Holder 94 5 57001 1330 S T571330S8T C Valve Guide Arbor 64 5 57001 1331 N S T5713318T Valve Guide Reamer 64 5 57001 1333 T5713338T C Valve Seat Cutter 60 633 57001 1334 ST5713348T C Filler Cap Driver 57001 1454
16. Intake Air Pressure Sensor A Downstream Injector B Upstream Injector A Capacitor A Throttle Sensor B Water Temperature Sensor C Gear Position Switch D Crankshaft Sensor E 3 14 FUEL SYSTEM DFI DFI Parts Location Intake Air Temperature Sensor A Fuel Pump A Specifications FUEL SYSTEM DFI 3 15 Item Standard Digital Fuel Injection System Idle Speed Throttle Body Assy Throttle Valve Bore ECU Make Type Fuel Pressure Fuel Pump Type Discharge Dual Injectors Downstream Injector Type Nozzle Type Resistance Upstream Injector Type Nozzle Type Resistance Throttle Sensor Input Voltage Output Voltage Resistance Intake Air Pressure Sensor Input Voltage Output Voltage Intake Air Temperature Sensor Output Voltage Resistance Water Temperature Sensor Output Voltage Resistance Gear Position Switch Resistance Vehicle down Sensor Detection Angle Input Voltage Output Voltage 2 050 50 r min rpm Single throttle valve 643 mm 1 69 in KEIHIN Digital memory type with built in IC igniter sealed with resin 294 kPa 3 0 kgf cm 2 43 psi with engine idling Wesco pump 40 mL 1 4 US oz or more for 5 seconds EAT291 Fine atomizing type with 4 holes About 11 7 12 3 O at 20 C 68 F EAT812 Fine atomizing type with 4 holes About 11 7 12 3 O at 20 C 68 F DC 4 75 5 25 V DC 0 58 0 62 V at idle th
17. Special Tool Top Plug Wrench 50 mm C 57001 1645 e Record the position of spring preload adjuster A and then turn B it to the hardest position e Holding the top plug wrench A with a vise unscrew the right front fork spring preload adjuster B on the spring adjuster unit with a top plug wrench C Special Tools Top Plug Wrench 50 mm 57001 1645 Top Plug Wrench 36 mm 57001 1705 e Hold the front fork at the inverted position to allow the fork oil to drain e Hold the axle holder part A with a vise B OProtect the axle holder part with a soft jaws C or heavy cloth when using a vise A WARNING If the axle holder is not securely clamped the front fork assembly may come out of the vise when com pressed which could cause an accident resulting in injury However clamping the axle holder too tightly can damage it which will affect riding stabil ity Use protective aluminum covers on the jaws of the vise and do not tighten the vise excessively e Unscrew the right front fork bottom plug D completely When removing the right front fork bottom plug do not force to unscrew it at once using an impact wrench PERIODIC MAINTENANCE 2 61 Periodic Maintenance Procedures When not using the Fork Spring Compressor Special Tool 57001 1771 e Compress the outer tube by hands and install the top plug wrench A between the axle holder bottom B and locknut C Special Tool
18. e Install the right front fork spring preload adjuster so that the projections A align to the holes B on the right front fork spring adjuster unit CAL T1 WM ALU Ce PERIODIC MAINTENANCE 2 69 Periodic Maintenance Procedures e Holding the top plug wrench A with a vise tighten the right front fork spring preload adjuster B on the right front fork spring adjuster unit C with a top plug wrench D Special Tools Top Plug Wrench 50 mm 57001 1645 Top Plug Wrench 36 mm 57001 1705 Torque Right Front Fork Spring Preload Adjuster 30 N m 3 1 kgf m 22 ft lb SIb P e Pour the specified fork oil A into the right front fork outer tube B Suspension Oil SHOWA SS 19 1 L 44091 0009 Fork Oil Capacity Standard 235 2 5 mL 7 95 0 085 US oz Adjustable Range 230 378 mL 7 78 12 78 US oz e Replace the O ring on the right front fork spring adjuster unit with a new one e Apply specified fork oil to the O ring e Temporarily install the right front fork spring adjuster unit A to the outer tube B Special Tool Top Plug Wrench 50 mm C 57001 1645 e Compare the length at assembly and at disassembly OThere should be same length xlf the length at assembly is longer than at disassembly check the right front fork bottom plug and locknut instal lation Length Standard 314 2 mm 12 4 0 08 in e Install the front forks to the motorcycle see Front Fork Installation in the Sus
19. lf the bearing stay on the crankshaft when splitting the crankcase or removing the crankshaft from the right crankcase remove the bearings from the crankshaft with a bearing puller A Special Tool Bearing Puller 57001 135 Crankshaft Installation e Apply engine oil to the outer side of the crankshaft bearing and use the bearing driver set A and a press to drive the bearing to the bottom of the crankcase B While driving the bearing in make sure to use a holder to support the boss area Special Tool Bearing Driver Set 57001 1129 e Insert the crankshaft jig A between the crankshaft fly wheels to protect flywheel alignment and press the crank shaft into the right crankcase OWhen pressing position the jig in the crankcase opening so the jig does not hit the crankcase Special Tool Crankshaft Jig 57001 1174 e Apply engine oil to the connecting rod big end bearing Crankshaft Disassembly Since the assembly of the crankshaft demands exacting tolerances the disassembly and reassembly of the crank shaft can only be done by a shop having the necessary tools and equipment lf it should be necessary to disassemble the crankshaft use a press to remove the crankpin Crankshaft Assembly Since the assembly of the crankshaft demands exacting tolerances the disassembly and reassembly of the crank shaft can only be done by a shop having the necessary tools and equipment 9 16 CRANKSHAFT TRANS
20. O spark plug loose tighten it O spark plug incorrect replace it O spark plug dirty broken or gap maladjusted remedy it knocking fuel poor quality or incorrect CO brake dragging O engine oil level too high O clutch slipping O engine oil viscosity too high O other O engine overheating 3 24 FUEL SYSTEM DFI DFI System Troubleshooting Guide NOTE OThis is not an exhaustive list giving every possible cause for each problem listed It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties in DFI system OThe ECU may be involved in the DFI electrical and ignition system troubles If these parts and circuits are checked out good be sure to check the ECU for ground and power supply If the ground and power supply are checked good replace the ECU Engine Won t Turn Over Symptoms or Possible Causes Actions chapter Gear position switch trouble Inspect see chapter 3 Vehicle down sensor OFF Reinstall see chapter 3 Crankshaft sensor trouble Inspect see chapter 16 Ignition coil shorted or not in good contact Inspect or Reinstall see chapter 16 Ignition 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 correct plug See chapter 2 ECU ground and power supply trouble Inspect see chapter 3 ECU trouble Insp
21. OApply silicone grease to the fluid seal s and install them into the cylinder s by hand e Replace the dust seal s B with new ones OApply brake fluid to the dust seal s and install them into the cylinder s by hand e Apply brake fluid to the outside of the piston s C and push them into each cylinder by hand e Install the anti rattle springs A 2 48 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Replace the friction boot A and dust boot B if they are damaged e Apply a thin coat of PBC Poly Butyl Cuprysil grease to the caliper holder shafts C and holder holes PBC is a special high temperature water resistance grease e Assemble the caliper and caliper holder e Install the pads see Brake Pad Installation in the Brakes chapter e Install the caliper see Caliper Installation in the Brakes chapter e Wipe up any spilled brake fluid on the caliper with wet cloth Brake Hoses and Connections Inspection e Inspect the brake hose and fittings for deterioration cracks and signs of leakage OThe high pressure inside the brake line can cause fluid to leak A or the hose to burst if the line is not properly main tained Bend and twist the rubber hose while examining it x Replace the hose if any cracks B or bulges C are no ticed Tighten any loose fittings Brake Hose Replacement Brake fluid quickly ruins painted surfaces any spilled fluid should be completely wash
22. Rear Master Cylinder Push Rod Length Standard 68 5 1 mm 2 70 0 04 in If it is not within the standard adjust the push rod in the master cylinder as follows OLoosen the push rod locknut A OTurn the adjusting bolt B to obtain the specified length OTighten the locknut Torque Rear Master Cylinder Push Rod Locknut 17 N m 1 7 kgf m 13 ft lb 2 40 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Fluid Level Inspection e Check the brake fluid level in the front or rear brake reser voir A and the front or rear reservoir must be kept above the lower level line B NOTE OHold the reservoir horizontal when checking brake fluid level If the fluid level in front or rear reservoir is lower than the lower level line fill the reservoir to the upper level line e Inside the reservoir is stopped end showing the upper level line C A WARNING Mixing brands and types of brake fluid can reduce the brake system s effectiveness and cause an ac cident resulting in injury or death Do not mix two brands of brake fluid Change the brake fluid in the brake line completely if the brake fluid must be re filled but the type and brand of the brake fluid that is already in the reservoir are unidentified PERIODIC MAINTENANCE 2 41 Periodic Maintenance Procedures Brake Fluid Change A WARNING When working with the disc brake observe the pre cautions listed below 1
23. e When assembling the new outer tube bushings washer and new oil seal A hold the oil seal against the new one and tap the oil seal with the fork oil seal driver B until it stops Special Tool Fork Oil Seal Driver 648 57001 1509 e Install the retaining ring to the outer tube e Push the dust seal into the outer tube and put the spring band on the dust seal e Insert the piston rod A into the fork cylinder B OWrap the piston rod end with a vinyl tape OPush in A the piston rod with a suitable tool B e Remove a vinyl tape and install the locknut C NOTE OAssemble the right front fork in the same way e Pour the fork oil see Front Fork Oil Change in the Periodic Maintenance chapter Front Fork Adjuster Assembly Inspection e Inspect the adjuster assembly A and push rod left front fork only B for damage lf they are damaged replace them with new ones e Replace the O ring C on the adjuster assembly with a new one Base Valve Assembly Inspection e Inspect the threads portion A and spring B of base valve assembly C for damage xlf they are damaged replace the base valve assembly with a new one e Replace the O rings D with new ones Cylinder Unit Inspection Inspect the piston rods A of the cylinder unit B spring adjuster unit C for scratches or bending lf it has scratches or is bent replace the cylinder unit and or spring adjuster unit with a new one Inn
24. xA small amount of play on the swingarm is normal and no corrective action is needed However if excessive play is felt remove the uni trak parts from the frame and check for wear Swingarm and Uni Trak Linkage Pivot Lubrication e Refer to the Swingarm Bearing Installation and Rocker Arm Bearing Installation in the Suspension chapter PERIODIC MAINTENANCE 2 79 Periodic Maintenance Procedures Steering Steering Inspection e Using the jack raise the front wheel off the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e With the front wheel pointing straight ahead alternately nudge each end of the handlebars OThe front wheel should swing fully to left and right from the force of gravity until the fork hits the stop x lf the steering binds or catches before the stop check the routing of the cables hoses and harnesses lf the steering feels tight adjust or lubricate the steering e Feel for steering looseness by pushing and pulling A the forks lf you feel looseness adjust the steering Steering Adjustment e Using the jack raise the front wheel off the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Remove Number Plate A see Number Plate Removal in the Frame chapter Handlebar Pad B Fuel Tank Breather Hose C e Remove Handlebar Clamp Bolts A Handlebar Clamps B Handlebars C 2 80 PERIODIC MAINTENANCE Periodic Maintenance
25. 0 62 V at idle throttle opening DC 3 65 3 85 V at full throttle opening for reference NOTE OOpen the throttle confirm the output voltage will be rise OThe standard voltage refers to the value when the volt age reading at the Input Voltage Inspection shows 5 V exactly OWhen the input voltage reading shows other than 5 V derive a voltage range as follows Example In the case of a input voltage of 4 75 V 0 58 x 4 75 5 00 0 55 V 0 62 x 4 75 5 00 0 59 V Thus the valid range is 0 55 0 59 V e Disconnect the power supply harness x If the reading is out of the standard check the throttle sen sor resistance see Throttle Sensor Resistance Inspec tion x lf the reading is within the standard remove the ECU and check the wiring for continuity between the main harness connectors Special Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A gt Throttle Sensor Connector B Y G lead C ECU terminal 15 GY lead D ECU terminal 17 BK lead E xlf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x lf the ground and power supply are good replace the ECU see ECU Removal Installation 6C17333FS1 C 3 40 FUEL SYSTEM DFI Throttle Sensor Service Code 11 Throttle Sensor Resistance Inspection e Disconnect the throttle sensor connector e Connect
26. A WARNING Fuel is extremely flammable and can be explosive under certain conditions resulting in serious injury or death Do not try to start the engine with the fuel hoses disconnected e Connect the fuel pump lead connector e Refer to the Self diagnosis Procedures connect the 12 V battery to the main harness NOTE Olnspect the fuel leakage from the connected portion of the special tools NOTICE Do not drive the fuel pump without the fuel in the fuel tank If the fuel pump is driven without the fuel it may be damaged FUEL SYSTEM DFI 3 79 3 80 FUEL SYSTEM DFI Fuel Line e Start the engine and let it idle e Measure the fuel pressure with the engine idling Fuel Pressure Standard 294 kPa 3 0 kgf cm 43 psi with engine idling NOTE OThe gauge needle will fluctuate Read the pressure at the average of the maximum and minimum indications e Stop the engine x If the fuel pressure is much higher than specified replace the fuel pump because the fuel pressure regulator in the fuel pump have been clogged or stuck lf the fuel pressure is much lower than specified check the following Fuel Line Leakage see Downstream Upstream Injector Fuel Line Inspection Amount of Fuel Flow see Fuel Flow Rate Inspection e After above checks measure the fuel pressure again e Remove the fuel pressure gauge hoses and adapter e Install the removed parts see appropriate chapters e Start
27. B Kawasaki KX250F Motorcycle Service Manual Quick Reference Guide General Information Periodic Maintenance Fuel System DFI Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal Installation Crankshaft Transmission Wheels Tires Final Drive Brakes Suspension Steering Electrical System ech sch ech N Bl OO IN QO OO No IG BIS NO Appendix This quick reference guide will assist you in locating a desired topic or pro cedure send 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 Kawasaki KX250F 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 Motorcycle amp Engine Company Kawasaki Heavy Industries Ltd Japan No liability can be accepted for any inaccuracies or omissions in this publication although every possible care has been taken to make it as complete and accurate as possible The right is reserved to make changes at any time without prior notice and without incurring
28. CLUTCH 6 7 6 8 CLUTCH Clutch Cover and Right Engine Cover Clutch Cover Removal e Drain the engine oil see Engine Oil Change in the Peri odic Maintenance chapter e Remove Brake Pedal Bolt A Brake Pedal Return Spring B e Remove the clutch cover bolts A and clutch cover B Clutch Cover Installation e Replace the clutch cover gasket with a new one e Install the clutch cover and new cover gasket e Tighten L 65 mm 2 6 in A L 25 mm 1 0 in B Torque Clutch Cover Bolts 9 8 N m 1 0 kgf m 87 mb Right Engine Cover Removal e Drain Engine Oil see Engine Oil Change in the Periodic Main tenance chapter Coolant see Coolant Draining in the Cooling System chapter e Remove Kick Pedal see Kick Pedal Removal in the Crank shaft Transmission chapter Oil Filter see Oil Filter Change in the Periodic Mainte nance chapter Brake Pedal Bolt A Brake Pedal Return Spring B CLUTCH 6 9 Clutch Cover and Right Engine Cover e Remove Bolt A Right Engine Guard B e Remove Water Pump Cover see Water Pump Cover Removal in the Cooling System chapter Clutch Cover Bolts A Right Engine Cover Bolts B Right Engine Cover C Right Engine Cover Installation e Install the dowel pins A e Replace the right engine cover gasket B with a new one e Wrap the spline C of the kick shaft with the vinyl tape to prevent damage e Apply grease to the kick shaft
29. Top Plug Wrench 50 mm 57001 1645 WARNING The fork spring applies pressure to the adjuster as sembly and can eject the special tool with substan tial force if the tool is not properly and securely placed Be sure the tool is fully in place as shown in the photo and keep fingers away to avoid getting them pinched between the tool adjuster assembly and axle holder e Hold the locknut A with a wrench B and remove the right front fork bottom plug C NOTE ODo not remove the locknut from the piston rod The piston rod may slide into the inner tube NOTICE When loosening the locknut the threads of the axle holder do not touch the push rod If the push rod is scratched it is possible to the damage in the cylin der unit e Compress the outer tube by hands and remove the top plug wrench When using the Fork Spring Compressor Special Tool 57001 1771 e Set the fork spring compressor A and a suitable jack B Special Tool Fork Spring Compressor 57001 1771 e Put the heavy cloth A on the fork spring compressor B e Set the front fork with its upper side facing downward on the fork spring compressor 2 62 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Insert the holder bar A of the fork spring compressor special tool 57001 1587 to the axle hole and secure it with the holder B of the fork spring compressor special tool 57001 1771 Special Tools Fo
30. Top Plug Wrench 50 mm C 57001 1645 e Slowly slide down the outer tube e Hold the left front fork tube A upside down over a clean container B and drain the oil NOTE OPump the outer tube up and down to discharge the fork oil e Temporarily install the left front fork cylinder unit A to the outer tube B a Special Tool Top Plug Wrench 50 mm C 57001 1645 ve e Hold the axle holder part A with a vise B OProtect the axle holder part with a soft jaws C or heavy cloth when using a vise A WARNING If the axle holder is not securely clamped the front fork assembly may come out of the vise when com pressed which could cause an accident resulting in injury However clamping the axle holder too tightly can damage it which will affect riding stabil ity Use protective aluminum covers on the jaws of the vise and do not tighten the vise excessively e Unscrew the adjuster assembly D completely NOTICE When removing the adjuster assembly do not force to unscrew it at once using an impact wrench 2 52 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Compress the outer tube by hands and remove the ad juster assembly from the axle holder part so that the lock nut appear about 20 30 mm 0 79 1 2 in e Hold the locknut A with a wrench B and remove the left front fork adjuster assembly C NOTE ODo not remove the locknut from the piston rod The piston rod may slide in
31. e Replace the gasket A with a new one and install the new gasket e Be sure to install the dowel pins B e Using a high flash point solvent clean off any oil or dirt that may be on the silicone sealant coating area Dry them with a clean cloth e Apply silicone sealant to the area A to the magneto lead grommet Sealant Liquid Gasket TB1211F 92104 0004 e Tighten L 35 mm 1 4 in A L 30 mm 1 2 in B Torque Magneto Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib e Hold the magneto lead and gear position switch lead with the clamps C according to the Cable Wire and Hose Routing section in the Appendix chapter e Connect the magneto lead connector e Install the removed parts see appropriate chapters Flywheel Removal e Remove the magneto cover see Magneto Cover Re moval Flywheel Magneto e Hold the flywheel steady with the rotor holder A and remove the flywheel nut B Special Tools Grip C 57001 1591 Rotor Holder 57001 1730 e Install the flywheel puller A to the flywheel e Install the rotor puller B to the flywheel puller e Remove the flywheel from the crankshaft by turning in the rotor puller and tapping the head of the puller lightly with a hammer while holding the puller body steady There is a woodruff key in the crankshaft tapered portion Special Tools Rotor Puller M16 M18 M20 M22 x 1 5 57001 1216 Flywheel Puller M28 x 1 0 57001 1
32. e Set the front fork with its upper side facing downward on the fork spring compressor 2 66 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Insert the holder bar A of the fork spring compressor special tool 57001 1587 to the axle hole and secure it with the holder B of the fork spring compressor special tool 57001 1771 Special Tools Fork Spring Compressor 57001 1587 Fork Spring Compressor 57001 1771 Compress the outer tube with a suitable jack while keep ing the front fork upright and install the top plug wrench A between the axle holder bottom B and locknut C Special Tool Top Plug Wrench 50 mm 57001 1645 A WARNING The fork spring applies pressure to the adjuster as sembly and can eject the special tool with substan tial force if the tool is not properly and securely placed Be sure the tool is fully in place as shown in the photo and keep fingers away to avoid getting them pinched between the tool adjuster assembly and axle holder e Remove the front fork from the fork spring compressor with care not to drop the top plug wrench and hold the axle holder with a vise NOTE OProtect the axle holder with a soft jaws or heavy cloth when using a vise A WARNING If the axle holder is not securely clamped the front fork assembly may come out of the vise when com pressed which could cause an accident resulting in injury However clamping the axle holder too
33. eH gt GM04765BS1 C 13 18 SUSPENSION Rear Shock Absorber e Adjust the high speed compression damping turn the high speed compression damping adjuster with a wrench If the damping feels too soft or too stiff adjust it in accor dance with the following table Do not force the compression damping adjuster beyond the fully seated position or the adjusting mechanism may be damaged Seated position A adjuster turned fully clockwise High Speed Compression Damping Adjuster Setting Standard 2 turns out B Softer Counterclockwise C Harder Clockwise D Although you can turn the adjuster beyond the ad justable range effecting no changes to damping force use it within the adjustable range e Adjust the low speed compression damping turn the low speed compression damping adjuster with a standard tip screwdriver If the damping feels too soft or too stiff adjust it in accor dance with the following table Do not force the compression damping adjuster beyond the fully seated position or the adjusting mechanism may be damaged Seated position A adjuster turned fully clockwise Low Speed Compression Damping Adjuster Setting Standard 12 clicks B counterclockwise Softer Counterclockwise C Harder Clockwise D Although you can turn the adjuster beyond the ad justable range effecting no changes to damping force use it within the adjustable range NOTE
34. ity Use protective aluminum covers on the jaws of the vise and do not tighten the vise excessively 2 58 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Replace the left front fork adjuster assembly O ring A with a new one and apply specified fork oil to it e Insert the push rod B into the piston rod C e Install the left front fork adjuster assembly D to the push rod e Slowly turn the left front fork adjuster assembly A clock wise until resistance is felt e Check the clearance between the locknut B and left front fork adjuster assembly for more than 1 mm 0 04 in C e Turn the locknut A counterclockwise until it contacts with the left front fork adjuster assembly B e With the locknut held immovable using a wrench C tighten the left front fork adjuster assembly locknut Torque Left Front Fork Adjuster Assembly Locknut 22 N m 2 2 kgf m 16 ft lb When tightening the locknut the threads of the axle holder do not touch the push rod If the push rod is scratched it is possible to the damage in the cylin der unit e Apply a non permanent locking agent to the left front fork adjuster assembly e Tighten Torque Left Front Fork Adjuster Assembly 69 N m 7 0 kgf m 51 ft lb e Compare the length A at assembly and at disassembly OThere should be same length lf the length at assembly is longer than at disassembly check the left front fork adjuster assembly an
35. just the sensor e Install the throttle body assy see Throttle Body Assy In stallation Throttle Sensor Input Voltage Inspection NOTE OBe sure the battery is fully charged e Remove Rear Frame with Air Cleaner Housing see Rear Frame Removal in the Frame chapter e Disconnect the throttle sensor connector and connect the measuring adapter A between these connectors Main Harness B Throttle Sensor C Special Tool Measuring Adapter 57001 1700 e Connect a digital meter D to the measuring adapter BK leads BK D Throttle Sensor Input Voltage Connections to Adapter Digital Meter R sensor BL lead Digital Meter BK sensor BK lead 6C17995ES1 C e Refer to the Self diagnosis Procedures connect the 12 V battery to the main harness 3 38 FUEL SYSTEM DFI Throttle Sensor Service Code 11 e Measure the input voltage with the engine stopped and with the connector joined Input Voltage Standard DC 4 75 5 25 V e Disconnect the power supply harness x If the reading is within the standard check the output volt age see Throttle Sensor Output Voltage Inspection x lf the reading is out of the standard remove the ECU and check the wiring for continuity between the main harness connectors Special Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Throttle Senso
36. 10 10 WHEELS TIRES Wheels Rims Rim Installation Position e When installing the rim set the rim following position OThe distance A from the brake disc seating surface B of the front hub C to left end of the front rim D should be as follows View from Front E Distance 26 8 0 5 mm 1 06 0 020 in OThe distance A from the brake disc seating surface B of the rear hub C to right end of the rear rim D should be as follows View from Rear E Distance 32 8 0 5 mm 1 29 0 020 in e Check the rim runout see Rim Runout Inspection in the Periodic Maintenance chapter Axle Inspection e Visually inspect the front and rear axle for damages If the axle is damaged or bent replace it e Place the axle on 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 e Turn C the axle to measure the runout OThe difference between the highest and lowest dial read ings is the amount of runout Axle Runout 100 mm 3 94 in Standard TIR 0 03 mm 0 001 in or less Service Limit TIR 0 2 mm 0 008 in If the runout exceeds the service limit replace the axle GJ04272BS1 C GJ04022BS1 WHEELS TIRES 10 11 Tires Air Pressure Inspection Adjustment e Refer to the Air Pressure Inspection Adjustment in the Pe riodic Maintenance chapter Tire Removal e Remove the wheel see Front Rear Wheel Remova
37. 11 0 kgf m 79 7 ft Ib e Insert a new cotter pin A NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle tighten the nut clockwise B up to next alignment Olt should be within 30 degrees OLoosen once and tighten again when the slot goes past the nearest hole e Bend the cotter pin A over the nut A WARNING A loose axle nut can lead to an accident resulting in serious injury or death Tighten the axle nut to the proper torque and install a new cotter pin e Adjust the drive chain slack see Drive Chain Slack In spection in the Periodic Maintenance chapter e Check the rear brake for good braking power and no brake drag A WARNING After servicing it takes several applications of the brake pedal before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the motorcycle until a firm brake pedal is obtained by pumping the pedal until the pads are against the disc Wheels Inspection e Refer to the Wheel Bearing Inspection in the Periodic Maintenance chapter Spoke Tightness Inspection e Refer to the Spoke Tightness Inspection in the Periodic Maintenance chapter Rim Runout Inspection e Refer to the Rim Runout Inspection in the Periodic Main tenance chapter WHEELS TIRES 10 9 GJ04273BS1 C G6J04082BS1 C
38. 3 01 kgf m 21 8 ft lb e Wipe off all oil from the shock absorber body and piston rod G6S14086BS1 C 6 14095BS1 C GS14087BSi C 2 78 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Inject the nitrogen gas up to the 980 kPa 10 0 kgf cm 142 psi pressure A WARNING High pressure gas is dangerous and can explode causing serious injury To avoid injury have a qual ified mechanic pressurize the shock reservoir with nitrogen gas only Do not use air or other gases since they may cause premature wear rust fire haz ard or substandard performance Install the spring see Rear Shock Absorber Spring Re placement e Install the rear shock absorber see Rear Shock Absorber Installation in the Suspension chapter e Adjust the spring preload see Spring Preload Adjustment in the Suspension chapter e Install the removed parts see appropriate chapters Swingarm and Uni Trak Linkage Inspection e Check the uni trak component parts for wear periodically or whenever excessive play is suspected e Using the jack under the frame raise the rear wheel off the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Pump the seat down and up A 4 or 5 times and inspect the smooth stroke lf the uni trak linkage does not smooth stroke or noise is found inspect the uni trak linkage bearings e Push and pull on the swingarm A to check for wear
39. C and hollow D on the spring guide G119044BS1 CRANKSHAFT TRANSMISSION 9 31 Bearings Oil Seals Bearing Replacement Do not remove the ball or needle bearings unless it is necessary Removal may damage them e Using a press or puller remove the ball bearing and or needle bearings NOTE Oln the absence of the above mentioned tools satisfac tory results may be obtained by heating the case to ap proximately 93 200 F max and tapping the bearing in or out NOTICE Do not heat the case with a torch This will warp the case Soak the case in oil and heat the oil e Using a press and the bearing driver set A install the new ball bearing until it stops at the bottom of its housing OThe new needle bearings must be pressed into the crankcase so that the end is flush with the end of the hole Special Tool Bearing Driver Set 57001 1129 6114060581 Bearing Wear Inspection NOTICE Do not remove the bearings for inspection Re moval may damage them e Inspect the ball bearings OSince the ball bearings are made to extremely close toler ances the wear must be judged by feel rather than mea surement OClean each bearing in a high flash point solvent dry it do not spin the bearing while it is dry and oil it with engine oil OSpin A the bearing by hand to check its condition lf the bearing is noisy does not spin smoothly or has any rough spots replace it
40. Clutch Cable Removal e Remove Number Plate see Number Plate Removal in the Frame chapter Left Radiator Shroud see Radiator Shroud Removal in the Frame chapter Left Radiator Screen see Radiator Removal in the Cool ing System chapter e Slide the dust cover A e Loosen the locknut B and screw in the adjuster C fully e Slide the dust cover A and knob B out of place Clutch Lever and Cable e Align the slit A of the adjusting nut to the slit B of the clutch lever e Free the clutch cable upper end from the clutch lever e Take the cable off the cable holder A e Take the cable lower end B off the clutch release lever C NOTICE Do not remove the clutch release shaft unless it is absolutely necessary If removed release shaft oil seal must be replaced with a new one e Open the clamps A e Pull the clutch cable out of the frame Clutch Cable Installation e Apply grease to the lips A of adjusting nut e Run the clutch cable correctly see Cable Wire and Hose Routing section in the Appendix chapter e Adjust the clutch cable see Clutch Operation Inspection in the Periodic Maintenance chapter e Install the removed parts see appropriate chapters Clutch Cable Inspection and Lubrication e During a periodic inspection or when the cable has been removed inspect and lubricate the cable see General Lubrication and Cable Inspection section in the Periodic Maintenance chapter
41. Environment when problem occurred indicator light LED Option Starting difficulty Weather O fine O cloudy O rain O snow O always O other Temperature O hot O warm O cold O very cold O always Ge O chronic O often O once Altitude O normal O high about 1 000 m or more Motorcycle conditions when problem occurred Orange FI O lights up immediately after starting the engine and goes off after 2 seconds warning with engine running normal O lights up for 2 seconds immediately after starting the engine and goes off for 3 seconds and then keeps going on with engine running DFI problem O unlights light ECU or its wiring fault O sometimes lights up probably wiring fault D no spark O no fuel flow O no fuel in tank O no fuel pump sound O engine flooded do not crank engine with throttle opened which promotes engine flooding Poor running at low speed Poor running or no power at high speed O other Engine stops O right after starting O when moving off O when opening throttle grip O when stopping the motorcycle O when closing throttle grip O when cruising O other O very low fast idle speed O very low idle speed O very high idle speed O rough idle speed O spark plug loose tighten it O spark plug dirty broken or gap maladjusted adjust it D afterfiring O engine oil viscosity too high D clutch slipping O engine overheating O other
42. H or uneven J repair the seat see Valve Seat Repair Valve Seating Surface Width GE15011782 Standard Exhaust 0 5 1 0 mm 0 02 0 04 in Intake 0 5 1 0 mm 0 02 0 04 in Valve Seat Repair e For the instructions on how to use the valve seat cutter A follow the operation manual provided by the tool man ufacturer Special Tools Valve Seat Cutter Holder 4 5 B 57001 1330 Valve Seat Cutter Holder Bar 57001 1128 Exhaust Valve Seat Cutter 45 627 5 57001 1114 Valve Seat Cutter 32 628 57001 1119 Valve Seat Cutter 60 25 57001 1328 Intake Valve Seat Cutter 45 632 57001 1115 Valve Seat Cutter 32 633 57001 1199 Valve Seat Cutter 60 633 57001 1334 lf the tool manufacturer s instructions are not available operate in accordance with the following procedure Supp Ki 5 30 ENGINE TOP END Valves Seat Cutter Operation Care 1 This valve seat cutter is developed to grind the valve for repair Therefore the cutter must not be used for other purposes than seat repair 2 Do not drop or shock the valve seat cutter or the dia mond particles may fall off 3 Do not fail to apply engine oil to the valve seat cutter before grinding the seat surface Also wash off ground particles sticking to the cutter with washing oil Do not use a wire brush to remove the metal par ticles from the cutter It will take off the diamond particles 4 Setting
43. Harder Clockwise C Softer Counterclockwise D Although you can turn the adjuster beyond the adjustable range effecting no changes to spring preload use it within the adjustable range Oil Change e Refer to the Front Fork Oil Change in the Periodic Main tenance chapter Front Fork Removal e Remove Number Plate see Number Plate Removal in the Frame chapter Bolts A and Brake Hose Clamps B Bolts C and Guard D Front Caliper Mounting Bolts E Front Wheel see Front Wheel Removal in the Wheels Tires chapter e Put the caliper A on suitable stand B so that it does not dangle e Loosen the upper A and lower B front fork clamp bolts SUSPENSION 13 11 311121314151617181937383940 HH t D LE A aai GM04772BS1 C 13 12 SUSPENSION Front Fork e Pull out the front fork downward with a twisting motion A Front Fork Installation e Install the front fork OThe length A between the upper end B of the outer tube and steering stem head C is 5 mm 0 20 in e Run the cables and hose according to the Cable Wire and Hose Routing section in the Appendix chapter e Remove the front fork clamp bolts upper A and apply a non permanent locking agent to the bolts e Tighten Torque Front Fork Clamp Bolts Upper 20 N m 2 0 kgf m 15 ft lb Front Fork Clamp Bolts Lower B 22 N m 2 2 kgf m 16 ft lb NOTE O Tighten the two clamp bolts altern
44. Never reuse old brake fluid 2 Do not use fluid from a container that has been left unsealed or that has been open for a long time 3 Do not mix two types and brands of fluid for use in the brake This lowers the brake fluid boiling point and could cause the brake to be ineffec tive 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 deterioration of the rubber parts Oil spilled on any part will be difficult to wash off completely and will eventually deteriorate the rubber used in the disc brake 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 sol vent Do not use one which will leave an oily residue Replace the pads with new ones if they cannot be cleaned satisfactorily 8 Brake fluid quickly ruins painted surfaces any spilled fluid should be completely wiped up im mediately 9 If any of the brake line fittings or the bleed valve is opened at
45. Repair seating surface if possible usable range Valve clearance is too narrow Adjust the valve clearance Piston cylinder clearance is too wide Replace the piston and or cylinder Piston seizure Inspect the cylinder and piston repair or replace them if necessary Bad condition of piston ring and or piston ring grooves Replace the piston and or the piston rings Auto decompressor do not move smoothly Replace the auto decompressor 5 22 ENGINE TOP END Cylinder Head Cylinder Head Removal e Drain the coolant see Coolant Draining in the Cooling System chapter e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Cylinder Head Cover see Cylinder Head Cover Re moval Camshafts see Camshaft Removal Exhaust Pipe see Exhaust Pipe Removal e Remove Throttle Body Assy A see Throttle Body Assy Removal in the Fuel System DFI chapter Capacitor B see Capacitor Removal in the Electrical System chapter Ignition Coil C see Ignition Coil Removal in the Elec trical System chapter Vehicle down Sensor D See Vehicle down Sensor Re moval in the Fuel System DFI chapter Bracket Bolt E Water Hose F Water Temperature Sensor Connector G Bolts H and Upper Engine Bracket I Both Sides Clamps J Open e Remove the cylinder head bolts M6 A e Loosen the cylinder bolt B e Remove the cylinder head bolts M10 C e Remove
46. and drain the oil NOTE OPump the piston rod up and down to discharge the fork oil 6S14061BS1 C e Hold the front fork at the inverted position for more than 20 minutes to allow the fork oil to fully drain GM04251BS1 e Clean the threads A of the left front fork cylinder unit and left front fork base valve assembly 2 54 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Hold the left front fork cylinder unit A upright with the piston rod fully stretched e Plug the oil hole B on the left front fork cylinder unit with finger e Pour the specified oil Suspension Oil SHOWA SS 19 1 L 44091 0009 Cylinder Unit Oil Capacity Standard 330 mL 11 16 US oz e Apply specified fork oil to the sliding surface of the piston rod e Purge the air from the fork cylinder A by gently moving B the piston rod up and down several times e With the piston rod fully stretched check the oil level in the left front fork cylinder unit OMeasure the oil level A from the top surface B in the left front fork cylinder unit using a suitable gauge Fork Cylinder Unit Oil Level Standard 115 123 mm 4 53 4 84 in NOTE OFork oil level may also be measured using the fork oil level gauge Special Tool Fork Oil Level Gauge 57001 1290 e Replace the O rings A on the left front fork base valve assembly with new ones e Apply specified fork oil to the O rings and bushings B NOTICE D
47. centi c 0 01 milli 0 001 Units of Torque micro u 0 000001 N m x 01020 kgfm N m x 0 7376 ftlb N m x 8 851 in lb Units of Mass kgf m x 9 807 N m kg x 2 205 Ib kgf m x 7 233 ft lb g x 0 03527 oz kgf m x 86 80 in lb Units of Volume Units of Pressure L x 0 2642 gal US kPa x 0 01020 kgf cm L x 0 2200 gal IMP kPa x 0 1450 psi L x 1 057 qt US kPa x 0 7501 cmHg L x 0 8799 qt IMP kgf cm x 98 07 kPa L x 2 113 pint US kgf cm x 14 22 psi L x 1 816 pint IMP cmHg x 1 333 kPa mL x 0 03381 oz US mL x 0 02816 oz IMP Units of Speed mL x 0 06102 cu in km h a 0 6214 mph Units of Force Units of Power N x 0 1020 kg kW x 1360 PS N x 0 2248 Ib kw x 1 341 HP kg x 9 807 A PS x 0 7355 kW kg x 2 205 lo PS x 0 9863 HP Units of Temperature 104 5 F 40 40 C 248 284 176 212 80 100 120 140 160 ep 200 220 240 260 280 300 F 320 26 7 40 48 9 714 80 400 93 3 116 dE d 138 160 C PERIODIC MAINTENANCE 2 1 Periodic Maintenance Table of Contents Periodic Maintenance Chart EE 2 3 Torque and Locking AGS cccscceedeecuicess cevtevnc wlocketodlagealeessbechentseesasudvdeuceteags i SASANIDE 2 5 EE e 2 9 Special e EEN 2 12 Periodic Maintenance Froe iscciacetcatenes sasnisidheetacdetandatehseadacdscataietiecetidion cxebtdeeeaneeeres 2 14 EE NR e EE 2 14 Fuel Hose and Connections Inspection 2 14 Throttle Grip Throttle
48. e Measure the gap A with a wire type thickness gauge lf the gap is incorrect carefully bend the side electrode B with a suitable tool to obtain the correct gap Spark Plug Gap Standard 0 8 0 9 mm 0 031 0 035 in a SSSSSSS N SE Le SN y SSSSS gt GP100108S1 e Insert the spark plug into the suitable 16 mm 0 63 in plug wrench and finger tighten it first e Tighten Torque Spark Plug 13 N m 1 3 kgf m 115 in lb e Install the ignition coil see Ignition Coil Installation in the Electrical System chapter Spark Plug Replacement e Refer to the Spark Plug Cleaning and Inspection 2 82 PERIODIC MAINTENANCE Periodic Maintenance Procedures General Lubrication and Cable Inspection Lubrication e Before lubricating each part clean off any rusty spots with rust remover and wipe off any grease oil dirt or grime e Lubricate the points listed below with indicated lubricant NOTE OWhenever the vehicle has been operated under wet or rainy conditions or especially after using a high pressure water spray perform the general lubri cation Points Lubricate with Grease Clutch Inner Cable Upper and Lower Ends A Throttle Inner Cable Upper End Brake Lever Pivot Bolt Clutch Lever Pivot Bolt Brake Pedal Bolt 6004010181 Cables Lubricate with Rust Inhibitor Throttle Inner Cables Clutch Inner Cable 6004011481 Pivots Lubricate with
49. 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 deterioration of the rubber parts Oil spilled on any part will be difficult to wash off completely and will eventually deteriorate the rubber used in the disc brake 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 sol vent Do not use one which will leave an oily residue Replace the pads with new ones if they cannot be cleaned satisfactorily 8 Brake fluid quickly ruins painted surfaces any spilled fluid should be completely wiped up im mediately 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 Brake Fluid Level Inspection e Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter Brake Fluid Change e Refer to the Brake Fluid Change in the Periodic Mainte nance chapter Brake Fluid 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 th
50. gears and bearings e Replace any circlips that were removed with new ones OAlways install the circlips A so that the opening B is aligned with a spline groove C and install toothed wash ers To install a circlip without damage first fit the circlip onto the shaft expanding it just enough to install it and then use a suitable gear to push the circlip into place Special Tool Outside Circlip Pliers 57001 144 e The drive shaft gears can be identified by size the small est diameter gear is 1st gear and the largest is 5th Be sure that all parts are put back in the correct sequence facing the proper direction and that all circlips and washer are properly in place OWhen install the bushing for 4th A to the drive shaft align the oil passage holes B each other e The output shaft gears can be identified by size the largest diameter gear is 1st gear and the smallest is 5th Be sure that all parts are put back in the correct sequence facing the proper direction and that the circlip is properly in place Olnstall the collar A with the flange B facing toward the 4th gear C side 2nd Gear D G113495BS1 CRANKSHAFT TRANSMISSION 9 21 Transmission 1 Circlip Small 11 Ball Bearing Right Crankcase 2 Toothed Washer 12 Output Shaft 3 Circlip Large 13 Ball Bearing Left Crankcase 4 Ball Bearing Left Crankcase One 14 Collar side sealed
51. 0 232 0 236 in Service Limit 5 8 mm 0 228 in Shift Drum Groove Width Standard 6 05 6 20 mm 0 238 0 244 in Service Limit 6 3 mm 0 25 in lf the guide pin on any shift fork is less than the service limit the fork must be replaced lf any shift drum groove is worn exceeding the service limit the drum must be replaced Gear Damage Inspection e Visually inspect the gear dogs A and gear dog holes B Replace any damaged gears or gears with excessively worn dogs or dog holes e Visually inspect the gear teeth C on the transmission gears x Replace lightly damaged gear teeth with an oilstone The gear must be replaced if the teeth are badly damaged x When gear is repaired or replaced the driving gear should also be inspected and repaired or replaced if necessary G113438BS1 C G113496BS1 G113238BS1 C CRANKSHAFT TRANSMISSION 9 23 Primary Gear Primary Gear Removal e Remove Right Engine Cover see Right Engine Cover Removal in the Clutch chapter Clutch see Clutch Removal in the Clutch chapter e Temporarily install the clutch housing A clutch hub B toothed washer and clutch hub nut C e Hold the primary gear D with the gear holder E OPull out the clutch housing a little so that the gear holder can be fit Special Tool Gear Holder m2 0 57001 1557 e Remove the primary gear nut F and washer OThe primary gear nut is left hand thre
52. 002 0 003 in Service Limit Top 0 18 mm 0 0071 in x If the piston ring groove clearance is greater than the ser vice limit measure the ring thickness and groove width as follows to decide whether to replace the rings the piston or both GE16257BS1 GE16054BS1 C GE16259BS1 Cylinder and Piston Piston Ring Groove Width Inspection e Measure the groove width at several points around the piston with a vernier caliper Piston Ring Groove Width Standard Top 0 83 0 85 mm 0 0327 0 0335 in Service Limit Top 0 93 mm 0 037 in If any of the groove widths exceeds the service limit re place the piston Piston Ring Thickness Inspection e Measure the thickness at several points around the ring with a micrometer Piston Ring Thickness Standard Top 0 77 0 79 mm 0 030 0 031 in Service Limit Top 0 70 mm 0 028 in lf any of the measurements is less than the service limit replace all rings NOTE OWhen using new rings in a used piston check for un even groove wear The rings should fit perfectly parallel to the groove sides If not replace the piston Piston Ring End Gap Measurement e Place the piston ring A inside the cylinder using the pis ton to locate the ring squarely in place Set it close to the bottom of the cylinder where cylinder wear is low e Measure the gap B between the ends of the ring with a thickness
53. 26 RE e i meaa EE 13 26 Heo INStall EE 13 26 Rocker Be EE 13 26 Rocker Arm Jeer degen eege Ten ENEE 13 27 Tie Rod and Rocker Arm Bearing Removal ss 13 27 Tie Rod and Rocker Arm Bearing Installation 13 28 Needle Bearing Inspection EE 13 29 Uni Trak Maintenance sxcctiietsetetegetenddelapdeieeacsaadas aiai A anaE EEKE NEKE inak Ets 13 30 Uni Trak Linkage Inspection geegent edd 13 30 Tie Rod and Rocker Arm Sleeve Wear Inspechon AE 13 30 Tie Rod and Rocker Arm Mounting Bolt Bend Inspection n se 13 30 13 2 SUSPENSION Exploded View Spa D y a Y 1 7887 0 p db re GM02367BW5 C Exploded View SUSPENSION 13 3 No Fastener E Remarks N m kgf m ft Ib 1 Air Pressure Relief Screws 1 3 0 13 12 in lb 2 Left Front Fork Base Valve Assembly 30 3 1 22 3 Front Fork Clamp Bolts Upper 20 2 0 15 AL L 4 Front Fork Clamp Bolts Lower 22 2 2 16 AL 5 Right Front Fork Spring Preload Adjuster 30 3 1 22 6 Leit Front Fork Cylinder Unit 7 Right Front Fork Spring Adjuster Unit 8 Left Front Fork Adjuster Assembly Locknut 9 Left Front Fork Adjuster Assembly L 10 Right Front Fork Bottom Plug Locknut 11 Right Front Fork Bottom Plug L AL Tighten the two clamp bolts alternately two times to ensure even tightening torque FO Apply front fork oil G Apply grease L Apply a non permanent locking agent R Replacement Parts 13
54. 3 Fuel line clogged Inspect and repair see chapter 3 Intake air pressure sensor trouble Inspect see chapter 3 DFI System Troubleshooting Guide FUEL SYSTEM DFI 3 25 Symptoms or Possible Causes Actions chapter Water temperature sensor trouble Inspect see chapter 3 Intake air temperature sensor trouble Inspect see chapter 3 Throttle sensor trouble Unstable rough idling Fuel pressure too low or too high Upstream downstream injector trouble Throttle sensor trouble Intake air pressure sensor trouble Water temperature sensor trouble Intake air temperature sensor trouble Engine stalls easily Spark plug dirty broken or gap maladjusted Ignition coil trouble Throttle sensor trouble Intake air pressure sensor trouble Water temperature sensor trouble Intake air temperature sensor trouble Fuel pump trouble Inspect see chapter 3 Inspect Inspect Inspect Inspect Inspect Inspect see chapter 3 see chapter 3 see chapter 3 see chapter 3 see chapter 3 see chapter 3 LS LS J SY S Inspect and replace see chapter 2 Inspect see chapter 16 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Upstream downstream injector trouble LT eS J NS Jl S Inspect see chapter 3 Fuel pressure too low or too high Inspect see chapter 3 Inspect see chapter 3
55. 5 38 5 39 5 39 5 39 5 40 5 40 5 40 5 40 5 40 5 2 ENGINE TOP END Exploded View LU i D eo KE xe ei ef ENGINE TOP END 5 3 Exploded View No Fastener sone Remarks N m kgf m ft Ib 1 Cylinder Head Cover Bolts 9 8 1 0 87 in lb 2 Camshaft Cap Bolts 9 8 1 0 87 in lb MO S 3 Plug 20 2 0 15 L 4 Cylinder Head Bolts M10 44 4 5 32 MO R S 5 Auto Decompressor Bolt 12 1 2 106 mb 6 Cylinder Head Bolts M6 12 1 2 106 in lb S 7 Cylinder Bolt 12 1 2 106 in lb S 8 Throttle Body Assy Holder Clamp Screw 2 0 0 20 18 in lb 9 Throttle Body Assy Clamp Screw 2 0 0 20 18 in lb 10 Lower Camshaft Chain Guide Bolt 9 8 1 0 87 in lb 11 Rear Camshaft Chain Guide Bolt 15 1 5 11 12 13 Camshaft Chain Tensioner Mounting Bolts EO Apply engine oil G Apply grease L Apply a non permanent locking agent LG Apply liquid gasket M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts S Follow the specified tightening sequence 5 4 ENGINE TOP END Exploded View GE02548BW5 C ENGINE TOP END 5 5 Exploded View G Apply grease L Apply a non permanent locking agent R Replacement Parts S Follow the specified tightening sequence SS Apply silicone sealant 5 6 ENGINE TOP END Specifications Ite
56. 8 0 kgf m 58 ft lb Front Axle Clamp Bolts Left D 20 N m 2 0 kgf m 15 ft lb NOTE O Tighten the two clamp bolts alternately two times to en sure even tightening torque e Loosen the front axle clamp bolts right e Remove the jack GJ04220BS1 WHEELS TIRES 10 7 Wheels Rims e Pump the front fork up and down A 4 or 5 times to align both fork positions NOTE OPut a block B in front of the wheel to stop moving ODo not apply the front brake e Tighten Torque Front Axle Clamp Bolts Right 20 N m 2 0 kgf m 15 ft lb GROS P NOTE O Tighten the two clamp bolts alternately two times to en sure even tightening torque e Check the front brake for good braking power and no brake drag WARNING After servicing it takes several applications of the brake lever before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the motorcycle until a firm brake lever is obtained by pumping the lever until the pads are against the disc Rear Wheel Removal e Using the jack under the frame so that the rear wheel is raised off the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Squeeze the front brake lever and hold it with a band A to prevent the motorcycle from running forward A WARNING Motorcycle may fall over unexpectedly r
57. After adjusting move the spring up and down to make sure that the spring is seated e Install the removed parts see appropriate chapters SUSPENSION 13 19 13 20 SUSPENSION Rear Shock Absorber Rear Shock Absorber Spring Tension Inspection e Since the spring becomes shorter as it weakens check its free length A to determine its condition Shock Absorber Spring Free Length Standard 265 mm 10 4 in Service Limit 260 mm 10 2 in x lf the free length falls below the service limit replace the spring Rear Shock Absorber Removal e Remove Seat see Seat Removal in the Frame chapter Side Covers see Side Cover Removal in the Frame chapter Muffler Body see Muffler Body Removal in the Engine Top End chapter Rear Frame see Rear Frame Removal in the Frame chapter e Place the jack under the frame so that the rear wheel is raised off the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1608 NOTICE When pulling out the mounting bolts lift the rear wheel slightly Forcing or tapping on a bolt could damage the bolt sleeve and bearing e Remove the upper mounting bolt and nut A e Remove the lower mounting bolt and nut B and take off the rear shock absorber OTake care not to hit the rear shock absorber to the swingarm Rear Shock Absorber Installation e Replace the rear shock absorber mounting nuts with new ones e Apply plenty of grease to the oil seals and g
58. Bearing Inspection Since the hub bearings are made to extremely close tol erances the clearance cannot normally be measured NOTE ODo not remove any bearings for inspection If any bear ings are removed they will need to be replaced with new ones e Turn each bearing in the hub back and forth A while checking for plays roughness or binding x If bearing play roughness or binding is found replace the bearing e Examine the bearing seal B for tears or leakage x lf the seal is torn or is leaking replace the bearing Hub Bearing Lubrication NOTE OSince the hub bearings are packed with grease and sealed lubrication is not required 6J06002BS1 C FINAL DRIVE 11 1 Final Drive Table of Contents ee WEE 11 2 ee 11 4 Sp cial TOO EEN 11 5 ED FIGS AUN EE 11 6 Drive Chain Slack Inspection tiennent 11 6 Drive Chain Slack Adjustment EE 11 6 Wheel Alignment Insp ction5 28 2tansse sine manne 11 6 Wheel Alignment Adjustment EE 11 6 Drive Chain Wear Inspection sine 11 6 Drive Chain Ee e EE 11 6 Drive Chain ME ee deed Ee 11 6 Drive Chain WStAlAUON EE 11 7 OC EEN 11 8 Engine Sprocket Removal eu arsenal titane A a ERa EaR 11 8 Engine Sprocket Installation SEET 11 8 Rear Sprocket Rememwal serran cia aaaea dhcnsadbictiborinuedsdeees diaeveiesiteeeuaeess 11 8 Rear Sprocket Installati n sens ennui EEEn acer nn Mae ee 11 9 sprocket Wear Inspection ER 11 9 Rear Sprock
59. Bolts Upper Rear Frame Mounting Bolts Electrical System Regulator Rectifier Nuts Spark Plug Flywheel Nut Cap Magneto Cover Bolts Timing Inspection Cap Flywheel Nut Stator Coil Bolts Crankshaft Sensor Bolts Gear Position Switch Screws Basic Torque for General Fasteners Threads Diameter mm N m 5 3 4 4 9 6 5 9 7 8 8 14 19 10 25 34 12 44 61 14 73 98 16 115 155 18 165 225 20 225 325 25 98 20 4 9 34 22 3 0 54 34 10 13 3 5 9 8 3 5 78 5 9 8 7 0 2 9 etm em Remarks 18 AL 2T 72 15 AL L 43 in lb T 25 R 16 AL 27 in lb 5 5 40 L 3 5 25 1 02 89 in lb R 1 3 115 in lo 0 36 31 in lb 1 0 87 in lb 0 36 31 in lb 8 00 57 9 1 0 87 in lb L 0 71 62 in lb L 0 30 26 in lb L Torque kgf m ft Ib 0 35 0 50 30 43 in lb 0 60 0 80 52 69 in lb 1 4 1 9 10 13 5 2 6 3 5 19 25 4 5 6 2 33 45 7 4 10 0 54 72 11 5 16 0 83 115 17 0 23 0 125 165 23 0 33 0 165 240 Specifications PERIODIC MAINTENANCE 2 9 Hem Standard Service Limit Fuel System DFI Throttle Grip Free Play Idle Speed Air Cleaner Element Oil Cooling System Coolant Type Recommended Color Mixed Ratio Freezing Point Total Amount Engine Top End Valve Clearance Exhaust Intake Cylinder Head Warp Cylinder Inside Diameter see text Piston Cylinder Clearance 2 3 mm 0 08 0 12 in a 2 050 50 r min rpm ees High quality foam air f
60. Change e Warm up the engine thoroughly so that the oil will pick Up Eme any sediment and drain easily Then stop the engine e Place an oil pan beneath the engine e Remove the oil filler plug A Special Tool Filler Cap Driver 57001 1454 GFO60602S1 C PSN PS GF13010781 PERIODIC MAINTENANCE 2 31 Periodic Maintenance Procedures e Remove the engine oil drain bolt A from the bottom of the engine and let the oil drain completely NOTE OHold the motorcycle upright so that the oil may drain completely e Replace the drain bolt gasket with a new one e Install the drain bolt with the gasket e Tighten Torque Engine Oil Drain Bolt 20 N m 2 0 kgf m 15 ft lb e Pour in the specified type and amount of oil Recommended Engine Oil Type Castrol POWER1 R4 Racing 5W 40 or API SG SH SJ SL or SM with JASO MA MA1 or MA2 Viscosity SAE 10W 30 10W 40 or 10W 50 Capacity 0 75 L 0 79 US qt when filter is not removed 0 80 L 0 85 US qt when filter is removed 1 00 L 1 06 US qt when engine is completely dry NOTE ODo not add any chemical additive to the oil Oils fulfilling the above requirements are fully formulated and provide adequate lubrication for both the engine and the clutch O The oil viscosity may need to be changed to accommo date atmospheric conditions in your riding area e Check the oil level see Oil Level Inspection in the Engine Lubri
61. Cylinder Push Rod Locknut 17 1 7 13 5 Brake Pedal Bolt 25 2 5 18 G L 6 Rear Caliper Holder Shaft 27 2 8 20 Si 7 Rear Brake Pad Pin 17 1 7 13 8 Rear Brake Pad Pin Plug 2 4 0 24 21 in lb 9 Caliper Bleed Valve 7 8 0 80 69 in lb 10 Rear Brake Disc Mounting Bolts 23 2 3 17 L B Apply brake fluid G Apply grease L Apply a non permanent locking agent R Replacement Parts Si Apply silicone grease ex PBC grease 12 6 BRAKES Specifications Item Brake Lever Lever Free Play Brake Fluid Grade Front Rear Brake Pads Lining Thickness Front Rear Brake Discs Thickness Front Rear Runout Standard Adjustable to suit rider DOT3 or DOT4 DOT3 or DOT4 4 0 mm 0 16 in 6 4 mm 0 25 in 2 85 3 15 mm 0 112 0 124 in 3 85 4 15 mm 0 152 0 163 in TIR 0 25 mm 0 010 in or less Service Limit 1 mm 0 04 in 1 mm 0 04 in 2 5 mm 0 10 in 3 5 mm 0 14 in TIR 0 3 mm 0 01 in BRAKES 12 7 Special Tools Jack Jack Attachment 57001 1238 57001 1608 ST5712388ST C ST571608ST C 12 8 BRAKES Brake Lever Brake Pedal Brake Lever Play Adjustment e Refer to the Brake Lever and Pedal Adjustment in the Periodic Maintenance chapter Brake Pedal Position Adjustment e Refer to the Brake Lever and Pedal Adjustment in the Periodic Maintenance chapter Brake Pedal Removal e Remove Cotter Pin A Joint Pin B Washer C NOTE
62. Dasa ace dad gd Ont ea eed ec saad den 4 7 Cooling System Pressure Testing 4 8 Cooling System FUSING EE 4 8 dE tr e EEN 4 9 Water Pump enne EE 4 9 Water Pump Cover Installation ses mesh diet 4 9 Impeller e CEET 4 10 fap e te ad NS rs BEE 4 10 Water Pump INSP Cton EE 4 10 Water Pump Gear REMOVAL seccciciceisoccdetvadadserysst sete ceas nt nent heart end pedaaseepineneege 4 10 Water Pump Gear Installation na meee EES 4 11 Oil Seal and Bearing EMO EE 4 11 Oil Seal and Bearing Installation 4 11 EE 4 12 Radidior ENEE EE ASS eeh 4 12 Radiator Installation seirena mnt en aude 4 13 Seele te SSSR ts Rois neutre CR ate ones 4 13 Radiator Cap Inspection ss issued e a a a iaaa 4 14 LE ANS LA 21 QE 815 16 ile E 4 14 Water Hoses and Overflow Hose Inspection sseesssneessssrnsserertertnerssrrrnserennrrrnnnnnsrerrseet 4 14 Water Hoses and Overflow Hose Installation iii 4 14 4 2 COOLING SYSTEM Exploded View COOLING SYSTEM 4 3 Exploded View Torque No Fastener Nm kgf m ftlb Remarks 1 Water Hose Clamp Screws 3 0 0 31 27 in lb 2 Water Pipe Bolt 9 8 1 0 87 in lb 3 Water Pump Cover Bolts L 55 mm 9 8 1 0 87 in lb L 4 Water Pump Impeller Bolt 7 0 0 71 62 mb 5 Water Pump Cover Bolts L 30 65 mm 9 8 1 0 87 in lb 6 Coolant Drain Bolt 7 0 0 71 62 in lb G Apply grease L Apply a non permanent locking agent R Replacement Parts WL Apply soap a
63. ECU see ECU Removal Installation x lf the reading is out of the standard remove the ECU and check the wiring for continuity between the main harness connectors Special Tool Hand Tester 57001 1394 ODisconnect the ECU and downstream injector connector Wiring Continuity Inspection ECU Connector A Downstream Injector Connector B BL R lead C ECU terminal 4 x If the wiring good check the ECU ground and power sup ply see ECU Power Supply Inspection lf the ground and power supply good replace the ECU see ECU Removal Installation GC17342FS1 GC17343FS1 Downstream Injector Service Code 41 Downstream Fuel Line Inspection e Remove Fuel Tank see Fuel Tank Removal Fuel Hose see Fuel Hose Replacement in the Periodic Maintenance chapter OPlace a piece of cloth around the fuel outlet pipe of fuel pump and delivery pipe of throttle body assy e Check the downstream injector fuel line for leakage as follows OApply engine oil to the delivery pipe lightly OConnect a commercially available vacuum pressure pump A to the delivery pipe B with the fuel hose C OHold both ends with the clamps D e Apply a soap and water solution to the areas E e Watching the pressure gauge squeeze the pump lever F and build up the pressure until the pressure reaches the maximum pressure Fuel Line Maximum Pressure Standard 300 kPa 3 06 kgf cm 44 psi N
64. 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 Fuel filter or pump screen clogged Fuel pump trouble Upstream downstream injector trouble Throttle sensor trouble Intake air pressure sensor trouble Water temperature sensor trouble Intake air temperature sensor trouble Spark plug dirty broken or gap maladjusted Ignition coil trouble Stumble Fuel pressure too low Upstream downstream injector trouble Change fuel Inspect and clean fuel system see chapter 3 Inspect and replace fuel pump see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect and replace see chapter 2 Inspect see chapter 16 Inspect Inspect see chapter 3 see chapter 3 Throttle sensor trouble Inspect see chapter 3 Intake air pressure sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Intake air temperature sensor trouble ee RY J SS KS Hs J BS J NY SY a Inspect see chapter 3 3 26 FUEL SYSTEM DFI DFI System Troubleshooting Guide Symptoms or Possible Causes Surge Unstable fuel pressure Action
65. GENEE eege tearm siete 15 4 Rear Frame Betount Deeg e eh cl le haa ele eg 15 4 Rear Frame Installaton diiescccencccesceceenecceneeeenceeeeneeeennsee 15 4 Engine Guards ROMO EE 15 5 Engine Guards Installation ssena kaaa aaaea pE ENE E R Eia Ra 15 5 aTe EE 15 6 Seat ne TEE 15 6 Seat Installations EE 15 6 Side Govefs iss sf nent ne PA ea ee ee A ea Ne ne ATE 15 7 Side Cover REMOVAL e E A E E E EE 15 7 Side Cover Installation iii iiiiiiieuiseceessceccecceceenecceeeceeneeeeeens 15 7 Radiator elef EE 15 8 Radiator Shroud Bemoval sirreeeccccnenncececeaeeeeeenneeecennsses 15 8 Radiator Shroud Installation iii iiieeesseceeesssceeeecseeecenneeee 15 8 N mberPBl te 2525 2e pre Re ee de eg 15 9 Number Plate REMOVal 0 cccccccccccccsecceueeeeueeeeesueeeuueeeuuaueesuuesaeeeuuaeueaeeeauaueeaueesausueaueneees 15 9 Number Plate Installation ed EELER AE EE 15 9 BCE EE 15 10 Front Fender Removal arreen tec eet dE See S 15 10 Front Fender Installation ccccccccccccccecccuccceueeceeueeceuueceuuaeeeuaaeeuuaeeeuaaeeuuaeeeuaeeeuaeeeuuaeesuaaees 15 10 Rear Fender Removal Installation ccccccccccccuseceseeceeueeeeuueceuueeeeuuaceuuaeeeuaueeuuaveuuaeeeuaneees 15 10 Rear Flap RemovalinStallationssss sens ege cae EE Oe d etat 15 10 FPOOUS EE 15 11 Footpeg FSI IOV EE 15 11 Footpeg Installations a r a E r aea a a ae a EAE aE RE nena NEEN 15 11 15 2 FRAME Exploded View 6002566845 C FRAME 15 3 Ex
66. Ignition System e Check the wiring for continuity between the terminals of each connector referring the connector circuit White Connector A Green Connector B Black Connector C Special Tool Hand Tester D 57001 1394 x lf the tester does not read 0 Q the connector is defective Replace the connector with a new one ELECTRICAL SYSTEM 16 29 GP10719BS2 16 30 ELECTRICAL SYSTEM Switches Engine Stop Switch Inspection e Using the hand tester check to see that the connections shown in the table have continuity about zero ohms Special Tool Hand Tester 57001 1394 lf the switch has an open or short replace it with a new one Engine Stop Switch Connection BK W BK Gear Position Switch Removal e Refer to the Gear Position Switch Removal in the Fuel System DEI chapter Gear Position Switch Installation e Refer to the Gear Position Switch Installation in the Fuel System DEI chapter Gear Position Switch Inspection e Refer to the Gear Position Switch Inspection in the Fuel System DEI chapter APPENDIX 17 1 Appendix Table of Contents Cable Wire and Hose RONDE eee ea needa EA ee 17 2 Troubleshooting EEN 17 13 17 2 APPENDIX Cable Wire and Hose Routing GB09 MD G Front Brake Hose Run the throttle cables inside of the number plate Throttle Cable Accelerator Throttle Cable Decelerator Clutch Cable Run the clutch cable
67. Locking Agent Tighten all bolts and nuts to the proper torque using an accurate torque wrench If insufficiently tightened a bolt or nut may become damaged strip an internal thread or break and then fall out The following table lists the tightening torque for the major bolts and nuts and the parts requiring use of a non permanent locking agent or silicone grease etc When checking the tightening torque of the bolts and nuts first loosen the bolt or nut by half a turn and then tighten to specified torque Letters used in the Remarks column mean AL Tighten the two clamp bolts alternately two times to ensure even tightening torque G Apply grease L Apply a non permanent locking agent Lh Left hand Threads MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts S Follow the specified tightening sequence Si Apply silicone grease ex PBC grease T First tighten the stem nut with 39 N m 4 0 kgf m 29 ft lb of torque then loosen it and retighten it with 4 9 N m 0 50 kgf m 43 in lb of torque 2T Apply 2 stroke oil Torque Fastener Nem kotm itib Remarks Fuel System DFI Throttle Pulley Cover Bolts 0 35 30 in lb Throttle Cable Bolts 0 31 27 in lb Air Cleaner Duct Clamp Bolt 0 20 18 in lb Throttle Case Mounting Screws 0 39 34 in lb Delivery Joint Bolt 0 36 31 in lb L Water Temperature Sensor 1 2 106 in
68. M6 D Torque Cylinder Bolt 12 N m 1 2 kgf m 106 in Ib Cylinder Head Bolts M6 12 N m 1 2 kgf m 106 in Ib e Install the removed parts see appropriate chapters Cylinder Head Cleaning e Refer to the Cylinder Head Warp Inspection in the Peri odic Maintenance chapter 5 24 ENGINE TOP END Cylinder Head Cylinder Head Warp Inspection e Refer to the Cylinder Head Warp Inspection in the Peri odic Maintenance chapter Valves Valve Clearance Inspection e Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter Valve Clearance Adjustment e Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter Valve Removal e Remove the cylinder head see Cylinder Head Removal e Remove the valve lifter and shim NOTE OMark and record the locations of the valve lifters and shims so that they can be reinstalled in their original positions e Using the valve spring compressor assembly A and adapter B compress the valve spring and then remove the split keepers Special Tools Valve Spring Compressor Assembly 57001 241 Valve Spring Compressor Adapter 22 57001 1202 Valve Spring Compressor Adapter 24 57001 1586 e Remove Spring Retainer Valve Spring Valve Oil Seal Spring Seat ENGINE TOP END 5 25 SEI P 5 26 ENGINE TOP END Valves Valve Installation NOTICE Do not lap the valve to the valve seat using the grinding compound It will come
69. Mounting Bolt Runout 12 clicks counterclockwise 980 kPa 10 0 kgf cm 142 psi 19 987 20 000 mm 0 78689 0 78740 in 19 987 20 000 mm 0 78689 0 78740 in 15 950 16 000 mm 0 62795 0 62992 in TIR 0 1 mm 0 004 in or less Adjustable Range 19 6 clicks 19 85 mm 0 7815 in 19 85 mm 0 7815 in 15 92 mm 0 6268 in TIR 0 2 mm 0 008 in 13 8 SUSPENSION Special Tools Oil Seal amp Bearing Remover 57001 1058 ST571058ST C Hook Wrench R37 5 R42 57001 1101 ST5711018ST Bearing Driver Set 57001 1129 ST571129ST Jack 57001 1238 ST5712388ST Fork Oil Seal Driver 648 57001 1509 ST571509ST C Hook Wrench T 3 2 R37 57001 1539 Jack Attachment 57001 1608 T 4 ST571539ST ST571608ST C Front Fork Air Pressure The standard air pressure in the front fork legs is atmo spheric pressure Air pressure in the fork legs increase with normal use so the fork action stiffens during operation Re lease air pressure prior to each race through the air pres sure relief screw e Place the jack under the frame so that the front wheel is raised off the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Remove the screws A on the base valve assembly left front fork B and spring preload adjuster right front fork C
70. OAdjustment of the compression damping adjusters for the rear suspension will slightly affect the rebound damping force Always make any damping adjust ments in small steps and test their effects before using them in competition GMO5416BS1 1918171312 11 10 9 Sb TUE Oo N E gt OI gt be N GMO5493BS1 C Rear Shock Absorber Spring Preload Adjustment e Remove Seat see Seat Removal in the Frame chapter Side Covers see Side Cover Removal in the Frame chapter Muffler Body see Muffler Body Removal in the Engine Top End chapter Rear Frame see Rear Frame Removal in the Frame chapter e Place the jack under the frame so that the rear wheel is raised off the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Using the hook wrenches A loosen the locknut B Special Tools Hook Wrench R37 5 R42 57001 1101 Hook Wrench T 3 2 R37 57001 1539 e Using the hook wrench A turn the adjusting nut B as required Turning the adjusting nut downward marks the spring action harder and upward softer Special Tool Hook Wrench R37 5 R42 57001 1101 Spring Preload Adjustment Lower surface of the adjusting nut from the center of the upper mounting hole A Standard 127 2 mm 5 01 in Adjustable 125 8 139 5 mm 4 95 5 49 in Range e Tighten Torque Rear Shock Absorber Spring Locknut 45 N m 4 6 kgf m 33 ft lb e
71. OPull off the joint pin while pressing down the brake pedal e Remove Brake Pedal Bolt A Brake Pedal Return Spring B Brake Pedal C and Washer Brake Pedal Installation e Install the return spring A e Replace the O rings A with new ones e Apply grease to the O rings and shaft portion B of the brake pedal bolt e Apply a non permanent locking agent to the thread of the brake pedal bolt e Install the brake pedal C Olnstall the washer D inside the pedal e Tighten Torque Brake Pedal Bolt 25 N m 2 5 kgf m 18 ft lb BRAKES 12 9 Brake Lever Brake Pedal e Replace the cotter pin with a new one e Install the joint pin washer and new cotter pin e Bend the ends A of the cotter pin e Check the brake pedal position see Brake Lever and Pedal Adjustment in the Periodic Maintenance chapter GLO4023BS1 C 12 10 BRAKES Brake Fluid A 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 brake This lowers the brake fluid boiling point and could cause the brake to be ineffec tive 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
72. P Y BK t ressure Sensor Downstream Upstream Ll Injector Injector Vd ENS ee gt 4 Lal i 8 lt oz ow gt pegs EE aoe R W BL R R W BL BK ie i i TE Ex Water Intake Sensor Temperature Z Sensor N gt e 288 H g Frame Ground 1 2s o lgnition Coil Vehicle down BK S Fuel GG ensor Pump x fa Frame 4 Color Code Ground 2 Spark Plug BK Black BL Blue eR Brown Gear Position G Green Switch 0 Orange P Pink Red R w White 98052 0684B W2ROGB4BWS C 16 10 ELECTRICAL SYSTEM Precautions There are numbers of important precautions that are musts when servicing electrical systems Learn and ob serve all the rules below OThe electrical parts should never be struck sharply as with a hammer or allowed to fall on a hard surface Such a shock to the parts can damage them OTo prevent damage to electrical parts do not disconnect any electrical connections while the engine is running OTroubles may involve one or in some cases all items Never replace a defective part without determining what CAUSED the failure If the failure was caused by some other item or items they too must be repaired or replaced or the new replacement will soon fail again OMake sure all connectors in the circuit are clean and tight and examine leads for signs of burning fraying etc Poor leads and bad connections wi
73. Pedal Bolt Rear Master Cylinder Push Rod Cotter Pin Rear Master Cylinder Mounting Bolts Rear Caliper Holder Shaft Suspension Front Fork Clamp Bolts Rear Shock Absorber Mounting Nuts Swingarm Pivot Shaft Nut Uni Trak Link Nuts Steering Steering Stem Head Nut Handlebar Clamp Bolts Engine Throttle Cable Adjuster Locknut Engine Mounting Bolts Nuts Engine Bracket Bolts Nuts Shift Pedal Bolt Muffler Mounting Bolts Exhaust Pipe Holder Nuts Muffler Pipe Clamp Bolt Clutch Cable Adjuster Locknut Clutch Lever Pivot Bolt Locknut Kick Pedal Bolt Others Footpeg Cotter Pins Rear Frame Mounting Bolts Front Fender Bolts FUEL SYSTEM DFI 3 1 Fuel System DFI Table of Contents EXO EE EE 3 4 D SE EP T E 3 8 DEE deene 3 13 EE EE 3 15 Sp cial TOONS RE e ET EE 3 17 DFI Servicing PreCaUtlons EE 3 18 DFI Servicing PRECAUTIONS E 3 18 Troubleshooting the DFI System ss 3 19 CTI oie dc LR RS TS A RS RG ND on At mes 3 19 ee Ode E EE 3 22 DFI System Troubleshooting Guide gedeelt deeg 3 24 EE eege eege gegen E he ached aan 3 28 Self diagnosis le 3 28 Self diagnosis ee E 3 28 How to Read Service Codes s icccssseiseeeicivece ciceenctaccepentsdelscheessdenecuabecteentsnde sandr ENEE 3 31 How to Erase Service Codes EE 3 31 Service Code Table ieac a a a E Aaa EENS AREER 3 32 ele EE EE 3 33 Throttle Sensor Service Code 11 ccs czvssssazeieagetncesstic ncecbtaaeeesdgec mate isecotagecsendsseestiewebease 3 35 Throttle
74. Procedures e Loosen the front fork clamp bolts upper A on both sides e Remove the steering stem head nut B and washer C e Remove the steering stem head D e Turn the steering stem nut A with the steering stem nut wrench B to obtain the proper adjustment x If the steering is too tight loosen the stem nut a fraction of a turn if the steering is too loose tighten the nut a fraction of a turn Special Tool Steering Stem Nut Wrench 57001 1100 NOTE O Turn the nut 1 8 turn at a time maximum e Install the steering stem head and washer e Apply a non permanent locking agent to the front fork clamp bolts upper e Tighten Torque Steering Stem Head Nut 98 N m 10 0 kgf m 72 ft Ib Front Fork Clamp Bolts Upper 20 N m 2 0 kgf m 15 ft lb NOTE O Tighten the two clamp bolts alternately two times to en sure even tightening torque e Check the steering again If the steering is too tight or too loose repeat the adjust ment as mentioned above e Install the removed parts see appropriate chapters Steering Stem Bearing Lubrication e Remove the steering stem see Steering Stem Stem Bearing Removal in the Steering chapter e Using a high flash point solvent wash the upper and lower tapered rollers in the cages and wipe the upper and lower outer races which are press fitted into the frame head pipe clean off grease and dirt e Visually inspect the outer races and rollers Replace th
75. Removal may damage them e Remove the reed valve A from the left crankcase half OUnscrew the screws B and remove the guide C Crankcase Assembly NOTICE Right and left crankcase halves are machined at the factory in the assembled state so if replaced they must be replaced as a set e Remove the old gasket from the mating surfaces of the crankcase halves and clean them off with a high flash point solvent e Using compressed air blow out the oil passages in the crankcase halves A WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the engine parts in a well ventilated area and take care that there is no spark or flame anywhere near the working areas Do not use gasoline or low flash point solvents to clean parts 9 10 CRANKSHAFT TRANSMISSION Crankcase e Support the crankcase bearing boss with a suitable re tainer A e Install the new bearing B with a press and the bearing driver set C Special Tool Bearing Driver Set 57001 1129 Support the crankcase bearing boss when the bear ing is pressed or the crankcase could be damaged Left Crankcase e Press the new crankshaft bearing A until it bottoms out e Press the new shift drum needle bearing B so that the bearing surface is flush with the crankcase surface Special Tool Bearing Driver Set 57001 1129 e Press the new drive shaft bearing A so that t
76. Remove Cotter Pin A Washer B Pivot Pin C Spring D Footpeg E Footpeg Bracket Bolts F Footpeg Bracket G G014043BS2 Footpeg Installation e Replace the cotter pin with a new one e Apply a non permanent locking agent to the footpeg bracket bolts A e Install the footpeg bracket B and tighten the bolts Torque Footpeg Bracket Bolt Upper 54 N m 5 5 kgf m 40 ft lb e Apply grease to the pivot pin C e Install the footpeg D spring E and pivot pin Olnsert the pivot pin from upper side e Install the washer F and new cotter pin G GO14039BS2 e Bend the longer side A of the cotter pin 6014016BS1 C ELECTRICAL SYSTEM 16 1 Electrical System Table of Contents EXO KT 16 2 SSC INC e EE 16 4 Sp cial E ee RE EE 16 5 Wiring DI AGAIN EE 16 7 PYG AU PIONS cca eege Edge geheelt 16 10 Electrical WIEDERE EE 16 11 Wiring PSPS CMON RE 16 11 Flywheel Magneto EE 16 12 Magneto Cover e EE 16 12 Magneto Cover instalation et ee RE A ae 16 12 Flywheel Removal ainireti A Na een rte tente eg 16 12 EMAWheelINSANlAtIONE SE A M er nt ee does 16 13 Stator Coil Remova EE 16 14 Stator Coll EE 16 14 Flywheel INSpection EE 16 15 Charging Syste EE 16 17 Regulator Rectifier Removal suss his een dent cietaeemioveeiseaceazieeeeie 16 17 Regulator Rectifier Installations Mientinnnessarianeentiarndendeesenes 16 17 Regulator Rectifier Output Voltage Inspection 16 17 Reg
77. Remove Screw A Delivery Pipe B e Remove Screws A Plate B Throttle Body Assy Assembly e Replace the O ring A of delivery pipe B with a new one e Apply engine oil to the new O ring e Install the delivery pipe in the joint C and tighten the screw securely e Install the plate so that fit the hollow A on the plate and projection B on the throttle body assy e Tighten the screws securely e Install the removed parts see appropriate chapters FUEL SYSTEM DFI 3 85 3 86 FUEL SYSTEM DFI Air Cleaner Air Cleaner Housing Removal e Remove the rear frame see Rear Frame Removal in the Frame chapter e Remove the air cleaner housing bolts A e Take the air cleaner housing off the rear frame Air Cleaner Housing Installation e Assemble the air cleaner housing see Exploded View section e Install the air cleaner element see Air Cleaner Element Installation in the Periodic Maintenance chapter e Install the air cleaner housing to the rear frame Olnsert the rear frame A to the holes B of the guard e Tighten the bolts C securely e Install the rear frame see Rear Frame Installation in the Frame chapter Element Removal installation e Refer to the Air Cleaner Element Cleaning and Inspection in the Periodic Maintenance chapter Element Cleaning and Inspection e Refer to the Air Cleaner Element Cleaning and Inspection in the Periodic Maintenance chapter
78. Standard 150 V or more A WARNING Electrical equipment can cause serious electrical shock To avoid being shocked do not touch the metal portion of the probe when measuring voltage x lf the voltage is less than the specified value see the Troubleshooting on next page GP10718BS1 Ignition System IC Igniter Inspection OThe IC igniter is built in the ECU e Refer to the following items Ignition System Troubleshooting see Ignition System section ECU Power Supply Inspection see ECU Power Supply Inspection in the Fuel System DFI chapter ELECTRICAL SYSTEM 16 25 16 26 ELECTRICAL SYSTEM Ignition System Troubleshooting Faulty ignition Malfunctioned engine Wiring and connect portion of the ignition Repair system inspection No good Spark plug inspection Good No good Spark plug cap inspection Good Ignition coil primary peak voltage inspection No good Voltage is less than the specified value No good Voltage is none Voltage is specified or almost but faulty ignition Defective ignition coil Inspect Inspection 1 Adapter connection is Speed of cranking engine is incorrect or adapter is slow Increase force of kicking directive engine 2 Engine stop switch Lower resistance in the tester 3 Crankshaft sensor peak Use KAWASAKI Hand Tester voltage Lacking of sampling Sampling Replace the few times malfunctioned Crankshaft
79. Stop the engine and remove the gauge and oil pressure gauge adapter A WARNING Hot oil can cause severe burns Beware of hot en gine oil that will drain through the oil passage when the gauge adapter is removed e Replace the water pump cover bolt washer with a new one e Install the water pump cover bolt and new washer e Tighten Torque Water Pump Cover Bolt 9 8 N m 1 0 kgf m 87 in Ib ENGINE REMOVAL INSTALLATION 8 1 Engine Removal Installation Table of Contents el EI Ee EAP 8 2 SOCIAL TOOIS EE 8 4 le e Enn E ALOR EE E 8 5 Engine une EE 8 5 Engine Ed EE 8 7 8 2 ENGINE REMOVAL INSTALLATION Exploded View GHO2187BW5 C ENGINE REMOVAL INSTALLATION 8 3 Exploded View Torque No Fastener Nem kgf m itib Remarks 1 Upper Engine Mounting Bolts 49 5 0 36 S 2 Upper Engine Bracket Bolts 29 3 0 21 S 3 Middle Engine Bracket Nuts 29 3 0 21 R S 4 Middle Engine Mounting Nut 49 5 0 36 R S 5 Lower Engine Mounting Nut 49 5 0 36 R S 6 R S R Replacement Parts S Follow the specified tightening sequence 8 4 ENGINE REMOVAL INSTALLATION Special Tools Jack Jack Attachment 57001 1238 57001 1608 ST5712388ST C ST571608ST C ENGINE REMOVAL INSTALLATION 8 5 Engine Removal installation Engine Removal e Remove the engine guards e Place the jack under the frame to support the motorcycle Special Tools Jack 570
80. US oz 115 123 mm 4 53 4 84 in 320 2 5 mL 10 82 0 085 US oz EUR BR 300 2 5 mL 10 14 0 085 US oz 235 2 5 mL 7 95 0 085 US oz 660 mm 26 0 in Adjustable Range 20 4 clicks Adjustable Range 22 6 clicks Adjustable Range 40 6 clicks Adjustable Range 300 340 mL 10 14 11 50 US oz Adjustable Range 230 378 mL 7 78 12 78 US oz 647 mm 25 5 in Rear Suspension Uni Trak Rear Shock Absorber Rebound Damping Adjustment from the seated position adjuster turned fully clockwise Spring Preload Adjustment Lower surface of the adjusting nut from the center of the upper mounting hole Rear Shock Spring Free Length Rear Shock Oil Type Capacity Gas Reservoir High Speed Compression Damping Adjustment from the seated position adjuster turned fully clockwise 12 clicks counterclockwise 127 2 mm 5 01 in 265 mm 10 4 in SHOWA SS 25 or equivalent approx 380 mL 12 8 US oz 2 turns out Adjustable Range 22 5 clicks Adjustable Range 125 8 139 5 mm 4 95 5 49 in 260 mm 10 2 in Adjustable Range 4 1 2 turns out Specifications SUSPENSION 13 7 Hem Standard Service Limit Low Speed Compression Damping Adjustment from the seated position adjuster turned fully clockwise Gas Pressure Tie Rod Rocker Arm Sleeve Outside Diameter Tie Rod Rocker Arm Large Small Rocker Arm
81. WARNING Leaking fuel can cause a fire or explosion resulting in serious burns Make sure the hose joint is in stalled correctly on the delivery pipe by sliding the joint lf it comes off reinstall the hose joint e Connect the fuel pump lead connector e Hook the band to the fuel tank e Tighten the fuel tank bolt e After installing the fuel tank make sure that both throttle cables A outer move slightly by pulling them back and forth in the upper space of the right side of the fuel tank B Check that both throttle cables run under the frame right side C NOTE OCheck the fuel hose position If the fuel hose interferes with the cylinder head cover move the fuel hose up ward e Install the removed parts see appropriate chapters Olnsert the fuel tank breather hose into the steering stem hole NOTE OFor easily starting the engine connect the 12 V battery to the main harness see Self diagnosis Procedures OWhen the battery is connected the fuel pump is driven and the pressure of the fuel line increases Fuel Tank Cleaning e Refer to the Fuel Tank Cleaning in the Periodic Mainte nance chapter COOLING SYSTEM 4 1 Cooling System Table of Contents EXO CSO TE 4 2 EE e EE 4 4 POC AU e EE 4 5 Eoo e LA EE EE 4 6 Coolant EE WE DE 4 6 Coolant Deterioration Inspection SEENEN vaut 4 6 Coolant BAIN nes ne ne SM eee te 4 6 Coolant RAIN 2 dE RU eege 4 7 Air BIB CGN es eee a oa Ta
82. allow fuel to leak and create the potential for a fire explosion To prevent fire or explosion from a damaged joint lock do not pry or excessively widen the joint lock ends when removing the fuel hose The joint lock has a retaining edge that locks around the housing GSO5269BS1 C 2 16 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Pull the fuel hose joint A out of the delivery pipe A WARNING Fuel is flammable and explosive under certain con ditions and can cause severe burns Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is dis connected fuel spills out from the hose and the pipe Cover the hose connection with a clean shop towel to prevent fuel spillage e Clean the delivery pipe e Cover the delivery pipe with the vinyl bag to keep it clean Air Cleaner Side When removing with standard tip screwdriver e Insert the standard tip screwdriver A into the slit B on the joint lock C e Turn the driver to disconnect the joint lock When removing with fingers e Open and push up A the joint lock B with your fingers Prying or excessively widening the joint lock ends for fuel hose removal will permanently deform the joint lock resulting in a loose or incomplete lock that may allow fuel to leak and create the potential for a fire explosion To prevent fire or explosion from a damaged joint lock do
83. 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 2012 Kawasaki Heavy Industries Ltd 1st Edition 0 Mar 30 2012 LIST OF ABBREVIATIONS A ampere s KDS Kawasaki Diagnostic System ABDC after bottom dead center km h kilometers per hour AC alternating current L liter s Ah ampere hour lb pound s ATDC after top dead center LED Light Emitting Diode BBDC before bottom dead center m meter s BDC bottom dead center min minute s BTDC before top dead center mph miles per hour C degree s Celsius N newton s cmHg centimeters of mercury oz ounce s cu in cubic inch s Pa pascal s DC direct current PS horsepower DFI Digital Fuel Injection psi pound s per square inch ECU Electronic Control Unit qt quart s F farad s r revolution F degree s Fahrenheit rpm revolution s perminute ft foot feet S second s g gram s TDC top dead center gal gallon s TIR total indicator reading h hour s V volt s HP horsepower s W watt s in inch s Q ohm s COUNTRY AND AREA CODES AU Australia EUR Europe BR Brazil US United States CA Canada
84. cap C e Adjust the tire air pressure to the specified pressure see Air Pressure Inspection Adjustment in the Periodic Main tenance chapter WHEELS TIRES 10 13 6J05130BS1 C 10 14 WHEELS TIRES Hub Bearing Front Hub Bearing Removal e Remove Front Wheel see Front Wheel Removal Grease Seals A e Use the bearing remover to remove the hub bearings A NOTICE Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place wooden blocks under the wheel so that the disc does not touch the ground Special Tools Bearing Remover Head 420 x 22 B 57001 1293 Bearing Remover Shaft 613 C 57001 1377 e Remove the collar D Rear Hub Bearing Removal e Remove Rear Wheel see Rear Wheel Removal Grease Seals A Circlip B Special Tool Inside Circlip Pliers 57001 143 e Use the bearing remover to remove the right hub bearing A NOTICE Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place wooden blocks under the wheel so that the disc does not touch the ground Special Tools Bearing Remover Head 425 x 28 B 57001 1346 Bearing Remover Shaft 13 C 57001 1377 e Remove the collar D GJ06074BS1 GJ06104BS1 GJ06076BS1 C GJ06106BS1 C WHEELS TIRES 10 15 Hub Bearing e Using a suitable bar A tap the around of
85. connector and connect the measuring adapter A between these connectors Main Harness B Upstream Injector C Special Tool Measuring Adapter 57001 1700 e Connect a digital meter D to the measuring adapter lead Upstream Injector Power Supply Voltage Connections the Adapter Digital Meter R Upstream Injector R W lead Digital Meter Battery Terminal 6C17046FS1 C e Refer to the Self diagnosis Procedures connect the 12 V battery to the main harness e Measure the power supply voltage with the engine stopped Power Supply Voltage Standard Battery Voltage lf the voltage is out of the standard check the power sup ply wiring see Upstream Injector Circuit x If the reading is within the standard check the output volt age see Upstream Injector Output Voltage Inspection 3 68 FUEL SYSTEM DFI Upstream Injector Service Code 42 Upstream Injector Output Voltage Inspection NOTE OBe sure the battery is fully charged e Remove the ECU see ECU Removal ODo not disconnect the ECU connector e Refer to the Self diagnosis Procedures connect the 12 V battery to the main harness e Using the needle adapter set and connect a digital meter A to the ECU connector B Special Tool Needle Adapter Set 57001 1457 Upstream Injector Output Voltage Connections to ECU Connector Digital Meter BL BK lead ECU terminal 8 Digital Meter Battery T
86. damage e Check the condition of the top and bottom sealing seats A in the filler neck They must be smooth and clean for the radiator cap to function properly Water Hoses and Overflow Hose Inspection e Refer to the Water Hoses and Connections Inspection in the Periodic Maintenance chapter Water Hoses and Overflow Hose Installation e Install the water hoses or overflow hose being careful to follow the performed bends see Cable Wire and Hose Routing section in the Appendix chapter Avoid sharp bending kinking flattening or twisting e Tighten the hose clamps securely Torque Water Hose Clamp Screws 3 0 N m 0 31 kgf m 27 in Ib GDO7O00BS1 GDO7001BS1 ENGINE TOP END 5 1 Engine Top End Table of Contents Exploded View cicc aac ticiietnnes Specifications EE Special Tools and Sealant Cylinder Head Cover Cylinder Head Cover Removal Cylinder Head Cover Installation Camshaft Chain Tensioner Camshaft Chain Tensioner REMOVA 4828488 Camshaft Chain Tensioner Installation Ru EE Camshaft Removal 006 Camshaft Installation 000nna Camshaft Chain Removal Camshaft Chain Installation Camshaft and Camshaft Cap Wear Inspection eee Camshaft Runout Inspection Cam Wear Inspection onnnenn Cylinder Head Cylinder Compression Measurement
87. e Remove Bolts A and Nuts Chain Guide Plate B Chain Guide C Screws D and Brake Hose Clamps E e Put the caliper A on suitable stand B so that it does not dangle e Remove the rocker arm pivot nut and bolt A e Remove the swingarm pivot shaft nut B e Pull out the swingarm pivot shaft C and remove the swingarm D When pulling out the mounting bolts lift the swingarm slightly Forcing or tapping on a bolt could damage the bolt sleeve and bearing e Remove the screws A e Remove the chain slipper B from the swingarm SUSPENSION 13 23 13 24 SUSPENSION Swingarm Swingarm Installation e Apply plenty of grease to the inside of the needle bear ings sleeves and grease seals e Apply a non permanent locking agent to the chain slipper screws e Install the chain slipper and tighten the screws e Replace with new ones Swingarm Pivot Shaft Nut Rocker Arm Pivot Nut e Apply 2 stroke oil to the threads of the rocker arm pivot bolt e Install the swingarm e Tighten Torque Swingarm Pivot Shaft Nut 98 N m 10 0 kgf m 72 ft Ib Rocker Arm Pivot Nut 59 N m 6 0 kgf m 44 ft lb e Install the removed parts see appropriate chapters Swingarm Bearing Removal e Remove Swingarm see Swingarm Removal Collars A Grease Seals B Sleeves C Needle Bearings D e Remove the needle bearings E using the oil seal amp bear ing remover Special Tool Oil Seal amp Bearing Re
88. e Tighten Special Tool Filler Cap Driver 57001 1454 Torque Timing Inspection Cap 3 5 N m 0 36 kgf m 31 in Ib Flywheel Nut Cap 3 5 N m 0 36 kgf m 31 in Ib Camshafts Camshaft Chain Removal e Remove Camshafts see Camshaft Removal Flywheel see Flywheel Removal in the Electrical Sys tem chapter Lower Camshaft Chain Guide Bolt A Lower Camshaft Chain Guide B e Disengage the camshaft chain C from the crankshaft Camshaft Chain Installation e Engage the camshaft chain to the crankshaft e Install the lower camshaft chain guide e Tighten Torque Lower Camshaft Chain Guide Bolt 9 8 N m 1 0 kgf m 87 in Ib e Install Flywheel see Flywheel Installation in the Electrical Sys tem chapter Camshafts see Camshaft Installation Camshaft and Camshaft Cap Wear Inspection e Measure each clearance between the camshaft journal and camshaft cap using plastigage press gauge A OTighten the camshaft cap bolts after applying molybde num disulfide oil to the seat and thread of them Torque Camshaft Cap Bolts 9 8 N m 1 0 kgf m 87 in Ib NOTE ODo not turn the camshaft when the plastigage is be tween the journal and camshaft cap Camshaft Journal Camshaft Cap Clearance Standard 0 020 0 062 mm 0 0008 0 0024 in Service Limit 0 15 mm 0 0059 in lf any clearance exceeds the service limit measure the diameter of each camshaft journal with a micrometer Camshaft Journal Diameter S
89. in Rear 3 85 4 15 mm 0 152 0 163 in pee Service Limit Front 2 5 mm 0 10 in Rear 3 5 mm 0 14 in x Replace the disc if it has worn past the service limit e Place a jack under the motorcycle so that the front rear wheel is raised off the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Set up a dial gauge against the disc A OFor the front disc turn the handlebars fully to one side e Measure the disc runout while rotating B the wheel slowly G6LO7073BS1 C Disc Runout Standard TIR 0 25 mm 0 010 in or less Service Limit TIR 0 3 mm 0 01 in lf the runout exceeds the service limit replace the disc 12 24 BRAKES Brake Hose Brake Hose Removal installation e Refer to the Brake Hose Replacement in the Periodic Maintenance chapter Brake Hose Inspection e Refer to the Brake Hoses and Connections Inspection in the Periodic Maintenance chapter SUSPENSION 13 1 Suspension Table of Contents Exploded NIEWEN eege Ee 13 2 DSC ISAT E 13 6 RSC e e EEN 13 8 Prnt EOK Senet Spctatg a ogc elena as ees peas ante Me ca eS 13 9 PAI POS E 13 9 Compression Damping Adjustment Left Fork only 13 9 Rebound Damping Adjustment Left Fork only 13 10 Spring Preload Adjustment Right Fork only 13 10 OOM ANOS EE 13 11 Front Fork ne EE 13 11 Front Eork ae EE 13 12 Front Fork Disassembly ainena ko en EBEN 13 12 Front For Assembly SA Sentinelles ete ent tite
90. in left and right pad wear OThe seal is stuck to the piston x If the fluid seal s is replaced replace the dust seal s B as well Also replace all seals every other time the pads are changed Front Caliper C Rear Caliper D Dust Seal Damage Inspection e Check that the dust seals are not cracked worn swollen or otherwise damaged xklf they show any damage replace them Caliper Dust Boot and Friction Boot Damage Inspection e Check that the dust boot A and friction boot B are not cracked worn swollen or otherwise damaged lf they show any damage replace it Front Caliper C Rear Caliper D BRAKES 12 15 12 16 BRAKES Caliper Caliper Piston and Cylinder Damage Inspection e Visually inspect the piston s A and cylinder surfaces Replace the caliper if the cylinder and piston are badly scores or rusty Front Caliper B Rear Caliper C 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 e Check to see that the caliper holder shafts are not badly worn or stepped and that the friction boots are not dam aged If the friction boot is damaged replace the friction boot To replace the friction boot remove the pads and caliper bracket xl
91. lb Gear Position Switch Screws 0 30 26 in lb L Cooling System Water Hose Clamp Screws 27 in lb Water Pipe Bolt i 87 in lb Water Pump Cover Bolts L 55 mm t 87 in lb L Water Pump Impeller Bolt 62 in lb Water Pump Cover Bolts L 30 65 mm E 87 in lb Coolant Drain Bolt 62 in lb Engine Top End Cylinder Head Cover Bolts 9 8 1 0 87 in lb Camshaft Cap Bolts 9 8 1 0 87 in lb MO S Plug 20 2 0 15 L Cylinder Head Bolts M10 44 4 5 32 MO R S Auto Decompressor Bolt 12 1 2 106 in lb Cylinder Head Bolts M6 12 1 2 106 in lb S Cylinder Bolt 12 1 2 106 in lb S Throttle Body Assy Clamp Screw 2 0 0 20 18 in lb Throttle Body Assy Holder Clamp Screw 2 0 0 20 18 in lb Lower Camshaft Chain Guide Bolt 9 8 1 0 87 in lb Rear Camshaft Chain Guide Bolt 15 1 5 11 2 6 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Torque Remarks Nm wn mb Camshaft Chain Tensioner Cap Bolt 20 2 0 15 Camshaft Chain Tensioner Mounting Bolts 9 8 Clutch Right Engine Cover Bolts 9 8 Clutch Cover Bolts 9 8 Oil Filler Plug 3 5 Clutch Hub Nut 98 Clutch Spring Bolts 9 0 Engine Lubrication System Oil Filter Cap Bolts 9 8 Piston Oil Nozzle 2 9 Breather Fitting 15 Oil Pump Idle Gear Shaft Screws 5 9 Oil Pump Mounting Bolts 7 0 Engine Oil Drain Bolt 20 Engine Removal Installation Upper Engine Mounting Bolts 49 Upper Engine Bracket Bolts 29 Middle Engine Bracket Nuts 29 Middle Engine Mounting Nut 49 Lower
92. lead over the capacitor lead 4 Run the regulator rectifier lead as shown 5 Run the regulator rectifier lead on the top position in the clamp 6 Run the ignition coil primary lead outside of the clamp 17 6 APPENDIX Cable Wire and Hose Routing 6809260 G APPENDIX 17 7 Cable Wire and Hose Routing NOOR D O Breather Hose Downstream Lead Throttle Sensor Lead Install the upstream injector connector boot so that notch side faces inside Run the downstream lead and throttle sensor lead over the throttle body assy rear side Fuel Hose Check the fuel hose position If the fuel hose interferes with the cylinder head cover move the fuel hose upward Run the fuel pump lead over the fuel hose Run the throttle sensor lead to the front side of the throttle body assy Clamp Hold the main harness Turn the lock position to backward 17 8 APPENDIX Cable Wire and Hose Routing wW L WS W 2 e SR SL i AC i K Q SS 1 Clamp Twist the clamp on the magneto lead and gear position switch lead at the gray taped position 2 Clamp Twist the clamp on the magneto lead and gear position switch lead 3 Run the gear position switch lead inside of the gasket 4 Do not pinch the gear position switch lead 5 Insert the gear position switch lead into the groove of the crankca
93. m 87 in Ib OTighten the screw first e Install the collar E e Apply grease to the oil seal lips A and shift shaft splines B GHI P e Install the washer A on the shift shaft B e Insert the shift shaft OTake care not to damage the oil seal when inserting the shift shaft e Install the removed parts See appropriate chapters External Shift Mechanism Inspection e Remove the shift shaft see External Shift Mechanism Re moval e Check the shift shaft A for bending or damage to the splines lf the shaft is bent straighten or replace it If the splines are damaged replace the shift shaft e Check the return spring B for cracks or distortion If the spring is damaged in any way replace it e Check the shift lever C for distortion lf the shift lever is damaged in any way replace the shift shaft CRANKSHAFT TRANSMISSION 9 27 External Shift Mechanism e Check the shift ratchet assembly for any damage xlf the ratchet A pawls B pins C or springs D are damaged in any way replace them 6116024BS1 C e Visually inspect the shift drum cam A If it is badly worn or if it shows any damage replace it 6116061BS1 C e Check the gear positioning lever A and its spring B for breaks or distortion x If the lever or spring is damaged in any way replace them 6116060BS1 C 9 28 CRANKSHAFT TRANSMISSION Kickstarter Kick Pedal Removal e Remo
94. not pry or excessively widen the joint lock ends when removing the fuel hose The joint lock has a retaining edge that locks around the housing GS05269BS1 C e Pull the fuel hose joint A out of the delivery pipe WARNING Fuel is flammable and explosive under certain con ditions and can cause severe burns Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is dis connected fuel spills out from the hose and the pipe Cover the hose connection with a clean shop towel to prevent fuel spillage e Clean the delivery pipe e Cover the delivery pipe with the vinyl bag to keep it clean PERIODIC MAINTENANCE 2 17 Periodic Maintenance Procedures e Remove the vinyl bag on each delivery pipe e Check that there are no flaws burrs and adhesion of foreign materials on each delivery pipe A A e Replace the fuel hose with a new one te e Run the fuel hose correctly see Cable Wire and Hose Routing section in the Appendix chapter GSO5265BS1 C e Apply engine oil to the fuel outlet pipe A lightly 6S05265BS1 C e Insert A the fuel hose joint B straight onto the delivery pipe until the hose joint clicks e Push C the joint lock D Throttle Body Assy Side E Air Cleaner Side F 2 18 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Push and pull A the fuel hose joint back and forth mor
95. not to tear the sponge filter e Assemble the element e Remove the towel from the air cleaner duct GS05025BS1 GS05026BS1 C PERIODIC MAINTENANCE 2 21 Periodic Maintenance Procedures e Apply grease to all connections and screw holes in the air cleaner housing and intake tract e Install the element onto its frame and coat the element lip and lip seat with a thick layer of all purpose grease to assure a complete seal 6S05027BS1 e Install the air cleaner element so that its tab A faces upward and its projections B align with the holes C of the air cleaner housing e Tighten the wing bolt securely e Install the seat see Seat Installation in the Frame chap ter Fuel Tank Cleaning A WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the tank in a well ventilated area and take care that there are no sparks or flame any where near the working area Do not use gasoline or low flash point solvents to clean the tank e Remove the fuel tank and drain the fuel see Fuel Tank Removal in the Fuel System DFI chapter e Remove the fuel pump see Fuel Pump Removal in the Fuel System DFI chapter e Pour some high flash point solvent into the fuel tank and shake the tank to remove dirt and fuel deposits e Drain the solvent out of the tank e Dry the tank with compressed air e Install
96. of Sensor Output Voltage V TO Throttle Full Open UR Usable Range of Sensor Output Voltage V Vv Intake Air Pressure Sensor Output Voltage V Digital Meter Reading 3 46 FUEL SYSTEM DFI Intake Air Pressure Sensor Service Code 12 Intake Air Pressure Sensor Circuit 2 le R Y 6c17312F 2 C 1 ECU 2 Intake Air Pressure Sensor FUEL SYSTEM DFI 3 47 Intake Air Temperature Sensor Service Code 13 Intake Air Temperature Sensor Removal Instal lation NOTICE Never drop the intake air temperature sensor espe cially on a hard surface Such a shock to the sensor can damage it e Remove the rear frame with air cleaner housing see Rear Frame Removal in the Frame chapter e Remove the bolts A e Pull out the intake air temperature sensor B e Put the intake air temperature sensor A into the air cleaner housing OFace the locks B to left side e Tighten the bolts C securely e Install the removed parts see appropriate chapters Intake Air Temperature Sensor Output Voltage Inspection NOTE OBe sure the battery is fully charged e Disconnect the intake air temperature sensor connector and connect the measuring adapter A between these connectors Main Harness B Intake Air Temperature Sensor C Special Tool Measuring Adapter 57001 1700 e Connect a digital meter D to the measuring adapter leads Intake Air Temperature Sensor Output Volta
97. oil leak e Replace the cylinder head cover gasket with a new one e Install the new cylinder head cover gasket B on the cylin der head cover C e Install the cylinder head cover ENGINE TOP END 5 13 Cylinder Head Cover e Install the cylinder head cover bolt washers with the metal side A upwards e Tighten Torque Cylinder Head Cover Bolts B 9 8 N m 1 0 kgf m 87 in Ib e Install the removed parts see appropriate chapters 5 14 ENGINE TOP END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal This is a non return type camshaft chain tensioner The push rod does not return to its original position once it moves out to take up camshaft chain slack Observe all the rules listed below When removing the tensioner do not take out the mounting bolts only halfway Retightening the mounting bolts from this position could damage the tensioner and the camshaft chain Once the bolts are loosened the tensioner must be removed and reset as described in Camshaft Chain Ten sioner Installation Do not turn over the crankshaft while the tensioner is removed This could upset the camshaft chain timing and damage the valves e Remove Cap Bolt A Washer B Spring Rod e Remove the mounting bolts C and take off the camshaft chain tensioner body D Camshaft Chain Tensioner Installation e Replace the O ring A with a new one e Apply grease to the O ring e Release
98. output shaft e Replace the circlip with a new one e Install the new circlip on the groove of the output shaft Special Tool Outside Circlip Pliers 57001 144 e Run the gear position switch lead properly see Cable Wire and Hose Routing section in the Appendix chapter e Install the drive chain guide and engine sprocket cover and then tighten the bolts ODo not pinch the gear position switch lead Rear Sprocket Removal e Remove the rear wheel see Rear Wheel Removal in the Wheels Tires chapter 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 FINAL DRIVE 11 9 Sprockets e Remove Rear Sprocket Bolts A and Nuts Washers Rear Sprocket B Rear Sprocket Installation e Replace the rear sprocket nuts with new ones e Install the rear sprocket A so that the marked side B faces out e Install the rear sprocket bolts and washers e Tighten Torque Rear Sprocket Nuts 34 N m 3 5 kgf m 25 ft Ib Sprocket Wear Inspection e Refer to the Sprocket Wear Inspection in the Periodic Maintenance chapter Rear Sprocket Warp Runout Inspection e Refer to the Rear Sprocket Warp Runout Inspection in the Periodic Maintenance chapter BRAKES 12 1 Brakes Table of Contents ee WEE 12 2 e 12 6 Sp cial e EN 12 7 Drake Lever Brake ig el geen eege ed eegene ge g
99. poor quality or incorrect Spark plug incorrect heat valve ECU trouble Other Throttle valve won t fully open Brake dragging Air cleaner clogged Water or foreign matter in fuel Clutch slipping Overheating Engine oil level too high Engine oil viscosity too high Drive train trouble Crankshaft bearing worn or damage Engine Overheating Firing incorrect Spark plug dirty broken or maladjusted Spark plug incorrect ECU trouble Fuel air mixture incorrect Throttle body assy holder loose Air cleaner duct loose Air cleaner poorly sealed or missing Air cleaner clogged Compression high Carbon built up in combustion chamber Engine load faulty Clutch slipping Engine oil level too high Engine oil viscosity too high Brake dragging Drive train trouble Lubrication inadequate Engine oil level too low Engine oil poor quality or incorrect Coolant incorrect Coolant level too low Coolant deteriorated Cooling system component incorrect Radiator clogged Radiator cap trouble Water pump not rotating Clutch Operation Faulty Clutch slipping No clutch lever play Clutch cable maladjusted Clutch inner cable sticking Friction plate worn or warped Steel plate worn or warped Clutch spring broken or weak Clutch release function trouble Clutch hub or housing unevenly worn Clutch not disengaging properly Clutch lever play excessive Clutch spring compression uneven Engine oil deteriorated Engine oil viscosity too high Eng
100. reading is out of the specification check the follow ing Power Supply Wiring see ECU Power Supply Circuit xlf the wiring is good replace the ECU see ECU Re moval Installation ECU Power Supply Circuit R W BK Y BK Y BK W 4 BK W 0 0 Y P NM 2 GC17322FH2 C 1 ECU 2 Capacitor 3 Frame Ground 1 Fuel Line Fuel Pressure Inspection NOTE OBe sure the battery is fully charged e Remove Fuel Tank see Fuel Tank Removal Fuel Hose see Fuel Hose Replacement in the Periodic Maintenance chapter OBe sure to place a piece of cloth around the fuel outlet pipe of the fuel pump and the delivery pipe of the throttle body assy A WARNING Fuel is flammable and explosive under certain con ditions and can cause severe burns Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is dis connected fuel spills out from the hose and the pipe because of residual pressure Cover the hose connection with a piece of clean cloth to prevent fuel spillage e Install the fuel pressure gauge adapter A and fuel hoses Special Tool 57001 1607 B between the fuel pump and throttle body assy e Secure the fuel hoses with the clamps e Connect the pressure gauge C to the fuel pressure gauge adapter Special Tools Oil Pressure Gauge 5 kgf cm 57001 125 Fuel Pressure Gauge Adapter 57001 1593 Fuel Hose 57001 1607
101. 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 6B02046BS1 Circlips Cotter Pins Replace circlips or cotter pins that were removed with new SF ones Take care not to open the clip excessively when in stalling to prevent deformation GB02026B S Lubrication It is important to lubricate rotating or sliding parts during oon SH assembly to minimize wear during initial operation Lubri i M7 o Kc cation points are called out throughout this manual apply fay a Jh the specific oil or grease as specified a 7 Vi c02021B S 1 6 GENERAL INFORMATION Before Servicing Direction of Engine Rotation When rotating the crankshaft by hand the free play amount of rotating direction will affect the adjustment Ro tate the crankshaft to positive direction clockwise viewed from output side Electrical Leads A two color lead is identified first by the primary color and then the stripe color Unless instructed otherwise electrical leads 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
102. reservoir runs out any time during the changing operation the brakes will need to be bled since air will have entered the brake line GS13257B82 C PERIODIC MAINTENANCE 2 43 Periodic Maintenance Procedures e Remove the clear plastic hose e Install the diaphragm and reservoir cap e Tighten Torque Front Brake Reservoir Cap Screws 1 5 N m 0 15 kgf m 13 in Ib e Tighten the bleed valve and install the rubber cap Torque Caliper Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib e After changing the fluid check the brake for good braking power no brake drag and no fluid leakage lf necessary bleed the air from the lines see Brake Line Bleeding in the Brakes chapter Brake Pad Wear Inspection e Check the lining thickness and condition of the brake pads in each caliper NOTE Olt is able to check with the pads installed lf either pad is damaged replace both pads in the caliper as a Set 7 q j l Brake Pad Lining Thickness Standard Front 4 0 mm 0 16 in Rear 6 4 mm 0 25 in Service Limit Front 1 mm 0 04 in Rear 1 mm 0 04 in xlf the lining thickness A of either pad is less than the service limit B replace both pads in the caliper as a set Front Pad C Rear Pad D 6S13255BS2 Brake Master Cylinder Rubber Parts Replacement Front Master Cylinder Disassembly e Remove the front master cylinder see Front Master Cylin der Removal in the Brakes chapter e Re
103. shock body e Slide up the stopper of the piston rod then lightly tap around the seal with a suitable rod and mallet and push the seal assembly A 10 mm 0 39 in down e Remove the circlip A e Wrap a heavy cloth around the rear shock body and piston rod to prevent the oil diffusion e Lightly move the piston rod B back and forth and pull out the piston rod assembly e Drain the remains oil 2 72 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Visually inspect the piston A O ring B and oil seal as sembly C xlf the piston O ring and oil seal assembly are badly scored rusty or damaged replace them Piston Rod Assembly Disassembly Assembly If necessary disassembly and assembly the piston rod assembly as follows e Using the grinder shave off the stake portions A of the piston rod e Hold the lower of the piston rod assembly in a vise with soft jaws or heavy cloth e Remove the locknut A and discard it NOTICE Do not tighten the rebound damping adjuster of the piston rod e Remove the piston rod assembly from the vise e Remove the piston assembly A OBe careful not to disassemble it OStick a suitable rod into the piston assembly and leave it until being reinstalled e Inspect the slide bushing A If the bushing is damaged replace it OCut the slide bushing e Replace the O rings B with new ones e Install the O rings and a new bushing on the piston
104. short Intake air pressure sensor malfunction wiring 1e T UUL open or short Intake air temperature sensor malfunction wiring 13 J LIUUL open or short Water temperature sensor malfunction wiring JUN open or short 2 IL H Crankshaft sensor malfunction wiring open or short 25 nonn Gear position switch malfunction wiring open or short 31 ime aaa Vehicle down sensor malfunction wiring open or short 41 NANM Downstream injector malfunction wiring open or short 42 N Upstream injector malfunction wiring open or short 46 Fuel pump malfunction wiring open or short 51 Ignition coil malfunction wiring open or short Notes OThe ECU may be involved in these problems If all the parts and circuits checked out good be sure to check the ECU for ground and power supply If the ground and power supply are checked good replace the ECU OWhen no service code is displayed the electrical parts of the DFI system has no fault and the mechanical parts of the DFI system and the engine are suspect Self Diagnosis Backups FUEL SYSTEM DFI 3 33 OThe ECU takes the following measures to prevent engine damage when the DFI or the ignition system parts have troubles Service Output Signal Usable Codes Fans Range or Criteria Backups by EGU If the throttle sensor system fails the signal is out of the usable range wiring short or open the ECU locks ignition timing into the ignition Throttle Sensor Output tim
105. the bearing inner race evenly to remove the bearings B G6J06078BS1 C Hub Bearing Installation e Before installing the hub bearings blow any dirt or foreign particles out of the hub with compressed air to prevent contamination of the bearings e Replace the bearings with new ones NOTE Olnstall the bearings so that the marked side or sealed side faces out e Install the front hub bearings in the following sequence OPress in the left side bearing A until it is bottomed Special Tool Bearing Driver Set 57001 1129 Olnsert the collar B in the front hub C OPress in the right side bearing D until it is bottomed Special Tool Bearing Driver Set 57001 1129 e Install the rear hub bearings in the following sequence OPress in the right side bearing until it is bottomed Special Tool Bearing Driver Set 57001 1129 Olnsert the collar in the rear hub OPress in the left side bearings until it is bottomed Special Tool Bearing Driver Set 57001 1129 OReplace the circlip with a new one and install a new circlip Special Tool Inside Circlip Pliers 57001 143 G6J06079BS1 C e Replace the grease seal A with a new one e Press in the grease seal so that the seal surface is flush B with the end of the hole e Apply high temperature grease to the grease seal lip Special Tool Bearing Driver Set C 57001 1129 GJ06080BS1 C 10 16 WHEELS TIRES Hub Bearing Hub
106. the engine and check for fuel leakage Fuel Flow Rate Inspection A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Always stop the engine and do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light NOTE OBe sure the battery is fully charged e Wait until the engine cools down e Prepare a fuel hose Special Tool 57001 1607 and a measuring cylinder Special Tool Fuel Hose 57001 1607 e Remove the radiator shrouds see Radiator Shroud Re moval in the Frame chapter e Remove the fuel tank bolt and band see Fuel Tank Re moval FUEL SYSTEM DFI 3 81 Fuel Line e Open the fuel tank cap A to lower the pressure in the tank e Remove the fuel hose from the fuel pump see Fuel Tank Removal OBe sure to place a piece of cloth around the fuel outlet pipe of the fuel pump A WARNING Fuel is flammable and explosive under certain con ditions and can cause severe burns Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is dis connected fuel spills out from the hose and the pipe because of residual pressure Cover the hose connection with a piece of clean cloth to prevent fuel spillage e Connect the prepared fuel hose A to the fuel outlet pipe e Secure the fuel hose with a clamp e Insert the fuel hose int
107. the stopper B and push the push rod C into the tensioner body D fully e Install the tensioner body so that the stopper faces up ward OTurn the stopper to right side of the motorcycle e Tighten Torque Camshaft Chain Tensioner Mounting Bolts A 9 8 N m 1 0 kgf m 87 in Ib e Install the spring B and rod C e Tighten the cap bolt D together with the washer E Torque Camshaft Chain Tensioner Cap Bolt 20 N m 2 0 kgf m 15 ft lb ENGINE TOP END 5 15 Camshafts Camshaft Removal e Remove Cylinder Head Cover see Cylinder Head Cover Re moval Timing Inspection Cap A Flywheel Nut Cap B Special Tool Filler Cap Driver 57001 1454 e Bring the piston to the TDC of the compression stroke OPlace a wrench over the flywheel nut A and turn it coun terclockwise to align the TDC mark B with the center of the groove C of the inspection hole e Remove Camshaft Chain Tensioner see Camshaft Chain Ten sioner Removal Camshaft Cap Bolts 1 8 sequence numbers Camshaft Cap A e Remove Positioning Rings A e Disengage the camshafts B from camshaft chain C e Staff a clean cloth into the camshaft chain tunnel to keep any parts from dropping into the crankcase NOTICE Always strain the camshaft chain while turning the crankshaft when the camshafts removed This avoids kinking the chain on the lower crank shaft sprocket A kinked chain could damage both th
108. their positions are as shown OThe other side is also the same procedures Front E Right Side F Left Side G Rear Shock Absorber H Tie Rod I Rocker Arm J Deep Groove K Groove L ON oO 9 G V 4 25mm GMO7106BW2 C Tie Rod Rocker Arm Needle Bearing Inspection Do not remove the bearings for inspection Re moval may damage them e Inspect the needle bearings installed in the tie rod and rocker arm OThe needle bearing normally wear very little and wear is difficult to measure Instead of measuring visually in spect the bearings for abrasion discoloration or other damage If there is any doubt as to the condition of either needle bearing replace the bearing and sleeve as a set SUSPENSION 13 29 13 30 SUSPENSION Uni Trak Maintenance Uni Trak Linkage Inspection e Refer to the Swingarm and Uni Trak Linkage Inspection in the Periodic Maintenance chapter Tie Rod and Rocker Arm Sleeve Wear Inspection e Pull out the sleeves A of the tie rod and rocker arm e Measure the outside diameter of the sleeve Sleeve Outside Diameter Standard Tie Rod 19 987 20 000 mm 0 78689 0 78740 in Rocker Arm Large 19 987 20 000 mm 0 78689 0 78740 in Small 15 950 16 000 mm 0 62795 0 62992 in Service Limit Tie Rod 19 85 mm 0 7815 in Rocker Arm Large 19 85 mm 0 7815 in Small 15 92 mm 0 6268 in lf the sleeve is worn pas
109. to improper adjustments 020778 S GBO2062BS1 GENERAL INFORMATION 1 7 Model Identification KX250ZD Left Side View KX250ZD Right Side View Frame Number Engine Number 1 8 GENERAL INFORMATION General Specifications Items Dimensions Overall Length Overall Width Overall Height Wheelbase Road Clearance Seat Height Curb Mass Front Rear Fuel Tank Capacity KX250ZD 2 170 mm 85 43 in 820 mm 32 3 in 1 270 mm 50 00 in 1 475 mm 58 07 in 330 mm 13 0 in 945 mm 37 2 in 106 2 kg 234 2 Ib US CA 106 0 kg 233 7 Ib 51 7 kg 114 0 Ib 54 5 kg 120 2 lb US CA 54 3 kg 119 7 Ib 6 1 L 1 6 US gal Engine Type Cooling System Bore and Stroke Displacement Compression Ratio Fuel System Starting System Ignition System Timing Advance Ignition Timing Spark Plug Standard Terminal Option Terminal Valve Timing Intake Open Close Duration Exhaust Open Close Duration Lubrication System Engine Oil Type Viscosity Capacity 4 stroke single cylinder DOHC 4 valve Liquid cooled 77 0 x 53 6 mm 3 03 x 2 11 in 249 cm 15 2 cu in 13 8 1 FI Fuel Injection KEIHIN 443 Primary kick Digital DC CDI Electronically advanced BTDC 4 at 2 000 r min rpm NGK CPR8EB 9 Solid post NGK CPR9EB 9 Solid post BTDC 36 ABDC 76 292 BBDC 69 ATDC 49 298 Forced lubrication s
110. to let the air pressure equalize NOTE ODo not use the sidestand when adjusting the air pres sure OAdjust the air pressure when the front forks are cold e Replace the O rings with new ones e Tighten Torque Air Pressure Relief Screws 1 3 N m 0 13 kgf m 12 in Ib Compression Damping Adjustment Left Fork only e Place the jack under the frame so that the front wheel is raised off the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Turn the adjuster A on the left front fork base valve as sembly B with a standard tip screwdriver until you feel a click Adjust the compression damping to suit your pref erence under special condition NOTICE Do not force the compression damping adjuster beyond the fully seated position or the adjusting mechanism may be damaged SUSPENSION 13 9 13 10 SUSPENSION Front Fork Seated position A adjuster turned fully clockwise Compression Damping Adjuster Setting Standard 8 clicks B EUR BR 10 clicks counterclockwise Softer Counterclockwise C Harder Clockwise D Although you can turn the adjuster beyond the ad justable range effecting no changes to damping force use it within the adjustable range Rebound Damping Adjustment Left Fork only e Place the jack under the frame so that the front wheel is raised off the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Turn the adjuster A on the lef
111. use a new circlip whenever the shock is reassembled e Mount the circlip in the groove in the gas reservoir 2 76 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Pull up the gas reservoir cap A against the circlip 2 6 mm 0 1 in B A WARNING Pressurized nitrogen gas can explode out of the shock reservoir cap if the circlip is not properly in stalled allowing oil and internal parts to burst out of the reservoir with great force and cause serious in jury To avoid injury be sure to install a new circlip in the proper position If the end of the gas reservoir cap and the end of the gas reservoir are not aligned the circlip is not correctly fitted in the groove in the gas reservoir or the circlip is deformed and should be replaced with a new one e Hold the upper portion of the rear shock absorber in a vise with soft jaws or heavy cloth e Apply shock absorber oil to the bushing and O ring of the piston rod assembly e Insert the piston end A of the piston rod assembly into the rear shock body B slowly Do not insert the seal assembly C yet e Push the seal assembly into the rear shock body until it just clears the circlip groove e Replace the circlip with a new one e Fit the circlip A into the groove in the rear shock body B e Pull up the piston rod assembly C against the circlip If the circlip is not a certain fit in the groove in the rear shock body the piston rod assembly
112. will not be obstructed x Replace the hose if it has been sharply bent or kinked Throttle Grip Throttle Cable Free Play Inspection e Check the throttle grip free play A by lightly turning the throttle grip B back and forth Throttle Grip Free Play Standard 2 3 mm 0 08 0 12 in If the free play is improper adjust the throttle cable e Check that the throttle grip moves smoothly from full open to close and the throttle closes quickly and completely in all steering positions by the return spring x 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 e Run the engine at the idle speed and turn the handlebars all the way to the right and left to ensure that the idle speed does not change x lf the idle speed increase check the throttle cable free play and the cable routing Throttle Grip Throttle Cable Free Play Adjustment e Loosen the locknut A at the upper end of the throttle cable e Screw the throttle cable adjuster B to give the throttle grip plenty of play e Tighten the locknut If the throttle grip free play cannot be adjusted with the adjuster replace the throttle cables e Turn the handlebars from side to side while idling the en gine If idle speed varies the throttle cable may be poorly routed or it may be damaged A WARNING Operation with improperly adjusted incorrectly routed or d
113. 0 30 mm 0 012 in 0 22 mm 0 009 in ENGINE TOP END 5 7 Specifications Item Standard Service Limit Valve Seating Surface Outside Diameter Exhaust 24 6 24 8 mm 0 969 0 976 in Intake 30 6 30 8 mm 1 205 1 213 in Width Exhaust 0 5 1 0 mm 0 02 0 04 in Intake 0 5 1 0 mm 0 02 0 04 in Se Valve Spring Free Length Exhaust 37 88 mm 1 491 in 36 5 mm 1 44 in Intake 36 20 mm 1 425 in 34 7 mm 1 37 in Cylinder Piston Cylinder Inside Diameter 77 000 77 012 mm 77 10 mm 3 0315 3 0320 in 3 035 in Piston Diameter 76 948 76 963 mm 76 80 mm 3 0294 3 0300 in 3 024 in Piston Cylinder Clearance 0 041 0 068 mm ae 0 0016 0 0027 in Piston Ring Ring Groove Clearance Top 0 04 0 08 mm 0 18 mm 0 002 0 003 in 0 0071 in Piston Ring Groove Width Top 0 83 0 85 mm 0 93 mm 0 0327 0 0335 in 0 037 in Piston Ring Thickness Top 0 77 0 79 mm 0 70 mm 0 030 0 031 in 0 028 in Piston Ring End Gap Top 0 15 0 25 mm 0 6 mm 0 0059 0 0098 in 0 02 in Oil 0 20 0 70 mm 1 0 mm 0 0079 0 0276 in 0 04 in Piston Pin Diameter 15 991 16 000 mm 15 96 mm 0 62957 0 62992 in 0 6283 in Piston Pin Hole Diameter 16 004 16 010 mm 16 08 mm 0 63008 0 63031 in 0 6331 in Connecting Rod Small End Inside 16 010 16 018 mm 16 05 mm Diameter 0 63031 0 63063 in 0 6319 in 5 8 ENGINE TOP END Specifications
114. 01 1238 Jack Attachment 57001 1608 A WARNING When the swingarm pivot shaft is removed the swingarm and rear wheel assembly will become detached and allow the frame to fall to the floor creating the potential for injury Removing the engine requires the swingarm pivot to be removed so support the bottom of the frame with a jack or other appropriate stand e Squeeze the brake lever slowly and hold it with a band A A WARNING Motorcycle may fall over unexpectedly resulting in an accident or injury Be sure to hold the front brake when removing the engine Be sure to hold the front brake when removing the engine or the motorcycle may fall over The engine or the motorcycle could be damaged e Drain Engine Oil see Engine Oil Change in the Periodic Main tenance chapter Coolant see Coolant Draining in the Cooling System chapter 8 6 ENGINE REMOVAL INSTALLATION Engine Removal Installation e Remove Rear Frame see Rear Frame Removal in the Frame chapter Exhaust Pipe see Exhaust Pipe Removal in the Engine Top End chapter Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Radiators and Water Hoses see Radiator Removal in the Cooling System chapter Throttle Body Assy see Throttle Body Assy Removal in the Fuel System DFI chapter Ignition Coil see Ignition Coil Removal in the Electrical System chapter Shift Pedal see Shift Pedal Removal in the Crank shaft Tran
115. 10ESi C 3 58 FUEL SYSTEM DFI Vehicle down Sensor Service Code 31 e Hold the sensor vertically e Refer to the Self diagnosis Procedures connect the 12 V battery to the main harness e Measure the output voltage with the engine stopped and with the connector joined OTilt the sensor 55 75 or more A right or left then hold the sensor almost vertical with the arrow mark B pointed up C Output Voltage Standard With sensor tilted 55 75 or more right or left DC 3 7 44 V With sensor arrow mark pointed up DC 0 4 1 4V If the reading is out of the standard replace the sensor GC17725DS81 x lf the reading is within the standard remove the ECU and check the wiring for continuity between the main harness connectors Special Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Vehicle down Sensor Connector B BR lead C ECU terminal 16 GY lead D ECU terminal 17 xlf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation GC17341FS1 Vehicle down Sensor Circuit R Y BR a er R Y BR GY 6C17317FW2 C 1 ECU 2 Vehicle down Sensor FUEL SYSTEM DFI 3 59 Downstream Injector Service Code 41 NOTICE Never drop the downstrea
116. 15 2nd Gear 28T 5 2nd Gear 16T 16 4th Gear 21T 6 Bushing 17 3rd Gear 26T 7 4th Gear 17T 18 5th Gear 23T 8 3rd Gear 18T 19 1st Gear 30T 9 5th Gear 22T 20 Ball Bearing Right Crankcase One side sealed 10 Drive Shaft 1st Gear 14T e Check that each gear spins or slides freely on the trans mission shaft without binding after assembly Shift Fork Bending Inspection e Visually inspect the shift forks and replace any fork that is bent A bent fork could cause difficulty in shifting or allow A the transmission to jump out of gear when under power 90 A 6113235BS1 C 9 22 CRANKSHAFT TRANSMISSION Transmission Shift Fork Gear Groove Wear Inspection e Measure the thickness A of the shift fork ears and mea sure the width B of the gear grooves with which the fork engages Shift Fork Ear Thickness Standard 4 9 5 0 mm 0 193 0 197 in Service Limit 4 8 mm 0 189 in Gear Groove Width Standard 5 05 5 15 mm 0 199 0 203 in Service Limit 5 3 mm 0 209 in If the thickness of a shift fork ear is less than the service limit the shift fork must be replaced If the gear groove is worn exceeding the service limit the gear must be replaced Shift Fork Guide Pin Shift Drum Groove Wear Inspection e Measure the diameter A of each shift fork guide pin and measure the width B of each shift drum groove Shift Fork Guide Pin Diameter Standard 5 9 6 0 mm
117. 4 SUSPENSION Exploded View SUSPENSION 13 5 Exploded View Torque No Fastener Nem kgf m itib Remarks 1 Rear Shock Absorber Mounting Nut Upper 39 4 0 29 R 2 Rear Shock Absorber Mounting Nut Lower 34 3 5 25 R 3 Tie Rod Mounting Nuts 59 6 0 44 R 4 Swingarm Pivot Shaft Nut 98 10 0 72 R 5 Rocker Arm Pivot Nut 59 6 0 44 R 6 Gas Reservoir Damping Adjuster Assembly 29 5 3 01 21 8 7 Rear Shock Absorber Spring Locknut 45 4 6 33 8 Piston Rod Locknut 37 3 8 27 R G Apply grease R Replacement Parts 2T Apply 2 stroke oil 13 6 SUSPENSION Specifications Item Standard Service Limit Front Fork Air Pressure Rebound Damping Adjustment Left Fork only from the seated position adjuster turned fully clockwise Compression Damping Adjustment Left Fork only from the seated position adjuster turned fully clockwise Spring Preload Adjustment Right Fork only from the seated position adjuster turned fully counterclockwise Fork Oil Type Capacity Left Front Fork Cylinder Unit Cylinder Unit Oil Level Outer Tube Capacity Right Front Fork Fork Spring Free Length Right Fork only Atmospheric pressure 10 clicks counterclockwise EUR BR 12 clicks counterclockwise 8 clicks counterclockwise EUR BR 10 clicks counterclockwise 15 clicks clockwise EUR BR 7 clicks clockwise SHOWA SS 19 or equivalent 330 mL 11 16
118. 471 NOTICE Never strike the grab bar or the flywheel itself Strik ing the bar can bond it If the flywheel is struck the magnets may lose their magnetism e Remove the woodruff key Flywheel Installation e Using a high flash point solvent clean off any oil or dirt that may be on the crankshaft taper A and in the hole B of the flywheel Dry them with a clean cloth e Fit the woodruff key C securely in the slot of the crank shaft e Install the flywheel according to the following procedures NOTE OConfirm the flywheel fit or not to the crankshaft before tightening it with specified torque Olnstall the flywheel OHold the flywheel steady with the rotor holder and tighten the flywheel nut with 54 N m 5 5 kgf m 40 ft lb of torque Special Tools Grip 57001 1591 Rotor Holder 57001 1730 ORemove the flywheel nut OCheck the tightening torque with rotor puller Special Tool Flywheel Puller M28 x 1 0 57001 1471 x If the flywheel is not pulled out with 20 N m 2 0 kgf m 15 ft lb of drawing torque it is installed correctly xlf the flywheel 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 flywheel tapered portion and dry them with a clean cloth Then confirm that it is not pulled out with above torque ELECTRICAL SYSTEM 16 13 218126 P 16 14 ELECTRICAL SYSTEM Flywheel Magneto e Hold the flywheel steady with th
119. 5 2 650 92180 0173 265 3 175 92180 0194 318 2 675 92180 0174 3 200 92180 0195 320 2 700 92180 0175 270 3 225 92180 0196 322 2 725 92180 0176 272 3 250 92180 0197 325 2 750 92180 0177 275 3 275 92180 0198 328 2 775 92180 0178 278 3 300 92180 0199 330 2 800 92180 0200 332 2 825 92180 0180 282 3 350 92180 0201 335 2 850 92180 0202 338 2 875 92180 0203 340 2 900 92180 0183 290 3 425 92180 0204 342 2 925 92180 0205 345 2 950 92180 0185 295 3 475 92180 0206 348 2 975 92180 0186 3 500 92180 0207 350 NOTE OBe sure to remeasure the clearance after selecting a shim The clearance can be out of the specified range because of the shim tolerance Olf there is no valve clearance use a shim that is a few sizes smaller and remeasure the valve clearance 2 26 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Install the shim OTurn the marked side A to upside OApply engine oil to the shim to keep the shim in place during camshaft installation Do not put shim stock under the shim This may cause the shim to pop out at high rpm causing ex tensive engine damage Do not grind the shim This may cause it to fracture causing extensive engine damage e Apply engine oil to the valve lifter B surface and install the lifter e Install Camshafts see Camshaft Installation in the Engine Top End chapter Camshaft Cap see Camshaft
120. 57001 1243 e Install the toothed washer B e Replace the clutch hub nut C with a new one OTurn the large chamfering side of the clutch hub nut to outside e Tighten Torque Clutch Hub Nut 98 N m 10 0 kgf m 72 ft lb e Install the friction plates and steel plates alternately Olnstall the friction plate first If new dry steel plates and friction plates are in stalled apply engine oil to the surfaces of each plate to avoid clutch plate seizure e Apply molybdenum disulfide grease to the rubbing portion A of push rod holder steel ball B and washers C e Install the steel ball and push rod holder assembly Clutch e f a clutch part was replaced install the standard adjusting washer 1 5 mm thickness A of the push rod holder as sembly and check the release lever position as explained later procedure e Install the clutch spring plate and clutch springs e Tighten the clutch spring bolts while holding the clutch housing with the hand Torque Clutch Spring Bolts 9 0 N m 0 92 kgf m 80 in Ib e Check the release shaft lever position A Cable Holder B Lever C Release Shaft Lever Position Standard 49 2 56 5 mm 1 94 2 22 in lf the lever position is not within the standard select the correct thickness of adjusting washer s according to the tables shown Adjusting Washers Thickness 1 5 mm 0 06 in 1 0 mm 0 04 in Part Number 92200 1548 92200 0045
121. 8 ft Ib e Bleed the brake line see Brake Line Bleeding e Check the brake for good braking power no brake drag and no fluid leakage A WARNING After servicing it takes several applications of the brake lever before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the motorcycle until a firm brake lever is obtained by pumping the lever until the pads are against the disc Rear Master Cylinder Removal e Remove Cotter Pin A Joint Pin B Washer C NOTE OPull off the joint pin while pressing down the brake pedal e Remove the master cylinder mounting bolts D and re move the master cylinder E backward e Remove the brake hose banjo bolt F OWhen removing the brake hose temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum Rear Master Cylinder Installation e Install the brake hose OReplace the washers A on each side of hose fitting B with new ones e Tighten Torque Brake Hose Banjo Bolt 25 N m 2 5 kgf m 18 ft Ib e Install the rear master cylinder e Tighten Torque Rear Master Cylinder Mounting Bolts 9 8 N m 1 0 kgf m 87 in Ib GL10000BS1 GL10000BS1 Master Cylinder e Replace the cotter pin with a new one e Install the joint pin washer and new cotter pin e Bend the ends
122. 82 3 82 3 82 3 82 3 83 3 83 3 84 3 84 3 84 3 84 3 84 3 85 3 85 3 86 3 86 3 86 3 86 3 86 3 87 3 87 3 89 3 90 FUEL SYSTEM DFI 3 3 This page intentionally left blank 3 4 FUEL SYSTEM DFI Exploded View FUEL SYSTEM DFI 3 5 Exploded View No Fastener pole Remarks N m kgf m ft Ib 1 Throttle Pulley Cover Bolts 3 4 0 35 30 in lb 2 Throttle Cable Bolts 3 0 0 31 27 in lb 3 Throttle Case Mounting Screws 3 8 0 39 34 in lb 4 Air Cleaner Duct Clamp Bolt 2 0 0 20 18 in lb 5 Delivery Joint Bolt 3 5 0 36 31 in lb L CL Apply cable lubricant EO Apply engine oil G Apply grease L Apply a non permanent locking agent O Apply high quality foam air filter oil R Replacement Parts 3 6 FUEL SYSTEM DEI Exploded View FUEL SYSTEM DFI 3 7 Exploded View No Fastener Jorgue Remarks N m kgf m ft Ib 1 Water Temperature Sensor 12 1 2 106 in lb 2 Gear Position Switch Screws 2 9 0 30 26 in lb L AD Apply adhesive EO Apply engine oil G Apply grease S Follow the specified tightening sequence L Apply a non permanent locking agent R Replacement Parts 3 8 FUEL SYSTEM DFI DFI System DEI System Sr ANSE ec VAE e Dei SZ K Pm er Si i 6C17323FW5 C DFI System MH HU HU HU ss nu ch D JO O1 P D Fuel Tank Pressure Regulator Fuel Pump Int
123. 92S1 3 22 FUEL SYSTEM DFI Troubleshooting the DFI System DFI Diagnosis Flow Chart Problem occurs Confirm problems Gather information from rider Connect the FI warning indicator light assy option Connect the power supply harness option and the 12 V battery to the capacitor lead connector and the state of the orange FI warning indicator light LED is seen Goes on for 2 seconds and then goes off Inspect the orange FI warning indicator light LED or harness and then goes on Kick the kick pedal about 10 times 1 Conduct non self diagnosis inspection Conduct self diagnosis inspection Conduct general fuel system inspection General fuel system air cleaner fuel tank etc 1 2 Refer to Self Diagnosis Flow Chart GCT7331F F Inquiries to Rider OEach rider reacts to problems in different ways so it is important to confirm what kind of symptoms the rider has encountered OTry to find out exactly what problem occurred under exactly what conditions by asking the rider knowing this information may help you reproduce the problem OThe following sample diagnosis sheet will help prevent you from overlooking any areas and will help you decide if it is a DFl system problem or a general engine problem FUEL SYSTEM DFI 3 23 Troubleshooting the DFI System Sample Diagnosis Sheet Rider name Engine No Date problem Model Frame No occurred
124. 98 0 0138 in Crankshaft Runout TIR 0 03 mm 0 001 in or less Connecting Rod Bend ee Connecting Rod Twist Le Service Limit 0 06 mm 0 0024 in 0 6 mm 0 02 in TIR 0 08 mm 0 003 in TIR 0 2 100 mm 0 008 3 94 in TIR 0 2 100 mm 0 008 3 94 in Transmission Shift Fork Ear Thickness 4 9 5 0 mm 0 193 0 197 in Gear Groove Width 5 05 5 15 mm 0 199 0 203 in Shift Fork Guide Pin Diameter 5 9 6 0 mm 0 232 0 236 in Shift Drum Groove Width 6 05 6 20 mm 0 238 0 244 in 4 8 mm 0 189 in 5 3 mm 0 209 in 5 8 mm 0 228 in 6 3 mm 0 25 in CRANKSHAFT TRANSMISSION 9 7 Special Tools and Sealant Bearing Puller Crankcase Splitting Tool Assembly 57001 135 57001 1362 ST570135ST C 8757136297 C Outside Circlip Pliers Gear Holder m2 0 57001 144 57001 1557 7570144ST C ST571557ST C Bearing Driver Set Liquid Gasket TB1216 57001 1129 92104 1063 RK ST5711298ST C ST921063ST C Crankshaft Jig 57001 1174 ST5711748T 9 8 CRANKSHAFT TRANSMISSION Crankcase Crankcase Disassembly e Remove the engine from the frame see Engine Removal in the Engine Removal Installation chapter e Set the engine on clean surface while parts are being re moved e Remove Piston see Piston Removal in the Engine Top End chap ter Right Engine Cover see Right Engine Cover Removal in the Clutch chapter Clutch see Cl
125. A of the cotter pin e Check the brake pedal position see Brake Lever and Pedal Adjustment in the Periodic Maintenance chapter e Bleed the brake line see Brake Line Bleeding e Check the brake for good braking power no brake drag and no fluid leakage A WARNING After servicing it takes several applications of the brake pedal before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the motorcycle until a firm brake pedal is obtained by pumping the pedal until the pads are against the disc Front Master Cylinder Disassembly e Refer to the Brake Master Cylinder Rubber Parts Re placement in the Periodic Maintenance chapter Rear Master Cylinder Disassembly e Refer to the Brake Master Cylinder Rubber Parts Re placement in the Periodic Maintenance chapter Master Cylinder Assembly e Refer to the Brake Master Cylinder Rubber Parts Re placement in the Periodic Maintenance chapter BRAKES 12 21 GLO4023BS1 C 12 22 BRAKES Master Cylinder Master Cylinder Inspection Visual Inspection e Disassemble the front and rear master cylinders e Check that there are no scratches rust or pitting on the inner wall of each master cylinder A and on the outside of each piston B If a master cylinder or piston shows any damage replace them e Inspect the primary C and secondary D cups
126. Air cleaner duct loose Air cleaner clogged Air cleaner poorly sealed or missing Handling and or Stability Unsatisfactory Handlebars hard to turn Cable hose wire routing incorrect Steering stem nut too tight Steering stem bearing damaged 17 16 APPENDIX Troubleshooting Guide Steering stem bearing lubrication inade quate Steering stem bent Tire air pressure too low Handlebars shakes or excessively vibrates Tire worn Swingarm pivot bearings worn Rim warped or not balanced Spokes loose Wheel bearing worn Handlebar clamp bolt loose Steering stem head nut loose Front rear axle runout excessive Handlebars pulls to one side Frame bent Rear wheel misalignment Swingarm bent or twisted Swingarm pivot shaft bent Steering maladjusted Steering stem bent Front fork bent Suspension operation trouble Too hard Tire air pressure too high Front fork oil excessive Front fork oil viscosity too high Rear shock absorber adjustment too hard Front fork bent Front fork air pressure too high Too soft Front fork oil insufficient or leaking Front fork oil viscosity too low Rear shock absorber adjusted too soft Front fork rear shock absorber spring weak Rear shock absorber oil or gas leaking Tire air pressure too low Brake Doesn t Hold Air in brake system Pad disc worn Brake fluid leakage Contaminated pad Brake fluid deteriorated Brake master cylinder cups damaged Master cylinder scratc
127. B Special Tool Top Plug Wrench 50 mm C 57001 1645 PERIODIC MAINTENANCE 2 65 Periodic Maintenance Procedures When not using the Fork Spring Compressor Special Tool 57001 1771 e Hold the axle holder part with a vise OProtect the axle holder part with a soft jaws or heavy cloth when using a vise A WARNING If the axle holder is not securely clamped the front fork assembly may come out of the vise when com pressed which could cause an accident resulting in injury However clamping the axle holder too tightly can damage it which will affect riding stabil ity Use protective aluminum covers on the jaws of the vise and do not tighten the vise excessively e Compress the outer tube by hands and install the top plug wrench A between the axle holder bottom and locknut Special Tool Top Plug Wrench 50 mm 57001 1645 A WARNING The fork spring applies pressure to the adjuster as sembly and can eject the special tool with substan tial force if the tool is not properly and securely placed Be sure the tool is fully in place as shown in the photo and keep fingers away to avoid getting them pinched between the tool adjuster assembly and axle holder When using the Fork Spring Compressor Special Tool 57001 1771 e Set the fork spring compressor A and a suitable jack B Special Tool Fork Spring Compressor 57001 1771 e Put the heavy cloth A on the fork spring compressor B
128. Breather hose inspect 2 32 Brake adjust t e 2 39 Brake pad wear inspect t e 2 43 Brake fluid level inspect t e 2 40 Brake fluid change Every 2 years 2 41 C Brake master cylinder cup and dust cover replace Every 2 years 2 43 H Brake caliper fluid seal and dust seal replace Every 2 years 2 44 A Brake hoses replace Every 4 years 2 48 Brake hoses connections inspect t 2 48 Spoke tightness and rim runout inspect t 2 34 S Wheel bearing inspect t 2 35 Frame inspect 2 80 Drive chain wear inspect t 2 35 Drive chain inspect and adjust 2 36 Drive chain lubricate 2 38 2 4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY Every 12 H races or Page OPERATION EE Wheels tires inspect 2 34 Rear sprocket inspect t Lo 2 38 Front fork clean and inspect 2 49 Front fork oil change e 2 49 Rear shock absorber oil change e 2 70 C Cable inspect 2 82 A Fuel hose replace Every 5 years 2 15 S Fuel hose connections inspect t 2 14 S Fuel system clean oe 2 21 s Steering play inspect 2 78 Steering stem bearing lubricate e 2 80 Swingarm and Uni Trak linkage pivots lubricate 2 78 Swingarm and Uni Trak linkage pivots inspect t oe 2 78 Nuts bolts fasteners inspect t 2 82 General lubrication perform 2 81 t Replace add adjust clean or torque if necessary PERIODIC MAINTENANCE 2 5 Torque and
129. C Touch the front brake hose fitting to the stopper D lt x soge XX E SE CG o DO zO 2 3 4 5 17 12 APPENDIX Cable Wire and Hose Routing X PER va GB09003EW4 C 1 Brake Hose 2 Clamps 3 Touch the rear brake hose fitting to the stopper 4 Cotter Pin 5 Viewed A APPENDIX 17 13 Troubleshooting Guide NOTE Valve spring broken or weak ORefer to the Fuel System DEI chapter for Valve not seating properly valve bent de most of DFI trouble shooting guide formed worn or carbon accumulation on OThis is not an exhaustive list giving every the seating surface possible cause for each problem listed It Decompression trouble is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties Spark weak Engine Doesn t Start Starting Spark plug dirty broken or gap malad Difficulty justed Engine won t turn over Spark plug cap or spark plug lead trouble Poor Running at Low Speed Valve seizure Valve lifter seizure Cylinder piston seizure Crankshaft seizure Connecting rod small end big end seizure Transmission gear or bearing seizure Camshaft seizure Kick shaft return spring broken Kick ratchet gear not engaging No fuel flow No fuel in fuel tank Fuel tank cap air vent obstructed Fuel line clogged Fuel filter clogged Engine flooded Clean spark plug and adjust plug gap Start
130. Cable Free Play Inspection AA 2 14 Throttle Grip Throttle Cable Free Play Acdhusiment 2 14 Throttle Body Cleaning casa te ee Sire Ee 2 15 Fuel Hose Replacement geed gege dee Wee dereen 2 15 Idle Speed INSP SCHON EE 2 18 Idle Speed AdjuSiMent else ennemie tentent dee eege 2 19 Air Cleaner Element Cleaning and Inspection ssseessseieeeenreertterssrrrnserernrernnnnnsserrseet 2 19 Push Tank Cleaner tenus ins satel ne nee dns 2 21 Cooling SYSIOM aise ee i en en E S nr nm attente date een nee 2 21 Coolant Level IMS Decision ee Re M A nn nenene 2 22 Coolant Deterioration Inspection tin Mine neeataeneennentate 2 23 Water Hoses and Connections Inspection 2 23 Engine TOPIC E 2 23 Valve Clearance Inspection EE 2 23 Valve Clearance Adjustment is 2 24 Cylinder Head Warp Inspection deeg 2 26 Cylinder Wear INSpection EE 2 26 Piston Cylinder e ele 2 27 Piston Piston Ring and Piston Pin Replacement 22 cccceeeessscceeeeeeeeeeeeeeeeeeeeneeeeeseees 2 27 Exhaust System Jospectmon ege unten hide 2 27 Silencer Wool REDlACE MEN sess seen cosa Peseceatpnd fuient ceeeeninaveninen te 2 28 GOLGI PAR tee EE SEENEN 2 29 Clutch Operation tee d e 2 29 Clutcn Plates Inspection sence Beete Oe EAR gue 2 29 Engine Lubrication System eege eege EE 2 30 Engine Cll Ee 2 30 EE E le 2 31 Breather Hose Inspection EEN 2 32 Crankshaft LETTRE ee E ned we hs E E E eaten sine dates 2 33 Crankshaft Inspection EE 2 33 W
131. D evenly and push the wheel forward until the chain is too loose lf the chain is too loose turn both chain adjusting bolts evenly until the drive chain has the correct amount of slack To keep the chain and wheel properly aligned the notch on the left chain adjuster should align with the same swingarm mark E as the right chain adjuster notch F e Check the wheel alignment see Wheel Alignment Inspec tion in the Final Drive chapter A WARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition Be sure the wheel is properly aligned e Tighten both chain adjuster locknuts securely e Tighten Torque Rear Axle Nut 108 N m 11 0 kgf m 79 7 ft Ib e Rotate the wheel measure the chain slack again at the tightest position and readjust if necessary e Insert a new cotter pin A NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle tighten the nut clockwise B up to next alignment Olt should be within 30 degrees OLoosen once and tighten again when the slot goes past the nearest hole e Bend the cotter pin A over the nut A WARNING A loose axle nut can lead to an accident resulting in serious injury or death Tighten the axle nut to the proper torque and install a new cotter pin G6J04082BS1 C e Check the rear brake effectiveness NOTE Oln wet and muddy co
132. DC mark OCheck the engine speed using the engine revolution tester A for high accuracy Ignition Timing Engine speed r min rpm Hole groove aligns with 2 000 Line mark on flywheel x lf the ignition timing is incorrect check the crankshaft sen sor see Crankshaft Sensor Inspection x lf the crankshaft sensor is normal replace the ECU e Replace the timing inspection cap O ring with a new one and apply grease it e Tighten Special Tool Filler Cap Driver 57001 1454 Torque Timing Inspection Cap 3 5 N m 0 36 kgf m 31 in Ib 16 22 ELECTRICAL SYSTEM Ignition System Safety Instructions A WARNING The ignition system produces extremely high volt age Do not touch the spark plug ignition coil or ig nition coil lead while the engine is running or you could receive a severe electrical shock Ignition Coil Removal e Disconnect the primary lead connector A e Pull off the spark plug cap B e Remove the ignition coil bracket bolt C and ignition coil with bracket e Remove the mounting bolts and nuts A and separate the ignition coil B and its bracket C Ignition Coil Installation e Assemble the ignition coil and its bracket and tighten the bolts and nuts e Install the spark plug cap A Front Side B Olnsert the spark plug cap to the cylinder head cover until the flange of the cap contacts the cover e Run the leads correctly see Cable Wire and Hose
133. E OPour in the coolant slowly so that it can expel the air from the engine and radiator OThe radiator cap must be installed in two steps First turn the cap clockwise to the first stop Then push down on it and turn it the rest of the way e Check the cooling system for leaks Air Bleeding e Start the engine warm up the engine thoroughly and then stop the engine e Wait until the engine cools down e Remove the radiator cap e Check the coolant level see Coolant Level Inspection in the Periodic Maintenance chapter lf the coolant level is low add coolant up to the bottom of the filler neck e Install the radiator cap e Check the cooling system for leaks COOLING SYSTEM 4 7 A G6D05024BS1 C 4 8 COOLING SYSTEM Coolant Cooling System Pressure Testing NOTICE During pressure testing do not exceed the pres sure for which the system is designed to work The maximum pressure is 123 kPa 1 25 kgf cm 18 psi e Remove the radiator cap and install a cooling system pressure tester A and adapter B on the radiator filler neck C NOTE OWet the adapter cap sealing surfaces with water or coolant to prevent pressure leaks e Build up pressure in the system carefully until the pres sure reaches 123 kPa 1 25 kgf cm 18 psi e Watch the gauge for at least 6 seconds x If the pressure holds steady the cooling system is all right lf the pressure drops and no ext
134. E TOP END 5 35 Cylinder and Piston NOTE OThe oil ring rails have no top or bottom e Install the oil ring expander A in the bottom piston ring groove so the ends B butt together e Install the oil ring steel rails on both sides of the oil ring expander OSpread the rail with your thumbs but only enough to fit the rail over the piston ORelease the rail into the bottom piston ring groove e Install the top ring A so that the R mark B faces up e Apply engine oil to the piston pin and inside wall of the connecting rod small end e Install the piston Front A Circle Mark B e Install the piston pin e Fit a new piston pin snap ring into the side of the piston so that the ring opening A does not coincide with the slit B of the piston pin hole OWhen installing the piston pin snap ring compress it only enough to install it and no more Do not reuse snap rings as removal weakens and deforms them They could fall out and score the cylinder wall e Replace the cylinder base gasket with a new one e Install Dowel Pins A New Cylinder Base Gasket B GEIGO53BS1 5 36 ENGINE TOP END Cylinder and Piston e The piston ring openings must be positioned as shown The openings of the oil ring steel rails must be 15 20 of angle from the opening of the oil ring expander Top Ring A Upper Oil Ring Steel Rail B Oil Ring Expa
135. ER P Upstream Injector Installation e Replace the dust seal A and O ring B with a new one e Assemble the delivery pipe A and upstream injector B SCHIER P 3 66 FUEL SYSTEM DEI Upstream Injector Service Code 42 e Fit the projection A on the delivery pipe to the hollow B of the air cleaner housing OFace the connector side to left side e Apply a non permanent locking agent to the threads of the delivery joint bolt A e Tighten Torque Delivery Joint Bolt 3 5 N m 0 36 kgf m 31 in Ib e Install the removed parts see appropriate chapters Upstream Injector Resistance Inspection e Remove Seat see Seat Removal in the Frame chapter Left Radiator Shroud see Radiator Shroud Removal in the Frame chapter Upstream Injector Connector A e Connect a digital meter to the terminals in upstream in jector A e Measure the upstream injector resistance Upstream Injector Resistance Connections R W terminal BL BK terminal Standard About 11 7 12 3 Q at 20 C 68 F x If the reading is out of the standard replace the upstream injector If the reading is within the standard check the power sup ply voltage see Upstream Injector Power Supply Voltage Inspection FUEL SYSTEM DFI 3 67 Upstream Injector Service Code 42 Upstream Injector Power Supply Voltage Inspection NOTE OBe sure the battery is fully charged e Disconnect the upstream injector
136. Engine Mounting Nut 49 Swingarm Pivot Shaft Nut 98 Crankshaft Transmission Primary Gear Nut 98 10 0 72 Lh R Reed Valve Screws 7 0 0 71 62 in lb Crankcase Bearing Retainer Screws 15 1 5 11 L Piston Oil Nozzle 2 9 0 30 26 in lb Crankcase Bolts L 50 mm 9 8 1 0 87 in lb S Crankcase Bolt L 65 mm 9 8 1 0 87 in lb S Crankcase Bolts L 70 mm 9 8 1 0 87 in lb S Crankcase Bolts L 60 mm 9 8 1 0 87 in lb S Kick Ratchet Guide Bolt 8 8 0 90 78 in lb L Kick Pedal Bolt 25 2 5 18 L Shift Drum Cam Bolt 24 2 4 18 L Gear Positioning Lever Nut 8 8 0 90 78 in lb Ratchet Plate Bolt 9 8 1 0 87 in lb L S Ratchet Plate Screw 15 1 5 11 L S Shift Pedal Bolt 9 8 1 0 87 in lb Wheels Tires Spoke Nipples Not less Not less than Not less than than 2 2 0 22 19 mb Front Axle Nut 78 8 0 58 Front Axle Clamp Bolts 20 2 0 15 AL S PERIODIC MAINTENANCE 2 7 Torque and Locking Agent Torque Fastener ES kaki fLIb Remarks Rear Axle Nut 108 11 0 79 7 Final Drive Rear Sprocket Nuts 34 3 5 25 R Brakes Brake Hose Banjo Bolts 25 2 5 18 Front Brake Reservoir Cap Screws 1 5 0 15 13 in lb Front Master Cylinder Clamp Bolts 8 8 0 90 78 in lb S Brake Lever Pivot Bolt 5 9 0 60 52 in lb Si Brake Lever Pivot Bolt Locknut 5 9 0 60 52 in lb Front Brake Disc Mounting Bolts 9 8 1 0 87 in lb L Front Brake Pad Pin 17 1 7 13 Caliper Bleed Valves 7 8 0 80 69 in lb Front Caliper Mounting Bolts 25 2 5 18 Rear Brake Reservoir Cap Bolts 1 5 0 15 13
137. GLO9064BS2 C Caliper Caliper Removal Front Brake e Loosen the brake pad pin A before the caliper B re moval if the caliper is to be disassembled e Loosen the banjo bolt C so as not to spill brake fluid NOTE Olf the caliper is to be disassembled after removal and compressed air is not available disassemble the caliper before brake hose removal see Caliper Rubber Parts Replacement in the Periodic Maintenance chapter e Remove Caliper Mounting Bolts D Banjo Bolt Caliper NOTICE Immediately wipe up any brake fluid that is spilled Rear Brake e Remove Caliper Guard Bolts A Caliper Guard B Disc Guard Bolts C Disc Guard D e Remove the pad pin plug A and loosen the pad pin B if the caliper C is to be disassembled e Loosen the banjo bolt D so as not to spill brake fluid NOTE Olf the caliper is to be disassembled after removal and compressed air is not available disassemble the caliper before brake hose removal see Caliper Rubber Parts Replacement in the Periodic Maintenance chapter e Remove Rear Wheel see Rear Wheel Removal in the Wheels Tires chapter Banjo Bolt Caliper NOTICE Immediately wipe up any brake fluid that is spilled BRAKES 12 13 12 14 BRAKES Caliper Caliper Installation e Install the brake pad if it was removed see Brake Pad Installation Front Brake e Install the caliper and tighten the bolts Torque Front Caliper Mounting B
138. IIG GIS TOS eegene Eed EES ee 2 33 Air Freet eenegen eebe ENEE Eege 2 33 Tires Inspection DEE 2 34 Spoke Tightness Inspection E 2 34 Rim tuell ee BEE 2 34 Wheel Bearing Inspection EE 2 35 PII E E E eege A TS 2 35 Drive Chain Wear Inspection EE 2 35 Drive Chain Slack Inspection lt oicasie ea Mie Sie dads cea vane nn Su AS ts sateen 2 36 Drive Chain Slack Eeer tg 2 37 Drive Chain REEL EE 2 38 Sprocket Wear NS peChOM REN 2 38 Rear Sprocket Warp Runout Inspection ss 2 38 2 2 PERIODIC MAINTENANCE Brakes Brake Lever and Pedal Adjustment ss Brake Fluid Level INSPOCton ieccsissstacieyectneness codes cee A EERSTEN EAR Brake Fluid Change Brake Rad EE deed Brake Master Cylinder Rubber Parts Heplacement Caliper Rubber Parts Replacement ss Brake Hoses and Connections Inspection nne Brake Hose Replacemente aicsiatrencvad n ant taime nent Suspension Front elle ere EE Front Fork Oil CMa CH Rear Shock Absorber Oil te tree his es ee me Swingarm and Uni Trak Linkage Inspection uk Swingarm and Uni Trak Linkage Pivot Lubrication ssssssssssreeesssneesrrrsserrrnnrrrnrrrsrerrsne Steering 2 eee Steering Inspection Steering Adjustment steering Stem Bearing Lubrication 2s ce ctncesiiedatendestncseaiacegeseeaionaedeennctestaed SEAN Frame seet coi der Frame Inspection Electrical System Spark Plug Cleaning and ASP OCUO E Spark Plug Replacement EE General Lubrication and Cable Ins
139. IR 1 0 mm 0 04 in or less TIR 1 0 mm 0 04 in or less 100 kPa 1 00 kgf cm 14 psi 80 100 21 51M DUNLOP MX51F Tube 100 90 19 57M DUNLOP MX51 Tube 52 58 mm 2 0 2 3 in 317 5 318 2 mm 12 50 12 53 in Service Limit TIR 2 0 mm 0 08 in TIR 2 0 mm 0 08 in 323 mm 12 7 in Rear Sprocket Warp Runout TIR 0 4 mm 0 016 in or less TIR 0 5 mm 0 020 in Brakes Brake Lever Free Play Adjustable to suit rider Brake Fluid Type Front DOT3 or DOT4 Rear DOT3 or DOT4 i Brake Pad Lining Thickness Front 4 0 mm 0 16 in 1 mm 0 04 in Rear 6 4 mm 0 25 in 1 mm 0 04 in Suspension Fork Oil Type SHOWA SS 19 or equivalent Capacity Left Front Fork Cylinder Unit 330 mL 11 16 US oz Cylinder Unit Oil Level 115 123 mm 4 53 4 84 in eee Outer Tube 320 2 5 mL 10 82 0 085 US oz Adjustable Range Capacity Right Front Fork Rear Shock Absorber Oil Type Capacity EUR BR 300 2 5 mL 10 14 0 085 US oz 235 2 5 mL 7 95 0 085 US oz SHOWA SS 25 or equivalent approx 380 mL 12 8 US oz 300 340 mL 10 14 11 50 US oz Adjustable Range 230 378 mL 7 78 12 78 US oz PERIODIC MAINTENANCE 2 11 Specifications Item Standard Service Limit Electrical System Spark Plug Gap 0 8 0 9 mm 0 031 0 035 in 2 12 PERIODIC MAINTENANCE Special Tools Inside Circlip Pliers 57001 143
140. Idle Speed see Idle Speed Adjustment in the Periodic Maintenance chapter e Check the brake effectiveness A WARNING After servicing it takes several applications of the brake lever before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the motorcycle until a firm brake lever is obtained by pumping the lever until the pads are against the disc CRANKSHAFT TRANSMISSION 9 1 Crankshaft Transmission Table of Contents elele CO RE 9 2 SP CICAUGNS ec acc an Oe aired as Res La eee msn a Nes 9 6 Special Tools and Sealant EE 9 7 KEE tee Eeer ee 9 8 Crankcase Deet Zuse eege eege cakarstemeraseesedeennse 9 8 Crankcase Assembly ss renier a RAM re du nn alerts tt 9 9 AD EL CUS E 9 15 Crankshatt Removals ieren eo eara inner areas EEE EREE AE AEE 9 15 Grankshaft E e VE 9 15 Crankshatt Disassembly is sisirin a iaa RE a E ekaa ENERE 9 15 Gra kshatt Assembly arreuso geseet Eed Eege 9 15 Crankshaft Inspection EE 9 16 Connecting Rod Bend ee 9 18 Connecting Rod Twist Inspection nennen nnene 9 18 Bel GE EE 9 19 Transmission Shaft Removal WEE 9 19 Transmission Shaft Installation is n e a a a 9 19 Transmission Shaft Disassembly eege edd ege eet eegne 9 19 Transmission Shaft Assembly nita aaea hate rade Rte 9 20 Shift Fork Bending Inge ccssciceasseuzeeesavcasiedausvasesuea des epee ean cedeehs sescuusgnceteuse s
141. If a cup is worn damaged softened rotted or swollen the piston assembly should be replace to renew the cups x lf fluid leakage is noted at the brake lever the piston as sembly should be replaced to renew the cup e Check the dust covers E for damage If they are damaged replace them e Check that the relief F and supply G ports are not plugged If the small relief port becomes plugged the brake pads will drag on the disc Blow the ports clean with com pressed air e Check the piston return springs H for any damage If a spring is damaged replace it Front Master Cylinder J Rear Master Cylinder K GLO7147B82 C BRAKES 12 23 Brake Disc Brake Disc Removal e Remove the wheels see Front Rear Wheel Removal in the Wheels Tires chapter e Remove the mounting bolts and take off the disc Brake Disc Installation e Install the brake disc on the wheel so that the marked side A faces out e Apply a non permanent locking agent to the threads of the brake disc mounting bolts B e Tighten Torque Front Brake Disc Mounting Bolts 9 8 N m 1 0 kgf m 87 in Ib Rear Brake Disc Mounting Bolts 23 N m 2 3 kgf m 17 ft lb Brake Disc Inspection e Visually inspect the disc A x lf it is scratched or damaged replace the disc e Measure the thickness of each disc at the point B where it has worn the most Disc Thickness Standard Front 2 85 3 15 mm 0 112 0 124
142. Installation in the Engine Top End chapter e Recheck the valve clearance and readjust if necessary e Install the removed parts see appropriate chapters Cylinder Head Warp Inspection e Remove the cylinder head see Cylinder Head Removal in the Engine Top End chapter e Lay a straightedge A across the lower surface of the head at several different points and measure warp by inserting a thickness gauge B between the straightedge and head Cylinder Head Warp Service Limit 0 05 mm 0 002 in If warp exceeds the service limit repair the mating sur face Replace the cylinder head if the mating surface is badly damaged e Remove the valves see Valve Removal in the Engine Top End chapter e Scrape the carbon out of the combustion chamber and exhaust port with a scraper A or a suitable tool e Clean the cylinder head using high flash point solvent e Blow out any particles which may obstruct the oil passage in the cylinder head using compressed air e Install the valves see Valve Installation in the Engine Top End chapter Cylinder Wear Inspection NOTE OMeasure the cylinder inside diameter when the cylinder is cold at room temperature e Visually inspect the inside of the cylinder for scratches and abnormal wear x If the cylinder is damaged or badly worn replace it with a new one PERIODIC MAINTENANCE 2 27 Periodic Maintenance Procedures e Take a side to side and a fron
143. M DFI 3 41 3 42 FUEL SYSTEM DFI Intake Air Pressure Sensor Service Code 12 Intake Air Pressure Sensor Input Voltage Inspection NOTE OBe sure the battery is fully charged e Disconnect the intake air pressure sensor connector and connect the measuring adapter A between these con nectors Main Harness B Intake Air Pressure Sensor C Special Tool Measuring Adapter 57001 1700 e Connect a digital meter D to the measuring adapter leads Intake Air Pressure Sensor Input Voltage Connections to Adapter Digital Meter R sensor R Y lead Digital Meter CH BK sensor GY lead e Refer to the Self diagnosis Procedures connect the 12 V battery to the main harness e Measure the input voltage with the engine stopped and with the connector joined Input Voltage Standard DC 4 75 5 25 V e Disconnect the power supply harness x If the reading is within the standard check the output volt age see Intake Air Pressure Sensor Output Voltage In spection x lf the reading is out of the standard remove the ECU and check the wiring for continuity between the main harness connectors Special Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Intake Air Pressure Sensor Connector B R Y lead C ECU terminal 12 GY lead D ECU terminal 17 xlf the wiring is good check the ECU for its ground and power su
144. M28 x 1 0 57001 1471 ST5714718T Grip 57001 1591 ST5715918ST Measuring Adapter 57001 1700 ST571700ST C Rotor Holder 57001 1730 ST571730ST C 16 6 ELECTRICAL SYSTEM Special Tools and Sealant Liquid Gasket TB1211F 92104 0004 RK ST9200048T C ELECTRICAL SYSTEM 16 7 Wiring Diagram This page intentionally left blank 16 8 ELECTRICAL SYSTEM Wiring Diagram DFI Setting DFI Data Selection Data Connector Black Connector ECU R W W BL BL R Self diagnosis Terminal e es Setting Selection DFI Setting Data Selection Connector Green White Regulator Rectifier hr tot 43 2 C3 CERN SSeS E oe gt Sp gt gt BK Y BL W BL BK P BK C o TT ne ee LI EE Y BK ec Y R a oe W Y G W BR EE af GEI LB i H WER LI STIL s o Kawasaki P Diagnostic BK W System R W Connector FI Warning Indicator Light Assy Option G BK W R W BL W BK BK W gt gt o s v S2 ed ez Flywheel K k Di o Fe P ij Engine Stop Switch Not Used Orange Sensor Fl Warning Indicator Light LED W Crankshaft W2LO684BW5 C ELECTRICAL SYSTEM 16 9 Wiring Diagram KX FI Calibration Kit Option Throttle Sensor BK W Intake R Air l Y R
145. MISSION Crankshaft e Carefully align the oil passage hole in the right flywheel A with the one in the crankpin B at rebuilding of the crankshaft e Reassemble the crankshaft according to the standard tol erances in Specifications OConnecting rod bend twist see Connecting Rod Bend Inspection Connecting Rod Twist Inspection OConnecting rod big end radial clearance see Crankshaft Inspection OCold fitting tolerance between crankpin and flywheels 0 4 0 8 mm 0 02 0 03 in A 57 25 mm 2 254 in B OSide clearance between the connecting rod big end and one of flywheels see Crankshaft Inspection OCrankshaft runout see Crankshaft Inspection Crankshaft Inspection Connecting Rod Big End Radial Clearance Inspection e Set the crankshaft on V blocks and place a dial gauge A against the connecting rod big end e Push B the connecting rod first towards the gauge and then in the opposite direction The difference between two gauge readings is the radial clearance Connecting Rod Big End Radial Clearance Standard 0 002 0 014 mm 0 00008 0 00055 in Service Limit 0 06 mm 0 0024 in lf the radial clearance exceeds the service limit crank shaft should be either replaced or disassembled and crankpin needle bearing and connecting rod big end should be examined for wear Connecting Rod Big End Side Clearance Inspection e Refer to the Crankshaft Inspection in the Periodic Main tenance chapter Cranks
146. No 26011 0246 and the battery to the capacitor lead connector and measure the voltage with the connector joined Incorrect reverse connection or short circuit by needle adapters could damage the DFI or electrical system parts OAfter measurement remove the needle adapters and ap ply sealant to the seals A of the connector B for water proofing Sealant Liquid Gasket TB1211 56019 120 e Always check the connected battery condition before re placing the DFI parts A fully charged battery is a must for conducting accurate tests of the DFI system e Trouble may involve one or in some cases all items Never replace a defective part without determining what CAUSED the problem If the problem was caused by some other item or items they too must be repaired or replaced or the new replacement part will soon fail again e Measure coil winding resistance when the DFI part is cold at room temperature e Make sure all connectors in the circuit are clean and tight and examine 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 G C17572C81 6017037381 FUEL SYSTEM DFI 3 21 Troubleshooting the DFI System e Pull each connectors A apart and inspect it for corrosion dirt and damage xlf the connector is corroded or d
147. OTICE During pressure testing do not exceed the maxi mum pressure for which the system is designed OWatch 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 delivery pipe assy downstream injector and related parts ORepeat the leak test and check the fuel line for no leak age e Install Fuel Hose see Fuel Hose Replacement in the Periodic Maintenance chapter Fuel Tank see Fuel Tank Installation e Start the engine check the fuel leakage FUEL SYSTEM DFI 3 63 GC17329FS2 3 64 FUEL SYSTEM DFI Downstream Injector Service Code 41 Downstream Injector Circuit w w zm E SON lt a R W BL R BK W gt EI F ofk BK W 0 Ov 6C17318FW2 C 1 ECU 2 Downstream Injector 3 Frame Ground 1 4 Capacitor FUEL SYSTEM DFI 3 65 Upstream Injector Service Code 42 NOTICE Never drop the upstream injector especially on a hard surface Such a shock to the upstream injector can damage it Upstream Injector Removal e Remove Rear Frame with Air Cleaner Housing see Rear Frame Removal in the Frame chapter e Remove the delivery joint bolt A e Remove the delivery pipe B together with the upstream injector e Separate the upstream injector A from the delivery pipe B SCHI
148. PERIODIC MAINTENANCE 2 75 Periodic Maintenance Procedures e Remove the tape from piston rod e Install the piston assembly A so that the thick side of the stopper B faces downward NOTE OBe careful not to change the original positions e Install the new piston rod locknut C e Tighten Torque Piston Rod Locknut 37 N m 3 8 kgf m 27 ft lb e Stake the end of the piston rod with the chisel A in three place B e Check the oil seal assembly moving smoothly on the rod Assembly for Oil Change e Check that the bladder A on the gas reservoir cap is not partially collapsed If it is push down the valve core with a screwdriver e Check the bladder for sign of damage or crack lf necessary replace it with a new one NOTICE Do not use a damaged or partially collapsed blad 6S148549 P der because it may burst gently reducing rear shock performance e Replace the gas reservoir cap B with a new one e Apply grease to the lip C of the bladder and install the reservoir cap e Push the bladder into the gas reservoir slowly until it just clears the circlip groove Wipe out any spilled oil e Replace the circlip with a new one A WARNING Pressurized nitrogen gas can explode out of the shock reservoir cap if a weakened deformed or flawed circlip is used allowing oil and internal parts to burst out of the reservoir with great force and cause serious injury To avoid injury always
149. Rout ing section in the Appendix chapter e Install Ignition Coil A with Bracket Frame Ground Lead Inside and Ignition Coil Ground Lead Outside B Ignition Coil Bracket Bolt OTurn the clamp side of the ignition coil ground lead termi nal and frame ground lead terminal outside e Connect the primary lead connector e Pull up the spark plug cap lightly to make sure of the in stallation of the spark plug cap Ignition System Ignition Coil Inspection Measuring Arcing Distance The most accurate test for determining the condition of the ignition coil is made by measuring arcing distance using the coil tester for the 3 needle method e Remove the ignition coil see Ignition Coil Removal e Measure the arcing distance using the coil tester A e Connect the ignition coil with the spark plug cap left in stalled on the spark plug lead B to the tester and mea sure the arcing distance A WARNING To avoid extremely high voltage shocks do not touch the coil or lead If the distance reading is less than the specified value the ignition coil or spark plug cap is defective 3 Needle Arcing Distance Standard 7 mm 0 28 in or more e To determine which part is defective measure the arcing distance again with the spark plug cap removed from the spark plug lead lf the arcing distance is subnormal as before the trouble is with the ignition coil itself If the arcing distance is now nor
150. STEERING 14 9 Handlebars Handlebar Removal e Remove Number Plate A see Number Plate Removal in the Frame chapter Handlebar Pad B Fuel Tank Breather Hose C e Remove Clutch Lever Assembly A Engine Stop Switch B Band C Left Handlebar Grip D e Remove Throttle Grip Assy A see Throttle Cable Replacement in the Fuel System DFI chapter Front Master Cylinder B see Front Master Cylinder Re moval in the Brakes chapter e Remove Handlebar Clamp Bolts A Handlebar Clamps B Handlebars C e Check the handlebars for bends or cracks If the handlebars was bended or cracked replace it 14 10 STEERING Handlebars Handlebar Installation e Apply adhesive cement to the innermost area of the left handlebar grip and all around inner surface of the left han dlebar grip hole entrance and also apply it to the roulette area on the handlebars e The left handlebar grip must be installed with the triangle mark A upward OWhen installing the left handlebar grip rotate the grip more than once first and then remove and install the grip alternately more than three times to spread adhesive ce ment Make sure that adhesive cement has been spread evenly OAfter installation hold the left handlebar grip area at more than three points to make the left handlebar grip stick to the handlebars e Install the clutch lever assembly see Clutch Lever Instal lation in the Clutch chapter e Install the eng
151. Sensor Replacement EE 3 35 Throttle Sensor Input Voltage Inspection 3 37 Throttle Sensor Output Voltage INSPECTION EE 3 38 Throttle Sensor Resistance Inspection 3 40 Intake Air Pressure Sensor Service Code 12 3 41 Intake Air Pressure Sensor Removal neern nne 3 41 Intake Air Pressure Sensor Installation nne 3 41 Intake Air Pressure Sensor Input Voltage Inspechon 3 42 Intake Air Pressure Sensor Output Voltage Inspechon 3 43 Intake Air Temperature Sensor Service Code 13 3 47 Intake Air Temperature Sensor Removal Installation 3 47 Intake Air Temperature Sensor Output Voltage Inspection 3 47 Intake Air Temperature Sensor Resistance Inspection 3 48 Water Temperature Sensor Service Code 14 3 50 Water Temperature Sensor Removal Installation cccceeeeeeeeeeeeeeeeeeeeeeneeeeeeneeeeeeeea 3 50 Water Temperature Sensor Output Voltage Inspection 3 50 Water Temperature Sensor Inspection EE 3 52 Crankshaft Sensor Service Cod Thann et nn ne nr SN de 3 53 Crankshaft Sensor Removal Installation 3 53 Crankshaft Sensor Resistance Inspection 3 53 Crankshaft Sensor Peak Voltage Inspection 3 53 Gear Position Switch Service Code 25 ss 3 54 Gear Position Switch Removal Hassan me Mann terne 3 54 Gear Position Switch Installation ciccceiciesssacecsiceest ceentaedotapeatendeat
152. To maintain the correct fuel air mixture F A there must be no intake air leaks in the DFI system Be sure to install the oil filler plug A after filling the engine oil Special Tool Filler Cap Driver 57001 1454 Torque Oil Filler Plug 3 5 N m 0 36 kgf m 31 in Ib GC170368S1 C Troubleshooting the DFI System Outline When an abnormality in the system occurs the condition of the problem is stored in the memory of the ECU Elec tronic Control Unit With the engine stopped and conduct a self diagnosis inspection the service code is indicated by the number of times the orange FI warning indicator light LED option blinks Ask the rider about the conditions A under which the problem occurred and try to determine the cause B e First conduct a self diagnosis inspection and then a non self diagnosis inspection The non self diagnosis items are not indicated by the orange FI warning indicator light LED Don t rely solely on the DFI self diagnosis function use common sense If the orange FI warning indicator light LED goes on by kicking the kick pedal about 10 times these parts are bro ken Even when the DFI system is operating normally the or ange FI warning indicator light LED may light up under strong electrical interference No repair needed When the orange FI warning indicator light LED goes on and the motorcycle is brought in for repair check the service codes When t
153. a digital meter A to the throttle sensor connector B e Measure the throttle sensor resistance Throttle Sensor Resistance Connections BL lead C BK lead D GC17997ES1 Standard 4 6kQO lf the reading is out of the standard replace the throttle sensor see Throttle Sensor Replacement lf the reading is within the standard but the problem still exists replace the ECU see ECU Removal Installation Throttle Sensor Circuit 8 Zo Y G A er 6C17311FW2 C 1 ECU 2 Throttle Sensor Intake Air Pressure Sensor Service Code 12 Intake Air Pressure Sensor Removal Never drop the intake air pressure sensor espe cially on a hard surface Such a shock to the sensor can damage it e Remove Fuel Tank See Fuel Tank Removal Fuel Hose see Fuel Hose Replacement in the Periodic Maintenance chapter Intake Air Pressure Sensor Connector A e Slide the rubber damper B to outside and remove it with the intake air pressure sensor C from the plate D e Remove the vacuum hose A from the throttle body assy e Remove the intake air pressure sensor B from the rubber damper C Intake Air Pressure Sensor Installation e Assemble the rubber damper A to the intake air pressure sensor B OFit the straight edges C e Install the vacuum hose A e Install the intake air pressure sensor B e Connect the intake air pressure sensor connector C FUEL SYSTE
154. ac rente tease 9 21 Shift Fork Gear Groove Wear Inspection 9 22 Shift Fork Guide Pin Shift Drum Groove Wear Inspection 9 22 Gear Damage INSPECCION SESCH aaee EES AAR SUE 9 22 Primary E 9 23 Primary Gear Removal EE 9 23 Primary Gear Installations sean ten ae Mans ee A TN rat 9 23 Ettel ege eegal ne Ut ete ae done 9 24 ShitP dal R mMOval ss re NS E 9 24 Shift Pedal Installation EG 9 24 External Shift Mechanism Removalissssssns nant dee 9 24 External Shift Mechanism Installation 9 25 External Shift Mechanism Inspection 9 26 PICKS nt 9 28 Kick Pedal Ferlens RS Sn nn re nie eee tin sienne aden 9 28 Kick Pedal Installation n sites ess ent A ne a Mise 9 28 Kick Pedal Disassembly iiri dds stiecetageeisaasccceneianesiaedeluidatendendaddaaales stieneiandoueneksnaeeeazbeentit 9 28 Kiek Pedal ASSOMUDLY EE 9 28 KICK SHAM GIOVE EE 9 29 KICK Shlath Installation EE 9 29 Kick Shaft Assembly Disassembly Assembly cccceeeeeeeeeeeeeeeeeeeeeseeeeeeeeeeeeeeeeeesenaeeees 9 29 Gelee Ee EE 9 31 Bearing Replacement EE 9 31 Bearing Wear INSPOCtOM E 9 31 ON SEAL IMSS EE 9 32 9 2 CRANKSHAFT TRANSMISSION Exploded View CRANKSHAFT TRANSMISSION 9 3 Exploded View No Fastener pone Remarks N m kgf m ft Ib 1 Primary Gear Nut 98 10 0 72 Lh R 2 Reed Valve Screws 7 0 0 71 62 in lb 3 Crankcase Bearing Retainer Screws 15 1 5 11 L 4 Piston Oil Nozzle 2 9 0 30 26 in lb 5 Crankc
155. ace with new ones Rear Shock Absorber Mounting Nut Lower Rocker Arm Pivot Nut Tie Rod Mounting Nut e Apply plenty of grease to the needle bearings oil seals and grease seals e Install Collars and Sleeve Rocker Arm e Apply 2 stroke oil to the threads of the rocker arm pivot bolt and tie rod mounting bolt e Tighten Torque Rear Shock Absorber Mounting Nut Lower 34 N m 3 5 kgf m 25 ft lb Rocker Arm Pivot Nut 59 N m 6 0 kgf m 44 ft lb Tie Rod Mounting Nut 59 N m 6 0 kgf m 44 ft lb Tie Rod and Rocker Arm Bearing Removal e Remove Tie Rod see Tie Rod Removal Rocker Arm see Rocker Arm Removal Collars A Sleeves B Oil Seals C Grease Seals D e Remove the needle bearing E using the bearing driver set e Remove the needle bearings F using the oil seal amp bear ing remover Special Tools Oil Seal amp Bearing Remover 57001 1058 Bearing Driver Set 57001 1129 GMO7034BS2 13 28 SUSPENSION Tie Rod Rocker Arm Tie Rod and Rocker Arm Bearing Installation e Replace the needle bearings oil seals and grease seals with new ones e Apply plenty of grease to the oil seals grease seals and needle bearings NOTE Olnstall the bearings so that the marked side faces out Olnstall the oil seals so that the deep groove side faces inward Olnstall the grease seals so that the groove side faces outward e Install the needle bearings A B oil seals C and grease seals D so that
156. addicaben needs 3 54 Gear Position Switch Inspection EE 3 55 Vehicle down Sensor Service Code 31 3 56 Vehicle down Sensor Removal E 3 56 Vehicle down Sensor Installation 3 56 Vehicle down Sensor Input Voltage Inspection 3 56 Vehicle down Sensor Output Voltage Inspection sssssseessserrsssrrtrerrnrttstrrsserrnnrrrnnnnernne 3 57 Downstream Injector Service Code 41 iii 3 59 3 2 FUEL SYSTEM DFI Downstream Injecto Downstream Injecto Downstream Injecto Downstream Injecto Downstream Injecto Downstream Injecto ne EE le EE elle EE ee e EE EE r Resistance Inspection its gd EE r Power Supply Voltage Inspection nsssessssesrnsesrnneenererssrrrnsrrrre r Output Voltage Inspection Downstream Fuel Line Insp ction ssissssnteidinnedann dns Upstream Injector Service Code A2 Upstream Injector REMOVAL ses Upstream Injector Installation ss Upstream Injector Resistance Inspection ccc eecesecseeeeeeeeceeeeeeeaeesaeeaaeeeceeeeeeeeeeeeeeeeeess Upstream Injector P ower Supply Voltage Inspection Upstream Injector Output Voltage Inspection EEN Upstream Injector F Fuel Pump Service Co Me Line INES DSCUON E EE Fuel PUMP ee EE EE Fuel Pump Installati DE een tege deeg et d e dE Ee Eei ESP eS NERS EEN ENEE ed dE EE Fuel Pump Operation Inspection epget regeert ee GEESS Fuel Pump Operating Voltage Inspection ss Pressure Regulator Fuel Filter Cleaning REMOVal esd un mise anni e
157. ads e Remove Clutch Housing Primary Gear Primary Gear Installation e Apply grease to the oil seal lip A e Replace the primary gear nut B with a new one e Install Primary Gear C Washer D Primary Gear Nut OTurn the inner rim of washer to outside OThe primary gear nut is left hand threads e Temporarily install the clutch housing A clutch hub B toothed washer and clutch hub nut C e Hold the primary gear D with the gear holder E OPull out the clutch housing a little so that the gear holder can be fit Special Tool Gear Holder m2 0 57001 1557 e Tighten Torque Primary Gear Nut F 98 N m 10 0 kgf m 72 ft lb e Install the removed parts see appropriate chapters 9 24 CRANKSHAFT TRANSMISSION External Shift Mechanism Shift Pedal Removal e Remove Shift Pedal Bolt A Shift Pedal B Shift Pedal Installation e Install the shift pedal so that the slit A on the pedal aligns with the punch mark B on the shift shaft e Tighten Torque Shift Pedal Bolt C 9 8 N m 1 0 kgf m 87 in Ib External Shift Mechanism Removal e Remove Right Engine Cover see Right Engine Cover Removal in the Clutch chapter Clutch see Clutch Removal in the Clutch chapter Shift Pedal see Shift Pedal Removal e Pull out the shift shaft A e Remove Washer A Ratchet Plate Bolt B Ratchet Plate Screw C Ratchet Plate D Shift Ratchet Assembly E e Remove the shift drum ca
158. ake Air Pressure Sensor Downstream Injector Upstream Injector Intake Air Temperature Sensor Air Cleaner Housing Ignition Coil Vehicle down Sensor Crankshaft Sensor Throttle Sensor Water Temperature Sensor Gear Position Switch ECU Capacitor Air Flow Fuel Flow FUEL SYSTEM DFI 3 9 3 10 FUEL SYSTEM DFI DFI System DFI System Wiring Diagram me si e DIR EEE he R Y n P EK BL BK BL W BK Y BL R tete Gig Ce ai SC 7 SE H oga Ee o ER SH WW IC E y L BK BK BL i e 4 St R Y ile R vO St ee ee Ka R H CTE 117 GCI7310FWS C DFI System Part Names 11 ECU Self diagnosis Terminal Throttle Sensor Intake Air Pressure Sensor Downstream Injector Upstream Injector Intake Air Temperature Sensor Water Temperature Sensor Frame Ground 1 10 Ignition Coil Spark Plug 12 13 14 15 16 17 18 19 20 21 22 Frame Ground 2 Fuel Pump Vehicle down Sensor Gear Position Switch Capacitor Crankshaft Sensor Engine Stop Switch Orange FI Warning Indicator Light LED Not Used FI Warning Indicator Light Assy Option Kawasaki Diagnostic System Connector OColor Codes BK Black GY Gray PU Purple BL Blue LB Light Blue R Red BR Brown LG Light Green V Violet CH Ch
159. amaged cables could result in an unsafe riding condition Follow the service manual to make sure to correct any of these conditions GS05214BS1 PERIODIC MAINTENANCE 2 15 Periodic Maintenance Procedures Throttle Body Cleaning e Check the throttle bore for cleanliness as follows ORemove the throttle body assy see Throttle Body Assy Removal in the Fuel System DFI chapter OCheck the throttle bore A at the throttle valve for carbon deposits by opening the throttle valve If any carbon accumulates wipe the carbon off the throt tle bore and the throttle valve using a lint free cloth pen etrated with a high flash point solvent Fuel Hose Replacement e Remove the fuel tank see Fuel Tank Removal in the Fuel System DFI chapter e Be sure to place a piece of cloth around each fuel hose joint e Wipe off the dirt of the surface A around the connection using a cloth or a soft brush JC16153BS1 Throttle Body Assy Side When removing with standard tip screwdriver e Insert the standard tip screwdriver A into the slit B on the joint lock C e Turn the driver to disconnect the joint lock When removing with fingers e Open and push up A the joint lock B with your fingers NOTICE Prying or excessively widening the joint lock ends for fuel hose removal will permanently deform the joint lock resulting in a loose or incomplete lock that may
160. ance chapter Steering Adjustment e Refer to the Steering Adjustment in the Periodic Mainte nance chapter Steering Stem Stem Bearing Removal e Remove Number Plate A see Number Plate Removal in the Frame chapter Handlebar Pad B Fuel Tank Breather Hose C e Remove Brake Hose Clamp Bolt A Handlebar Clamp Bolts B Handlebar Clamps C Handlebars D Steering Stem Head Nut E and Washer e Remove Front Wheel see Front Wheel Removal in the Wheels Tires chapter Front Fender see Front Fender Removal in the Frame chapter Front Forks see Front Fork Removal in the Suspension chapter Steering Stem Head A e Hold the stem base A by hand and remove the steering stem nut B with the steering stem nut wrench C Special Tool Steering Stem Nut Wrench 57001 1100 e Remove the steering stem D and stem base from the head pipe STEERING 14 5 14 6 STEERING Steering e Remove the upper stem bearing inner race tapered roller bearing A e Drive out the bearing outer races from the head pipe ORemove the outer races pressed into the head pipe using the head pipe outer race remover A and hammer the head pipe outer race remover to drive it out Special Tool Head Pipe Outer Race Remover ID gt 37 mm 57001 1107 NOTE Olf either steering stem bearing is damaged it is recom mended that both the upper and lower bearing includ ing outer races should be replaced with new ones
161. and Piston section in the Engine Top End chapter Exhaust System Inspection e The exhaust system in particular the muffler body is de signed to reduce exhaust noise and conduct the exhaust gases away from the rider while minimizing power loss If carbon has built up inside the muffler body exhaust effi ciency is reduced causing engine performance to drop If the muffler body is badly damaged dented cracked or rusted replace it lf the exhaust noise becomes too loud or engine perfor mance drops replace the silencer wool 2 28 PERIODIC MAINTENANCE Periodic Maintenance Procedures Silencer Wool Replacement e Remove Right Side Cover see Side Cover Removal in the Frame chapter Muffler Body Cover Bolts A Muffler Mounting Bolt B e Remove the muffler cover A OTap the bracket B with a plastic mallet C to separate the cover and pipe e Replace the silencer wool with a new one e Clean the adhered silicone sealant e Insert the new silencer wool A and muffler cover B OFit the pipe end C and exhaust hole of the baffle e Apply a non permanent locking agent to the threads of the muffler cover bolts and tighten them e Tighten the muffler mounting bolt securely e Using a high flash point solvent clean off any oil or dirt that may be on the silicone sealant coating area Dry them with a clean cloth e Apply silicone sealant to the mating surface A e Install the right side cover see Side Cov
162. any time the AIR MUST BE BLED FROM THE BRAKE LINE Recommended Disc Brake Fluid Type Front and Rear DOT3 or DOT4 2 42 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTE OThe procedure to change the front brake fluid is as fol lows Changing the rear brake fluid is the same as for the front brake e Level the brake fluid reservoir e Remove Screws A Reservoir Cap B Diaphragm e Remove the rubber cap A on the bleed valve B e Attach a clear plastic hose A to the bleed valve on the caliper and run the other end of the hose into a container e Fill the reservoir with fresh specified brake fluid e Change the brake fluid as follows ORepeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes 1 Open the bleed valve A 2 Apply the brake and hold it B 3 Close the bleed valve C 4 Release the brake D A WARNING Mixing brands and types of brake fluid can reduce the brake system s effectiveness and cause an ac cident resulting in injury or death Do not mix two brands of brake fluid Change the brake fluid in the brake line completely if the brake fluid must be re filled but the type and brand of the brake fluid that is already in the reservoir are unidentified NOTE O The fluid level must be checked often during the chang ing operation and replenished with fresh brake fluid If the fluid in the
163. ase Bolts L 50 mm 9 8 1 0 87 in lb S 6 Crankcase Bolt L 65 mm 98 10 87 in S 7 Crankcase Bolts L 70 mm 98 10 87 in lb S 8 Crankcase Bolts L 60 mm 98 10 87 in lb S EO Apply engine oil G Apply grease L Apply a non permanent locking agent LG Apply liquid gasket Lh Left hand Threads R Replacement Parts S Follow the specified tightening sequence 9 4 CRANKSHAFT TRANSMISSION Exploded View CRANKSHAFT TRANSMISSION 9 5 Exploded View Torque No Fastener Nem kgf m Op Remarks 1 Kick Ratchet Guide Bolt 8 8 0 90 78 in lb L 2 Kick Pedal Bolt 25 2 5 18 L 3 Shift Drum Cam Bolt 24 2 4 18 L 4 Gear Positioning Lever Nut 8 8 0 90 78 in lb 5 Ratchet Plate Bolt 9 8 1 0 87 in lb L S 6 Ratchet Plate Screw 15 1 5 11 L S 7 Shift Pedal Bolt 9 8 1 0 87 in lb EO Apply engine oil G Apply grease L Apply a non permanent locking agent M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts S Follow the specified tightening sequence St Stake the fasteners to prevent loosening 9 6 CRANKSHAFT TRANSMISSION Specifications Item Standard Crankshaft Connecting Rod Connecting Rod Big End Radial Clearance 0 002 0 014 mm 0 00008 0 00055 in Side Clearance 0 25 0 35 mm 0 00
164. ately two times to en sure even tightening torque e Install the removed parts see appropriate chapters Front Fork Disassembly e Drain the fork oil see Front Fork Oil Change in the Peri odic Maintenance chapter e Remove the locknut A e Wrap the piston rod end B with a vinyl tape e Push out C the piston rod D SUSPENSION 13 13 Front Fork e Separate the inner tube A from the outer tube B as follows OSlide up the spring band C OSlide up the dust seal D ORemove the retaining ring A from the outer tube OGrasp the tubes and stroke the inner tube up and down A several times The shock to fork seal separates the inner tube from the outer tube e Remove Bushings A Washer B Oil Seal C Retaining Ring D Dust Seal E Spring Band F e Wipe off the oil from the removed parts NOTE ODisassemble the right front fork in the same way Front Fork Assembly e Replace the following parts with new ones Dust Seal A with Spring Band Retaining Ring B Oil Seal C Bushings D e Place an oil coated plastic bag E over the end of the E2 inner tube to protect the oil seals OThe inner tube bushings groove has a sharp edge F that G cut out the sealing lip of the seals as they are pushed down over the inner tube e Apply grease to the oil seal e Install in order these parts on the inner tube GM04313BS1 C 13 14 SUSPENSION Front Fork
165. cation System chapter e Replace the oil filler plug O ring with a new one e Apply grease to the O ring e Tighten Special Tool Filler Cap Driver 57001 1454 Torque Oil Filler Plug 3 5 N m 0 36 kgf m 31 in Ib Oil Filter Change e Drain Engine Oil see Engine Oil Change e Remove Oil Filter Cap Bolts A Oil Filter Cap B 20 10 0 10 20 30 40 4 14 32 50 68 86 104 F UE D D a 6S09013BS1 2 32 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Remove the oil filter A e Replace the oil filter with a new one e Apply grease to the grommet A e Install the oil filter OTurn the grommet to inside Inside out installation stop oil flow causing engine seizure e Replace the oil filter cap O ring A with a new one e Apply grease to the O ring e Install Spring B Oil Filter Cap e Tighten Torque Oil Filter Cap Bolts 9 8 N m 1 0 kgf m 87 in Ib e Pour the specified engine oil see Engine Oil Change Breather Hose Inspection e Be certain that the breather hose A are routed without being flattened or kinked and is connected correctly If it is not correct it e Inspect the breather hose for damage or signs of deteri oration OThis hose should not be hard and brittle nor should be soft swollen Replace it if any damage is noticed PERIODIC MAINTENANCE 2 33 Periodic Maintenance Procedures Cranks
166. ck Pedal see Kick Pedal Removal in the Crank shaft Transmission chapter Right Engine Cover see Right Engine Cover Removal in the Clutch chapter Clutch see Clutch Removal in the Clutch chapter Primary Gear see Primary Gear Removal in the Crank shaft Transmission chapter e Remove Circlip A Oil Pump Idle Gear B Special Tool Outside Circlip Pliers 57001 144 e Remove Oil Pump Mounting Bolts A Oil Pump Assembly B e Remove Inner A and Outer B Rotors Scavenge Dowel Pin C Pin D 7 12 ENGINE LUBRICATION SYSTEM Oil Pump e Disassemble the oil pump assembly Pins A Oil Pump Cover B Inner C and Outer D Rotors Feed Oil Pump Body E Oil Pump Gear F GG09080BS1 Oil Pump Installation e Apply molybdenum disulfide grease to the shaft of the oil pump gear e Apply engine oil to the inner and outer rotors e Assemble Oil Pump Body A Gear B Pin C Inner Rotor Feed D OFit the slot E of the inner rotor onto the pin e Install Outer Rotor Feed A Cover B e Install Pin A Inner Rotor Scavenge B OFit the slot C of the inner rotor onto the pin e Install Outer Rotor Scavenge A Pin B Dowel Pin C Oil Pump Assembly e Apply a non permanent locking agent to the oil pump mounting bolts e Tighten Torque Oil Pump Mounting Bolts 7 0 N m 0 71 kgf m 62 in Ib ENGINE LUBRICATION SYSTEM 7 13 Oil Pump e Apply eng
167. cover Flat Side A Kick Shaft Oil Seal B OPress the new crankshaft oil passage oil seal A so that the seal surface is flush with the surface of the right engine cover Flat Side B Olnstall the new circlip C Special Tool Inside Circlip Pliers 57001 143 e Apply grease to the oil seal lips GRO4015BS1 GRO4020BS1 CLUTCH 6 11 Clutch Clutch Removal e Drain the engine oil see Engine Oil Change in the Peri odic Maintenance chapter e Remove Clutch Cover see Clutch Cover Removal Clutch Spring Bolts A Clutch Springs Clutch Spring Plate B e Remove Push Rod Holder Assembly A Steel Ball Friction Plates B Steel Plates C e Hold the clutch hub A with the clutch holder B Special Tool Clutch Holder 57001 1243 e Remove Clutch Hub Nut C Toothed Washer D Clutch Hub Thrust Washer Clutch Housing E e Remove Needle Bearing A Sleeve B Clutch Installation e Apply molybdenum disulfide oil solution to the outside of the sleeve A e Install the sleeve so that the flange B faces inside e Install the needle bearing C 6 12 CLUTCH Clutch e Install the clutch housing A OTurn the kickstarter idle gear and oil pump idle gear with a suitable tool B to fit in the clutch housing e Install Thrust Washer A Clutch Hub B e Hold the clutch hub with the clutch holder A Special Tool Clutch Holder
168. crank shaft sensor see Crankshaft Sensor Inspection 16 28 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Inspection e Disconnect the magneto lead connector see Magneto Cover Removal e Set the hand tester A to the x 10 Q range and connect it to the Green White B and White Yellow C leads in the connector Special Tool Hand Tester 57001 1394 Crankshaft Sensor Resistance Standard 180 280 Q at 20 C 68 F If there is more resistance than the specified value the coil has an open lead and must be replaced Much less than this resistance means the coil is shorted and must be replaced e Using the highest resistance range of the tester measure the resistance between the crankshaft sensor leads and chassis ground Any tester reading less than infinity indicates a short necessities replacement of the crankshaft sensor assem bly Engine Stop Switch System Check e Start the engine e Push the engine stop switch A stop the engine If the engine does not stop check the engine stop switch for continuity see Engine Stop Switch Inspection If the engine stop switch is good check the wiring see Wiring Inspection x lf the wiring is good replace the ECU DFI Setting Data Selection Connector Inspection White Connector A for Soft Track Condition Green Connector B for Standard Black Connector C for Hard Track Condition GP10582BS1 C
169. ction e Refer to the Throttle Grip Free Play Inspection in the Pe riodic Maintenance chapter Throttle Grip Throttle Cable Free Play Adjustment e Refer to the Throttle Grip Free Play Adjustment in the Periodic Maintenance chapter Throttle Cable Replacement e Slide out the dust cover A and cable housing dust cover B e Remove the screws C e Separate the throttle cable housing D e Free the tips A from the grip B e Remove Throttle Body Assy see Throttle Body Assy Removal Throttle Pulley Cover Bolts A Throttle Pulley Cover B FUEL SYSTEM DFI 3 83 Throttle Grip and Cable e Loosen the locknut A and bolts B e Remove the cables C from the throttle body assy e Free the tips D from the pulley e Pull out the cables from the frame e Lubricate the throttle cables see Lubrication in the Peri odic Maintenance chapter e Apply grease to the throttle cable tips e Install the throttle cable tips A e Install the bolts B OThe accelerator cable has washer the bent side faces inside e While holding the decelerator cable bolt tighten the throt tle cable locknut C securely Torque Throttle Cable Bolts 3 0 N m 0 31 kgf m 27 in Ib e Install the throttle pulley cover OFit the projection A to the groove B e Tighten Torque Throttle Pulley Cover Bolts 3 4 N m 0 35 kgf m 30 in Ib e Install the removed parts see appropriate chapters Torqu
170. d fit the rear portion of the engine to the swingarm 8 8 ENGINE REMOVAL INSTALLATION Engine Removal Installation e Insert the swingarm pivot shaft from the right side e Install all engine brackets bolts and nuts temporarily Olnsert the following bolts from left side Middle Engine Mounting Bolt A Middle Engine Bracket Bolts B Lower Engine Mounting Bolt C e Install the swingarm pivot shaft nut with the washer e Tighten the bolts and nuts in the numbered sequence 1 6 Torque Swingarm Pivot Shaft Nut 1 98 N m 10 0 kgf m 72 ft lb Lower Engine Mounting Nut 2 49 N m 5 0 kgf m 36 ft lb Middle Engine Mounting Nut 3 49 N m 5 0 kgf m 36 ft lb Middle Engine Bracket Nuts 4 29 N m 3 0 kgf m 21 ft lb Upper Engine Bracket Bolts 5 29 N m 3 0 kgf m 21 ft lb Upper Engine Mounting Bolts 6 49 N m 5 0 kgf m 36 ft lb e Install the removed parts see appropriate chapters e Run the cables hoses and leads according to the Cable Wire and Hose Routing section in the Appendix chapter e Pour Engine Oil see Engine Oil Change in the Periodic Main tenance chapter Coolant see Coolant Filling in the Cooling System chap ter e Adjust Throttle Cable see Throttle Grip Free Play Adjustment in the Periodic Maintenance chapter Clutch Cable see Clutch Operation Inspection in the Pe riodic Maintenance chapter Drive Chain see Drive Chain Slack Adjustment in the Periodic Maintenance chapter
171. d replace the hub bearing e Turn the handlebars until the handlebars does not move to either side front wheel e The wheel edge is moved A to one direction gripping the edge of the wheel by both hands and the play of the wheel bearing is checked lf the play is found replace the bearing Final Drive Drive Chain Wear Inspection e Rotate the rear wheel to inspect the drive chain for dam aged rollers and loose pins and links xlf there is any irregularity replace the drive chain x Lubricate the drive chain if it appears dry Bushing A Roller B Pin C Pin Link D Roller Link E GJ040610S1 GHGS GT 4 gi 4 72 EEN PYLLIT NUUTILA EE oi EE N HEEN N Dasz d e Y d 6K04011BS1 2 36 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Stretch the chain taut by hanging a 10 kg 22 lb weight A on the chain e Measure the length of 20 links B on the straight part C of the chain from the pin center of the 1st pin to the pin center of the 21st pin Since the chain may wear unevenly take measurements at several places Chain 20 link Length Standard 317 5 318 2 mm 12 50 12 53 in Service Limit 323 mm 12 7 in If any measurements exceed the service limit replace the chain Also replace the front and rear sprockets when the drive chain is replaced A WARNING A chain that breaks or jumps off the sprockets could snag
172. d by a barometer Pv Vacuum Pressure Absolute of Throttle Body Vv Sensor Output Voltage V then Pv PI Pg For example suppose the following data is obtained Pg 8 cmHg Vacuum Gauge Reading PI 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 x If the reading is out of the usable range replace the sen sor x lf the reading is within the usable range check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation GC17119BS2 C Intake Air Pressure Sensor Service Code 12 FUEL SYSTEM DFI 3 45 v Vv 4 5 ce Cee coy 7 7 4 0 3 5 3 0 2 5 2 0 1 5 1 0 7 7 7 7 T EE yi ae 77 ie 7 10 20 30 40 50 60 70 76 80 90 ene Ps 2 1 1 1 1 1 1 20 40 60 80 101 32 120 kPa Ps D lt _ gt TO0 Pv abs G6C17120BW4 C ID Idling Ps Standard Atmospheric Pressure Absolute Pv Throttle Vacuum Pressure Absolute ST Standard
173. d locknut installation Axle Holder B Outer Tube C Length Standard 314 2 mm 12 4 0 08 in NOTE OKeep the length while tighten the left front fork cylinder unit PERIODIC MAINTENANCE 2 59 Periodic Maintenance Procedures e Using the top plug wrench unscrew the left front fork cylinder unit from the outer tube A e Slowly slide down the outer tube e Pour the specified fork oil into the left front fork outer tube Suspension Oil SHOWA SS 19 1 L 44091 0009 Outer Tube Oil Capacity Standard 320 2 5 mL 10 82 0 085 US oz EUR BR 300 2 5 mL 10 14 0 085 US oz Adjustable Range 300 340 mL 10 14 11 50 US oz e Replace the O ring on the left front fork cylinder unit with a new one and specified fork oil to the O ring e Temporarily install the left front fork cylinder unit A to the outer tube B using the top plug wrench C Special Tool Top Plug Wrench 50 mm 57001 1645 Right Front Fork e Unscrew the right front fork spring adjuster unit A from the outer tube B Special Tool Top Plug Wrench 50 mm C 57001 1645 e Slowly slide down the outer tube e Hold the right front fork tube A upside down over a clean container B and drain the oil NOTE OPump the outer tube up and down to discharge the fork oil 2 60 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Temporarily install the right front fork spring adjuster unit A to the outer tube B
174. d on any part will be difficult to wash off completely and will eventually deteriorate the rubber used in the disc brake e Apply brake fluid to the removed parts and to the inner wall of the cylinder e Take care not to scratch the piston assy and the inner wall of the cylinder e Apply silicone grease ex PBC grease to the following parts Brake Lever Pivot Bolt Front Brake Lever Contact Front Push Rod Contact Dust Covers e Tighten Torque Brake Lever Pivot Bolt 5 9 N m 0 60 kgf m 52 in Ib Brake Lever Pivot Bolt Locknut 5 9 N m 0 60 kgf m 52 in Ib GS13299BS1 C PERIODIC MAINTENANCE 2 45 Periodic Maintenance Procedures Caliper Rubber Parts Replacement Front Caliper Disassembly e Remove Front Caliper see Caliper Removal in the Brakes chap ter Brake Pads see Brake Pad Removal in the Brakes chapter e Separate the caliper holder A from the caliper B e Remove the anti rattle springs C e Using compressed air remove the pistons One way to remove the pistons is as follows OCover the caliper opening with a clean heavy cloth A ORemove the pistons by lightly applying compressed air B to the hose joint opening A WARNING The piston in the brake caliper can crush hands and fingers Never place your hand or fingers in front of the piston e Pull out the pistons A by hand e Remove the dust seal B and fluid seal C on each cylin der NOTE Olf c
175. ded in the Owner s Manual Replace it with correct plug see chapter 2 Ignition coil trouble ECU trouble Inspect see chapter 16 Inspect see chapter 3 16 Intake air pressure sensor trouble Water temperature sensor trouble Inspect see chapter 3 Inspect see chapter 3 Intake air temperature sensor trouble Miscellaneous Throttle valve will not fully open Inspect see chapter 3 Inspect throttle cables and lever linkage see chapter 3 Engine overheating Water temperature sensor see Overheating of Troubleshooting Guide in or crankshaft sensor trouble Exhaust Smokes Excessively chapter 17 Black smokes Air cleaner element clogged Clean element see chapter 3 Fuel pressure too high Inspect see chapter 3 Upstream downstream injector trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Intake air temperature sensor trouble Brown smoke Inspect see chapter 3 Air cleaner housing loose Fuel pressure too low Reinstall see chapter 3 Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Inspect see chapter 3 Intake air temperature sensor trouble 3 28 FUEL SYSTEM DFI Self Diagnosis Self diagnosis Outline The self diagnosis system has three modes and can be switched to another mode by grounding the self diagnosis t
176. e Throttle Case Mounting Screws 3 8 N m 0 39 kgf m 34 in Ib e Install the throttle cables in accordance with the Cable Wire and Hose Routing section in the Appendix chapter e After the installation adjust each cable properly see Throttle Grip Free Play Adjustment in the Periodic Main tenance chapter A WARNING Operation with improperly adjusted incorrectly routed or damaged cables could result in an unsafe riding condition Follow the service manual to make sure to correct any of these conditions Throttle Cable Lubrication e Whenever the throttle cable is removed or in accordance with the Periodic Maintenance Chart lubricate the these cables see Lubrication in the Periodic Maintenance chapter OApply a thin coating of grease to the cable upper end OUse acommercially available pressure cable lubricator to lubricate these cables Throttle Cable Inspection e Refer to the Cable Inspection in the Periodic Maintenance chapter 3 84 FUEL SYSTEM DFI Throttle Body Assy Idle Speed Inspection e Refer to the Idle Speed Inspection in the Periodic Main tenance chapter Throttle Bore Cleaning e Refer to the Throttle Body Cleaning in the Periodic Main tenance chapter Throttle Body Assy Removal A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Always stop the engine and do not smoke Make sure the area is well ventilated and free from any source of flame
177. e e Tapping evenly around the inner race to remove the ball bearing B e Remove the oil seal C from the right engine cover in the same way as ball bearing removal G6D06101BS1 C e Insert a bar A into the water pump shaft hole from the inside e Remove the oil seal B by tapping C evenly around the seal lips 6D06029BS1 Oil Seal and Bearing Installation NOTICE If the oil seal or ball bearing is removed replace all of them with new ones at the same time e Replace the oil seals with new ones e Apply plenty of grease to the oil seal lips e Press in the oil seals direction as shown OPress in the oil seal using a bearing driver set so that the seal surface is flush with the surface of the right engine cover Flat Side A Water Pump Oil Seals B Special Tool Bearing Driver Set 57001 1129 e Press the ball bearing C into the hole until the face of the bearing is even with the end of the hole Special Tool Bearing Driver Set 57001 1129 e Install the removed parts see appropriate chapters EX G6D06102BS1 C 4 12 COOLING SYSTEM Radiator Radiator Removal e Drain the coolant see Coolant Draining e Remove Radiator Shrouds see Radiator Shroud Removal in the Frame chapter e Remove the capacitor A see Capacitor Removal in the Electrical System chapter e Loosen Water Hose Clamp Screws B e Slide the clamp C e Pull the water hoses D
178. e than two times and make sure it is locked and does not come off Throttle Body Assy Side B Air Cleaner Side C A WARNING Leaking fuel can cause a fire or explosion resulting in severe burns Make sure the fuel hose joint is installed correctly on the delivery pipe and that it doesn t leak lf it comes off reinstall the hose joint e Install the fuel tank see Fuel Tank Installation in the Fuel System DFI chapter e Start the engine and check the fuel hose for leaks Idle Speed Inspection This motorcycle is designed for competition use only Therefore the radiator does not incorporate a coolant reserve tank or cooling fan Prolonged idling of the engine with no airflow through the radiator can cause coolant loss and engine over heating resulting in possible engine damage Any riding conditions that increase engine temperature will further reduce idling time before coolant loss occurs These conditions include high ambient temperature sandy or muddy terrain or other con ditions causing high engine loads at low speeds Furthermore warming the engine up excessively before operation or leaving idling with the hot engine temperature after operation results in the engine overheating too e Start the engine and warm it up thoroughly e With the engine idling turn the handlebars to both sides A If handlebars movement changes the idle speed the throttle cable may be improperly adjusted or incorr
179. e Remove the lower stem bearing inner race tapered roller bearing A with its grease seal from the stem using bear ing pullers Special Tools Bearing Puller 57001 135 Bearing Puller 57001 1575 OAssemble the bearing puller Special Tool 57001 1575 Olnsert the each half split base B under the bottom of bearing inner race and connect the both bases by tight ening the bolts C and nuts D NOTE OTighten evenly two bases by the two stud bolts OAssemble the parts of the bearing puller Special Tool 57001 135 Stud Bolts E Arm F Center Bolt G Adapter H OTurn the center bolt by a wrench and pull the bearing inner race Steering Stem Stem Bearing Installation e Replace the bearing outer races with new ones e Apply grease to the outer races e Drive the outer races into the head pipe at the same time with the special tools Special Tools Head Pipe Outer Race Press Shaft A 57001 1075 Head Pipe Outer Race Driver 651 5 B 57001 1076 Head Pipe Outer Race Driver 654 5 C 57001 1077 GNO4015BS1 GNO4022BS1 C Steering e Replace the inner races with new ones e Apply grease to the lower tapered roller bearing A and drive it onto the stem with the steering stem bearing driver B and adapter C Special Tools Steering Stem Bearing Driver 57001 137 Steering Stem Bearing Driver Adapter 34 5 57001 1074 e Apply grease to the upper tapered roller beari
180. e bearing assemblies if they show wear or damage e Pack the upper and lower tapered roller bearings A in the cages with grease and apply a light coat of grease to the upper and lower outer races e Install the steering stem see Steering Stem Stem Bear ing Installation in the Steering chapter e Adjust the steering see Steering Adjustment PERIODIC MAINTENANCE 2 81 Periodic Maintenance Procedures Frame Frame Inspection e Clean the frame with steam cleaner e Visually inspect the frame and rear frame for cracks dents bending or warp x lf there is any damage to the frame replace it A WARNING A repaired frame may fail in use possibly causing an accident resulting in injury or death If the frame is bent dented cracked or warped replace it Electrical System Spark Plug Cleaning and Inspection e Remove the ignition coil see Ignition Coil Removal in the Electrical System chapter e Clean the plug hole using the compressed air A e Remove the spark plug A using a suitable 16 mm 0 63 in plug wrench B e Clean the spark plug preferably in a sandblasting device and then clean off any abrasive particles The plug may also be cleaned using a high flash point solvent and a wire brush or other suitable tool lf the spark plug electrodes are corroded or damaged or if the insulator is cracked replace the plug Use the standard spark plug
181. e caliper for braking action Air however is easily compressed When air enters the brake lines brake lever or pedal movement will be partially used in compressing the air This will make the lever or pedal feel spongy and there will be a loss in braking power A WARNING Air in the brake lines diminish braking performance and can cause an accident resulting in injury or death If the brake lever has a soft or spongy feel ing mushy when it is applied there might be air in the brake lines or the brake may be defective Do not operate the vehicle and service the brake sys tem immediately NOTE O The procedure to bleed the front brake line is as follows Bleeding the rear brake line is the same as for the front brake e Level the brake fluid reservoir e Remove Screws A Reservoir Cap B Diaphragm e Check that there is plenty of fluid in the reservoir e Slowly pump the brake lever several times until no air bubbles rise up from the bottom of the reservoir OBleed the air completely from the master cylinder by this operation e Remove the rubber cap A from the bleed valve on the Caliper e Attach a clear plastic hose B to the bleed valve on the caliper and run the other end of the hose into a container BRAKES 12 11 12 12 BRAKES Brake Fluid e Bleed the brake line and caliper as follows ORepeat this operation until no more air can be seen com ing out into the clear plastic hose 1 Pump
182. e chain and the sprocket 5 16 ENGINE TOP END Camshafts e Remove Bolt A Auto Decompressor B Spring C Camshaft Installation e When installing the spring A on the auto decompressor B put the spring end C onto the outside coil e Install the auto decompressor A in the exhaust camshatt e Tighten Torque Auto Decompressor Bolt B 12 N m 1 2 kgf m 106 in Ib OThe intake camshaft has projection A e Replace the O ring A with a new one and apply grease it e Fill the oil passage B of the cylinder head with engine oil e Apply molybdenum disulfide oil solution to the ball bear ing all cam and journal surfaces of the camshafts If the new camshatt is installed apply a thin coat of molyb denum disulfide grease to the cam and journal surfaces of the camshaft GE11347BS1 GE11348BS1 C ENGINE TOP END 5 17 Camshafts e Bring the piston to the TDC OPlace a wrench over the flywheel nut A and turn it coun terclockwise to align the TDC mark B with the center of the groove C of the inspection hole e Engage the camshaft chain with the camshaft sprockets OAlign the timing marks on the sprockets with the cylinder head upper surface OStarting with the timing mark on the front of the exhaust sprocket count to the 1st pin Feed the exhaust camshaft thought the chain and align the 28th pin with the timing ma
183. e potential for an accident resulting in serious injury or death Immediately replace any broken spoke s Rim Runout Inspection e Place the jack under the frame so that the front rear wheel off the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Inspect the rim for cracks dents bending or warping If there is any damage to the rim it must be replaced oe ebe Ty 6J05002BS1 GS11047BS1 PERIODIC MAINTENANCE 2 35 Periodic Maintenance Procedures e Set a dial gauge against the side of the rim and rotate the rim to measure the axial runout A OThe difference between the highest and lowest dial read ings is the amount of runout e Set a dial gauge against the outer circumference of the rim and rotate the rim to measure radial runout B Rim Runout with tire installed Standard Axial TIR 1 0 mm 0 04 in or less Radial TIR 1 0 mm 0 04 in or less Service Limit Axial TIR 2 0 mm 0 08 in Radial TIR 2 0 mm 0 08 in lf rim runout exceeds the service limit check the wheel bearings first lf the problem is not due to the bearings loosen some spokes and tighten others within the standard torque Wheel Bearing Inspection e Raise the front rear wheel off the ground using the jack Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Rotate A the wheel lightly and check for roughness binding or noise If any damage is foun
184. e rotor holder and tighten the flywheel nut Special Tools Grip 57001 1591 Rotor Holder 57001 1730 Torque Flywheel Nut 78 5 N m 8 00 kgf m 57 9 ft Ib e Install the magneto cover see Magneto Cover Installa tion Stator Coil Removal e Remove Magneto Cover see Magneto Cover Removal Stator Coil Bolts A Crankshaft Sensor Bolts B Holder C Magneto Lead Grommet D e Remove the stator coil E and crankshaft sensor F as a set Stator Coil Installation e Apply a non permanent locking agent to the threads of the stator coil bolts e Install the stator coil and crankshaft sensor as a set e Tighten Torque Stator Coil Bolts 9 8 N m 1 0 kgf m 87 in Ib e Apply a non permanent locking agent to the threads of the crankshaft sensor bolts e Install the holder A and tighten the crankshaft sensor bolts OHold the magneto lead with the guide B of the holder Torque Crankshaft Sensor Bolts 7 0 N m 0 71 kgf m 62 in Ib e Using a high flash point solvent clean off any oil or dirt that may be on the silicone sealant coating area Dry them with a clean cloth e Apply silicone sealant to the circumference of the mag neto lead grommet C and fit the grommet into the notch D of the cover securely Sealant Liquid Gasket TB1211F 92104 0004 e Install the magneto cover see Magneto Cover Installa tion 218129 P Flywheel Magneto Flywheel Inspection There are thr
185. e specified range adjust it Valve Clearance Adjustment e Remove Camshaft Cap A see Camshaft Removal in the Engine Top End chapter Camshafts B see Camshaft Removal in the Engine Top End chapter e Remove the valve lifters C of the applicable valve e Remove the shims D NOTE OMark and record the locations of the valve lifters and shims so that they can be reinstalled in their original positions GSO7008BS1 Periodic Maintenance Procedures e Clean the shim to remove any dust or oil e Measure the thickness of the removed shim A e 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 Exhaust 0 195 mm Intake 0 125 mm d Replace Shim Thickness Example Intake 2 60 0 31 0 125 2 785 mm OExchange the shims for the 2 800 size shim PERIODIC MAINTENANCE 2 25 NOTICE could cause wear of the valve stem end and valve stem damage Do not use the shims for another models This the Adjustment Shims G6S07066BS1 C 3 000 92180 0187 300 mick P No Mark P No Mark 2 500 92180 0167 250 92180 0188 302 2 525 92180 0168 252 3 050 92180 0189 305 2 550 92180 0190 308 2 575 92180 0191 310 2 600 92180 0171 260 3 125 92180 0192 312 2 625 92180 0193 31
186. e tire is pried off e Pry the other side of the tire off the rim Tire Installation NOTE OThe tires should be installed so that the ID serial NO A faces to left side e Inspect the rim and tire before installing the tire and re place them if necessary e Install the tube band onto the rim e Apply a soap and water solution or rubber lubricant to both the tire bead and rim flange GJ05122BS1 C 6J05010481 90 215 DAN IN wn k E 4 O A gt 4 n ne mi mu MASTA Si GJ05133B S Tires e Position the tire on the rim so that the air valve A is at the tire balance mark B the chalk mark made during removal OThe new tire is no marked e Insert the valve stem into the rim and screw the nut on loosely e Fit the rim protectors and use tire irons to install the tire bead Special Tools Rim Protector 57001 1063 Bead Breaker Assembly 57001 1072 NOTICE To prevent rim damage be sure to place the rim protectors at any place the tire irons are applied e Install the tire on the rim from the opposite side of the air valve OFit the rim protectors and insert the tire irons so deeply that the tube is not damaged e Install the bead protector onto the rim e Similarly slip the tire bead over the rim on the other side e Check that the tube is not pinched between the tire and rim e Tighten the bead protector nut A air valve nut B and air valve
187. easure the free length A of the clutch springs If any clutch spring is shorter than the service limit it must be replaced Clutch Spring Free Length Standard 45 82 mm 1 804 in Service Limit 43 9 mm 1 73 in Clutch Housing Finger Damage Inspection e Visually inspect the clutch housing fingers A that come in contact with the friction plate tangs x lf they are damaged or if there are groove cuts in the areas that come in contact with the tangs replace the housing Replace the friction plates if their tangs are damaged as well GFO6O0603S1 C GRO5036BS1 CLUTCH 6 15 Clutch Friction Plate Clutch Housing Clearance Inspection e Measure the clearance between the tangs A on the fric tion plate and the fingers B of the clutch housing x lf this clearance is excessive the clutch will be noisy x lf the clearance exceeds the service limit replace the fric tion plates Friction Plate Clutch Housing Clearance Standard 0 04 0 55 mm 0 002 0 022 in Service Limit 0 6 mm 0 02 in Clutch Hub Spline Damage Inspection e Visually inspect the areas of the clutch hub splines that come in contact with the teeth of the steel plates lf there are notches worn into the clutch hub splines A replace the clutch hub Replace the steel plates if their teeth are damaged as well GRO50105S1 GRO50140S1 ENGINE LUBRICATION SYSTEM 7 1 Engi
188. ect see chapter 3 16 No or little fuel in tank Supply fuel see Owner s Manual Upstream downstream injector trouble Inspect and replace see chapter 3 Fuel pump not operating Inspect 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 chapter Spark weak Ignition coil shorted or not in good contact Inspect or Reinstall see chapter 16 Ignition 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 correct plug see chapter 2 ECU trouble Inspect see chapter 3 16 Fuel air mixture incorrect Little fuel in tank Supply fuel see Owner s Manual Air cleaner clogged poorly sealed or missing Clean element or inspect sealing See chapter 3 Air cleaner duct loose Reinstall see chapter 3 Throttle body assy holder loose Reinstall see chapter 3 Upstream downstream injector dust seal damage Replace see chapter 3 Upstream downstream injector O ring damage 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
189. ectly routed or it may be damaged Be sure to correct any of these conditions before riding see Cable Wire and Hose Routing section in the Appendix chapter A WARNING Operation with improperly adjusted incorrectly routed or damaged cables could result in an unsafe riding condition Follow the service manual to make sure to correct any of these conditions PERIODIC MAINTENANCE 2 19 Periodic Maintenance Procedures e Check the idle speed using the engine revolution tester A for high accuracy x lf the idle speed is out of specified range adjust it Idle Speed Standard 2 050 50 r min rpm Idle Speed Adjustment e Start the engine and warm it up thoroughly e Turn the idle adjusting screw A until the idle speed is correct To increase idle speed B To decrease idle speed C e Open and close the throttle a few times to make sure that the idle speed is within the specified range Readjust if necessary Air Cleaner Element Cleaning and Inspection NOTE Oln dusty areas the element should be cleaned more frequently than recommended interval OAfter riding through rain or on muddy roads the element should be cleaned immediately OSince repeated cleaning opens the pores of the ele ment replace it with a new one in accordance with the Periodic Maintenance Chart Also if there is a break in the element material or any other damage to the ele ment replace the element w
190. ector click at a regular intervals the downstream injector is normal e Stop the engine If downstream injector does not click check the down stream injector resistance see Downstream Injector Re sistance Inspection Downstream Injector Resistance Inspection e Remove Fuel Tank see Fuel Tank Removal Downstream Injector Connector A SCHIER P SCIIERO P Downstream Injector Service Code 41 e Connect a digital meter to the terminals in downstream injector A e Measure the downstream injector resistance Downstream Injector Resistance Connections R W terminal BL R terminal Standard About 11 7 12 3 Q at 20 C 68 F xlf the reading is out of the standard replace the down stream injector lf the reading is within the standard check the power sup ply voltage see Downstream Injector Power Supply Volt age Inspection Downstream Injector Power Supply Voltage Inspection NOTE OBe sure the battery is fully charged e Disconnect the downstream injector connector and con nect the measuring adapter A between these connec tors Main Harness B Downstream Injector C Special Tool Measuring Adapter 57001 1700 e Connect a digital meter D to the measuring adapter lead Downstream Injector Power Supply Voltage Connections the Adapter Digital Meter R Downstream Injector R W lead Digital Meter Battery Terminal e Refer to the S
191. ed away immediately GL1001018S1 PERIODIC MAINTENANCE 2 49 Periodic Maintenance Procedures Front Brake Hose e Remove Brake Hose Clamp Bolts A Brake Hose Clamps B Rear Brake Hose e Remove Bolts A Caliper Guard B Screws C Brake Hose Clamp D e Remove Screws A Brake Hose Clamp B Rear Master Cylinder Mounting Bolts C e Remove the front rear brake hose banjo bolts A and washers B e Replace the washers with new ones OWhen removing the brake hose take care not to spill the brake fluid on the painted or plastic parts OWhen removing the brake hose temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum GS13256BS1 C e When installing the hoses avoid sharp bending kink ing flattening or twisting and run the hoses according to Cable Wire and Hose Routing section in the Appendix chapter e Tighten Torque Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft Ib e Install the removed parts see appropriate chapters e Bleed the brake line after installing the brake hose see Brake Line Bleeding in the Brakes chapter 2 50 PERIODIC MAINTENANCE Periodic Maintenance Procedures Suspension Front Fork Inspection e Visually inspect the front fork for oil leakage scoring or scratches on the outer surface of the inner tubes A e Holding the brake lever pump the front fork down and up
192. ed mallet whenever tapping is necessary Gasket O ring Hardening shrinkage or damage of both gaskets and O rings after disassembly can reduce sealing per formance Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains Install new gaskets and replace used O rings when re assembling Liquid Gasket Non permanent Locking Agent For applications that require Liquid Gasket or a Non permanent Locking Agent clean the surfaces so that no oil residue remains before applying liquid gasket or non permanent locking agent Do not apply them exces sively Excessive application can clog oil passages and cause serious damage Press For items such as bearings or oil seals that must be pressed into place apply small amount of oil to the con tact area Be sure to maintain proper alignment and use smooth movements when installing 02018 S 020148 S c02016 S GENERAL INFORMATION 1 5 Before Servicing 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
193. ee types of magneto problems short open lead burned out or loss in flywheel magnetism A short or open in one of the coil leads will result in either a low output or no output at all A loss in flywheel magnetism which may be caused by dropping or hitting the flywheel by leaving it near an electromagnetic field or just by aging will result in low output NOTE OBe sure the prepared battery is fully charged e Check the magneto output voltage do the following pro cedures ORemove the left radiator shroud See Radiator Shroud Re moval in the Frame chapter ODisconnect the magneto lead connector see Magneto Cover Removal OUse the engine revolution tester A for high accuracy OConnect the measuring adapter B between the discon nected connectors OConnect the hand tester C to the magneto lead connec tor Main Harness D Flywheel E Special Tools Hand Tester 57001 1394 Measuring Adapter 57001 1700 ORefer to the Self diagnosis Procedures in the Fuel Sys tem DFI chapter connect the 12 V battery to the main harness OStart the engine ORun it at the rpm given in the table 1 ONote the voltage readings total 3 measurements Table 1 Magneto Output Voltage at 4 000 r min rpm Tester Reading Range Tester to Tester to Another yellow AC 250 V One yellow lead lead 37 Vor more x If the output voltage shows the value in the table the mag neto operates properly x If the outpu
194. elf diagnosis Procedures connect the 12 V battery to the main harness e Measure the power supply voltage with the engine stopped Power Supply Voltage Standard Battery Voltage x lf the voltage is out of the standard check the power sup ply wiring see Downstream Injector Circuit lf the reading is within the standard check the output voltage see Downstream Injector Output Voltage Inspec tion FUEL SYSTEM DFI 3 61 SCHIER P 6c17730DS1 C 3 62 FUEL SYSTEM DFI Downstream Injector Service Code 41 Downstream Injector Output Voltage Inspection NOTE OBe sure the battery is fully charged e Remove the ECU see ECU Removal ODo not disconnect the ECU connector e Refer to the Self diagnosis Procedures connect the 12 V battery to the main harness e Using the needle adapter set and connect a digital meter A to the ECU connector B Special Tool Needle Adapter Set 57001 1457 Downstream Injector Output Voltage Connections to ECU Connector Digital Meter BL R lead ECU terminal 4 Digital Meter Battery Terminal e Measure the output voltage with the engine stopped with the connector jointed Output Voltage Standard Battery Voltage e Disconnect the power supply harness lf the reading is within the standard check the ECU for its ground and power supply see ECU Power Supply In spection x If the ground and power supply are good replace the
195. emi dry sump API SG SH SJ SL or SM with JASO MA MA1 or MA2 SAE 10W 40 1 0 L 1 1 US qt GENERAL INFORMATION 1 9 General Specifications Items KX250ZD Drive Train Primary Reduction System Type Gear Reduction Ratio 3 350 67 20 Clutch Type Wet multi disc Manual Transmission Type 5 speed constant mesh return shift Gear Ratios 1st 2 142 30 14 2nd 1 750 28 16 3rd 1 444 26 18 4th 1 235 21 17 5th 1 045 23 22 Final Drive System Type Chain drive Reduction Ratio 3 846 50 13 Overall Drive Ratio 13 470 at Top gear Frame Type Tubular semi double cradle Steering Angle 42 to either side Caster Rake Angle 28 7 Trail 126 4 mm 4 976 in Front Wheel Tire Size 80 100 21 51M Tire Make Type DUNLOP MX51F Tube type Rim Size 21 x 1 60 Rear Wheel Tire Size 100 90 19 57M Tire Make Type DUNLOP MX51 Tube type Rim Size 19 x 1 85 Front Suspension Type Telescopic fork upside down Wheel Travel 315 mm 12 4 in Rear Suspension Type Swingarm New Uni trak Wheel Travel 310 mm 12 2 in Brake Type Front and Rear Single disc Effective Disc Diameter Front 225 mm 8 86 in Rear 215 mm 8 46 in Specifications are subject to change without notice and may not apply to every country 1 10 GENERAL INFORMATION Unit Conversion Table Prefixes for Units Units of Length Prefix Symbol Power ES as te ee mega M 1 000 000 n JE o kilo k 1 000 mm x 0 03937 in
196. en cleaning parts High flash point solvent should be used according to directions of the solvent manufacturer Cleaning Vehicle before Disassembly Clean the vehicle thoroughly before disassembly Dirt or other foreign materials entering into sealed areas during ve hicle disassembly can cause excessive wear and decrease performance of the vehicle 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 02007 S Before Servicing 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 cotter pins or self locking nuts must be replaced with new ones whenever disassembled Assembly Order In most cases assembly order
197. engine oil Rear Master Cylinder Joint Pin PERIODIC MAINTENANCE 2 83 Periodic Maintenance Procedures Cable Inspection e With the cable disconnected at the both ends the cable should move freely A within the cable housing lf cable movement is not free after lubricating if the cable is frayed B or if the cable housing is kinked C replace the cable 6004020152 C Nut Bolt and Fastener Tightness Inspection Tightness Inspection e Check the tightness of the bolts and nuts listed here in accordance with the Periodic Maintenance Chart Also check to see that each cotter pin is in place and in good condition NOTE OFor the engine fasteners check the tightness of them when the engine is cold at room temperature 2 84 PERIODIC MAINTENANCE Periodic Maintenance Procedures If there are loose fasteners retighten them to the spec ified torque following the specified tightening sequence Refer to the Torque and Locking Agent section in this chapter for torque specifications For each fastener first loosen it by 1 2 turn then tighten it lf cotter pins are damaged replace them with new ones Nut Bolt and Fastener to be checked Wheels Spoke Nipples Front Axle Nut Front Axle Clamp Bolts Rear Axle Nut Cotter Pin Rear Axle Nut Final Drive Chain Adjuster Locknut Rear Sprocket Nuts Brakes Front Master Cylinder Clamp Bolts Brake Lever Pivot Bolt Locknut Front Caliper Mounting Bolts Brake
198. er e Drain the coolant see Coolant Draining e Remove the water pipe bolt A and disconnect the water pipe B e Remove the water pump cover bolts C e Using the pry points A remove the pump cover B Water Pump Cover Installation e Install Dowel Pins A e Replace the pump cover gasket B with a new one e Apply grease to the pump cover gasket e Install the water pump cover e Replace the washers A with new ones e Apply a non permanent locking agent to the 55 mm 2 2 in bolts B e Tighten Torque Water Pump Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib Coolant Drain Bolt 7 0 N m 0 71 kgf m 62 in Ib e Replace the water pipe O ring A with a new one e Apply soap and water solution to the new O ring e Insert the water pipe B straightly into the hole of the wa ter pump cover e Tighten Torque Water Pipe Bolt 9 8 N m 1 0 kgf m 87 in Ib e Install the oil filter see Oil Filter Change in the Periodic Maintenance chapter e Fill the coolant see Coolant Filling e Bleed the air from the cooling system see Air Bleeding e Check the engine oil level and add the engine oil see Engine Oil Change in the Periodic Maintenance chapter 4 10 COOLING SYSTEM Water Pump Impeller Removal e Remove Water Pump Cover see Water Pump Cover Removal e Remove the impeller bolt A and take out the impeller B and washer Impeller Installation e Install the washer A and impeller B e T
199. er Clutch Lever Free Play 8 13 mm 0 3 0 5 in Clutch Friction Plate Thickness 2 72 2 88 mm 0 107 0 113 in 2 5 mm 0 10 in Friction Plate Warp 0 15 mm 0 0059 in or less 0 3 mm 0 012 in Steel Plate Warp 0 15 mm 0 0059 in or less 0 3 mm 0 012 in Clutch Spring Free Length 45 82 mm 1 804 in 43 9 mm 1 73 in Friction Plate Clutch Housing 0 04 0 55 mm 0 002 0 022 in 0 6 mm 0 02 in Clearance CLUTCH 6 5 Special Tools Inside Circlip Pliers Clutch Holder 57001 143 57001 1243 C ST5701438ST ST5712438ST Bearing Driver Set 57001 1129 ST571129ST 6 6 CLUTCH Clutch Lever and Cable Due to friction plate wear and clutch cable stretch over a long period of use the clutch must be adjusted in accor dance with the Periodic Maintenance Chart A WARNING The engine and exhaust system get extremely hot during normal operation and can cause serious burns Never touch the engine or exhaust pipe during clutch adjustment Clutch Lever Clutch Cable Free Play Inspection e Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter Clutch Lever Clutch Cable Free Play Adjustment e Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter Clutch Lever Installation e Install the clutch lever assembly A 25 35 B Horizontal Line of Frame C 160 5 mm 6 32 in D Ze
200. er B e Disconnect the regulator rectifier lead connector C e Remove Regulator Rectifier Nuts A Regulator Rectifier B Regulator Rectifier Installation e Replace the regulator rectifier nuts with new ones e Install the regulator rectifier and tighten the nuts Torque Regulator Rectifier Nuts 10 N m 1 02 kgf m 89 in Ib e Run the regulator rectifier lead according to the Cable Wire and Hose Routing section in the Appendix chapter e Connect the regulator rectifier lead connector e Cover the lead connector with dust cover e Install the removed parts see appropriate chapters Regulator Rectifier Output Voltage Inspection NOTE OBe sure the prepared battery is fully charged 16 18 ELECTRICAL SYSTEM Charging System ORefer to the Self diagnosis Procedures in the Fuel Sys tem DEI chapter connect the 12 V battery to the main harness e Connect the hand tester A to the battery terminals B Special Tool Hand Tester 57001 1394 e Start the engine and note the voltage readings at various engine speeds But they must be kept the specified volt age Charging Voltage Tester Range Reading Tester to Tester to DC 25 V Battery Battery 14 0 145 V e Stop the engine x If the charging voltage is kept between the values given in the table the charging system is considered to be working normally lf the charging voltage is much higher than the values spec
201. er Installation in the Frame chapter PERIODIC MAINTENANCE 2 29 Periodic Maintenance Procedures Clutch Clutch Operation Inspection Clutch Lever Clutch Cable Free Play Inspection e Slide the clutch cable adjuster knob A out of place e Check that the clutch cable upper end B is fully seated in the adjusting bolt C e Install the knob to original position e Pull the clutch lever A lightly and check the flee play B Clutch Lever Free Play Standard 8 13 mm 0 3 0 5 in xlf the play is too wide the clutch may not release fully If the play is too narrow the clutch may not engage fully In either case adjust it Clutch Lever Clutch Cable Free Play Adjustment e Turn the clutch cable adjuster knob A so that the clutch lever will have 8 13 mm 0 3 0 5 in of play Be sure that the outer cable end at the clutch lever is fully seated in the adjuster at the clutch lever or it could slip into the place later creating enough cable play to prevent clutch disengagement xklf the free play can not be adjusted with the clutch cable adjuster use the adjusting nut e Slide the dust cover A e Loosen the locknut B at the clutch cable and turn the adjusting nut C so that clutch lever has 8 13 mm 0 3 0 5 in of play e Tighten the locknut and start the engine and check that the clutch does not slip and that it release properly Clutch Plates Inspection e Remove the c
202. er Tube Inspection e Visually inspect the inner tube A xlf there is any damage replace the inner tube Since damage to the inner tube damages the oil seal and dust seal replace the oil seal and dust seal whenever the inner tube is replaced If the inner tube is badly bent or creased replace it Excessive bending followed by subsequent straightening can weaken the inner tube SUSPENSION 13 15 13 16 SUSPENSION Front Fork e Temporarily assemble the inner A and outer B tubes and pump them back and forth manually to check for smooth operation lf you feel binding or catching the inner and outer tubes must be replaced A WARNING A straightened inner or outer fork tube may fall in use possibly causing an accident resulting in seri ous injury or death Replace a badly bent or dam aged inner or outer tube and inspect the other tube carefully before reusing it Dust Seal Inspection e Inspect the dust seal A for any signs of deterioration or damage Replace it if necessary Front Fork Spring Tension Inspection Right Fork only Since a spring becomes shorter as it weakens check its free length A to determine its condition lf the spring is shorter than the service limit it must be replaced Fork Spring Free Length Standard 660 mm 26 0 in Service Limit 647 mm 25 5 in GM040116S1 Rear Shock Absorber To suit to various ridin
203. erioration 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 C or bulges D are noticed e Check that the hoses are securely connected and clamps are tightened correctly Torque Water Hose Clamp Screws 3 0 N m 0 31 kgf m 27 in Ib 6S06010BS1 Engine Top End Valve Clearance Inspection NOTE O Valve clearance must be checked and adjusted when the engine is cold at room temperature e Remove Cylinder Head Cover see Cylinder Head Cover Re moval in the Engine Top End chapter Timing Inspection Cap A Flywheel Nut Cap B Special Tool Filler Cap Driver 57001 1454 2 24 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Bring the piston to the TDC of the compression stroke to inspect the valve clearance the position at the end of the compression stroke when the cam lobe faces outside of the camshaft OPlace a wrench over the flywheel nut A and turn it coun terclockwise to align the TDC mark B with the center of the groove C of the inspection hole e Using a thickness gauge A measure the clearance be tween each cam lobe and valve lifter for all 4 valves OFor the purpose of adjusting the valve clearances record the measured values Valve Clearance Standard Exhaust 0 17 0 22 mm 0 0067 0 0087 in Intake 0 10 0 15 mm 0 0039 0 0059 in If the valve clearance is not within th
204. erminal Orange FI warning indicator light LED blinks to display the service code Locate the problem with the service code table and check and repair DFI or ignition system according to inspection procedure on all service codes Make sure the orange FI warning indicator light LED does not go on Disconnect the connected harness and stop the self diagnosis inspection Run the engine for several minutes at idling above in order to confirm no problem 1 When the engine is rotated there are parts crankshaft sensor upstream downstream injector and ignition coil by which ECU recognizes the fault Kick for that 2 The blink 0 16 seconds cycle is warning of impossible starting The warning of impossible starting displays when connecting the battery and kicked The starting becomes impossible when the crankshaft sensor upstream downstream injector ignition coil fuel pump and vehicle down sensor are fault GC17327F F FUEL SYSTEM DFI 3 31 Self Diagnosis How to Read Service Codes OService codes are shown by a series of long and short blinks of the orange FI warning indicator light LED as shown below ORead 10th digit and unit digit as the orange FI warning indicator light LED blinks OWhen there are a number of problems all the service codes can be stored and the display will begin starting from the lowest number service code in the numerical order Then after completing all codes the display is repeated u
205. erminal User Mode The ECU connected orange FI warning indicator light LED option goes on when DFI system and ignition system parts are faulty In case of serious troubles the ECU stops the injection ignition operation Dealer Mode 1 The orange FI warning indicator light LED emits service code s to show the problem s which the DFI system and ignition system has at the moment of diagnosis Dealer Mode 2 The orange FI warning indicator light LED emits service code s to show the problem s which the DFI system and ignition system had in the past Self diagnosis Procedures e Disconnect the connector A e Connect the FI warning indicator light assy option A e Disconnect the capacitor lead connector A GNET P Self Diagnosis e Connect the power supply harness option P No 26011 0246 A to the capacitor lead connector B of the main harness e Connect the power supply harness option P No 26011 0246 to the 12 V battery C e The orange FI warning indicator light LED will go on for 2 seconds for bulb inspection when the ECU activates If the orange FI warning indicator light LED does not go on inspect the harness or replace the FI warning indicator light assy NOTE OUse a fully charged battery when conducting self diagnosis Otherwise the light blinks very slowly or doesn t blink e Disconnect the self diagnosis connector A and connect an auxiliary lead B for grou
206. erminal e Measure the output voltage with the engine stopped with the connector jointed Output Voltage Standard Battery Voltage e Disconnect the power supply harness lf the reading is within the standard check the ECU for its ground and power supply see ECU Power Supply In spection x If the ground and power supply are good replace the ECU see ECU Removal Installation x lf the reading is out of the standard remove the ECU and check the wiring for continuity between the main harness connectors Special Tool Hand Tester 57001 1394 ODisconnect the ECU and upstream injector connector Wiring Continuity Inspection ECU Connector A Upstream Injector Connector B BL BK lead C ECU terminal 8 x If the wiring good check the ECU ground and power sup ply see ECU Power Supply Inspection lf the ground and power supply good replace the ECU see ECU Removal Installation e Install the removed parts see appropriate chapters Olnstall the upstream injector connector boot so that notch side faces inside GC17047FS1 GC17344FS1 C Upstream Injector Service Code 42 Upstream Injector Fuel Line Inspection e Remove Fuel Hose see Rear Frame Removal in the Frame chap ter OPlace a piece of cloth around the delivery pipe of air cleaner housing e Check the upstream injector fuel line for leakage as fol lows OApply engine oil to the delivery pipe l
207. ernal source is found check for internal leaks Check the cylinder head gasket for leaks e Remove the pressure tester replenish the coolant and install the radiator cap Cooling System Flushing Over a period of time the cooling system accumulates rust scale and lime in the water jacket and radiator When this accumulation is suspected or observed flush the cool ing system If this accumulation is not removed it will clog up the water passages and considerably reduce the effi ciency of the cooling system e Drain the cooling system see Coolant Draining e Fill the cooling system with fresh water mixed with a flush ing compound Avoid the use of a flushing compound which is harmful to the aluminum engine and radiators Carefully follow the instructions supplied by the manufacture of the cleaning product e Warm up the engine and run it at normal operating tem perature for about 10 minutes e Stop the engine and drain the cooling system after the coolant cools down e Fill the system with fresh water e Warm up the engine and drain the system after the coolant cools down e Repeat the previous two steps once more e Fill the system with a permanent type coolant and bleed the air from the system see Air Bleeding COOLING SYSTEM 4 9 Water Pump Water Pump Cover Removal e Remove the oil filter see Oil Filter Change in the Periodic Maintenance chapter ODrain the engine oil from the water pump cov
208. esulting in an accident or injury Be sure to hold the front brake when removing the rear wheel Be sure to hold the front brake when removing the rear wheel or the motorcycle may fall over The rear wheel or the motorcycle could be damaged 10 8 WHEELS TIRES Wheels Rims e Remove the cotter pin A rear axle nut B and washer C e Pull out the axle D and remove the chain adjuster E on both sides e Disengage the drive chain from the rear sprocket e Remove the rear wheel e Remove the collars A with caps B on both sides 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 the disc does not touch the ground e Insert a wood wedge between the brake pads OThis prevents them from being moved out of their proper position should the brake pedal be squeezed acciden tally Rear Wheel Installation e Fit the groove A of the caliper holder and swingarm rib e Apply high temperature grease to the grease seal lips e Install the caps and collars to the hub on both sides OFit the projection A and groove B Wheels Rims e Install the rear wheel e Engage the drive chain with the rear sprocket e Install the chain adjusters on the swingarm Adjuster A Left Side Flat Adjuster B Right Side e Insert the axle from left side and tighten the axle nut Torque Rear Axle Nut 108 N m
209. et Warp Runout Inspection ss 11 9 11 2 FINAL DRIVE Exploded View FINAL DRIVE 11 3 Exploded View No Fastener sone Remarks N m kgf m ft Ib 1 Rear Sprocket Nuts 34 3 5 25 R HO Apply heavy oil L Apply a non permanent locking agent R Replacement Parts 11 4 FINAL DRIVE Specifications Item Drive Chain Chain Slack Chain 20 link Length Standard Chain Make Type Link Sprocket Rear Sprocket Warp Standard 52 58 mm 2 0 2 3 in 317 5 318 2 mm 12 50 12 53 in DAIDO DID 520DMA4 114 links TIR 0 4 mm 0 016 in or less Service Limit 323 mm 12 7 in TIR 0 5 mm 0 020 in FINAL DRIVE 11 5 Special Tool Outside Circlip Pliers 57001 144 ST5701448T 11 6 FINAL DRIVE Drive Chain Drive Chain Slack Inspection e Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter Drive Chain Slack Adjustment e Refer to the Drive Chain Slack Adjustment in the Periodic Maintenance chapter Wheel Alignment Inspection e Check that the notch A of the chain adjuster B aligns with the same swingarm mark C as the other side one A WARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition Be sure the wheel is properly aligned Wheel Alignment Adjustment e This procedure is the same as Drive Chain Slack Adjust ment see Drive Chain S
210. f the caliper holder shaft is damage replace the caliper assembly front caliper caliper bracket or holder shaft rear caliper Torque Rear Caliper Holder Shaft 27 N m 2 8 kgf m 20 ft lb Front Caliper B Rear Caliper C BRAKES 12 17 Brake Pad Brake Pad Removal Front Brake e Remove the pad pin A e Remove the piston side pad B e Push the caliper holder toward the piston and then re move another pad C Rear Brake e Remove Pad Pin Plug A e Remove the pad pin A e Remove the piston side pad B e Push the caliper holder toward the piston and then re move another pad C Brake Pad Installation e Push the caliper piston s in by hand as far as they will go e Install the piston side pad first and then another pad OFit the pad end into the groove A of the anti rattle spring securely Front Brake B Rear Brake C 12 18 BRAKES Brake Pad e Tighten the brake pad pin Torque Brake Pad Pin 17 N m 1 7 kgf m 13 ft lb Rear Brake Pad Pin Plug 2 4 N m 0 24 kgf m 21 in Ib e Check the brake for good braking power no brake drag and no fluid leakage A WARNING After servicing it takes several applications of the brake lever or pedal before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the motorcycle until a firm brake lever o
211. ff completely from the left front fork cylin der unit A e Compress the piston rod B to 200 250 mm 7 87 9 84 in C and hold the left front fork cylinder unit upright position for 10 minutes VC SCH CAN k CET d a CH GM04314BS1 C PERIODIC MAINTENANCE 2 57 Periodic Maintenance Procedures e There should be no oil leak from the base valve assembly part A or bottom of the cylinder B lf oil leaks from the base valve assembly part or bottom of the cylinder replace the cylinder unit e Hold the left front fork cylinder unit on level ground e Release the piston rod then check that the piston rod extends to maximum e Tighten the locknut A fully so that the piston rod thread protrudes 10 12 mm 0 39 0 47 in B e Wipe the fork oil off completely from the left front fork cylin der unit A e Install the left front fork cylinder unit into the fork e Temporarily tighten the left front fork cylinder unit using the top plug wrench Special Tool Top Plug Wrench 50 mm 57001 1645 e Hold the axle holder part with a vise OProtect the axle holder part with a soft jaws or heavy cloth when using a vise A WARNING If the axle holder is not securely clamped the front fork assembly may come out of the vise when com pressed which could cause an accident resulting in injury However clamping the axle holder too tightly can damage it which will affect riding stabil
212. fuel tank on a flat surface and plug the fuel pipes to prevent fuel leakage Fuel Tank e Clean the pipe A e Cover the pipe and hose joint B with the vinyl bags C to keep them clean Fuel Tank Installation e Note the above WARNING see Fuel Tank Removal e Run the hoses correctly see Cable Wire and Hose Rout ing section in the Appendix chapter e Check that the dampers A are in place on the frame If the dampers are damaged or deteriorated replace it OUsing a high flash point solvent clean any oil or dirt that may be on the adhesive cement coating area Dry them with a clean cloth lf necessary apply adhesive cement to the underside of the dampers and stick them e Remove the vinyl bags on the pipe and hose joint e Check that there are no flaws burrs and adhesion of foreign materials on fuel outlet pipe A e Check the joint lock for deformation and wear elt the joint lock is deformed replace the fuel hose with a new one e Apply engine oil to the fuel outlet pipe A lightly e Insert A the fuel hose joint B straight onto the fuel outlet pipe until the hose joint clicks e Push C the joint lock D FUEL SYSTEM DFI 3 89 JC16155BS1 6S05265BS1 C 6S05265BS1 C 3 90 FUEL SYSTEM DEI Fuel Tank e Push and pull A the fuel hose joint back and forth more than two times and make sure it is locked and does not come off A
213. g Driver Set 57001 1129 e Apply grease to the oil seal lip 6104371BS1 C e Install the reed valve A and guide B e Tighten Torque Reed Valve Screws C 7 0 N m 0 71 kgf m 62 in Ib G104333BS2 Right Crankcase e Press the new crankshaft bearing A and new drive shaft bearing B until they bottom out Special Tool Bearing Driver Set 57001 1129 9 12 CRANKSHAFT TRANSMISSION Crankcase e Press the new shift drum ball bearing A and new output shaft bearing B so that the sealed side C faces outside of the engine Special Tool Bearing Driver Set 57001 1129 e Install the right crankcase bearing retainers OThe right crankcase bearing retainers are larger than left ones e Apply a non permanent locking agent to the crankcase bearing retainer screws A e Tighten Torque Crankcase Bearing Retainer Screws 15 N m 1 5 kgf m 11 ft Ib e Tighten Torque Piston Oil Nozzle A 2 9 N m 0 30 kgf m 26 in Ib e Press the new crankshaft oil seal A so that the flat side B faces inside of the engine OPress the oil seal from the outside clutch cover side so that the oil seal end is flush with the crankcase surface C Special Tool Bearing Driver Set 57001 1129 e Apply grease to the oil seal lip G104394BS1 CRANKSHAFT TRANSMISSION 9 13 Crankcase e Install Crankshaft see Crankshaft Installation Transmissio
214. g broken or weak Valve not seating properly valve bent de formed worn or carbon accumulation on the seating surface Decompression trouble Other ECU trouble Engine oil level to high Engine oil viscosity too high Brake dragging Drive train trouble Engine overheating Clutch slipping Poor Running or No Power at High Speed Firing incorrect Spark plug dirty broken or gap malad justed Spark plug cap or spark plug lead trouble 17 14 APPENDIX Troubleshooting Guide Spark plug cap shorted or not in good con tact Spark plug incorrect heat value ECU trouble Crankshaft sensor trouble Flywheel damage Ignition coil trouble Wiring connector not in good contact 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 de formed worn carbon accumulation on the seating surface Decompression trouble Knocking Carbon built up in combustion chamber Fuel
215. g conditions the spring preload of the shock absorber can be adjusted or the spring can be replaced with an optional one Also the damping force can be adjusted easily so changing oil viscosity unnecessary Rebound Damping Adjustment e Turn the rebound damping adjuster A on the rear shock absorber lower end with a standard tip screwdriver until you feel a click If the damper setting feels too soft or too stiff adjust it in accordance with the following table NOTICE Do not force the rebound damping adjuster beyond the fully seated position or the adjusting mecha nism may be damaged Seated position A adjuster turned fully clockwise Rebound Damping Adjuster Setting Standard 12 clicks B counterclockwise Softer Counterclockwise C Harder Clockwise D Although you can turn the adjuster beyond the ad justable range effecting no changes to damping force use it within the adjustable range NOTE OAdjustment of the rebound damping adjuster for the rear suspension will slightly affect the compression damping force Always make any damping adjustments in small steps and test their effects before using them in com petition Compression Damping Adjustment There are two adjustments you can make to the rear shock absorber gas reservoir High Speed Compression Damping Adjuster A Low Speed Compression Damping Adjuster B SUSPENSION 13 17 222120131211109 8 765 432 A S E a E
216. gauge Piston Ring End Gap Standard Top 0 15 0 25 mm 0 0059 0 0098 in Oil 0 20 0 70 mm 0 0079 0 0276 in Service Limit Top 0 6 mm 0 02 in Oil 1 0 mm 0 04 in lf the ring end gap exceeds the service limit replace all rings ENGINE TOP END 5 37 6E16055BS1 5 38 ENGINE TOP END Cylinder and Piston Piston Piston Pin Connecting Rod Wear Inspection e Visually inspect the snap rings A still fitted in place lf the ring shows weakness or deformation replace the ring Also if the pin hole groove shows excessive wear replace the piston e Measure the diameter of the piston pin B with a microm eter Piston Pin Diameter Standard 15 991 16 000 mm 0 62957 0 62992 in Service Limit 15 96 mm 0 6283 in If the piston pin diameter is less than the service limit at any point replace the piston pin e Using a cylinder gauge measure the diameter of both piston pin holes C in the piston and the inside diameter of the connecting rod small end D Piston Pin Hole Diameter Standard 16 004 16 010 mm 0 63008 0 63031 in Service Limit 16 08 mm 0 6331 in Connecting Rod Small End Inside Diameter Standard 16 010 16 018 mm 0 63031 0 63063 in Service Limit 16 05 mm 0 6319 in x If either piston pin hole diameter exceeds the service limit replace the piston lf the connecting rod small end inside diameter exceeds the service limit replace the connect
217. ge Connections to Adapter Digital Meter R sensor LB lead Digital Meter BK sensor GY lead GCI7708ES1 C e Refer to the Self diagnosis Procedures connect the 12 V battery to the main harness 3 48 FUEL SYSTEM DFI Intake Air Temperature Sensor Service Code 13 e Measure the output voltage with the engine stopped and the connector joined Output Voltage Standard About DC 2 28 3 43 V at intake air temperature 20 C 68 F NOTE O The output voltage changes according to the intake air temperature e Disconnect the power supply harness lf the reading is within the standard check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation x lf the reading is out of the standard remove the ECU and check the wiring for continuity between the main harness connectors Special Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Intake Air Temperature Sensor Connector B LB lead C ECU terminal 19 GY lead D ECU terminal 17 x If the wiring is good check the intake air temperature sen sor resistance see Intake Air Temperature Sensor Resis tance Inspection GC17338FS1 C Intake Air Temperature Sensor Resistance Inspection e Remove the intake air temperature senso
218. ghten the 12 bolt together with the clamp Torque Crankcase Bolts 9 8 N m 1 0 kgf m 87 in Ib NOTE OAfter tightening the crankcase bolts wipe up the liquid gasket seeping out around the mating surface espe cially around the area e Make sure that the crankshaft drive shaft and output shaft rotate smoothly in the neutral position xklf the crankshaft will not turn probably the crankshaft is not centered tap the mount portion of the engine with a plastic hammer to reposition it If it does not free up split the crankcase again and find the cause 9 14 CRANKSHAFT TRANSMISSION Crankcase e Install the gear positioning lever and shift drum cam see External Shift Mechanism Installation e Check to see that gears shift smoothly from 1st to 5th gear and 5th to 1st while spinning the output shaft e Set the shift drum in the neutral position e Replace the O rings A on the output shaft with new ones e Apply grease to the O rings e Install the O rings on the output shaft while expanding the O ring e Insert the collar B with the groove C faces inside e Install the removed parts see appropriate chapters G104442BS1 CRANKSHAFT TRANSMISSION 9 15 Crankshaft Crankshaft Removal e Split the crankcase see Crankcase Disassembly e Remove the transmission shafts and shift drum see Transmission Shaft Removal e Using a press remove the crankshaft A from the right crankcase
219. haft Runout Inspection e Set the crankshaft in a flywheel alignment jig or on V blocks and place a dial gauge and turn the crankshaft slowly The maximum difference in gauge reading is the crankshaft runout 8 mm 0 3 in A Crankshaft Runout Standard TIR 0 03 mm 0 001 in or less Service Limit TIR 0 08 mm 0 003 in If the runout at either point exceeds the service limit re place the crankshaft assembly with a new one or align the crankshaft so that the runout falls within the service limit G105114BS1 G105216BS1 6105018BS1 GS10001BS1 CRANKSHAFT TRANSMISSION 9 17 Crankshaft e First correct the horizontal misalignment by striking the projecting crank half A with a plastic soft lead or brass hammer e Recheck the runout with a dial gauge and repeat the process until the runout falls within the service limit e Next correct the vertical misalignment by either driving a wedge A in between the crank halves or by squeezing them in a vise depending on the nature of the misalign ment Do not hammer the crank half at the point B x lf flywheel misalignment cannot be corrected by the above method replace the crankpin or the crankshaft itself Connecting Rod Big End Seizure Inspection In case of serious seizure with damaged flywheels the crankshaft must be replaced In case of less serious damage disassemble the crank shaft and replace t
220. haft Transmission Crankshaft Inspection e Remove Cylinder Head see Cylinder Head Removal in the En gine Top End chapter Cylinder see Cylinder Removal in the Engine Top End chapter Piston see Piston Removal in the Engine Top End chap ter e Make sure that the crankshaft rotate A smoothly in the neutral position lf the crankshaft will not turn smoothly check the connect ing rod big end side clearance If the connecting rod big end side clearance is good check the bearings see Bearing Inspection in the Crank shaft Transmission chapter Connecting Rod Big End Side Clearance e Measure the connecting rod big end side clearance at right side of big end using a thickness gauge A Connecting Rod Big End Side Clearance Standard 0 25 0 35 mm 0 0098 0 0138 in Service Limit 0 6 mm 0 02 in lf the clearance exceeds the service limit replace the crankshaft assembly or reassemble the crankshaft e Make sure that the crankshaft rotates smoothly after as sembling the engine Wheels Tires Air Pressure Inspection Adjustment e Using an air pressure gauge A measure the air pressure when the tires are cold e Adjust the tire air pressure to suit track conditions and rider preference but do not stray too far from the recom mended pressure When the track is wet muddy sandy or slippery reduce the tire pressure to increase the tire tread surface on 80 kPa 0 8 kgf cm 12 psi the ground t
221. hapter 7 10 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter Oil Screen Scavenge e Remove the magneto cover see Magneto Cover Re moval in the Electrical System chapter e Remove the oil screen scavenge A e Clean the oil screen with a high flash point solvent and remove any particles stuck to them A WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the screen in a well ventilated area and take care that there are no sparks or flame anywhere near the working area this includes any appliance with a pilot light Do not use gasoline or a low flash point solvent to clean the screen NOTE O While cleaning the screen check for any metal particles that might indicate internal engine damage e Check the oil screen scavenge A carefully for any dam age holes broken wires or gasket pulling off If the screen is damaged replace it with a new one e Apply engine oil to the three sides A of screen e Install the oil screen scavenge Narrow Side B e Install the magneto cover see Magneto Cover Installation in the Electrical System chapter ENGINE LUBRICATION SYSTEM 7 11 Oil Pump Oil Pump Removal e Drain Engine Oil see Engine Oil Change in the Periodic Main tenance chapter Coolant see Coolant Draining in the Cooling System chapter e Remove Brake Pedal see Brake Pedal Removal in the Brakes chapter Ki
222. haust Pipe Removal in the Engine Top End chapter Connector A Water Temperature Sensor B e Replace the O ring with a new one and apply grease to it e Install the new O ring to the water temperature sensor e Tighten Torque Water Temperature Sensor 12 N m 1 2 kgf m 106 in Ib e Fill the engine with coolant and bleed the air from the cooling system see Coolant Filling in the Cooling System chapter e Install the removed parts see appropriate chapters Water Temperature Sensor Output Voltage Inspection NOTE OBe sure the battery is fully charged e Disconnect the water temperature sensor connector and connect the measuring adapter A between these con nectors Main Harness B Water Temperature Sensor C Special Tool Measuring Adapter 57001 1700 e Connect a digital meter D to the measuring adapter leads Water Temperature Sensor Output Voltage Connections to Adapter Digital Meter R sensor W lead Digital Meter CH BK sensor GY lead GC17718DS1 Water Temperature Sensor Service Code 14 e Refer to the Self diagnosis Procedures connect the 12 V battery to the main harness e Measure the output voltage with the engine stopped and the connector joined Output Voltage Standard About DC 2 80 2 97 V at water temperature 20 C 68 F NOTE OThe output voltage changes according to the coolant temperature in the engine e Disconnect the power supp
223. he crankpin needle bearing and con necting rod 6105004BS2 C 9 18 CRANKSHAFT TRANSMISSION Crankshaft Connecting Rod Bend Inspection e Remove the connecting rod e Select an arbor A of the same diameter as the connect ing rod big end and insert the arbor through the connect ing rod big end e Select an arbor B of the same diameter as the piston pin and more than 105 mm 4 13 in long and insert the arbor through the connecting rod small end e On a surface plate set the big end arbor on a V block C e With the connecting rod held vertically use a height gauge to measure the difference in the height of the arbor above the surface plate over a 100 mm 3 94 in length to determine the amount of connecting rod bend If connecting rod bend exceeds the service limit the con necting rod must be replaced Connecting Rod Bend Service Limit TIR 0 2 100 mm 0 008 3 94 in Connecting Rod Twist Inspection e With the big end arbor A still on the V block B hold the connecting rod horizontally and measure the amount that the arbor C varies from being parallel with the surface plate over a 100 mm 3 94 in length of the arbor to de termine the amount of connecting rod twist If connecting rod twist exceeds the service limit the con necting rod must be replaced Connecting Rod Twist Service Limit TIR 0 2 100 mm 0 008 3 94 in 100mm 6105040681 G105336BS1
224. he 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 Much of the DEI 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 FUEL SYSTEM DFI 3 19 6C17752DSi C 3 20 FUEL SYSTEM DFI Troubleshooting the DFI System e When checking the DFI parts use a digital meter which can be read two decimal place voltage or resistance OThe DFI part connectors A have seals B including the ECU When measuring the input or output voltage with the connector joined use the needle adapter set C Insert the needle adapter inside the seal until the needle adapter reaches the terminal Special Tool Needle Adapter Set 57001 1457 NOTICE 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 Connect the power supply harness option P
225. he sealed side B faces outside of the engine e Press the new output shaft bearing C so that the stepped side D faces inside of the engine Special Tool Bearing Driver Set 57001 1129 e Install the left crankcase bearing retainers OThe left crankcase bearing retainers are smaller than right ones e Apply a non permanent locking agent to the crankcase bearing retainer screws A e Tighten Torque Crankcase Bearing Retainer Screws 15 N m 1 5 kgf m 11 ft lb e Press the new release shaft needle bearing lower A so that the marked side faces upward and the distance from the engine surface to the bearing end is 10 10 5 mm 0 394 0 413 in B e Press the new release shaft needle bearing upper C so that the bearing surface is flush with the crankcase surface D and the marked side faces upward e Press the new release shaft oil seal E so that the oil seal surface is flush with the crankcase surface F OTurn the flat side of the oil seal to upside Special Tool Bearing Driver Set 57001 1129 e Apply grease to the oil seal lip G104393BS1 C CRANKSHAFT TRANSMISSION 9 11 Crankcase e Press the new output shaft oil seal A so that the oil seal surface is flush with the crankcase surface OTurn the metal side to outside of the engine e Press the new shift shaft oil seal B so that the oil seal surface is flush with the crankcase surface Special Tool Bearin
226. head gasket leaking Exhaust pipe leaking at cylinder head con nection Crankshaft runout excessive Engine mounts loose Crankshaft bearing worn Camshaft chain tensioner trouble Camshaft chain sprocket chain guide worn Primary gear worn or damaged Decompressor spring broken Magneto flywheel loose Abnormal Drive Train Noise Clutch noise Clutch housing finger and friction plate tang worn Clutch housing gear worn Metal chips jammed in clutch housing gear teeth Transmission noise Bearings worn Transmission gears worn or chipped Metal chips jammed in gear teeth Engine oil insufficient low viscosity Kick ratchet gear not properly disengaging from kick gear Kick shaft idle gear worn or chipped Drive chain noise Drive chain maladjusted Drive chain worn Rear and or engine sprocket worn Drive chain lubrication insufficient Rear wheel misaligned Abnormal Frame Noise Front fork noise Oil insufficient or too thin Spring weak or broken Front fork air pressure high Rear shock absorber noise Shock absorber trouble Spring weak or broken Disc brake noise Pad surface glazed Disc warped Caliper trouble Pad installed incorrectly Master cylinder damaged Other noise Bracket nut bolt etc not properly mounted or tightened Abnormal Exhaust Color White smoke Piston oil ring worn Cylinder worn Valve oil seal damaged Valve guide worn Engine oil level too high Black smoke Air cleaner element clogged Brown smoke
227. hed inside Disc warped MODEL APPLICATION Year Model Beginning Frame No JKAKXMZCUODA000001 2013 REH JKAKX250ZZA000001 O This digit in the frame number changes from one machine to another WE Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Motorcycle amp Engine Company Part No 99924 1459 01 Printed in Japan
228. iagnosis Procedures connect the 12 V battery to the main harness e Make sure that the fuel pump operates make light sounds for 5 seconds and then stops e Disconnect the power supply harness If the pump does not operate as described above check the operating voltage see Fuel Pump Operating Voltage Inspection Fuel Pump Operating Voltage Inspection NOTE OBe sure the battery is fully charged e Remove the radiator shrouds see Radiator Shroud Re moval in the Frame chapter e Remove the fuel tank bolt and band e Lift the fuel tank and hold it e Disconnect the fuel pump lead connector and connect the measuring adapter A between these connectors Main Harness B Fuel Pump C Special Tool Measuring Adapter 57001 1700 e Connect a digital meter D to the measuring adapter leads Fuel Pump Operating Voltage Connections to Adapter Digital Meter R pump R lead Digital Meter BK pump BK lead e Refer to the Self diagnosis Procedures connect the 12 V battery to the main harness GC17345FS1 FUEL SYSTEM DEI 3 73 Fuel Pump Service Code 46 e Measure the operating voltage with engine stopped and with the connector joined Operating Voltage Standard Battery Voltage xklf the reading is not battery voltage check the wiring for continuity see Fuel Pump Circuit xlf the wiring is good check the ECU for its ground and power supply see ECU Power Supply In
229. iao tededaicudansianesindaataduadia cadvcotiins 12 8 Brake Lever Play Adjustment sni usa enitintmernndienienennanteene 12 8 Brake Pedal Position e EE E EE 12 8 Brake Pedal erneuert getigert eebe 12 8 Brake Pedal InStallation ses ne Merde TN 12 8 e lU RE 12 10 Brake Fluid Level Inspection sen cece readme 12 10 Brake Fluid CHATS RS RS acca he A dance 12 10 Brake Line BIGCGING ancient a ent nn teen a ie 12 11 ANN estate eege eege eege 12 13 Caliper e CEET 12 13 Caliper WiStallAtiony EE 12 14 Caliper Disassemblp suergt rggeugee eege EeEEE ENNEN 12 14 Fluid Seal RE a Ee TEE 12 15 Dust Seal Damage Inspection cise scceseisdatencesndceeesceentteeeiahioceadsetaddsasicietaelounteehend ances EEN 12 15 Caliper Dust Boot and Friction Boot Damage Inspection 12 15 Caliper Piston and Cylinder Damage Inspection c ceeceeeeeeeeceeeeeeeeeeeeeeeeeeeeeeeeeneeeeeeea 12 16 Caliper Holder Shaft Wear Inspection 12 16 POPU 2 O EE Brake Pad Hemoval ii iii iii eerreereeseenereneeeneecneeeneeeeeeeecneeceeeceeeneeeeeeeeeneee Brake Pad Installation Brake Pad Inspection Master Cylinder ns nan A Re nt ne nr en nn ae Front Master Cylinder R emoval sss nina hs ein ananas 12 19 Front Master Cylinder Installation 12 19 Rear Master Cylinder Removal isss sauna ces sdeeeenneiedaess ciaeseueeittienneess 12 20 Rear Master Cylinder rett ege Guns e eebe 12 20 Front Master Cylinder Disassembly AAA 12 21 Rear Master Cylinder DISASSOMDIY 2 50 0 c hc nains de
230. ide diameter of seat area to specification Measure Seating Width Tool Vernier Caliper Purpose check seat width against specification Results 45 Grind a dye Tool 45 Cutter Purpose increase width of seat area beyond specification to increase outside diameter 60 Grind Tool 60 Cutter P FINISHED urpose reduce seat width to specification GE15223B F 5 34 ENGINE TOP END Cylinder and Piston Cylinder Removal e Remove Cylinder Head see Cylinder Head Removal Front Camshaft Chain Guide A Cylinder Bolt B e Tap lightly up with a plastic mallet to separate the cylinder C from the crankcase e Remove the cylinder base gasket Piston Removal e Remove the cylinder see Cylinder Removal e Remove the piston pin snap ring A NOTE OLay a clean cloth under the piston to prevent dropping dirt or parts into the crankcase e Remove the piston pin using a piston pin puller A Special Tool Piston Pin Puller 57001 1568 e Remove the piston B e Carefully spread the piston ring opening with your thumbs and then push up on the opposite side of the ring A to remove it e Remove the oil ring in the same procedure Cylinder and Piston Installation NOTE Olf a new piston or cylinder is used check piston cylinder clearance see Piston Cylinder Clearance Inspection in the Periodic Maintenance chapter and use new piston rings ENGIN
231. ified 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 magneto output is insufficient for the loads Check the magneto and regulator rectifier to determine which part is defective Regulator Rectifier Inspection e Remove Regulator Rectifier see Regulator Rectifier Removal e Set the hand tester to the x 1 KQ range and make the measurements shown in the table Special Tool Hand Tester 57001 1394 e Connect the hand tester to the regulator rectifier If the tester readings are not as specified replace the regulator rectifier Use only Kawasaki Hand Tester 57001 1394 for this test A tester other than the Kawasaki Hand Tester may show different readings If a megger or a meter with a large capacity battery is used the regulator rectifier will be damaged ELECTRICAL SYSTEM 16 19 Charging System Regulator Rectifier Resistance Unit kQ Tester Lead Connection A pme scope i 6 20 4 12 4 12 d SU EE GPO9332BS1 C Tester Lead Connection e Install the regulator rectifier see Regulator Rectifier In stallation Capacitor Removal e Disconnect the connector A e Remove the bolts B e Remove the capacitor C from the bracket Capacitor Installation e Ins
232. ighten Torque Water Pump Impeller Bolt 7 0 N m 0 71 kgf m 62 in Ib e Install the water pump cover see Water Pump Cover In stallation Water Pump Inspection e Visually check the impeller A lf the surface is corroded or if the blades B are dam aged replace the impeller e Check the drainage outlet passage A at the bottom of the right engine cover for coolant leaks lf the oil seal is damaged the coolant leaks through the seal and drains through the passage Replace the oil seals Water Pump Gear Removal e Remove Water Pump Cover see Water Pump Cover Removal Impeller see Impeller Removal Right Engine Cover see Right Engine Cover Removal in the Clutch chapter e Pull out the water pump gear A together with shaft COOLING SYSTEM 4 11 Water Pump Water Pump Gear Installation e Press in the water pump gear shaft A to the gear B until it is bottomed e Apply grease to the water pump gear shaft e Install the gear shaft from bearing side C Be sure to apply grease to the water pump shaft when installing If it is installed dry the seals may wear excessively RE e Install the impeller and check to see that the impeller turn freely Oil Seal and Bearing Removal e Remove Right Engine Cover see Right Engine Cover Removal in the Clutch chapter Water Pump Gear see Water Pump Gear Removal e Insert a bar A into the water pump shaft hole from the outsid
233. ightly OConnect a commercially available vacuum pressure pump A to the delivery pipe B with the fuel hose C OHold both ends with the clamps D e Apply a soap and water solution to the areas E e Watching the pressure gauge squeeze the pump lever F and build up the pressure until the pressure reaches the maximum pressure Fuel Line Maximum Pressure Standard 300 kPa 3 06 kgf cm 44 psi NOTICE During pressure testing do not exceed the maxi mum pressure for which the system is designed OWatch the gauge for at least 6 seconds lf 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 delivery pipe assy upstream injector and related parts ORepeat the leak test and check the fuel line for no leak age e Install Fuel Hose see Rear Frame Installation in the Frame chapter e Start the engine check the fuel leakage FUEL SYSTEM DFI 3 69 6C17330FS2 3 70 FUEL SYSTEM DFI Upstream Injector Service Code 42 Upstream Injector Circuit BK Y R W BL BK BL BK BK Y BK W O Y BK W 0 eo 6C17319FW2 C 1 ECU 2 Upstream Injector 3 Frame Ground 1 4 Capacitor Fuel Pump Service Code 46 Fuel Pump Removal A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Always stop the engine and d
234. il the diameter is within the specified range Original Seating Surface B NOTE ORemove all pittings of flaws from 45 ground surface OAfter grinding with 45 cutter apply thin coat of machin ist s dye to seating surface This makes seating surface distinct and 32 and 60 grinding operation easier OWhen the valve guide is replaced be sure to grind with 45 cutter for centering and good contact lf the outside diameter A of the seating surface is too large make the 32 B grind described below x lf the outside diameter of the seating surface is within the specified range measure the seat width as described be low e Grind the seat at a 32 angle until the seat outside diam eter is within the specified range OTo make the 32 grind fit a 32 cutter into the holder and slide it into the valve guide OTurn the holder one turn at a time while pressing down very lightly Check the seat after each turn The 32 cutter removes material very quickly Check the seat outside diameter frequently to pre vent overgrinding OAfter making the 32 grind return to the seat outside di ameter measurement step above e To measure the seat width use a vernier caliper to mea sure the width of the 45 angle portion of the seat at sev eral places around the seat lf 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
235. ilter oil Permanent type antifreeze SSS Green Sen Soft water 50 coolant 50 35 C 31 F 1 2 L 1 3 US qt 0 17 0 22 mm 0 0067 0 0087 in ee 0 10 0 15 mm 0 0039 0 0059 in 0 05 mm 0 002 in 77 000 77 012 mm 77 10 mm 3 0315 3 0320 in 3 035 in 0 041 0 068 mm 0 0016 0 0027 in Clutch Clutch Lever Free Play Friction Plate Thickness Friction Plate Warp Steel Plate Warp 8 13 mm 0 3 0 5 in 2 72 2 88 mm 0 107 0 113 in 2 5 mm 0 10 in 0 15 mm 0 0059 in or less 0 3 mm 0 012 in 0 15 mm 0 0059 in or less 0 3 mm 0 012 in Engine Lubrication System Engine Oil Type Viscosity Capacity Castrol POWER1 R4 Racing 5W 40 or API SG SH SJ SL or SM with JASO MA MA1 or MA2 SAE 10W 30 10W 40 or 10W 50 0 75 L 0 79 US qt when filter is not ere removed 0 80 L 0 85 US qt when filter is removed 1 00 L 1 06 US qt when engine is completely dry Crankshaft Transmission Connecting Rod Big End Side Clearance 0 25 0 35 mm 0 0098 0 0138 in 0 6 mm 0 02 in 2 10 PERIODIC MAINTENANCE Specifications Item Wheels Tires Rim Runout with tire installed Axial Radial Tires Air Pressure Front Rear Standard Tire Front Size Make Type Rear Size Make Type Final Drive Drive Chain Slack Drive Chain 20 link Length Standard T
236. in heel ddr unir eee Ignition Coll Service Gode bla sik ee nee de te ete nie en lue Ignition Coil Hemovallnstallaton AAA Ignition Coil Primary Peak Voltage Inspection ss sssssssesessnresssrrrnereenrrrrenrssrrrrserrrnnerrrene EGU ting Sans amp ECU Identification ECU Removal ECU Installation ECU Power Supply Fuel Line Jet DEE Fuel ee D EE Fuel Flow Rate Inspection EE EE Throttle Grip and Cable Throttle Grip Thrott Throttle Grip Thrott le Cable Free Play Inspection AE le Cable Free Play Adjustment Throttle Cable Replacement AAA Throttle Cable Lubri er rel GE Throttle Cable Inspection E Throttle Body Assy idle Speed Inspection EE Throttle Bore Cleaning E Throttle Body Assy Enge EE Throttle Body Assy Installation anna tanins Throttle Body Assy Disassembly ss eessen eda ales ai Throttle Body Assy Assembly Air Cleaner Air Cleaner Housing Removal sise Air Cleaner Housing Jeekelen teg eet edel eege ee nds Element Removal Installation ss Element Cleaning a Fuel Tank Fuel Tank Removal Fuel Tank Installatio Fuel Tank Cleaning nd Inspection DEE R G 3 59 3 59 3 60 3 60 3 61 3 62 3 63 3 65 3 65 3 65 3 66 3 67 3 68 3 69 3 71 3 71 3 71 3 72 3 72 3 73 3 73 3 75 3 75 3 75 3 76 3 76 3 76 3 76 3 77 3 79 3 79 3 80 3
237. in lb Rear Master Cylinder Mounting Bolts 9 8 1 0 87 in lb Rear Master Cylinder Push Rod Locknut 17 1 7 13 Brake Pedal Bolt 25 2 5 18 G L Rear Caliper Holder Shaft 27 2 8 20 Si Rear Brake Pad Pin 17 1 7 13 Rear Brake Pad Pin Plug 2 4 0 24 21 in lb Rear Brake Disc Mounting Bolts 23 2 3 17 L Suspension Air Pressure Relief Screws 1 3 0 13 12 in lb Left Front Fork Base Valve Assembly 30 3 1 22 Front Fork Clamp Bolts Upper 20 2 0 15 AL L Front Fork Clamp Bolts Lower 22 2 2 16 AL Right Front Fork Spring Adjuster Unit 34 3 5 25 Left Front Fork Cylinder Unit 34 3 5 25 Left Front Fork Adjuster Assembly Locknut 22 2 2 16 Left Front Fork Adjuster Assembly 69 7 0 51 L Right Front Fork Spring Preload Adjuster 30 3 1 22 Right Front Fork Bottom Plug Locknut 22 2 2 16 Right Front Fork Bottom Plug 69 7 0 51 L Rear Shock Absorber Mounting Nut 39 4 0 29 R Upper Rear Shock Absorber Mounting Nut 34 3 5 25 R Lower Tie Rod Mounting Nuts 59 6 0 44 R Swingarm Pivot Shaft Nut 98 10 0 72 R Rocker Arm Pivot Nut 59 6 0 44 R Gas Reservoir Damping Adjuster 29 5 3 01 21 8 Assembly Rear Shock Absorber Spring Locknut 45 4 6 33 Piston Rod Locknut 37 3 8 27 R 2 8 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Steering Handlebar Clamp Bolts Steering Stem Head Nut Front Fork Clamp Bolts Upper Steering Stem Nut Handlebar Holder Nuts Front Fork Clamp Bolts Lower Brake Hose Clamp Bolt Frame Footpeg Bracket
238. inals A of the ECU connectors If the terminals of the main harness connector are dam aged replace the main harness xlf the terminals of the ECU connector are damaged re place the ECU e Disconnect the capacitor lead connector A e Set the hand tester A to the x 1 Q range and check the following wiring for continuity Special Tool Hand Tester 57001 1394 ECU Grounding Inspection Capacitor Connector B BK W lead ECU Connector C BK Y lead D ECU terminal 6 BK Y lead E ECU terminal 22 BK W lead F ECU terminal 33 Criteria 0 Q x If no continuity check the connector or main harness and repair or replace them if necessary lf the wiring is good check the power supply voltage of the ECU NOTE OBe sure the battery is fully charged e Connect the ECU connector e Refer to the Self diagnosis Procedures connect the 12 V battery to the main harness FUEL SYSTEM DFI 3 77 GD Ce GC1I7346FSi C 3 78 FUEL SYSTEM DFI ECU e Connect a digital meter A to the ECU connector B with the needle adapter set Special Tool Needle Adapter Set 57001 1457 ECU Power Supply Inspection Connections Digital Meter R W lead ECU terminal 1 Digital Meter Battery Terminal GC17347FS1 Standard When battery is not connected DC 0 V When battery is connected Battery Voltage If the
239. indicated below e Insert a new valve A into the guide B and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface e Move the stem back and forth C to measure the valve valve guide clearance e Repeat the measurement in a direction at a 90 angle to the first measurement x If the reading exceeds the service limit replace the guide NOTE O The reading is greater than the actual valve valve guide clearance because the measurement is taken outside of the guide Valve Valve Guide Clearance Wobble Method Standard Exhaust 0 07 0 13 mm 0 0028 0 0051 in Intake 0 02 0 09 mm 0 0008 0 0035 in Service Limit Exhaust 0 30 mm 0 012 in Intake 0 22 mm 0 009 in GE15255BS1 C ENGINE TOP END 5 29 Valves Valve Seat Inspection e Remove the valve see Valve Removal e Check the valve seating surface A between the valve B and valve seat C e Measure the outside diameter D of the seating pattern on the valve seat x lf the outside diameter is too large or too small repair the seat see Seat Repair Valve Seating Surface Outside Diameter Standard Exhaust 24 6 24 8 mm 0 969 0 976 in Intake 30 6 30 8 mm 1 205 1 213 in OMeasure the seat width E of the portion where there is no build up carbon white portion of the valve seat with a vernier caliper Good F x lf the width is too wide G too narrow
240. ine oil level too high Clutch housing seized Clutch release function trouble Clutch hub nut loose Clutch plate warped or rough Clutch hub spline damaged Gear Shifting Faulty Doesn t go into gear shift pedal doesn t return Clutch not disengaging Shift fork bent worn or seized Shift return spring pin loose Shift return spring weak or broken Shift shaft lever broken Pawl guide plate broken Shift pawl broken Shift pawl spring tension lose Troubleshooting Guide APPENDIX 17 15 Gear seized Gear positioning lever operation trouble Shift drum broken Jumps out of gear Shift fork ear worn bent Gear groove worn Gear dogs and or dog holes worn Shift drum groove worn Gear positioning lever spring weak or bro ken Shift fork guide pin worn Drive shaft output shaft and or gear splines worn Overshifts Gear positioning lever spring weak or bro ken Pawl guide plate worn Abnormal Engine Noise Knocking ECU trouble Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect heat value 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 or cam face worn Valve lifter worn Other noise Connecting rod big end small end clear ance excessive Piston ring worn broken or stuck Piston seizure damage Cylinder
241. ine oil to the shaft of the oil pump idle gear A A e e Install the oil pump idle gear e Turn B the oil pump idle gear to check that the oil pump operates smoothly e Replace the circlip C with a new one e Install the new circlip Special Tool Outside Circlip Pliers 57001 144 e Install the removed parts see appropriate chapters Oil Pump Inspection e Disassemble the oil pump assembly see Oil Pump Re moval e Visually inspect the oil pump body outer rotors and the inner rotors If the oil pump is any damage or uneven wear replace the rotors cover body or the crankcase 7 14 ENGINE LUBRICATION SYSTEM Oil Pressure Oil Pressure Measurement e Remove the water pump cover bolt e Install the oil pressure gauge adapter A to the water pump cover Special Tool Oil Pressure Gauge Adapter M6 x 1 0 57001 1664 e Attach the oil pressure gauge A Special Tool Oil Pressure Gauge 5 kgf cm 57001 125 e Start the engine NOTE OWarm up the engine thoroughly before measuring the oil pressure e Run the engine at the specified speed and read the oil pressure gauge Oil Pressure Standard About 98 kPa 1 0 kgf cm 14 2 psi at 4 000 r min rpm Oil Temperature 40 C 104 F x If the reading is much lower than the standard check the feed oil pump and crankshaft oil seal x If the reading is much higher than the standard check the oil filter first and oil passages for dirt or clogging e
242. ine stop switch e Apply grease to the throttle cable upper end and clutch cable upper end e Apply 2 stroke oil to the edge slash area of the handle bars 120 mm 4 72 in A e Install the throttle grip assembly so that the grip A is in as far as it will go OPosition the throttle grip assembly so that the cable gate way B of the throttle case is above the handlebars e Install the front master cylinder see Front Master Cylinder Installation in the Brakes chapter e Install the handlebars A on the steering stem head as follows OThe handlebars angle position can be adjusted to suit your preference using the gauge marks B OPosition the handlebars so that the gauge marks is equal positions C Bridge Bar D e Apply 2 stroke oil to the handlebar clamp bolts e Install the handlebar clamps E and handlebar clamp bolts F GNOGO71BS1 GNOGO29BS1 C GNO6095BS1 STEERING 14 11 Handlebars e Tighten the handlebar clamp bolts A OEqualize the front and rear gaps B NOTE O Tighten the two clamp bolts alternately two times to en sure even tightening torque Torque Handlebar Clamp Bolts 25 N m 2 5 kgf m 18 ft Ib e Install Handlebar Pad A Fuel Tank Breather Hose B Number Plate C See Number Plate Installation in the Frame chapter FRAME 15 1 Frame Table of Contents ae WEE 15 2 Be LE 15 4 Frame Jee ee See
243. ing at closed throttle position and sets the 11 Throttle Sensor Voltage DFI in the D J method 1 0 58 3 85 V Also the throttle sensor system and intake air pressure fails the ECU locks ignition timing into the ignition timing at closed throttle position and sets the DFI in the a N method If the intake air pressure sensor system fails the signal Pv is out of the usable range wiring Intake Air Intake Air Pressure 12 Pressure Absolute short or open the ECU sets the DFI in the Sensor Pv 20 106 7kPa N method ee Conduct ignition and injection operations whenever crank rotates by 360 degrees Intake Air Intake Air Temperature e 13 Temperature 30 120C ECU sets Ta at 26 C Sensor Water Water Temperature S 14 Temperature _30 4120 ECU sets Tw at 80 C Sensor Crankshaft sensor must 2 Crankshaft send 18 signals output If crankshaft sensor generates other than 18 Sensor signal to the ECU at signals the engine stops by itself the one cranking 25 Gear Position Gear Position Switch lr the gear position switch fails set the low Switch 0 469 4 727 V gear position Vehicle down Vehicle down Sensor lfthe vehicle down sensor system has failures 31 Sim Output Voltage the ECU shuts off the fuel system and the 0 4 4 4V ignition system ECU does not backup If the downstream injector break down wiring 41 Downstream In succession pulse is short or open the ECU stops the signal out Injector o
244. ing rod GE16260BS2 C ENGINE TOP END 5 39 Throttle Body Assy Holder Throttle Body Assy Holder Removal e Remove Cylinder Head see Cylinder Head Removal Throttle Body Assy Holder Clamp Screw A Loosen Throttle Body Assy Holder B and Holder Clamp Throttle Body Assy Holder Installation e Install Throttle Body Assy Holder Throttle Body Assy Holder Clamp OTurn the mark A to the throttle body assy OTurn the screw head B to the engine left side OFit the projection C of the cylinder head and the recess D of the holder e Tighten Torque Throttle Body Holder Clamp Screw 2 0 N m 0 20 kgf m 18 in Ib e Install the removed parts see appropriate chapters 5 40 ENGINE TOP END Muffler A WARNING The muffler can become extremely hot during nor mal operation and cause severe burns Do not re move the muffler while it is hot Muffler Body Removal e Remove the right side cover see Side Cover Removal in the Frame chapter e Loosen the muffler clamp bolt A e Remove the mounting bolts B and pull out the muffler body C backward Exhaust Pipe Removal e Remove Muffler Body see Muffler Body Removal Exhaust Pipe Holder Nuts A Exhaust Pipe B Muffler Installation e Replace the exhaust pipe gasket and muffler pipe gasket with new ones e Apply grease to the exhaust pipe gasket and install it to the engine e Install the gasket to the muffler pipe until i
245. ing technique faulty When flooded do not crank the engine with the throttle fully opened This promotes engine flood because more fuel is supplied automatically by DEI No spark spark weak Spark plug dirty broken or gap malad justed Spark plug cap or spark plug lead trouble Spark plug cap shorted or not in good con tact Spark plug incorrect heat value ECU trouble Crankshaft sensor trouble Ignition coil trouble Engine stop switch shorted Wiring shorted or open Flywheel damage 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 Spark plug cap shorted or not in good con tact Spark plug incorrect heat value ECU trouble Crankshaft sensor trouble Flywheel damaged Ignition coil trouble Wiring connector not in good contact Fuel air mixture incorrect 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 Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve sprin
246. inside of the number plate Run the front brake hose outside of the number plate Band Hold the engine stop switch lead Engine Stop Switch Lead Run the engine stop switch lead and clutch cable into the guide Run the throttle cables into the guide OO JO O1 P D ch ch APPENDIX 17 3 Cable Wire and Hose Routing 6609950 G Clutch Cable Engine Stop Switch Lead Main Harness Run the clutch cable outside of the main harness Clamps Firmly twist the clamp from near bolted point around the clutch cable Throttle Cables Run the throttle cables between the joint hose and radiator overflow hose Run the regulator rectifier lead as shown Put the regulator rectifier lead connector on the top position Run the throttle cables over the main harness I O O1 W ND 17 4 APPENDIX Cable Wire and Hose Routing Engine Stop Switch Lead 2 Clamp Hold the main harness and engine stop switch lead on the main harness at the white taped position 3 Position the engine stop switch lead connector behind the clamp and between the main harness and frame 4 Run the capacitor lead to the right side of the capacitor 5 Joint Hose 6 Main Harness APPENDIX 17 5 Cable Wire and Hose Routing 1 Clamp Turn the lock position to upward 2 Clamp Turn the lock position to upward 3 Run the main harness and option
247. int lock When removing with fingers e Open and push up A the joint lock B with your fingers Prying or excessively widening the joint lock ends for fuel hose removal will permanently deform the joint lock resulting in a loose or incomplete lock that may allow fuel to leak and create the potential for a fire explosion To prevent fire or explosion from a damaged joint lock do not pry or excessively widen the joint lock ends when removing the fuel hose The joint lock has a retaining edge that locks around the housing GS05269BS1 C e Pull the fuel hose joint A out of the fuel outlet pipe A WARNING Fuel is flammable and explosive under certain con ditions and can cause severe burns Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is dis connected fuel spills out from the hose and the pipe because of residual pressure Cover the hose connection with a piece of clean cloth to prevent fuel spillage e Close the fuel tank cap e Remove the fuel tank and place a it on a flat surface ODo not apply the load to the fuel outlet pipe of the fuel pump A WARNING Gasoline is extremely flammable and can be explo sive under certain conditions creating the poten tial for serious burns Store the fuel tank in an area which is well ventilated and free from any source of flame or sparks Do not smoke in this area Place the
248. ion Coil Circuit R W BK Y BK Y BK W 0 Y BK W 0 EE NM 2 6C17321F 2 C 1 ECU 2 Capacitor 3 Frame Ground 1 4 Frame Ground 2 5 Ignition Coil 6 Spark Plug 3 76 FUEL SYSTEM DFI ECU ECU Identification OMost countries have their own regulations so each ECU has different characteristic So do not confuse ECU with each other and use only the ECU for your model Other wise the motorcycle cannot clear the regulation ECU Identification Part Number A Specification 21175 0782 US CA 21175 0792 AU EUR 21175 0800 BR ECU Removal NOTICE Never drop the ECU especially on a hard surface Such a shock to the ECU can damage it e Remove Number Plate see Number Plate Removal in the Frame chapter Bolt A Connector Bracket B e Disconnect the ECU connector A e Pull the ECU B together with rubber protector ECU Installation e Install the ECU A to the rubber protector B GC17720ES81 GOIETA P SCHUED P ECU e Insert the slits A of the rubber protector to the ECU bracket e Connect the ECU connector B ECU Power Supply Inspection e Remove the number plate see Number Plate Removal in the Frame chapter e Visually inspect the ECU connector If the connector is clogged with mud or dust blow it off with compressed air e Remove the ECU see ECU Removal e Visually inspect the term
249. ions that should be followed servicing the DFI system OConnect these connectors until they click A ONever any of the DFI electrical connectors are discon nected The ECU memorizes service codes ODo not spray water on the electrical parts DFI parts con nectors leads and wiring OWhen any fuel hose is disconnected do not start the en gine The fuel pump will operate and fuel will spout from the fuel hose ODo not operate the fuel pump if it is completely dry This is to prevent pump seizure OBefore removing the fuel system parts blow the outer sur faces of these parts clean with compressed air OWhen any fuel hose is disconnected fuel may spout out by residual pressure in the fuel line Cover the hose joint with a piece of clean cloth to prevent fuel spillage OWhen installing the fuel hoses avoid sharp bending kink ing flattening or twisting and run the fuel hoses with a minimum of bending so that the fuel flow will not be ob structed ORun the hoses according to Cable Wire and Hose Rout ing section in the Appendix chapter OTo prevent corrosion and deposits in the fuel system do not add to fuel any fuel antifreeze chemicals to fuel Olf 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 hoses A x Replace the fuel hose if any fraying cracks or bulges are noticed O
250. irty clean it carefully If it is damaged replace it Connect them securely e Check the wiring for continuity OUse the wiring diagram to find the ends of the lead which is suspected of being a problem OConnect the hand tester between the ends of the leads Special Tool Hand Tester 57001 1394 OSet the tester to the x 1 Q range and read the tester lf the tester does not read 0 Q the lead is defective Re place the lead or the main harness Olf both ends of a harness A are far apart ground B the one end C using a jumper lead D and check the con tinuity between the end E and the ground F This en ables to check a long harness for continuity If the harness is open repair or replace the harness OWhen checking a harness A for short circuit open one end B and check the continuity between the other end C and ground D If there is continuity the harness has a short circuit to ground and it must be repaired or re placed e Narrow down suspicious locations by repeating the con tinuity tests from the ECU connectors If no abnormality is found in the wiring or connectors the DFI parts are the next likely suspects Check the part starting with input and output voltages However there is no way to check the ECU itself If an abnormality is found replace the affected DFI part xlf no abnormality is found in the wiring connectors and DFI parts replace the ECU GPO7060BS1 C 6C1702
251. is the reverse of disassem bly however if assembly order is provided in this Service Manual follow the procedures given Tightening Sequence Generally when installing a part with several bolts nuts or screws start them all in their holes and tighten them to a snug fit Then tighten them according to the specified 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 GENERAL INFORMATION 1 3 02010 S 4 OX OZ ch fa amp S D wl e eeng sl Wi e NS CH KF I j SE A S TN 6020115 S H AK t ewe g TT x 2S ENN NZ ER A L A bk les LC S Se KZ Ge a br 6 a a 02018 S 1 4 GENERAL INFORMATION Before Servicing Tightening Torque Incorrect torque applied to a bolt nut or screw may lead to serious damage Tighten fasteners to the specified torque using a good quality torque wrench Often the tightening sequence is followed twice initial tightening and final tightening with torque wrench Force Use common sense during disassembly and assembly excessive force can cause expensive or hard to repair dam age When necessary remove screws that have a non permanent locking agent applied using an impact driver Use a plastic fac
252. ith a new one WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the element in a well ventilated area and take care that there is no spark or flame any where near the working areas Do not use gasoline or low flash point solvents to clean the element 2 20 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Remove Seat see Seat Removal in the Frame chapter Wing Bolt A Air Cleaner Element B e Stuff a clean lint free towel into the air cleaner duct so no dirt is allowed to enter the throttle body assy e Wipe out the inside of the air cleaner housing with a clean damp towel Check inside of the intake tract and throttle body assy for dirt If dirt is present clean the intake tract and throttle body assy thoroughly You may also need to replace the element and seal the housing and intake tract e Separate the element A from the frame B e Clean the element A in a bath of a high flash point sol vent using a soft bristle brush e Squeeze it dry in a clean towel A Do not wring the ele ment or blow it dry the element can be damaged e Check all parts of the element for visible damage lf any parts of the element are damaged replace them e After cleaning saturate the element with a high quality foam air filter oil squeeze out the excess then wrap it in a clean towel and squeeze it as dry as possible OBe careful
253. l NOTICE Do not lay the wheel directly on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground e To maintain wheel balance mark A the air valve position on the tire with chalk so that the tire can be reinstalled in the same position Align B e Remove the air valve cap C e Take out the valve core A to let out the air e Remove the air valve nut 6J05126BS1 C e Loosen the bead protector nut A e Lubricate the tire beads and rim flanges on both sides with a soap and waiter solution or rubber lubricant This helps the tire beads slip off the rim flanges Never lubricate with engine oil or petroleum distil lates because they will deteriorate the tire 10 12 WHEELS TIRES Tires e Break the beads away from both sides of the rim with the bead breaker A Special Tool Bead Breaker Assembly 57001 1072 e Lubricate the tire irons A included in Bead Breaker As sembly 57001 1072 and rim protectors B with soap and water solution or rubber lubricant Special Tool Rim Protector 57001 1063 e Step on the side of the tire opposite air valve and pry the tire off the rim with the tire irons of the bead breaker protecting the rim with rim protectors Take care not to insert the tire irons so deeply that the tube gets damaged e Remove the tube and bead protector when one side of th
254. l see chapter 16 Ignition 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 correct plug see chapter 2 ECU trouble Inspect see chapter 3 16 Fuel air mixture incorrect Air cleaner clogged poorly sealed or missing Clean element or inspect sealing see chapter 3 Air cleaner housing loose Reinstall see chapter 3 Throttle body assy holder loose Reinstall see chapter 3 Upstream downstream injector dust seal damage Replace see chapter 3 Water or foreign matter in fuel Upstream downstream injector O ring damage Upstream downstream injector clogged Fuel line clogged Fuel pump trouble Intake air pressure sensor trouble Change fuel Inspect and clean fuel system see chapter 3 Replace see chapter 3 Inspect and repair see chapter 3 Inspect and repair see chapter 3 Inspect see chapter 3 Inspect see chapter 3 FUEL SYSTEM DFI 3 27 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions chapter Water temperature sensor trouble Inspect see chapter 3 Intake air temperature sensor trouble Inspect see chapter 3 Throttle sensor trouble Inspect see chapter 3 Knocking Fuel poor quality or incorrect Spark plug incorrect Fuel change Use the gasoline recommen
255. lack Adjustment in the Periodic Maintenance chapter Drive Chain Wear Inspection e Refer to the Drive Chain Wear Inspection in the Periodic Maintenance chapter Drive Chain Lubrication e Refer to the Drive Chain Lubrication in the Periodic Main tenance chapter Drive Chain Removal e Remove the engine sprocket cover see Engine Sprocket Removal e Remove the clip A from the master link with pliers e Remove Link Plate A Master Link B Drive Chain C FINAL DRIVE 11 7 Drive Chain Drive Chain Installation e Fit the drive chain onto the sprockets OPlace the drive chain ends on the rear sprocket e Install the master link A from the wheel side e Install the link plate A so that the mark faces out e Install the clip B so that the closed end C of the U pointed in the direction of chain rotation D e Adjust the drive chain slack see Drive Chain Slack Ad justment in the Periodic Maintenance chapter e Install the engine sprocket cover see Engine Sprocket Installation 11 8 FINAL DRIVE Sprockets Engine Sprocket Removal e Remove Engine Sprocket Cover Bolts A Engine Sprocket Cover B Drive Chain Guide C e Remove Circlip A Special Tool Outside Circlip Pliers 57001 144 e Remove the engine sprocket B from the drive chain C Engine Sprocket Installation e Engage the drive chain A to the engine sprocket B and install the engine sprocket on the
256. ll affect electrical system operation OMeasure coil and winding resistance when the part is cold at room temperature Electrical Wiring Wiring Inspection e Visually inspect the wiring for signs of burning fraying etc lf any wiring is poor replace the damaged wiring e Pull each connector A apart and inspect it for corrosion dirt and damage x lf the connector is corroded or dirty clean it carefully If it is damaged replace it e Check the wiring for continuity OUse the wiring diagram to find the ends of the lead which is suspected of being a problem OConnect the hand tester between the ends of the leads Special Tool Hand Tester 57001 1394 OSet the tester to the x 1 Q range and read the tester x If the tester does not read 0 Q the lead is defective Re place the lead or the wiring harness if necessary ELECTRICAL SYSTEM 16 11 GPO7060BS1 C 16 12 ELECTRICAL SYSTEM Flywheel Magneto Magneto Cover Removal e Drain the engine oil see Engine Oil Change in the Peri odic Maintenance chapter e Remove Left Radiator Shroud see Radiator Shroud Removal in the Frame chapter Shift Pedal see Shift Pedal Removal in the Crank shaft Transmission chapter e Disconnect the magneto lead connector A from the main harness e Open the clamps A then free the magneto lead B e Remove Bolt C and Engine Guard D Magneto Cover Bolts E Magneto Cover F Magneto Cover Installation
257. lutch plates see Clutch Removal in the Clutch chapter e Visually inspect the friction and steel plates to see if they show signs of seizure uneven wear or any other damage lf any plates show signs of damage replace the friction plates and steel plates as a set 2 30 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Measure the thickness A of the friction and at several points with vernier calipers Friction Plate Thickness Standard 2 72 2 88 mm 0 107 0 113 in Service Limit 2 5 mm 0 10 in x If they have worn past the service limit replace them with new ones e Place each friction plate or steel plate on a surface plate A e Measure the gap between the surface plate and each fric tion plate or steel plate B with a thickness gauge C The gap is the amount of friction or steel plate warp Friction and Steel Plates Warp Standard Friction Plate 0 15 mm 0 0059 in or less Steel Plate 0 15 mm 0 0059 in or less Service Limit Friction Plate 0 3 mm 0 012 in Steel Plate 0 3 mm 0 012 in If any plate is warped over the service limit replace it with a new one Engine Lubrication System A WARNING Vehicle operation with insufficient deteriorated or contaminated engine oil will cause accelerated wear and may result in engine seizure accident and injury Check the oil level before each use and change the oil and filter according to the periodic maintenance chart Engine Oil
258. lve guide up to 120 150 C 248 302 F 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 e Hammer lightly on the valve guide arbor A to remove the guide Special Tool Valve Guide Arbor 64 5 57001 1331 Valve Guide Installation e Apply a thin coat of engine oil to the outer surface of the valve guide e Heat the area around the valve guide up to 120 150 C 248 302 F NOTICE 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 e Using the valve guide driver A and attachment press and insert the valve guide in until the attachment bottom surface touches the cylinder head surface B Exhaust 13 8 14 0 mm 0 543 0 551 in C Intake 15 3 15 5 mm 0 602 0 610 in D Special Tools Valve Guide Driver 57001 1564 Valve Guide Driver Attachment F E 57001 1722 ENGINE TOP END 5 27 6E15045BS1 GE15254BS1 C 5 28 ENGINE TOP END Valves e Ream the valve guide with valve guide reamer A even if the old guide is reused OAlways rotate the reamer clockwise Special Tool Valve Guide Reamer 44 5 57001 1333 Valve Valve Guide Clearance Measurement Wobble Method If a small bore gauge is not available inspect the valve guide wear by measuring the valve valve guide clearance with the wobble method as
259. ly harness lf the reading is within the standard check the ECU for its ground and power supply see ECU Power Supply Inspection x lf the ground and power supply are good replace the ECU see ECU Removal Installation x If the reading is out of the standard remove the ECU and check the wiring for continuity between the main harness connectors Special Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Water Temperature Sensor Connector B W lead C ECU terminal 21 GY lead D ECU terminal 17 xlf the wiring is good check the water temperature sensor resistance see Water Temperature Sensor Inspection FUEL SYSTEM DFI 3 51 6C17339FS1 C 3 52 FUEL SYSTEM DFI Water Temperature Sensor Service Code 14 Water Temperature Sensor Inspection e Remove the water temperature sensor see Water Tem perature Sensor Removal Installation e Suspend the sensor A in a container of machine oil so that the heat sensitive portion and threaded portion are submerged e Suspend a thermometer B with heat sensitive portions C located in almost the same depth NOTE OThe sensor and thermometer must not touch the con tainer side or bottom e Place the container over a source of heat and gradually raise the temperature of the oil while stirring the oil gently for even temperature e Using the hand tester measure the in
260. m Standard Service Limit Camshafts Cam Height Exhaust 33 943 34 057 mm 33 84 mm 1 3363 1 3408 in 1 332 in Intake 35 243 35 357 mm 35 14 mm 1 3875 1 3920 in 1 383 in Camshaft Journal Camshaft Cap 0 020 0 062 mm 0 15 mm Clearance 0 0008 0 0024 in 0 0059 in Camshaft Journal Diameter 21 959 21 980 mm 21 93 mm 0 8645 0 8654 in 0 8634 in Camshaft Bearing Inside Diameter 22 000 22 021 mm 22 08 mm 0 8661 0 8670 in 0 8693 in Camshaft Runout TIR 0 02 mm 0 0008 in or less TIR 0 1 mm 0 004 in Cylinder Head Cylinder Compression Cylinder Head Warp Valves Valve Clearance Exhaust Intake Valve Stem Bend Valve Stem Diameter Exhaust Intake Valve Guide Inside Diameter Exhaust Intake Valve Valve Guide Clearance Wobble Method Exhaust Intake Valve Seat Cutting Angle Usable Range 427 708 kPa 4 4 7 2 kgf cm 62 103 psi at 5 times 0 17 0 22 mm 0 0067 0 0087 in 0 10 0 15 mm 0 0039 0 0059 in TIR 0 01 mm 0 0004 in or less 4 455 4 470 mm 0 1754 0 1760 in 4 475 4 490 mm 0 1762 0 1768 in 4 500 4 512 mm 0 1772 0 1776 in 4 500 4 512 mm 0 1772 0 1776 in 0 07 0 13 mm 0 0028 0 0051 in 0 02 0 09 mm 0 0008 0 0035 in 32 45 60 0 05 mm 0 002 in TIR 0 05 mm 0 002 in 4 44 mm 0 175 in 4 46 mm 0 176 in 4 58 mm 0 180 in 4 58 mm 0 180 in
261. m bolt A e Hold the gear positioning lever B with suitable tool and remove the shift drum cam C e Remove Gear Positioning Lever Nut D and Washer E CRANKSHAFT TRANSMISSION 9 25 External Shift Mechanism e Remove Pin A Gear Positioning Lever B Collar C Spring D External Shift Mechanism Installation Install Pin A Spring B Collar C Gear Positioning Lever D Washer e Tighten Torque Gear Positioning Lever Nut 8 8 N m 0 90 kgf m 78 in lb e Hold the gear positioning lever A with the suitable tool B and install the shift drum cam C OFit the groove D on the pin E e Apply a non permanent locking agent to the shift drum cam bolt e Tighten Torque Shift Drum Cam Bolt 24 N m 2 4 kgf m 18 ft lb e Align the roller of the gear positioning lever with the slot of the shift drum cam e Fit the spring end A to the notch of the gear positioning lever e Turn the input shaft to check that the shift changes smoothly Set up the shift ratchet assembly Ratchet A Pawls B Pins C Springs D 6116032BS1 C 9 26 CRANKSHAFT TRANSMISSION External Shift Mechanism e Install the shift ratchet assembly A and ratchet plate B as a set e Apply a non permanent locking agent to the ratchet plate screw and bolt e Tighten Torque Ratchet Plate Screw C 15 N m 1 5 kgf m 11 ft Ib Ratchet Plate Bolt D 9 8 N m 1 0 kgf
262. m injector especially on a hard surface Such a shock to the downstream injector can damage it Downstream Injector Removal e Remove the throttle body assy see Throttle Body Assy Removal e Remove the delivery pipe mounting screw A e Remove the delivery pipe B together with the down stream injector NOTE ODo not damage the insertion portions of the down a stream injector when they are pulled out from the CE P throttle body e Separate the downstream injector A from the delivery pipe B Downstream Injector Installation e Replace the O ring A and dust seal B with a new one e Apply engine oil to the O ring and dust seal e Assemble the delivery pipe A and downstream injector B ness P 3 60 FUEL SYSTEM DFI Downstream Injector Service Code 41 e Fit the projections A on the delivery pipe to the hollows B of the throttle body assy e Tighten the delivery pipe mounting screw A e Install the removed parts see appropriate chapters Downstream Injector Audible Inspection e Remove Left Radiator Shroud see Radiator Shroud Removal in the Frame chapter e Start the engine and let it idle e Apply the standard tip screwdriver A to the downstream injector e Put the grip end into your ear and listen whether the downstream injector is clicking or not OA sound scope can also be used OThe click interval becomes shorter as the engine speed rises If the downstream inj
263. mal the trouble is with the spark plug cap Measuring Coil Resistance If the arcing tester is not available the coil can be checked for a broken or badly shorted winding with the hand tester However the hand tester cannot detect layer shorts and shorts resulting from insulation breakdown under high volt age Special Tool Hand Tester 57001 1394 e Remove the ignition coil see Ignition Coil Removal e Measure the primary winding resistance A as follows OConnect the hand tester between the coil terminals OSet the tester to the x 1 Q range and read the tester e Measure the secondary winding resistance B as follows ORemove the spark plug cap from the spark plug lead OConnect the hand tester between the spark plug lead and the ground lead terminal OSet the tester to the x 1 KQ range and read the tester Ignition Coil Winding Resistance Primary Windings 0 28 0 38 Q at 20 C 68 F Secondary Windings 7 65 10 4 kQ at 20 C 68 F x lf the tester does not read as specified replace the ignition coil xlf the tester reads as specified the ignition coil windings are probably good However if the ignition system still does not perform as it should after all other components have been checked test replace the coil with one known to be good e Check the spark plug lead for visible damage lf the spark plug lead is damaged replace the ignition coil ELECTRICAL SYSTEM 16 23 GP10722BSi C
264. manually to check for smooth operation If the fork shown damages or oil leak replace the dam aged parts x If the fork rattles inspect the oil level or tightening torque If the inner tube is badly bent or creased replace it Excessive bending followed by subsequent straightening can weaken the inner tube Front Fork Oil Change e Remove the number plate see Number Plate Removal in the Frame chapter e Loosen the front fork clamp bolts upper A e Loosen the cylinder unit left front fork B spring adjuster unit right front fork using the top plug wrench C Special Tool Top Plug Wrench 50 mm 57001 1645 e Remove the front forks see Front Fork Removal in the Suspension chapter e Thoroughly clean the fork before disassembly Be careful not scratch the inner tube and not to damage the dust seal Avoid scratching or damaging the inner tube or the dust seal Use a mild detergent and sponge out dirt with plenty of water e Measure the length A between the top surface of the axle holder B and under surface of the outer tube C ORecord the length before disassembling the fork Length Standard 314 2 mm 12 4 0 08 in Left Front Fork e Record the position of each damping adjuster A and then turn B them to the softest position PERIODIC MAINTENANCE 2 51 Periodic Maintenance Procedures e Unscrew the left front fork cylinder unit A from the outer tube B Special Tool
265. may come out of the shock absorber when injecting the nitro gen gas or riding the motorcycle e Force the stopper A into the rear shock body by lightly tapping around the edge of the stopper with a plastic mal let e Fully extend the piston rod assembly PERIODIC MAINTENANCE 2 77 Periodic Maintenance Procedures e Remount the upper portion of the shock absorber in a vise with soft jaws or heavy cloth e Fill the specified oil A into the damping adjuster assem bly hole Suspension Oil SHOWA SS 25 1 L 45024 0001 Rear Shock Absorber Oil Capacity Standard approx 380 mL 12 8 US oz e Purge the air from between the gas reservoir A and rear shock body B by slowly pumping the piston rod C in and out e Add the specified oil up to the damping adjuster assembly hole neck A NOTE OHold the adjuster assembly hole facing up and turn the shock absorber to bleed the air from the reservoir com pletely e Fully extend the piston rod assembly e Inject the nitrogen gas to a pressure of 50 kPa 0 5 kgf cm 7 psi through the valve on the gas reservoir e Check the rear shock body and gas reservoir for oil and gas leaks x lf there are leaks reassemble the related parts e Replace the O rings A with new ones and apply shock absorber oil e Install the gas reservoir damping adjuster assembly B slowly e Tighten Torque Gas Reservoir Damping Adjuster Assembly 29 5 N m
266. move the reservoir cap and diaphragm and pour the brake fluid into a container e Remove the locknut and pivot bolt and remove the brake lever e Pull the push rod A and dust cover B out of place and remove the circlip C Special Tool Inside Circlip Pliers 57001 143 e Remove the washer D e Remove the piston assy E include primary and sec ondary cups We D A 6 13325BS1 C 2 44 PERIODIC MAINTENANCE Periodic Maintenance Procedures Rear Master Cylinder Disassembly e Remove the rear master cylinder see Rear Master Cylin der Removal in the Brakes chapter NOTE ODo not remove the push rod clevis since removal re quires brake pedal position adjustment e Remove the reservoir cap and diaphragm and pour the brake fluid into a container e Slide the dust cover A on the push rod B out of place and remove the circlip C Special Tool Inside Circlip Pliers 57001 143 e Pull out the push rod e Remove the piston assy D include primary and sec ondary cups Master Cylinder Assembly e Before assembly clean all parts including the master cylinder with brake fluid or alcohol 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 of these parts Gasoline engine oil or any other petroleum distillate will cause de terioration of the rubber parts Oil spille
267. mover 57001 1058 Swingarm Bearing Installation e Replace the needle bearings and grease seals with new ones e Apply plenty of grease to the grease seals and needle bearings A B NOTE Olnstall the needle bearings so that the manufacturer s marks face out Olnstall the grease seals so that the deep groove side of the rip inward Special Tool Bearing Driver Set 57001 1129 e Install the needle bearings grease seals C sleeve D and collar E OThe installation procedure is the same as the counter side mm GMO6121BS1 Swingarm Drive Chain Guide Guide Roller Chain Slipper Wear Inspection e Visually inspect the drive chain guide A and replace it if excessively worn or damaged e Visually inspect the upper and lower chain guide rollers A and replace them if excessively worn or damaged e Visually inspect the chain slipper A on the swingarm and replace it if excessively worn or damaged Swingarm Bearing Sleeve Inspection NOTICE Do not remove the bearings for inspection Re moval may damage them e Inspect the needle bearing A installed in the swingarm OThe rollers in a bearing normally wear very little and wear is difficult to measure Instead of measuring visually inspect the bearing for abrasion discoloration or other damage lf the needle bearing and sleeve show any signs of ab normal wear discoloration or damage replace them as a set SUSPENSION 13 25
268. n running the engine with the oil level low Then at your earliest convenience change the oil completely Engine Oil Change e Refer to the Engine Oil Change in the Periodic Mainte nance chapter ENGINE LUBRICATION SYSTEM 7 9 Engine Oil and Oil Filter Oil Filter Replacement e Refer to the Oil Filter Replacement in the Periodic Main tenance chapter Oil Screen Cleaning and Inspection Oil Screen Feed e Split the crankcase see Crankcase Disassembly in the Crankshaft Transmission chapter e Remove the oil screen feed A Left Crankcase B e Clean the oil screen with a high flash point solvent and remove any particles stuck to them A WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the screen in a well ventilated area and take care that there are no sparks or flame anywhere near the working area this includes any appliance with a pilot light Do not use gasoline or a low flash point solvent to clean the screen NOTE O While cleaning the screen check for any metal particles that might indicate internal engine damage e Check the screen feed A carefully for any damage holes broken wires or gasket pulling off If the screen is damaged replace it with a new one e Install the oil screen feed A Projection B Left Crankcase C e Assemble the crankcase see Crankcase Assembly in the Crankshaft Transmission c
269. n Shafts see Transmission Shaft Installa tion e Install the oil screen feed A so that the shorter pipe side faces upward e Position the connecting rod in BDC e Install the crankshaft jig B between the crankshaft fly wheels Special Tool Crankshaft Jig 57001 1174 e Check to see that the dowel pins C are in place in the mating surfaces of the crankcase halves e Using a high flash point solvent clean off any oil or dirt that may be on the liquid gasket coating area Dry them with a clean cloth e Apply liquid gasket to the mating surface A of the left crankcase half Sealant Liquid Gasket TB1216 92104 1063 NOTE OEspecially apply liquid gasket so that it shall be filled up on the groove OMake the application finish within 20 minutes when the liquid gasket to the mating surface of the left crankcase half is applied OMoreover fit the case and tighten the case bolts just after finishing the application of the liquid gasket 6104331BS1 C e Assemble the crankcase halves evenly while maintaining the mating surfaces of them constantly parallel NOTE OPress the crankcase rear portion A and tap the area around the crankshaft with a plastic hammer B OConstantly check the alignment of the crankcase halves and the position of the transmission shafts and shift drum e Remove the crankshaft jig C e Tighten the crankcase bolts starting with the around of the crankshaft then outward OTi
270. n in the Periodic Maintenance chapter e Attach the compression gauge A and compression gauge adapter B firmly into the spark plug hole e Measure the compression pressure OWith the throttle fully open turn the engine over sharply with the kickstarter several times until the compression gauge stops rising the compression is the highest read ing obtainable Special Tools Compression Gauge 20 kgf cm 57001 221 Compression Gauge Adapter M10 x 1 0 57001 1317 Cylinder Compression Usable Range 427 708 kPa 4 4 7 2 kgf cm 62 103 psi at 5 times e Install the removed parts see appropriate chapters x If the compression pressure is not within the usable range check the following table ENGINE TOP END 5 21 Problem Diagnosis Remedy Action The cylinder compression is higher than the usable range Carbon accumulation on piston and in cylinder head combustion chamber is suspected due to damaged valve stem or piston oil rings Incorrect cylinder head gasket thickness Remove the carbon deposits and replace damaged parts if necessary Replace the gasket with a standard one Damaged auto decompressor spring or decompressor do not move smoothly Replace the spring or auto decompressor The cylinder compression is Exhaust gas leakage around cylinder head Replace the damaged gasket and inspect cylinder head warp lower than the Incorrect seating surface of valve
271. n the vehicle down sensor is broken the engine will stop at 3 seconds after the engine starts Vehicle down Sensor Removal NOTICE Never drop the vehicle down sensor especially on a hard surface Such a shock to the sensor can damage it e Remove the fuel tank see Fuel Tank Removal e Pull the vehicle down sensor A from the bracket e Disconnect the connector B Vehicle down Sensor Installation e The UPPER mark A of the sensor should face upward and install the sensor e Connect the connector A WARNING Incorrect installation of the vehicle down sensor could cause sudden loss of engine power The rider could lose balance during certain riding situ ations like leaning over in a turn with the potential BEE 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 OBe sure the battery is fully charged e Disconnect the vehicle down sensor connector and con nect the measuring adapter A between these connec tors Main Harness B Vehicle down Sensor C Special Tool Measuring Adapter 57001 1700 e Connect a digital meter D to the measuring adapter leads 3 Vehicle down Sensor Input Voltage Connections to Adapter Digital Meter R sensor R Y lead Digital Meter BK sensor GY lead GC17709ES1 e Refer t
272. nd water solution 4 4 COOLING SYSTEM Specifications Item Recommended Coolant Type Color Mixed Ratio Freezing Point Total Amount Standard Permanent type antifreeze soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators Green Soft water 50 coolant 50 35 31 F 1 2 L 1 3 US qt Radiator Radiator Cap Relief Pressure 93 123 kPa 0 95 1 25 kgf cm 13 18 psi COOLING SYSTEM 4 5 Special Tool Bearing Driver Set 57001 1129 ST571129ST 4 6 COOLING SYSTEM Coolant Coolant Level Inspection e Refer to the Coolant Level Inspection in the Periodic Main tenance chapter Coolant Deterioration Inspection e Refer to the Coolant Deterioration Inspection in the Peri odic Maintenance chapter Coolant Draining A WARNING Coolant can be extremely hot and cause severe burns is toxic and very slippery Do not remove the radiator cap or attempt to change the coolant when the engine is hot allow it cool completely Immediately wipe any spilled coolant from tires frame engine or other painted parts Do not ingest coolant The coolant should be changed periodically to en sure long engine life e Remove Right Radiator Shroud see Radiator Shroud Removal in the Frame chapter Radiator Cap A NOTE ORemove the radiator cap in two steps First turn the cap counterclockwise to the fi
273. nder C Lower Oil Ring Steel Rail D e Apply engine oil to the cylinder bore and piston side wall e Install the cylinder while compressing the piston rings with your fingers or the special tool A OUpturn the chamfering side of the belt Special Tools Piston Ring Compressor Grip 57001 1095 Piston Ring Compressor Belt 67 79 57001 1097 e Install the removed parts see appropriate chapters Cylinder Wear Inspection e Refer to the Cylinder Wear Inspection in the Periodic Maintenance chapter Piston Wear Inspection e Using a micrometer measure the outside diameter A of the piston 6 mm 0 24 in B up from the bottom of the piston at a right angle to the direction of the piston pin x lf the piston outside diameter is smaller than the service limit replace the piston Piston Diameter Standard 76 948 76 963 mm 3 0294 3 0300 in Service Limit 76 80 mm 3 024 in Piston Cylinder Clearance Inspection e Refer to the Piston Cylinder Clearance in the Periodic Maintenance chapter Piston Ring Ring Groove Clearance Inspection e Check for uneven groove wear by inspecting the ring seat ing x The rings should fit perfectly parallel to groove surfaces If not replace the piston and all piston rings e With the piston rings in their grooves make several mea surements with a thickness gauge A to determine piston ring groove clearance Piston Ring Ring Groove Clearance Standard Top 0 04 0 08 mm 0
274. nding to the self diagnosis terminal C NOTE OKeep the self diagnosis terminal grounded during self diagnosis e To enter the self diagnosis dealer mode 1 ground the self diagnosis terminal A for more than 2 seconds B and then keep it grounded continuously C Ground D Open E e Count the blinks of the light to read the service code OKeep the lead ground until you finish reading the service code e To enter the self diagnosis dealer mode 2 ground the self diagnosis terminal A and open it and then ground the self diagnosis terminal more than 3 times within 3 sec onds B and then keep it grounded continuously C Ground D Open E e Count the blinks of the light to read the service code OKeep the lead ground until you finish reading the service code FUEL SYSTEM DFI 3 29 6C17877DS1 C GC17966ES1 C G6C17967ES1 C 3 30 FUEL SYSTEM DFI Self Diagnosis Self Diagnosis Flow Chart Stop the engine Connect the FI warning indicator light assy option Connect the power supply harness option and the 12 V battery to the capacitor lead connector Orange Fl warning indicator light LED goes on for 2 seconds and then goes off for 3 seconds Orange FI warning indicator light LED Orange FI warning indicator light LED stays unlit goes on Kick the kick pedal about 10 times 1 Blinks 2 or goes on Ground the self diagnosis t
275. nditions mud sticks to the chain and sprockets resulting in an overly tight chain and the chain may break To prevent this adjust the chain to 62 68 mm 2 4 2 7 in of slack whenever necessary 2 38 PERIODIC MAINTENANCE Periodic Maintenance Procedures Drive Chain Lubrication OThe chain should be lubricated with a lubricant which will both prevent the exterior from rusting and also absorb shock and reduce friction in the interior of the chain If the chain is especially dirty it should be washed in diesel oil or kerosene and afterward soaked in a heavy oil Shake the chain while it is in the oil so that oil will pen etrate into the inside of each roller e An effective good quality lubricant specially formulated for chains is best for regular chain lubrication e f a special lubricant is not available a heavy oil such as SAE90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication e Apply oil to the sides of the rollers so that oil will penetrate into the rollers and bushings e Wipe off any excess oil Oil Applied Area A Sprocket Wear Inspection e Visually inspect the front and rear sprocket teeth for wear and damage If they are worn as illustrated or damaged replace the sprocket and inspect the drive chain wear Worn Tooth Engine Sprocket A Worn Tooth Rear Sprocket B Direction of Rotation C NOTE Olf a sprocket requires replacement the chain is
276. ne Exploded View Lubrication System Chart Specifications Special Tools Engine Oil and Oil Filter Engine Oil Level Inspection Engine Oil Change Lubrication System Table of Contents 7 2 7 6 7 7 7 8 7 8 7 9 7 9 7 11 7 11 7 12 7 13 7 14 7 14 7 2 ENGINE LUBRICATION SYSTEM Exploded View ENGINE LUBRICATION SYSTEM 7 3 Exploded View Torque No Fastener Remarks S Nm kgfm ft lb 1 Oil Filter Cap Bolts 9 8 1 0 87 in lb 2 Piston Oil Nozzle 2 9 0 30 26 in lb 3 Breather Fitting 15 1 5 11 4 Oil Pump Idle Gear Shaft Screws 5 9 0 60 52 in lb L 5 Oil Pump Mounting Bolts 7 0 0 71 62 in lb L 6 Engine Oil Drain Bolt 20 2 0 15 EO Apply engine oil G Apply grease L Apply a non permanent locking agent M Apply molybdenum disulfide grease R Replacement Parts 7 4 ENGINE LUBRICATION SYSTEM Lubrication System Chart 66042438 G Lubrication System Chart OO X gt J oO O1 R CO ND A Oil Screen Scavenge Oil Shower to Transmission Piston Oil Nozzle Breather Hose Oil Filter Oil Screen Feed Oil Pump Scavenge Oil Pump Feed Kick Starter Idle Gear Crank Room Oil Transmission Room Oil Blowby Gas Engine Oil ENGINE LUBRICATION SYSTEM 7 5 7 6 ENGINE LUBRICATION SYSTEM Specifications Item Engine Oil Ty
277. ng and in stall it in the head pipe e Install the stem through the head pipe and upper bearing and hand tighten the stem nut while pushing up the stem base e Install the stem head and washer and tighten the stem head nut lightly e Settle the bearing in place as follows OTighten the stem nut to 39 N m 4 0 kgf m 29 ft lb of torque To tighten the steering stem nut to the specified torque hook the wrench A on the stem nut and pull the wrench at the hole by 22 2 kgf force B in the direction shown Special Tool Steering Stem Nut Wrench 57001 1100 OCheck that there is no play and the steering stem turns smoothly without rattles If not the steering stem bearings may be damaged OAgain back out the stem nut a fraction of a turn until it turns lightly OTurn the stem nut lightly clockwise until it just becomes hard to turn Do not overtighten or the steering will be too tight Torque Steering Stem Nut 4 9 N m 0 50 kgf m 43 in Ib e Install the stem head e Install the washer and temporary tighten the stem head nut e Install the front forks see Front Fork Installation in the Suspension chapter e Apply a non permanent locking agent to the front fork clamp bolts upper e Tighten Torque Front Fork Clamp Bolts Upper 20 N m 2 0 kgf m 15 ft lb Steering Stem Head Nut 98 N m 10 0 kgf m 72 ft Ib Front Fork Clamp Bolts Lower 22 N m 2 2 kgf m 16 ft lb NOTE O Tighten the fork clamp b
278. nition timing according to engine rpm and throttle opening Input Terminal A Output Terminal B Ground Terminal C 6C17127BS1 Throttle Sensor Replacement Never drop the throttle sensor A especially on a hard surface Such a shock to the throttle sensor can damage it NOTE O These procedures are explained on the assumption that the intake and exhaust systems of the engine are in good condition O When adjusting the throttle sensor use a digital voltage meter which can be read the third decimal place The DC voltage accuracy must be less than 0 05 reading and 4 digits at DC 1 V ORead the manufacture s instructions thoroughly before using the meter incorrect values may cause improper adjustments e Remove the throttle body assy see Throttle Body Assy Removal e Check the paint on the stop screw A and make sure that the stop screw has not been adjusted If stop screw has been adjusted throttle body assy has to be replaced Don t tamper with stop screw e Remove Throttle Sensor Screw A Throttle Sensor B 3 36 FUEL SYSTEM DFI Throttle Sensor Service Code 11 e Replace Throttle Sensor Screw A Throttle Sensor B O ring C e Apply engine oil to the new O ring and install it to the new throttle sensor e Engage the inner rotor groove A with the throttle shaft B e Insert the throttle sensor A into the throttle body OSet the throttle
279. nsit s 12 21 Ee ele ele E 12 21 Master Cylinder Inspection Visual Inspection 12 22 le IS Carre ra eh tant ha a ee ae net et rate St eo a 12 23 Brake Disc REMOVAl E 12 23 Brakes Eelere dee art aude cas 12 23 Brake Bisc InSp ction E 12 23 Brake E 12 24 Brake Hose Removal Installation 12 24 Brake Hose reent is on euer denge 12 24 12 2 BRAKES Exploded View Exploded View BRAKES 12 3 No Fastener sore Remarks N m kgf m ft Ib 1 Brake Hose Banjo Bolts 25 2 5 18 2 Front Brake Reservoir Cap Screws 1 5 0 15 13 in lb 3 Front Master Cylinder Clamp Bolts 8 8 0 90 78 mb S 4 Brake Lever Pivot Bolt 5 9 0 60 52 in lb Si 5 Brake Lever Pivot Bolt Locknut 5 9 0 60 52 in lb 6 Front Brake Disc Mounting Bolts 9 8 1 0 87 in lb L 7 Front Brake Pad Pin 17 1 7 13 8 Caliper Bleed Valve 7 8 0 80 69 in lb 9 Front Caliper Mounting Bolts 25 2 5 18 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 12 4 BRAKES Exploded View BRAKES 12 5 Exploded View No Fastener E Remarks N m kgf m ft Ib 1 Brake Hose Banjo Bolts 25 2 5 18 2 Rear Brake Reservoir Cap Bolts 1 5 0 15 13 in lb 3 Rear Master Cylinder Mounting Bolts 9 8 1 0 87 in lb 4 Rear Master
280. nstant a en Te ete ne Right Engine Cover Removal sie Right Engine Cover Installations ete Seda eee ess Right Engine Cover Assembly E 6 10 NSS hi a e a deeg 6 11 CHAT FSO EE 6 11 Cluten Installation zen E EEN 6 11 Release Shaft Removal a sissu eaire sn TS dlads GES ESSIE REE AEREE EEAS es 6 14 Release Shaft Installation Sege eier eer deeg Eed ee EEN 6 14 Clutch Plates Wear Damage Inspection AE 6 14 Clutch Plates Warp Inspection aceesineeniaedotigdd etdendads ENEE nace 6 14 Clutch Spring Free Length Inspection us 6 14 Clutch Housing Finger Damage Inspection s ssssseesesssnessserrrserrrrternrresttrrssetrnnnrrnnrennnee 6 14 Friction Plate Clutch Housing Clearance Inspechon 6 15 Clutch Hub Spline Damage Inspection 6 15 6 2 CLUTCH Exploded View GF02206BW5 C Exploded View CLUTCH 6 3 CL Apply cable lubricant EO Apply engine oil G Apply grease 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 Torque No Fastener es kotm ilb Remarks 1 Right Engine Cover Bolts 9 8 1 0 87 in lb 2 Clutch Cover Bolts 9 8 1 0 87 in lb 3 Oil Filler Plug 3 5 0 36 31 in lb 4 Clutch Hub Nut 98 10 0 72 R 5 Clutch Spring Bolts 9 0 0 92 80 in lb 6 4 CLUTCH Specifications Item Service Limit Clutch Lev
281. ntil the self diagnosis terminal is open When the self diagnosis terminal is opened the orange FI warning indicator light LED will go on in one second Olf there is no problem no code and the orange FI warning indicator light LED blinks with cycle of 0 5 seconds OFor example if two problems occurred in the order of 21 12 the service codes are displayed from the lowest number in the order listed 12 21 12 21 gt repeated Self diagnosis Terminal Grounded Open il Orange Fl Warning Indicator om 1 1s 10th digit 0 5s 0 5s a digit iis Lie 0 5s Light LED OFF oe El bk k k l H H H DN H H H H 2sec 3s 1 5s D 5s 3s 1 s 1 58 6C17324F 1 C Olf the problem is with the following parts the ECU cannot memorize these problems the orange FI warning indicator light LED doesn t go on and no service codes can be displayed ECU Power Source Wiring and Ground Wiring see ECU Power Supply Inspection How to Erase Service Codes OEven if the battery or the ECU are disconnected or the problem is solved all service codes remain in the ECU Oln this model the problem history cannot be erased However the past service code can be erased using the KDS 3 version kit 3 32 FUEL SYSTEM DFI Self Diagnosis Service Code Table Service Orange FI Warning Indicator Pr bl ms Codes Light LED 11 a Throttle sensor malfunction wiring open or
282. o not damage the bushings when assembling the left front fork base valve sienna P PERIODIC MAINTENANCE 2 55 Periodic Maintenance Procedures e With the piston rod A appear about 20 mm 0 79 in B from fully compressed gently install the left front fork base valve assembly C slowly to the left front fork cylinder unit D NOTE OPlug the oil hole E on the left front fork cylinder unit with finger O While pulling the piston rod install the base valve as sembly slowly and pushing down it fully Olf there is difficulty in assembling the base valve it may be because the oil level is too high Check the oil level in the left front fork cylinder unit e Hold the top plug wrench A with a vise e Hold the left front fork cylinder unit B with the top plug wrench Special Tool Top Plug Wrench 50 mm 57001 1645 e Tighten the left front fork base valve assembly C Torque Left Front Fork Base Valve Assembly 30 N m 3 1 kgf m 22 ft lb e Turn the locknut fully in e Apply specified fork oil to the piston rod sliding surface e Protect the piston rod end with a heavy cloth A to prevent thread damage e Hold the left front fork cylinder unit B at the upright posi tion e Slowly pump the piston rod C several times about 100 mm 3 94 in D Take care not to bent or damage the piston rod e Discharge the extra oil off the left front fork cylinder unit A by pumping the piston r
283. o not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Never drop the fuel pump especially on a hard sur face Such a shock to the pump can damage it e Draw the fuel out from the fuel tank with a commercially available electric pump e Remove the fuel tank see Fuel Tank Removal OBe careful of fuel spillage from the fuel tank since fuel still remains in the fuel tank and fuel pump Plug the fuel pipe of the fuel tank e Turn the fuel tank upside down e Loosen the fuel pump bolts evenly following the specified loosening sequence 1 5 and remove the fuel pump A Do not pull the leads of the fuel pump If they are pulled the lead terminals may be damaged e Discard the fuel pump gasket A Fuel Pump Installation e Remove the dirt or dust from the fuel pump A by lightly applying compressed air e Replace the fuel pump gasket with a new one FUEL SYSTEM DFI 3 71 3 72 FUEL SYSTEM DFI Fuel Pump Service Code 46 e Install the fuel pump A to the fuel tank e Apply a non permanent locking agent to the threads of the fuel pump bolts e Gradually tighten the fuel pump bolts evenly following the specified tightening sequence 1 6 e Install the removed parts see appropriate chapters Fuel Pump Operation Inspection NOTE OBe sure the battery is fully charged e Refer to the Self d
284. o the Self diagnosis Procedures connect the 12 V battery to the main harness FUEL SYSTEM DFI 3 57 Vehicle down Sensor Service Code 31 e Measure the input voltage with the engine stopped and with the connector joined Input Voltage Standard DC 4 75 5 25 V x lf the reading is within the standard check the output volt age see Vehicle down Sensor Output Voltage Inspec tion x If the reading is out of the standard remove the ECU and check the wiring for continuity between the main harness connectors Special Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Vehicle down Sensor Connector B R Y lead C ECU terminal 12 GY lead D ECU terminal 17 xlf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x lf the ground and power supply are good replace the ECU see ECU Removal Installation Vehicle down Sensor Output Voltage Inspection e Remove the vehicle down sensor and connect the mea suring adapter A Special Tool Measuring Adapter 57001 1700 Main Harness B Vehicle down Sensor C e Connect a digital meter D to the measuring adapter leads Vehicle down Sensor Output Voltage Connections to Adapter Digital Meter W sensor BR lead Digital Meter BK sensor GY lead 6C17340FS1 C ES WT 6 E pe ect d P GCI77
285. o the measuring cylinder B A WARNING Wipe off spilled out fuel immediately Be sure to hold the measuring cylinder vertical e Close the fuel tank cap e Refer to the Self diagnosis Procedures connect the 12 V battery to the main harness OThen the fuel pump operates and fuel is discharged NOTICE Do not operate the fuel pump without fuel in the fuel tank If the fuel pump is driven without fuel it may be damaged e Measure the discharge for 5 seconds ORepeat this operation several times Amount of Fuel Flow Standard 40 mL 1 4 US oz or more for 5 seconds x If the fuel flow is much less than the specified replace the fuel pump see Fuel Pump Removal Installation e Install the fuel tank see Fuel Tank Installation e Start the engine and check for fuel leakage 3 82 FUEL SYSTEM DFI Throttle Grip and Cable If the throttle grip has excessive free play due to cable stretch or misadjustment there will be a delay in throttle re sponse Also the throttle valve may not open fully at full throttle On the other hand if the throttle grip has no play the throttle will be hard to control and the idle speed will be erratic Check the throttle grip play periodically in accor dance with the Periodic Maintenance Chart and adjust the play if necessary The throttle cable routing is shown in Cable Wire and Hose Routing section in the Appendix chapter Throttle Grip Throttle Cable Free Play Inspe
286. obstructions or irreparably de formed fins replace the radiator with a new one NOTICE 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 64 ft B from the radiator core Hold the steam gun perpendicular to the core surface Run the steam gun following the core fin direction C COOLING SYSTEM 4 13 G6D07083BS1 C 4 14 COOLING SYSTEM Radiator Radiator Cap Inspection e Check the top and bottom valve seals A of the radiator cap and the condition of the valve spring B If any one of them shows visible damage replace the cap e Wet the top and bottom valve seals with water or coolant to prevent pressure leaks e Install the cap A on a cooling system pressure tester B e Watching the pressure gauge slowly pump the pressure tester to build up the pressure The gauge hand must remain within the relief pressure range in the table below at least 6 seconds Continue to pump the tester until the relief valve opens indicated by the gauge hand flicking downward The relief valve must open within the specified range Radiator Cap Relief Pressure Standard 93 123 kPa 0 95 1 25 kgf cm 13 18 psi x If the cap cannot hold the pressure or if the relief pressure is too high or too low replace the cap with a new one Filler Neck Inspection e Check the radiator filler neck for signs of
287. ocking agent to the threads of the right front fork bottom plug A e Compress the outer tube with a suitable jack while keep ing the front fork upright and remove the top plug wrench B e Remove the front fork from the fork spring compressor 2 68 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Hold the axle holder part with a vise OProtect the axle holder part with a soft jaws or heavy cloth when using a vise A WARNING If the axle holder is not securely clamped the front fork assembly may come out of the vise when com pressed which could cause an accident resulting in injury However clamping the axle holder too tightly can damage it which will affect riding stabil ity Use protective aluminum covers on the jaws of the vise and do not tighten the vise excessively e Tighten the right front fork bottom plug A Torque Right Front Fork Bottom Plug 69 N m 7 0 kgf m 51 ft lb e Unscrew the right front fork spring adjuster unit A from the outer tube B Special Tool Top Plug Wrench 50 mm C 57001 1645 e Slowly slide down the outer tube e Clean the threads A of the right front fork spring adjuster unit and right front fork spring preload adjuster e Replace the O ring B on the right front fork spring preload adjuster C with a new one e Turn the right front fork spring preload adjuster counter clockwise to the softest position e Apply specified fork oil to the O ring
288. ocolate O Orange W White DG Dark Green P Pink Y Yellow G Green FUEL SYSTEM DFI 3 11 3 12 FUEL SYSTEM DFI DFI System Terminal Numbers of ECU Connectors GC17004FH2 C Terminal Names Power Supply to ECU R W Unused DFI Setting Data Selection 1 W BL Downstream Injector BL R Unused Ground for ECU BK Y Fl Warning Indicator Light BL W Upstream Injector BL BK Unused 10 Fuel Pump P BK 11 Ignition Coil O 12 Power Supply to Sensors R Y 13 External Communication Line Y R 14 External Communication Line Y BK 15 Throttle Sensor Y G 16 Vehicle down Sensor BR 17 Ground for Sensors GY 18 Unused OONDOAaARWND ch 19 20 21 22 24 Intake Air Temperature Sensor LB Unused Water Temperature Sensor W Ground for ECU BK Y 23 Crankshaft Sensor W Y Crankshaft Sensor G W 25 26 27 28 29 30 31 32 33 KDS Kawasaki Diagnostic System Unused External Communication Line KDS P Intake Air Pressure Sensor BL Gear Position Switch G R DFI Setting Data Selection 2 W R Engine Stop Switch BK Unused Self diagnosis Terminal Y Ground for Control System BK W FUEL SYSTEM DFI 3 13 DFI Parts Location Kawasaki Diagnostic System Connector A ECU B Fl Warning Indicator Light Harness Connector C Self diagnosis Terminal D Vehicle down Sensor A Ignition Coil B
289. od B to full stroke C Service carefully because oil flies out from the oil hole of the left front fork cylinder unit 2 56 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Check the compression damping force setting to the soft est e Check the piston rod sliding surface for damage e Drain the extra oil from the left front fork cylinder unit oil hole A e Blow out the extra oil from the oil hole of the left front fork cylinder unit with the compressed air B blow to the oil hole e Wipe the oil off completely from the cylinder unit NOTE Olf you cannot use compressed air remove the air pres sure relief screw of the left front fork base valve assem bly Upside down the fork damper for 10 minutes and drain the oil from the left front fork cylinder unit e Protect the piston rod end with a heavy cloth to prevent damage e Check the piston rod for smooth operation OPump the piston rod A to full stroke B by pushing down the left front fork cylinder unit C x lf the piston rod operation is not smooth check the piston rod for bend or damage e Hold the fork cylinder unit on level ground A while piston rod is full stroked by your hand e Release the piston rod then check that the piston rod extends to maximum B lf the piston rod does not extend to maximum bleed the left front fork cylinder unit again NOTICE Take care not to bend or damage the piston rod e Wipe the fork oil o
290. off oxide film treated surface of the valve e Visually inspect the valve surface If the surface is damaged replace the valve e Replace the oil seal A with a new one e Apply a thin coat of molybdenum disulfide grease to the valve stem B and install the valve e Check to make sure that the valve moves up and down smoothly e Check to make sure that the valve and valve seat are making proper contact e Install Oil Seal Spring Seat C Valve Spring D OTurn the painted side of the valve spring to the spring retainer E Exhaust White Paint Intake Pink Paint NOTE OThe flange thicknesses of the spring seats are different in the exhaust and intake side Take care not to install them oppositely Exhaust Valve Spring Seat F Intake Valve Spring Seat G e Install the spring retainer e Compress the valve spring to install the split keepers H in order to secure the spring retainer in place Special Tools Valve Spring Compressor Assembly 57001 241 Valve Spring Compressor Adapter 22 57001 1202 Valve Spring Compressor Adapter 24 57001 1586 e Install the shim to original position OThe shim J must be installed with its thickness indication facing up towards the retainer e Apply engine oil to the valve lifter K surface and install the lifter Keck GE15218BS3 C Valves Valve Guide Removal e Remove Valve see Valve Removal Oil Seal Spring Seat e Heat the area around the va
291. off the radiator e Remove Radiator Screen Bolt E Left Radiator Screen F OClear the projection G from the hole e Remove Radiator Mounting Bolts A Clamps and Washers Left Radiator B e Loosen Water Hose Clamp Screws A e Slide the clamp B e Pull the water hoses C off the radiator e Remove Radiator Screen Bolt D Right Radiator Screen E OClear the projection F from the hole e Remove Radiator Mounting Bolts A and Washers Overflow Hose B Right Radiator C Radiator Radiator Installation e Install Radiators Washers Clutch Cable Clamps A Left Side e Tighten the radiator mounting bolts securely e Run the overflow hose and water hoses correctly see Cable Wire and Hose Routing section in the Appendix chapter e Tighten Torque Water Hose Clamp Screws 3 0 N m 0 31 kgf m 27 in lb e Install the radiator screens on both sides OFit the projections A and holes B e Tighten the radiator screen bolts securely e Fill the coolant see Coolant Filling e Install the removed parts see appropriate chapters Radiator Inspection e Check the radiator core lf there are obstructions to air flow remove them lf the corrugated fins A are deformed carefully straighten them with the standard tip screwdriver Do not tear the radiator tubes while straightening the fins xlf the air passages of the radiator core are blocked more than 20 by unremovable
292. oft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators Water and Coolant Mixture Ratio Soft Water 50 Coolant 50 Freezing Point 35 C 31 F Total Amount 1 2 L 1 3 US qt For refilling add the specified mixture of coolant and soft water Adding water alone dilutes the coolant and degrades its anticorrosion properties The diluted coolant can attack the aluminum en gine parts In an emergency soft water alone can be added But the diluted coolant must be returned to the correct mixture ratio within a few days A B GDO4016BS1 C 6S06008BS1 C PERIODIC MAINTENANCE 2 23 Periodic Maintenance Procedures Coolant Deterioration Inspection e Visually inspect the coolant lf 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 Water Hoses and Connections Inspection e Remove the radiator shrouds see Radiator Shroud Re moval in the Frame chapter OThe high pressure inside the water hoses A can cause coolant to leak B or the hose to burst if the line is not properly maintained Visually inspect the hoses for signs of det
293. oil seal lip e When installing the cover does not go well the cover is installed according to the following procedures Olnstall the cover while turning the impeller A e Tighten L 35 mm 1 4 in A L 25 mm 1 0 in B Torque Right Engine Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib Clutch Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib 6 10 CLUTCH Clutch Cover and Right Engine Cover e Remove the vinyl tape from the kick shaft e Install Water Pump Cover see Water Pump Cover Installation in the Cooling System chapter Brake Pedal see Brake Pedal Installation in the Brakes chapter Oil Filter see Oil Filter Change in the Periodic Mainte nance chapter Kick Pedal see Kick Pedal Installation in the Crank shaft Transmission chapter e Pour Engine Oil see Engine Oil Change in the Periodic Main tenance chapter Coolant see Coolant Filling in the Cooling System chap ter e Check the rear brake effectiveness see Brakes section in the Periodic Maintenance chapter Right Engine Cover Assembly e Refer to the Oil Seal and Bearing Installation in the Cool ing System chapter for water pump oil seals and bearing installation e Replace the removed oil seal and circlip with new ones e Press in the oil seals direction as shown Special Tool Bearing Driver Set 57001 1129 OPress in the new oil seal using a press and suitable tools so that the seal surface is flush with the surface of the right engine
294. olts 25 N m 2 5 kgf m 18 ft lb Rear Brake e Install the rear wheel and caliper see Rear Wheel Instal lation in the Wheels Tires chapter e Install the brake hose lower end OReplace the washers A on each side of hose fitting B with new ones e Tighten Torque Brake Hose Banjo Bolt 25 N m 2 5 kgf m 18 ft Ib e Install the removed parts see appropriate chapters e Bleed the brake line see Brake Line Bleeding e Check the brake for good braking power no brake drag and no fluid leakage A WARNING After servicing it takes several applications of the brake lever or pedal before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the motorcycle until a firm brake lever or pedal is obtained by pumping the lever or pedal until the pads are against the disc Caliper Disassembly e Refer to the Caliper Rubber Parts Replacement in the Pe riodic Maintenance chapter GL10000BS1 Caliper Fluid Seal Damage Inspection The fluid seal s A around the piston maintains the proper pad disc clearance If this seal is not in good condi tion pad wear will increase and constant pad drag on the disc will raise brake and brake fluid temperature e Replace the fluid seals under any of the following condi tions OFluid leakage around the pad OBrakes overheat OThere is a large difference
295. olts upper first next the stem head nut last the fork clamp bolts lower O Tighten the two clamp bolts alternately two times to en sure even tightening torque STEERING 14 7 GNO50605S1 14 8 STEERING Steering e Install the removed parts see appropriate chapters Torque Brake Hose Clamp Bolt 3 0 N m 0 31 kgf m 27 in Ib A WARNING If the handlebar does not turn to the steering stop it may cause an accident resulting in injury or death Be sure the cables harnesses and hoses are routed properly and do not interfere with handlebar move ment see Cable Wire and Hose Routing section in the Appendix chapter e Check and Adjust Steering Front Brake Clutch Cable Throttle Cable Stem Bearing Lubrication e Refer to the Steering Stem Bearing Lubrication in the Pe riodic Maintenance chapter Stem Bearing Wear Damage Inspection e Using a high flash point solvent wash the upper and lower tapered rollers in the cages and wipe the upper and lower outer races which are press fitted into the head pipe clean off grease and dirt e Visually check the outer race and the rollers x Replace the bearing assembly if it show damage Stem Warp Inspection e Whenever the steering stem is removed or if the steering cannot be adjusted for smooth action check the steering stem shaft A for straightness x lf the steering stem shaft is bent replace the steering stem
296. om and give a false low reading at the oil level inspection window which indi cates oil volume in the transmission room Engine Oil Level Inspection e Situate the motorcycle so that it is vertical e Check that the engine oil level is between the upper A and lower B levels in the inspection window C NOTE Olf the motorcycle has just been used wait several min utes for all the oil to drain down Olf no oil appears in the inspection window tip the motor cycle slightly to the right until oil is visible then return to an upright position If no oil appears even when tipped at an extreme angle remove the drain bolt to empty any oil reinstall the drain bolt and refill with the speci fied amount of oil Olf the oil has just been changed start the engine and run it for several minutes at idle speed This fills the oil filter with oil ODo not run the engine at high engine speed Stop the engine then wait several minutes until the oil settles Racing the engine before the oil reaches every part can cause engine seizure x lf the oil level is too high remove the excess oil through the filler opening using a syringe or some other suitable device lf the oil level is too low add the correct amount of oil through the oil filler opening Use the same type and make of oil that is already in the engine NOTE Off the engine oil type and make are unknown use any brand of the specified oil to top off the level rather tha
297. ompressed air is not available with the brake hose connected to the caliper OPrepare a container for brake fluid and perform the work above it ORemove the spring and pads see Brake Pad Removal in the Brakes chapter OPump the brake lever until the pistons come out of the cylinders Rear Caliper Disassembly e Remove Rear Caliper see Caliper Removal in the Brakes chap ter Brake Pads see Brake Pad Removal in the Brakes chapter 2 46 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Separate the caliper holder A from the caliper B e Remove the anti rattle springs C e Using compressed air remove the piston OCover the caliper opening with a clean heavy cloth A ORemove the piston by lightly applying compressed air B to the hose joint opening A WARNING The piston in the brake caliper can crush hands and fingers Never place your hand or fingers in front of the piston e Pull out the piston A by hand e Remove the dust seal B and fluid seal C Caliper Assembly e Clean the caliper parts except for the pads For cleaning of the parts use only disc brake fluid isopropyl alcohol or ethyl alcohol x If you removed the bleed valve install the bleed valve and rubber cap Torque Caliper Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib PERIODIC MAINTENANCE 2 47 Periodic Maintenance Procedures e Replace the fluid seal s A with new ones
298. on the engine sprocket or lock the rear wheel severely damaging the motorcycle and causing it to go out of control Inspect the chain for damage and proper adjustment before each ride If chain wear exceeds the service limit replace it with the standard chain Standard Chain Make DAIDO Type DID 520DMA4 Link 114 links Drive Chain Slack Inspection e Using the jack raise the rear wheel until the rear shock absorber stretched fully Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Check the wheel alignment see Wheel Alignment Inspec tion in the Final Drive chapter and adjust it if necessary see Wheel Alignment Adjustment in the Final Drive chap ter NOTE OClean the drive chain if it is dirty and lubricate it if it appears dry e Rotate the rear wheel to find the position where the chain is tightest because it wears unevenly e Measure the space chain slack A between the bottom of the chain and the rear of the chain slipper Chain Slack Standard 52 58 mm 2 0 2 3 in If the drive chain slack exceeds the standard adjust it E GKO406068S1 C GS12041B82 C PERIODIC MAINTENANCE 2 37 Periodic Maintenance Procedures Drive Chain Slack Adjustment e Loosen the left and right chain adjuster locknuts A e Remove the cotter pin B and loosen the rear axle nut C xlf the chain is too tight back out the left and right chain adjusting bolts
299. or Connector B G W lead C ECU terminal 24 W Y lead D ECU terminal 23 xlf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x lf the ground and power supply are good replace the ECU see ECU Removal Installation 6C17336FS1 C Crankshaft Sensor Circuit wW Y G W E G W W Y al G W W Y or 6C17315F 2 C 1 ECU 2 Crankshaft Sensor 3 54 FUEL SYSTEM DFI Gear Position Switch Service Code 25 Gear Position Switch Removal e Remove Left Radiator Shroud see Radiator Shroud Removal in the Frame chapter Shift Pedal see Shift Pedal Removal in the Crank shaft Transmission chapter Engine Sprocket Cover and Drive Chain Guide see En gine Sprocket Removal in the Final Drive chapter Gear Position Switch Connector A e Open the clamps A e Remove Screws A Gear Position Switch B e Remove O ring A Gear Position Switch Fingers B Springs Gear Position Switch Installation e Install the spring A on the switch finger B e Insert the switch finger so that the small diameter C is toward the shift drum e Replace the O ring D with a new one and apply grease to it e Clean the contact points on the position switch e Apply a non permanent locking agent to the gear position switch screws e Tighten Torque Gear Position Switch Screws 2 9 N m 0 30 kgf m 26 in Ib e Install the removed par
300. or sparks this includes any appliance with a pilot light Never drop the throttle body assy especially on a hard surface Such a shock to the throttle body assy can damage it e Remove Fuel Tank see Fuel Tank Removal Fuel Hose see Fuel Hose Replacement in the Periodic Maintenance chapter Air Cleaner Housing with Rear Frame see Rear Frame Removal in the Frame chapter e Disconnect Intake Air Pressure Sensor Connector A Downstream Injector Connector B Throttle Sensor Connector C e Loosen the clamp screw A e Pull the throttle body assy backward e Remove the throttle cable lower ends see Throttle Cable Replacement Throttle Body Assy Installation e Install the throttle body assy so that fit the projection A on throttle body assy and groove B of the throttle body holder e Install the removed parts see appropriate chapters NOTE OFor easily starting the engine connect the 12 V battery to the main harness see Self diagnosis Procedures OWhen the battery is connected the fuel pump is driven and the pressure of the fuel line increases Throttle Body Assy Throttle Body Assy Disassembly e Remove Throttle Body Assy see Throttle Body Assy Removal Intake Air Pressure Sensor A see Intake Air Pressure Sensor Removal Downstream Injector B see Downstream Injector Re moval Throttle Sensor C see Throttle Sensor Replacement Idle Adjusting Screw Assy D e
301. pe Viscosity Capacity Oil Level Standard Castrol POWER1 R4 Racing 5W 40 or API SG SH SJ SL or SM with JASO MA MA1 or MA2 SAE 10W 30 10W 40 or 10W 50 0 75 L 0 79 US qt when filter is not removed 0 80 L 0 85 US qt when filter is removed 1 00 L 1 06 US qt when engine is completely dry Between upper and lower level lines after warm up or driving Oil Pressure Measurement Oil Pressure About 98 kPa 1 0 kgf cm 14 2 psi at 4 000 r min rpm Oil Temperature 40 C 104 F ENGINE LUBRICATION SYSTEM 7 7 Special Tools Oil Pressure Gauge 5 kgf cm Oil Pressure Gauge Adapter M6 x 1 0 57001 125 57001 1664 S T5701258T C ST5716648T C Outside Circlip Pliers 57001 144 ST5701448T 7 8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter A WARNING Vehicle operation with insufficient deteriorated or contaminated engine oil will cause accelerated wear and may result in engine seizure accident and injury Check the oil level before each use and change the oil and filter according to the periodic maintenance chart The engine oil level indicated in the oil level inspection window is very sensitive to the motorcycle s position and engine rpm at time of shut down Because of the semi dry sump lubrication system with separate oil chambers in the crank room and transmission room under certain condi tions oil can accumulate in the crank ro
302. pechon Lubrication Cable Inspection Nut Bolt and Fastener Tightness Inspection Tightness Inspection 2 39 2 39 2 40 2 41 2 43 2 43 2 45 2 48 2 48 2 50 2 50 2 50 2 70 2 78 2 78 2 79 2 79 2 19 2 80 2 81 2 81 2 81 2 81 2 81 2 82 2 82 2 83 2 83 2 83 PERIODIC MAINTENANCE 2 3 Periodic Maintenance Chart The maintenance must be done in accordance with this chart to keep the motorcycle in good running condition FREQUENCY Each Every Every 6 Every 12 race 3races races s OF See or 2 5 or 7 5 or 15 30 hours Page OPERATION hours hours hours Spark plug clean and inspect e 2 81 Spark plug replace e 2 81 Clutch inspect e Wl 2 29 Clutch plates inspect t e 2 29 Throttle cable inspect and adjust e 2 14 Air cleaner element clean e K 2 19 Air cleaner element replace If damaged 2 19 Throttle body assy inspect and adjust e 2 15 Engine oil change e 2 30 2 27 e 2 26 Piston and piston ring replace Cylinder head cylinder inspect Piston pin replace e 2 27 e 2 23 Oil filter replace e 2 31 mz ozm Valve clearance inspect t Kick pedal and shift pedal clean Engine sprocket inspect t 2 38 Coolant level inspect 2 21 Water hoses and connections inspect t 2 23 Exhaust system inspect t e 2 27 Silencer wool change 2 28 Crankshaft inspect e 2 33
303. pension chapter e Remove the front fork clamp bolts upper e After installing the front fork tighten the cylinder unit left front fork A spring adjuster unit right front fork Special Tool Top Plug Wrench 50 mm B 57001 1645 2 70 PERIODIC MAINTENANCE Periodic Maintenance Procedures The torque of left front fork cylinder unit and right front fork spring adjuster unit are specified to 34 N m 3 5 kgf m 25 ft lb however when you use the top plug wrench A reduce the torque to 90 of the specified value 31 N m 3 1 kgf m 23 ft lb due to the distance B between the center of the square hole where the torque wrench is fitted and that of the octagonal hole of the wrench This torque value 31 N m 3 1 kgf m 23 ft lb is appli cable when you use a torque wrench whose length gives leverage of approximately 310 mm 12 2 in between the grip point to the center of the coupling square OApply a non permanent locking agent to the threads of the front fork clamp bolts upper Torque Left Front Fork Cylinder Unit 34 N m 3 5 kgf m 25 ft lb Right Front Fork Spring Adjuster Unit 34 N m 3 5 kgf m 25 ft lb Front Fork Clamp Bolts Upper 20 N m 2 0 kgf m 15 ft lb e Install the removed parts see appropriate chapters Rear Shock Absorber Oil Change The oil should be changed in the rear shock absorber at least once per racing season The frequency for best per formance must be based upon riding condi
304. piston rod The piston rod may slide into the inner tube NOTICE When loosening the locknut the threads of the axle holder do not touch the push rod If the push rod is scratched it is possible to the damage in the cylin der unit estaBsi4 P e Reset the front fork on the fork spring compressor with care not to drop the top plug wrench e Compress the outer tube with a suitable jack while keep ing the front fork upright and remove the top plug wrench e Remove the front fork from the fork spring compressor e Unscrew the right front fork spring adjuster unit A from the outer tube B Special Tool Top Plug Wrench 50 mm C 57001 1645 e Slowly slide down the outer tube e Remove the following parts from the outer tube Right Front Fork Spring Adjuster Unit A Collar B Spring Seat C Fork Spring D e Hold the front fork at the inverted position for more than 20 minutes to allow the fork oil to fully drain N GM04251BS1 2 64 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Tighten the locknut A fully e Install the piston rod puller A to the threads on the piston rod end B Special Tool Fork Piston Rod Puller M12 x 1 25 57001 1289 e Install the following parts in the outer tube Fork Spring A Spring Seat B Collar C Right Front Fork Spring Adjuster Unit D e Temporarily install the right front fork spring adjuster unit A to the outer tube
305. ploded View No Fastener Torque Remarks N m kgf m ft Ib 1 Footpeg Bracket Bolts Upper 54 5 5 40 L 2 Rear Frame Mounting Bolts 34 3 5 25 G Apply grease L Apply a non permanent locking agent R Replacement Parts S Follow the specified tightening sequence 15 4 FRAME Frame Frame Inspection e Refer to the Frame Inspection in the Periodic Mainte nance chapter Rear Frame Removal e Remove Seat see Seat Removal Side Covers see Side Cover Removal Muffler Body see Muffler Body Removal in the Engine Top End chapter Rear Fender see Rear Fender Removal Rear Flap see Rear Flap Removal Upstream Injector Connector A Fuel Hose B see Fuel Hose Replacement in the Peri odic Maintenance chapter e Disconnect the intake air temperature sensor connector A e Loosen the air cleaner duct clamp bolt B e Remove the rear frame mounting bolts A on both sides e Take off the rear frame B together with the air cleaner housing OSeparate the air cleaner duct from the throttle body assy OTake care not to damage the frame and rear shock ab sorber with the air cleaner duct clamp Rear Frame Installation e Fit the claw A of the clamp and the groove B of the air cleaner duct e Install the rear frame Olnsert the duct onto the throttle body assy e Tighten Torque Rear Frame Mounting Bolts 34 N m 3 5 kgf m 25 ft lb e Tighten the air cleaner duct clamp bolt e Install the
306. pply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation GC17334FS1 C GC17335FS1 FUEL SYSTEM DFI 3 43 Intake Air Pressure Sensor Service Code 12 Intake Air Pressure Sensor Output Voltage Inspection e Measure the intake air pressure sensor output voltage in the same way as input voltage inspection ODisconnect the intake air pressure sensor connector and connect the measuring adapter A between these con nectors Main Harness B Intake Air Pressure Sensor C Digital Meter D Special Tool Measuring Adapter 57001 1700 Intake Air Pressure Sensor Output Voltage Connections to Adapter Digital Meter W sensor BL lead Digital Meter BK sensor GY lead GCI7984ESi C e Refer to the Self diagnosis Procedures connect the 12 V battery to the main harness e Measure the output voltage with the engine stopped and with the connector joined Output Voltage Usable Range DC 3 80 4 20 V at standard atmospheric pressure 101 32 kPa 76 cmHg NOTE OThe output voltage changes according to local atmo spheric pressure e Disconnect the power supply harness If the reading is out of the usable range replace the sen sor x lf the reading is within the usable range remove the ECU and check the wiring for continuity between the main har ness connector
307. proba bly worn also When replacing a sprocket inspect the chain Rear Sprocket Warp Runout Inspection e Using the jack raise the rear wheel off the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Set a dial gauge A against the rear sprocket B near the teeth as shown e Rotate C the rear wheel slowly to measure the sprocket warp runout OThe difference between the highest and lowest dial gauge readings is the amount of warp runout Rear Sprocket Warp Runout Standard TIR 0 4 mm 0 016 in or less Service Limit TIR 0 5 mm 0 020 in If the runout exceeds the service limit replace the rear sprocket GKO0403038S1 C GKO5017BS1 GS12024BS1 C PERIODIC MAINTENANCE 2 39 Periodic Maintenance Procedures Brakes Brake Lever and Pedal Adjustment e Slide the dust cover A e Adjust the brake lever to suit you OLoosen the adjuster locknut B and turn the adjuster C to either side e After adjustment tighten the locknut A WARNING An improperly adjusted brake could drag and cause the brake to overheat damaging the brake assem bly and possbily locking the rear wheel resulting in loss of control Always maintain the proper brake adjustment NOTE OUsually it is not necessary to adjust the pedal position but always adjust it when the master cylinder is disas sembled or pedal position is incorrect e Measure the length A
308. r see Intake Air Temperature Sensor Removal Installation e Suspend the sensor A in a container of machine oil so that the heat sensitive portion is submerged e Suspend a thermometer B with the heat sensitive por tions C located in almost the same depth NOTE OThe sensor and thermometer must not touch the con tainer side or bottom e Place the container over a source of heat and gradually raise the temperature of the oil while stirring the oil gently for even temperature e Using a digital meter measure the internal resistance of the sensor Intake Air Temperature Sensor Resistance Standard 909 1 363 Q at 40 C 104 F YUN GC17716DS2 C 124 186 Q at 100 C 212 F If the reading is out of the standard replace the sensor x lf the reading is within the standard but the problem still exists replace the ECU see ECU Removal Installation FUEL SYSTEM DFI 3 49 Intake Air Temperature Sensor Service Code 13 Intake Air Temperature Sensor Circuit GEIF 1 ECU 2 Intake Air Temperature Sensor 6C17313FW2 C 3 50 FUEL SYSTEM DEI Water Temperature Sensor Service Code 14 Water Temperature Sensor Removal installation NOTICE Never drop the water temperature sensor espe cially ona hard surface Such a shock to the sensor can damage it e Drain the coolant see Coolant Draining in the Cooling System chapter e Remove Exhaust Pipe see Ex
309. r Clamp Bolts 25 2 5 18 AL 2T 2 Front Fork Clamp Bolts Upper 20 2 0 15 AL L 3 Steering Stem Head Nut 98 10 0 72 4 Handlebar Holder Nuts 34 3 5 25 R 5 Steering Stem Nut 4 9 0 50 43 in lb T 6 Brake Hose Clamp Bolt 3 0 0 31 27 in lb 7 Front Fork Clamp Bolts Lower 22 2 2 16 AL AD Apply adhesive AL Tighten the two clamp bolts alternately two times to ensure even tightening torque G Apply grease L Apply a non permanent locking agent R Replacement Parts T First tighten the stem nut with 39 N m 4 0 kgf m 29 ft lb of torque then loosen it and retighten it with 4 9 N m 0 50 kgf m 43 in lb of torque 2T Apply 2 stroke oil 14 4 STEERING Special Tools Bearing Puller 57001 135 ST570135ST C Steering Stem Bearing Driver 57001 137 Steering Stem Bearing Driver Adapter 634 5 57001 1074 ST5701378T ST5710748T Head Pipe Outer Race Press Shaft 57001 1075 ei ST5710758ST Head Pipe Outer Race Driver 651 5 57001 1076 ST5710768T C Head Pipe Outer Race Driver 654 5 57001 1077 ST571077ST Steering Stem Nut Wrench 57001 1100 ST5711008ST C Head Pipe Outer Race Remover ID gt 37 mm 57001 1107 ST571107ST Bearing Puller 57001 1575 ST5715758ST Steering Steering Inspection e Refer to the Steering Inspection in the Periodic Mainte n
310. r Connector B R Y lead C ECU terminal 12 lt gt BL lead D GY lead E ECU terminal 17 lt BK lead F xlf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation Throttle Sensor Output Voltage Inspection e Measure the throttle sensor output voltage in the same way as input voltage inspection ODisconnect the throttle sensor connector and connect the measuring adapter A between these connectors Main Harness B Throttle Sensor C Digital Meter D Special Tool Measuring Adapter 57001 1700 Throttle Sensor Output Voltage Connections to Adapter Digital Meter W sensor Y lead Digital Meter BK sensor BK lead e Start the engine and warm it up thoroughly e Check the idle speed to ensure the throttle opening is correct Idle Speed Standard 2 050 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 GC17332FS1 BK S JEZO GC17994ES1 FUEL SYSTEM DFI 3 39 Throttle Sensor Service Code 11 e Refer to the Self diagnosis Procedures connect the 12 V battery to the main harness e Measure the output voltage with the engine stopped and with the connector joined Output Voltage Standard DC 0 58
311. r pedal is obtained by pumping the lever or pedal until the pads are against the disc Brake Pad Inspection e Refer to the Brake Pad Wear Inspection in the Periodic Maintenance chapter BRAKES 12 19 Master Cylinder NOTICE Brake fluid quickly ruins painted or plastic sur faces any spilled fluid should be completely washed up immediately Front Master Cylinder Removal e Remove the banjo bolt A to disconnect the brake hose upper end B from the master cylinder C OWhen removing the brake hose temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum e Remove the clamp bolts A and take off the master cylin der B as an assembly with the brake lever Front Master Cylinder Installation e Install the master cylinder A 176 95 mm 6 967 in B Horizontal Line of Frame C Handlebars D Horizontal Line of Cap Surface E GLO7165BS2 12 20 BRAKES Master Cylinder e The master cylinder clamp must be installed with the ar row mark A upward e Tighten the upper clamp bolt B first and then the lower clamp bolt C OThere will be a gap at the lower mating surface of the clamp after tightening Torque Front Master Cylinder Clamp Bolts 8 8 N m 0 90 kgf m 78 in Ib e Install the brake hose OReplace the washers A on each side of hose fitting B with new ones e Tighten Torque Brake Hose Banjo Bolt 25 N m 2 5 kgf m 1
312. reads of the kick ratchet guide bolt e Install the ratchet guide A and tighten the bolt Torque Kick Ratchet Guide Bolt B 8 8 N m 0 90 kgf m 78 in Ib e Apply molybdenum disulfide grease to the kick shaft end Ka e Insert the kick shaft assembly into the crankcase be F ETC OSecurely engage the stopper portion D of the ratchet EE gear with the guide e Insert the spring end E into the hole F e Apply molybdenum disulfide oil solution to the idle shaft e Install the removed parts see appropriate chapters Kick Shaft Assembly Disassembly Assembly e The kick shaft assembly consists of the following parts Circlips A Washer 27 5 x 18 3 B Spring C Ratchet Gear D Washer 22 x 18 3 E Kick Gear F Kick Shaft G Kick Spring H Spring Guide I e Check the kick shaft assembly parts for damage Any damaged parts should be replaced with new ones 6119041BS1 C 9 30 CRANKSHAFT TRANSMISSION Kickstarter e Apply molybdenum disulfide grease A to the kick gear ratchet gear and kick shaft e Replace the circlips that were removed with new ones Special Tool Outside Circlip Pliers 57001 144 G119042BS1 NOTE OWhen assembling the ratchet gear A onto the kick shaft B align the punch mark C on the ratchet gear with the punch mark D on the kick shaft G119043BS1 e Apply grease A to the inside of the spring guide B e Fit the spring end
313. rease seals e Install the rear shock absorber e Tighten Torque Rear Shock Absorber Mounting Nut Upper 39 N m 4 0 kgf m 29 ft Ib Rear Shock Absorber Mounting Nut Lower 34 N m 3 5 kgf m 25 ft lb e Install the removed parts see appropriate chapters Rear Shock Absorber Spring Replacement In addition to the standard spring heavy and light springs are available If the standard spring is improper for your purpose select a proper one according to the rider s weight or course conditions e Remove the rear shock absorber see Rear Shock Ab sorber Removal e Clean the threaded portion on the upper of the rear shock absorber GMO5196BS1 Rear Shock Absorber e Hold the upper end of the rear shock absorber in a vise with soft jaws A or a heavy cloth e Using the hook wrenches B loosen the locknut C and turn the adjusting nut all way up Special Tools Hook Wrench R37 5 R42 57001 1101 Hook Wrench T 3 2 R37 57001 1539 e Slide the spring seat A e Remove the circlip B from the shock absorber and lift off the spring seat and spring C e Remove the rear shock absorber from the vise e Exchange the spring for an optional part Olnstall the spring so that large diameter end A faces up ward e Replace the circlip with a new one e Install the spring seat and new circlip e Adjust the spring preload see Spring Preload Adjust ment e Install the rear shock absorber
314. removed parts see appropriate chapters FRAME 15 5 Frame Engine Guards Removal e Remove the engine guards Right Engine Guard A Left Engine Guard B Lower Engine Guard C Bolts D Collars E Engine Guards Installation e Installation is the reverse of removal OFit the projection A of the right engine guard and hole B of the frame OFit the left engine guard similarly 15 6 FRAME Seat Seat Removal e Remove the side cover bolt A on both sides e Spread A the side covers lightly e Take off the seat B backward C Seat Installation e Install the seat Olnsert the hooks A of the seat under the flange collar B and brackets C OTake care not to damage the side covers with the bracket of seat e Tighten the side cover bolts Side Covers Side Cover Removal e Remove the bolts A and take off the side cover B OClear the side cover tabs C from the air cleaner housing Side Cover Installation e Stick the pad A on the inside of the right side cover e Install the damper B securely e Install the side covers Olnsert the tabs A of the side cover into the slots B of the air cleaner housing Olnsert the side cover rib A between the rear fender B and the rear frame C e Tighten the bolts FRAME 15 7 15 8 FRAME Radiator Shroud Radiator Shroud Removal e Remove Bolts A Radiator Shroud B OClear
315. rk Spring Compressor 57001 1587 Fork Spring Compressor 57001 1771 Compress the outer tube with a suitable jack while keep ing the front fork upright and install the top plug wrench A between the axle holder bottom B and locknut C Special Tool Top Plug Wrench 50 mm 57001 1645 A WARNING The fork spring applies pressure to the adjuster as sembly and can eject the special tool with substan tial force if the tool is not properly and securely placed Be sure the tool is fully in place as shown in the photo and keep fingers away to avoid getting them pinched between the tool adjuster assembly and axle holder e Remove the front fork from the fork spring compressor with care not to drop the top plug wrench and hold the axle holder with a vise NOTE OProtect the axle holder with a soft jaws or heavy cloth when using a vise A WARNING If the axle holder is not securely clamped the front fork assembly may come out of the vise when com pressed which could cause an accident resulting in injury However clamping the axle holder too tightly can damage it which will affect riding stabil ity Use protective aluminum covers on the jaws of the vise and do not tighten the vise excessively PERIODIC MAINTENANCE 2 63 Periodic Maintenance Procedures e Hold the locknut A with a wrench B and remove the right front fork bottom plug C NOTE ODo not remove the locknut from the
316. rk on the intake camshaft sprocket NOTE O Strain the exhaust side of the chain while installing the camshaft GET11508 2 C 1st Pin A Punch Marks Exhaust D 2nd Pin B Punch Marks Intake E 28th Pin C Cylinder Head Upper Surface F 5 18 ENGINE TOP END Camshafts e Install the dowel pins A and positioning rings B e Apply molybdenum disulfide oil solution to the threads and seating surface of the camshaft cap bolts e Tighten all camshaft cap bolts evenly and lightly and then tighten them with specified torque OFollow the numbers 1 8 of tightening sequence on the camshaft cap OBolt 5 is long Torque Camshaft Cap Bolts 9 8 N m 1 0 kgf m 87 in Ib e Replace the O ring A with a new one and apply grease it e Install the camshaft chain tensioner see Camshaft Chain Tensioner Installation e Check the camshaft chain timing OConfirm the timing mark and punch mark align with the cylinder head upper surface xlf the timing mark and punch mark do not align with the cylinder head upper surface reinstall the camshafts OTurn the crankshaft slowly x If the crankshaft does not turn smoothly the timing is dif ferent Stop turning immediately The improper camshaft chain timing may damage the valves e Install Cylinder Head Cover see Cylinder Head Cover Instal lation e Replace the timing inspection cap and flywheel nut cap O rings with new ones and apply grease them
317. rottle opening DC 3 65 3 85 V at full throttle opening for reference 4 6kQ DC 4 75 5 25 V DC 3 80 4 20 V at standard atmospheric pressure see text for details About DC 2 28 3 43 V at intake air temperature 20 C 68 F 909 1 363 Q at 40 C 104 F 124 186 Q at 100 C 212 F About DC 2 80 2 97 V at water temperature 20 C 68 F see text see text More than 55 75 for each bank DC 4 75 5 25 V 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 3 16 FUEL SYSTEM DFI Specifications Standard Throttle Grip and Cables Throttle Grip Free Play 2 3 mm 0 08 0 12 in Special Tools and Sealant FUEL SYSTEM DFI 3 17 Oil Pressure Gauge 5 kgf cm 57001 125 S T5701258T Fork Oil Level Gauge 57001 1290 CS ST5712908ST Vacuum Gauge 57001 1369 ST571369ST C Hand Tester 57001 1394 ST5713948T Filler Cap Driver 57001 1454 ST5714548T Needle Adapter Set 57001 1457 a Fuel Pressure Gauge Adapter ST571457ST C 57001 1593 ST571593ST CG Fuel Hose 57001 1607 ST571607ST Measuring Adapter 57001 1700 ST571700ST C Liquid Gasket TB1211 56019 120 ST560120ST C 3 18 FUEL SYSTEM DFI DFI Servicing Precautions DFI Servicing Precautions There are a number of important precaut
318. rst stop and wait there for a few seconds Then push down and turn it further in the same direction and remove the cap e Place a container under the coolant drain bolt A e Remove the drain bolt to drain the coolant e Inspect the old coolant see Coolant Deterioration Inspec tion in the Periodic Maintenance chapter Coolant Coolant Filling NOTICE Use coolant containing corrosion inhibitors made specifically for aluminum engines and radiators in accordance with the instruction of the manufac ture s Soft or distilled water must be used with the antifreeze see below for antifreeze in the cooling system If hard water is used in the system it causes scale accumulation in the water passages and considerably reduces the efficiency of the cooling system Recommended Coolant Type Permanent type antifreeze soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators Color Green Mixed Ratio Soft water 50 coolant 50 Freezing Point 35 C 31 F Total Amount 1 2 L 1 3 US qt e Replace the drain bolt gasket with a new one e Tighten Torque Coolant Drain Bolt 7 0 N m 0 71 kgf m 62 in Ib e Fill the radiator up to the bottom of the radiator filler neck A with coolant B and install the cap OLean the motorcycle slightly so that the filler neck is lo cated uppermost in order to exhaust the air accumulated in the radiator NOT
319. s Special Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Intake Air Pressure Sensor Connector B BL lead C ECU terminal 27 GY lead D ECU terminal 17 6C17337FS1 C 3 44 FUEL SYSTEM DFI Intake Air Pressure Sensor Service Code 12 x If the wiring is good check the sensor for various vacuum e Remove the intake air pressure sensor A and disconnect the vacuum hose from the sensor e Connect an auxiliary hose B to the intake air pressure sensor e Temporarily install the intake air pressure sensor OConnect a digital meter C vacuum gauge D the fork oil level gauge E and the measuring adapter to the intake air pressure sensor Special Tools Fork Oil Level Gauge 57001 1290 Vacuum Gauge 57001 1369 Measuring Adapter 57001 1700 Intake Air Pressure Sensor Output Voltage Connections to Adapter Digital Meter W sensor BL lead Digital Meter BK sensor GY lead e Refer to the Self diagnosis Procedures connect the 12 V battery to the main harness e Measure the intake air pressure sensor output voltage from various vacuum readings while pulling the handle of the fork oil level gauge e Check the intake air pressure sensor output voltage us ing the following formula and chart Suppose Pg Vacuum Pressure Gauge of Throttle Body PI Local Atmospheric Pressure Absolute measure
320. s chapter Fuel pressure regulator trouble Inspect and replace fuel pump or kinked fuel line Inspect and replace fuel pump see chapter 3 Upstream downstream injector trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Backfiring when deceleration Spark plug dirty broken or gap maladjusted Inspect and replace see chapter 16 Fuel pressure too low Inspect see chapter 3 Fuel pump trouble Inspect see chapter 3 Throttle sensor trouble Intake air pressure sensor trouble Water temperature sensor trouble Intake air temperature sensor trouble After fire Spark plug burned or gap maladjusted Upstream downstream injector trouble Intake air pressure sensor trouble Water temperature sensor trouble Intake air temperature sensor trouble Other Intermittent any DFI fault and its recovery Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Replace see chapter 16 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 NY Check that DFI connectors are clean and tight and examine leads for signs of burning or fraying see chapter 3 Poor Running or No Power at High Speed Symptoms or Possible Causes Actions chapter Firing incorrect Ignition coil shorted or not in good contact Inspect or Reinstal
321. s are listed in the Parts Catalog e Follow the procedures in this manual care fully Don t take shortcuts e Remember to keep complete records of main tenance and repair with dates and any new parts installed How to Use This Manual In this manual the product is divided into its major systems and these systems make up the manual s chapters The Quick Reference Guide shows you all of the product s system and assists in locating their chapters Each chapter in turn has its own comprehensive Ta ble of Contents For example if you want stick coil information use the Quick Reference Guide to locate the Electrical System chapter Then use the Table of Contents on the first page of the chapter to find the Stick Coil section Whenever you see symbols heed their in structions Always follow safe operating and maintenance practices A DANGER DANGER indicates a hazardous situa tion which if not avoided will result in death or serious injury A WARNING WARNING indicates a hazardous situa tion which if not avoided could result in death or serious injury NOTICE is used to address practices not related to personal injury This manual contains four more symbols which will help you distinguish different types of information NOTE OThis note symbol indicates points of par ticular interest for more efficient and con venient operation e Indicates a procedural step or work
322. se GB09999DW3 C Cable Wire and Hose Routing APPENDIX 17 9 CA A ui NA Et GB09000EW4 C Viewed Rear Radiator Overflow Hose Clamps Joint Hose Turn the blue paint to upside Clamps Turn the screw head to outside Right Radiator Water Pipe Run the radiator overflow hose in the front of the water hose and between the engine brackets o ND e O gt Capacitor Position the lead downward Run the radiator overflow hose in the left of the frame pipe and in the front of the water hose Left Radiator Viewed A 45 Viewed B Bottom Engine Guard 17 10 APPENDIX Cable Wire and Hose Routing GB09001EW4 C Install the mesh protector side of the breather hose to the engine 2 Clamp Turn the claw to the exhaust pipe side 3 Clamp Run the breather hose into the clamp 4 Breather Hose 5 Align the green paint to the stopper 6 Stoppers 7 Align the red paint to the stopper 8 Clamps Turn the screw head to front Clamps Turn the screw head to exhaust pipe side Joint Pipe Clamp Turn the screw head to outside Turn the green paint to outside Viewed A Insert the water hose to the pipe up to the clamp screw Clamp Turn the screw head to front Turn the green paint to front Water Pipe APPENDIX 17 11 Cable Wire and Hose Routing GB09002EW4
323. see Rear Shock Absorber Installation e Install the removed parts see appropriate chapters Rear Shock Absorber Disassembly Oil Change e Refer to the Rear Shock Absorber Oil Change in the Pe riodic Maintenance chapter Rear Shock Absorber Assembly e Refer to the Rear Shock Absorber Oil Change in the Pe riodic Maintenance chapter Rear Shock Absorber Inspection e Remove the rear shock absorber see Rear Shock Ab sorber Removal e Visually inspect the following items Smooth Stroke Oil Leakage Crack or Dent lf there is any damage to the rear shock absorber replace it e Visually inspect the oil seal A lf it show any signs of damage replace it SUSPENSION 13 21 II GM05197BS1 C 13 22 SUSPENSION Rear Shock Absorber Rear Shock Absorber Scrapping A WARNING Pressurized nitrogen may explode when heated The rear shock contains nitrogen gas To avoid an explosion do not incinerate the shock body without first releasing the nitrogen and removing the shraeder valve e Remove the rear shock absorber see Rear Shock Ab sorber Removal e Insert a suitable tool into the gas reservoir cap hole A to release the nitrogen gas Swingarm Swingarm Removal e Remove Rear Wheel see Rear Wheel Removal in the Wheels Tires chapter Rear Flap see Rear Flap Removal in the Frame chap ter Brake Pedal Bolt and Return Spring see Brake Pedal Removal in the Brakes chapter
324. sensor peak voltage no good parts All good ECU is defective No good Replace the malfunctioned parts or inspect in proper way All good GP10584B F ELECTRICAL SYSTEM 16 27 Ignition System Crankshaft Sensor Peak Voltage Check e Disconnect the magneto lead connector see Magneto Cover Removal NOTE OMeasure the voltage with each lead connected cor rectly The correct value may not be obtained if disconnected OMaintain the correct value of compression pressure for the cylinder Be sure to measure the voltage with the spark plug installed to the cylinder head A WARNING Electrical equipment can cause serious electrical shock To avoid being shocked do not touch the metal portion of the probe when measuring voltage e Set the hand tester to DC 25 V range and connect it to the peak voltage adapter A Special Tools Hand Tester 57001 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B e Connect the adapter to the terminals of the magneto lead connector B Connections GP10581BS1 C Magneto Lead Peak Voltage Connector Adapter mand Tester G W lead C R lead gt W Y lead D BKlead e Shift the gear to the neutral position e Crank the engine by kicking the pedal several times to measure the peak voltage of the crankshaft sensor Crankshaft Sensor Peak Voltage Standard 2 5 V or more If the voltage is less than the specified check the
325. sensor to the throttle body assy e Turn the throttle sensor counterclockwise B until the mounting holes align e Tighten the throttle sensor screw lightly e Connect the measuring adapter A between the main har ness B and throttle sensor C Special Tool Measuring Adapter 57001 1700 e Connect a digital meter D to the measuring adapter leads Throttle Sensor Output Voltage Connections to Adapter Digital Meter W sensor Y lead Digital Meter CH BK sensor BK lead e Refer to the Self diagnosis Procedures connect the 12 V battery to the main harness BK S K GC17994ES1 FUEL SYSTEM DFI 3 37 Throttle Sensor Service Code 11 e Adjust the sensor position so that the output voltage is within the specified voltage range Throttle Sensor Output Voltage Standard DC 0 58 0 62 V x lf the input voltage reading shows other than 5 V calculate a valid output voltage range as follows Example In the case of an input voltage of 4 75 V 0 58 x 4 75 5 00 0 55 V 0 62 x 4 75 5 00 0 59 V Thus the valid range is 0 55 0 59 V e Once the sensor is properly adjusted tighten the throttle sensor screw NOTE O Take care not to vary the output voltage when tightening the throttle sensor screw e Turn the throttle from closed to full open more than 2 times and measure the output voltage x If the output voltage is not within the specified range read
326. smission chapter Engine Sprocket see Engine Sprocket Removal in the Final Drive chapter Kick Pedal see Kick Pedal Removal in the Crank shaft Transmission chapter Clutch Cable Lower End see Clutch Cable Removal in the Clutch chapter Brake Pedal Bolt and Return Spring see Brake Pedal Removal in the Brakes chapter e Disconnect Gear Position Switch Lead Connector A Magneto Lead Connector B e Remove the bolt C e Remove the vehicle down sensor bracket bolts A ENGINE REMOVAL INSTALLATION 8 7 Engine Removal Installation e Disconnect the water temperature sensor connector A e Remove the following parts on both sides Upper Engine Bracket Bolts B Upper Engine Mounting Bolts C and Nuts Upper Engine Brackets D e Remove Middle Engine Bracket Bolts A and Nuts Middle Engine Mounting Bolt B and Nut Middle Engine Bracket C Both Sides Lower Engine Mounting Bolt D and Nut e Remove Swingarm Pivot Shaft Nut A Swingarm Pivot Shaft B e Remove the engine from the motorcycle to right side OClear the engine rear portion from the swingarm and then remove the engine Engine Installation e Replace with new ones Upper Engine Mounting Nuts Middle Engine Mounting Nut Middle Engine Bracket Nuts Lower Engine Mounting Nut Swingarm Pivot Shaft Nut e Install the engine OFirst insert the front portion of the engine from the right side and then install the rear portion OSecon
327. sor Bolts 62 in lb L 9 Gear Position Switch Screws 26 in lb L G Apply grease L Apply a non permanent locking agent R Replacement Parts Si Apply silicone grease SS Apply silicone sealant 16 4 ELECTRICAL SYSTEM Specifications Item Flywheel Magneto Magneto Output Voltage Stator Coil Resistance Charging System Charging Voltage Regulator Rectifier Output Voltage Capacitor Internal Resistance Ignition System Ignition Timing Ignition Coil 3 Needle Arcing Distance Primary Winding Resistance Secondary Winding Resistance Primary Peak Voltage Crankshaft Sensor Resistance Crankshaft Sensor Peak Voltage Spark Plug Type Gap Standard 37 V or more at 4 000 r min rpm 0 4 1 1 Q at 20 C 68 F 14 0 14 5 V see text 4 BTDC at 2 000 r min rpm 7 mm 0 28 in or more 0 28 0 38 Q at 20 C 68 F 7 65 10 4 KQ at 20 C 68 F 150 V or more 180 280 Q at 20 68 F 2 5 V or more NGK CPR8EB 9 0 8 0 9 mm 0 031 0 035 in Special Tools and Sealant ELECTRICAL SYSTEM 16 5 Rotor Puller M16 M18 M20 M22 x 1 5 57001 1216 T5712168T Timing Light 57001 1241 T5712418T Hand Tester 57001 1394 ST5713948T Peak Voltage Adapter 57001 1415 ST571415ST C Filler Cap Driver 57001 1454 EE ST5714548T Needle Adapter Set 57001 1457 ST571457ST C Flywheel Puller
328. spection x If the ground and power supply are good replace the ECU see ECU Removal Installation lf the reading is in specification but the fuel pump does not operate replace the fuel pump see Fuel Pump Re moval Installation Pressure Regulator Removal OThe pressure regulator A is built into the fuel pump and can not be removed Fuel Filter Cleaning OThe fuel filter A is built into the pump and can not be cleaned or checked x lf the fuel filter is suspected of clogging or being damaged replace it with the fuel pump as a set 3 74 FUEL SYSTEM DFI Fuel Pump Service Code 46 Fuel Pump Circuit R BK Y P BK BK Y 1 ECU 2 Capacitor 3 Fuel Pump 4 Frame Ground 1 BK 0 Y R W P BK TE es R BK ET LE 9 6C17320F 2 C FUEL SYSTEM DFI 3 75 Ignition Coil Service Code 51 Ignition Coil Removal installation e Refer to the Ignition Coil Removal Installation in the Elec trical System chapter Ignition Coil Primary Peak Voltage Inspection e Refer to the Ignition Coil Primary Peak Voltage Check in the Electrical System chapter lf the peak voltage is much lower than standard check the wiring for continuity see Ignition Coil Circuit xlf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x lf the ground and power supply are good replace the ECU see ECU Removal Installation Ignit
329. step above ENGINE TOP END 5 31 GE150119S1 GE150121S1 GE15012281 5 32 ENGINE TOP END Valves If the seat width is too wide make the 60 A grind de scribed below x If the seat width is within the specified range lap the valve to the seat as described below e Grind the seat at a 60 angle until the seat width is within the specified range B OTo make the 60 grind fit a 60 cutter into the holder and slide it into the valve guide OTurn the holder while pressing down lightly OAfter making the 60 grind return to the seat width mea surement step above NOTICE Do not lap the valve to the valve seat using the grinding compound It will come off oxide film treated surface of the valve e When the engine is assembled be sure to adjust the valve clearance see Valve Clearance Adjustment in the Peri odic Maintenance chapter GE15012381 ENGINE TOP END 5 33 Valves Valve Seat Repair Machinist s dye on seat 45 Grind Tool 45 Cutter Purpose make seating area smooth and round Measure Seating Area Outside Diameter Tool Vernier Caliper Purpose check seat outside diameter against specification Results Too smal Machinist s dye on seat Tool 32 Cutter Purpose reduce outside diameter of seat area to specification 45 Grind Tool 45 Cutter Purpose increase outs
330. t front fork cylinder valve B with a standard tip screwdriver until you feel a click Adjust the rebound damping to suit your preference under special condition NOTICE Do not force the rebound damping adjuster beyond the fully seated position or the adjusting mecha nism may be damaged Seated position A adjuster turned fully clockwise Rebound Damping Adjuster Setting Standard 10 clicks B EUR BR 12 clicks counterclockwise Softer Counterclockwise C Harder Clockwise D Although you can turn the adjuster beyond the ad justable range effecting no changes to damping force use it within the adjustable range Spring Preload Adjustment Right Fork only e Place the jack under the frame so that the front wheel is raised off the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Turn the adjuster A with the wrench until you feel a click Adjust the spring preload to suit your preference under special condition Do not force the spring preload adjuster beyond the fully seated position or the adjusting mechanism may be damaged 22212013121110 9 t al III 2019181312111 al III CH rl CS CO a to N Oot GM04721BS1 C Front Fork Seated position A adjuster turned fully counterclock wise Spring Preload Adjuster Setting Standard 15 clicks B EUR BR 7 clicks clockwise
331. t is bottomed e Install the exhaust pipe muffler body and muffler clamp temporary OTurn the punch mark A of the exhaust pipe holder to right side of the motorcycle OTighten the exhaust pipe holder nuts first and then the muffler mounting bolt rear e Tighten the muffler mounting bolts securely OTighten the front bolt first and then the rear bolt e Tighten the exhaust pipe holder nuts securely e Upturn the muffler clamp opening and fit the hole B of the muffler clamp to the projection C of the muffler body e Tighten the muffler clamp bolt securely e Thoroughly warm up the engine wait until the engine cools down and then retighten all bolts and nuts Silencer Wool Replacement e Refer to the Silencer Wool Replacement in the Periodic Maintenance chapter CLUTCH 6 1 Clutch Table of Contents elele CO RE 6 2 SDE CIICAUONG EE 6 4 DEC IA EE 6 5 Gluten ever and Cable eege ee 6 6 Clutch Lever Clutch Cable Free Play Inspection 6 6 Clutch Lever Clutch Cable Free Play Adjustment AA 6 6 Gluten Lever Installations ustensiles lee et tan tte 6 6 Cluteh Cable Removal sireni na rase SEENEN 6 6 Renee EE RE 6 7 Clutch Cable Inspection and Lubrication cccceeeceeeee scene ee eeeeeeeeeeeeeeeeeeeaeeeeeenaeeeeeeea Clutch Cover and Right Engine Cover icce iccidscdacsessesecccaeecactcndasusccapesdeunesns eds eeeedaibedeastecnineentte Clutch Cover REMOVAL etek ee ee Gl teh Cover I
332. t the service limit replace the sleeve Tie Rod and Rocker Arm Mounting Bolt Bend Inspection A bent bolt causes vibration poor handling and instabil ity e To measure the bolt runout remove the bolt place it in V blocks and set a dial gauge to the bolt at a point halfway between the blocks e Turn A the bolt to measure the runout OThe amount of dial variation is the amount of runout Rocker Arm Mounting Bolt Runout Standard TIR 0 1 mm 0 004 in or less Service Limit TIR 0 2 mm 0 008 in If runout exceeds the service limit replace the bolt GMO7036BS1 GMO7038BS1 STEERING 14 1 Steering Table of Contents Se ee te 14 2 Special TOOS e e aa a a a pE Aa T EEEE ERE AAR Ea 14 4 HS ONE Re ee en os sn sn 14 5 Steering le Te 14 5 SUSE ING Be TE EE 14 5 Steering Stem Stem Bearing Removal EEN 14 5 Steering Stem Stem Bearing Installation EE 14 6 Stem Bearing EU DHGa OM aces nisl set li ccpeatiaen ecreastc ec aishathccathtne ne du eos 14 8 Stem Bearing Wear Damage Inspection 14 8 Stem Warp E e EE ethan Mad A net etes 14 8 e ME 14 9 Handlebar ne EE EE 14 9 Handlebar Installation c cece ceeccsecceecceeeceeeeeececeeeceeeeeeeaeseaeceaeeeeceeeeeeeeereeeneeeneteneneneeenenens 14 10 14 2 STEERING Exploded View WY FIN 6 JVHRUNSE STEERING 14 3 Exploded View No Fastener pone Remarks N m kgf m ft Ib 1 Handleba
333. t to back measurement as shown total 6 measurements OThe cylinder wear is uneven in different places 10 mm 0 39 in A 25 mm 0 98 in B 60 mm 2 36 in C Cylinder Inside Diameter Standard 77 000 77 012 mm 3 0315 3 0320 in and less than 0 01 mm 0 0004 in difference between any two measurements Service Limit 77 10 mm 3 035 in or more than 0 05 mm 0 0020 in difference between any two measurements lf any of the cylinder inside diameter measurements ex ceeds the service limit the cylinder must be replaced with a new one OSince the PLATING cylinder cannot be bored or honed Piston Cylinder Clearance Inspection The piston cylinder clearance is measured whenever a piston or cylinder is replaced with a new one The standard piston cylinder clearance must be adhered to whenever the cylinder is replaced If only a piston is replaced the clearance may exceed the standard slightly But it must be within the standard in order to avoid piston seizure The most accurate way to find the piston clearance is by making separate piston and cylinder diameter measure ments and then computing the difference between the two values Measure the piston diameter as just described and measure the cylinder diameter at the very bottom of the cylinder Piston Cylinder Clearance Standard 0 041 0 068 mm 0 0016 0 0027 in Piston Piston Ring and Piston Pin Replacement e Refer to the Cylinder
334. t voltage shows a much lower reading than that given in the table indicates that the magneto is defective e To check the stator coil resistance as follows OStop the engine OConnect the hand tester as shown in the table 2 Special Tool Hand Tester 57001 1394 ONote the resistance readings total 3 measurements Table 2 Stator Coil Resistance at 20 C 68 F Tester Connections Reading Range Tester to Tester to Another yellow lead 0 4 1 10 x10 One yellow lead ELECTRICAL SYSTEM 16 15 GP21011BS1 C 16 16 ELECTRICAL SYSTEM Flywheel Magneto lf there is more resistance than shown in the table or no hand tester reading infinity the stator has an open lead and must be replaced Much less than this resistance means the stator is shorted and must be replaced e Using the highest resistance range of the hand tester measure the resistance between each leads and chas sis ground Any hand tester reading less than infinity indicates a short necessitating stator replacement If the stator coil has normal resistance but the voltage check showed the magneto to be defective then the fly wheel have probably weakened and the flywheel must be replaced ELECTRICAL SYSTEM 16 17 Charging System Regulator Rectifier Removal e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter e Open the clamp A and free the lead e Slide the dust cov
335. tallation is the reverse of removal ORun the lead correctly see Cable Wire and Hose Rout ing section in the Appendix chapter 16 20 ELECTRICAL SYSTEM Charging System Capacitor Inspection e Remove Capacitor see Capacitor Removal e Set the hand tester to the x 1 kQ range connect the tester to the leads of the capacitor and check the internal resis tance the following table Special Tool Hand Tester 57001 1394 NOTICE Use only Kawasaki Hand Tester 57001 1394 for this test A tester other than the Kawasaki Hand Tester may show different readings x If the readings do not correspond to the table replace the capacitor unit Capacitor Internal Resistance Tester Positive Lead Connection Color O BK W Tester o more than 5 kQ Negative GERS Should not be Connection BK W inspected 2 1 Check the capacitor after 2 minutes 2 Do not check the resistance because of opposite of the polarity Capacitor Capacity 10 000 4F 50 V ELECTRICAL SYSTEM 16 21 Ignition Timing Ignition Timing Inspection e Remove the timing inspection cap A Special Tool Filler Cap Driver 57001 1454 e Attach the timing light A to the ignition coil lead in the manner prescribed by the manufacturer Special Tool Timing Light 57001 1241 e Start the engine and aim the timing light at the TDC mark B on the flywheel e Run the engine at the speeds specified and note the align ment of the T
336. tandard 21 959 21 980 mm 0 8645 0 8654 in Service Limit 21 93 mm 0 8634 in lf the camshaft journal diameter is less than the service limit replace the camshaft with a new one and measure the clearance again xklf the clearance still remains out of the service limit re place the cylinder head unit ENGINE TOP END 5 19 5 20 ENGINE TOP END Camshafts Camshaft Runout Inspection e Remove the camshafts see Camshaft Removal e Set the camshaft in a camshaft alignment jig or on V blocks e Measure the runout with a dial gauge A at the specified place xlf 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 Cam Wear Inspection e Remove the camshafts see Camshaft Removal e Measure the height A of each cam with a micrometer Cam Height Standard Exhaust 33 943 34 057 mm 1 3363 1 3408 in Intake 35 243 35 357 mm 1 3875 1 3920 in Service Limit Exhaust 33 84 mm 1 332 in Intake 35 14 mm 1 383 in If the cams are worn down past the service limit replace the camshaft GE11374BS1 GE11012281 Cylinder Head Cylinder Compression Measurement e Warm up the engine thoroughly e Stop the engine e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Spark Plug see Spark Plug Cleaning and Inspectio
337. ternal resistance of the sensor Water Temperature Sensor Resistance 20 C CAF 0C GF 20 104 100 C 212 Reference Information x lf the measurement is out of the range replace the sensor x lf the reading is within the standard but the problem still exists replace the ECU see ECU Removal Installation Water Temperature Sensor Circuit GP18055BS2 C w GY OLJE 6C17314FW2 C 1 ECU 2 Water Temperature Sensor FUEL SYSTEM DFI 3 53 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 e Refer to the Stator Coil Removal Installation in the Elec trical System chapter Crankshaft Sensor Resistance Inspection e Refer to the Crankshaft Sensor Inspection in the Electrical System chapter lf the reading is within the standard check the peak volt age see Crankshaft Sensor Peak Voltage Inspection Crankshaft Sensor Peak Voltage Inspection e Refer to the Crankshaft Sensor Peak Voltage Inspection in the Electrical System chapter xlfthe reading is within the standard remove the ECU and check the wiring for continuity between the main harness connectors Special Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Crankshaft Sens
338. 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 holding the brake applied 3 Release the brake C NOTE O 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 almost out any time during bleeding operation the bleeding opera tion must be done over again from the beginning since air will have entered the line O Tap the brake hose lightly from the caliper to the reser voir for easier bleeding e Remove the clear plastic hose e Tighten the bleed valve and install the rubber cap Torque Caliper Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib e Check the fluid level see Brake Fluid Level Inspection in the Periodic Maintenance chapter e Install the diaphragm and reservoir cap e Tighten Torque Brake Reservoir Cap Screws 1 5 N m 0 15 kgf m 13 in Ib e After bleeding is done check the brake for good braking power no brake drag and no fluid leakage A WARNING After servicing it takes several applications of the brake lever before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the motorcycle until a firm brake lever is obtained by pumping the lever until the pads are against the disc
339. the cylinder head A upward NOTE OWhen do not remove the cylinder head easily tap lightly up with a plastic mallet to separate the cylinder head from the cylinder OTake care not to damage the chain guides NOTICE Do not touch the radiator core This could damage the radiator fins resulting in loss of cooling effi ciency e Remove the cylinder head gasket ENGINE TOP END 5 23 Cylinder Head Cylinder Head Installation e Install the front camshaft chain guide OFit the projection A in the groove B of the cylinder Olnsert the guide end C into the recess of the crankcase securely NOTE Oln this figure the magneto cover and flywheel has been removed for clarity e Replace the cylinder head gasket with a new one e Install Dowel Pins A New Cylinder Head Gasket B e Install the cylinder head NOTE OThe camshaft cap is machined with the cylinder head so if a new cylinder head is installed use the cap that is supplied with the new head e Replace the cylinder head bolts M10 with new ones e Apply molybdenum disulfide oil solution to the following areas Cylinder Head Bolt M10 Washer Both Sides A Cylinder Head Bolt M10 Thread B e Tighten the cylinder head bolts M10 in the numbered sequence 1 4 Torque Cylinder Head Bolts M10 44 N m 4 5 kgf m 32 ft lb e Install the clamps A 90 B e Tighten Cylinder Bolt C Cylinder Head Bolts
340. the fuel pump see Fuel Pump Installation in the Fuel System DFI chapter e Install the fuel tank see Fuel Tank Installation in the Fuel System DFI chapter Cooling System A WARNING Coolant can be extremely hot and cause severe burns is toxic and very slippery Do not remove the radiator cap or attempt to change the coolant when the engine is hot allow it cool completely Immediately wipe any spilled coolant from tires frame engine or other painted parts Do not ingest coolant 2 22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Coolant Level Inspection NOTE OCheck the level when the engine is cold room or ambi ent temperature e Remove the right radiator shroud see Radiator Shroud Removal in the Frame chapter e Lean the motorcycle slightly until the radiator cap is level to the ground so that the radiator cap is located uppermost in order to exhaust the air accumulated in the radiator e Remove the radiator cap A NOTE ORemove the radiator cap in two steps First turn the cap counterclockwise to the first stop and wait there for a few seconds Then push down and turn it further in the same direction and remove the cap e Check the coolant level The coolant level A should be at the bottom of the filler neck B lf the coolant level is low add coolant through the filler opening to the bottom of the filler neck Install the cap Recommended Coolant Permanent type antifreeze s
341. the radiator shroud tabs C from the air cleaner housing Radiator Shroud Installation e Install the radiator shrouds Olnsert the tabs A of the radiator shroud into the slots B of the air cleaner housing e Temporarily install the bolts as shown sequence 1 4 L 13mm 0 51 in 1 3 L 20 mm 0 79 in 4 e Tighten all bolts securely FRAME 15 9 Number Plate Number Plate Removal e Unlock the band A of the number plate B e Remove the bolt C e Clear the projections D and remove the number plate Number Plate Installation e Fit the holes A of the number plate and projections B of the steering stem base ORun the brake hose through the front of the number plate e Install the band to the handlebar pad and tighten the bolt 15 10 FRAME Fender Front Fender Removal e Remove the bolts A and take off the front fender B Front Fender Installation e Temporarily install the front bolts A first and then the rear bolts B e Tighten all bolts securely Rear Fender Removal installation e Remove the side covers see Side Cover Removal e Remove the bolts A e Remove the bolt A on both sides and take off the rear fender B e Installation is the reverse of removal Rear Flap Removal installation e Remove the screws A and take off the rear flap B e Installation is the reverse of removal FRAME 15 11 Footpegs Footpeg Removal e
342. the valve seat cutter holder in position operate the cutter in one hand Do not apply too much force to the diamond portion NOTE OPrior to grinding apply engine oil to the cutter and dur ing the operation wash off any ground particles sticking to the cutter with washing oil 5 After use wash it with washing oil and apply thin layer of engine oil before storing Marks Stamped on the Cutter The marks stamped on the back of the cutter A represent the following LEE Cutter Angle B BT OD anime Cutter Outer Diameter C Repair Operating Procedures e Clean the seat area carefully e Coat the seat with machinist s dye e Fit a 45 cutter into the holder and slide it into the valve guide e Press down lightly on the handle and turn it right or left Grind the seating surface only until it is smooth 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 GE15006BS1 C Valves Widened Width A of engagement by machining with 45 cutter Ground Volume B by 32 cutter 32 C Correct Width D Ground Volume E by 60 cutter 60 F e Measure the outside diameter of the seating surface with a vernier caliper If the outside diameter of the seating surface is too small repeat the 45 A grind unt
343. tightly can damage it which will affect riding stabil ity Use protective aluminum covers on the jaws of the vise and do not tighten the vise excessively e Remove the piston rod puller A PERIODIC MAINTENANCE 2 67 Periodic Maintenance Procedures e Replace the O ring A on the right front fork bottom plug with a new one and apply specified fork oil to it e Slowly turn the right front fork bottom plug A clockwise until resistance is felt Check the clearance between the locknut B and right front fork bottom plug for more than 1 mm 0 04 in e Turn the locknut counterclockwise until it contacts with the right front fork bottom plug e Hold the right front fork bottom plug with a wrench C and tighten the locknut Torque Right Front Fork Bottom Plug Locknut 22 N m 2 2 kgf m 16 ft Ib NOTICE When tightening the locknut the threads of the axle holder do not touch the push rod If the push rod is scratched it is possible to the damage in the cylin der unit When not using the Fork Spring Compressor Special Tool 57001 1771 e Apply a non permanent locking agent to the threads of the right front fork bottom plug A e Compress the outer tube by hands and remove the top plug wrench B When using the Fork Spring Compressor Special Tool 57001 1771 e Reset the front fork on the fork spring compressor with care not to drop the top plug wrench e Apply a non permanent l
344. tions and rider ability The disassembly procedure is included in the oil change procedure Disassembly for Oil Change e Remove the rear shock absorber see Rear Shock Ab sorber Removal in the Suspension chapter e Remove the shock absorber spring see Spring Replace ment in the Suspension chapter e Insert a suitable tool to center A of the reservoir cap and release the nitrogen gas completely keep the suitable tool inserted OFor instructions on how to use the tool follow the opera tion manual provided by the manufacturer A WARNING The shock contains high pressure nitrogen gas that when suddenly released can eject oil and internal shock parts at high velocity causing serious injury To avoid injury do not point a suitable tool toward your face or body when releasing nitrogen gas pres sure since an oil mist is often released with the ni trogen Always release nitrogen gas pressure be fore disassembling the rear shock absorber to pre vent explosive separation of parts GM04254BS1 PERIODIC MAINTENANCE 2 71 Periodic Maintenance Procedures e Adjust the gas reservoir damping adjusters A to the soft est position e Remove the adjuster assembly B and pump the rear shock to drain the oil e Using the hand press push the reservoir cap A e Remove Circlip B Reservoir Cap e Tap A the hole B in the stopper C with suitable tools D to free the stopper from the rear
345. to be done Olndicates a procedural sub step or how to do the work of the procedural step it follows It also precedes the text of a NOTE Indicates a conditional step or what action to take based on the results of the test or inspec tion in the procedural step or sub step it fol lows In most chapters an exploded view illustration of the system components follows the Table of Contents In these illustrations you will find the instructions indicating which parts require spec ified tightening torque oil grease or a locking agent during assembly GENERAL INFORMATION 1 1 General Information Table of Contents Before Servicing DEE Model Identificati EE General SPSCIICAONG ER ata ee GE enee CINE ee Ee TEE E 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 Edges of Parts Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts GhO20MB S Solvent Use a high flash point solvent wh
346. to the inner tube NOTICE When loosening the locknut the threads of the axle holder do not touch the push rod If the push rod is scratched it is possible to the damage in the cylin der unit e Remove the push rod A NOTICE Removing the locknut and pushing the piston rod thread into the left front fork cylinder unit will dam age the oil seal Do not remove the locknut from the piston rod e Remove the fork leg from the vise e Unscrew the left front fork cylinder unit A from the outer tube B Special Tool Top Plug Wrench 50 mm C 57001 1645 e Remove the left front fork cylinder unit A from the outer tube B PERIODIC MAINTENANCE 2 53 Periodic Maintenance Procedures e Holding the top plug wrench A with a vise unscrew the left front fork base valve assembly B on the fork cylinder unit C OUse a box wrench D Special Tool Top Plug Wrench 50 mm 57001 1645 e Pull out the left front fork base valve assembly A from the fork cylinder unit B OSlowly compress the piston rod until it stops so that the left front fork base valve assembly can be removed easily NOTICE Be careful not to damage the bushing of the left front fork base valve assembly Disassembling the left front fork base valve assem bly can lead to trouble Do not disassemble the left front fork base valve assembly e Hold the left front fork cylinder unit A upside down over a clean container B
347. ts see appropriate chapters GP18462BS1 C FUEL SYSTEM DFI 3 55 Gear Position Switch Service Code 25 Gear Position Switch Inspection NOTE OBe sure the transmission mechanism Is good condition e Remove the left radiator shroud see Radiator Shroud Re moval in the Frame chapter e Disconnect the gear position switch lead connector A e Set the hand tester A to the x 1 KQ or x 100 Q range and connect it to the terminals in the gear position switch lead connector B and ground Internal Circuit C Special Tool Hand Tester 57001 1394 Gear Position Switch Resistance Gear Connections if Position G R Lead D Ground BK Lead E Ground SE Neutral 1 43 1 58 kO about 0 Q 1st 2 23 2 46 kO about 0 Q 2nd 0 95 1 06 kQ about 0 Q 3rd 644 711 Q about 0 Q 4th 410 453 Q about 0 Q 5th 241 266 Q about 0 Q xlf the tester reading is not as specified replace the gear position switch with a new one GCI7711ES2 Gear Position Switch Circuit G R 6C17316FW2 C 1 ECU 2 Gear Position Switch 3 Frame Ground 1 3 56 FUEL SYSTEM DFI Vehicle down Sensor Service Code 31 When the motorcycle is down the engine stops according to the condition of the below table Engine Speed Time Engine Condition 2 500 rom or less After 30 seconds Stop 2 500 rpm or more After 3 seconds Stop Whe
348. tue 13 13 Adjuster Assembly Inspection tibeinie 13 15 Base Valve Assembly Inspection hein anne re de PRE 13 15 Cylinder Unit Inspection MEET 13 15 Inner Tube lnspecti i eege a te Bla el S 13 15 DUSE Seal IMS oe 01o a ee ee E AE AEE T 13 16 Front Fork Spring Tension Inspection Right Fork only 13 16 Rear Shock eege 13 17 Rebound Damping AGjUSIMOENt 2 siiscccd cages NEE ER telnet dental 13 17 Compression Damping Adjustment AE 13 17 Spring Preload Adiustm nt sss is tin dite EEEEE ENNEN EES lees 13 19 Rear Shock Absorber Spring Tension Inspection cceeeeeeeeeeeeeeeeeeeeeeeeeeeteeeeeeeeeeeneeeees 13 20 Rear Shock Absorber Removal sus ntenanatinndtentenatennte Rear Shock Absorber Installation Rear Shock Absorber Spring Replacement c ccccecceeeeeeeeeeeeeeeeeeeeeeeeeeeeteeneeeeeeeenaeeees 13 20 Rear Shock Absorber Disassembly Oil Change 13 21 Rear Shock Absorber Assembly 13 21 Rear Shock Absorber Inspection EE 13 21 Rear Shock Absorber Scrapping BEE 13 22 Swingal M eeh eege 13 23 SWINGALNY RAM OVA eegene gien Eegen n Ed ee etre eege eege 13 23 Swingarm installations ses aae ni Reine ele Rte 13 24 Swingarm Bearing Removal en nus tent ann tre eme teen et ta tte 13 24 swingarm Bearing Installation sante en emmener uiereteitRee een 13 24 Drive Chain Guide Guide Roller Chain Slipper Wear Inspection 13 25 Swingarm Bearing Sleeve Inspection 13 25 Tie ROd ROCKET AMM DEE 13
349. ulator Rectifier Inspection ssh pieds aed Serato teed ons Capacitor Removal ae An hte At at tee ne need es Capacitor lista latin Essen AS ne ne ml Capacitor Inspection RE lonion NG BEE Ignition Timing Inspection EEN lantion Syst m DEE Safety IMSIUCUONS keder aee eaae a ara a E OA LS nn er tt ss NRE lgniti n C il Ee TEE Ignition Coil Installation EE ignition Coil De Spark Plug Cleaning and INSPOCtin ss vicceceicaccegessesceveesnseteceeedzetcagesenseeanesssseeseacadeneeessieseaneze Spark Plug Gap Inspection E Ignition Coil Primary Peak Voltage Check ssnssssseenessssenesrerrsssrrrnsrrnrrrrrnnrssrrrnnerrnnnnennnne IC Igniter Inspection EE EE Crankshaft Sensor Peak Voltage Check Crankshaft Sensor Te DEE Engine Stop e EE Ener DFI Setting Data Selection Connector Inspection 16 28 e 16 30 Engine Stop Switch Inspection EE 16 30 Gear Position Switch Removal sautent n faste 16 30 Gear Position Switch Installation EE 16 30 Gear Position Switch Inspection ARENS ee nace nee 16 30 16 2 ELECTRICAL SYSTEM Exploded View GPO2631BWS C Exploded View ELECTRICAL SYSTEM 16 3 No Fastener sole Remarks N m kgf m ft Ib 1 Regulator Rectifier Nuts 10 1 02 89 in lb R 2 Spark Plug 13 1 3 115 in lb 3 Flywheel Nut Cap 3 5 0 36 31 in lb 4 Magneto Cover Bolts 9 8 1 0 87 in lb 5 Timing Inspection Cap 3 5 0 36 31 in lb 6 Flywheel Nut 57 9 7 Stator Coil Bolts 87 in lb L 8 Crankshaft Sen
350. utch Removal in the Clutch chapter Primary Gear see Primary Gear Removal Oil Pumps see Oil Pump Removal in the Engine Lubri cation System chapter Kick Shaft see Kick Shaft Removal External Shift Mechanism see External Shift Mecha nism Removal Flywheel see Flywheel Removal in the Electrical Sys tem chapter Gear Position Switch see Gear Position Switch Re moval in the Fuel System DFI chapter e Slide out the clamp A and remove the breather hose B e Remove the output shaft collar A and O rings e Remove the crankcase bolts B e Position the connecting rod in BDC e Install the crankshaft jig A between the crankshaft fly wheels Special Tool Crankshaft Jig 57001 1174 CRANKSHAFT TRANSMISSION 9 9 Crankcase e Attach the crankcase splitting tool A to the left crankcase OAdjust the gap with suitable collars or nuts B Special Tool Crankcase Splitting Tool Assembly 57001 1362 e Tighten the center bolt to split the crankcase halves OThe front and rear portion of the crankcase must be pulled apart evenly e Remove Oil Screen Feed see Oil Screen Cleaning and Inspec tion in the Engine Lubrication System chapter Shift Rods A Shift Forks B Shift Drum C see Transmission Shaft Removal Transmission Shafts D see Transmission Shaft Re moval Crankshaft E see Crankshaft Removal NOTICE Do not remove the bearings and the oil seals unless it is necessary
351. utput from ECU put to both injectors and the fuel delivery is stopped If the upstream injector break down wiring 42 Upstream In succession pulse is short or open the ECU stops the signal out Injector output from ECU put to both injectors and the fuel delivery is stopped Supply Voltage If the pump fails wiring short or open the ECU FUSE PUMP 6 15V stops the pump operations ECU sends signals 51 ignition Coil output voltage If the ignition coil fails the ECU shuts off the continuously to the ignition coil signal to the ignition coil 3 34 FUEL SYSTEM DFI Self Diagnosis Note 1 D J Method and a N Method When the engine load is light like at idling or low speed the ECU determines the injection quantity by calculating from the throttle vacuum intake air pressure sen sor output voltage and engine speed crankshaft sensor output voltage This method is called D J method low speed mode As the engine speed increases and the engine load turns middle to heavy the ECU determines the injection quantity by calculating from the throttle opening throt tle sensor output voltage and the engine speed This method is called a N method high speed mode FUEL SYSTEM DFI 3 35 Throttle Sensor Service Code 11 The throttle sensor is a rotating variable resistor that change output voltage according to throttle operating MOO The ECU senses this voltage change and determines fuel injection quantity and ig
352. ve Kick Pedal Bolt A and Washer Kick Pedal Assy B Kick Pedal Installation e Install the kick pedal assy OPut the pedal end A near the cylinder head cover mating surface B e Apply a non permanent locking agent to the threads of the kick pedal bolt e Install the washer and tighten the kick pedal bolt Torque Kick Pedal Bolt 25 N m 2 5 kgf m 18 ft Ib Kick Pedal Disassembly e Remove the kick pedal assy see Kick Pedal Removal e Remove Plug Screw A Spring B Steel Ball C Detent Screw D Boss E Oil Seal F Kick Pedal Assembly e Replace the oil seal A and plug screw B with a new one e Apply grease to the steel ball oil seal lip spring and the sliding portion of the pedal e Install Oil Seal Boss C Detent Screw D Steel Ball E Spring F Plug Screw e Tighten the detent screw and plug screw e After tightening the plug screw stake it with a punch G119040BS1 CRANKSHAFT TRANSMISSION 9 29 Kickstarter Kick Shaft Removal e Remove Right Engine Cover see Right Engine Cover Removal in the Clutch chapter Clutch see Clutch Removal in the Clutch chapter Kickstarter Idle Gear A e Pull the spring end B out of the hole e Turn the kick shaft counterclockwise C and pull out the kickstarter assembly D e Remove the bolt A and take off the ratchet guide B Kick Shaft Installation e Apply a non permanent locking agent to the th

"service manual"

Contents

Download Pdf Manuals

Related Search

Related Contents

&quot;service manual&quot;

Contents

Download Pdf Manuals

Related Search

Related Contents

"service manual"