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Kawasaki ZX6R ZX600P7F service manual

1. Immobilizer System Parts Immobilizer System Inspection Switches and Sensors Brake Light Timing Inspection Brake Light Timing Adjustment Gear Position Switch Removal Gear Position Switch Installation Gear Position Switch Inspection Switch Inspection Water Temperature Sensor 1 5 Speed Sensor Remowval Speed Sensor Installation 16 105 Speed Sensor Inspection 16 107 Fuel Reserve Switch Inspection 16 108 Oxygen Sensor Removal Equipped Models 16 108 Oxygen Sensor Installation Equipped Models 16 109 Oxygen Sensor Inspection Equipped Models 16 109 Relay 16 110 Relay Box Removal 16 110 Relay Circuit Inspection 16 110 Diode Circuit Inspection 16 111 gi E 16 113 30 A Main Fuse Remowval 16 113 Fuse Box Fuse Remowval 16 113 10 A ECU Fuse Remowval 16 113 Fuse Installation 16 114 Fuse 16 114 ELECTRICAL SYSTEM 16 3 Parts Location oie P P 1 Immobilizer Amplifier Equipped Models 2 Meter Unit 3 Ignition Switch with
2. Air Suction Valve Remowval Air Suction Valve Installation Air Suction Valve Inspection Air Switching Valve Removal Air Switching Valve Installation Air Switching Valve Operation Air Switching Valve Unit Test Clean Air System Hose Cylinder Head Cylinder Head Cover Removal Cylinder Head Cover Installation Camshaft Chain Tensioner Camshaft Chain Tensioner Camshaft Chain Tensioner Installation Camshaft Camshaft Chain Camshaft Removal Camshaft Installation Camshaft Camshaft Cap Wear Camshaft Runout Cylinder Head Cylinder Compression 5 2 5 6 5 8 5 9 5 11 5 11 5 11 5 11 5 12 5 12 5 12 5 12 5 13 5 13 5 13 5 15 5 15 5 15 5 16 5 16 5 18 5 18 5 21 5 22 5 22 5 22 5 23 5 23 Cylinder Head Removal Cylinder Head Installation Cylinder Head Warp 222222 Valve Clearance Inspection Valve Clearance Adjustment Valve Valve Installation
3. O 8 2 Special m 8 4 Engine Removal lnstallation 8 5 Engine REMOVAL ML 8 5 Engline lnstallatlon 8 8 8 2 ENGINE REMOVAL INSTALLATION Exploded View 6 02098 5 C ENGINE REMOVAL INSTALLATION 8 3 Exploded View Torque No Fastener Nm kgf m ftlb Remarks 1 Adjusting Collar Locknut 49 5 0 36 S 2 Adjusting Collar 9 8 1 0 87 in lb S 3 Lower Engine Mounting Nut 44 4 5 33 S 4 Middle Engine Mounting Bracket Bolts 25 2 5 18 S 5 Middle Engine Mounting Nut 44 4 5 33 S 6 Upper Engine Mounting Bolts 44 4 5 33 S S Follow the specified tightening sequence 8 4 ENGINE REMOVAL INSTALLATION Special Tool Engine Mount Nut Wrench 57001 1450 875714505 C ENGINE REMOVAL INSTALLATION 8 5 Engine Removal Installation Engine Removal e Support the rear part of the swingarm with a stand e Squeeze the brake lever slowly and hold it with a band A A WARNING Be sure to hold the front brake when removing the engine or the motorcycle may fall over It could cause an accident and injury CAUTION Be sure to hold the front brake when removing the engine or the motorcycle may fall over The engine or the motorcycle could be damaged e Drain Engine Oil see Engine Oil Change in the Periodic Main
4. Type API SE SF or SG API SH SJ or SL with JASO MA Viscosity SAE 10W 40 SAE 10W 50 Capacity 2 9 L 3 1 US qt when filter is not 0 SAE 104 30 3 2 L 3 4 US qt when filter is removed B E MEE TREES 3 8 L 4 0 US qt when engine is a 034 32 50 as 038 TOM completely dry 8509010881 NOTE OAlthough 10W 40 engine oil is the recommended oil for most conditions the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area Oil Filter Replacement e Drain the engine oil see Engine Oil Change e Remove the oil filter A with the oil filter wrench B Special Tool Oil Filter Wrench 57001 1249 e With a high flash point solvent clean of the saucer and wipe up with wet cloth e Replace the filter with a new one e Apply engine oil to the gasket A before installation e Tighten the filter with the oil filter wrench Torque Oil Filter 31 3 2 kgf m 23 ft Ib NOTE OHand tightening of the oil filter can not be allowed since it does not reach to this tightening torque e Pour in the specified type and amount of oil see Engine Oil Change 6005040251 2 54 PERIODIC MAINTENANCE Maintenance Procedure Brake Hose and Pipe Replacement CAUTION Brake fluid quickly ruins painted plastic surfaces any spilled fluid should be completely washed away immediately e Remove the brake hose banjo bolts A
5. Hose Installation Hose Inspection Water Temperature Sensor Water Temperature Sensor Removal Water Temperature Sensor Inspection 4 2 4 4 4 5 4 6 4 8 4 8 4 8 4 8 4 9 4 9 4 10 4 11 4 11 4 11 4 11 4 11 4 11 4 12 4 12 4 13 4 13 4 14 4 16 4 16 4 17 4 18 4 18 4 18 4 19 4 20 4 20 4 20 4 21 4 21 4 21 4 2 COOLING SYSTEM Exploded View COOLING SYSTEM 4 3 Exploded View Torque No Fastener NS Korm ftlb Remarks 1 Coolant By pass Fitting Bolt 8 8 0 90 78 in lb L 2 Coolant Drain Bolt Cylinder 9 8 1 0 87 3 Coolant Drain Bolt Water Pump 8 8 0 90 78 in Ib 4 Coolant Reserve Tank Mounting Bolts 7 0 0 70 61 in lb 5 Bolt 9 8 1 0 87 in lb 6 Oil Cooler Mounting Bolts 20 2 0 15 7 Radiator Bracket Mounting Bolt 9 8 1 0 87 in lb 8 Radiator Lower Bolt 6 9 0 70 61 in Ib 9 Radiator Upper Bolts 9 8 1 0 87 in lb 10 Thermostat Housing Cover Bolts 5 9 0 60 52 in lb 11 Water Hose Clamp Screws 2 0 0 20 17 in lb 12 Water Hose Fitting Bolts Cylinder 9 8 1 0 87 in lb 13 Water Hose Fitting Bolts Head Cover 15 1 5 11 L 14 Water Pump Cover Bolts 12 1 2 106 in Ib L 15 Water Temperature Sensor 25 2 5 18 SS G Apply grease Apply high temperature grease Apply a non permanent locking a
6. 5 hoy v hi 14 mic M NC ZU qi 6809291CW5 C APPENDIX 17 9 Cable Wire and Hose Routing Run the oxygen sensor lead backside of the water hose return Run the right switch hosing lead inside of the right front fork from the front side of the right front fork and through the under bracket of the steering stem upside Clamp Clamp Insertion Type Bands Cut the excess portion of the band Clamp the divergence portion of the lead and cut the excess portion of band Clamp Hold the front right turn signal right switch housing leads Front Right Turn Signal Light Lead Connector Right Switch Housing Leads Main harness side Clamp Run the oxygen sensor lead 1 and oil pressure switch lead Be sure inserted the connectors into the bracket Detail drawing of Oxygen Sensor Routing Crankshaft Sensor Lead Install the oil pressure switch lead direction right side of the engine as shown in the figure Oxygen Sensor 2 Connectors Gray Oxygen Sensor 1 Connectors Black Oxygen Sensors Equipped Models 17 10 APPENDIX Cable Wire and Hose Routing S 0 NES 6 lt PAKS V X 3 NES 4 4 Ss 2 M AN XS N x N L9 D 4 4 22 i my E 8809290C85 APPENDIX 17 11 Cable Wire and Hose Routing
7. Duty 50 GP17849BS2 16 72 ELECTRICAL SYSTEM Meter Gauge Indicator Unit e Disconnect the terminal 16 e Check that the tachometer needle A back to the mini mum 0 position x If the meter unit does not work replace the meter assem bly e If the oscillator is not available the tachometer can be checked as follows OConnect the 12 V battery and terminals in the same man ner as specified in the Liquid Crystal Display LCD Seg ments Check OUsing an auxiliary lead quickly open and connect the ter minal 17 to the terminal 12 repeatedly OThen the tachometer segment A should flick B xIf the hand does not flick replace the meter assembly Check 12 Stop Watch Check e Connect the leads in the same circuit as Check 1 e Press the mode button A each time to set the stop watch mode B e Connect the auxiliary lead to the terminal 6 as shown then stop watch start to count e Disconnect the terminal 6 and reconnect it e Stop Watch stop to count GP17879BS1 GP17880BS1 8 17881 52 C ELECTRICAL SYSTEM 16 73 Meter Gauge Indicator Unit e While count the stop watch connect the auxiliary lead to the terminal 5 as shown then indicate the counted time A during ten seconds GP17882BS2 C e Check that the meter moves to the lap display stored
8. 6617909651 C FUEL SYSTEM DFI 3 65 Gear Position Switch Service Code 25 Gear Position Switch Circuit 66179106 2 1 ECU 2 Gear Position Switch 3 Battery 12 V 8 Ah 4 Frame Ground 3 66 FUEL SYSTEM DFI Vehicle down Sensor Service Code 31 This sensor has a weight A with two magnets inside and sends a signal to the ECU But when the motorcycle banks 60 70 or more to either side in fact falls down the weight turns and shuts off the signal The ECU senses this change and stops the fuel pump the fuel injectors and the ignition system Hall IC When the motorcycle is down the ignition switch is left ON If the starter button is pushed the electric starter turns but the engine doesn t start To start the engine again raise the motorcycle turn the ignition switch OFF and then ON When the ignition switch is turned ON current flows through the latch up circuit and the transistor in the circuit is turned ON to unlock the latch up circuit Vehicle down Sensor A Ground Terminal BR BK B Output Terminal Y G C Power Source Terminal BL D Vehicle down Sensor Removal CAUTION Never drop the vehicle down sensor especially on a hard surface Such a shock to the sensor can damage it e Remove Windshield see Windshield Removal in the Frame chapter Rubber Cover A Connector B Bolts C Vehicle down Sensor D and collars Vehicle down
9. GP30374BS1 C Master Key Collation Error 0 3second QOO UU GP30373BS1 e Turn the master key OFF and remove the master key OThe warning indicator light LED A blinks continuously to display that the ECU is in the registration mode for 15 seconds NOTE Olnsert next key and turn ON within 15 seconds after pre Nis cx ca EM vious key is turned off and removed otherwise registra EES tion mode will be ended and the warning indicator light 88 LIA LED stops flashing GP30376BS1 OTo return to the registration mode start the master key verification procedure This applies to all user key reg istration e Insert the user key 1 to the ignition switch and turn it ON NOTE OKeep the other user key away from the immobilizer an tenna 16 84 ELECTRICAL SYSTEM Immobilizer System Equipped Models Olf there is any problem in the registration the warning indicator light LED A blinks to display the collation error Immobilizer Amplifier Failure 0 2second GP30374BS1 C When Registered User Key is Inserted 0 5second 0 5second USE GP30376BS1 User Key Collation Error 0 3second GO e UL GP30373BS1 e The user key 1 is successfully registered in the ECU OThe warning indicator light LED A blinks 2 times and stops for 1 second and
10. TAILS 0 10 GCi7939CH2 C ECU Ignition Switch Joint Connector C Cylinder Head Cover Ground ECU Fuse 10A Fuse Box Relay Box ECU Main Relay Frame Ground Main Fuse 30 A Starter Relay Battery 12 V 8 Ah 5 X iX N gt FUEL SYSTEM DFI 3 101 DFI Power Source ECU Fuse Removal e Refer to the Electrical System chapter for the 10 A ECU Fuse Removal see ECU Fuse Removal in the Electrical System chapter ECU Fuse Installation xIf a fuse fails during operation inspect the DFI system to determine the cause and then replace it with a new fuse of proper amperage e Refer to the Electrical System chapter for the Fuse In stallation see Fuse Installation in the Electrical System chapter ECU Fuse Inspection e Refer to the Electrical System chapter for the Fuse In spection see Fuse Inspection in the Electrical System chapter 3 102 FUEL SYSTEM Warning Indicator Light LED Warning Indicator Light LED Inspection OThe warning indicator light LED A is used for the FI indicator immobilizer indicator immobilizer models and oil pressure warning indicator Oln this model the warning indicator light LED Fl immo bilizer blink by the data sent from the ECU e Refer to the Meter Unit Inspection in the Electrical System chapter for the warning indicator light LED Fl immobi lizer inspection GP17880CS1
11. Valve Guide Removal Valve Guide Installation Valve to Guide Clearance Measurement Wobble Method aeter etn Valve Seat Inspection Valve Seat Throttle Body Assy Holder Throttle Body Assy Holder Throttle Body Holder Installation DO sss Muffler Body Remowval Muffler Body Installation Rear Exhaust Pipe Removal Rear Exhaust Pipe Installation Front Exhaust Pipe Removal Front Exhaust Pipe Installation Exhaust Butterfly Valve Cable Exhaust Butterfly Valve Cable Installation 5 24 5 24 5 25 5 26 5 26 5 26 5 26 5 26 5 27 5 27 5 28 5 29 5 29 5 34 5 34 5 34 5 35 5 35 5 36 5 37 5 38 5 39 5 40 5 41 5 42 5 2 ENGINE TOP END Exploded View GE023238W5 C ENGINE END 5 3 Exploded View No Fastener Torque Remarks N m kgf m ft Ib 1 Air Suction Valve Cover Bolts 9 8 1 0 87 in lb L 2 Camshaft Cap Bolts 12 1 2 106 in Ib 3 Camshaft Chain Tensioner Cap Bolt 20 2 0 15 4 Camshaft Chain Tensioner Mounting Bolts 11 1 1 97 in lb 5 Cam Sprocket Mounting Bolts 15 1 5 11 L 6 Water Passage Plugs 20 2 0 15 7
12. clutch slipping engine overheating engine oil level too high engine oil viscosity too high other 3 30 FUEL SYSTEM 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 Neutral starter lockout or sidestand switch Inspect each switch see chapter 16 trouble Immobilizer system trouble Inspect see chapter 3 Vehicle down sensor coming off Reinstall see chapter 3 Vehicle down sensor trouble Inspect see chapter 3 Crankshaft sensor trouble Inspect see chapter 16 Inspect or Reinstall see chapter 16 inspect see chapter 16 Inspect and replace see chapter 2 Replace it with the correct plug see chapter 2 inspect see chapter 3 inspect see chapter 3 Supply fuel see Owner s Manual Inspect and replace see chapter 3 inspect see chapter 3 Inspect and replace see chapter 3 Inspect and replace fuel pump see chapter 3 Fuel pressure regulator trou
13. W2L0329885 C ELECTRICAL SYSTEM 16 15 Wiring Diagram Australia Gear Position Sensor Alternator Wain Subthrottle Throttle Sensor Sensor Regulator ectifier iH 1 R ifi Subthrottle water 4 Valve Temperature a Actuator Switch Camshaft had 2 Postion 011 Sensor So z Pressure 255 288 Switch Crank Pressure T haft Breve xxx Exhaust Butterfly PEELE mma m Sensor Valve Actuator N Sensor 59 Speed Sensor gt Inlet Air Temperature Inlet Air Sensor Pressure Sensor a gt wy Y R BR W E License Plate HH H Light 12V5W 1 7 Rear Right Turn Signal Light 12V21W as ze es 5 vs 2 2 9 Es Tail Brake Light LED 12V0 1 1 68 as Joint lt 1 Connector B S frane 5 dh amp Se Rear Left z 8 Turn Turn Signal Rear Vehicle Signal Light 12V2iN Brake down Relay 3328 Light Sensor i 7 Switch Starter Fuel TOUR EUN Notor Reserve DSL EAE Main Battery Engi Switch Kawasaki Fus 12V84h Fu Fuel Self Relay Box SOA 621 a diagnositic System i Fan Relay 4 Fuel Pump Connector 2 Headlight Relay Relay 5 Starter 3 ECU Wain Relay Circuit Relay LB Light Blue 0 Orange
14. 5 6 P GP11119BS1 C 16 48 ELECTRICAL SYSTEM Electric Starter System eAlignthe groove the right hand end cover the hollow mark the yoke GP11120BS1 C e Align the hollow mark A on the left hand end cover the hollow mark B on the yoke Brush Inspection e Measure the length A of each brush If any is worn down to the service limit replace the brush holder assembly Starter Motor Brush Length Standard 7 mm 0 28 in Service Limit 3 5 mm 0 14 in Commutator Cleaning and Inspection e Smooth the commutator surface A if necessary with fine emery cloth B and clean out the grooves 8 11061051 C e Measure the diameter A of the commutator B x If the commutator diameter is less than the service limit replace the starter motor with a new Commutator Diameter Standard 24 mm 0 94 in Service Limit 23 mm 0 91 in GP11060781 C ELECTRICAL SYSTEM 16 49 Electric Starter System Armature Inspection e Using the x 1 hand tester range measure the resis tance between any two commutator segments A Special Tool Hand Tester 57001 1394 x If there is a high resistance or no reading between two segments a winding is open and the starter motor must be replaced e Using the highest hand tester range measure the resis tance between the segments and the shaft B x If there
15. 12 12 Caliper Piston and Cylinder Damage pp 12 12 Rear Caliper Holder Shaft 12 12 a eee le ts Front Brake Pad Removal Front Brake Pad Installation Rear Brake Pad Removal Rear Brake Pad Installation Brake Pad Wear Inspection Master Cylinder Front Master Cylinder Removal 12 15 Front Master Cylinder Installation 0 12 15 Rear Master Cylinder Rernoval uie tie eicere tr totum aues en don tim bees 12 16 Rear Master Cylinder 2 222 22 2 nnne rtt 12 16 Front Master Cylinder Disassembly pp 12 16 Rear Master Cylinder Disassembly 4 12 16 Master Cylinder Inspection Visual 12 16 Master Cylinder Assembly Ne 12 17 DISC Em 12 18 Brake Disc 12 18 Brake Disc 5 eerie erem 12 18 Brake DISC Wearer E C T 12 18 Brake Disc Wal pics isset E RE Oa ee e ka eis 12 18 Brake Fluid TP 12 19 Brake Fluid Level Inspection pp 12 19 Brake Fluid Charge scit A Easa 12 19 Brake kine Bleeding utat bett 12 19
16. ECU communication error Stick coil 1 malfunction wiring open or short Stick coil 2 malfunction wiring open or short Stick coil 3 malfunction wiring open or short Stick coil 4 malfunction wiring open or short Radiator fan relay malfunction wiring open or short Subthrottle valve actuator malfunction wiring open or short 63 Exhaustbulterly valve actuator malfunction wiring open or shot 4 Air switching valve malfunction wiring open or shot 83 Oxygen Sensor 2 inactivation wiring open or shout Equipped Models Oxygen sensor 1 malfunction wiring open or short Equipped Models 95 O Oxygen sensor 2 malfunction wiring open or short Equipped Models 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 3 40 FUEL SYSTEM DFI Self Diagnosis Backups OThe ECU takes the following measures to prevent engine damage when the DFI ignition or immo bilizer system parts have troubles Parts Service Codes Main Throttle Sensor Inlet Air Pressure Sensor Output Signal Usable Range or Criteria Output Voltage 0 2 4 8 V Inlet Air Press
17. Kawasaki Ninja ZX 6R Motorcycle Service Manual This quick reference guide will assist you in locating a desired topic or pro cedure Bend the pages back to match the black tab of the desired chapter num ber with the black tab on the edge at each table of contents page Refer to the sectional table of contents for the exact pages to locate the spe cific topic required Quick Reference Guide General Information Periodic Maintenance Fuel System DFI Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal Installation Crankshaft Transmission Wheels Tires Final Drive Brakes Suspension Steering Electrical System a Ol ol NI IOl I Appendix Kawasaki Ninja ZX 6R Motorcycle Service Manual All rights reserved No parts of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Quality Assurance Division Consumer Products amp Machinery Company Kawasaki Heavy Industries Ltd Japan No liability can be accepted for any inaccuracies or omissions in this publication although every possible care has been taken to make it as complete and accurate as possible The right is reserved to make changes at any time without prior notice an
18. 15 2 15 8 Rear Seat Removal to6 o a tute 15 8 Rear Seat Installation ete et EE 15 8 Front Seat Removal cre alo rte e c 15 8 Front Seat Installation 15 6 b 15 9 Lower Fairing Removal pp 15 9 Lower Fairing Installation m 15 9 Middle REMOVAL doeet ideo or Eee Bp e Eb aa 15 9 Windshield 102 1 15 11 Windshield Installation pt 15 11 Upper Fairing Disassembly s ai QURE di bee 15 12 UpperdTalring Assembly isrener ta ease ot age dgio Read on ort 15 12 Upper Fairing Installation sse 15 12 Inner Gover REMOVAl ec taceo 15 12 Inner Cover 15 13 Center Inner Fairing Removal sme et tesa uacua Pon due 15 13 Center Inner Fairing Installation ertt ttn te e etch Sete Epod 15 13 Lower Inner Fairing Removal eee ote Dod eb desees Ce Y Gu duet ecu bie 15 13 Lower Inner Fairing Installations orte iret padre tee iP nad 15 14 DIMES COVES
19. 9 24 Transmission Assy Installation Crankshaft Runout 9 25 Transmission Shaft Removal Crankshaft Main Bearing Transmission Shaft Installation Insert Journal Wear 9 25 Transmission Shaft Disassembly PIS ODS i e ei ed p iet 9 27 Transmission Shaft Assembly Piston Remowval 9 27 Shift Drum and Fork Removal Piston Installation 9 28 Shift Drum and Fork Installation Cylinder Wear Upper Shift Drum Disassembly Crankcase is 9 29 Shift Drum Assembly Piston Wear pp 9 29 Shift Fork Bending Piston Ring Piston Ring Groove Shift Fork Gear Groove Wear 9 29 Shift Fork Guide Pin Drum Piston Ring Groove Width 9 30 Groove 9 46 Piston Ring Thickness 9 30 Gear Dog and Gear Dog Hole Piston Ring End Gap 9 30 9 46 Starter Idle Gear and Starter Clutch 9 31 9 2 CRANKSHAFT TRANSMISSION Exploded View 6102211BW5 C CRANKSHAFT TRANSMISSION 9 3 Exploded View No Fastener Torgus Remarks Nm kgf m ft Ib 1 Coolant Drain Plug Cylinder 9 8 1 0 87 in Ib 2 Breather Plate Bolts 9 8 1 0 87 in lb L 3 Oil Passage Plugs Taper 20 2 0 15 L
20. Friction Plate Thickness Standard 2 72 2 88 mm 0 107 0 113 in 6F06060281 Service Limit 2 5 mm 0 098 in Clutch Plate Warp Inspection e Place each friction plate or steel plate on a surface plate and measure the gap between the surface plate A and each friction plate or steel plate B with a thickness gauge C The gap is the amount of friction or steel plate warp x If any plate is warped over the service limit replace it with a new one Friction and Steel Plate Warp Standard 0 15 mm 0 006 in or less Service Limit 0 3 mm 0 012 in GF13010781 6 16 CLUTCH Clutch Clutch Spring Free Length Measurement e Measure the free length of the clutch springs A xIf any spring is shorter than the service limit it must be replaced Clutch Spring Free Length Standard 41 6 mm 1 64 in Service Limit 40 1 mm 1 58 in GF06060381 C Damper Cam Inspection e Remove the clutch see Clutch Removal in this chapter e Visually inspect the damper cam A cam follower B and the torque limiter spring C e Replace the part if it appears damaged GF06033BS1 C ENGINE LUBRICATION SYSTEM 7 1 Engine Lubrication System Exploded Specifications Special Tools and Sealant Engine Oil Flow Chart Engine Oil and Oil Filter Oil Le
21. Subthrottle Valve Actuator Input Voltage Inspection Exhaust Butterfly Valve Actuator Service Code 63 Exhaust Butterfly Valve Actuator Exhaust Butterfly Valve Actuator Installation 3 71 3 73 3 74 3 74 3 74 3 76 3 76 3 76 3 77 3 78 3 79 3 79 3 79 3 80 3 80 3 82 3 82 3 83 3 83 3 83 3 85 3 85 3 85 3 87 3 87 3 87 3 87 3 88 3 89 3 89 3 89 Exhaust Butterfly Valve Actuator Inspection pp Exhaust Butterfly Valve Actuator Output Voltage Inspection Air Switching Valve Service Code Air Switching Valve Removal Installation Air Switching Valve Inspection Oxygen Sensor Heaters 1 2 Service Code 67 Equipped Models e eren Oxygen Sensor Heater Removal Installation Oxygen Sensor Heater Inspection Oxygen Sensors Incorrect Output Voltage 1 2 Service Code 94 95 Equipped Modlels Oxygen Sensor Removal Installa CE Oxygen Sensor Inspection zm ECU Identification ECU ECU Installation ECU Power Supply Inspection DFI Power Source ECU Fuse Removal ECU Fuse Installation ECU
22. Tighten Torque Exhaust Butterfly Valve Cable Adjuster Locknut 6 9 N m 0 70 kgf m 61 in Ib e Stretch the close cable black by using the adjuster B OTurn the adjuster counterclockwise until the play of the close cable becomes no play e Then return the adjuster of the close cable by about 3 4 rotation 5 44 ENGINE TOP END Muffler Tighten Torque Exhaust Butterfly Valve Cable Adjuster Locknut 6 9 N m 0 70 kgf m 61 in Ib Cover the dust covers e Install the removed parts see appropriate chapters e Confirm the operation of the pulley as follows OTurn the ignition switch ON OConfirm the pulley turns clockwise and then counterclock wise and clockwise again xIf the operation of the pulley is different readjust the ex haust butterfly valve cables OConfirm the pulley angle 41 7 7 xIf the angle is wrong adjust the pulley see Exhaust But terfly Valve Actuator Installation in the Fuel System DFI chapter and readjust the exhaust butterfly valve cables OStart the engine Open the throttle and then confirm the operation of the pulley xIf the pulley does not operate readjust the exhaust but terfly valve cables CLUTCH 6 1 Clutch Table of Contents Exploded E 6 2 EEUU 6 4 Special Tool and 6 5 Clutch Lever and 6 6 Clutch Lever
23. Apply the brake and hold it B Close the bleed valve C Release the brake D NOTE OThe fluid level must be checked often during the chang ing operation and replenished with fresh brake fluid If the fluid in the reservoir runs out any time during the changing operation the brakes will need to be bled since air will have entered the brake line OFront Brake Repeat the above steps for the other caliper AON e Follow the procedure below to install the front rear brake fluid reservoir cap correctly OFirst tighten the front rear brake fluid reservoir cap B clockwise C by hand until the resistance is felt fully then tighten the cap an additional 1 6 turn D while holding the brake fluid reservoir body A e Tighten Torque Front Brake Reservoir Cap Stopper Screw 1 2 N m 0 12 kgf m 10 in Ib Tighten the bleed valve and install the rubber cap Torque Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib e After changing the fluid check the brake for good braking power no brake drag and no fluid leakage If necessary bleed the air from the lines GS13198BS2 C M ZH eds 2 56 PERIODIC MAINTENANCE Maintenance Procedure Master Cylinder Rubber Parts Replacement Front Master Cylinder Disassembly Remove the front master cylinder see Front Master Cylin der Removal in the Brakes chapter Remove the seal cover A circlip connector and
24. Engine No ZX600PE008560 Crankcase Main Bearing Crankshaft Main Journal Bearing Insert Inside Diameter Marking Diameter Marking 92139 0172 92139 0190 92139 0171 92139 0189 The bearing inserts for Nos 1 2 3 and 4 journals have an oil groove respectively Engine No ZX600PE008561 Crankcase Main Bearing Crankshaft Main Journal Bearing Insert Inside Diameter Marking Diameter Marking Size Color Part Number Journal Nos 92139 0173 3 5 1 Brown 92139 0191 1 2 4 92139 0172 3 5 Black 92139 0190 1 2 4 92139 0171 3 5 Blue 92139 0189 1 2 4 The bearing inserts for Nos 1 2 4 journals have groove respectively e Install the new inserts in the crankcase halves and check insert journal clearance with the plastigage CRANKSHAFT TRANSMISSION 9 27 Pistons Piston Removal Split the crankcase see Crankcase Splitting Remove the connecting rod nuts A and big end caps NOTE OMark and record the locations of the connecting rods and their big end caps so that they can be reassembled in their original positions e Remove Camshaft Chain C Crankshaft D e Remove the connecting rods with pistons to the cylinder head side E e Remove the piston pin snap rings A 2108146 e Using the piston puller assembly remove pis ton pins Special Tool
25. Joint z E Connector SX 55 Rear Left ES Ground E ER Turn Turn Signal Rear Vehicle Signal 1 24 Light 12V108 Brake down Relay 3 25 Light Sensor i 7 Switch Starter Fuel RUE Notor Reserve mmobilizer Nain Battery Engine Switch Fuel Kawasaki Fuse i2veah Engine Seles Relay Box 30A 2 diagnositic System i Fan Relay 4 Fuel Pump 2 Headlight Relay Connector Relay 5 Starter 3 ECU Wain Relay Circuit Relay LB Light Blue _ 0 Orange P Pink Pu Purple BL Color Color Y R Color BK RJBK R Color Red Brake Lever OFF Free White rem 2 P PARK CO 98052 02930 W2RO293DH5 C IGNITION SWITCH CONNECTIONS RIGHT HANDLEBAR SWITCH CONNECTIONS Ignition Battery Taili Tail2 Front Brake Light Switch Engine Stop Switch Starter Button Stop Watch Button 16 14 ELECTRICAL SYSTEM Wiring Diagram Australia Right Switch Housing 1 Front Brake Engine Light Switch Right Switch i Head E 2 Engine Stop Gaver Switch around s starter Button 4 8 Watch ed Bitten Spark Plugs ti Fan 00060 Neutral Indicator Light LED Fuel Level Warning Indicator Light LED Meter Unit M WT Turn Signal Indicator Light LED Horn INNS rimaly Fuel Injectors High Beam Indicator Light LED E d Stick 1 84 2011 Pressure Warning Fl Immobilizer E Indicator Li
26. Left Side Cover Removal Left Side Cover Installation Nt Right Side Cover Removal ee Right Side Cover Installation SEA Seat Cover Removal c eni ener ee Seat Gover InsStallations he aedes elut ale fea date rel COVE e m Heat Insulation Plate Removal Heat Insulation Plate Installation 15 17 Heat Insulation Rubber Plate Pemoval 15 17 Heat Insulation Rubber Plate Installation eeeeeee nn 15 18 FON GEMS RN 15 19 Front Fender Removal ccccccccccssececeeceeeeeeeueeseeeuseeeueeeaeeeaeueeaueeeaeueaueeuaeeuaueeeaseueeeueenes 15 19 Front Fender Installation Nt 15 19 Flap and Rear Fender Removal pp 15 19 Flap and Rear Fender 15 22 Frane Se Re eS Ere 15 23 Rear Frame Removal enn Beni ien er bete te bes 15 23 22 2 teneret n ates 15 23 Frame Inspection oett 15 23 Sidasta flee 15 24 15 24 Sidestand 15 24 15 2 FRAME Exploded View 6002244BW5 C
27. of the water pump cover white mark of water hose e Install the water hose clamp as shown Tighten Torque Water Hose Clamp Screw 2 0 0 20 kgf m 17 in Ib e Fill the engine with engine oil see Engine Oil Change in the Periodic Maintenance chapter NOTE Olf the oil pump and camshaft or cylinder head were re moved as a set remove the oil cooler oil filter case and pour the engine oil into the oil passages of the upper crankcase see Oil Cooler Oil Filter Case Installation e Fill the engine with coolant and bleed the air from the cool ing system see Coolant Change in the Periodic Mainte nance chapter Oil Pump Gear Removal e Remove the clutch see Clutch Removal in the Clutch chapter e Fitthe suitable tool A into the hole of the oil passage plug B e Hold the oil pump gear A steady with the suitable tool B and remove the bolt C e Remove the oil pump gear Oil Pump Gear Installation e Align the groove A of the oil pump gear to the oil pump gear shaft B to install the oil pump gear e Apply a non permanent locking agent to the threads of the oil pump gear bolt e Hold the oil pump gear steady with the suitable tool and tighten the bolt Torque Oil Pump Gear Bolt 9 8 N m 1 0 kgf m 87 in Ib 7 16 ENGINE LUBRICATION SYSTEM Oil Pump Oil Pump Gear Shaft Removal e Remove Oil Pump Gear see Oil Pump Gear Removal Oil Pan see
28. on PARS 5 3 02 v rrj 46 66178726 2 ECU Engine Stop Switch Ignition Switch Cylinder Head Cover Ground Joint Connector C ECU Fuse 10A Ignition Fuse 10 A Fuse Box ECU Main Relay 10 Fuel Pump Relay 11 Relay Box 12 Joint Connector B 13 Frame Ground 14 Main Fuse 30 A 15 Battery 12 V 8 Ah 16 Fuel Pump 5 FUEL SYSTEM DFI 3 109 Fuel Pump Relay Fuel Pump Relay Removal CAUTION Never drop the relay especially on a hard surface Such a shock to the relay can damage it OThe fuel pump relay is included in the relay box e Remove Right Inner Cover see Inner Cover Removal in the Frame chapter Fuse Box A e Disconnect the connectors B and remove the relay box A from the bracket Fuel Pump Relay Inspection Remove the relay box see Fuel Pump Relay Removal e Connect the hand tester A and one 12 V battery to the relay connector as shown Special Tool Hand Tester 57001 1394 Relay Coil Terminals 1 and 2 Relay Switch Terminals 3 and 4 Testing Relay Tester range 1 range Criteria When battery is connected 0 When battery is disconnected gt x lf the relay does not work as specified replace the relay box 3 110 FUEL SYSTEM DFI Fuel Injectors CAUTION Never drop the injector
29. 3 87 insert user key t and tum RON e263 0 2 1 66 4 gt ECU checks 4 mH hn mencbizer ampifier Wiarneg incheator light NOTE blinking NOTES 39303 0 3 8 3 teecend 2 HHHhnn_ mn 5 5 if 1 NOTES 2 gt 6 7 Warreng indicator 7 Panem 4 10293 030 1 0202 0 3 6 3 tuecend T OFF and remove user koy t 2 Repair tated parts in case 8 err eem A 9393032322023 9193 93913 Venti 9 f on HU user key Not Regater H Register imertuserimy2 SandtumtON Tum OFF and remove user H kay 2 5 ECU checks 1 Warning exscator light 1 binking NOTES ot confirms the mes H O Connection of Amplifier H Time of Transmitting and Receiving Signals 2 ECU confirms the following CGU chers immobilizer Ampiifier Fadure Pattern 1 O Master Key Collation Error Pattem 6 3 ECU confirms the following Master Key Code 4 Matching Unique Code i 4 Key Repstaton Waiting Time Warning indicator fight Blinking 15 seconds eer previous keys tumad OFF 5 ECU the following 4 O Matching Unique Code Not Registered User Key O User key or not 1 6 ECU confirms the Vacant Regater Immobilizer Amplifier Fadure Pattern 1 y User Key 1 Collation Error Pattern 6 Nore Registered User Key is inserted Pattern 2 LI G30084B F 16 88 ELECTRICAL SYST
30. FRAME 15 3 Exploded View Torque No Fastener NE kgf m fb Remarks 1 Front Footpeg Bracket Bolts 25 2 5 18 2 Footpeg Bracket Bolts 25 2 5 18 3 Frame Bolts 44 4 5 32 L 4 Sidestand Bolt 44 4 5 32 G 5 Sidestand Bracket Bolts 49 5 0 36 L 6 Sidestand Switch Bolt 8 8 0 90 78 L G Apply grease L Apply a non permanent locking agent R Replacement Parts 15 4 FRAME Exploded View FRAME 15 5 Exploded View N Fastener Tordus Remarks i Nm kgfm ftlb 1 Front Fender Mounting Bolts 3 9 0 40 35 in lb 2 United States and Canada Models 15 6 FRAME Exploded View FRAME 15 7 Exploded View Torque No Fast Remarks Nm kgfm ftlb 1 Windshield Mounting Bolts 0 4 0 04 4 15 8 FRAME Seats Rear Seat Removal e Insert the ignition switch key A into the seat lock turning the key counterclockwise pulling the front part of the seat B up and pull the seat forward Rear Seat Installation e Put the rear seat hook A on the rib B e Insert the seat pins C into the latch holes D Front Seat Removal e Remove Side Covers Both Side see Right Left Side Cover Re moval Mounting Bolts A Both Side e Remove the front seat B by pulling the front of it up and forward Front Seat Installation e Slip the front seat hooks A under the br
31. About 2 25 2 50 V at 20 C 68 F see Electrical System chapter About 3 6 V at 20 C 68 F About DC 9 11 V at Ignition Switch ON About DC 0 05 0 07 V at Ignition Switch ON and 0 km h FUEL SYSTEM DFI 3 11 Specifications Item Standard Vehicle down Sensor Detection Method Detection Angle Detection Time Output Voltage Subthrottle Sensor Input Voltage Output Voltage Resistance Exhaust Butterfly Valve Actuator Sensor Input Voltage Output Voltage Resistance Immobilizer Amplifier Antenna Resistance Exhaust Butterfly Valve Actuator Resistance Subthrottle Valve Actuator Resistance Input Voltage Oxygen Sensor Output Voltage Rich Output Voltage Lean Heater Resistance Magnetic flux detection method More than 60 70 for each bank with in 1 0 1 5 sec with sensor arrow mark pointed up 3 55 4 45 V with sensor tilted 60 70 or more 0 65 1 35 V Non adjustable and non removal DC 4 75 5 25 V between BL and BR BK leads DC 1 1 0 02 V between BR and BR BK leads completely closed 4 6 DC 4 75 5 25 V DC 3 46 3 76 V at pulley original position 4 6 About 0 6 0 9 O 5 200 for reference About 5 5 7 5 Q About DC 8 0 16 0 V 0 45 2 5 V 0 05 0 45 V About 8 at 20 C 68 F Throttle Grip and Cables Throttle Grip Free Play 2 3mm 0 08 0 12 in 3 12 FUEL SYSTEM DFI Special Tools and Sealant Oil Pres
32. 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 For the duration of the warranty period we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty To get the longest life out of your vehicle Follow the Periodic Maintenance Chart in the Service Manual eBe alert for problems and non
33. Maintenance Procedure Clutch Clutch Operation Inspection e Pull the clutch lever just enough to take up the free play A e Measure the gap between the lever and the lever holder xIf the gap is too wide the clutch may not release fully If the gap is too narrow the clutch may not engage fully In either case adjust it Clutch Lever Free Play Standard 2 3 mm 0 08 0 12 in WARNING To avoid a serious burn never touch the engine exhaust pipe during clutch adjustment Turn the adjuster A so that 4 6 mm 0 16 0 24 in of threads is visible e Slide the dust cover A at the clutch cable lower end out of place e Loosen both adjusting nuts B at the clutch cover as far as they will go Pull the clutch outer cable C tight and tighten the adjust ing nuts against the bracket D e Slip the rubber dust cover back onto place e Turn the adjuster at the clutch lever until the free play is correct e Push the release lever A toward the front of the motor cycle until it becomes hard to turn OAt this time the release lever should have the proper an gle shown 60 B xIf the angle is wrong check the clutch and release parts for wear A WARNING Be sure that the outer cable end at the clutch lever is fully seated in the adjuster at the clutch lever or it could slip into place later creating enough cable play to prevent clutch disengagement e After the adjustment
34. Throttle Body Assy Disassembly 66179176 2 1 Subthrottle Valve Actuator 2 Subthrottle Sensor 3 Main Throttle Sensor 4 Throttle Body Assy 5 Injector 6 Delivery Pipe Assy CAUTION Do not remove disassemble or adjust the main throttle sensor subthrottle sensor subthrottle valve actuator throttle link mechanism and throttle body assy because they are adjust or set surely at the manufacturer Adjustment of these parts could result in poor performance requiring replacement of the throttle body assy e Remove the throttle body assy see Throttle Body Assy Removal Remove the injector connectors e Remove the screws A to pull out the injector assys from the throttle body assy together with the delivery pipe B NOTE ODo not damage the part of insert of the injectors when they are pulled out from the throttle body 17 515 3 120 FUEL SYSTEM Throttle Body Assy e Pull out the injectors A from the delivery pipe B NOTE ODo not damage the part of insert of the injectors when they are pulled out from the delivery pipe e Separate the delivery pipes Throttle Body Assy Assembly e Before assembling blow away dirt or dust from the throttle body and delivery pipes by applying compressed air e Apply engine oil to the new O rings A of each injector insert them to the delivery pipe B and confirm whether the injectors turn smoothly or not NOTE O
35. Torque Brake Pedal Bolt 8 8 N m 0 90 kgf m 78 in Ib GL04018BS1 C e Hook the upper end of the return spring A on the pedal hook e Hook the lower end of the rear brake light switch spring B on the return spring hook Olnstall the switch spring so that the hook faces outside C as shown Footpeg Bracket D GL04031BS1 C e Replace the cotter pin with a new one Olnsert the cotter pin A and bend the pin ends B e Install the right footpeg bracket Torque Front Footpeg Bracket Bolts 25 N m 2 5 kgf m 18 ft lb ODepress the brake pedal A and then align the bolts holes of the master cylinder B Torque Rear Master Cylinder Mounting Bolts 25 N m 2 5 kgf m 18 ft Ib e Check the brake pedal position see Brake Pedal Position Inspection 12 10 BRAKES Calipers Front Caliper Removal e Loosen the banjo bolt A at the brake hose lower end and tighten it loosely e Unscrew the caliper mounting bolts B and detach the caliper C from the disc CAUTION Do not loosen the caliper assembly bolts D Take out only the caliper mounting bolts for caliper re moval Loosening the caliper assembly bolts will cause brake fluid leakage e Unscrew the banjo bolt and remove the brake hose E from the caliper see Brake Hose Removal Installation CAUTION Immediately wash away any brake fluid that spills NOTE Olf the caliper is to be disassembled after rem
36. nude 6 6017868085 C FUEL SYSTEM DFI 3 19 DFI System Part Name Ignition Switch Warning Indicator Light LED Joint Connector C Oxygen Sensor Fuse 10 A ECU Fuse 10 A Ignition Fuse 10 A ECU Main Relay Fuel Pump Relay Relay Box Joint Connector B Main Fuse 30 A Frame Ground Battery 12 V 8 Ah Fuel Pump Vehicle down Sensor Kawasaki Self diagnostic System KDS Connector Engine Stop Switch Starter Button Oxygen Sensor 1 Equipped Models Oxygen Sensor 2 Equipped Models Cylinder Head Cover Ground Spark Plugs Stick Coils 1 2 3 4 Primary Fuel Injectors Secondary Fuel Injectors Subthrottle Valve Actuator Water Temperature Sensor Speed Sensor Camshaft Position Sensor Atmospheric Pressure Sensor Inlet Air Temperature Sensor Subthrottle Sensor Main Throttle Sensor Inlet Air Pressure Sensor Exhaust Butterfly Valve Actuator Gear Position Switch Crankshaft Sensor ECU Electronic Control Unit Immobilizer Antenna Equipped Models Immobilizer Amplifier Equipped Models 3 20 FUEL SYSTEM DFI System Terminal Numbers of ECU Connectors Terminal Names 1 Subthrottle Valve Actuator Drive Signal 3 2 Subthrottle Valve Actuator Drive Signal 1 3 Exhaust Butterfly Valve Actuator 4 Exhaust Butterfly Valve Actuator 5 Exhaust Butterfly Valve Senso
37. 10 Gear Position Switch 12 13 14 15 16 17 18 Left Switch Housing Lead Connectors Ignition Switch and Immobilizer Antenna Lead Connectors Clamps Clamp Front Left Turn Signal Light Lead Bracket for the Canister California Model only Screw Left Middle Fairing Clamp Hold the speed sensor lead gear position switch lead idle adjusting screw cable and drain hose Speed Sensor Gear position switch lead has no play in this area for preventing it from being caught in the drive chain Clamp Hold the side stand switch and gear position switch leads Bracket for Gear Position Sensor Side Stand Switch Side Stand Switch Lead Catch Tank Position the tank rear side of the bracket Clamp Install the clamp direction back side of the bracket and run the gear position switch and side stand leads Clamp Install the clamp direction front side of the bracket and run the drain harness Clamp Install the clamp so that smaller clamp faces to backward and hold it to the idle adjusting screw cable Front Left Turn Signal Light Lead Connector Push the main harness into the under of the headlight housing Clamp Run the tail brake Light rear turn signal lights and licence plate light leads Hooks Hold the tail brake Light rear turn signal lights and licence plate light leads and bend the hooks 17 12 APPENDIX Cable Wire and Hose Routing AE
38. Footpeg Bracket Bolts Front Fender Mounting Bolts Side Stand Bolt 2 46 PERIODIC MAINTENANCE Maintenance Procedure Replacement Parts Air Cleaner Element Replacement NOTE Oln dusty areas the element should be replaced more frequently than the recommended interval OAfter riding through rain or on muddy roads the element should be replaced immediately A WARNING If dirt or dust is allowed to pass through into the throttle assy the throttle may become stuck possi bly causing an accident CAUTION If dirt gets through into the engine excessive en gine wear and possibly engine damage will occur e Remove Front Seat see Front Seat Removal in the Frame chap ter e Remove Fuel Tank Bolts A e Remove Hoses A California Model e Set up the fuel tank A using the suitable tool or bar B OThe steering position is straight NOTE OBe careful not to drop or damage the fuel tank PERIODIC MAINTENANCE 2 47 Maintenance Procedure e Remove Inlet Air Temperature Sensor A Inlet Air Pressure Sensor B e Remove Air Cleaner Housing Assembly Screws A Upper Air Cleaner Housing B e Discard Air Cleaner Element e Install a new element A Tighten Torque Air Cleaner Housing Screws 1 1 N m 0 11 kgf m 9 7 in Ib CAUTION Use only the recommended air cleaner element Kawasaki part number 11013 0016 Using another air cleaner element will wear
39. GP17879BS1 ELECTRICAL SYSTEM 16 65 Meter Gauge Indicator Unit e Connect the terminal 16 to the terminal 17 e When the terminals are connected check that following items OThe tachometer needle A momentarily points it last read ings and back to the minimum position OAII LCD segments B appear for 1 5 seconds and all LCD segments appear for 1 second OThe oil pressure warning indicator light LED blinks C LCD segment actions for 1 5 seconds Speedometer ODO 617840881 Gear Position Indicator meter Clock and Water Temperature Gauge Segments appear from Segments appear from to down left to right Segments disappear Segments disappear Action 2 from up to down from left to right Action 3 Segments appear from Segments appear from up to down left to right x lf the LCD segments LED warning light will not ap pear replace the meter assembly e Disconnect the terminal 16 the LCD segments and warning light LED disappear xIf the segments do not disappear replace the meter as sembly 16 66 ELECTRICAL SYSTEM Meter Gauge Indicator Unit Check 2 Meter Communication Line Service Code 39 Check the leads in the same circuit as Check 1 e Wait 10 seconds and the FI A in the display and warning light LED B flash Set the ODO mode A by pushing the MODE button e Push the MODE bu
40. O unlights light LED ECU or its wiring fault sometimes lights up probably wiring fault Starting O starter motor not rotating difficulty starter motor rotating but engine doesn t turn over L1 starter motor and engine don t turn over no fuel flow O no fuel in tank O no fuel pump sound no spark L1 choke lever is not pulled fully when using the lever pull it fully when using other Engine stalls right after starting when opening throttle grip O when closing throttle grip when moving off 1 when stopping the motorcycle when cruising other FUEL SYSTEM DFI 3 29 Troubleshooting the DFI System Poor running at low speed Poor running or no power at high speed very low idle speed O very high idle speed O rough idle speed battery voltage is low charge the battery spark plug loose tighten it spark plug dirty broken or gap maladjusted remedy it backfiring afterfiring hesitation when acceleration engine oil viscosity too high brake dragging engine overheating clutch slipping other spark plug loose tighten it spark plug dirty broken or gap maladjusted remedy it spark plug incorrect replace it knocking fuel poor quality or incorrect use high octane gasoline brake dragging
41. Projection Install the hose so that the white paint faces upward Large Outside Diameter Side white paint Position the claw of the clamp right side of engine Catch Tank Position the tank rear side of the bracket Fuel Tank Drain Hose Clamp Position the clamp forward of the bracket Run the alternator lead behind the breather Hose Air Cleaner Hosing Drain Hose Clamp Hold the air cleaner hosing drain hose fuel tank drain hose idle adjusting cable speed sensor lead side stand switch lead alternator lead and gear position switch lead Run the drain hoses between water hoses Bracket Breather Hose Clamp 17 24 APPENDIX Cable Wire and Hose Routing SS SS 4 SX 2 7064 M al 7 re a NAY 6809295093 C 1 Drain Fuel 2 Clamp Hold the drain hoses 3 Run the drain hose Fuel Tank out off the left lower fairing exposed length about 40 50 mm 4 Catch Tank Position the tank rear side of the bracket 5 Clamp Run the drain hoses 6 Run the hoses between the water hoses 7 Drain Hose Air Cleaner Housing APPENDIX 17 25 Cable Wire and Hose Routing 317 S AN Mp JR De GB09328CW4 Front Reservoir Brake Hose Clamp Viewed A Brake Hose Clamps Blue Painted White Painted Left Front Caliper Right Front Caliper Viewed B Left Front Di
42. do euge 10 11 Balance Weight Peroval e ee 10 11 Balance Weight InstellatUol E rote ec eres ete esee 10 11 E ERU EM EEUU 10 13 Air Pressure Inspection Adjustment nennen nemen 10 13 Tire Inspection Hire e Tire Installation TELE PIU BS AIAG Hub Bearing Removal retrato rhe rh eto neant Re Ea ve ER ee lata ERR AM ELS DEED DLE ded 10 16 Hub Bearingdnstallallon 59 2 oie Roa pins cin ie Dev eu oue C 10 16 Hub Bearing Inspection 10 16 H b Bearing EUbFICAon esas 10 17 10 2 WHEELS TIRES Exploded View WHEELS TIRES 10 3 Exploded View Torque No Fastener Nem kgfm ftlb Remarks 1 Front Axle Clamp Bolts 20 2 0 15 AL 2 Front Axle Nut 127 13 94 3 Rear Axle Nut 127 13 94 AL Tighten the two clamp bolts alternately two time to ensure even tightening G Apply grease HG Apply high temperature grease R Replacement Parts WL Apply soap and water solution or rubber lubricant 10 4 WHEELS TIRES Specifications Standard Service Limit Wheels Rims Rim Runout Axial TIR 0 5 mm 0 02 in or less TIR 1 0 mm 0 04 in Radial TIR 0 8 mm 0 03 in or less TIR 1 0 mm 0 04 in Axle Runout 100 mm 0 05 mm 0 002
43. pull out the oil water pump B as a assembly e Remove the outer rotor C e Remove Water Pump Body A Oil Pump Cover B Inner Rotor C Pin D Oil Water Pump Shaft E 7 14 ENGINE LUBRICATION SYSTEM Oil Pump Oil Pump Installation e Install the outer rotor A into the crankcase e Install the pin B and inner rotor C to the oil water pump shaft D and install the assy OTurn the pump shaft so that the slot E in its shaft fits onto the projection F of the pump drive gear shaft e Fit the pin A of the oil pump cover B into the hole C in the crankcase 6009014851 C e Replace the O ring A with a new one e Apply grease to the new O ring e Install the dowel pins B e Fit the pin of the crankcase into the holes C in the water pump body D e Apply coolant to the surface of the rubber seal A on the impeller e Tighten Torque Impeller Bolt 9 8 N m 1 0 kgf m 87 in Ib e Install the water hose A and hose clamp B as shown White Mark C e Tighten Torque Water Hose Clamp Screw 2 0 0 20 kgf m 17 in Ib e Replace the O ring D with a new one e Apply grease to the new O ring e Install the dowel pins E e Apply a non permanent locking agent to the threads of the water pump cover bolts and tighten them Torque Water Pump Cover Bolts 12 1 2 kgf m 106 in Ib ENGINE LUBRICATION SYSTEM 7 15 Oil Pump eAlign the line
44. to x10 One Black lead Another Black lead 0 1 0 3 xIf there is more resistance than shown in the table or no tester reading infinity for any two leads the stator has an open lead and must be replaced Much less than this resistance means the stator is shorted and must be replaced e Using the highest resistance range of the hand tester measure the resistance between each of the black leads and chassis ground xAny hand tester reading less than infinity indicates a short necessitating stator replacement x If the stator coils have normal resistance but the voltage check showed the alternator to be defective then the rotor magnets have probably weakened and the rotor must be replaced Special Tool Hand Tester 57001 1394 Reading Regulator Rectifier Removal e Set up the Fuel Tank see Speed Sensor Removal e Remove Clamp A Connectors B e Remove Bolts A Regulator Rectifier B 16 32 ELECTRICAL SYSTEM Charging System Regulator Rectifier Inspection e Set the hand tester to the x 1 range and make the measurements shown in the table Special Tool Hand Tester 57001 1394 e Connect the hand tester to the regulator rectifier xIf the tester readings not as specified replace the regulator rectifier CAUTION Use only Kawasaki Hand Tester 57001 1394 for this test A tester other than the Kawasaki Hand Tester may show different readings If a m
45. xH 7 A lt 222 us AT X A amp LZ ae FE au EUR Exp C AG i T 1 d IZ 5 i gt Ji LN foo 2 Z Hh em W D Ber zl uU SSF A 6809293085 C APPENDIX 17 15 Cable Wire and Hose Routing Throttle Sensor Connectors upper side Subthrottle Sensor Lower side Main Throttle Sensor Gear Position Side Stand Switch Lead Connector Clamp Run the gear position switch lead and crankshaft sensor lead Crankshaft Sensor Connector Rear Brake Switch Lead Connector Stater Motor Cable Battery Negative Lead Connector Clamps Hold the regulator rectifier lead Frame Fuel Pump Lead Connector Speed Sensor Connector Clamp Hold the alternator lead Clamps Hold the primary fuel injector water temperature sensor lead Subthrottle Valve Actuator Connector Clamp Run the horn lead and subthrottle valve actuator lead Air Switching Valve Connector Horn Lead Camshaft Position Sensor Connector Bracket Hold the camshaft position sensor lead connector Clamp Run the camshaft position sensor lead of the main harness 17 16 APPENDIX Cable Wire and H
46. 3 116 FUEL SYSTEM DFI Throttle Grip and Cables Free Play Inspection e Refer to the Throttle Control System Inspection in the Pe riodic Maintenance chapter see Throttle Control System Inspection in the Periodic Maintenance chapter Free Play Adjustment e Refer to the Throttle Control System Inspection in the Pe riodic Maintenance chapter see Throttle Control System Inspection in the Periodic Maintenance chapter Cable Installation e Install the throttle cables in accordance with the Cable Wire and Hose Routing section in the Appendix chapter e Install the lower ends of the throttle cables in the cable bracket on the throttle body assy after installing the upper ends of the throttle cables in the grip e After installation adjust each cable properly see Throttle Control System Inspection in the Periodic Maintenance chapter WARNING Operation with incorrectly routed or improperly ad justed cables could result in an unsafe riding con dition Cable Lubrication e Refer to the Chassis Parts Lubrication in the Periodic Maintenance chapter see Chassis Parts Lubrication in the Periodic Maintenance chapter FUEL SYSTEM 3 117 Throttle Body Assy Idle Speed Inspection e Refer to the Idle Speed Inspection in the Periodic Main tenance chapter Synchronization Inspection Refer to the Engine Vacuum Synchronization Inspection in the Periodic Maintenance chapter Synchronization Adjust
47. 4 Oil Passage Plug Left Side 17 1 7 12 5 Oil Pressure Switch 15 1 5 11 SS 6 Oil Pressure Switch Terminal Bolt Hand tighten 7 Bearing Holder Screws 4 9 0 50 43 in Ib L 8 Transmission Case Bolts 8 20 2 0 15 9 Transmission Case Bolt M6 9 8 1 0 87 in lb 10 Connecting Rod Big End Nuts see the text 11 Crankcase Bolts M8 Lower First 15 1 5 11 5 Crankcase Bolts M8 Lower Final 31 3 2 23 MO S 12 Crankcase Bolts M6 L 50 mm Lower 13 Crankcase Bolts M6 L 68 mm Upper 4 1 15 12 12 1 2 1 2 106 inib 106 in Ib Crankcase Bolts M8 L 90 mm Upper 27 2 8 20 7 2 8 20 Crankcase Bolt M8 L 75 mm Upper 21 Install the thrust washers so that the grooves face the crankshaft and apply molybdenum disul fide grease to grooves side EO Apply engine oil G Apply grease HG Apply high temperature grease L Apply a non permanent locking agent LG Apply liquid gasket MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts S Follow the specified tightening sequence SS Apply silicone sealant 9 4 CRANKSHAFT TRANSMISSION Exploded View 6102212885 C CRANKSHAFT TRANSMISSION 9 5 Exploded View Torque No Fastener Nm kg m ftlb Remarks 1 Gear Positioning Lever Bolt 12 1 2 106 in Ib 2 Gea
48. 9105252851 CRANKSHAFT TRANSMISSION 9 25 Crankshaft and Connecting Rods Crankshaft Runout e Measure the crankshaft runout x If the measurement exceeds the service limit replace the crankshaft Crankshaft Runout Standard TIR 0 02 mm 0 0008 in or less Service Limit TIR 0 05 mm 0 0020 in 9105244851 Crankshaft Main Bearing Insert Journal Wear e Using a plastigage press gauge A measure the bear ing insert journal B clearance NOTE OTighten the crankcase bolts to the specified torque see Crankcase Assembly in this chapter ODo not turn the crankshaft during clearance measure ment OJournal clearance less than 0 025 mm 0 00098 in E E not be measured by plastigage however using genuine parts maintains the minimum standard clearance Crankshaft Main Bearing Insert Journal Clearance Standard 0 028 0 060 mm 0 0011 0 0024 in Service Limit 0 09 mm 0 0035 in x If the clearance is within the standard no bearing replace ment is required x If the clearance is between 0 061 mm 0 0024 in and the service limit 0 09 mm 0 0035 in replace the bearing in serts A with inserts painted blue B Check insert journal clearance with the plastigage The clearance may exceed the standard slightly but it must not be less than the min imum in order to avoid bearing seizure xIf the clearance exceeds the service limit measure the diameter C of
49. A Idle Speed Standard 1 300 50 r min rpm x If the idle speed is out of the specified range adjust it with the adjusting screw see Idle Speed Adjustment CAUTION Do not measure the idle speed by the tachometer of the meter unit e When idling the engine inspect the throttle body vacuum using the vacuum gauge B Engine Vacuum Standard 27 3 1 333 kPa 205 10 mmHg at idle speed PERIODIC MAINTENANCE 2 17 Maintenance Procedure any vacuum is not within the specifications first syn chronize the balance of the left 1 42 throttle valves and right 3 4 throttle valves assemblies Example 311 165 mmHg 2 190 mmHg 3 170 mmHg 4 200 mmHg e With the engine at the correct idle speed equalize the highest vacuum of 3 and 4 example 200 mmHg to the highest vacuum of 1 and 2 example 190 mmHg by turning the center adjusting screw A Rear View B NOTE OAfter adjustment the final vacuum measurement be tween the lowest throttle valves may not be 205 mmHg in this example The goal is to have the lower two vac uums between the left 1 and 2 and right 3 and 4 banks be the same 9505130851 Open and close the throttle after each measurement adjust the idle speed as necessary e Once the throttle valves have been synchronized inspect the main throttle sensor output voltage to ensure proper operation procedure is at the end of
50. A in the master and or user key is mal function OWhen the spare key of unregistration is used OWhen the master key is registered in the registered ECU Therefore the service code 36 will disappear when the above issue is solved User Key Inspection Register the user key correctly see Key Registration in the Electrical System chapter x lf the service code 36 appears again the transponder in the key is malfunction replace it FUEL SYSTEM DFI 3 81 Blank Key Detection Service Code 36 Immobilizer System Circuit iow TrON CES SEC MAILI ET ECU Ignition Switch Immobilizer Amplifier Cylinder Head Cover Ground Joint Connector C Immobilizer Antenna Joint Connector B Meter Unit ECU Fuse 10 A Ignition Fuse 10 A Fuse Box Relay Box ECU Main Relay Frame Ground Main Fuse 30 A Starter Relay Battery 12 V 8 Ah Immobilizer Kawasaki Diagnostic System Connector GP30369BW3 C 3 82 FUEL SYSTEM ECU Communication Error Service Code 39 ECU Communication Line Inspection OWhen the data is not sent from the ECU to the meter unit for more than about 10 seconds the service code 39 is displayed OThe service code 39 is detected with meter unit e Remove the ECU and meter unit check the wiring be tween these connector ODisconnect th
51. Air suction system damage inspect Clutch Clutch operation play disengagement engagement inspect Wheels and Tires Tire air pressure inspect Wheel tire damage inspect Tire tread wear abnormal wear inspect Wheel bearing damage inspect year e e Drive Train Drive chain lubrication condition inspect Every 600 km 400 mile Drive chain slack inspect Every 1 000 km 600 mile 2 4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY Whichever ODOMETER READING comes a gt x 1 000 km first x 1 000 mile V 1 6 12 18 24 30 36 INSPECTION Every 0 6 4 1 7 5 12 15 20 24 Drive chain wear inspect e e e Drive chain guide wear inspect e o Brake System Brake fluid leak brake hose and pipe inspect year Brake hose and pipe damage inspect year Brake pad wear inspect Brake hose installation condition inspect year e Brake fluid level inspect 6 months e e Brake operation effectiveness play no drag inspect Brake light switch operation inspect e Suspensions Front forks rear shock absorber operation damping and smooth stroke inspect Front forks rear shock absorber oil leak inspect Rocker arm operation inspect Tie Rods operation inspect e Steering System Steering play inspect year e e Steering stem bearings lubricate 2 years Elec
52. Apply grease to the new O rings e Apply non permanent locking agent to the treads of the oil cooler oil filter case mounting bolts and tighten them Torque Oil Cooler Oil Filter Case Mounting Bolts 20 N m 2 0 kgf m 15 ft Ib e Apply non permanent locking agent to the treads of the oil filter guard bolts and tighten them Torque Oil Filter Guard Bolts 4 0 N m 0 41 kgf m 35 in Ib e Install Oil Cooler see Oil Cooler Installation Oil Filter see Oil Filter Replacement in the Periodic Maintenance chapter 7 20 ENGINE LUBRICATION SYSTEM Oil Pressure Measurement Pressure e Remove Lower Fairings see Lower Fairing Removal in the Frame chapter Oil Passage Plug A e Attach the adapter A and gauge B to the plug hole Special Tools Oil Pressure Gauge 10 kgf cm 57001 164 Oil Pressure Gauge Adapter PT3 8 57001 1233 e Start the engine and warm up the engine e Run the engine at the specified speed and read the oil pressure gauge x If the oil pressure is much lower than the standard check the oil pump relief valve and or crankshaft bearing insert wear x If the reading is much higher than the standard check the oil passages for clogging Oil Pressure Standard 96 126 kPa 0 98 1 28 kgf cm 14 18 psi at 4 000 r min rpm oil temperature 90 C 194 F e Stop the engine Remove the oil pressure gauge and adapter WARNING Take care agains
53. Brake MOSQ Gee Mears 12 23 Brake Hose 111111111 12 23 Brake Hose Inspection cin rre ether hee eer be a derat 12 23 12 2 BRAKES Exploded View A a BRAKES 12 3 Exploded View Torque No Fastener Nm kg m ftlb Remarks 1 Bleed Valves 7 8 0 80 69 in Ib 2 Brake Hose Banjo Bolts 25 2 5 18 3 Lever Pivot Bolt 1 0 0 10 9 4 Lever Pivot Bolt Locknut 5 9 0 60 52 in lb 5 Front Brake Disc Mounting Bolts 27 2 8 20 L 6 Front Brake Light Switch Screw 1 2 0 12 10 in Ib 7 Front Brake Pad Pins 17 1 7 12 8 Front Brake Reservoir Cap Stopper Screw 10 in Ib 9 Front Caliper Assembly Bolts 27 2 8 20 10 Front Caliper Mounting Bolts 34 3 5 25 11 Front Master Cylinder Bleed Valve 5 9 0 60 52 in lb 12 Front Master Cylinder Clamp Bolts 8 8 0 90 78 in Ib S B Apply brake fluid L Apply a non permanent locking agent R Replacement Parts S Follow the specified tightening sequence Si Apply silicone grease 12 4 BRAKES Exploded View SN D A 2 2 AS BRAKES 12 5 Exploded View Torque No Fastener m kgf m ftlb Remarks 1 Bleed Valve 7 8 0 80 69 in Ib 2 Brake Ho
54. Connector to Injector 1 2 3 4 Meter W R lead Meter Battery Terminal Primary Fuel Injector Power Source Voltage Connector to Injector 1 2 3 4 Meter W R lead Meter Battery Terminal e Install the fuel tank see Fuel Tank Installation e Turn the ignition switch ON Power Source Voltage at Injector Connector Standard Battery Voltage 12 8 V or more x If the power source voltage is less than standard check the wiring see wiring diagram fuel pump relay see Fuel Pump Relay Inspection and ECU power source see ECU Power Supply Inspection e Turn the ignition switch OFF e Set up the fuel tank see Air Cleaner Housing Removal e Connect a digital voltmeter A to the connector B with the needle adapter set C Special Tool Needle Adapter Set 57001 1457 6617024451 FUEL SYSTEM 3 113 Fuel Injectors Secondary Fuel Injector Output Voltage Connections to Injector 1 Meter O R lead Meter gt Battery Terminal Connections to Injector 2 Meter O G lead Meter gt Battery Terminal Connections to Injector 3 Meter O BK lead Meter gt Battery Terminal Connections to Injector 4 Meter O Y lead Meter Battery Terminal 9017640852 Fuel Injector Output Voltage Connections to Injector 1 Meter BL R lead Meter Batt
55. LED A blinks to display the registration mode NOTE OTurn off the ignition switch and wait for the period more than 15 seconds The registration mode automatically 0 5second 0 5second ends and warning indicator light goes off cux OThis procedure has registered the master key and one A 01 ae user key 8 30376881 OContinue the procedure to program the second and later keys e Insert the user key 2 to the ignition switch and turn it ON ELECTRICAL SYSTEM 16 91 Immobilizer System Equipped Models Olf there is any problem in the registration the warning indicator light LED A blinks to display the collation error Immobilizer Amplifier Failure 0 2second Gat GP30374BS1 C When Registered User Key is Inserted 0 5second 0 5second A Ste gE GP30376BS1 User Key Collation Error 0 3second A 38 UL GP30373BS1 C e The user key 2 is successfully registered in the ECU OThe warning indicator light LED A blinks 3 times and stops for 1 second and then repeat this cycle to indicate successful programming of user key 2 e Turn OFF the ignition switch and wait for period more than 15 seconds e The registration mode automatically ends SU d tue nm GP30371BS1 C e FI indicator light goes off A GP30370BS1 16 92 ELECTRICAL SY
56. OMeasure the inlet air pressure sensor output voltage from various vacuum readings while pulling the handle of the fork oil level gauge OCheck the inlet air pressure sensor output voltage using the following formula and chart Suppose Pg Vacuum Pressure gauge of Throttle Assy Local Atmospheric Pressure absolute measured by a barometer Pv Vacuum Pressure absolute of Throttle Assy Vv Sensor Output Voltage V then Pv PI Pg For example suppose the following data is obtained Pg 8 cmHg vacuum gauge reading 70 cmHg barometer reading Vv 3 2 V digital volt meter reading then Pv 70 8 62 cmHg abs Plot this Pv 62 cmHg at a point 1 on the chart and draw a vertical line through the point Then you can get the usable range 2 of the sensor output voltage Usable range 3 08 3 48 V Plot Vv 3 2 V on the vertical line Point 3 Results In the chart Vv is within the usable range and the sensor is normal 6017119852 C FUEL SYSTEM DFI 3 51 Inlet Air Pressure Sensor Service Code 12 90 cmHg 30 76 80 PS 120 kPa 40 ID T0 ID Idling Ps Standard Atmospheric Pressure Absolute Pv Throttle Vacuum Pressure Absolute ST Standard of Sensor Output Voltage V TO Throttle Full Open UR Usable Range of Sensor Output Voltage V 101 32 PS gt abs GC17120B
57. R BK BR R BK LG Joint Connactor BKZY i i i BK AY SLED Light Emitting Diode A BK Y BK Y Front Right A Turn Signal Ss Light 12V21W Headlight eye 12 55 Headlight en 12V65W Front Left er 6 Turn Signal ae Light 12V21W Left Switch Housing Joint 1 Button 2 Passing Button Pin SLT ace Left Switch Housing Fuse Box Rekar Box 4 Dimmer Switch 1 Fuse 15 4 Weadlight Fuse 10A Starter Lockout Switch 2 ECU Fuse 10 5 Taillight Fuse 10A 6 Lap Time Button Turn Signal Relay 6 lgniton Fuse 10 Fuse 10 Horn Fuse 10 LEET HANDLEBAR SWITCH CONNECTIONS Horn Button Turn Signal ch Dimmer Switch Starter Lockout Switch Lap Time Button Passing auton pr leete E epe prx urere HI Clutch Lever eus Tul Pulled in W2L0328BW5 C ELECTRICAL SYSTEM 16 17 Wiring Diagram Malaysia Position Sensor Gear Alternator Nain Subthrottle Throttle Sensor ensor Jorr on Regulator Rectifier 1 Subthrottle Water REA Valve Temperature Actuator Ssi Eeh Camshaft L 1 L 3 2 Postion T oil Sensor So z Pressure Atmospheric Switch Crank dx Pressure Exhaust Butterfly shaft 3555 S55 Sensor N Sensor 55 Valve Actuator Speed ri Sensor gt Inlet TEN x Aic Bee
58. Right Inner Cover see Inner Cover Removal in the Frame chapter e Disconnect the connector A e Using an auxiliary wires supply battery power to the fan motor xIf the fan does not rotate the fan motor is defective and must be replaced xIf the fan rotate inspect the fan system circuit Radiator Fan Circuit w Y W BK BL BK BL W Li BK BL JON PARK 1ONITION O BR 0 j 6 15055 1 10 Fuse 10 2 Water Temperature 11 Ignition Fuse 10 3 Radiator Fan 12 Fuse Box 4 Joint Connector C 13 Radiator Fan Relay 5 Cylinder Head Cover Ground 14 ECU Main Relay 6 Engine Stop Switch 15 Relay Box 7 Ignition Switch 16 Main Fuse 30 A 8 Joint Connector B 17 Frame Ground 9 Fan Fuse 15 18 Battery 12 V 8 Ah ELECTRICAL SYSTEM 16 63 Meter Gauge Indicator Unit Meter Unit Removal e Remove Windshield see Windshield Removal in the Frame chapter e Pull out the rubber cover A e Disconnect the connector B Bolts C e Remove Nut A Bolts B Fairing Bracket with Meter C e Remove the screws A CAUTION Place the meter unit so that the face is up If a meter unit is left upside down or sideways for any length of time it will malfunction Meter Unit Disassembly e Remove Meter Unit see Meter Unit Removal Screws A Separ
59. Routing section in the Appendix chapter Air Switching Valve Operation Test e Refer to the Air Suction System Damage Inspection in the Periodic Maintenance chapter Air Switching Valve Unit Test e Refer to the Air Switching Valve Unit Test in the Electrical System chapter Clean Air System Hose Inspection e Be certain that all the hoses are routed without being flat tened or kinked and are connected correctly to the air cleaner housing air switching valve and air suction valve covers xIf they are not correct them Replace them if they are damaged Cylinder Head Cover ENGINE TOP END 5 13 Cylinder Head Cover Removal e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Air Cleaner Housing see Air Cleaner Housing Removal in the Fuel System DFI chapter Air Switching Valve see Air Switching Valve Removal Throttle Body Assy see Throttle Body Assy Removal in the Fuel System DFI chapter Stick Coils see Stick Coil Removal in the Electrical Sys tem chapter e Remove Breather Hose Cylinder Head Cover Ground Bolt A Cylinder Head Cover Bolts B Cylinder Head Cover C Cylinder Head Cover Installation e Replace the head cover gasket A with a new one e Apply silicone sealant B to the cylinder head as shown Sealant Kawasaki Bond Silicone Sealant 92104 0004 e Be sure to install the following parts Dowel Pins A Plug Hole Gaskets B Olnstall the gaskets so that th
60. Spark Plugs see Spark Plug Removal in the Electrical System chapter e Attach the compression gauge A and adapter B firmly into the spark plug hole e Using the starter motor turn the engine over with the throt tle fully open until the compression gauge stops rising the compression is the highest reading obtainable Special Tools Compression Gauge 20 kgf cm A 57001 221 Compression Gauge Adapter M10 x 1 0 B 57001 1317 Cylinder Compression Usable Range 980 1 498 kPa 10 0 15 3 kgf cm 142 217 psi at 240 r min rpm e Repeat the measurement for the other cylinders e Install the spark plugs Torque Spark Plugs 13 N m 1 3 kgf m 113 in Ib OThe following table should be consulted if the obtainable compression reading is not within the us able range Problem Diagnosis Remedy Action Cylinder Carbon accumulation on piston and in Remove the carbon deposits and compression combustion chamber possibly due to replace damaged parts if necessary is higher than damaged valve stem oil seal and or usable range damaged piston oil rings This may be indicated by white exhaust smoke Incorrect cylinder head gasket thickness Replace the gasket with a standard part Cylinder Gas leakage around cylinder head Replace damaged check gasket and compression cylinder head warp is lower than Bad condition of valve seating Repair if necessary usable range Incorrect valve clearanc
61. Standard Value C Current starts to flow D e Determine the battery condition after refresh charge ODetermine the condition of the battery left for 30 minutes after completion of the charge by measuring the terminal voltage according to the table below Criteria Judgement 12 8 V or higher Good 12 0 lower than 12 8 V Charge insufficient Recharge lower than 12 0 V Unserviceable Replace 16 28 ELECTRICAL SYSTEM Charging System Alternator Cover Removal e Remove Left Middle Fairing see Middle Fairing Removal in the Frame chapter Set up the Fuel Tank see Speed Sensor Removal Alternator Lead Connector A Clamp B e Remove Heat Insulation Cover A Bolts B Cover C Alternator Cover Installation e Apply silicone sealant to the alternator lead grommet and crankcase halves mating surface A on the front and rear sides of the cover mount Sealant Kawasaki Bond Silicone Sealant 92104 0004 e Check that dowel pins B in place on the crankcase Install New Gasket Alternator Cover Brackets e Tighten Torque Alternator Cover Bolts 12 1 2 kgf m 106 in Ib Stator Coil Removal e Remove Alternator Cover see Alternator Cover Removal Stator Coil Bolts A Holding Plate Bolts B and Plate C Alternator Lead Grommet D e Remove the stator coil E from the alternator cover ELECTRICAL SYSTEM 16 29 Charging System Stator Coil Installat
62. Starter Relay Main Fuse 30 A Frame Ground Battery 12 V 8 Ah 5 66179326 2 FUEL SYSTEM DFI 3 85 Radiator Fan Relay Service Code 56 Radiator Fan Relay Removal installation OThe radiator fan relay is built in the relay box A e Refer to the Relay Box Removal in the Electrical System chapter Radiator Fan Relay Inspection e Refer to the Relay Circuit Inspection in the Electrical Sys tem chapter x lf the radiator fan relay is normal check the wiring for continuity xIf 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 3 86 FUEL SYSTEM DFI Radiator Fan Relay Service Code 56 Radiator Fan Relay Circuit BR BK Y w Y W BK BL BK BL W JON PARK IGNITION G BR 7 1 GP15055BW3 C 1 ECU 10 ECU Fuse 10 2 Water Temperature Sensor 11 Ignition Fuse 10 A 3 Radiator Fan 12 Fuse Box 4 Joint Connector C 13 Radiator Fan Relay 5 Cylinder Head Cover Ground 14 ECU Main Relay 6 Engine Stop Switch 15 Relay Box 7 Ignition Switch 16 Main Fuse 30 A 8 Joint Connector B 17 Frame Ground 9 Radiator Fan Fuse 15 18 Battery 12 V 8 Ah FUEL SYSTEM 3 87 Subthrottle
63. Strong Bad High Counterclockwise Clockwise Softer Harder 1514131211109 8 76 54 32 1 Seated position adjuster turned fully clockwise M04432BS1 13 10 SUSPENSION Front Fork Compression Damping Force Adjustment e To adjust the compression damping force turn the com pression damping adjuster A until you feel a click OThe standard adjuster setting for the average build rider of 68 kg 150 Ib with no passenger and no accessories is the 1 1 2 turn out from the fully clockwise position A WARNING If both adjusters are not adjusted equally handling may be impaired and a hazardous condition may result OThe damping force can be left soft for average riding But it should be adjusted harder for high speed riding or riding with a passenger If the damping feels too soft or too stiff adjust it in accordance with the following table Compression Damping Force Adjustment Adjuster Damping Front Fork Removal Each Fork Leg e Remove Middle Fairings see Middle Fairing Removal in the Frame chapter Upper Inner Fairings see Upper Inner Fairing Removal in the Frame chapter Front Wheel see Front Wheel Removal in the Wheels Tires chapter Front Fender see Front Fender Removal in the Frame chapter Loosen the handlebar bolt A upper fork clamp bolt B and fork top plug C beforehand if the fork leg is to
64. Water Temperature Sensor Connector E OTurn up the front side of the heat insulation rubber plate A ORemove Blowby Hose B Engine Ground Bolt C Starter Motor Cable Bolt D OOpen the clamps A ODisconnect the regulater rectifire connector B ENGINE REMOVAL INSTALLATION 8 7 Engine Removal Installation e Turn up the rear side of the heat insulation rubber plate A e Loosen the middle engine mounting bracket bolts B e Support the engine with a suitable stand A OPut a plank B onto the suitable stand for engine balance e Remove Right Upper Engine Mounting Bolt A Left Upper Engine Mounting Bolt e Using the nut wrench A loosen the locknut B Special Tool Engine Mount Nut Wrench 57001 1450 e Using the Hexagon Wrench turn the adjusting collar A counterclockwise to make the gap between the engine and oollar 8 8 ENGINE REMOVAL INSTALLATION Engine Removal Installation e Remove the middle and lower engine mounting nuts e Turn the lower mounting bolts A clockwise to make the gap between the collar and frame e Pull out the engine mounting bolts from the right side e Using the stand take out the engine Engine Installation e Install the adjusting collar A to crankcase backside until end of the threads e Install the adjusting collar bolt A to the frame until end of the threads e Support the engine with a suitable stand OPut a plank onto the suitable
65. e Check the wiring for continuity Camshaft Position Sensor Circuit 1 ECU 2 Camshaft Position Sensor 6C176338W2 3 62 FUEL SYSTEM DFI Speed Sensor Service Code 24 Speed Sensor Removal Installation e See the Speed Sensor Removal Installation in the Elec trical System chapter Speed Sensor Inspection e See the Speed Sensor Inspection in the Electrical System chapter Speed Sensor Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Set up the fuel tank see Air Cleaner Housing Removal e Disconnect the speed sensor connector and connect the harness adapter A between the harness connector B and speed sensor connector C e Connect a digital meter to the harness adapter leads Special Tool Throttle Sensor Setting Adapter 1 57001 1400 Speed Sensor Input Voltage Connector to Sensor Meter P lead C Meter BK Y lead D e Measure the sensor input voltage with the engine stopped and with the connector joined e Turn the ignition switch ON Input Voltage at Sensor Standard About DC 9 11 V xIf the reading is out of the range check the wiring see wiring diagram and meter see Electronic Combination Meter Unit Inspection in the Electrical System chapter x If the reading is good check the output voltage e Turn the ignition switch OFF Speed Sensor Output Voltage Inspection e Before this inspection inspe
66. inspect the brake system A WARNING When inspecting by running the vehicle note a surrounding traffic situation enough in the place of safety 6513093851 C Brake Fluid Level Inspection e Check that the brake fluid level in the front brake reservoir A is above the lower level line B NOTE OHold the reservoir horizontal by turning the handlebar when checking brake fluid level x If the fluid level is lower than the lower level line fill the reservoir to the upper level line C e Check that the brake fluid level in the rear brake reservoir A is above the lower level B x If the fluid level is lower than the lower level line fill the reservoir to the upper level line C A WARNING Change the brake fluid in the brake line completely if the brake fluid must be refilled but the type and brand of the brake fluid that is already in the reser voir are unidentified After changing the fluid use only the same type and brand of fluid thereafter Recommended Disc Brake Fluid Grade DOT4 e Follow the procedure below to install the front and rear brake fluid reservoir cap correctly OFirst tighten the front brake fluid reservoir cap B clock wise C by hand until slight resistance is felt indicating 520 NW that the cap is seated on the reservoir body then tighten Bo ca the an additional 1 6 turn while holding the brake 00 fluid reservoir body A 2 34 PERIODIC
67. memory A at leaving the button when pushing the RE SET button B less than 2 seconds while stopping the stop watch xIf the display function does not work replace the meter assembly GP17922BS1 e Check that the all lap time stored memory A is clear after 2 seconds passed when pushing the RESET button B more than 2 seconds while stop watch display x If the memory does not eliminate replace the meter as sembly GP17921BS1 16 74 ELECTRICAL SYSTEM Meter Gauge Indicator Unit Check that the stop watch display has 00 00 00 display A And lap No display has water temperature display B when connecting 16 to terminal again after discon necting it while operating the stop watch xIf the display function does not work replace the meter assembly Check 13 Gear Position Indication Inspection e Install the meter unit see Meter Unit Installation e Turn the ignition switch ON e Check that the N mark neutral indicator light LED A goes on e Set the low gear position check that the display changes to 1 mark e For the other gear position indication e Using the stand raise the rear wheel off the ground see Interlock Operation Inspection e Start the engine change the gear position e Check that the display corresponding to each gear posi tion appears A e Turn the ignition switch OFF xIf the display function does not work go to the Check 1 and check the f
68. of head pipe and applying it to both recess alternately hammer it to drive the race out NOTE Olf either steering stem bearing is damaged it is recom mended that both the upper and lower bearings includ ing outer races should be replaced with new ones STEERING 14 7 Steering Stem e Remove the lower bearing inner race with its oil seal A which is pressed onto the steering stem B with the bearing puller C and adapter D Special Tools Bearing Puller 57001 135 Bearing Puller Adapter 57001 136 Stem Stem Bearing Installation e Replace the bearing outer races with new ones e Drive them into the head pipe at the same time Special Tools Head Pipe Outer Race Press Shaft A 57001 1075 Bearing Driver Set 57001 1129 Head Pipe Outer Race Driver 55 57001 1446 e Apply grease to the outer races Replace the bearing inner races and oil seal with new ones e Install the oil seal D on the steering stem and drive the lower ball bearing inner race A applied the grease onto the stem Special Tools Steering Stem Bearing Driver 42 5 57001 1344 Steering Stem Bearing Driver Adapter 41 5 C 57001 1345 e Install the lower ball bearing A onto the stem e Apply grease Inner and Outer Races Lower and Upper Ball Bearings OThe lower and upper ball bearings are identical Install the stem A through the head pipe and install the ball bearing B and inner race
69. ter e Do refresh charge by following method according to the battery terminal voltage A WARNING This battery is sealed type Never remove sealing cap B even at charging Never add water Charge with current and time as stated below 8 08010851 C GPOS025BS1 C 10090 807570 60 50 40 30 20 10 0 8 09001251 C ELECTRICAL SYSTEM 16 27 Battery Terminal Voltage 11 5 less than 12 8 V Standard Charge 0 9 A x 5 10 h see following chart Quick Charge 4 1 CAUTION If possible do not quick charge If quick charge is done unavoidably do standard charge later on Charge Time h 1 1 1 L 1 11 6 11 8 12 0 12 2 12 4 12 6 12 8 13 0 Terminal Voltage less than 11 5 V Battery Terminal Vel ene Charging Method 0 9Ax 20h NOTE Olncrease the charging voltage to a maximum voltage of 25 V if the battery will accept current initially Charge Ky for no more than 5 minutes at the increased voltage then 0 check if the battery is drawing current If the battery 1 will accept current decrease the voltage and charge by the standard charging method described on the battery A L case If the battery will not accept current after 5 EOM utes replace the battery ap08022BS1 Battery A Battery Charger B
70. the needle adapter set Special Tool Needle Adapter Set 57001 1457 Inlet Air Pressure Sensor Input Voltage Connections to ECU Meter BL lead terminal 10 Meter BR BK lead terminal 28 e Measure the input voltage with the engine stopped and with the connectors joined e Turn the ignition switch ON Input Voltage at ECU Standard DC 4 75 5 25 V xIf the reading is less than the standard range check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see ECU Removal Installation 6617882651 3 48 FUEL SYSTEM DFI Inlet Air Pressure Sensor Service Code 12 x If the reading is within the standard range and check the input voltage again at the sensor connector e Disconnect the inlet air pressure sensor connector and connect the harness adapter A between the sub harness connector and inlet air pressure sensor connector Connect a digital meter to the harness adapter leads Special Tool Sensor Harness Adapter 57001 1561 Inlet Air Pressure Sensor Input Voltage Connections to Sensor Meter BL lead C Meter BR BK lead D e Measure the input voltage with the engine stopped e Turn the ignition switch ON Input Voltage at Sensor Connector Standard DC 4 75 5 25 V xIf the reading is out of the standard range check the wiring see wiring diagram x If the reading is
71. 27 ME ROGAREMOV Alle Tr 13 27 Aie Rod Installation ssnin d eee Ata lg vede teo 13 27 Rocker Arm Removals ee a cepe Ex SORS 13 27 Rocker Arm 13 28 Tie Rod and Rocker Arm Bearing 13 29 Tie Rod and Rocker Arm Bearing Installation pp 13 29 Rocker Arm Tie Rod Bearing Sleeve Inspection pp 13 31 Rocker Arm Tie Rod Bearing Lubrication 4 13 31 13 2 SUSPENSION Exploded View GM021888W5 C SUSPENSION 13 3 Exploded View No Fastener Torque Remarks N m kgf m ft Ib 1 Front Axle Clamp Bolts 20 2 0 15 AL 2 Front Fork Bottom Allen Bolts 35 3 5 26 3 Front Fork Clamp Bolts Lower 25 2 5 18 AL 4 Front Fork Clamp Bolts Upper 20 2 0 15 5 Front Fork Top Plugs 35 3 5 26 6 Piston Rod Nuts 20 2 0 15 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 13 4 SUSPENSION Exploded View SUSPENSION 13 5 Exploded View No Fastener Torque Remarks Nm kgf m ft Ib 1 Shock Absorber Bracket Nut 59 6 0 43 2 Rear Shock Absorber Nut Lower 34 3 5 25 3 Rear Shock Absorber Nut Upper 34 3 5 25 4 Swingarm Pivot Adjusting Collar 20 2 0 15 S 5 Swingarm Pivot Adjusting Collar Locknut 9
72. 9 8 1 0 87 Coolant Drain Bolt Water Pump 8 8 0 90 78 in lb Coolant Reserve Tank Mounting Bolts 7 0 0 70 61 Impeller Bolt 9 8 1 0 87 Oil Cooler Mounting Bolts 20 2 0 15 Radiator Bracket Mounting Bolt 9 8 1 0 87 Radiator Lower Bolt 6 9 0 70 61 in lb Radiator Upper Bolts 9 8 1 0 87 Thermostat Housing Cover Bolts 5 9 0 60 52 Water Hose Clamp Screws 2 0 0 20 17 in lb Water Hose Fitting Bolts Cylinder 9 8 1 0 87 in lb PERIODIC MAINTENANCE 2 7 Torque and Locking Agent Torque Fastener m kaim ilb Remarks Water Hose Fitting Bolts Head Cover 15 1 5 11 L Water Pump Cover Bolts 12 1 2 106 in Ib L Water Temperature Sensor 25 2 5 18 SS Engine Top End Air Suction Valve Cover Bolts 9 8 1 0 87 in lb L Camshaft Cap Bolts 12 1 2 106 in Ib S Camshaft Chain Tensioner Cap Bolt 20 2 0 15 Camshaft Chain Tensioner Mounting Bolts 11 1 1 97 in lb Cam Sprocket Mounting Bolts 15 1 5 11 L Cylinder Head Bolts M9 39 4 0 29 5 Cylinder Head Bolts 6 12 1 2 106 in Ib S Cylinder Head Cover Bolts 9 8 1 0 87 Exhaust Butterfly Valve Actuator Mounting Nuts 6 9 0 70 61 in Ib Exhaust Butterfly Valve Actuator Pulley Bolt 4 9 0 50 43 in lb Exhaust Butterfly Valve Cable Adjuster Locknuts 6 9 0 70 61 in Ib Exhaust Butterfly Valve Cable Locknuts 6 9 0 70 61 in lb Exhaust Butterfly Valve Cover Bolt 6 9 0 70 61 in Ib Exhaust Pipe Clamp Bolt 17 1 7 13 Exhaus
73. B with the upper and lower grooves C in the socket ant turn the bulb clockwise Turn Signal Light Removal For the Front Turn Signal Light e Remove Left Middle Fairings see Middle Fairing Removal in the Frame chapter Canister Bracket A California Model Screws B Left Turn Signal Light C e Remove Right Middle Fairing see Middle Fairing Removal in the Frame chapter Screws A Relay Box Bracket with Relay Box B Right Turn Signal Light For the Rear Turn Signal Light e Remove Seat Cover see Seat Cover Removal in the Frame chapter Right and Left Turn Signal Light Connectors A e Remove Screws A Left Muffler Side Cover B OPull the cover forward to clear the hook portion C 16 58 ELECTRICAL SYSTEM Lighting System e Remove Quick Rivet A Screws Left Turn Signal Light with Cover e Remove Tail Brake Light see Tail Brake Light Removal Screws A Right Turn Signal Light with Cover B e Remove Screws A e Separate the light C and cover B Turn Signal Relay Inspection e Remove Right Inner Cover see Inner Cover Removal in the Frame chapter Turn Signal Relay A E dim ELECTRICAL SYSTEM 16 59 Lighting System United States Canada and Australia Models 12 V battery and turn signal lights as indi cated in the figure and count how may times the lights flash for one minute Turn Signal Relay A Turn Signal
74. Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation Lubri AH p TN cation points are called out throughout this manual apply A VAT a the specific oil or grease as specified e A x 68020218 5 Direction of Engine Rotation When rotating the crankshaft by hand the free play MN amount of rotating direction will affect the adjustment Ro tate the crankshaft to positive direction clockwise viewed r from output side UM 68020228 5 Electrical Wires A two color wire is identified first by the primary color and then the stripe color Unless instructed otherwise electrical Y R wires must be connected to those of the same color e oar e GB020238 5 Instrument Use a meter that has enough accuracy for an accurate measurement Read the manufacture s instructions thor oughly before using the meter Incorrect values may lead to improper adjustments GB02082BS1 C GENERAL INFORMATION 1 7 Model Identification ZX600P7F Europe Left Side View 66038292 ZX600P7F Europe Right Side View 1 8 GENERAL INFORMATION Model Identification ZX600P7F US and Canada Left Side View 203824 P ZX600P7F US and Canada Right Side View 66038205 GENERAL INFORMATION 1 9 General Specifications ltems ZX600P7F Ninja ZX 6R Dime
75. C Mounting Bolts D e Remove the starter motor E from the engine right side Starter Motor Installation CAUTION Do not tap the starter motor shaft or body Tapping the shaft or body could damage the motor e Replace the O ring A with a new one e Apply grease to the O ring e When installing the starter motor clean the starter mo tor legs A and crankcase B where the starter motor is grounded NOTE OTemporary install the starter motor mounting bolts e Install Starter Clutch Cover see Starter Clutch Cover Installa tion in the Crankshaft Transmission chapter OFit the cover hole A and starter fitting portion B then install the cover to the crankcase e Tighten Torque Starter Motor Mounting Bolts 9 8 N m 1 0 kgf m 87 in Ib Starter Motor Cable Terminal Bolt 2 9 N m 0 30 26 in Ib eas P ELECTRICAL SYSTEM 16 47 Electric Starter System Starter Motor Disassembly e Take off the starter motor through bolts A e Remove Left hand End Cover A Right hand End Cover B Armature C Yoke D Starter Motor Assembly Apply a thin coat of grease to the oil seal A e Fit the groove B of the toothed washer C on the projec tion D left hand end cover e Install the washer E e Press the springs holding the brush leads with suitable clips A as shown e Put the armature B among the brushes e Install the new O rings A as shown
76. C on it e Install Stem Cap D Steering Stem Nut E A GN05078BS1 14 8 STEERING Steering Stem Settle the bearings in place as follows OTighten the steering stem nut with 55 N m 5 6 kgf m 41 ft lb of torque first and loosen it a fraction of a turn until it turns lightly To tighten the stem nut to the specified torque hook the wrench on the stem nut and pull the wrench at the hole by 305 N 31 0 kgf 69 Ib B force in the direction shown Afterward tighten it again with specified torque using a special tool A Special Tool Steering Stem Nut Wrench 57001 1100 Torque Steering Stem Nut 20 N m 2 0 kgf m 15 ft lb OFor the torque of 20 N m 2 0 kgfm 15 ft lb pull the wrench at the hole by 101 N 11 1 kgf 25 Ib force e Install the claw washer A so that its bent side B faces upward and engage the bent claws with the grooves of stem locknut C e Hand tighten the stem locknut until it touches the claw washer e Tighten the stem locknut clockwise until the claws are aligned with the grooves ranging from 2nd to 4th of stem nut D and bend the 2 claws downward E e Install the stem head A with handlebars to the steering stem B e Install the washer C and temporary tighten the stem head nut D e Install the front fork see Front Fork Installation in the Sus pension chapter GNO5060581 C STEERING 14 9 Steering Stem NOTE OTighten th
77. C 879210645 C 9 10 CRANKSHAFT TRANSMISSION Crankcase Splitting Crankcase Splitting Remove the engine see Engine Removal the Engine Removal Installation chapter e Set the engine on a clean surface and hold the engine steady while parts are being removed e Remove Cylinder Head see Cylinder Head Removal in the En gine Top End chapter Clutch see Clutch Removal in the Clutch chapter Starter Motor see Starter Motor Removal in the Electri cal System chapter Starter Clutch see Starter Clutch Removal Oil Pump see Oil Pump Removal in the Engine Lubri cation System chapter Alternator Rotor see Alternator Rotor Removal in the Electrical System chapter Oil Cooler Oil Filter Case see Oil Cooler Oil Filter Case Removal in the Engine Lubrication System chapter Oil Pan see Oil Pan Removal in the Engine Lubrication System chapter Oil Screen see Oil Pressure Relief Valve Removal in the Engine Lubrication System chapter External Shift Mechanism see External Shift Mecha nism Removal Transmission Assy see Transmission Assy Removal e Remove the upper crankcase bolts OFirst loosen the M6 bolts M6 Bolts A M8 Bolt L 90 mm B M8 Bolts L 75 mm C ORemove the bracket for oxygen sensor lead connector Equipped Models 2 S92 Se e 9104267851 e Remove the lower crankcase bolts OFirst loosen the M6 bolts M6 Bolts A Mp e SUI M8 Bolts B
78. California Model install the separator L Torque Separator Bracket Mounting Bolt M 0 8 Nm 0 08 kgf m 7 in Ib ORoute the canister and separator hoses according to Cable Wire and Hose Routing section in the Appendix chapter 227 f 7 2222 2 an as GD0705 BW3 C 4 16 COOLING SYSTEM Radiator Radiator Inspection e Remove the radiator see Radiator and Radiator Fan Re moval e Check the radiator core x If there are obstructions to air flow remove them the corrugated fins A are deformed carefully straighten them xIf the air passages of the radiator core are blocked more than 20 by unremovable obstructions or irreparably de formed fins replace the radiator with a new one CAUTION When cleaning the radiator with steam cleaner be careful of the following to prevent radiator damage Keep the steam gun A away more than 0 5 m 1 6 ft B from the radiator core Hold the steam gun per pendicular C not oblique D to the core surface Run the steam gun following the core fin direction Radiator Cap Inspection e Remove the radiator cap see Pressure Testing e Check the condition of the bottom A and top B valve seals and valve spring C x If any one of them shows visible damage replace the cap with a new one e Install the cap A on a cooling system pressure tester B NOTE OWet the cap sealin
79. Cylinder Head Bolts 9 First 15 1 5 11 5 Cylinder Head Bolts 9 39 4 0 29 S Cylinder Head Bolts 6 12 1 2 we in Ib Cylinder Head Cover Bolts m Front Camshaft Chain Guide Bolt Lower 11 1 2 Front Camshaft Chain Guide Bolt Upper 2 5 18 Upper Camshaft Chain Guide Bolt 106 in Ib E Spark Plugs 1 3 113 in Ib Throttle Body Assy Holder Clamp Bolts 0 30 26 in Ib z Throttle Body Assy Holder Bolts 1 2 in Ib Breather Hose Fitting 17 Apply engine oil to the 1 4 cam lobes around before the camshaft cap installation EO Apply engine oil G Apply grease HG Apply high temperature grease L Apply a non permanent locking agent M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts S Follow the specified tightening sequence SS Apply silicone sealant 5 4 ENGINE TOP END Exploded View GE023248W5 C ENGINE TOP END 5 5 Exploded View Torque No Fastener kgf m ftlb Remarks 1 Exhaust Butterfly Valve Actuator Mounting Bolts 6 9 0 70 61 in Ib 2 Exhaust Butterfly Valve Actuator Pulley Bolt 4 9 0 50 43 in Ib 3 Exhaust Butterfly Valve Cable Adjuster Locknuts 6 9 0 70 61 in Ib 4 Exhaust Butterfly Valve Cable Locknuts 6 9 0 70 61 in lb 5 Exhaust Butterfly Valve Cover Bolt 6 9 0 70 61 in Ib 6 Exhau
80. E 9104268851 CRANKSHAFT TRANSMISSION 9 11 Crankcase Splitting OLoosen the M8 bolts 1 10 sequence numbers Tap lightly around the crankcase mating surface with plastic mallet and split the crankcase Take care not to damage the crankcase 9104278851 Crankcase Assembly CAUTION The upper and lower crankcase halves are ma chined at the factory in the assembled state so the crankcase halves must be replaced as a set e With a high flash point solvent clean off the mating sur faces of the crankcase halves and wipe dry e Using compressed air blow out the oil passages in the crankcase halves e When installing the breather plate to upper crankcase replace the gasket A with a new one e Apply a non permanent locking agent to the threads tighten the bolts A Torque Breather Plate Bolts 9 8 1 0 kgf m 87 in lb 9 12 CRANKSHAFT TRANSMISSION Crankcase Splitting e Press and insert the fitting A in the upper crankcase B until it is bottomed Special Tool Bearing Driver Set 57001 1129 mil e Apply a non permanent locking agent to threads of the breather hose fitting C and tighten it Torque Breather Hose Fitting 15 N m 1 5 kgf m 11 ft Ib e Press and insert the plug D in the upper crankcase so that the plug surface E is flush with the end of the hole 0104280852 e Install the oil
81. E Shift Drum Assembly e Press and insert the ball bearing A on the shift drum B until it is bottomed e Install Ball Bearing C Pin D and Shift Drum Cam E e Align the pin with the groove in the shift drum cam e Apply a non permanent locking agent to the shift drum cam holder bolt F and tighten it Torque Shift Drum Cam Holder Bolt 12 N m 1 2 kgf m 106 in Ib Shift Fork Bending e Visually inspect the shift forks and replace any fork that is bent A bent fork could cause difficulty in shifting or allow the transmission to jump out of gear when under power 90 A A 9113366851 C 9113359851 C 6113014581 C 9 46 CRANKSHAFT TRANSMISSION Transmission Shift Fork Gear Groove Wear e Measure the thickness of the shift fork ears A and mea sure the width B of the gear grooves x If the thickness of a shift fork ear is less than the service limit the shift fork must be replaced Shift Fork Ear Thickness Standard 5 9 6 0 mm 0 232 0 236 in Service Limit 5 8 mm 0 228 in xIf the gear groove is worn over the service limit the gear must be replaced Gear Groove Width Standard 6 05 6 15 mm 0 238 0 242 in Service Limit 6 25 mm 0 246 in Shift Fork Guide Pin Drum Groove Wear e Measure the diameter of each shift fork guide pin A and measure the width B of each shift drum groove xIf the guide pin on any shift fork is less than the s
82. Electrical System chapter Rear Brake Light Switch see Switch Inspection in the Electrical System chapter Harness see Wiring Inspection in the Electrical System chapter Suspensions Front Forks Rear Shock Absorber Operation Inspection e Pump the forks down and up A 4 or 5 times and inspect the smooth stroke x If the forks do not smoothly or noise is found inspect the fork oil level or fork clamps see Front Fork Oil Change in the Suspension chapter e Pump the seat down and up A 4 or 5 times and inspect the smooth stroke x If the shock absorber does not smoothly stroke or noise is found inspect the oil leak or shock absorber clamps see Rear Shock Absorber Oil Leak Inspection in this chapter Front Fork Oil Leak Inspection e Visually inspect the front forks A for oil leakage Replace or repair any defective parts if necessary 2 36 PERIODIC MAINTENANCE Maintenance Procedure Rear Shock Absorber Oil Leak Inspection e Visually inspect the shock absorber A for oil leakage x If the oil leakage is found on it replace the shock absorber with a new one Rocker Arm Operation Inspection e Pump the seat down and up 4 or 5 times and inspect the smooth stroke xIf the rocker arm A does not smoothly stroke or noise is found inspect the fasteners and bearings see Rocker Arm Tie Rod Bearing Sleeve Inspection in the Suspen sion chapter Tie Rod Operation Inspection e Pump the seat
83. Electrical System chapter Turn Signal Relay Fuse 10 A see Fuse Inspection in the Electrical System chapter Turn Signal Switch see Wiring Diagram in the Electrical System chapter Turn Signal Relay see Turn Signal Relay Inspection in the Electrical System chapter Harness see Wiring Inspection in the Electrical System chapter e Push the turn signal switch e The turn signal lights and indicator light LED should go off x lf the light does not go off inspect or replace the following item Turn Signal Switch see Switch Inspection in the Electri cal System chapter Fourth Step e Set the dimmer switch A to low beam position e Start the engine e The low beam headlight should go on xIf the low beam headlight does not go on inspect or re place the following item Headlight Low Beam Bulb see Headlight Bulb Replace ment in the Electrical System chapter Headlight Fuse 10 A see Fuse Inspection in the Electri cal System chapter Dimmer Switch see Wiring Diagram in the Electrical System chapter Headlight Relay see Relay Circuit Inspection in the Electrical System chapter Harness see Wiring Inspection in the Electrical System chapter 2 40 PERIODIC MAINTENANCE Maintenance Procedure e Set the dimmer switch to high beam position e The low beam A and high beam B headlights should go on e The high beam indicator light LED C should go on x If the high beam headlight and or high beam indica
84. Excessive bending followed by subsequent straightening can weaken the inner tube e Temporarily assemble the inner and outer tubes and pump them back and forth manually to check for smooth operation e f you feel binding or catching the inner and outer tubes must be replaced A WARNING A straightened inner or outer fork tube may fall in use possibly causing an accident Replace a badly bent or damaged inner or outer tube and inspect the other tube carefully before reusing it Dust Seal Inspection e Inspect the dust seals A for any signs of deterioration or damage Replace it if necessary Spring Tension e Since a spring becomes shorter as it weakens check its free length A to determine its condition xIf the spring of either fork leg is shorter than the service limit it must be replaced If the length of a replacement spring and that of the remaining spring vary greatly the remaining spring should also be replaced in order to keep the fork legs balanced for motorcycle stability Spring Free Length Standard 257 mm 10 1 in Service Limit 252 mm 9 92 in GM04128BS1 C 8 04011851 C SUSPENSION 13 19 Rear Shock Absorber Rebound Damping Force Adjustment e To adjust the rebound damping force turn the lower damping adjuster A to the desired position until you feel a click OThe standard adjuster setting for an average build rider of 68 kg 150 Ib with no passenger
85. First turn the cap counterclockwise to the first stop Then push and turn it further in the same direction and remove the cap e Install the cooling system pressure tester A on the filler neck NOTE OWet the cap sealing surfaces with water or coolant to prevent pressure leaks e Build up pressure in the system carefully until the pres sure reaches 123 kPa 1 25 kgf cm 18 psi CAUTION During pressure testing do not exceed the pres sure for which the system is designed The maxi mum pressure is 123 kPa 1 25 kgf cm 18 psi e Watch the gauge for at least 6 seconds xIf the pressure holds steady the system is all right xIf the pressure drops and no external source is found check for internal leaks Droplets in the engine oil indicate internal leakage Check the cylinder head gasket and the water pump e Remove the pressure tester replenish the coolant and install the radiator cap 6005011151 C COOLING SYSTEM 4 9 Coolant Cooling System Flushing Over a period of time the cooling system accumulates rust scale and lime in the water jacket and radiator When this accumulation is suspected or observed flush the cool ing system If this accumulation is not removed it will clog up the water passage and considerable reduce the effi ciency of the cooling system e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Fill the cooling system with fresh water m
86. Free Play Inspection eee ies 6 6 Clutch Lever Free Play Adjustment pp 6 6 Cable Removal citet eb P esr terree D RP Cable ril io Cable E brication tecti en o ER ace a ER REEL RSS Clutch Lever Installations iii ite Rec etaed Rte deut ba ted es doe Clutch COV eT iecit e reb be bes e RE e dec E rig ek be de e Removal HER Le ade a t rr dr p ped Clutch Cover Installation 4 6 7 Release Shaft 6 7 Release Shaft Installation pp 6 8 Clutch Cover Disassembly 2 crt e e erred iie erg eg ede e rice t P DERE 6 8 Clutch Cover ASSeIiblya ace dc ipd tet tee 6 9 Uie 6 10 Cut REMOVAL bett tante teres 6 10 Clutch Iristallation ioter e cute P ee 6 10 Spring Plate Free Play Measurement cessent teneret rnnt tentent 6 13 Spring Plate Free Play Adjustment pp 6 14 Clutch Plate Wear Damage Inspection Ne 6 15 Clutch Plate Warp INSpection ener nennen nnne nennen 6 15 Clutch Spring Free Length Measurement pp 6 16 Damper Cam Inspection pp 6 16 6 2 CLUTCH Exploded View GF021098W5 C CLUTCH 6 3 Exploded View Torque No Fastener Nm kgf m 16 1 Clutch Cover Bolts 6 L 25 mm 9 8 1 0 87 in lb 2 Clutch Cover Bolts
87. Indicator Light LED 12V2 5A saad SS 1 2 3 94 Neutral Indicator Light LED 1 2 3 Coils 4 Fuel Level Warning Indicator Light LED 5 011 Pressure Warning Fl Immobilizer wee SS wo Indicator Light LED ae 6 Odometer Trip Meter Stop Watch Indicator 5 7 8ear Position Indicator s s gs s 8 Clock Air Te ctm qom 9 Water Temperature Gauge gERS QE xd RE Switch 10 Tachometer 5 Ea Zz 257 ing 11 Speadometer Valve 12 Meter Light LED 13 Shift Up Indicator Light LED SI Secondary Fuel BR REESE MEE Injectors Ignition LT b 202 Switch R rm Antenna R Immobilizer Tanapi E Hll H H 0 W R 4 Meter Unit S BL W BK Y BKZY 16 Gy BL R R BK BR R BK LG 18 wy W BK BR W BL Y ctor BK Y 1 i i i BK AY SLED Light Emitting Diode BK Y BK Y Front Right Turn Signal Sr 4 Light 12V21W Headlight 12 55 City Light 3 H 125 BK Y BKZ Y 12V65 d Front Left Turn Signal eh i Light 12V21W s Left Switch Housing oo Horn Button Passing Button Rel B Turn Signal Switch Left Switch Housing Fuse Box elay Box Dimmer Switch Oxgen Sensor 10 5 Headlight Fu
88. Inspection RN 2 34 SUSPENSIONS s 2 2 35 Front Forks Rear Shock Absorber Operation 2 35 Front Fork Oil Leak 2 4 2 2 0 00000 000000000 000000000000 2 2 35 Rear Shock Absorber Oil Leak Inspection pp 2 36 Rocker Arm Operation Inspection pp 2 36 Tie Rod Operation Inspection 2 36 Steering SV SUSI cuz ote ed isst Lee uie 2 36 steering Play Inspection iier e Paletten lana kae eere eem beet i be ri Demande be eius 2 36 2 2 PERIODIC MAINT ENANCE Steering Play Adjustment Steering Stem Bearing Lubrication pp Lights and Switches Operation Headlight Aiming Inspecti a e E Side Stand Switch Operation Inspectionm Engine Stop Switch Operation Inspection pp Others i ceste eS Chassis Parts Lubrication Bolts Nuts and Fasteners Tightness Inspection pp Replacement Parts Air Cleaner Element Repl Fuel Hose Replacement Coolant Change acemert ricos ete tits Rs EM PRO REEL OE Eu Radiator Hose and O ring Replacement essen Engine Oil Change Oil Filter Replacement Brake Hose and Pipe Repl
89. Install the timing inspection cap and starter clutch bolt cap Torque Timing Inspection Cap Hand tighten Starter Clutch Bolt Cap Hand tighten e Install the cylinder head cover NOTE Olf the oil pump was removed refer to the Oil Pump In stallation in the Engine Lubrication System chapter Camshaft Camshaft Cap Wear e Remove Camshaft Cap see Camshaft Removal in this chapter e Cut strips of plastigage to journal width Place a strip on each journal parallel to the camshaft installed in the correct position e Measure each clearance between the camshaft journal and the camshaft cap using plastigage press gauge A GE11089BS1 C e Tighten see Camshaft Installation Torque Camshaft Cap Bolts 12 N m 1 2 106 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 0 038 0 081 mm 0 0015 0 0032 in Service Limit 0 17 mm 0 0067 in 5 22 ENGINE TOP END Camshaft If any clearance exceeds the service limit measure the diameter of each camshaft journal with a micrometer Camshaft Journal Diameter Standard 23 940 23 962 mm 0 9425 0 9434 in Service Limit 23 91 mm 0 941 in x If the camshaft journal diameter is less than the service limit replace the camshaft with a new one and measure the clearance again x If the clearance still remains out of the limit replace the cylinder
90. Light LED 14 Headlight Relay 3 Joint Connector C 15 Relay Box 4 Headlight Low Beam 16 Joint Connector B 5 City Light 17 Starter Relay 6 Headlight High Beam 18 Main Fuse 30 A 7 Joint Connector A 19 Frame Ground 8 Passing Button 20 Battery 12 V 8 Ah 9 Dimmer Switch 21 License Plate Light 10 Left Handlebar Switch 22 Tail Brake Light LED 11 Headlight Fuse 10 A 23 Cylinder Head Cover Ground 12 Tail Light Fuse 10 A 24 Alternator Turn Signal Light Bulb Replacement For the Front Turn Signal Light e Remove Inner Cover see Inner Cover Removal in the Frame chapter Canister California Model left side Relay Box see Relay Box Removal 16 56 ELECTRICAL SYSTEM Lighting System Turn the socket A counterclockwise and pull out the socket together with the bulb e Push A and turn B the bulb C counterclockwise and remove it e Insert the new bulb A by aligning its upper and lower pins B with the upper and lower grooves C in the socket and turn the bulb clockwise OTurn the bulb about 15 degrees e Pushing the socket and turn it clockwise OFit the projections D of the socket into the grooves of the light For the Rear Turn Signal Light e Unscrew the screw A and remove the turn signal lens B e Push and turn the bulb A counterclockwise and remove it ELECTRICAL SYSTEM 16 57 Lighting System elnsertthe new bulb A by aligning its upper and lower pins
91. M6 L 40 mm 9 8 1 0 87 in lb 3 Clutch Hub Nut 135 14 100 R 4 Clutch Lever Clamp Bolts 7 8 0 80 69 in Ib S 5 Clutch Spring Bolts 8 8 0 90 78 in Ib 6 Sub Clutch Hub Bolts 25 2 5 18 L CL Apply cable lubricant EO Apply engine oil Apply grease Apply a non permanent locking agent Apply molybdenum disulfide grease Replacement Parts Follow the specified tightening sequence 6 4 CLUTCH Specifications Item Standard Service Limit Clutch Lever Free Play 2 3 mm 0 08 0 12 in Clutch Spring Plate Free Play Clutch Plate Assembly Length Friction Plate Thickness Friction and Steel Plate Warp Clutch Spring Free Length Usable Range 0 05 0 70 mm 0 002 0 028 in Reference 40 6 mm 1 60 in 2 72 2 88 mm 0 107 0 113 in 0 15 mm 0 006 in or less 41 6 mm 1 64 in 2 5 mm 0 098 in 0 3 mm 0 012 in 40 1 mm 1 58 in CLUTCH 6 5 Special Tool and Sealant Clutch Holder Kawasaki Bond Silicone Sealant 57001 1243 92104 0004 gt 7571243ST C 879200045 6 6 CLUTCH Clutch Lever and Cable Clutch Lever Free Play Inspection e Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter Clutch Lever Free Play Adjustment e Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter Cable Removal Remove the right middle fairing see Middle Fairing Re moval in the
92. MAINTENANCE Maintenance Procedure Brake Pad Wear Inspection Check the lining thickness of the pads in each caliper Pad Lining Thickness Standard Front A 4 0 mm 0 16 in Rear B 5 0 mm 0 20 in LLL Service Limit C 1 mm 0 04 in x If the lining thickness of either pad is less than the service limit B replace both pads in the caliper as a set 9513202851 9513203851 Brake Light Switch Operation Inspection e Turn on the ignition switch e The brake light A should go on when the brake lever is applied or after the brake pedal is depressed about 10 mm 0 39 in x lf it does not adjust the brake light switch e While holding the switch body turn the adjusting nut to adjust the switch Switch Body A Adjusting Nut B Light sooner as the body rises C Light later as the body lowers D CAUTION To avoid damaging the electrical connections in side the switch be sure that the switch body does not turn during adjustment PERIODIC MAINTENANCE 2 35 Maintenance Procedure x If it does not go on inspect or replace the following items M Battery see Charging Condition Inspection in the Elec trical System chapter Brake Light see Tail Brake Light Removal in the Electri cal System chapter Main Fuse 30 A and Taillight Fuse 10 A see Fuse In spection in the Electrical System chapter Front Brake Light Switch A see Switch Inspection in the
93. O ring D Special Tool Inside Circlip Pliers 57001 143 e Unscrew the locknut E and pivot bolt F and remove the brake lever e Remove dust cover and circlip Pull out the piston assy Replace Seal Cover A Circlip B O ring D Circlip G Piston Assy H Rear Master Cylinder Disassembly Remove the rear master cylinder see Rear Master Cylin der Removal in the Brakes chapter e Remove the circlip A connector B and O ring C Special Tool Inside Circlip Pliers 57001 143 e Slide the dust cover D out of place and remove the cir clip E e Pull out the push rod assy F e Take off the piston assy G CAUTION Do not remove the secondary cup from the piston since removal will damage it e Replace Circlip A O ring C Circlip E Push Rod Assy F Piston Assy G 9813200852 C Master Cylinder Assembly e Before assembly clean all parts including the master cylinder with brake fluid or alcohol CAUTION Except for the disc pads and disc use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning brake parts Do not use any other fluid for cleaning these parts Gasoline engine oil or any other petroleum distillate will cause deterioration of the rubber parts Oil spilled on any part will be diffi cult to wash off completely and will eventually de teriorate the rubber used in the disc brake PERIODIC MAINTEN
94. Oil Pan Removal Circlip A Washer B Oil Pump Gear Shaft C Special Tool Outside Circlip Pliers 57001 144 Oil Pump Gear Shaft Installation e Apply molybdenum disulfide oil solution to the journal por tions A on the oil pump gear shaft e Install the washer B as shown e Install the new circlip C into the groove of the oil pump gear shaft Special Tool Outside Circlip Pliers 57001 144 9009065851 C ENGINE LUBRICATION SYSTEM 7 17 Oil Cooler Oil Cooler Removal Drain Coolant see Coolant Change the Periodic Mainte nance chapter Engine Oil see Engine Oil Change in the Periodic Main tenance chapter e Remove Starter Motor see Starter Motor Removal in the Electri cal System chapter Clutch Cable Lower End see Cable Removal in the Clutch chapter Clutch Cover Bolts A Bracket B Water Hoses C Oil Cooler Mounting Bolts D Oil Cooler E Oil Cooler Installation e Replace the O ring A with a new one e Apply grease to the new O ring e Install the oil cooler A e Tighten Torque Oil Cooler Mounting Bolts 20 N m 2 0 kgf m 15 ft lb e Install the water hoses B and hose clamps C as shown Upside View D Tighten Torque Water Hose Clamp Screws 2 0 N m 0 20 kgf m 3 17 in Ib 80811009851 C e Install the removed parts see appropriate chapters e Pour Coolant see Coolant Change in the Periodic Mainte nance chapter Engine
95. Pink W White Y IGNITION SWITCH CONNECTIONS RIGHT HANDLEBAR SWITCH CONNECTIONS Ignition Battery Taili Tail2 Front Brake Light Switch Engine Stop Switch Starter Button Stop Watch Button WEE dee OFF Lock Brake Lever OFF Free P PAR 98052 0329B 280329 5 16 16 ELECTRICAL SYSTEM Wiring Diagram Malaysia Right Switch Housing 1 Front Brake Engine Light Switch Right Switch i Head E 2 Engine Stop Gaver Switch around s starter Button 4 8 Watch ed Bitten Spark Plugs ti Fan 00060 Neutral Indicator Light LED Fuel Level Warning Indicator Light LED Meter Unit M WT Turn Signal Indicator Light LED Horn INNS rimaly Fuel Injectors High Beam Indicator Light LED E d Stick 1 84 2011 Pressure Warning Fl Immobilizer E Indicator Light LED Meter Light LED Shift Up Indicator Light LED 6 0dometer Trip Meter Stop Watch Indicator 5 Poy ovr oy 7 8ear Position Indicator 55 55 SS 8 Clock Tar mar 9 Water Temperature Gauge z Mrs 0 Tachometer cas 5 M c Usspeedame ter 3 Secondary Fue Injectors Ignition 1 2 Switch R 0 6 Antenna Immobilizer Amplifier 0 0 W R Meter Unit R E BL R
96. Piston Pin Puller Assembly 57001 910 eRemove the pistons GE16158BS1 C e Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring A to remove it e Remove the 3 piece oil ring with your thumbs in the same manner GE16159BS1 C 9 28 CRANKSHAFT TRANSMISSION Pistons Piston Installation e Apply molybdenum disulfide oil solution to the oil ring ex pander and install the oil ring expander A in the bottom piston ring groove so the ends B butt together e Apply molybdenum disulfide oil solution to the oil ring steel rails and install the oil ring steel rails one above the ex pander and one below it OSpread the rail with your thumbs but only enough to fit the rail over the piston ORelease the rail into the bottom piston ring groove NOTE OThe oil ring rails have no top or bottom e Do not mix up the top and second ring e Install the top ring A so that the mark B faces up e Install the second ring C so that the RN mark D faces up OApply molybdenum disulfide oil solution to the piston rings NOTE new piston is used use new piston ring e Fit a new piston pin snap ring into the side of the piston so that the ring opening A does not coincide with the slit B of the piston pin hole OApply molybdenum disulfide oil solution to the piston pins and piston journals OWhen installing the piston pin snap ring compr
97. Remove the stem head E e Bend the claws A of the claw washer straighten e Remove the steering stem locknut B and claw washer C e Adjust the steering Special Tool Steering Stem Nut Wrench A 57001 1100 xIf the steering is too tight loosen the stem nut a fraction of a turn x If the steering is too loose tighten the stem nut a fraction of a turn NOTE OTurn the stem nut 1 8 turn at time maximum GS15039BS1 C e Install the claw washer A so that its bent side B faces upward and engage the bent claws with the grooves of stem locknut C e Hand tighten the stem locknut until it touches the claw washer e Tighten the stem locknut clockwise until the claws are aligned with the grooves ranging from 2nd to 4th of stem nut D and bend the 2 claws downward E 6515022851 C e Apply a non permanent locking agent to the handlebar position bolts e Tighten Torque Steering Stem Head Nut 78 N m 8 0 kgf m 58 ft lb Upper Front Fork Clamp Bolts 20 N m 2 0 kgf m 15 16 Handlebar Position Bolts 9 8 N m 1 0 kgf m 87 in Ib e Check the steering again x If the steering is still too tight or too loose repeat the ad justment 2 38 PERIODIC MAINTENANCE Maintenance Procedure Steering Stem Bearing Lubrication Remove the steering stem see Stem Stem Bearing Re moval in the Steering chapter e Using a high flash point solvent wash the upper and lower ball bearings
98. Secondary Fuel Hose e Set up the fuel tank see Air Cleaner Element Replace ment e Be sure to place a piece of cloth A around the fuel hose joint e Push the joint lock claws C Pull the joint lock A as shown e Pull the fuel hose joint B out of the delivery pipe C A WARNING Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is disconnected fuel spills out from the hose and the pipe because of residual pressure Cover the hose connection with a piece of clean cloth to prevent fuel spillage e Remove Fuel Hose Mounting Screw A Fuel Hose B e Apply engine oil to the new O ring A e Tighten Torque Fuel Hose Mounting Screw B 9 9 N m 0 50 kgf m 43 ft Ib GC17746BS1 e Insert the fuel hose joint A straight onto the delivery pipe until the hose joint clicks e Push B the joint lock C until the hose joint clicks A WARNING Make sure the fuel hose joint is installed correctly on the delivery pipe or the fuel could leak e Run the fuel hose in accordance with the Cable Wire and Hose Routing section in the Appendix chapter e Install the removed parts see appropriate chapters e Start the engine and check the fuel hose for leaks 2 50 PERIODIC MAINTENANCE Maintenance Procedure Coolant Change WARNING To avoid burns do not remove the radiator cap or try to change the coo
99. Sensor Setting Adapter 1 57001 1400 Connections Meter BL Lead G in Adapter Y Lead of Actuator Meter BK BL Lead in Adapter BK Lead of Actuator GC17646BS1 C Actuator Output Voltage Pulley Original Position Standard 3 46 3 76 V xIf the output voltage is out of the standard remove the actuator and check the original position of pulley see Ex haust Butterfly Valve Actuator Installation 3 92 FUEL SYSTEM Exhaust Butterfly Valve Actuator Service Code 63 Exhaust Butterfly Valve Actuator Circuit 2 gt m a P 6C176488W2 C 1 ECU 2 Exhaust Butterfly Valve Actuator FUEL SYSTEM DFI 3 93 Air Switching Valve Service Code 64 Air Switching Valve Removal Installation e Refer to Clean Air System section in the Engine Top End chapter Air Switching Valve Inspection e Referto Air Switching Valve Unit Test in the Electrical Sys tem chapter e Check the wiring continuity using the following diagram Air Switching Valve Circuit Other than Europe Models 2 orr Yu i Ld tox GCi7935CW3 C 1 ECU 10 Main Fuse 30 A 2 Engine Stop Switch 11 Starter Relay 3 Ignition Switch 12 Battery 12 V 8 Ah 4 Ignition Fuse 10 A 13 Joint Connector C 5 ECU Fuse 10 14 Joint Connector B 6 Fuse Box 15 Frame Ground 7 ECU Main Relay 16 Cylinder Head Cover Ground 8 F
100. Splitting e Apply liquid gasket A to the mating surface of the lower crankcase half Sealant Kawasaki Bond 92104 1064 e Pile up the liquid gasket to groove B CAUTION Do not apply liquid gasket to the inside of the grooves C around the crankshaft main bearing inserts and oil passage NOTE OMake the application finish within 20 minutes when the liquid gasket to the mating surface of the lower crankcase half is applied LR MEZ mb ee 5 972 RL PEF 22 AR 2 AN Zl 0 0 7 L 7 VA K Do PEO OOA e Replace the washers A of the M8 bolts B with new ones e Apply molybdenum disulfide oil solution to both sides C of the washers and threads D of M8 bolts CRANKSHAFT TRANSMISSION 9 15 Crankcase Splitting Following the sequence numbers on the lower crankcase half tighten M8 bolts 1 10 with washers Torque Crankcase Bolts 8 A First 15 N m 1 5 kgf m 11 1 Final 31 N m 3 2 kgf m 23 ft Ib Install the bracket for oxygen sensor lead connector as shown in the figure equipped models e Tighten the 6 bolts C Torque Crankcase Bolts 6 12 N m 1 2 kgf m 106 in Ib a win 3 Vo i T HEU rat i 14172 Oe 90 2 b d 6104271BS1 e Replace the washers A of the M8
101. Surface B NOTE ORemove all pittings of flaws from 45 ground surface OAfter grinding with 45 cutter apply thin coat of machin ist s dye to seating surface This makes seating surface distinct and 32 and 60 grinding operation easier OWhen the valve guide is replaced be sure to grind with 45 cutter for centering and good contact xIf the outside diameter A of the seating surface is too large make the 32 grind described below x If the outside diameter of the seating surface is within the specified range measure the seat width as described be low e Grind the seat at a 32 angle B until the seat outside diameter is within the specified range OTo make the 32 grind fit a 32 cutter into the holder and slide it into the valve guide OTurn the holder one turn at a time while pressing down very lightly Check the seat after each turn CAUTION The 32 cutter removes material very quickly Check the seat outside diameter frequently to pre vent overgrinding OAfter making the 32 grind return to the seat outside di ameter measurement step above e To measure the seat width use a vernier caliper to mea sure the width of the 45 angle portion of the seat at sev eral places around the seat xIf the seat width is too narrow repeat the 45 grind until the seat is slightly too wide and then return to the seat outside diameter measurement step above 8 15011951 C GE1501218
102. and tighten the adjusting collar B counterclockwise until the clearance C between the engine D and collar come to 0 mm 0 in OEighth holding the collar and tighten the adjusting collar locknut E Special Tool Engine Mount Nut Wrench 57001 1450 Torque Adjusting Collar Locknut 49 N m 5 0 kgf m 36 ft Ib OLastly tighten the right upper engine mounting bolt Torque Right Upper Engine Mounting Bolt 44 N m 4 5 kgf m 33 ft lb GH04082BS2 GHO4080BS1 GHO4081BS1 C ENGINE REMOVAL INSTALLATION 8 11 Engine Removal Installation e Run the leads cable and hoses correctly see Cable Wire and Hose Routing section in the Appendix chap ter e Install the removed parts see appropriate chapters e Adjust Throttle Cables see Throttle Control System Inspection in the Periodic Maintenance chapter Clutch Cable see Clutch Operation Inspection in the Pe riodic Maintenance chapter Drive Chain see Drive Chain Slack Inspection in the Periodic Maintenance chapter e Fill the engine with engine oil see Engine Oil Change in the Periodic Maintenance chapter e Fill the engine with coolant and bleed the air from the cool ing system see Coolant Change in the Periodic Mainte nance chapter CRANKSHAFT TRANSMISSION 9 1 Crankshaft Transmission Table of Contents Exploded 9 2 Starter Idle Gear Removal 9 31 Spe
103. and washers e When removing the brake hose take care not to spill the brake fluid on the painted or plastic parts e When removing the brake hoses B temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum e Immediately wash away any brake fluid that spills e There are washers on each side of the brake hose fitting Replace them with new ones when installing e Tighten Torque Brake Hose Banjo Bolts 34 N m 3 5 kgf m 25 ft lb e When installing the hoses avoid sharp bending kink ing flatting or twisting and route the hoses according to Cable Wire and Hose Routing section in the Appendix chapter e Fill the brake line after installing the brake hose see Brake Fluid Change Brake Fluid Change NOTE OThe procedure to change the front brake fluid is as fol lows Changing the rear brake fluid is the same as for the front brake e Level the brake fluid reservoir e Remove Screw A Stopper B Reservoir Cap C e Remove the rubber cap from the bleed valve A on the caliper e Attach a clear plastic hose B to the bleed valve and run the other end of the hose into a container e Fill the reservoir with fresh specified brake fluid PERIODIC MAINTENANCE 2 55 Maintenance Procedure e Change the brake fluid ORepeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes Open the bleed valve A
104. be disassembled NOTE OLoosen the top plug after loosening the handlebar bolt and upper fork clamp bolt Counterclockwise Clockwise Softer Harder STD 3 2 1 H 3 3 3 Seated position adjuster turned fully clockwise 0004433851 C SUSPENSION 13 11 Front Fork e Loosen the handlebar bolt upper fork clamp bolt and lower fork clamp bolts A e With a twisting motion work the fork leg down and out Front Fork Installation e Install the fork so that the top end A of the outer tube as shown 8 5 mm 0 33 in B e Tighten the lower fork clamp bolts and fork top plug Torque Front Fork Clamp Bolts Lower 25 N m 2 5 18 ft lb Front Fork Top Plug 35 N m 3 5 kgf m 26 ft Ib e Tighten the handlebar bolt and upper fork clamp bolt Torque Handlebar Bolt 25 N m 2 5 18 ft lb Front Fork Clamp Bolt Upper 20 N m 2 0 kgf m 15 16 NOTE OTighten the two clamp bolts alternately two times to en sure even tightening torque OTighten the top plug before tightening the handlebar bolt and upper fork clamp bolt e Install the removed parts see appropriate chapters e Adjust the spring preload and the damping force Front Fork Oil Change e Remove the front fork see Front Fork Removal e Hold the inner tube lower end in a vice e Unscrew the top plug A out of the outer tube e Install the fork spring compressor as shown NOTE OSet the fork spring
105. broken or weak Clutch hub or housing unevenly worn No clutch lever play Clutch inner cable trouble Clutch release mechanism trouble Clutch not disengaging properly Clutch plate warped or too rough Clutch spring compression uneven Engine oil deteriorated Engine oil viscosity too high Engine oil level too high Clutch housing frozen on drive shaft Clutch hub nut loose Clutch hub spline damaged Clutch friction plate installed wrong Clutch lever play excessive Clutch release mechanism trouble Gear Shifting Faulty Doesn t go into gear shift pedal doesn t return Clutch not disengaging Shift fork bent or seized Gear stuck on the shaft Gear positioning lever binding Shift return spring weak or broken Shift return spring pin loose Shift mechanism arm spring broken Shift mechanism arm broken Shift pawl broken Jumps out of gear Shift fork ear worn bent Gear groove worn Gear dogs and or dog holes worn Shift drum groove worn Gear positioning lever spring weak or bro ken Shift fork guide pin worn Drive shaft output shaft and or gear splines worn Overshifts Gear positioning lever spring weak or bro ken Shift mechanism arm spring broken Abnormal Engine Noise Knocking ECU trouble Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Overheating Piston slap Cylinder piston clearance excessive Cylinder piston worn Connecting rod bent Piston pin piston pin hole worn Valve nois
106. compressor so that the end of the handle A passes the upper side hole on the spacer B by screwing the handle in the holder C to the bottom Special Tool Fork Spring Compressor 57001 1685 GM04428BS1 13 12 SUSPENSION Front Fork e While holding up the top plug A by one person push down B the fork spring compressor and insert the fork spring stopper C between the piston rod nut D and the spacer E Special Tool Fork Spring Stopper 57001 1374 e Holding the spring preroad adjuster A with a wrench B loosen the piston rod nut C e Remove the top plug D with the rebound damping ad juster rod from the piston rod e Remove Damper A Spacer B Spring Joint C Fork Spring D GM04419BS1 C e Drain the fork oil into a suitable container OPump the piston rod B up and down at least ten times to expel the oil from the fork Special Tool Fork Piston Rod Puller M10 x 1 0 A 57001 1298 8 04021251 C e Hold the fork tube upright press the inner tube A and the piston rod all the way down Pour in the type and amount of fork oil specified Fork Oil Viscosity SHOWA 5547 or equivalent SAE 10W Amount per side When changing oil approx 430 mL 14 5 US oz 9 gt D My My y After disassembly and completely dry 505 2 5 mL 17 1 0 085 US oz 8 04042851 C SUSPENSION 13 13 Fr
107. crankshaft sensor or speed sensor trouble Inspect throttle cables and lever linkage see chapter 3 see Overheating of Troubleshooting Guide in chapter 17 Air switching valve trouble Inspect and replace see chapter 16 Air suction valve trouble Inspect and replace see chapter 5 Exhaust Smokes Excessively Black smokes Air cleaner element clogged Fuel pressure too high Clean element see chapter 2 Inspect see chapter 3 Fuel Injector trouble Inspect see chapter 3 Water temperature sensor trouble Inlet air temperature sensor trouble Inspect see chapter 3 Inspect see chapter 3 Brown smoke Air duct loose Reinstall see chapter 3 Fuel pressure too low Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Inlet air temperature sensor trouble Inspect see chapter 3 FUEL SYSTEM DFI 3 35 Self Diagnosis The warning indicator light LED A is used for the FI indicator immobilizer indicator immobilizer models and oil pressure warning indicator Self diagnosis Outline The self diagnosis system has two modes and can be switched to another mode by operating the meter unit User Mode The ECU notifies the rider of troubles in DFI system ig nition system and immobilizer system by blinking the warn ing indicator light LED A Fl warning symbol B and im mobilizer warning symbol C when DFI ignit
108. down and up 4 or 5 times and inspect the smooth stroke x If the tie rods A do not smoothly stroke or noise is found inspect the fasteners and tie rod bearings see Rocker Arm Tie Rod Bearing Sleeve Inspection in the Suspen sion chapter Steering System Steering Play Inspection e Remove the lower fairings see Lower Fairing Removal in the Frame chapter e Lift the front wheel off the ground using the jack Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e With the front wheel pointing straight ahead alternately tap each end of the handlebar The front wheel should swing fully left and right from the force of gravity until the fork hits the stop x If the wheel binds or catches before the stop the steering is too tight e Feel for steering looseness by pushing and pulling the forks x If you feel looseness the steering is too loose NOTE OThe cables and wiring will have some effect on the mo tion of the fork which must be taken into account OBe sure the wires and cables are properly routed OThe bearings must be in good condition and properly lubricated in order for any test to be valid PERIODIC MAINTENANCE 2 37 Maintenance Procedure Steering Play Adjustment Raise the front wheel off the ground with the jack e Remove Upper End of Clutch Cable Upper End of Throttle Cables Stem Head Nut A and Washer B Handlebar Position Bolts C e Loosen the upper fork clamp bolts D e
109. good the input voltage is normal Check the output voltage e Turn the ignition switch OFF Inlet Air Pressure Sensor Output Voltage Inspection e Measure the output voltage at the ECU in the same way as input voltage inspection Inlet Air Pressure Sensor Output Voltage Connections to ECU Meter Y BL lead terminal 8 Meter BR BK lead terminal 28 Output Voltage at ECU Usable Range DC 3 80 4 20 V at the standard atmospheric pressure 101 32 kPa 76 cmHg abs NOTE OThe output voltage changes according to the local at mospheric pressure OThe inlet air pressure sensor output voltage is based on a nearly perfect vacuum in the small chamber of the sensor So the sensor indicates absolute vacuum pres sure x If the output voltage is within the usable range check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see ECU Removal Installation GC17142BS1 C 80179000651 FUEL SYSTEM DFI 3 49 Inlet Air Pressure Sensor Service Code 12 x If the output voltage is far out of the usable range check the output voltage again at the sensor connector A when the lead is open the output voltage is about 1 8 V e Connect a digital meter to the harness adapter leads Inlet Air Pressure Sensor B Special Tool Sensor Harness Adapter 57001 1561 Inlet Air Pressure Sensor Output Volt
110. ignition switch ON and make sure that the fuel pump operates make light sounds for 3 seconds and then stops e Turn the ignition switch OFF xIf the pump does not work as described above inspect the operating voltage Fuel Pump Operating Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Remove Left Side Cover see Side Cover Removal in the Frame chapter e Connect the hand tester 25 V DC to the connector A with needle adapter set Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 OMeasure the operating voltage with the engine stopped and with the connector joined e Turn the ignition switch ON OThe tester needle should indicate battery voltage for 3 seconds and then 0 V Pump Operating Voltage at Pump Connections to Pump Connectors Tester Y R Lead Tester BK W Lead Operating Voltage at Pump Connector Standard Battery Voltage 12 8 V for 3 seconds and then 0 V GC10058BS1 C 3 108 FUEL SYSTEM DFI Fuel Pump x If the reading stays on battery voltage and never shows 0 V Check the ECU and fuel pump relay x lf the voltage is in specification but the pump doesn t work replace the pump see Fuel Pump Removal Instal lation x lf there is still no battery voltage check the pump re lay see Relay Circuit Inspection in the Electrical System chapter Fuel Pump Circuit
111. ignition switch is turned OFF NA 9017926652 C Self Diagnosis Flow Chart Turn the ignition switch OFF Turn the ignition switch ON Display the odometer and push the MODE button for more than two seconds Then self diagnosis mode starts The service code s is displayed on the LCD Liquid Crystal Display Turn the ignition switch OFF Locate the problem with the service code table and inspect and repair DFI ignition and immobilizer system immobilizer models according to inspection procedure on all the service codes Turn the ignition switch ON Make sure the Fl and or immobilizer symbols go off Run the engine for several minutes at idling and run the motorcycle at 30 km h 18 mph or above in order to confirm no problem 00176836 F 3 38 FUEL SYSTEM Self Diagnosis Service Code Reading OThe service code s is displayed on the LCD by the number of two digits OWhen there are a number of problems all the service codes can be stored and the display will begin starting from the lowest number service code in the numerical order OThen after completing all codes the display is repeated until the ignition switch is turned OFF or MODE button is pushed for more than two seconds OFor example if three problems occurred in the order of 56 15 35 the service codes are displayed each two seconds from the lowest numb
112. in the Brakes chapter Right Switch Housing B Throttle Case C Handlebar Weight D Throttle Grip E e Remove Steering Stem Head Nut A and Washer B Steering Stem Head C with Handlebars e Remove Handlebar Position Bolts A Remove the handlebars e Remove the left handlebar grip C STEERING 14 11 Handlebar Handlebar Installation e Apply adhesive cement to the inside of the left handlebar grip e Apply a non permanent locking agent to the threads of handlebar position bolts e Tighten Torque Steering Stem Head Nut 78 N m 8 0 kgf m 58 ft lb Handlebar Bolts 25 N m 2 5 kgf m 18 16 Handlebar Position Bolts 9 8 N m 1 0 kgf m 87 in Ib e Install the front brake master cylinder see Front Master Cylinder Installation in the Brakes chapter e Install the left and right switch housings OFit the projection A into a small hole B in the handlebar Torque Switch Housing Screws 3 5 0 36 kgf m 31 in Ib e Install Clutch Lever see Clutch Lever Installation in the Clutch chapter e Install Throttle Grip Throttle Cable Tips Throttle Cases OFit the projection A into a small hole B in the handlebar e Apply a non permanent locking agent to the threads of handlebar weight bolts and tighten them e Install the removed parts see appropriate chapters FRAME 15 1 Frame Table of Contents Exploded
113. is any reading at all the armature has a short and the starter motor must be replaced NOTE OEven if the foregoing checks show the armature to be good it may be defective in some manner not readily detectable with the hand tester If all other starter motor and starter motor circuit components check good but the starter motor still does not turn over or only turns over weakly replace the starter motor with a new one Brush Lead Inspection Using the x 1 hand tester range measure the resis tance as shown Terminal Bolt and Positive Brush A Right hand End Cover and Negative Brush B Special Tool Hand Tester 57001 1394 xIf there is not close to zero ohms the brush lead has an open Replace the positive brush assembly and or the negative brush subassembly Right hand End Cover Assembly Inspection e Using the highest hand tester range measure the resis tance as shown Terminal and Right hand End Cover A Special Tool Hand Tester 57001 1394 x If there is any reading the right hand end cover assembly have a short Replace the right hand end cover assembly Starter Relay Inspection e Disconnect Battery Terminal e Remove Front Seat see Front Seat Removal in the Frame chap ter Pull out the starter relay A 8 11080851 C 16 50 ELECTRICAL SYSTEM Electric Starter System e Remove Connector A Battery Cable B Starter Cable C Connect t
114. is dirtied or the carbon is accumulated replace the spark plug e Measure the gap D with a wire type thickness gauge x If the is incorrect replace the spark plug Spark Plug Gap 0 7 0 8 mm 0 028 0 031 in e Use the standard spark plug or its equivalent Spark Plug CR9E 6517009851 C ELECTRICAL SYSTEM 16 41 Ignition System Camshaft Position Sensor Removal e Remove Air Cleaner Housing see Air Cleaner Housing Removal in the Fuel System DFI chapter Camshaft Position Sensor Connector A e Remove Middle Fairings see Middle Firing Removal in the Frame chapter Radiator Mounting Bolts see Radiator Removal in the Cooling System chapter Heat Installation Plate A Camshaft Position Sensor Bolt A Camshaft Position Sensor B Camshaft Position Sensor Installation e Apply high temperature grease to the O ring A Tighten Torque Camshaft Position Sensor Bolt 9 8 1 0 kgf m 87 in lb e Install the heat insulation plate A so that the left side projections first OFit the projections B of the plate into the holes C of the frame e Install the radiator see Radiator Installation in the Cooling System chapter Camshaft Position Sensor Inspection e Remove Camshaft Position Sensor Connector A 16 42 ELECTRICAL SYSTEM Ignition System e Set the hand tester to the x 10 range and connect it to the terminals Special Tool Hand Tester 57001 1394 x
115. 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 3 28 FUEL SYSTEM DFI Troubleshooting the DFI System Sample Diagnosis Sheet Registration No license plate No Year of initial registration Mode Engine Nos No Date problem occurred Mileage Environment when problem occurred Weather fine CJ cloudy rain snow O always O other Temperature hot warm cold O cold O always O other Problem O chronic often once frequency Road street O highway O mountain road O uphill C1 downhill 0 bumpy O pebble Altitude normal O high about 1 000 m or more Motorcycle conditions when problem occurred Fl indicator O lights up immediately after ignition switch ON and goes off after 1 2 seconds light LED normal O lights up immediately after ignition switch ON and stays on DFI problem L1 lights up immediately after ignition switch ON and blinks immobilizer system problem O lights up immediately after ignition switch ON but goes off after about 10 seconds DFI problem
116. its press ing depth GM07030BS1 Special Tools Bearing Driver Set 57001 1129 Needle Bearing Driver 17 18 57001 1609 Spacer 18 57001 1636 NOTE Olnstall the needle bearings so that the marked side faces out Needle Bearing A Oil Seals B Front C Right Side D Left Side E Rear Shock Absorber F Tie Rods G Rocker Arm H 7 5 mm 0 30 in I 5 0 mm 0 20 in J 5 5 mm 0 22 in K GM070658W2 C SUSPENSION 13 31 Rocker Arm Rocker Arm Tie Rod Bearing Sleeve Inspection CAUTION Do not remove the bearings for inspection Re moval may damage them e Visually inspect the rocker arm or tie rod sleeves A and needle bearings B e The rollers in a needle bearing normally wear very little and wear is difficult to measure Instead of measuring inspect the bearing for abrasion color change or other damage xIf there is any doubt as to the condition of any of the needle bearings or sleeve replace the sleeve and nee dle bearings as a set Rocker Arm Tie Rod Bearing Lubrication NOTE OSince the bearings are packed with grease lubrication is not required STEERING 14 1 Steering Table of Contents Exploded Vie Wisiri roneo te er dev pe 14 2 Special TOONS 14 4 SteenIng T serti 14 5 Steering Ins pecllQDis
117. key and turn ON within 15 seconds after pre vious key is turned off and removed otherwise registra 0 5second 0 5second tion mode will be ended and the warning indicator light LED goes off QN OTo return to the registration mode start the master key 2930376861 verification procedure This applies to all user key reg istration e Insert the user key 1 to the ignition switch and turn it ON NOTE OKeep the other user keys away from the immobilizer antenna olf there is any problem in the registration the warning indicator light LED A blinks to display the collation error Immobilizer Amplifier Failure 0 2second GP30374BS1 When Registered User Key is Inserted 0 5second 0 5second A 0f GP30376BS1 C 16 94 ELECTRICAL SYSTEM Immobilizer System Equipped Models User Key Collation Error 0 3second QOO UA GP30373BS1 e The user key 1 is registered in the ECU OThe warning indicator light LED A blinks 2 times and stops for 1 second and then repeats this cycle to indicate successful registration of user key A Bh Uuo mmo GP30372BS1 e Turn off and remove the user key 1 OThe warning indicator light LED A blinks to display the registration mode codes NOTE Olnsert next key and turn ON within 15 seconds after pre viou
118. lever and the pads are against the disc The brake will not function on the first application of the lever if this is not done Rear Brake Pad Removal Remove the caliper with the hose installed e Remove Clip A Pad Pin B Brake Pads C 12 14 BRAKES Brake Pads Rear Brake Pad Installation e Push the caliper piston in by hand as far as it will go e Install the pad spring in place e Install the piston side pad A first and then another pad OFit the projections B of the pad into the recess C of the caliper holder e Install the pad pin and clip The clip must be outside of the pads e Install the caliper see Caliper Installation A WARNING Do not attempt to drive the motorcycle until a full brake pedal is obtained by pumping the brake pedal until the pads are against the disc The brake will not function on the first application of the pedal if this is not done Brake Pad Wear Inspection e Refer to the Brake Pad Wear Inspection in the Periodic Maintenance chapter 4068137 P BRAKES 12 15 Master Cylinder Front Master Cylinder Removal Remove the reservoir bracket nut A e Remove the banjo bolt A to disconnect the brake hose from the master cylinder see Brake Hose stallation in this chapter Unscrew the clamp bolts and take off the master cylin der C as an assembly with the reservoir brake lever and brake switch inst
119. low one direction and more than ten times as much in the other direction If any diode shows low or high in both directions the diode is defective and the relay box must be replaced NOTE OThe actual meter reading varies with the meter or tester used and the individual diodes but generally speaking the lower reading should be from zero to one half the scale Tester Connection 16 112 ELECTRICAL SYSTEM Relay Box Relay Box Internal Circuit 090902030 PONDO 6 19010 2 C Headlight Relay B ECU Main Relay Fuel Pump Relay D Starter Circuit Relay E Fan Relay ELECTRICAL SYSTEM 16 113 Fuse 30 A Main Fuse Removal e Remove Front Seat see Front Seat Removal in the Frame chap ter Pull out the starter relay e Remove 30 A Main Fuse Connector A Pull out the main fuse B from the starter relay with needle nose pliers Fuse Box Fuse Removal Remove the right upper inner cover see Inner Cover Re moval in the Frame chapter e Push the hook A to lift up the lid B e Pull the fuses A straight out of the fuse box with needle nose pliers 10 A ECU Fuse Removal e Remove Right Upper Inner Cover see Rear Seat Removal in the Frame chapter Pull the hook A to lift up the lid 16 114 ELECTRICAL SYSTEM Fuse e Pull the ECU fuse A straight out of the fuse box with needle nose pliers Fuse Installation e f a fuse fails during oper
120. main throttle sensor connector and con nect the harness adapter A between the harness con nector and main throttle sensor connector e Connect a digital meter B to the harness adapter leads Special Tool Throttle Sensor Setting Adapter 57001 1538 Main Throttle Sensor Output Voltage Connections to Sensor Meter Y W lead Meter BR BK lead e Measure the sensor output voltage with the engine stopped and with the connector joined e Turn the ignition switch ON e Measure the output voltage when the throttle is fully opened or completely closed Output Voltage at Sensor Standard DC 1 025 1 055 V at idle throttle opening Approximately DC 4 22 4 42 V full throttle opening CAUTION Do not remove or adjust the main throttle sensor It has been adjusted and set with precision at the factory e After throttle sensor voltage inspection remove the har ness adapter xIf the reading is out of the standard range inspect the throttle sensor resistance x If the output voltage is normal check the wiring for conti nuity see next diagram Main Throttle Sensor Resistance Inspection e Turn the ignition switch OFF e Disconnect the main throttle sensor connector e Connect a digital meter A to the main throttle sensor connector B e Measure the main throttle sensor resistance Main Throttle Sensor Resistance Connections BL lead C BR BK lead D Standard Approximate
121. mark CAUTION If the connecting rods big end bearing inserts or crankshaft are replaced with new ones select the bearing insert and check clearance with a plasti gage press gauge before assembling engine to be sure the correct bearing inserts are installed e Apply molybdenum disulfide oil solution to the inner sur face of the upper and lower bearing inserts A e Apply molybdenum disulfide oil solution to the threads B and seating surface C of the connecting rod nuts e Install the inserts so that their nails D are on the same side and fit them into the recess of the connecting rod and cap CAUTION Wrong application of oil and grease could cause bearing damage 6105060181 C eO 6105037851 CRANKSHAFT TRANSMISSION 9 19 Crankshaft and Connecting Rods OWhen installing the inserts A be careful not to damage the insert surface with the edge of the connecting rod B or the cap C One way to install inserts is as follows Installation D to Cap Installation E to Connecting Rod Push F Spare Dowel Pin G Connecting Rod Bolts H e Remove debris and clean the surface of inserts e Install the pistons see Piston Installation e Install each connecting rod on its original position e Install the crankshaft see Crankshaft Installation e Install the cap on the connecting rod aligning the weight and diameter marks OThe connecting rod
122. new spark plug in the plug hole and finger tighten it first e Using the plug wrench A vertically tighten the plug CAUTION The insulator of the spark plug may break if when the wrench is inclined during tightening Torque Spark Plugs 13 N m 1 3 kgf m 113 in Ib e Install the stick coils securely OBe sure the stick coils are installed by pulling up it lightly 65128527 FUEL SYSTEM 3 1 Fuel System DFI Table of Contents Exploded Specifications Special Tools and Sealant DFI Parts Location DFI System DFI Servicing Precautions Troubleshooting the DFI System Oute aint tes Inquiries to Rider DFI System Troubleshooting Guide Self Diagnosis Self diagnosis Outline Self diagnosis Procedures Service Code Reading Service Code Erasing Backups sess Main Throttle Sensor Service Code Main Throttle Sensor Removal Adjustment Main Throttle Sensor Input Voltage Inspection Main Throttle Sensor Output Voltage Inspection Main Throttle Sensor Resistance Inlet Air Pres
123. not to have it touch your skin or eyes If touched wash it off with liberal amount of water Get medial attention if severe Interchange A sealed battery can fully display its performance only when combined with a proper vehicle electric system Therefore replace a sealed battery only on a motorcycle which was originally equipped with a sealed battery Be careful if a sealed battery is installed on a motorcycle which had an ordinary battery as original equipment the sealed battery s life will be shortened 16 26 ELECTRICAL SYSTEM Battery Charging Condition Inspection OBattery charging condition can be checked by measuring battery terminal voltage with a digital voltmeter A e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Battery Cable Caps see Battery Removal in this chap ter e Disconnect the battery terminals CAUTION Be sure to disconnect the negative cable first e Measure the battery terminal voltage NOTE OMeasure with a digital voltmeter which can be read one decimal place voltage xIf the reading is 12 8 V or more no refresh charge is re quired however if the read is below the specified refresh charge is required Battery Terminal Voltage Standard 12 8 V or more Terminal Voltage V A Battery Charge Rate 96 B Good C Refresh charge is required D Refreshing Charge e Remove the battery A see Battery Removal in this chap
124. part of any key Do not drop the key and or apply any shocks to the key When a user key is lost the user should go to his dealer to invalidate the lost key registration in the electronic control unit ECU 10 When the master key is lost the user should go to his dealer and have a new ECU installed and register a new master key and user keys coc o Ord eor NOTE ONo 9 and 10 are strongly recommended to the customer to ensure security of the motorcycle Key Registration Case 1 When the user key has been lost or additional spare user key is required e Prepare a new spare user key e Cut the key in accordance with the shape of the current user key e Remove Front Seat see Front Seat Removal in the Frame chap ter e Disconnect the immobilizer Kawasaki self diagnosis sys tem connector A e Connect the key registration unit A Special Tool Key Registration Unit 57001 1582 ELECTRICAL SYSTEM 16 83 Immobilizer System Equipped Models e Insert the master key to the ignition switch and turn it ON Verified OThe warning indicator light LED A blinks to display the registration mode go to the next step 0 5second 0 5second A 8 a aE SES GP30376BS1 C Not Verified OThe Warning indicator light LED A blinks to display the collation error refer to the following failure illustrations Immobilizer Amplifier Failure 0 2second
125. plugs A so that its surface is flush with the end of the hole e Install the oil nozzles A in the upper crankcase tighten them Torque Oil Nozzles 2 9 N m 0 30 kgf m 26 in Ib e Install Position Ring B Ball Bearing C e Press and insert the race A in the lower crankcase B so that the big stepped side faces to inside of the crankcase until it is bottomed e Install the race holder C as shown in the figure e Apply a non permanent locking agent to the race holder screw D e Tighten Torque Race Holder Screw 4 9 0 50 kgf m 43 in Ib 9104283851 CRANKSHAFT TRANSMISSION 9 13 Crankcase Splitting e Press and insert the new needle bearing A for the shift shaft so that its marked side faces outside B and its sur face C is flush with the end of the hole e Install the new oil seal D so that its surface E is flush with the end of the hole e Apply grease to the lips of the oil seal yi 9104284851 Install the oil passage nozzle the lower crankcase and tighten it Torque Oil Passage Nozzle 4 9 N m 0 50 kgf m 43 in Ib 9104279851 Install Crankshaft Connecting Rods Camshaft Chain Dowel Pins B O rings C e Before fitting the lower case on the upper case check the following OBe sure to hang the camshaft chain on the crankshaft 9 14 CRANKSHAFT TRANSMISSION Crankcase
126. rm Al CLE 313 Er cc quj 6809297085 C APPENDIX 17 13 Cable Wire and Hose Routing the crankshaft sensor oil pressure switch lead into the clamp as shown in the figure Crankshaft sensor oil pressure switch lead Run the crankshaft sensor oil pressure switch lead behind the water hose Clamp Run the oil pressure switch lead Crankshaft Sensor Lead Oil Pressure Switch Clamp Hold the alternator lead with delivery pipe Run the gear position switch sidestand switch lead into the clamp Run the alternator lead between water hose and engine Run the gear position switch sidestand switch lead between water hoses Clamp Hold the idle adjuster screw cable Clamp Hold the gear position switch lead and sidestand switch lead Gear position switch has no play in this area for preventing it from being caught in the drive chain 17 14 APPENDIX Cable Wire and Hose Routing mb gt N 409 AS ea 2 e a TIN A HEN MEI p 3 USE B aS TET iu 2 p 4 jg p D pd AN E H 72 35 7 p Jti di eS LX Gr mE N ee N 7 A V b CON Ti m Bi N EAA e LW SAC CAR e NC
127. start the engine and check that the clutch does not slip and that it releases properly xIf the clutch operation is insufficiency inspect the clutch system WARNING When inspecting by running the vehicle note a surrounding traffic situation enough in the place of safety PERIODIC MAINTENANCE 2 27 Maintenance Procedure Wheels Tires Air Pressure Inspection e Remove the air valve cap Measure the tire air pressure with an air pressure gauge A when the tires are cold that is when the motorcycle has not been ridden more than a mile during the past 3 hours x Adjust the tire air pressure according to the specifications if necessary Air Pressure when Cold Front Up to 180 kg 397 Ib 250 kPa 2 5 kgf cm 36 psi Rear Up to 180 kg 397 Ib 290 kPa 2 9 kgf cm 42 psi e Install the air valve cap Wheel Tire Damage Inspection e Remove any imbedded stones A or other foreign parti cles B from tread e Visually inspect the tire for cracks and cuts and replace the tire if necessary Swelling or high spots indicate inter nal damage requiring tire replacement e Visually inspect the wheel for cracks cuts and dents dam age xIf any damage is found replace the wheel if necessary Tire Tread Wear Inspection As the tire tread wears down the tire becomes more sus ceptible to puncture and failure An accepted estimate is that 90 of all tire failures occur during the last 1096 of tre
128. tenance chapter Coolant see Coolant Change in the Periodic Mainte nance chapter e Remove Middle Fairings see Middle Fairing Removal in the Frame chapter Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Air Cleaner Housing see Air Cleaner Housing Removal in the Fuel System DFI chapter Throttle Body Assy see Throttle Body Assy Removal in the Fuel System DFI chapter Clutch Cable Lower End see Clutch Cable Removal in the Clutch chapter Radiator see Radiator and Radiator Fan Removal in the Cooling System chapter Exhaust Pipe see Exhaust Pipe Removal in the Engine Top End chapter Shift Lever see Shift Pedal Removal in the Crank shaft Transmission chapter Drive Chain see Engine Sprocket Removal in the Final Drive chapter Coolant Reserve Tank see Coolant Reserve Tank Re moval in the Cooling System chapter e Remove the heat insulation plate A OPull out the right side of the plate to the inside of the frame 8 6 ENGINE REMOVAL INSTALLATION Engine Removal Installation ODisconnect the connectors from the engine and free the wiring from the clamps Stick Coil Connectors A Cylinder Head Cover Ground Terminal B Air Switching Valve Connector C Camshaft Position Sensor Connector D ODisconnect Alternator Lead Connector A Rear Brake Light Switch Connector B Gear Position Switch Side Stand Switch Lead Connec tor C Crankshaft Sensor Oil Pressure Switch Lead Connector D
129. the Frame chapter Raise the front wheel off the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Remove the axle nut and pull out the axle to the right and drop the front wheel out of the forks CAUTION Do not lay the wheel down on one of the discs This can damage or warp the disc Place blocks un der the wheel so that the disc does not touch the ground Front Wheel Installation NOTE OThe direction of the wheel rotation A is shown by an arrow B on the wheel spoke e Check the wheel rotation mark on the front wheel and install it 6J04053BS1 C WHEELS TIRES 10 7 Wheels Rims e Apply high temperature grease to the grease seal lip e Fit the collars A on the both sides of the hub OThe collars are identical e Insert the axle e Tighten the axle nut B Right Axle Clamp Bolts C Left Axle Clamp Bolts D Viewed from Rear E Torque Front Axle Nut 127 N m 13 kgf m 94 16 e Before tightening the axle clamp bolts on the right front fork leg pump the front fork up and down A 4 or 5 times to all on the right front fork leg to seat on the front axle NOTE OPut a block B in front of the front wheel to stop moving e Tighten the axle clamp bolts on the right fork leg first Next tighten the left axle clamp bolts Torque Front Axle Clamp Bolts 20 N m 2 0 kgf m 15 ft Ib NOTE OTighten the two clamp bolts alternately two times to en sure ev
130. the clamp to the heat insulation plate claw face direction outside of the frame Fan Motor Lead Clamp 17 4 APPENDIX Cable Wire and Hose Routing RS a f 2 20 l N 3 wn NM LS Xo alg A 2 P ENTR w gu Ne PY NO 20 AAN lesa 6 hy me NE Gill j m NI my J 2 Ryd pum d mm ate T H Ci hek LOA mi X 6809292085 C APPENDIX 17 5 Cable Wire and Hose Routing 5 Turn Signal Relay Clamp the harness do not touch the clamp and harness to the turn signal relay Clamp Fuse Box Clamp Replay Box Clamp Headlight Connector Low Clamp Run the low beam headlight lead and main harness City Light Lead Connector Clamp Run the high beam headlight lead position light lead and main harness Headlight Connector High Clamp Run the main harness Clamp Hold the subthrottle valve actuator lead and born lead Bracket Hold the camshaft position sensor lead connector Camshaft Position Sensor Connector Air Switching Valve Connector Clamp Hold the lead from the main harness Install the cylinder head cover ground lead direction left si
131. the connector to prevent short circuit between terminals e Make sure that measuring points are correct in the con nector noting the position of the lock D and the lead color before measurement Do not reverse connections of a digital meter e Be careful not to short circuit the leads of the DFI or elec trical system parts by contact between adapters e Turn the ignition switch ON and measure the voltage with the connector joined CAUTION Incorrect reverse connection or short circuit by needle adapters could damage the DFI or electrical system parts OAfter measurement remove the needle adapters and ap ply silicone sealant to the seals A of the connector B for waterproofing Sealant Kawasaki Bond Silicone Sealant 56019 120 e Always check battery condition before replacing the parts A fully charged battery is a must for conducting accurate tests of the DFI system e Trouble may 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 wires for signs of burning fraying short etc Deteriorated wires and bad connections can cause r
132. the engine prema turely or lower the engine performance e Install Hoses California Model Inlet Air Temperature Sensor see Inlet Air Temperature Sensor Installation in the Fuel System DFI chapter Inlet Air Pressure Sensor see Inlet Air Pressure Sensor Installation in the Fuel System DFI chapter Fuel Tank see Fuel Tank Installation in the Fuel System DFI chapter Fuel Hose Replacement e Set up the fuel tank see Air Cleaner Element Replace ment 2 48 PERIODIC MAINTENANCE Maintenance Procedure For Primary Fuel Hose e Be sure to place a piece of cloth A around the fuel hose joint e Insert the screw driver into the slot C of the joint lock e Pull the joint lock A as shown e Pull the fuel hose joint B out of the delivery pipe A WARNING Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is disconnected fuel spills out from the hose and the pipe Cover the hose connec tion with a clean shop towel to prevent fuel spillage NOTE ORemoving the hose joint of the fuel pump side is the same as for the throttle body assy side e Install the new fuel hose Pull A the joint lock B fully as shown e Insert the fuel hose joint A straight onto the delivery pipe until the hose joint clicks e Push B the joint lock C until the hose joint clicks PERIODIC MAINTENANCE 2 49 Maintenance Procedure For
133. the hoses from the canister OVisually inspect the canister for cracks or other damage x If the canister has any cracks or bad damage replace it with a new one NOTE OThe canister is designed to work well through the motor cycle s life without any maintenance if it is used under normal conditions 2 20 PERIODIC MAINTENANCE Maintenance Procedure e Check the liquid vapor separator as follows ORemove Left Middle Fairing see Middle Fairing Removal in the Frame chapter ODisconnect the hoses from the separator and remove the separator A from the motorcycle left side OVisually inspect the separator for cracks and other dam age x If the separator has any cracks or damage replace it with a new one OTo prevent the gasoline from flowing into or out of the canister hold the separator perpendicular to the ground e Check the hoses of the evaporative emission control sys tem as follows OCheck that the hoses are securely connected and clips are in position OReplace any kinked deteriorated or damaged hoses ORoute the hoses according to Cable Wire and Hose Routing section in the Appendix chapter OWhen installing the hoses avoid sharp bending kinking flattening or twisting and route the hoses with a minimum of bending so that the emission flow will not be obstructed Engine Top End Valve Clearance Inspection NOTE OValve clearance must be checked and adjusted when the engine is cold at room tem
134. the left wheel alignment indicator F should align with the same swingarm mark or position G that the right indicator notch aligns with A WARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition e Tighten both chain adjuster locknuts securely e Tighten the axle nut Torque Rear Axle Nut 127 N m 13 kgf m 94 ft Ib e Turn the wheel measure the chain slack again at the tight est position and readjust if necessary e Insert a new cotter pin into the axle and bend its end se curely e Insert a new cotter pin A NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle tighten the nut clockwise B up to next alignment Olt should be within 30 degree OLoosen once and tighten again when the slot goes past the nearest hole e Bend the cotter pin A over the nut 1 07000851 GK04001BS1 C PERIODIC MAINTENANCE 2 31 Maintenance Procedure Wheel Alignment Inspection e Check that the notch A on the left alignment indicator B aligns with the same swingarm mark or position C that the right alignment indicator notch aligns with x If they do not adjust the chain slack and align the wheel alignment see Drive Chain Slack Adjustment NOTE OWheel alignment can be also checked using the straightedge or string method A WARNING Misalignment of the wheel will resu
135. the type of charger used Let battery sit 30 minutes after initial charge then check voltage using a voltmeter If it is not at least 12 8 V repeat charging cycle e After charging is completed press down firmly with both hands to seat the strip of caps A into the battery don t pound or hammer When properly installed the strip of the caps will be level with the top of the battery Eee EN CAUTION Once the strip of the caps A is installed onto the battery never remove the caps nor add water or electrolyte to the battery GPOS012BS1 C 8 08010851 C ELECTRICAL SYSTEM 16 25 Battery NOTE ensure maximum battery life and customer satisfac tion it is recommended the battery be load tested at three times its amp hour rating for 15 seconds Re check voltage and if less than 12 8 V repeat the charging cycle and load test If still below 12 8 V the battery is defective Precautions 1 No need of topping up No topping up is necessary in this battery until it ends its life under normal use Forcibly prying off the seal cap to add water is very dangerous Never do that 2 Refreshing charge If an engine will not start a horn sounds weak or lamps are dim it indicates the battery has been discharged Give refresh charge for 5 to 10 hours with charge current shown in the specification see Specifications in this chapter When a fast charge is inevitably required do it fol
136. this section any one vacuum measurement is out of the standard measurement after left and right synchronization turn in the bypass screws A until it seats fully but not tightly Rear View B Special Tool Pilot Screw Adjuster A C 57001 1239 CAUTION Do not over tighten them They could be damaged requiring replacement e Turn out the bypass screw of the higher vacuum between 1 and 2 to the lower vacuum e Turn out the bypass screw of the higher vacuum between 3 and 4 to the lower vacuum e Open and close the throttle valves after each measure ment and adjust the idle speed as necessary e Inspect the vacuums as before If all vacuums are within the specification finish the en gine vacuum synchronization x If any vacuum can not be adjusted within the specification 2805131861 C remove the bypass screws 1 4 and clean them 2 18 PERIODIC MAINTENANCE Maintenance Procedure eRemove the bypass screw Al spring B washer C and O ring D OCheck the bypass screw and its hole for carbon deposits x If any carbon accumulates wipe the carbon off the bypass screw and the hole using a cotton pad penetrated with a high flash point solvent OReplace the O ring with a new one OCheck the tapered portion E of the bypass screw for wear or damage x If the bypass screw is worn or damaged replace it Turn in the bypass screw until it seats fully but not tightly e R
137. throttle cable slack e Remove Bolt A Holding Plate B Throttle Cables C e After removing the throttle body assy stuff pieces of lint free clean cloths into the throttle body holders CAUTION If dirt gets into the engine excessive engine wear and possible engine damage will occur Throttle Body Assy Installation e Install the holder clamp bolts in the direction as shown Heat Insulation Rubber Plate A Bolt Heads B OPut the hole C of the clamp on the projection D of the holder e Install the lower ends of the throttle cables in the throttle body assy e Apply a non permanent locking agent Torque Throttle Cable Holder Plate Bolt 3 9 N m 0 40 kgf m 35 CAUTION When installing the throttle body assy put the main throttle valves in the throttle bore be careful to damage to valves e Tighten Torque Throttle Body Assembly Holder Clamp Bolts 3 0 N m 0 30 kgf m 27 in Ib e Install the removed connectors e Run the vacuum hoses as shown in the Cable Wire and Hose Routing section in the Appendix chapter e When installing the fuel hose refer to Fuel Tank Installa tion in this chapter 6617916651 C FUEL SYSTEM 3 119 Throttle Body Assy e Adjust Throttle Grip Free Play see Throttle Control System In spection in the Periodic Maintenance chapter Idle Speed see Idle Speed Adjustment in the Periodic Maintenance chapter
138. to the slot C of delivery pipe 6617921651 C e Apply engine oil to the new dust seals A e Insert the delivery pipe assy in the stay plate 80179230651 e Tighten the screws A Torque Delivery Pipe Mounting Screws 3 4 N m 0 35 kgf m 30 in Ib 80179220651 e Apply engine oil to the new O ring A Tighten Torque Fuel Hose Mounting Screw B 4 9 N m 0 50 kgf m 43 e Check the injector fuel line for leakage see Injector Fuel Line Inspection GC17746BS1 3 124 FUEL SYSTEM Air Cleaner Air Cleaner Element Removal e Refer to the Air Cleaner Element Replacement in the Pe riodic Maintenance chapter see Air Cleaner Element Re placement in the Periodic Maintenance chapter Air Cleaner Element Installation e Refer to the Air Cleaner Element Replacement in the Pe riodic Maintenance chapter see Air Cleaner Element Re placement in the Periodic Maintenance chapter Air Cleaner Element Inspection e Remove the air cleaner element see Air Cleaner Element Replacement in the Periodic Maintenance chapter e Visually check the element A for tears or breaks xIf the element has any tears or breaks replace the ele ment Air Cleaner Housing Removal e Remove the front side bolt of the fuel tank e Set up the fuel tank A using the suitable tool or bar A OPosition the steering straight e Remove Hose Joint see Nozzle Assy Remova
139. two clamp bolts alternately two times to ensure even tightening torque G Apply grease to the threads L Apply a non permanent locking agent to the threads MO Apply molybdenum disulfide grease oil solution R Replacement Parts S Follow the specified tightening sequence SI Apply silicone grease SS Apply silicone sealant Torque Fastener Nam kgfm ftlb Remarks Fuel System Air Cleaner Housing Screws 1 1 0 11 9 7 in lb Air Cleaner Housing Clamp Bolts 2 0 0 20 17 in lb Air Cleaner Housing Mounting Bolt 6 9 0 70 61 in lb Air Inlet Duct Mounting Bolts 9 8 1 0 87 6 L Camshaft Position Sensor Bolt 9 8 1 0 87 in lb Crankshaft Sensor Bolts 5 9 0 60 52 in lb Delivery Pipe Mounting Screws Nozzle Assy 3 4 0 35 30 6 Delivery Pipe Mounting Screws Throttle Body 3 4 0 35 30 in lb Exhaust Butterfly Valve Actuator Mounting Bolts 6 9 0 70 61 in lb Exhaust Butterfly Valve Actuator Pulley Bolt 4 9 0 50 43 in lb Fuel Pump Bolts 9 8 1 0 87 in lb L S Nozzle Assy Mounting Bolts 6 9 0 70 61 in lb Nozzle Assy Fuel Hose Screw 4 9 0 50 43 in lb Separator Bracket Mounting Bolt 0 8 0 08 7 in lb Throttle Body Assembly Holder Clamp Bolts 3 0 0 30 27 in lb Throttle Body Holder Bolts 12 1 2 106 L Throttle Cable Holder Plate Bolt 3 9 0 40 35 in lb L Vehicle down Sensor Bolts 2 9 0 60 52 in lb Water Temperature Sensor 25 2 5 18 SS Cooling System Coolant By pass Fitting Bolt 8 8 0 90 78 in lb L Coolant Drain Bolt Cylinder
140. upper and lower level lines 96 126 kPa 0 98 1 28 kgf cm 14 18 psi at 4 000 r min rpm Oil Temperature 90 C 194 F ENGINE LUBRICATION SYSTEM 7 5 Special Tools and Sealant Outside Circlip Pliers Oil Pressure Gauge Adapter PT3 8 57001 144 57001 1233 7570144ST C 875712335 6 Oil Pressure Gauge 10 kgf cm Kawasaki Bond Silicone Sealant 57001 164 56019 120 7570164ST C 875601205 C 7 6 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart 011 Cooler AN d MAS 5 A JU LA AUN Ve Y ARS WANN gt A 2 b c NM au s NES 41 amp 0 Qu ANS AO IZ Q0 Ne Am Camshaft 011 Passage Exhaust Camshaft Camshaft 65041058 5 ENGINE LUBRICATION SYSTEM 7 7 Engine Oil Flow Chart lt Blowby Gas 7 8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter A WARNING Motorcycle operation with insufficient deteri orated or contaminated engine oil will cause accelerated wear and may result in engine or trans mission seizure accident and injury Oil Level Inspection e Check that the engine oil level is between the upper A and lower B levels in the gauge NOTE OSituate the motorcycle so that it is perpendicular to the ground Olf the motorcycle has just been used wait several min utes for all the oil to drain down Olf the oil has just been change
141. while inflating the tire e Center the rim in the tire beads and inflate the tire with compressed air until the tire beads seat in the sealing surfaces 6J05044BS1 C A WARNING Be sure to install the valve core whenever inflating the tire and do not inflate the tire to more than 400 kPa 4 0 kgf cm 57 psi Overinflation can explode the tire with possibility of injury and loss of life WHEELS TIRES 10 15 Tires e Check to see that the rim lines A on both sides of the tire sidewalls are parallel with the rim flanges x If the rim flanges and tire sidewall rim lines are not parallel remove the valve core e Lubricate the rim flanges and tire beads e Install the valve core and inflate the tire again e After the tire beads seat in the rim flanges check for air leakage Olnflate the tire slightly above standard inflation OUse a soap and water solution or submerge the tire and check for bubbles that would indicate leakage e Adjust the air pressure to the specified pressure see Air Pressure Inspection in the Periodic Maintenance chap ter e Install the air valve cap e Adjust the wheel balance see Balance Adjustment in this chapter Tire Repair Currently two types of repair for tubeless tires have come into wide use One type is called a temporary external re pair which can be carried out without removing the tire from the rim and the other type is called permanent internal repair wh
142. 0 87 Starter Clutch Bolt Cap Hand tighten Timing Inspection Cap Hand tighten The table below relating tightening torque to thread diameter lists the basic torque for the bolts and nuts Use this table for only the bolts and nuts which do not require a specific torque value All of the values are for use with dry solvent cleaned threads Basic Torque for General Fasteners Threads Diameter mm 5 3 4 4 9 0 35 0 50 30 43 in lb 6 5 9 7 8 0 60 0 80 52 69 in lb 8 14 19 1 4 1 9 10 13 5 10 25 34 2 6 3 5 19 25 12 44 61 4 5 62 33 45 14 73 98 7 4 10 0 54 72 16 115 155 11 5 16 0 83 115 18 165 225 17 0 23 0 125 165 20 225 325 23 0 33 0 165 240 2 12 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Fuel System DFI Throttle Grip Free Play Idle Speed Throttle Body Vacuum Air Cleaner Element 2 3mm 0 08 0 12 in 1 300 x50 r min rpm 27 3 1 333 kPa 205 10 mmHg at idle speed Viscous paper element Cooling System Coolant Type Recommended Color Mixed Ratio Freezing Point Total Amount Engine Top End Valve Clearance Exhaust Inlet Clutch Clutch Lever Free Play Engine Lubrication System Engine Oil Type Viscosity Capacity Wheels Tires Tread Depth Front Rear Air Pressure when Cold Front Rear Permanent type antifreeze Green Soft water 5096 coolant 50
143. 0BS1 C BRAKES 12 1 Brakes Table of Contents Exploded AUI 12 2 daveadacdaduagieuasadeneadvenddiaasaedetiaceineds 12 6 jer 12 7 Brake Lever Brake Pedal EUIS 12 8 Brake Lever Position Adjustment oc 12 8 Brake Pedal Position Inspection 12 8 Brake Pedal Position Adjustment pp 12 8 Brake Pedal Removal pp 12 8 Brake Pedal Installation 12 9 12 10 Front Caliper REMOVAl etr tte eire eee een denne terat eere Eee e ud enu D e ten 12 10 Rear Caliper Removal 12 10 Caliper Installation ottenere teen pen Er Pe EEG bete oes 12 10 Front Caliper Disassembly 12 11 Front Caliper Assemlbly rs ba e Ite deo Me de er 12 11 Rear Caliper Disassembly sacer eap ter a eap gate tool e Me 12 11 Rear Caliper Assembly tert oth e erento orte ere SELL e scl ERR AME 12 11 CaliperFluid seal tenet tuto Poi atus 12 11 Rear Caliper Dust Boot and Friction Boot
144. 1 GE15012281 5 32 ENGINE TOP END Valves xIf the seat width is too wide make the 60 A grind de scribed below x If the seat width is within the specified range lap the valve to the seat as described below e Grind the seat at a 60 angle until the seat width is within the specified range OTo make the 60 grind fit 60 cutter into the holder and slide it into the valve guide OTurn the holder while pressing down lightly OAfter making the 60 grind return to the seat width mea surement step above Correct Width B e Lap the valve to the valve seat once the seat width and outside diameter are within the ranges specified above OPut a little coarse grinding compound on the face of the valve in a number of places around the valve head OSpin the valve against the seat until the grinding com pound produces a smooth matched surface on both the seat and the valve ORepeat the process with a fine grinding compound Lapper A Valve Seat B Valve C e The seating area should be marked about in the middle of the valve face x If the seat area is not in the right place on the valve check to be sure the valve is the correct part If it is it may have been refaced too much replace it e Be sure to remove all grinding compound before assem bly e When the engine is assembled be sure to adjust the valve clearance see Valve Clearance Inspection in the Periodic Maintenance
145. 139 0166 Blue 92139 0165 Crankcase Main Crankshaft Main Bearing Insert Bearing Inside Journal Diameter Diameter Marking Marking Size Color Part Number Journal Nos 92139 0173 5 92139 0191 1 2 3 4 92139 0172 5 92139 0190 1 2 3 4 92139 0171 5 N N BI d idi i 92139 0189 1 2 3 4 The bearing inserts for Nos 1 2 and 4 journals oil groove respectively Crankshaft Main Bearing Insert Selection Engine No ZX600PE008561 Crankcase Main Crankshaft Main Bearing Insert Bearing Inside Journal Diameter Diameter Marking Marking Size Color Part Number Journal Nos 92139 0173 3 9 92139 0191 1 2 4 92139 0172 3 5 92139 0190 1 2 4 92139 0171 3 5 N N BI T SR m 92139 0189 1 2 4 The bearing inserts for Nos 1 2 and 4 journals have an oil groove respectively CRANKSHAFT TRANSMISSION 9 9 Special Tools and Sealant Outside Circlip Pliers Grip 57001 144 57001 1591 4 7570144ST C 7571591ST C Piston Pin Puller Assembly Rotor Holder 57001 910 57001 1666 8888 8 5716665 875709105 C Piston Ring Compressor Grip Stopper 57001 1095 57001 1679 ST571095ST C 875716795 6 Piston Ring Compressor Belt 67 79 Kawasaki Bond Silicone Sealant 57001 1097 92104 0004 7571097ST C 879200045 Bearing Driver Set Kawasaki Bond 57001 1129 92104 1064 7571129ST
146. 2 52 PERIODIC MAINTENANCE Maintenance Procedure Radiator Hose and O ring Replacement e Drain the coolant see Coolant Change e Remove Middle Fairings see Middle Fairing Removal in the Frame chapter Throttle Body Assy see Throttle Body Assy Removal in the Fuel System DFI chapter Thermostat Housing Cover A see Thermostat Re moval in the Cooling System chapter Fitting B Hoses C O rings D e Apply grease to the new O rings and install them e Install the new hoses and tighten the clamps securely e Tighten Torque Water Hose Clamp Screws 2 0 N m 0 20 kgf m 17 in lb e Install the removed parts e Fill the coolant see Coolant Change e Install the hose correctly see Cable Wire and Hose Routing in the Appendix chapter e Check the cooling system for leaks GS06037BW3 C PERIODIC MAINTENANCE 2 53 Maintenance Procedure Engine Oil Change Remove the left lower fairing see Lower Fairing Removal in the Frame chapter e Situate the motorcycle so that it is vertical after warming up the engine Remove the engine oil drain bolt A to drain the oil OThe oil in the oil filter can be drained by removing the filter see Oil Filter Replacement Replace the drain bolt gasket with a new one Tighten the drain bolt 65070148 Torque Engine Oil Drain Bolt 29 N m 3 0 kgf m 22 ft lb Pour in the specified type and amount of oil Recommended Engine Oil
147. 2 PERIODIC MAINTENANCE Maintenance Procedure Chain Guide Wear Inspection e Remove Swingarm see Swingarm Removal in the Suspension chapter e Visually inspect the chain guide A x Replace the chain guide if it shows any signs of abnormal wear or damage Brake System Brake Fluid Leak Brake Hose and Pipe Inspection e Apply the brake lever or pedal and inspect the brake fluid leak from the brake hoses A and fittings xIf the brake fluid leaked from any position inspect or re place the problem part Brake Hose Damage and Installation Condition Inspection Inspect the brake hoses and fittings for deterioration cracks and signs of leakage OThe high pressure inside the brake line can cause fluid to leak A or the hose to burst if the line is not properly main tained Bend and twist the rubber hose while examining it Replace the hose if any crack B bulge C or leakage is noticed Tighten any brake hose banjo bolts Torque Brake Hose Banjo Bolts 25 2 5 kgf m 18 ft lb e Inspect the brake hose routing If any brake hose routing is incorrect route the brake hose according to Cable Wire and Hose Routing section in the Appendix chapter 6508004851 C PERIODIC MAINTENANCE 2 33 Maintenance Procedure Brake Operation Inspection e Inspect the operation of the front and rear brake by run ning the vehicle on the dry road xIf the brake operation is insufficiency
148. 20188 5 GENERAL INFORMATION 1 5 Before Servicing Press For items such as bearings or oil seals that must be r pressed into place apply small amount of oil to the con D uua tact area Be sure to maintain proper alignment and use dai d smooth movements when installing gt GB020178 Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is N absolutely necessary Replace with new ones whenever m removed Press bearings with the manufacturer and size MI marks facing out Press the bearing into place by putting RSs pressure on the correct bearing race as shown 2 B Bh B Pressing the incorrect race can cause pressure between Ic 5 A the inner and outer race and result in bearing damage 77 orem 68020188 5 Oil Seal Grease Seal Do not remove pressed oil or grease seals unless removal is necessary Replace with new ones whenever removed H L Press new oil seals with manufacture size marks facing out Make sure the seal is aligned properly when installing NS V 2 68020198 5 specified grease to the lip of seal before installing the seal Grease GBO2046BS1 Circlips Cotter Pins Replace the circlips or cotter pins that were removed with new ones Take care not to open the clip excessively when installing to prevent deformation 68020268 5 1 6 GENERAL INFORMATION
149. 2180 0114 145 1 475 92180 0115 148 1 500 92180 0116 150 1 525 92180 0117 152 1 550 92180 0118 155 1 575 92180 0119 158 1 600 92180 0120 160 1 625 92180 0121 162 1 650 92180 0122 165 1 675 92180 0123 168 1 700 92180 0124 170 1 725 92180 0125 172 1 750 92180 0126 175 1 775 92180 0127 178 1 800 92180 0128 180 1 825 92180 0129 182 1 850 92180 0130 185 1 875 92180 0131 188 1 900 92180 0132 190 1 925 92180 0133 192 1 950 92180 0134 195 1 975 92180 0135 198 2 000 92180 0136 200 2 025 92180 0137 202 2 050 92180 0138 205 2 075 92180 0139 208 2 100 92180 0140 210 2 125 92180 0141 212 2 150 92180 0142 215 2 175 92180 0143 218 2 200 92180 0144 220 2 225 92180 0145 222 2 250 92180 0146 225 2 275 92180 0147 228 2 300 92180 0148 230 2 24 PERIODIC MAINTENANCE Maintenance Procedure CAUTION Be sure to remeasure the clearance after selecting a shim The clearance 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 e When installing the shim face the marked side toward the valve lifter At this time apply engine oil to the shim or the valve lifter to keep the shim in place during camshaft installation CAUTION Do not put shim stock under the shim This may cause the shim to pop out at high rpm causing ex tensive engine damage Do not grind the shim This may cause it to fra
150. 23158W2 C ELECTRICAL SYSTEM 16 61 Air Switching Valve Air Switching Valve Operation Test e Refer to the Air Suction System Damage Inspection in the Periodic Maintenance chapter see Air Suction System Damage Inspection in the Periodic Maintenance chapter Air Switching Valve Unit Test Remove the air switching valve see Air Switching Valve Removal in the Engine Top End chapter Set the hand tester A to the x range and connect it to the air switching valve terminals as shown Special Tool Hand Tester 57001 1394 Air Switching Valve Resistance Standard 18 22 at 20 C 68 F x If the tester does not read as specified value replace it with a new one GEO4030BS1 C Connect the 12 V battery A to the air switching valve terminals as shown GE04033BS1 C e Blow the air to the inlet air duct A and make sure does not flow the blown air from the outlet air ducts B GE04031BS1 C e Disconnect the 12 V battery e Blow the air to the inlet air duct A again and make sure flow the blown air from the outlet air ducts B xIf the air switching valve dose not operate as described replace it with a new one NOTE OTo check air flow through the air switching valve just E blow through the air switching valve hose inlet side SES C 604032851 16 62 ELECTRICAL SYSTEM Radiator Fan System Fan Motor Inspection e Remove
151. 2992 1 2998 in Marking None 33 000 33 008 mm 1 2992 1 2995 in 33 009 33 016 mm 1 2996 1 2998 in Connecting Rod Big End Bearing Insert Thickness Brown 1 475 1 480 mm 0 05807 0 05827 in Black 1 480 1 485 mm 0 05827 0 05846 in Blue 1 485 1 490 mm 0 05846 0 05866 in Connecting Rod Bolt Stretch Usable Range 0 28 0 38 mm 0 0110 0 0150 in Crankshaft Side Clearance 0 05 0 25 mm 0 45 mm 0 0020 0 0098 in 0 0177 in Crankshaft Runout TIR 0 02 mm 0 0008 in or less TIR 0 05 mm 0 0020 in Crankshaft Main Bearing 0 028 0 060 mm 0 09 mm Insert Journal Clearance 0 0011 0 0024 in 0 0035 in Crankshaft Main Journal Diameter 30 984 31 000 mm 30 96 mm 1 2198 1 2205 in 1 2189 in Marking None 30 984 30 992 mm 1 2198 1 2202 in 30 993 31 000 mm 1 2202 1 2205 in CRANKSHAFT TRANSMISSION 9 7 Specifications Item Standard Service Limit Crankcase Main Bearing Inside Diameter Marking Crankshaft Main Bearing Insert Thickness Brown Black Blue 34 000 34 016 mm 1 3386 1 3392 in 34 000 34 008 mm 1 3386 1 3389 in 34 009 34 016 mm 1 3390 1 3392 in 1 491 1 495 mm 0 0587 0 0589 in 1 495 1 499 mm 0 0589 0 0590 in 1 499 1 503 mm 0 0590 0 0592 in Cylinder Piston Cylinder Upper
152. 3BS1 C e Turn off and remove the new user key 1 e Temporarily place the antenna A on the new ignition switch B e Insert the user key 1 C again into the new ignition switch and turn it ON NOTE OPlace the antenna on the ignition switch insert the next key and turn ON within 15 seconds after previous key is turned off and removed otherwise registration mode will be ended and the warning indicator light LED stops flashing OTo return to the registration mode start the master key verification procedure This applies to all user key reg istration OKeep other user keys away from the immobilizer an tenna 16 90 ELECTRICAL SYSTEM Immobilizer System Equipped Models Olf there is any problem in the registration the warning indicator light LED A blinks to display the collation error Immobilizer Amplifier Failure 0 2second GP30374BS1 C When Registered User Key is Inserted 0 5second 0 5second USE GP30376BS1 User Key Collation Error 0 3second GO e UL GP30373BS1 e The user key 1 is successfully registered in the ECU OThe warning indicator light LED A blinks 2 times and stops for 1 second and then repeats this cycle to indicate successful registering of user key 1 A Bee uio mmo GP30372BS1 e Turn off and remove user key 1 OThe warning indicator light
153. 4 T5712748T C 5 10 ENGINE TOP END Special Tools and Sealant Valve Seat Cutter Holder 4 57001 1275 875712755 Compression Gauge Adapter M10 x 1 0 57001 1317 7571317ST C Valve Seat Cutter 60 525 57001 1328 7571328ST C Valve Seat Cutter 60 627 57001 1409 7571328ST C Valve Guide Driver 57001 1564 7571564ST C Valve Spring Compressor Adapter 24 57001 1586 ST571586ST Attachment C 57001 1624 875716245 Kawasaki Bond Silicone Sealant 92104 0004 879200045 Clean Air System ENGINE TOP END 5 11 Air Suction Valve Removal e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Air Cleaner Housing see Air Cleaner Housing Removal in the Fuel System DFI chapter Separate the hoses A from the air suction valve cover e Remove Air Suction Valve Cover Bolts B Air Suction Valve Cover C Air Suction Valve Air Suction Valve Installation e Install the air suction valve so that the openings A of the reeds face the rear and downward e Install the clamps A and bracket B as shown e Apply a non permanent locking agent to the threads of the air suction valve cover bolts and tighten them with the specified torque Torque Air Suction Valve Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib Air Suction Valve Inspection e Remove the air suction valve
154. 5 N m 1 5 kgf m 11 ft Ib Final 39 N m 4 0 kgf m 29 ft Ib e Tighten the M6 cylinder head bolts 11 12 Torque Cylinder Head Bolts M6 12 N m 1 2 kgf m 106 in Ib e Install Front Camshaft Chain Guide Bolt A O ring B OApply grease to the new O ring e Tighten Torque Front Camshaft Chain Guide Bolt Upper 25 N m 2 5 kgf m 18 ft Ib e Install the removed parts see appropriate chapters NOTE Olf the oil pump was removed refer to the Oil Pump In stallation in the Engine Lubrication System chapter GE14101BS2 C Cylinder Head Warp e Clean the cylinder head Lay a straightedge across the lower surface of the cylinder head at several positions e Use a thickness gauge A to measure the space between the straightedge B and the head Cylinder Head Warp Standard Service Limit 0 05 mm 0 002 in GE14038BS1 0 x If the cylinder head is warped more than the service limit replace it xIf the cylinder head is warped less than the service limit repair the head by rubbing the lower surface on emery paper secured to a surface plate first No 200 then No 400 5 26 ENGINE TOP END Valves Valve Clearance Inspection e Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter Valve Clearance Adjustment e Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter Valve Removal Remove the cylinder head see Cyli
155. 57001 1129 e Install the race holder D as shown in the figure e Apply a non permanent locking agent to the race holder screw E A Tighten 6113357BS1 C Torque Race Holder Screw 4 9 0 50 kgf m 43 in Ib e Press and insert the dowel pins F in the transmission case until they are bottomed e Press and insert the ball bearing A in the transmission case B so that the stepped side faces outside until it is bottomed e Install the bearing holder C as shown in the figure e Apply a non permanent locking agent to the bearing holder screw D Tighten Torque Bearing Holder Screw 4 9 0 50 43 in Ib 6113358BS1 C e Install Shift Drum Assembly A Bearing Holder Olnstall the bearing holder so that the taper side faces out side e Apply a non permanent locking agent to the bearing holder screws C e Tighten Torque Bearing Holder Screws 4 9 N m 0 50 kgf m 43 in Ib 9113360851 C 9 40 CRANKSHAFT TRANSMISSION Transmission e Install the drive shaft A and output shaft B as a set in the transmission case C e Install the shift forks as shown in the figure OThe shift fork D for drive shaft gears has the short ears OThe shift forks E F for output shaft gears have the long ears OThe shift fork E has R mark F OThe shift fork G has L mark H e Install the shift rods so that the ends of the rods are same height OThe shif
156. 57001 1457 OMeasure the input voltage to each primary winding of the ignition coils with the engine stopped and with the con nectors joined e Turn the ignition switch ON Stick Coil Input Voltage at ECU Connections for Stick Coil 1 Meter BK lead terminal 51 Meter BK Y lead terminal 67 Connections for Stick Coil 2 Meter BK G lead terminal 50 Meter gt BK Y lead terminal 67 Connections for Stick Coil 3 Meter BK W lead terminal 49 Meter BK Y lead terminal 67 Connections for Stick Coil 4 Meter BK O lead terminal 68 Meter BK Y lead terminal 67 Input Voltage at ECU Standard Battery Voltage 12 8 V or more x If the reading is out of the standard check the wiring see wiring diagram x If the reading is good the input voltage is normal Crank the engine and check the peak voltage of the stick coils see Stick Coil Primary Peak Voltage Inspection in the Electrical System chapter in order to check the primary coils 80179140651 3 84 FUEL SYSTEM DFI Stick Coils 1 2 3 4 Service Code 51 52 53 54 Stick Coil Circuit gt ON PARK BATTERY O33 O31 TAIL TAIL2 656 Ignition Switch Engine Stop Switch Stick Coil 1 Stick Coil 2 Stick Coil 3 Stick Coil 4 ECU Fuse Box Ignition Fuse 10 A
157. 6 Air suction valve trouble Inspect and replace see chapter 5 After fire Spark plug burned or gap maladjusted Replace see chapter 2 Fuel Injector trouble Inspect see chapter 3 Inlet air pressure sensor trouble Inspect see chapter 3 Atmospheric pressure sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 FUEL SYSTEM DFI 3 33 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions chapter Inlet air temperature sensor trouble Inspect see chapter 3 Other Intermittent any DFI fault and its recovery Check that DFI connectors are clean and tight and examine leads for signs of burning or fraying see chapter 3 Poor Running or No Power at High Speed Firing incorre O OO O O Inspect or Reinstall see chapter 16 Fuelair incorre y y Throttle body assy dust seal damage Replace see chapter 3 Water or foreign matter in fuel Change fuel Inspect and clean fuel system see chapter 3 Fuel Injector O ring damage Replace see chapter 3 Fuel Injector clogged Inspect and repair see chapter 3 Fuel line clogged Inspect and repair see chapter 3 Fuel pump operates intermittently and often DFI Fuel pump bearings may wear Replace the fuel fuse blows pump see chapter 3 Fuel pump trouble Inspect see chapter 3 Inlet air pressure sensor trouble Inspect see chapter 3 Cracked or obstructed inlet air pres
158. 617947651 FUEL SYSTEM DFI 3 77 Exhaust Butterfly Valve Actuator Sensor Service Code 34 Exhaust Butterfly Valve Actuator Sensor Output Voltage Inspection NOTE OBefore this inspection confirm the pulley A is original position see Exhaust Butterfly Valve Actuator Installa tion e Remove Exhaust Butterfly Valve Actuator see Exhaust Butterfly Valve Actuator Removal e Disconnect 2 pins Connector B 3 pins Connector C Connect the harness adapter A between the 3 pins con nectors Special Tool Throttle Sensor Setting Adapter 1 57001 1400 Connect a digital meter to the harness adapter leads Exhaust Butterfly Valve Actuator Sensor Output Voltage Connections to Adapter Digital Meter BL actuator Y lead Digital Meter BK BL actuator BK lead Measure the output voltage at the 3 pins connector of the exhaust butterfly valve actuator when the pulley is original position e Turn the ignition switch ON Output Voltage at Actuator Standard DC 3 46 3 76 V at pulley original position Turn the ignition switch OFF xIf the reading is out of the standard check the exhaust butterfly valve actuator sensor resistance see Exhaust Butterfly Valve Actuator Sensor Resistance Inspection x If the reading is within the standard remove the ECU and check the wiring between these connectors ODisconnect the ECU and sensor connectors Wiring Connections ECU Connector
159. 8 10 72 S 6 Swingarm Pivot Shaft Nut 108 11 81 S 7 Tie Rod Nuts 59 6 0 43 8 Uni Trak Rocker Arm Nut 34 3 5 25 G Apply grease L Apply a non permanent locking agent R Replacement Parts 13 6 SUSPENSION Specifications Standard Front Fork Per One Unit Fork Inner Tube Diameter Air Pressure Rebound Damper Setting Compression Damper Setting Fork Spring Preload Setting Fork Oil Viscosity Amount When Changing Oil After Disassembly and Completely Dry Fork Oil Level Fully Compressed without Spring below from the Top of the Outer Tube Fork Spring Free Length Rear Shock Absorber Rebound Damper Setting Compression Damper Setting High Speed Low Speed Spring Preload Setting Position Standard Usable Range Gas Pressure 41 mm 1 6 in Atmospheric pressure non adjustable 1 1 2 turns out from the fully clockwise position Usable range 0 3 1 2 turns out 1 1 2 turns out from the fully clockwise position Usable range 0 turns out 5 turns in from the fully counterclockwise position Usable range 15 0 turns in SHOWA SS47 or equivalent SAE 10W Approx 430 mL 14 5 US oz 505 2 5 mL 17 1 0 085 US oz 97 2 mm 3 8 0 08 in 257 mm 10 1 in Service Limit 252 mm 9 92 in 19th click from the first click of the fully clockwise position Usable range 0 25th click 2 1 2 turns out from the fully
160. 9 0 5 mm 0 020 in TIR 0 01 mm 0 0004 in or less 3 955 3 970 mm 0 1557 0 1563 in 3 975 3 990 mm 0 1565 0 1571 in 4 000 4 012 mm 0 1575 0 1580 in 4 000 4 012 mm 0 1575 0 1580 in 0 09 0 17 mm 0 0035 0 0067 in 0 03 0 10 mm 0 0012 0 0039 in 32 45 60 0 8 1 2 mm 0 031 0 047 in 0 5 1 0 mm 0 020 0 039 in 22 8 23 0 mm 0 898 0 906 in 26 9 27 1 mm 1 059 1 067 in 38 2 mm 1 504 in 39 2 mm 1 543 in 0 6 mm 0 024 in 0 25 mm 0 001 in TIR 0 05 mm 0 002 in 3 94 mm 0 155 in 3 96 mm 0 156 in 4 08 mm 0 161 in 4 08 mm 0 161 in 0 38 mm 0 015 in 0 30 mm 0 012 in 37 1 mm 1 461 in 37 9 mm 1 492 in ENGINE TOP END 5 9 Special Tools and Sealant Compression Gauge 20 kgf cm 57001 221 Valve Spring Compressor Assembly 57001 241 7570221ST C 7570241ST C Valve Seat Cutter 45 524 5 57001 1113 C 2 8 5711135 C Valve Seat Cutter 32 25 57001 1118 Valve Seat Cutter 32 530 57001 1120 7571199ST C 7571120ST C Valve Seat Cutter Holder Bar 57001 1128 7571128ST C Valve Spring Compressor Adapter 20 57001 1154 875711545 C Valve Seat Cutter 45 30 57001 1187 8 5711875 C Valve Guide Arbor 4 57001 1273 875712735 C Valve Guide Reamer 4 57001 127
161. 9 in Second 0 82 0 84 mm 0 0323 0 0331 Service Limit Top A 0 94 mm 0 037 in Second B 0 92 mm 0 036 in x lf the width of any of the two grooves is wider than the service limit at any point replace the piston Piston Ring Thickness Measure the piston ring thickness OUse the micrometer to measure at several points around the ring Piston Ring Thickness Standard Top A 0 77 0 79 mm 0 0303 0 0311 in Second B 0 77 0 79 mm 0 0303 0 0311 in Service Limit Top A 0 70 mm 0 028 in Second B 0 70 mm 0 028 in xIf any of the measurements is less than the service limit on either of the rings replace all the rings NOTE OWhen using new rings in a used piston check for un even groove wear The rings should fit perfectly parallel to the groove sides If not replace the piston Piston Ring End Gap e Place the piston ring A inside the cylinder upper crankcase using the piston to locate the ring squarely in place Set it close to the bottom of the cylinder where cylinder wear is low e Measure the gap B between the ends of the ring with a thickness gauge Piston Ring End Gap Standard Top 0 12 0 22 mm 0 0047 0 0087 in Second 0 30 0 45 mm 0 0118 0 0177 in Service Limit Top 0 5 mm 0 020 in Second 0 8 mm 0 031 in xIf the end gap of either ring is greater than the service limit replace all the rings GE16070781 G
162. 96 35 31 F 2 6 L 2 7 US qt 0 24 0 31 mm 0 0094 0 0122 in 0 13 0 19 mm 0 0051 0 0075 in 2 3 mm 0 08 0 12 in API SE SF or SG API SH SJ or SL with JASO MA SAE 10W 40 2 9 L 3 1 US qt when filter is not removed 3 2 L 3 4 US qt when filter is removed 3 8 L 4 0 US qt when engine is completely dry Between upper and lower level lines Wait 2 3 minutes after idling or running BRIDGESTONE 3 6 mm 0 14 in BRIDGESTONE 4 8 mm 0 19 in Up to 180 kg 397 Ib load 250 kPa 2 5 kgf cm 36 psi Up to 180 kg 397 Ib load 290 kPa 2 9 kgf cm 42 psi 1 mm 0 04 in AT CH DE 1 6 mm 0 06 in Up to 130 km h 80 mph 2 mm 0 08 in Over 130 km h 80 mph 3 mm 0 12 in PERIODIC MAINTENANCE 2 13 Specifications Item Standard Service Limit Final Drive Drive Chain Slack Drive Chain Wear 20 link Length Standard Chain 30 40 mm 1 2 1 6 in 317 5 318 2 mm 12 50 12 53 in 323 mm 12 7 in Make ENUMA Type EK520MVXL1 Link 112 links Brakes Brake Fluid Grade DOT4 Brake Pad Lining Thickness Front 4mm 0 16 in 1 mm 0 04 in Rear 5 mm 0 20 in 1 mm 0 04 in Brake Light Timing Front Pulled ON Rear after about 10 mm 0 39 of travel 2 14 PERIODIC MAINTENANCE Special Tools Inside Circlip Pli
163. 9851 Rear Frame Installation e Apply a non permanent locking agent to the threads of rear frame bolt Tighten Torque Rear Frame Bolts and Nuts 59 N m 6 0 kgf m 44 ft lb Rear Footpeg Bracket Bolts 25 N m 2 5 kgf m 18 ft lb Frame Inspection e Visually inspect the frame for cracks dents bending or warp x If there is any damage to the frame replace it A WARNING A repaired frame may fail in use possibly causing an accident If the frame is bent dented cracked or warped replace it 9009030851 15 24 FRAME Sidestand Sidestand Removal Raise the rear wheel off the ground with the stand e Remove Lower Fairings see Lower Fairing Removal e Disconnect the sidestand switch lead connector A e Remove Spring A Sidestand Bolt Locknut Sidestand Bolt B Sidestand C Switch Bracket Bolts D Sidestand Bracket Bolts E Sidestand Installation e Apply a non permanent locking agent to the bracket bolts e Apply grease to the sliding area A of the sidestand B and thread of the sidestand bolt C Tighten the bolt and lock them with the nut Torque Sidestand Bracket Bolts D 49 N m 5 0 kgf m 36 ft lb Sidestand Bolt 44 N m 4 5 kgf m 32 ft lb e Hook the spring E so that the long spring end side up ward Olnstall the spring hook direction as shown Install the switch bracket and sidestand switch OApply a non permanent locking agent to the thr
164. A lt Exhaust Butterfly Valve Actuator Sensor Connector B R BK lead ECU terminal 5 C BR BK lead ECU terminal 28 D xIf 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 6617948651 3 78 FUEL SYSTEM Exhaust Butterfly Valve Actuator Sensor Service Code 34 Exhaust Butterfly Valve Actuator Sensor Inspection e Remove Seat Cover see Seat Cover Removal in the Frame chapter Bolts A Screw B e Pull out the exhaust butterfly valve actuator C e Turn the ignition switch OFF e Disconnect the exhaust butterfly valve actuator sensor connector A Connect a digital meter to the exhaust butterfly valve actuator sensor connector e Measure the exhaust butterfly valve actuator sensor re sistance Exhaust Butterfly Valve Actuator Sensor Resistance Connections W lead C BK lead D Standard 4 6 x If the reading is out of the range replace the exhaust but terfly valve actuator see Exhaust Butterfly Valve Actuator Removal Exhaust Butterfly Valve Actuator Sensor Circuit x x E gt La a P 6C176488W2 C 1 ECU 2 Exhaust Butterfly Valve Actuator FUEL SYSTEM DFI 3 79 Immobilizer Amplifier Service Code 35 Equipped Models Antenna Resistance Inspection e Remove Left Inne
165. ANCE 2 57 Maintenance Procedure e Apply brake fluid to the new parts and to the inner wall of the cylinder Take care not to scratch the piston or the inner wall of the cylinder e Tighten the brake lever pivot bolt and the locknut Silicone Grease Brake Lever Pivot Bolt Torque Brake Lever Pivot Bolt 1 0 0 10 kgf m 9 in Ib Brake Lever Pivot Bolt Locknut 5 9 N m 0 60 kgf m 52 in lb Caliper Rubber Parts Replacement Front Caliper Disassembly e Loosen the front caliper pad pins A and banjo bolt B and tighten them loosely e Remove Front Caliper C see Front Caliper Removal in the Brakes chapter Brake Pad see Front Brake Pad Removal in the Brakes chapter Front Caliper Assembly Bolts O rings e Using compressed air remove the pistons One way to remove the pistons is as follows Olnstall a rubber gasket A and a wooden board B more than 10 mm 0 4 in thick on the caliper half and fas ten them together with a suitable bolt and nut as shown Leave one of the oil passages C open OLightly apply compressed air D to the oil passage until the pistons hit the rubber gasket OFor the hose joint side caliper half block the hose joint opening during this operation if the caliper half has the opening Bolt and Nut E Push down F A WARNING To avoid serious injury never place your fingers or palm in front of the piston If you apply compressed air into the caliper the piston ma
166. AUTION GF05025BS1 C When inserting the release shaft be careful not to remove the spring of the oil seal e Fit the spring A as shown Viewed from Rear B Release Shaft C Clutch Cover D GF05017BS1 C Clutch Cover Disassembly e Remove Clutch Cover see Clutch Cover Removal Release Lever and Shaft Assembly see Release Shaft Removal Oil Seal A Filler Cap B Oil Level Gauge C e Remove the needle bearings A CLUTCH 6 9 Clutch Cover Clutch Cover Assembly Replace the needle bearings and oil seal with new ones NOTE Olnstall the needle bearings so that the manufacture s mark face out e Install the needle bearings A and oil seal B as shown OPress the bearing do not protrude from the boss C of the clutch cover OPress the bearing so that the bearing surface D is flush with the housing end of clutch cover E OPress the oil seal until the bottom e Apply water to the rubber portion A of the oil level gauge e Press the gauge so that its projection B faces inside of the clutch cover C e Replace the O ring of the oil filler cap e Apply grease to the new O ring e Tighten Torque Oil Filler 2 0 N m 0 20 kgf m 17 in Ib GFO5026BS1 C GF05045BS1 6 10 CLUTCH Clutch Clutch Removal v e Remove Clutch Cover see Clutch Cover Removal Clutch Spring Bolts A Clutch Springs with Sprin
167. About 6 mm 0 24 in J Viewed from Rear K e Tighten Torque Front Exhaust Pipe Holder Nuts L 17 N m 1 7 kgf m 13 ft Ib Front Exhaust Pipe Mounting Bolt M 28 N m 2 8 kgf m 21 ft Ib Rear Exhaust Pipe Clamp Bolt 17 N m 1 7 kgf m 13 ft Ib e For the Europe Models route the oxygen sensor leads correctly see Cable Wire and Hose Routing section in the Appendix chapter GE180738W2 e Tighten the radiator lower and upper bolts see Radiator and Radiator Fan Installation in the Cooling System chap ter e Throughly warm up the engine wait until the engine cools down retighten all the bolt and nuts ENGINE END 5 41 Muffler Exhaust Butterfly Valve Cable Removal e Remove Seat Cover see Seat Cover Removal in the Frame chapter Bolt A Exhaust Butterfly Valve Cover B e Slide the dust covers A e Loosen the adjuster locknuts B and turn the adjuster C to give the cable plenty of play e Loosen the locknuts D e Remove the exhaust butterfly valve cable lower ends E from the pulley F e Remove the clamp A e Remove the exhaust butterfly valve cable upper ends B from the pulley C e Remove the exhaust butterfly valve cables D 5 42 ENGINE TOP END Muffler Exhaust Butterfly Valve Cable Installation e Install the exhaust butterfly valve cable lower ends to the pulley of muffler body Open Cable White A Close Cable Black B
168. Align the white paint of the hose parallel to the mating surface of the fitting 17 20 APPENDIX Cable Wire and Hose Routing 68093030 5 C APPENDIX 17 21 Cable Wire and Hose Routing Radiator Pads Putthe pad along the right side face of the radiator Align the lower ends of the pad and radiator Viewed Rear of Frame Main Harness Frame Clutch Cable Water Hose Crankshaft Sensor Lead Oil Pressure Switch Lead Put the projection of the pad between the water hose and idle gear cover Idle Gear Cover Fit the groove of the pad to the idle gear cover bolt backward portion and install it along the inclination of the cylinder Viewed Right Side of Frame Inastall the alternator Lead through the slit Put the projection of the pad between the water hose and alternator cover Alternator Cover Install the rubber pad along the inclination of cylinder Viewed Left Side of Frame 17 22 APPENDIX Cable Wire and Hose Routing 2 LA 2 TD T YEN f SA OF LES WA cr NaN e APPENDIX 17 23 Cable Wire and Hose Routing 12 Speed Sensor Lead 14 15 16 Align the projection 2 of the hose and the center line of the air switching valve
169. Assembly 16 49 Starter Relay Inspection 16 49 Lighting System 16 52 Headlight Beam Horizontal Adjustment 16 52 Headlight Beam Vertical Adjustment 16 52 Headlight Bulb Replacement 16 52 City Light Bulb Replacement 16 53 Headlight Removal Installation 16 53 Tail Brake Light LED Removal 16 53 Tail Brake Light LED Installation 16 54 License Plate Light Bulb Replacement Turn Signal Light Bulb Replacement Turn Signal Light Remowval 16 57 Turn Signal Relay Inspection 16 58 Air Switching Valve 16 61 Air Switching Valve Operation EE 16 61 Air Switching Valve Unit Test 16 61 Radiator Fan System 16 62 Fan Motor Inspection 16 62 Meter Gauge Indicator Unit 16 63 Meter Unit Removal 16 63 Meter Unit Disassembly 16 63 Electronic Combination Meter Unit Inspection 16 64 Fuel Level Sensor Line Self Diagnosis Mode 16 80 16 2 ELECTRICAL SYSTEM Immobilizer System Equipped Medals ntis c dtr en Operational Cautions Key
170. B Pull out the side cover Left Side Cover Installation e Insert the projections A into the holes B e Tighten the bolt Right Side Cover Removal e Remove Bolts A Projections B e Pull out the side cover C Right Side Cover Installation e Insert the projections A into the holes B 15 16 FRAME Seat Cover Seat Cover Removal e Remove Seats see Rear Front Seat Removal Bolts A with Washer e Remove Bolts A with Washer e Remove Bolt A with Washer Seat Cover B backward Seat Cover Installation e Install the removed parts FRAME 15 17 Engine Cover Heat Insulation Plate Removal e Remove Lower Fairing see Lower Fairing Removal Middle Fairing see Left Middle Fairing Removal Radiator Upper Bolts A both side Radiator Lower Bolt B e Move the radiator to the front side e Remove the heat insulation plate B OPull out the right side of the plate to clear the projections A from the stoppers Heat Insulation Plate Installation e Insert the projections A into the holes B of the frame NOTE Olnstall the plate from the left side first e Install the removed parts see appropriate chapters Heat Insulation Rubber Plate Pemoval e Remove Fuel Tank see Fuel Tank Removal in the Fuel System chapter Air Cleaner Housing see Air Cleaner Housing Removal in the Fuel System chapter Throttle Body Assy see Throttle Body Assy Removal in
171. Code Crankshaft Sensor Removal Installation Crankshaft Sensor Inspection Camshaft Position Sensor Service Camshaft Position Sensor Removal Installation Camshaft Position Sensor Speed Sensor Service Code 24 Speed Sensor Removal Installa Speed Sensor Inspection Speed Sensor Input Voltage Speed Output Voltage Gear Position Switch Service Code Gear Position Switch Remowval Installation Gear Position Switch Inspection Gear Position Switch Input Voltage Inspection Vehicle down Sensor Service Code Vehicle down Sensor Removal Vehicle down Sensor Installation Vehicle down Sensor Inspection Subthrottle Sensor Service Code Subthrottle Sensor Removal Adjustment Subthrottle Sensor Input Voltage 3 55 3 56 3 56 3 56 3 56 3 57 3 60 3 60 3 60 3 61 3 61 3 61 3 62 3 62 3 62 3 62 3 62 3 64 3 64 3 64 3 64 3 66 3 66 3 66 3 67 3 70 3 70 3 70 3 2 FUEL SYSTEM Subthrottle Sensor Output Voltage Inspection pp Resistance Inspection Oxygen Sensor not activated 1 2 Ser
172. Connec tor Stick Coil Lead Connectors Left to Right 1 2 3 4 Air Switching Valve Lead Connector Camshaft Position Sensor Lead Connec tor Horn Lead Connectors Front Left Turn Signal Light Lead Connec tor Ignition Switch Lead Connector Immobilizer Antenna Equipped Models Left Switch Housing Lead Connector Meter Connector Immobilizer Amplifier Equipped Models Vehicle down Sensor Fan Motor Lead Connector APPENDIX 17 7 Cable Wire and Hose Routing CD 9 6 2 O 220949 02 sl 71 el GB09326BW3 C Frame Ground Clamps Insertion type Run the alternator lead into the notch of rear fender Run the regulator rectifier lead lower side of the main harness Clamps Battery Negative Terminal and Lead Battery Positive Terminal Kawasaki Diagnosis System KDS Con nector ECU Connectors Rear Right Turn Signal Light Connector Tail Brake Light Connector Rear Left Turn Signal Light Connector Licence Plate Light Connector Exhaust Butterfly Valve Actuator Connec tors Atmospheric Pressure Sensor Connector Starter Relay Fuel Pump Connector Clamp Starter Motor Cable Regulator Rectifire Lead Viewed Front of the Frame Battery Positive Cable Starter Motor Cable Viewed Rightside of Battery 17 8 APPENDIX Cable Wire and Hose Routing f A E m
173. Crankcase Inside 67 000 67 012 mm 68 09 mm Diameter 2 6378 2 6383 in 2 64 in Piston Diameter 66 975 66 990 mm 66 83 mm 2 6368 2 6374 in 2 631 in Piston Cylinder Clearance 0 010 0 037 mm UM 0 0004 0 0015 in Piston Ring Groove Clearance Top 0 05 0 09 mm 0 19 mm 0 0020 0 0035 in 0 0075 in Second 0 03 0 07 mm 0 17 mm 0 0012 0 0028 in 0 0067 in Piston Ring Groove Width Top 0 84 0 86 mm 0 94 mm 0 0331 0 0339 in 0 037 in Second 0 82 0 84 mm 0 92 mm 0 0323 0 0331 in 0 036 in Piston Ring Thickness Top 0 77 0 79 mm 0 70 mm 0 0303 0 0311 in 0 028 in Second 0 77 0 79 mm 0 70 mm 0 0303 0 0311 in 0 028 in Piston Ring End Gap Top 0 12 0 22 mm 0 5 mm 0 0047 0 0087 in 0 020 in Second 0 30 0 45 mm 0 8 mm 0 0118 0 0177 in 0 031 in Transmission Shift Fork Ear Thickness 5 9 6 0 mm 5 8 mm 0 232 0 236 in 0 228 in Gear Groove Width 6 05 6 15 mm 6 25 mm 0 238 0 242 in 0 246 in 9 8 CRANKSHAFT TRANSMISSION Specifications Item Standard Service Limit Shift Fork Guide Pin Diameter 5 9 6 0 mm 5 8 mm 0 232 0 236 in 0 228 in Shift Drum Groove Width 6 05 6 20 mm 6 3 mm 0 238 0 244 in 0 248 in Connecting Rod Big End Bearing Insert Selection Con rod Big End Bearing Insert Crankpin Diameter Inside Diameter Markin Marking 9 Size Color Part Number Brown 92139 0167 Black 92
174. Drive Chain Slack emen E 11 6 Drive Chain Slack Adjustment etit teer e Bae t 11 6 Wheel Alignment nennen nnns 11 6 Drive Chain Wear Inspection Drive Chaim LUBrICAUON adeat Drive Chain Removal pp 1 5 EEE SPFOCkeSt EE Engirie Sprocket Removal a Engine Sprocket Installati n Rear Sprocket Removal Rear Sprocket Installation iint en ee i etii ao t EO ERR EAE Coupling Installation reete rettet tant Coupling Bearing REMOWAl s ei io utente os af as Pon a Pei ibus Coupling Bearing Installation Coupling Bearing Inspection pp Coupling Bearing Lubrication Coupling Damper 9 a Sprocket Wear Inspection pp Rear Sprocket Warp 11 14 11 2 FINAL DRIVE Exploded View FINAL DRIVE 11 3 Exploded View Torque No Fastener kgfm ftlb Remarks 1 Engine Sprocket Cover Bolts 9 8 1 0 87 in lb 2 Chain Guide Bolts Front 9 8 1 0 87 in lb L 3 Sprocket Nut 125 13 92 MO 4 Rear Sprocket Nuts 59 6 0 43 5 Chain Guide Bolt Rear 4 9 0 50 43 in Ib L G Apply grease HG Apply high temper
175. E16070881 9105249851 C CRANKSHAFT TRANSMISSION 9 31 Starter Idle Gear and Starter Clutch Starter Idle Gear Removal e Remove Right Middle Fairing see Right Middle Fairing Removal in the Frame chapter Heat Insulation Cover A Bolts B Idle Gear Cover C e Pull out the idle gear starter motor side A with the shaft B e Remove Bolts A Bracket B Starter Clutch Cover B e Pull out the idle gear starter clutch side A with the shaft B Starter Idle Gear Installation e Apply molybdenum disulfide grease A to the idle gear shaft starter clutch side B e Fit the pin C into the groove D of the crankcase 9 32 CRANKSHAFT TRANSMISSION Starter Idle Gear and Starter Clutch e Install the idle gear starter clutch side A on the shaft e Engage the idle gear with the starter clutch gear e Apply silicone sealant to the following portion Crankshaft Sensor Lead Grommet B Crankcase Halves Mating Surfaces C Sealant Kawasaki Bond Silicone Sealant 92104 0004 e Install the dowel pins D and new gasket e Apply grease to the O rings of starter motor e Install Starter Clutch Cover A Bracket B e Tighten Torque Starter Clutch Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib L 20 mm 0 79 in C L 30 mm 1 18 in D e Apply molybdenum disulfide grease to the idle gear shaft starter motor side A e Install the idle gear starter motor sid
176. EM Immobilizer System Equipped Models Case 2 When the ignition switch is faulty and to be replaced e Prepare a new ignition switch A and two new user keys B OThese parts are available as a set Prepare the current master key C e Remove Ignition Switch and Immobilizer Antenna see Immobi lizer System Parts Replacement Front Seat see Front Seat Removal in the Frame chap ter e Disconnect the immobilizer Kawasaki self diagnostic sys tem connector e Connect the key registration unit A Special Tool Key Registration Unit 57001 1582 e Connect New Ignition Switch Lead Connector A Immobilizer Antenna Lead Connector B NOTE OKeep the antenna more than 15 cm from the ignition switch e Put the current master key A at the antenna B Insert the new user key 1 C to the new ignition switch D and turn it ON Verified OThe warning indicator light LED A blinks to display the ECU is in the registration mode go to the next step GP30029BS1 C 0 5second 0 5second peg Ste GP30376BS1 ELECTRICAL SYSTEM 16 89 Immobilizer System Equipped Models Not Verified OThe warning indicator light LED A blinks to display the collation error Immobilizer Amplifier Failure 0 2second GP30374BS1 Master Key Collation Error 0 3second A Be ULL GP3037
177. Electrical System chapter ECU Fuse 10 A see Fuse Inspection in the Electrical System chapter x If the power source is normal check the output voltage 8017357 52 C 3 68 FUEL SYSTEM Vehicle down Sensor Service Code 31 e Turn the ignition switch OFF e Remove the sensor see Vehicle down Sensor Removal ODo not disconnect the connector Connect a digital volt meter A to the connector with nee dle adapter set B Special Tool Needle Adapter Set 57001 1457 Vehicle down Sensor Output Voltage Connections to Sensor Meter Y G lead C Meter gt BR BK lead D Hold the sensor vertically e Turn the ignition switch ON and measure the output volt age with the connector joined OTilt the sensor 60 70 or more E right or left then hold the sensor almost vertical with the arrow mark pointed up and measure the output voltage Output Voltage at Sensor Standard with sensor arrow mark pointed up 3 55 4 45 with sensortilted 60 70 more right left 0 65 1 35 V NOTE Olf you need to test again turn the ignition switch OFF and then ON e Turn the ignition switch OFF e Remove the needle adapter set and apply silicone sealant to the seals of the connector for waterproofing Sealant Kawasaki Bond Silicone Sealant 56019 120 x If the output voltage is out of the specified replace the vehicle down sensor GC17358B83 FUEL S
178. Frame chapter e Slide the dust cover A at the clutch cable lower end out of place e Loosen the nuts B and slide the lower end of the clutch cable to give the cable plenty of play e Screw in the adjuster Line up the slots A in the clutch lever and adjuster B and then free the cable from the lever e Free the clutch inner cable tip from the clutch release lever e Push the release lever toward the front of the motorcycle and tape the release lever to the clutch cover to prevent the release shaft from falling out e Pull the clutch cable out of the frame Cable Installation e Run the clutch cable correctly see Cable Wire and Hose Routing section in the Appendix chapter e Adjust the clutch cable see Clutch Operation Inspection in the Periodic Maintenance chapter Cable Lubrication e Refer to the Chassis Parts Lubrication in the Periodic Maintenance chapter Clutch Lever Installation e Install the clutch lever so that the mating surface A of the clutch lever clamp is aligned with the punch mark B e Tighten the upper clamp bolt first and then the lower clamp bolt OThere will be a gap at the lower part of the clamp after tightening Torque Clutch Lever Clamp Bolts 7 8 N m 0 80 kgf m 69 in Ib CLUTCH 6 7 Clutch Cover Clutch Cover Removal e Drain the engine oil see Engine Oil Change in the Peri odic Maintenance chapter e Remove Right Middle Fairing see Middle Fairi
179. Fuse Inspection Warning Indicator Light LED Warning Indicator Light LED Fuel Line Fuel Pressure Inspection Fuel Flow Rate Inspection Fuel Pump sss Fuel Pump Removal Fuel Pump Installation Fuel Pump Operation Inspection Fuel Pump Operating Voltage Fuel Pump Fuel Pump Relay Removal Fuel Pump Relay Inspection Fuel Injectors ree Audible Inspection Injector Signal Test Injector Resistance Inspection Injector Unit Test Injector Voltage Inspection Injector Fuel Line Inspection Throttle Grip and Cables Free Play Inspection Free Play Adjustment Cable Installation 3 91 3 91 3 93 3 93 3 93 3 94 3 94 3 94 3 111 3 112 3 112 3 114 3 116 FUEL SYSTEM DFI 3 3 Cable Lubrication Throttle Body Assy Idle Speed Inspection Synchronization Inspection Synchronization Adjustment Throttle Body Assy Remowval Throttle Body Assy In
180. ION During pressure testing do not exceed the maxi mum pressure for which the system is designed e Watch the gauge for at least 6 seconds x If the pressure holds steady the system is good x If the pressure drops at once or if bubbles are found in the area the line is leaking Replace the delivery pipe injectors and related parts see appropriate sections ORepeat the leak test and check the fuel line for no leak age e Install the throttle body assy see Throttle Body Assy In stallation e Install the nozzle assy see Nozzle Assy Installation e Run the hoses correctly see Cable Wire and Hose Rout ing section in the Appendix chapter 9017933652 C FUEL SYSTEM 3 115 Fuel Injectors Fuel Injector Circuit gt x BR GC17934CH3 C Secondary Fuel Injector 1 Secondary Fuel Injector 2 Secondary Fuel Injector 3 Secondary Fuel Injector 4 Primary Fuel Injector 1 Primary Fuel Injector 2 Primary Fuel Injector 3 Primary Fuel Injector 4 10 Engine Stop Switch 11 Ignition Switch 12 Cylinder Head Cover Ground 13 Joint Connector C 14 Battery 12 V 8 Ah 15 Frame Ground 16 Starter Relay 17 Main Fuse 30 A 18 Joint Connector B 19 Fuel Pump Relay 20 Relay Box 21 ECU Main Relay 22 Fuse 10 A 23 Ignition Fuse 10 A 24 Fuse Box
181. If the reading exceeds the specified length cut and rejoin the chain again e Check Movement of the Rollers e Adjust the drive chain slack after installing the chain see Drive Chain Slack Adjustment in the Periodic Mainte nance chapter GK04026BS1 GK04028BS1 11 10 FINAL DRIVE Sprocket Coupling Engine Sprocket Removal e Remove Speed Sensor Bolt A Speed Sensor B Engine Sprocket Cover Bolts C Engine Sprocket Cover D e Flatten out the bended washer A e Remove the engine sprocket nut B and washer NOTE OWhen loosening the engine sprocket nut hold the rear brake on Raise the rear wheel off the ground Remove the axle cotter pin and loosen the rear axle nut e Loosen the both chain adjuster locknut to loosen the drive chain e Remove the drive chain from the rear sprocket toward the right e Pull the engine sprocket A with drive chain B off the output shaft C e Disengage the drive chain from the engine sprocket Engine Sprocket Installation e Replace the sprocket washer and axle cotter pin e Install the engine sprocket onto the shaft so that the mark side A faces outwards e Apply molybdenum disulfide oil solution to the threads of the output shaft and the seating surface of the engine sprocket nut e After torquing the engine sprocket nut bend the one side B of the washer C over the nut NOTE OTighten the nut while applying the rear brak
182. Immobilizer Antenna 4 Starter Lockout Switch 5 Stick Coils 6 Battery 12 V 8 Ah 7 Starter Relay with Main Fuse 8 Immobilizer Diagnostic System Connec tor 9 Water Temperature Sensor 10 Alternator 11 Speed Sensor 12 Side Stand Switch 13 Gear Position Switch 14 Regulator rectifier 15 ECU Electric Control Unit 16 Fuel Pump with Fuel Reserve Switch 17 Front Brake Light Switch 18 Turn Signal Relay 19 Fuse Box with ECU Main Fuse 20 Rear Brake Light Switch 21 Starter Motor 22 Crankshaft Sensor 23 Oil Pressure Switch 24 Oxygen Sensors 25 Camshaft Position Sensor 26 Relay Box 16 4 ELECTRICAL SYSTEM Exploded View GP023388W5 C ELECTRICAL SYSTEM 16 5 Exploded View Torque No Fastener kori ftlb Remarks 1 Meter Mounting Screws 1 2 0 12 10 in Ib 2 Headlight Mounting Screws 1 2 0 12 10 in Ib 3 Turn Signal Light Mounting Screws 1 2 0 12 10 in Ib 4 Turn Signal Light Mounting Screws 1 2 0 12 10 in Ib 5 Rear Turn Signal Light Lens Screws T 0 10 9 in Ib 6 Tail Brake Light Mounting Bolts 0 40 20 in Ib ereergnwemmaseem 12 tmb 8 Licence Light Assembly Screws 0 09 8 in Ib am 9 United States and Canada Models 10 California Model 16 6 ELECTRICAL SYSTEM Exploded View ELECTRICAL SYSTEM 16 7 Exploded View Torque No Fastener kgfm ftlb
183. Lights B 12 V Battery C x lf the lights do not flash as specified replace the turn sig nal relay Testing Turn Signal Relay Load The Number of Turn Flashing Times Signal Lights Wattage W c m ds 21 140 250 2 42 75 95 Cycle s per minute Correspond to one light burned out Other than United States Canada and Australia Models e Connect one 12 V battery and turn signal lights as indi cated in the figure and count how may times the lights flash for one minute Turn Signal Relay A Turn Signal Lights B 12 V Battery C x If the lights do not flash as specified replace the turn sig nal relay Testing Turn Signal Relay Load The Number of T Flashing Times e Number of Turn Signal Lights em 42 75 95 Cycle s per minute Correspond to one light burned out 8 12040251 C GP12001BS1 C 16 60 ELECTRICAL SYSTEM Lighting System Turn Signal Light Circuit Meter Unit Ignition Switch Front Right Turn Signal Light Front Left Turn Signal Light Joint Connector A Turn Signal Switch Joint Connector C Turn Signal Relay Fuse 10 A Fuse Box Cylinder Head Cover Ground Turn Signal Relay Joint Connector B Main Fuse 30 A Battery 12 V 8 Ah Frame Ground Rear Left Turn Signal Light Rear Right Turn Signal Light GPi
184. M04021381 C 8 04041752 C GM04388BS1 13 14 SUSPENSION Front Fork e Screw the fork piston rod puller A onto the end of the piston rod Special Tool Fork Piston Rod Puller M10 x 1 0 57001 1298 Pull the puller upward above the outer tube top Install Fork Spring B e Assemble the following parts and install them to the inner tube Spring Joint C Spacer D Damper E e Set the distance between the upper end A of the spring preload adjuster B and rebound damping adjuster C 1 5 mm 0 059 in D e Set the fork spring compressor on the spacer A Special Tool Fork Spring Compressor 57001 1685 NOTE OSet the fork spring compressor so that the end of the handle B passes the upper side hole on the spacer by screwing the handle in the holder C to the bottom e While holding up the piston rod puller A by one person push down B the fork spring compressor and insert the fork spring stopper C between the piston rod nut D and the spacer E Special Tool Fork Piston Rod Puller M10 x 1 0 57001 1298 Fork Spring Stopper 57001 1374 e Remove the piston rod puller GM04427BS1 GM04390BS1 SUSPENSION 13 15 Front Fork e Replace O ring on the top plug with a new e Apply grease to the O ring Insert the rebound damping adjuster rod A into the holes of the piston rod Screw in the top plug stopped
185. Motor Connector B Relay Box Connectors C Fuse Box D e Remove the right middle fairing Right Middle Fairing Installation e Install the Fuse Box e Connect Relay Box Connectors Fan Motor Connector Right Turn Signal Lead Connector e Insert the projections A into the slots B e Install Right Inner Cover see Inner Cover Installation Washers and Bolts Windshield Removal e Remove Bolts A and Washers Windshield B Windshield Installation e Put the front tongue A into the hollow B e Install the washers and bolts Torque Windshield Mounting Bolts 0 4 N m 0 04 kgf m 4 in Ib 15 12 FRAME Fairings Upper Fairing Removal e Remove Lower Fairings see Lower Fairing Removal Middle Fairing see Left Middle Fairing Removal Windshield see Windshield Removal Inner Cover see Inner Cover Removal Headlight Lead Connectors Clamps Open B City Light Connector e Disconnect Meter Lead Connector A Vehicle down Sensor Connector B Immobilizer Amplifier Connector Equipped Models e Remove Turn Signal Relay C Bolts D Upper Fairing out the upper fairing forward Upper Fairing Disassembly e Remove Center Inner Fairing A see Center Inner Fairing Re moval Nuts B Rear View Mirrors Right and Left Meter Unit C with bracket see Meter Unit Removal in the Electrical System chapter Screws D Bolts E Headlight see Headlight Removal in the Electrical
186. Oil see Engine Oil Change in the Periodic Main tenance chapter 7 18 ENGINE LUBRICATION SYSTEM Oil Cooler Oil Cooler Oil Filter Case Removal e Remove Oil Filter see Oil Filter Replacement in the Periodic Maintenance chapter Oil Cooler see Oil Cooler Removal Bolt A e Pull the oil filter guard A forward as shown e Remove Bolt B Oil Filter Guard e Remove the bolts A e Remove Bolts A Oil Cooler Oil Filter Case B ORemove the oil filter holder bolt C as necessary ENGINE LUBRICATION SYSTEM 7 19 Oil Cooler Oil Cooler Oil Filter Case Installation xIf the crankcase was disassembled pour the engine oil into the oil passages A until O ring insert portions B of the upper crankcase NOTE OPour the engine oil into the oil passages because of quick supply of the engine oil to the cylinder head OThe engine oil capacity of the oil passages is approxi mately 0 2 L 0 2 US qt Therefore after assembling the engine pour the engine oil of the 3 6 L 3 8 US qt into the filler hole on the clutch cover The total amount of the engine oil becomes 3 8 L 4 0 US qt of the stan dard when engine is completely dry x If the oil filter holder bolt A was removed install it OApply non permanent locking agent to the treads of the oil filter holder bolt and tighten it Torque Oil Filter Holder Bolt 25 N m 2 5 kgf m 18 ft Ib Replace the O rings A with new ones
187. Oxygen Sensor 2 G Measure the power source voltage with the engine stopped and with the oxygen sensor connector joined e Turn the ignition switch ON Power Source Voltage at Sensor Connector D 8017358081 Standard Battery Voltage FUEL SYSTEM 3 95 Oxygen Sensor Heaters 1 2 Service Code 67 Equipped Models xIf the reading is incorrect check the following Battery see Charging Condition Inspection in the Elec trical System chapter Main Fuse 30 A see Fuse Inspection in the Electrical System chapter Oxygen Sensor Heater Fuse 10 A see Fuse Inspection in the Electrical System chapter xIf the reading is good the power source voltage is nor mal Inspect the Green lead between the oxygen sensor connector and the ECU for continuity using the following diagram xIf the wiring is good inspect the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see ECU section e Remove the needle adapter set and apply silicone sealant to the connector for water proofing Sealant Kawasaki Bond Silicone Sealant 56019 120 Oxygen Sensor Circuit o 1 amp 5 NE e e Se Li LG Li 8 BK W BL BR BK Li LG wW 8 BK BR W BR BK BR BK Y 6C17938CW2 ECU Oxygen Sen
188. Periodic Maintenance chapter GD05021BS2 C COOLING SYSTEM 4 11 Water Pump Water Pump Removal Refer to the Oil Pump Removal in the Engine Lubrication System chapter Water Pump Installation e Refer to the Oil Pump Installation in the Engine Lubrica tion System chapter Water Pump Impeller Disassembly Assembly Remove the impeller see Oil Pump Removal in the En gine Lubrication System chapter e The sealing seat and rubber seal may be removed easily by hand e Apply water around the surfaces of the rubber seal and sealing seat e Install the rubber seal A and sealing seat B into the impeller by pressing them by hand until the seat stops at the bottom of the hole e Tighten the impeller bolt with the specified torque Torque Impeller Bolt 9 8 N m 1 0 kgf m 87 in Ib Water Pump Impeller Inspection Remove the left lower fairing see Lower Fairing Removal in the Frame chapter e Check the drainage outlet passage A at the bottom of the water pump body for coolant leaks x lf the mechanical seal is damaged the coolant leaks through the seal and drains through the passage Re place the mechanical seal unit see Water Pump Housing Disassembly Assembly e Remove the water pump cover see Oil Pump Removal in the Engine Lubrication chapter e Visually inspect the impeller A xIf the surface is corroded or if the blades are damaged replace the impeller Water Pump Housing Disassem
189. Primary Injector Resistance Connections to Injector Meter Meter 1 WIR BL R Terminal 2 WIR BL G Terminal 3 W R lt BL BK Terminal 4 WIR lt BL Y Terminal Standard about 11 7 12 3 20 C 68 F x If the reading is out of the range perform the Injector Unit Test in this chapter xIf the reading is normal perform the Injector Unit Test for confirmation 3 112 FUEL SYSTEM Fuel Injectors Injector Unit Test e Use two leads A and the same test light set B as in Injector Signal Test Rating of Bulb C 12 V x 3 3 4 W 12 V Battery D CAUTION Be sure to connect the bulb in series The bulb works as a Current limiter to protect the solenoid in the injector from excessive current e Connect the test light set to the injector E as shown Open and connect F the end of the lead to the battery terminal repeatedly The injector should click xIf the injector does not click replace the injector xIf the injector clicks check the wiring again If the wiring is good replace the ECU Injector Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Set up the fuel tank see Air Cleaner Housing Removal e Connect a digital voltmeter A to the connector B with the needle adapter set Special Tool Needle Adapter Set 57001 1457 Secondary Fuel Injector Power Source Voltage
190. Remarks 1 Switch Housing Screws 3 5 0 36 31 in Ib 2 Front Brake Light Switch Screw 1 2 0 12 10 in Ib 3 Cylinder Head Cover Ground Bolt 9 8 1 0 87 4 Crankshaft Sensor Bolts 5 9 0 60 52 in Ib 5 Alternator Lead Holding Plate Bolt 9 8 1 0 87 in lb L 6 Alternator Cover Bolts 9 8 1 0 87 Gear Cover Bolts 9 8 1 0 87 with Washer 8 Idle Gear Cover Bolts 9 8 1 0 87 9 Timing Inspection Cap Hand tighten 87 inb 13 16 Immobilizer Models G Apply grease L Apply a non permanent locking agent M Apply molybdenum disulfide grease MO Apply molybdenum disulfide grease oil solution R Replacement Parts SS Apply silicone sealant 16 8 ELECTRICAL SYSTEM Exploded View ELECTRICAL SYSTEM 16 9 Exploded View Torque No Fastener kgf m ftlb Remarks 1 Spark Plugs 13 1 3 113 in Ib 2 Starter Relay Cable Terminal Bolts 4 0 0 41 35 in Ib 3 Camshaft Position Sensor Bolt 9 8 1 0 87 in lb 4 Water Temperature Sensor 25 2 5 18 SS 5 Sensors 25 2 5 18 6 Fuel Pump Bolts 9 8 1 0 87 in lb L S Gear Position Switch Screws 29030 Ll 9 ReguiatoriRectfier Bots 69 07 69 076 69 070 x t 5 Turn Signal Relay Immobilizer Amplifier 17 Stick Coils 18 Relay Box 19 Battery 12 V 8 Ah 20 Starter Relay 21 Fuel Pump 22 Rear Brake Light Switch 23 Regulator Rectifier 24 Gear Position Switch 25 Speed
191. Remove Right Middle Fairing see Right Middle Fairing Removal in the Frame chapter Cap Bolt A Washer B Spring C Rod D Remove the mounting bolts E and take off the camshaft chain tensioner Camshaft Chain Tensioner Installation e Apply grease to the O ring Release the stopper A and push the push rod into the interior of tensioner body C e Install the tensioner body so that the stopper faces up ward e Tighten the tensioner mounting bolts A Torque Camshaft Chain Tensioner Mounting Bolts 11 N m 1 1 kgf m 97 in Ib e Install the rod spring and washer e Tighten the cap bolt B Torque Camshaft Chain Tensioner Cap Bolt 20 N m 2 0 kgf m 15 ft lb 5 16 ENGINE TOP END Camshaft Camshaft Chain Camshaft Removal e Remove the cylinder head cover see Cylinder Head Cover Removal Remove the timing inspection cap A and starter clutch bolt cap B on the starter clutch cover C e Using a wrench on the starter clutch bolt A turn the crankshaft clockwise until the line B TDC mark for 1 4 pistons on the starter clutch is aligned with the notch C in the edge of the timing inspection hole D in the starter clutch cover x If the starter clutch cover is removed perform the next procedure OUsing a wrench on the starter clutch bolt A turn the crankshaft clockwise until the line B TDC mark for 1 4 pistons on the starter clutch C is aligned with the mating surfa
192. Replace the O ring of injectors and the dust seals of delivery pipe to new one e Apply engine oil to the new dust seals A insert the in jectors installed to the delivery pipe to the throttle body NOTE OReplace the dust seals of the throttle body to new one e Install the delivery pipe assy to the throttle body Torque Delivery Pipe Mounting Screws 3 4 N m 0 35 kgf m 30 in lb e Insert the each hoses to the throttle body fittings e Install the throttle body assy see Throttle Body Assy In stallation e P 617658 P FUEL SYSTEM DFI 3 121 Nozzle Assy Nozzle Assy Removal e Set up the fuel tank see Air Cleaner Housing Removal e Be sure to place a piece of cloth A around the fuel hose joint B e Push the joint lock claws C e Pull the joint lock A as shown e Pull the fuel hose joint B out of the delivery pipe C A WARNING Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is disconnected fuel spills out from the hose and the pipe because of residual pressure Cover the hose connection with a piece of clean cloth to prevent fuel spillage e Remove Nozzle Assy Lead Connectors A Nozzle Assy Mounting Bolts B Nozzle Assy C Nozzle Assy Installation e Install the nozzle assy Torque Nozzle Assy Mounting Bolts 6 9 N m 0 70 kgf m 61 in Ib e Install Nozzle Assy Lead Connector
193. SS o OSs 9113354851 9113355851 C CRANKSHAFT TRANSMISSION 9 37 Transmission e Remove Clutch see Clutch Removal in the Clutch chapter Remove the shift shaft assembly A while pulling the shift mechanism arm e Remove Gear Positioning Lever Bolt A Gear Positioning Lever B Collar and Spring External Shift Mechanism Installation e Install the gear positioning lever A as shown Spring B Collar C Bolt D Tighten Torque Gear Positioning Lever Bolt 12 N m 1 2 kgf m 106 in Ib 6113200BS1 e Install Washer A Shift Shaft Assembly B Olnstall the spring C and shift mechanism arm D on the return spring pin E e Install UJ PILSEN d Washer F NEN Circlip G ES Special Tool Outside Circlip Pliers 57001 144 9113356851 C External Shift Mechanism Inspection e Examine the shift shaft A for any damage xIf the shaft is bent replace it xIf the serration B are damaged replace the shaft x If the springs C are damaged in any way replace them xIf the shift mechanism arm D is damaged in any way replace the shift shaft 9113342851 9 38 CRANKSHAFT TRANSMISSION Transmission e Check the return spring pin A is not loose xf it is loose unscrew it apply a non permanent locking agent to the threads and tighten it Torque Shift Shaft Return Spring Pin 28 N m 2 9
194. STEM Battery Battery Removal e Remove Side Covers see Side Cover Removal in the Frame chapter Front Seat see Front Seat Removal in the Frame chap ter Slide the caps A e Disconnect the negative cable B and then positive cable C CAUTION Be sure to disconnect the negative cable first e Remove the band D Remove the battery Battery Installation e Visually inspect the surface of the battery container xIf any signs of cracking or electrolyte leakage from the sides of the battery e Put the battery into the battery case e Install the fuel tank bracket and connector Connect the positive cable A red cap to the terminal first and then the negative cable black cap B to the terminal e Apply a light coat of grease on the terminals to prevent corrosion e Cover the terminals with the caps C CAUTION If each battery cable is not correctly disconnected or connected sparks can arise at electrical connec tions causing damage to electrical and DFI parts Battery Activation Electrolyte Filling e Make sure that the model name A of the electrolyte con tainer matches the model name B of the battery These names must be the same Battery Model Name for ZX600P7F YTX9 BS CAUTION Be sure to use the electrolyte container with the same model name as the battery since the elec trolyte volume and specific gravity vary with th
195. STEM Immobilizer System Equipped Models e Remove the key registration unit and connect the immo bilizer Kawasaki self diagnostic system connector NOTE OTurn the ignition switch ON with the registered user key OCheck that the engine can be started using all regis tered user keys e Install the new ignition switch and antenna Case 3 When the electric control unit ECU is faulty and has to be replaced e Prepare a new ECU A current master key B and cur rent user keys C NOTE OThe key registration unit is not required e Replace Electric Control Unit A see ECU Removal in the Fuel System DFI chapter e Insert the current master key into the ignition switch and turn it ON olf there is any problem in the registration the warning indicator light LED A blinks to display the collation error Immobilizer Amplifier Failure Master Key Collation Error 0 2second GP30374BS1 C 0 3second UA GP30373BS1 ELECTRICAL SYSTEM 16 93 Immobilizer System Equipped Models e The master key is registered in the ECU OThe warning indicator light LED A blinks 1 time and stops for 1 second and the repeats this cycle to indicate successful registration of the master key e Turn of the master key and remove it OThe warning indicator light LED A blinks to display the registration mode NOTE Olnsert next
196. Sensor 26 ECU 27 Side Stand Switch G Apply grease L Apply a non permanent locking agent R Replacement Parts S Follow the specific tightening sequence SS Apply silicone sealant 16 10 ELECTRICAL SYSTEM Wiring Diagram United States and Canada Right Switch Housing 1 Front Brake Engine Light Switch Right Switch i Head E 2 Engine Stop Cavar Switch around D s starter Button Z 4 8 Watch ed Bitten Spark Plugs ti Fan 00060 Neutral Indicator Light LED Fuel Level Warning Indicator Light LED Meter Unit M WT Turn Signal Indicator Light LED Horn INNS rimaly Fuel Injectors High Beam Indicator Light LED E d Stick 1 84 2011 Pressure Warning Fl Immobilizer E Indicator Light LED BK Y Es 0dometeryTrip Meter Stop Watch Indicator Gear Position Indicator Clock Water Temperature Gauge Mrs Tachometer m in Speadometer Wala Meter Light LEB Shift Up Indicator Light LED 6 P Secondary Fuel Be Injectors Ignition R BL NI 1 42 Switch li ITATES Eis R BK R BL BL R BR W R R BK R wy wey R BL Meter Unit L6 UNI H 8 BL R R BK BR R um Joint Connactor BK Y D Li i i i BK AY SLED Light Emitting Dio
197. Sensor Service Code 13 If the output voltage is out of the specified check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see ECU Removal Installation x If the output voltage is far out of the specified e g when the wiring is open the voltage is about DC 5 0 V check the wiring e Remove the needle adapter set and apply silicone sealant to the seals of the connector for waterproofing Sealant Kawasaki Bond Silicone Sealant 56019 120 x If the wiring is good check the sensor resistance Inlet Air Temperature Sensor Resistance Inspection e Remove the inlet air temperature sensor see Inlet Air Temperature Sensor Removal e Suspend the sensor A in a container of machine oil so that the heat sensitive portion is submerged e Suspend a thermometer B with the heat sensitive por tion C located in almost the same depth with the sensor NOTE OThe sensor and thermometer must not touch the con tainer side or bottom e Place the container over a source of heat and gradually raise the temperature of the oil while stirring the oil gently for even temperature e Using a digital meter measure the internal resistance of the sensor across the terminals at the temperatures shown in the table Inlet Air Temperature Sensor Resistance Standard 2 09 2 81 at 20 68 60171008 About 0 322 at 80 C 176 F ref
198. Sensor Installation e The UP mark A of the sensor should face upward e Tighten Torque Vehicle down Sensor Bolts 5 9 N m 0 60 kgf m 52 in lb WARNING Incorrect installation of the vehicle down sensor could cause sudden loss of engine power The rider could lose balance during certain riding situ ations like leaning over in a turn with the potential for an accident resulting in injury or death Ensure that the sensor is held in place by the fuel tank bracket GC17354BS1 C 90170165 P GC17356BS1 FUEL SYSTEM DFI 3 67 Vehicle down Sensor Service Code 31 Vehicle down Sensor Inspection NOTE OBe sure the battery is fully charged e Remove Windshield see Windshield Removal in the Frame chapter Rubber Cover pry open e Connect a digital volt meter A to the connector of the vehicle down sensor B with the needle adapter set C Special Tool Needle Adapter Set 57001 1457 Vehicle down Sensor Power Source Voltage Connections to Sensor Meter BL lead D Meter BR BK lead E e Turn the ignition switch ON and measure the power source voltage with the connector joined Power Source Voltage at Sensor Standard DC 4 75 5 25 V e Turn the ignition switch OFF x lf there is no voltage check the following Battery see Charging Condition Inspection in the Elec trical System chapter ECU Main Relay see Relay Circuit Inspection in the
199. 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 U S A without Immobilizer Canada without Immobilizer Other than U S A U S A California 21175 0109 Canada Malaysia and Australia with Immobilizer 21175 0114 Malaysia with Immobilizer 21175 0111 U S A California without Immobilizer GC17650BS1 C 21175 0113 Australia with Immobilizer ECU Removal e Remove Muffler Body Seat Cover see Muffler Body Removal in the Engine Top End chapter Battery see Battery Removal in the Electrical System chapter Rear Fender A see Flap and Rear Fender Removal in the Frame chapter e Pull out ECU B with rubber protector e Remove ECU Lead Connectors A Rubber Protector B ECU C FUEL SYSTEM DFI 3 99 ECU ECU Installation e Install ECU A In rubber protector B ECU Lead Connectors C e Insert the slots A of the protector onto the brackets B ECU Power Supply Inspection e Visually inspect the terminals A of the ECU connectors xIf the connector is clogged with mud or dust blow it off with compressed air Replace the main harness if the terminals of the main harness connectors are cracked bent or otherwise dam aged Replace the ECU if the terminals of the ECU connectors are cracked bent or otherwise damage
200. Starter Idle Gear and Starter Clutch OExamine the starter clutch gear C as well Replace the clutch gear if it is worn or damaged Gee 9 36 CRANKSHAFT TRANSMISSION Transmission Shift Pedal Removal e Remove Shift Lever Bolt A Shift Pedal Mounting Bolt B Tie Rod C and Shift Pedal D Shift Pedal Installation e Apply grease to the sliding surface A on the shift pedal mounting bolt B e Install Washers C Shift Pedal Assembly D OThe front side of the tie rod has the grooves E OThe grooves side of the tie rod and front locknut F have left hand threads e Tighten Torque Shift Pedal Mounting Bolt 25 N m 2 5 kgf m 18 16 eAlignthe punch mark the shift shaft with the slit of the shift lever e Tighten Torque Shift Lever Bolt C 6 9 N m 0 70 kgf m 61 in Ib e Install the shift pedal as follows About 90 D About 95 E 1 3 mm 0 04 0 12 in F The length is distance between the center line of the tie rod G and center in the shift pedal end OTo adjust the pedal position loosen the locknuts H and then turn the tie rod e Tighten Torque Shift Tie Rod Locknuts 6 9 N m 0 70 kgf m 61 in Ib External Shift Mechanism Removal e Remove Engine Oil see Drain Engine Oil Change in the Periodic Maintenance chapter Shift Pedal see Shift Pedal Removal Circlip A Washer B Special Tool Outside Circlip Pliers 57001 144 DES S
201. Sys tem chapter City Light Holders Upper Fairing Assembly e Install the removed parts see appropriate chapters Upper Fairing Installation e Install the removed parts see appropriate chapters Inner Cover Removal e Remove the bolt A e Remove the inner cover B ORemove the inner cover by pulling the rear portion C of it up and forward clear the cover from the stoppers ORemove the inner cover by pulling the front portion D of it up and backward clear the cover from the stoppers FRAME 15 13 Fairings Inner Cover Installation e Insert the rear portion of the cover under the middle fair ing e Fit the projections B of the inner cover on to the holes A of the upper fairing e Tighten the bolt Center Inner Fairing Removal e Remove Upper Fairing see Upper Fairing Removal Screws A Center Inner Fairing B OSlide out the center inner fairing backward C Center Inner Fairing Installation e Insert the tangs A of the center inner fairing into the holes B of the upper fairing Lower Inner Fairing Removal e Remove Middle Fairing see Middle Fairing Removal Bolts A Quick Rivet B Inner Fairing C 15 14 FRAME Fairings Lower Inner Fairing Installation Tighten Bolts A Quick Rivets B e Install the removed parts see appropriate chapters FRAME 15 15 Side Covers Left Side Cover Removal e Remove Bolt A Projections
202. TDC 288 63 BBDC 23 ATDC 1 10 GENERAL INFORMATION General Specifications ltems ZX600P7F Ninja ZX 6R Duration 266 Lubrication System Forced lubrication wet sump with cooler Engine Oil Type API SE SF or SG SH SJ SL with JASO MA Viscosity SAE10W 40 Capacity 3 8 L 4 0 US qt Drive Train Primary Reduction System Type Reduction Ratio Clutch Type Transmission Type Gear Ratios 1st 2nd 3rd 4th 5th 6th Final Drive System Type Reduction Ratio Overall Drive Ratio Frame Type Caster Rake Angle Trail Front Tire Type Size Rear Tire Type Size Rim Size Front Rear Front Suspension Type Wheel Travel Rear Suspension Type Wheel Travel Gear 1 900 76 40 Wet multi disc 6 speed constant mesh return shift 2 714 2 200 1 850 1 600 1 421 1 300 38 14 33 15 37 20 32 20 27 19 26 20 Chain drive 2 688 43 16 6 638 Top gear Tubular diamond 25 110 mm 4 3 in Tubeless 120 70 ZR17 M C 58 W Tubeless 180 55 ZR17 73 W 17 x 3 50 17 x 5 50 Telescopic fork upside down 120 mm 4 7 in Swingarm uni trak 133 mm 5 2 in GENERAL INFORMATION 1 11 General Specifications ltems ZX600P7F Ninja ZX 6R Brake Type Front Dual discs Rear Single disc Electrical Equipment Battery 12V 8 Ah Headlight Type Semi sealed beam Bulb High 12 V 55 W 65 W q
203. TRICAL SYSTEM 16 99 Immobilizer System Equipped Models e Install the clamp A e Tighten a new Torx bolt B until the bolt head C is bro ken e Run the leads correctly see Cable Wire and Hose Rout ing section in the Appendix chapter Immobilizer Amplifier Replacement e Remove Windshield see Windshield Removal in the Frame chapter e Pull out the amplifier A e Disconnect the connector A e Pull the amplifier B backward to clear the hooks ECU Electric Control Unit Replacement for Equipped Models e Refer to the ECU Removal in the Fuel System DFI chap ter ECU Removal in the Fuel System DFI chapter 16 100 ELECTRICAL SYSTEM Immobilizer System Equipped Models Immobilizer Relational Parts Replacement Chart Failed or Lost Part Master User Ignition Ampli Switch Ignition Switch An tenna Ampli fier Replacement Part e Main Replacement Part Additional Replacement Part Immobilizer System Inspection e Refer to the Immobilizer Amplifier and Blank Key Detec tion section in the Fuel System DFI chapter ELECTRICAL SYSTEM 16 101 Immobilizer System Equipped Models Immobilizer System Circuit on PARK iow TrON CES SEC MAILI ET GP30369BW3 C ECU Ignition Switch Immobilizer Amplifier Cylinder Head Cover Ground J
204. To avoid extremely high voltage shocks do not touch the spark plugs or tester connections Turn the ignition switch and the engine stop switch ON e Pushing the starter button turn the engine 4 5 seconds with the transmission in neutral to measure the primary peak voltage Repeat the measurements 5 times for one stick coil Stick Coil Primary Peak Voltage Standard 80 V or more Repeat the test for the other stick coil xIf the reading is less than the specified value check the following Stick Coils see Stick Coil Inspection Crankshaft Sensor see Crankshaft Sensor Inspection ECU see ECU Power Supply Inspection in the Fuel Sys tem DFI chapter Spark Plug Removal e Refer to the Spark Plug Replacement in the Periodic Maintenance chapter see Spark Plug Replacement in the Periodic Maintenance chapter Spark Plug Installation e Refer to the Spark Plug Replacement in the Periodic Maintenance chapter see Spark Plug Replacement in the Periodic Maintenance chapter Spark Plug Clean and Inspection e Remove the spark plug and visually inspect 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 xIf the spark plug center electrode A and or side elec trode B are corroded or damaged or if the insulator C is cracked replace the plug xIf the spark plug
205. Using a wrench on the starter clutch bolt A turn the crankshaft clockwise until the line B TDC mark for 1 4 pistons on the starter clutch is aligned with the notches C in the edge of the timing inspection hole D in the starter clutch cover CAUTION The crankshaft may be turned while the camshafts are removed Always pull the chain taut while turn ing the crankshaft This avoids kinking the chain on the lower crankshaft sprocket A kinked chain could damage both the chain and the sprocket Sippy P Camshaft ENGINE TOP END 5 19 x lf the starter clutch cover is removed perform the next procedure OUsing a wrench on the starter clutch bolt A turn the crankshaft clockwise until the line B TDC mark for 1 4 pistons on the starter clutch C is aligned with the mating surface D of crankcase rear side e Pull the tension side exhaust side A of the chain taut to install the chain e Engage the camshaft chain with the sprockets so that tim ing marks on the sprockets are positioned as shown OThe timing marks must be aligned with the cylinder head upper surface B EX Timing Mark C IN Timing Mark D 1 Pin E 2 Pin F 26 Pin G 27 Pin H OThe below illustration is viewed from the right side of the engine when the engine removed GE 1220882 C 5 20 ENGINE TOP END Camshaft e Apply molybdenum disulfide oil solution A A
206. V FUEL SYSTEM DFI 3 97 Oxygen Sensors Incorrect Output Voltage 1 2 Service Code 94 95 Equipped Models e Next remove the plugs A both sides from the fittings with idling e Measure the output voltage of the sensor with the con nector joined Oxygen Sensor Output Voltage without Plugs Standard 0 05 0 45 V xIf the reading is within range with plugs 0 45 2 5 V without plugs 0 05 0 45 V the oxygen sensor is good x If the reading is without range inspect the engine and fuel supply system xIf the engine and fuel supply system good replace the Oxygen sensor e Remove the needle adapter set and apply silicone sealant to the seals of the connector for waterproofing Sealant Kawasaki Bond Silicone Sealant 56019 120 Oxygen Sensor Circuit 0 1 amp 5 ao T a Qe zo BR BK Y 66179386 2 C ECU Oxygen Sensor 1 Oxygen Sensor 2 Ignition Switch Fuse Box Oxygen Sensor Fuse 10 A Main Fuse 30 A Starter Relay Battery Frame Ground 1 2 3 4 5 6 7 8 9 0 3 98 FUEL SYSTEM DFI ECU CAUTION Never drop the ECU especially on a hard surface Such a shock to the ECU can damage it ECU Identification OMost countries have their own regulations so each ECU has different characteristic
207. Valve Actuator Service Code 62 Subthrottle Valve Actuator Removal CAUTION Do not remove the subthrottle valve actuator A since it has been adjusted and set with precision at the factory Never drop the throttle body assy especially on a hard surface Such a shock to the actuator can damage it Subthrottle Valve Actuator Inspection e Remove Air Cleaner Housing see Air Cleaner Housing Removal Fuel Pump Lead Connector see Fuel Tank Removal e Turn the ignition switch ON e Check to see that all subthrottle valves A open and close smoothly x If the subthrottle valves do not operate check the actuator internal resistance see Resistance Inspection Subthrottle Valve Actuator Resistance Inspection e Turn the ignition switch OFF e Remove the subthrottle valve actuator connector A e Connect a digital meter to the connector A e Measure the subthrottle valve actuator resistance Subthrottle Valve Actuator Resistance Connections lead 1 W BL lead 3 BK BL lead 2 P BL lead 4 Standard About 5 7 x If the reading is out of the range replace the throttle body assy see Throttle Body Assy Removal x If the reading is within the range check the input voltage see Input Voltage Inspection 80179150651 3 88 FUEL SYSTEM DFI Subthrottle Valve Actuator Service Code 62 Subthrottle Valve Actuator Input Voltage Inspection NOTE OBe sure the battery is full
208. Voltage Adapter Stopper 57001 1415 57001 1679 875714155 C 875716795 6 Lead Wire Peak Voltage Adapter Kawasaki Bond Silicone Sealant 57001 1449 92104 0004 7571449ST C 879200045 Key Registration Unit 57001 1582 875715825 16 20 ELECTRICAL SYSTEM Precautions There a number of important precautions that musts when servicing electrical systems Learn and ob serve all the rules below ODo not reverse the battery cable connection This will burn out the diodes on the electrical parts OAlways check battery condition before condemning other parts of an electrical system A fully charged battery is a must for conducting accurate electrical system tests OThe electrical parts should never be struck sharply as with a hammer or allowed to fall on a hard surface Such a shock to the parts can damage them OTo prevent damage to electrical parts do not disconnect the battery cables or any other electrical connections when the ignition switch is on or while the engine is running OBecause of the large amount of current never keep the starter button pushed when the starter motor will not turn over or the current may burn out the starter motor wind ings OTake care not to short the cables that are directly con nected to the battery positive terminal to the chassis ground OTroubles may involve one or in some cases all items Never replace a defective part without determi
209. W4 Vv Inlet Air Pressure Sensor Output Voltage V Digital Meter Reading 3 52 FUEL SYSTEM DFI Inlet Air Temperature Sensor Service Code 13 Inlet Air Temperature Sensor Removal Installation CAUTION Never drop the sensor especially on a hard surface Such a shock to the sensor can damage it e Set up the fuel tank see Air Cleaner Housing Removal e Disconnect the connector A from the inlet air tempera ture sensor e Pull out the inlet air temperature sensor B e Install the inlet air temperature sensor A in the grommet B Inlet Air Temperature Sensor Output Voltage Inspection NOTE sure the battery is fully charged e Remove the ECU see ECU Removal Do not disconnect the ECU connectors e Connect a digital voltmeter A to the ECU connector us ing needle adapter set B Special Tool Needle Adapter Set 57001 1457 Inlet Air Temperature Sensor Output Voltage Connections to ECU Connector Meter Y lead terminal 26 Meter BR BK lead terminal 28 e Measure the sensor output voltage with the engine stopped and the connector joined e Turn the ignition switch ON Output Voltage at ECU Standard About 2 25 2 50 V at inlet air temperature 20 C 68 F NOTE OThe output voltage changes according to the inlet air temperature e Turn the ignition switch OFF 86617901651 FUEL SYSTEM DFI 3 53 Inlet Air Temperature
210. Warning Indicator Light LED Fl Immobilizer Circuit BR R BK Y BR R BK Y BK Y 6Cc17924CW2 C T e 1 ECU 2 Battery 12 V 8 Ah 3 Frame Ground 4 Meter Unit 5 Warning Indicator Light LED FUEL SYSTEM DFI 3 103 Fuel Line Fuel Pressure Inspection NOTE OBe sure the battery is fully charged e Remove Front Seat see Front Seat Removal in the Frame chap ter e Set up the fuel tank see Air Cleaner Removal e Be sure to place a piece of cloth around the fuel supply pipe of the throttle body assembly and fuel pump e Remove the fuel hose see Fuel Tank Removal A WARNING Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is disconnected fuel spills out from the hose and the pipe because of residual pressure Cover the hose connection with a piece of clean cloth to prevent fuel spillage e Install the fuel pressure gauge adapter A and fuel hoses B between the fuel supply pipes of the fuel pump and throttle body assy e Connect the pressure gauge C to the fuel pressure gauge adapter Special Tools Oil Pressure Gauge 5 kgf cm 57001 125 Fuel Pressure Gauge Adapter 57001 1593 Fuel Hose 57001 1607 A WARNING Do not try to start the engine with the fuel hoses disconnected e Turn the ignition switch ON The fuel pump will turn for 3 seconds and then stop CAUTION Do not d
211. YSTEM 3 75 Oxygen Sensor not activated 1 2 Service Code 33 83 Equipped Models e Next remove the plugs A both sides from the fittings with idling e Measure the output voltage of the sensor with the con nector joined Oxygen Sensor Output Voltage without Plugs Standard 0 05 0 45 V xIf the reading is within range with plugs 0 45 2 5 V without plugs 0 05 0 45 V the oxygen sensor is good x If the reading is without range replace the oxygen sensor e Remove the needle adapter set and apply silicone sealant to the seals of the connector for waterproofing Sealant Kawasaki Bond Silicone Sealant 56019 120 Oxygen Sensor Circuit 6GC17912CW2 ECU Oxygen Sensor 1 Oxygen Sensor 2 Oxygen Sensor Heater Fuse 10 A Main Fuse 30 A Starter Relay Battery 12 V 8 Ah Frame Ground 3 76 FUEL SYSTEM Exhaust Butterfly Valve Actuator Sensor Service Code 34 Exhaust Butterfly Valve Actuator Sensor Removal Installation The exhaust butterfly valve actuator sensor is built in the exhaust butterfly valve actuator So the sensor itself can not be removed Remove the exhaust butterfly valve actu ator see Exhaust Butterfly Valve Actuator Removal Exhaust Butterfly Valve Actuator Sensor Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Remove S
212. YSTEM DFI 3 69 Vehicle down Sensor Service Code 31 Vehicle down Sensor Circuit 6C176398W2 C 1 ECU 2 Vehicle down Sensor 3 70 FUEL SYSTEM DFI Subthrottle Sensor Service Code 32 Subthrottle Sensor Removal Adjustment CAUTION Do not remove or adjust the subthrottle sensor A since it has been adjusted and set with precision at the factory Never drop the throttle body assy especially on a hard surface Such a shock to the sensor can dam age it Subthrottle Sensor Connector B Subthrottle Sensor Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Remove the ECU see ECU Removal Do not disconnect the ECU connectors e Connect a digital voltmeter A to the connector B using the needle adapter set Special Tool Needle Adapter Set 57001 1457 Subthrottle Sensor Input Voltage Connections to ECU Connector Meter BL lead terminal 10 Meter BR BK lead terminal 28 e Measure the input voltage with the engine stopped and with the connectors joined e Turn the ignition switch ON Input Voltage at ECU Connector Standard DC 4 75 5 25 V e Turn the ignition switch OFF xIf the reading of input voltage is less than the standard check the ECU for its ground power supply and wiring shorted x If the input voltage is within the standard range check the input voltage at the subthrottle sensor connecto
213. ace B of the bracket e Tighten the mounting bolts FRAME 15 9 Fairings Lower Fairing Removal e Remove Bolts A with Washers e Clear the hook portion from the slot e Pull up the core A by the thin blade screw driver e Remove Quick Rivets B e Separate the right lower fairing from the left lower fairing Lower Fairing Installation Set the quick rivet A and push the core e Insert the hook portion A into the slot B Middle Fairing Removal Left Middle Fairing Removal e Remove Lower Fairings see Lower Fairing Removal Bolts A with Washers Left Inner Cover B see Right and Left Inner Cover Re moval 15 10 FRAME Fairings e Remove Quick Rivets A e Remove Quick Rivets A Left Turn Signal Lead Connector Separator Band California Model e Remove the left middle fairing with lower inner fairing Left Middle Fairing Installation e Install the separator band California Model e Connect the left turn signal lead connector e Insert the projections A into the slots B e Install Left Inner Cover see Inner Cover Installation Washers and Bolts Right Middle Fairing Removal e Remove Lower Fairings see Lower Fairing Removal Bolts A with Washers Right Inner Cover B see Inner Cover Removal e Remove Quick Rivets A FRAME 15 11 Fairings e Remove Quick Rivets A e Remove Right Turn Signal Lead Connector A Fan
214. ace glazed Disc warped Caliper trouble Other noise Bracket nut bolt etc mounted or tightened not properly Warning Indicator Light Oil Pressure Warning Doesn t Go OFF Engine oil pump damaged Engine oil screen clogged Engine oil filter clogged Engine oil level too low Engine oil viscosity too low Camshaft bearing worn Crankshaft bearing worn Oil pressure switch damaged Wiring faulty Relief valve stuck open O ring at the oil passage in the crankcase damaged Exhaust Smokes Excessively White smoke Piston oil ring worn Cylinder worn Valve oil seal damaged Valve guide worn Engine oil level too high Black smoke Air cleaner clogged Brown smoke Air cleaner housing holder loose Air cleaner poorly sealed or missing Handling and or Stability Unsatisfactory Handlebar hard to turn Cable routing incorrect Hose routing incorrect Wiring routing incorrect Steering stem nut too tight Steering stem bearing damaged Steering stem bearing lubrication inade quate Steering stem bent Tire air pressure too low Handlebar shakes or excessively vibrates Tire worn Swingarm pivot bearing worn Rim warped or not balanced Wheel bearing worn Handlebar holder bolt loose Steering stem nut loose Front rear axle runout excessive Engine loose Handlebar pulls to one side Frame bent Wheel misalignment Swingarm bent or twisted Swingarm pivot shaft runout excessive Steering maladjusted Front fork bent Right and left fron
215. acement pp Brake Fluid Change Master Cylinder Rubber Parts Replacement pp Caliper Rubber Parts Replacement pp Spark Plug Replacement 2 37 2 38 2 38 2 40 2 41 2 42 2 43 2 43 2 44 2 46 2 46 2 47 2 50 2 52 2 53 2 53 2 54 2 54 2 56 2 57 2 60 PERIODIC MAINTENANCE 2 3 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition The initial maintenance is vitally important and must not be neglected Periodic Inspection FREQUENCY Whichever ODOMETER READING comes x 1 000 km first x 1 000 mile INSPECTION Fuel System Throttle control system play smooth return no drag inspect Engine vacuum synchronization inspect Idle speed inspect Fuel leak fuel hose and pipe inspect Fuel hose and pipe damage inspect Fuel hose and pipe installation condition inspect Evaporative Emission Control System California Model only Evaporative emission control system function inspect Cooling System Coolant level inspect Coolant leak radiator hose and pipe inspect Radiator hose damage inspect Radiator hose installation condition inspect Engine Top End Valve clearance inspect United States and Canada Models Valve clearance inspect Other than United States and Canada Models Air Suction System Every 42 000 km 26 000 mile
216. ad life 9096 worn So it is false economy and unsafe to use the tires until they are bald e Measure the tread depth at the center of the tread with a depth gauge A Since the tire may wear unevenly take measurement at several places If any measurement is less than the service limit replace the tire see Tire Removal Installation in the Wheels Tires chapter Tread Depth Standard Front 3 6 mm 0 14 in Rear 4 8 mm 0 19 in Service Limit Front 1 mm 0 04 in AT CH DE 1 6 mm 0 06 in Rear 2 mm 0 08 in Up to 130 km h 80 mph 3 mm 0 12 in Over 130 km h 80 mph 6J05007BS1 C 2 28 PERIODIC MAINTENANCE Maintenance Procedure WARNING To ensure safe handling and stability use only the recommended standard tires for replacement in flated to the standard pressure NOTE OMost countries may have their own regulations a mini mum tire tread depth be sure to follow them OCheck and balance the wheel when a tire is replaced with a new one Wheel Bearing Damage Inspection e Using a jack and attachment raise the front wheel off the ground see Front Wheel Removal in the Wheels Tires chapter e Turn the handlebar all the way to the right or left e Inspect the roughness of the front wheel bearing by push ing and pulling A the wheel Spin the front wheel lightly and check for smoothly turn roughness binding or noise x If roughness binding o
217. age Connections to Sensor Meter Y BL lead C Meter BR BK lead D Output Voltage at Sensor Connector Usable Range DC 3 80 4 20 V at the standard atmospheric pressure 101 32 kPa or 76 cmHg abs x If the output voltage is normal check the wiring for conti nuity xIf the output voltage is out of the usable range replace the sensor e Turn the ignition switch OFF e Remove the sensor harness adapter Inlet Air Pressure Sensor Circuit LI GC17143BS1 C EI m Y BR BK a e Y BL 2 6C176318W2 C 1 ECU 2 Inlet Air Pressure Sensor If you need to check the inlet air pressure sensor for vac uum other than 76 cmHg abs check the output voltage as follows 3 50 FUEL SYSTEM DFI Inlet Air Pressure Sensor Service Code 12 e Remove the inlet air pressure sensor A and disconnect the vacuum hose from the sensor ODo not disconnect the sensor connector e Connect an auxiliary hose B to the inlet air pressure sen sor Temporarily install the inlet air pressure sensor OConnect a commercially available digital meter C vac uum gauge D and the fork oil level gauge E to the inlet air pressure sensor Special Tools Fork Oil Level Gauge 57001 1290 Sensor Harness Adapter 57001 1561 Inlet Air Pressure Sensor Output Voltage Connection to Sensor Meter Y BL lead Meter BR BK lead OTurn the ignition switch ON
218. ain Fuse A Relay Box B Ignition Key A Transponder Equipped Models Immobilizer Antenna B Equipped Models Ignition Switch C Immobilizer Amplifier D Equipped Models Vehicle down Sensor E Oxygen Sensor A Equipped Models 3 16 FUEL SYSTEM DFI System DFI System e e FUEL SYSTEM DFI 3 17 DFI System ECU Electrical Control Unit Battery 12 V 8 Ah Air Flow Air Cleaner Element Inlet Air Temperature Sensor Inlet Air Pressure Sensor Subthrottle Valve Actuator Subthrottle Sensor Secondary Fuel Injectors Primary Fuel Injectors Delivery Pipe Fuel Filter Pressure Regulator Fuel Pump Fuel Flow Camshaft Position Sensor Main Throttle Sensor Crankshaft Sensor Water Temperature Sensor Speed Sensor Vehicle down Sensor Atmospheric Pressure Sensor Gear Position Switch Starter Clutch Case Oxygen Sensors Equipped Models Air Switching Valve 3 18 FUEL SYSTEM DFI System DFI System Wiring Diagram 63 41342483344 nul m n I E a i HH d mz sie il wv In I jd Q nra I Lea LB 9
219. airing Removal in the Frame chapter Water Hoses A Radiator Fan Lead Connector B e Remove Coolant Reserve Tank see Coolant Reserve Tank Re moval Separator California Model A Water Hose B Remove the radiator lower bolt A e Remove Right Radiator Upper Bolt A Horn B Remove Left Radiator Upper Bolt A Radiator B CAUTION Do not touch the radiator core This could damage the radiator fins resulting in loss of cooling effi ciency 4 14 COOLING SYSTEM Radiator ORemove the bolt A and radiator bracket as necessary e Remove Radiator Fan Mountings A Radiator Fan B Radiator and Radiator Fan Installation e Install the radiator fan A e Install the rubber dampers B and collars C as shown CES pA 2222 Vr 9007056852 C COOLING SYSTEM 4 15 Radiator xIf the radiator bracket A was removed install it Torque Radiator Bracket Mounting Bolt B 9 8 N m 1 0 kgf m 87 in lb e Install the horn C e Tighten Torque Radiator Upper Bolts D 9 8 N m 1 0 kgf m 87 in Ib Radiator Lower Bolt E 6 9 N m 0 70 kgf m 61 in Ib e Route the radiator fan lead F over the clutch cable G e Face the white marks of the radiator hoses I direction as shown e Install the water hose clamps J as shown Upside View K Torque Water Hose Clamp Screws 2 0 N m 0 20 kgf m 17 in Ib e For the
220. alled e Disconnect the front brake light switch connector D CAUTION Immediately wash away any brake fluid that spills e Remove Brake Lever Pivot Bolt A and Nut Brake Lever B Clamp C Slide Out Brake Hose D Front Brake Light Switch E Front Master Cylinder Installation e Set the front master cylinder to match its mating surface A to the punch mark B of the handlebar The master cylinder clamp must be installed with the ar row mark C upward e Tighten the upper clamp bolt first and then the lower clamp bolt Torque Front Master Cylinder Clamp Bolts 8 8 N m 0 90 kgf m 78 in lb Replace the washers that on each side of the hose fitting with new ones Tighten Torque Brake Hose Banjo Bolt 25 N m 2 5 kgf m 18 ft Ib Bleed the brake line see Brake Line Bleeding e Check the brake for good braking power no brake drag and no fluid leakage 12 16 BRAKES Master Cylinder Rear Master Cylinder Removal e Unscrew the brake hose banjo bolt A and brake hose e Remove Cotter Pin Joint Pin D Bolts E Foot Guard F Rear Master Cylinder Slide out the clamp e Pull off the reservoir hose lower end and drain the brake fluid into a container Rear Master Cylinder Installation Replace the cotter pin with a new one e Replace the washers that are on each side of hose fitting with new ones e Tighten Torque Rear Master Cy
221. amp Bearing Remover A 57001 1058 Swingarm Bearing Installation e Replace the ball and needle bearings A with new ones e Install the ball and needle bearings so that the manufac turer s marks face out Special Tools Bearing Driver Set 57001 1129 Needle Bearing Driver 528 B 57001 1610 Spacer 028 57001 1637 GM06137BS1 C GM06138BS1 C 8 06071 51 C 13 26 SUSPENSION Swingarm e Install the needle bearings ball bearing and oil seals C position as shown Circlip D 32 5 mm 1 28 in E 0 5 mm 0 02 in F 1 mm 0 04 5 mm 0 20 in H 6 06133 1 C Swingarm Bearing Sleeve Inspection CAUTION Do not remove the bearings for inspection Re moval may damage them e Inspect the needle bearings A and ball bearing installed in the swingarm OThe rollers and ball in a bearing normally wear very little and wear is difficult to measure Instead of measuring visually inspect the bearing for abrasion discoloration or other damage x lf the needle bearing and sleeve B show any sings of abnormal wear discoloration or damage replace them as a set e Turn the bearings in the swingarm back and forth A while checking for plays roughness or binding xIf bearing play roughness or binding is found replace the bearing e Examine the bearing seal on the right side ball bearing for tears or leakage x lf the seal is torn or is
222. amshaft seizure Starter idle gear seizure No fuel flow No fuel in tank Fuel pump trouble Fuel tank air vent obstructed Fuel filter clogged Fuel line clogged No spark spark weak Vehicle down sensor DFI coming off Ignition switch not ON Engine stop switch turned OFF Clutch lever not pulled in or gear not in neu tral Battery voltage low Immobilizer system trouble Spark plug dirty broken or gap malad justed Spark plug incorrect Stick coil shorted or not in good contact Bypass screw and or idle adjusting screw maladjusted Air passage clogged Air cleaner clogged poorly sealed or miss ing Leak from oil filler cap crankcase breather hose or air cleaner drain hose Compression Low Spark plug loose Cylinder head not sufficiently tightened down Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak No valve clearance Valve not seating properly valve bent worn or carbon accumulation on the seating surface Poor Running at Low Speed Spark weak Battery voltage low Immobilizer system trouble Stick coil trouble Stick coil shorted or not in good contact Spark plug dirty broken or maladjusted Spark plug incorrect ECU trouble Camshaft position sensor trouble Crankshaft sensor trouble Fuel air mixture incorrect Bypass screw maladjusted Air
223. an not be adjusted with the adjusters replace the cable Engine Vacuum Synchronization Inspection NOTE OThese procedures are explained on the assumption that the inlet and exhaust systems of the engine are in good condition e Situate the motorcycle so that it is vertical e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Air Cleaner Housing see Air Cleaner Housing Removal in the Fuel System DFI chapter Fuel Hose see Fuel Hose Replacement in the Periodic Maintenance chapter OWhen removing the air cleaner housing do not remove the inlet air pressure sensor hose e Pull off the rubber caps A from the fittings of each throttle body e For the California Model pull off the vacuum hose B 2 16 PERIODIC MAINTENANCE Maintenance Procedure e Connect a vacuum gauge special tool and hoses A to the fittings on the throttle body Special Tool Vacuum Gauge 57001 1369 e Connect a highly accurate tachometer B to one of the stick coil primary lead e Plug the air switching valve hose end A and air cleaner housing fitting B e Install the air cleaner housing see Air Cleaner Housing Installation in the Fuel System DFI chapter e Connect the following parts temporary Fuel Pump Lead Connector A Extension Tube B Special Tool Extension Tube 57001 1578 e Start the engine and warm it up thoroughly e Check the idle speed using a highly accurate tachometer
224. ance value to the approximately 100 OThe fuel level warning indicator light LED lists B and FUEL segments flashes in the display x If the lights LED and or symbol does not go on replace the meter assembly Check 16 Immobilizer Flashing Mode Inspection Equipped Models e Connect the leads in the same circuit as Check 1 e Disconnect the terminal 16 e Check that the warning light LED A starts flashing Im mobilizer Warning Light Flashing Mode e Push the MODE B and RESET C buttons more than 2 second within 20 seconds after the terminal 9 discon nected e Check that the warning light LED goes on one second and then the light goes off Immobilizer Warning Light No Flashing Mode NOTE OFor this inspection be sure the battery is 12 2 V or more Olmmobilizer Warning Light Flashing Mode does not work when the battery voltage is less than 12 0 2 V GP17926BS2 C GP17892BS1 ELECTRICAL SYSTEM 16 77 Meter Gauge Indicator Unit e Connect the terminal 16 to the battery terminal e And then disconnect the terminal 16 e Push the MODE and RESET buttons more than 2 second within 20 seconds after the terminal 9 disconnected e Check that the warning light LED goes on one second and then the light starts flashing Immobilizer Warning Light Flashing Mode x If the meter function does not work replace the meter assembly Check 17 Shift Up Indicato
225. and no accessories is the 19th click from the 1st click of the fully clockwise position Rebound Damping Force Adjustment Aduster Damping setting Load Road Speed 25 Weak Soft Light Good Low T 1 1 1 1 i 0 Strong Hard Heavy Bad High Compression Damping Force 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 To adjust the low speed compression damping force turn the upper damping adjuster with a flat head screwdriver to the desired position until you feel a click OThe standard adjuster setting for the average build rider of 68 kg 150 Ib with no passenger and no accessories is the 2 turns out from the fully clockwise position 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 e To adjust the high speed compression damping force turn the upper damping adjuster with a 14 mm wrench to the desired position until you feel a click OThe standard adjuster setting for the average build rider of 68 kg 150 Ib with no passenger and no accessories is the 2 1 2 turns out from the fully clockwise position NOTE OAdjustment of the rebound damping adjuster for the rear suspension will slightly affect the compression damping force Always ma
226. and weight D as shown e Pry the balance weight with two screwdrivers and remove the balance weight e Discard the used balance weight CAUTION Do not tap the screwdrivers The rim could be dam aged Balance Weight Installation e Check if the weight portion has any play on the blade A and clip B xIf it does discard it A WARNING If the balance weight has any play on the rib of the rim the blade and or clip have been stretched Re place the loose balance weight Do not reuse used balance weight Unbalanced wheels can create an unsafe riding condition 6J04076BS1 6J04077BS1 6J04088BS1 C 10 12 WHEELS TIRES Wheels Rims Balance Weight Part Number Weight 41075 0007 10 g 0 35 oz 41075 0008 20 g 0 71 oz 41075 0009 30 g 1 06 oz NOTE OBalance weights are available from Kawasaki dealers in 10 20 and 30 gram 0 35 oz 0 71 oz and 1 06 oz sizes An imbalance of less than 10 grams 0 35 oz will not usually affect running stability ODo not use four or more balance weight more than 90 gram 3 2 oz If the wheel requires an excess balance weight disassemble the wheel to find the cause e Slip the balance weight A on to the rib B by pushing or lightly hammering C the clip D Left Side E Right Side F e Be sure to install the balance weight OCheck that the blade A and clip B are fully sea
227. at the chamfer side face to the muffler body I e Touch the gasket stoppers J of the muffler body to the end of the gasket e Install the muffler body OPass the muffler stays K through the holes of the rear fender Upside L Outside M About 8 mm 0 32 in N e Tighten Torque Muffler Body Mounting Bolts 28 N m 2 8 kgf m 21 ft lb Muffler Body Clamp Bolt P 17 N m 1 7 kgf m 12 16 GE18071BW3 C ENGINE TOP END 5 37 Muffler e Install the exhaust butterfly valve cable and adjust see Exhaust Butterfly Valve Cable installation e Throughly warm up the engine wait until the engine cools down retighten all the bolts e Install the removed parts see appropriate chapters Rear Exhaust Pipe Removal e Remove Muffler Body see Muffler Body Removal Cover Bolts A Cover B move e Remove Rear Footpeg Bracket Bolts A Rear Footpeg Bracket B move e Remove Bolts A Cover B e Remove Bolts A Rear Exhaust Pipe B 5 38 ENGINE TOP END Muffler Rear Exhaust Pipe Installation e Replace the rear exhaust pipe gasket A with a new one e Install the rear exhaust pipe gasket until it is bottomed so that the chamfer side B faces to the rear exhaust pipe Touch the gasket stopper of the rear exhaust pipe to the end of the gasket e Install the rear exhaust pipe clamp bolt E as shown e Install the rear exhaust pipe Front Exhaust Pipe F Upsid
228. ate the lower meter cover A meter assembly and upper meter cover C ress P 16 64 ELECTRICAL SYSTEM Meter Gauge Indicator Unit Electronic Combination Meter Unit Inspection e Remove the meter unit A 1 Neutral Indicator Light LED Ground 2 Right Turn Signal Indicator Light LED 3 High Beam Indicator Light LED 4 Water Temperature Sensor 5 Lap Time 6 Stop Watch 7 Unused 8 Unused 9 Unused 10 Left Turn Signal Indicator Light LED 11 Warning Indicator Light LED Ground 12 Tachometer Pulse 13 Speed Sensor Pulse 14 ECU Communication Pulse 15 Fuel Reserve Switch 16 Ignition 17 Battery 18 Speed Sensor Supply Voltage 19 Ground 20 Unused CAUTION Do not drop the meter unit Place the meter unit so that it faces upward If the meter unit is left upside down or sideways for a long time or dropped it will malfunction Do not short each terminals Check 1 Meter Unit Primary Operation e Using the auxiliary leads connect the 12 V battery A to the meter unit connector as follows OConnect the battery positive terminal to the terminal 17 OConnect the battery negative terminal to the terminal 19 e Check that the tachometer needle A momentarily points their last readings and back to the minimum position x If the meter unit does not work replace the meter assem bly GP17850BS2 C
229. ating from the throttle opening throttle sensor output voltage and the engine speed This method is called a N method This depends on the number of stopped cylinders FUEL SYSTEM DFI 3 43 Main Throttle Sensor Service Code 11 The main throttle sensor is a rotating variable resistor that changes output voltage according to throttle operating The OOO ECU senses this voltage change and determines fuel injec tion quantity and ignition timing according to engine rpm and throttle opening Input Terminal A Output Terminal B Ground Terminal C 6C17127BS1 Main Throttle Sensor Removal Adjustment CAUTION Do not remove or adjust the main throttle sensor since it has been adjusted and set with precision at the factory Never drop the throttle body assy especially on a hard surface Such a shock to the sensor can dam age it Main Throttle Sensor Connector A Main Throttle Sensor Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Remove the ECU see ECU Removal Do not disconnect the ECU connectors e Connect a digital voltmeter A to the connectors B using the needle adapter set Special Tool Needle Adapter Set 57001 1457 Main Throttle Sensor Input Voltage Connections to ECU Connector Meter BL lead terminal 10 Meter BR BK lead terminal 28 e Measure the input voltage with the engine stopped a
230. ation inspect the electrical sys tem to determine the cause and then replace it with a new fuse of proper amperage e Install the fuse box fuses on the original position as spec ified on the lid Fuse Inspection Remove the fuse see Fuse Removal e Inspect the fuse element x lf it is blown out replace the fuse Before replacing a blown fuse always check the amperage in the affected circuit If the amperage is equal to or greater than the fuse rating check the wiring and related components for a short circuit Housing A Fuse Element B Terminals C Blown Element D CAUTION When replacing a fuse be sure the new fuse matches the specified fuse rating for that circuit Installation of a fuse with a higher rating may cause damage to wiring and components 8 20000151 APPENDIX 17 1 Appendix Table of Contents Cable Wire Hose Routing pp 17 2 Troubleshooting 17 30 17 2 APPENDIX Cable Wire and Hose Routing 08809300045 C APPENDIX 17 3 Cable Wire and Hose Routing Throttle Cable Accelerator Throttle Cable Decelerator Clamp Run the clutch cable backside of the throttle cables Clutch Cable Run the clutch cable front side of the front fork and brake hose Run the throttle cables front side of the clutch cable Front Brake Hose Install
231. ator Unit Fuel Level Sensor Line Self Diagnosis Mode Inspection NOTE OUsually when the open or short of the fuel level sensor circuit is detected it becomes the Fuel Level Sensor Line Self Diagnosis Mode OThe fuel level warning indicator light A and FUEL B in the display will flash This function is Fuel Level Sensor Line Self Diagnosis Mode x If the meter enters the self diagnostic mode when the me ter is installed in the motorcycle check the fuel reserve switch see Fuel Reserve Switch Inspection and wiring x If the fuel reserve switch and wiring are good replace the meter assembly GP17927BS1 ELECTRICAL SYSTEM 16 81 Met Gauge Indicator Unit Meter Circuit EEEERE i E I Tiri d BAirERYjOS ODI aani Ignition Switch Meter Unit Joint Connector C Lap Switch ECU Fuse 10A Ignition Fuse 10 A Horn Fuse 10 A Fuse Box Joint Connector B Main Fuse 30 A Frame Ground Battery 12 V 8 Ah Fuel Reserve Switch Stop Watch Switch Cylinder Head Cover Ground Water Temperature Sensor Speed Sensor Gear Position Switch Oil Pressure Switch ECU GPi7865BW3 C 16 82 ELECTRICAL SYSTEM Immobilizer System Equipped Models This motorcycle is equipped with an immobilizer system to protect the motorcycle from theft This system provides a the
232. ature grease HO Apply heavy oil L Apply a non permanent locking agent MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts 11 4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain Drive Chain Slack 30 40 mm 1 2 1 6 in v etes Drive Chain Wear 20 link Length 317 5 318 2 mm 12 50 12 53 in 323 mm 12 7 in Standard Chain Make ENUMA mE Type EK520MVXL1 Link 112 links Sprockets Rear Sprocket Warp 0 4 mm 0 016 in or less 0 5 mm 0 02 in FINAL DRIVE 11 5 Special Tools Inside Circlip Pliers Bearing Driver Set 57001 143 57001 1129 7570143ST C 7571129ST C 11 6 FINAL DRIVE Drive Chain Drive Chain Slack Inspection e Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter see Drive Chain Slack Inspection in the Periodic Maintenance chapter Drive Chain Slack Adjustment Refer to the Drive Chain Slack Adjustment in the Periodic Maintenance chapter see Drive Chain Slack Adjustment in the Periodic Maintenance chapter Wheel Alignment Inspection Adjustment e Refer to the Wheel Alignment Inspection in the Periodic Maintenance chapter see Wheel Alignment Inspection in the Periodic Maintenance chapter Drive Chain Wear Inspection e Refer to the Drive Chain Wear Inspection in the Periodic Maintenance chapter s
233. ay see Clutch Spring Plate Free Play Measurement and then replace the steel plate s which brings the free play within the usable range Spring Plate Free Play Usable Range 0 05 0 70 mm 0 002 0 028 in OReplace the following steel plate s Thickness Part Number 2 3 mm 0 090 in 13089 0008 2 6 mm 0 102 in STD 13089 0009 2 9 mm 0 114 in 13089 1093 NOTE ODo not use the steel plate of 2 3 mm 0 090 in and 2 9 mm 0 114 in thickness at the same time GF06070BS2 C CLUTCH 6 15 Clutch Clutch Plate Assembly Length Reference Information e Assemble the following parts Clutch Hub A Spring Seat B Spring C Sub Clutch Hub D Sub Clutch Hub Bolts E New Friction Plates F Steel Plates G Spring Plate H Clutch Springs I Clutch Spring Holders J Clutch Spring Bolts K Torque Clutch Spring Bolts 8 8 N m 0 90 kgf m 78 in Ib e Measure the clutch plate assembly length L Clutch Plate Assembly Length Reference 40 6 mm 1 60 in NOTE OThe length of the clutch plate assembly changes by the steel plate thickness Clutch Plate Wear Damage Inspection e Visually inspect the friction and steel plates for signs of seizure overheating discoloration or uneven wear e Measure the thickness of each friction plate A at several points xIf any plates show signs of damage or if they have worn past the service limit replace them with new ones
234. ber with the arrow mark B on the lever holder OThe distance from the grip to the lever is minimum at num ber 6 and maximum at number 1 Brake Pedal Position Inspection e Check that the brake pedal A is in the correct position Footpeg B Pedal Position Standard About 78 mm 3 1 in C below top of footpeg x lf it is incorrect adjust the brake pedal position Brake Pedal Position Adjustment NOTE OUsually it is not necessary to adjust the pedal position but always adjust it when push rod locknut has been loosened e Loosen the locknut A and turn the push rod with the hex head B to achieve the correct pedal position x lf the length C shown is 70 1 mm 2 8 0 04 in the pedal position will be within the standard range e Tighten Torque Rear Master Cylinder Push Rod Locknut 18 N m 1 8 13 ft lb e Check the brake light switch operation see Brake Light Switch Operation Inspection in the Periodic Maintenance chapter Brake Pedal Removal e Remove Rear Master Cylinder Mounting Bolts A Right Footpeg Bracket Bolts B BRAKES 12 9 Brake Lever Brake Pedal e Remove Cotter Pin A Joint Pin B Rear Brake Light Switch Spring C Return Spring D e Remove the mounting bolt E and take out the brake pedal Brake Pedal Installation e Apply high temperature grease to the pivot shaft A and install the washer B Install Brake Pedal C Washer D Brake Pedal Bolt E
235. big end is bolted using the plastic region fastening method OThis method precisely achieves the needed clamping force without exceeding it unnecessarily allowing the use of thinner lighter bolts further decreasing connecting rod weight OThere are two types of the plastic region fastening One is a bolt length measurement method and other is a rotation angle method Observe one of the following two but the bolt length measurement method is preferable because this is a more reliable way to tighten the big end nuts CAUTION The connecting rod bolts are designed to stretch when tightened Never reuse the connecting rod bolts See the table below for correct bolt and nut usage CAUTION Be careful not to overtighten the nuts The bolts must be positioned on the seating surface correctly to prevent the bolt heads from hitting the crankcase 9 20 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods 1 Bolt Length Measurement Method e Be sure to clean the bolts nuts and connecting rods thoroughly with a high flash point solvent because the new connecting rods bolts and nuts are treated with an anti rust solution A WARNING Clean the bolts nuts and connecting rods in a well ventilated area and take care that there is no spark or flame anywhere near the working area This in cludes any appliance with a pilot light Because of the danger of highly flammable liquids do not use gasoline or
236. ble is frayed B or if the cable housing is kinked C replace the cable Bolts Nuts and Fasteners Tightness Inspection e Check the tightness of the bolts and nuts listed here Also check to see that each cotter pin is in place and in good condition NOTE OFor the engine fasteners check the tightness of them when the engine is cold at room temperature there are loose fasteners retorque them to the spec ified torque following the specified tightening sequence Refer to the appropriate chapter for torque specifications If torque specifications are not in the appropriate chapter see the Standard Torque Table For each fastener first loosen it by 1 2 turn then tighten it x If cotter pins are damaged replace them with new ones 80904020152 C PERIODIC MAINTENANCE 2 45 Maintenance Procedure Bolt Nut and Fastener to be checked Engine Clutch Lever Pivot Bolt Locknut Engine Mounting Bolts Exhaust Pipe Clamp Bolts Exhaust Pipe Manifold Holder Nuts Muffler Body Mounting Bolts Wheels Front Axle Clamp Bolts Front Axle Nut Rear Axle Nut Rear Axle Nut Cotter Pin Brakes Brake Lever Pivot Nut Brake Pedal Bolt Brake Rod Joint Cotter Pin Caliper Mounting Bolts Front Master Cylinder Clamp Bolts Rear Master Cylinder Mounting Bolts Suspension Front Fork Clamp Bolts Rear Shock Absorber Mounting Nuts Swingarm Pivot Shaft Nut Uni Trak Link Nuts Steering Handlebar Bolts Steering Stem Head Nut Others
237. ble 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 Stick coil shorted or not in good contact Inspect or Reinstall see chapter 16 Stick coil trouble Inspect see chapter 16 Spark plug dirty broken or gap maladjusted Inspect and replace see chapter 2 Spark plug incorrect Replace it with the correct plug see chapter 2 ECU trouble Inspect see chapter 3 Fuel air mixture incorrect Little fuel in tank Supply fuel see Owner s Manual Air cleaner clogged poorly sealed or missing Clean element or inspect sealing see chapter 2 Air duct loose Reinstall see chapter 3 Throttle body assy holder loose Reinstall see chapter 3 Throttle body assy dust seal damage Replace see chapter 3 Fuel Injector O ring damage Replace see chapter 3 Fuel filter or pump screen clogged Inspect and replace fuel pump see chapter 3 FUEL SYSTEM DFI 3 31 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions chapter Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump see chapter 3 Fuel line clogged Inspect and repair see chapter 3 Unstable rough Fuel Injector trouble Inspect see chapter 3 Main throttle sensor trouble Inspect see chapter 3 Subthrottle sensor
238. bly CAUTION Do not damage the hole wall of the water pump housing e Insert a bar A into the pump housing B and hammer evenly around the circumference of the mechanical seal bottom C 9006015851 C 4 12 COOLING SYSTEM Water Pump Take the oil seal A out of the housing with a hook Water Pump Housing Assembly CAUTION e Apply high temperature grease to the oil seal lips A e Press the new oil seal into the housing with a bearing driver B until it stops at the bottom surface C of the housing Special Tool Bearing Driver Set 57001 1129 6D06016BS1 CAUTION Be careful not to damage the sealing surface of the mechanical seal e Press the new mechanical seal into the housing with stem bearing driver A until its flange B touches the surface C of the housing Special Tool Bearing Driver 032 57001 382 Mechanical Seal Inspection e Remove the impeller see Oil Pump Removal in the En gine Lubrication System chapter e Visually inspect the mechanical seal xIf any one of the parts is damaged replace the mechani cal seal as a unit Impeller Sealing Seat Surface A Rubber Seal B Mechanical Seal C 6006017851 C COOLING SYSTEM 4 13 Radiator Radiator and Radiator Fan Removal e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Remove Right Middle Fairing see Middle F
239. bolts B C with new ones e Tighten the upper crankcase bolts Torque Crankcase Bolts M8 L 90 mm B 27 N m 2 8 kgf m 20 ft Ib Crankcase Bolts M8 L 75 mm C 27 N m 2 8 kgf m 20 ft lb Crankcase Bolts 6 D 12 N m 1 2 106 in Ib e After tightening all crankcase bolts check the following item OCrankshaft turns freely 6104277BS1 9 16 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods Crankshaft Removal Split the crankcase see crankcase splitting e Remove the connecting rod nuts Remove the crankshaft Crankshaft Installation NOTE Olf the crankshaft is replaced with a new one refer to the Connecting Rod Big End Bearing Crankshaft Main Bearing Insert Selection in the Specifications CAUTION If the crankshaft bearing inserts or crankcase halves are replaced with new ones select the bear ing inserts and check clearance with a plastigage press gauge before assembling engine to be sure the correct bearing inserts are installed e Apply molybdenum disulfide oil solution to the crankshaft main bearing inserts e Install the crankshaft with the camshaft chain A hanging on it e Install the connecting rod big end caps B see Connect ing Rod Installation CRANKSHAFT TRANSMISSION 9 17 Crankshaft and Connecting Rods e Apply molybdenum disulfide grease A to the outside sur faces of both thrust washers B Slide one t
240. ccelerator Throttle Cable Decelerator Apply engine oil 3 8 FUEL SYSTEM DFI Exploded View i P A 6002295BW5 C FUEL SYSTEM DFI 3 9 Exploded View No Fastener Torgus Remarks N m kgf m ft Ib 1 Separator Bracket Mounting Bolt 0 8 0 08 7 2 Spark Plugs 13 1 3 113 in Ib 3 Camshaft Position Sensor Bolt 9 8 1 0 87 4 Water Temperature Sensor 25 2 5 18 SS 5 Crankshaft Sensor Bolts 5 9 0 60 52 in Ib 6 Fuel Pump Bolts 9 8 1 0 87 in lb L S 7 Exhaust Butterfly Valve Actuator Mounting Bolts 6 9 0 70 61 in lb 8 Gear Position Switch Screws 2 9 0 30 26 in Ib L 9 Speed Sensor Bolt 3 9 0 40 35 L Exhaust Butterfly Valve Actuator Pulley Bolt 0 50 43inlb 11 Canister 12 Separator 13 Relay Box 14 Battery 12 V 8 Ah Atmospheric Pressure Sensor ECU Stick Coil Fuel Pump Exhaust Butterfly Valve Crankshaft Sensor Speed Sensor Gear Position Sensor Exhaust Butterfly Valve Actuator Camshaft Position Sensor Apply grease Apply a non permanent locking agent Replacement Parts Follow the specific tightening sequence Apply silicone sealant 3 10 FUEL SYSTEM DFI Specifications Item Standard Digital Fuel Injection System Idle Speed Throttle Assy Type Bore Throttle Body Vacuum Bypass Screws ECU Electronic Control Unit Make Type Fuel Pressure High Pres
241. ce D of crankcase rear side e Remove the camshaft chain tensioner see Camshaft Chain Tensioner Removal e Loosen the upper chain guid bolts and camshaft cap bolts as shown sequence 1 20 in the figure and remove them e Remove Upper Chain Guide A Camshaft Caps B Camshafts C e Stuff a clan cloth into the chain tunnel to keep parts from dropping into the crankcase GE11227BS1 ENGINE TOP END 5 17 Camshaft Camshaft Chain sro Gre sed edi Enc 1 MX 7 DB GU 19 5 6 D 5 19 Remove the cam sprocket mounting bolts A Remove the cam sprocket CAUTION The crankshaft may be turned while the camshafts are removed Always pull the chain taut while turn ing the crankshaft This avoids kinking the chain on the lower crankshaft sprocket A kinked chain could damage both the chain and the sprocket 5 18 ENGINE TOP END Camshaft Camshaft Installation NOTE OThe exhaust camshaft has a 4516 EX mark A and the inlet camshaft has a 4516 IN mark B Be careful not to mix up these shafts e Install the cam sprockets as shown in the figure 4 Cam Positions A Inlet Cam Sprocket B Exhaust Cam Sprocket C e Apply a non permanent locking agent to the threads and tighten the bolts Torque Cam Sprocket Mounting Bolts 15 N m 1 5 kgf m 11 ft lb e Apply molybdenum disulfide oil solution A All Journals and Tappets e
242. ce the fuel pump NOTE Olt may take a long time to turn on the test light in case that the fuel reserve switch is inspected just after the fuel pump is removed Leave the fuel reserve switch with leads for inspection connected for few minutes GP18340BS1 C Oxygen Sensor Removal Equipped Models e Remove Right Middle Fairing see Middle Fairing Removal in the Frame chapter e Disconnect the oxygen sensor lead connectors A e Remove the oxygen sensors B ELECTRICAL SYSTEM 16 109 Switches and Sensors Oxygen Sensor Installation Equipped Models CAUTION Never drop the oxygen sensor A especially on a hard surface Such a shock to the unit can damage it Do not touch the sensing part B to prevent oil contact oil contamination from hands can reduce sensor performance 5 e Install Left Side Oxygen Sensor A Connector Color Black Right Side Oxygen Sensor B Connector Color Gray GP18346BS1 Tighten Torque Oxygen Sensor 25 N m 2 5 kgf m 18 ft Ib e Run the oxygen sensor lead correctly see Cable Wire and Hose Routing section in the Appendix chapter Oxygen Sensor Inspection Equipped Models e Refer to the Oxygen Sensor Inspection in the Fuel Sys tem DFI chapter Oxygen Sensor Inspection in the Fuel System DFI chapter 16 110 ELECTRICAL SYSTEM Relay Box The relay box A has relays and diodes The relays and diodes ca
243. ch can lead to malfunction Conversely when loosening the bolts nuts or screws first loosen all of them by about a quar ter turn and then remove them If the specified tightening sequence is not indicated tighten the fasteners alternating diagonally Tightening Torque Incorrect torque applied to a bolt nut or screw may lead to serious damage Tighten fasteners to the specified torque using a good quality torque wrench Force Use common sense during disassembly and assembly excessive force can cause expensive or hard to repair dam age When necessary remove screws that have a non permanent locking agent applied using an impact driver Use a plastic faced mallet whenever tapping is necessary Gasket O ring Hardening shrinkage or damage of both gaskets and O rings after disassembly can reduce sealing performance Remove the old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material re mains Install the new gaskets and replace the used O rings when re assembling Liquid Gasket Non permanent Locking Agent For applications that require Liquid Gasket or a Non permanent Locking Agent clean the surfaces so that no oil residue remains before applying liquid gasket or non permanent locking agent Do not apply them exces sively Excessive application can clog oil passages and cause serious damage 68020128 5 GB020138 5 68020148 5 J 2 68020158 5 680
244. chapter GE15012381 GE15012081 C ENGINE TOP END 5 33 Valves Valve Seat Repair START Machinist s dye on seat 45 Grind 45 Cutter make seating area smooth and round Tool Purpose Measure Seating Area Outside Diameter Vernier Caliper check seat outside Tool Purpose diameter against spec Too small 45 Grind Tool 45 Cutter Purpose increase outside diameter of seat area to spec Measure Seating Width Tool Vernier Caliper Purpose check seat width against spec 45 Grind Tool Purpose 45 Cutter increase width of seat area beyond spec to increase outside diameter Lap Valve Tool Valve Lapper Grinding Compound perfectly match valve and valve seat are check valve head for damage Purpose Machinist s dye on seat 32 Grind Tool 32 Cutter Purpose reduce outside diameter of seat area to spec Machinist s dye on seat 60 Grind Tool 60 Cutter Purpose reduce seat width to spec FINISHED GE15095B F 5 34 ENGINE TOP END Throttle Body Assy Holder Throttle Body Assy Holder Removal e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Air Cleaner Housing Air Cleaner Housing Removal in the Fuel System DFI chapter Throttle Body Assy Throttle Body Assy Removal in the Fuel System DFI chapter Clamps A Holder Bolts B Holders C Throttle Body Assy Holder I
245. cifications 9 6 Starter Idle Gear Installation 9 31 Special Tools and Sealant 9 9 Starter Clutch Removal 9 33 Crankcase Splitting 9 10 Starter Clutch Installation 9 33 Crankcase Splitting 9 10 Starter Clutch Disassembly 9 33 Crankcase Assembly 9 11 Starter Clutch Assembly 9 34 Crankshaft and Connecting Rods 9 16 Starter Clutch Inspection 9 34 Crankshaft Removal 9 16 Transmission 9 36 Crankshaft Installation 9 16 Shift Pedal Removal 9 36 Connecting Rod Remowval 9 18 Shift Pedal Installation 9 36 Connecting Rod Installation 9 18 External Shift Mechanism Crankshaft Connecting Rod Removal aetoncttsetutes ben 9 36 1 9 22 External Shift Mechanism Connecting Rod 9 22 Installation pp 9 37 Connecting Rod Twist 9 22 External Shift Mechanism Connecting Rod Big End Side InSpectOn aee tete 1 9 22 Transmission Assy Removal Connecting Rod Big End Bearing Transmission Assy Disassembly Insert Crankpin Wear 9 23 Transmission Assy Assembly Crankshaft Side Clearance
246. ck that the hour display start flashing This flashing returns the hour setting display 77 GANT xIf the display function does not work replace the meter assembly OIf the terminal 15 disconnected when the clock is setting clock is set at time of that time GP17810BS1 Check 6 Speedometer Inspection e Connect the leads in the same circuit as Check 1 e The speed equivalent to the input frequency is indicated in the oscillator A if the square wave illustrated as shown would be input into the terminal 13 Olndicates approximately 60 mph in case the input fre quency would be approximately 525 Hz Olndicates approximately 60 km h in case the input fre quency would be approximately 840 Hz NOTE OThe input frequency of the oscillator adds the integrated value of the odometer OThe integrated value of the odometer cannot be reset Duty 50 Np HM 8 17848 52 C e f the oscillator is not available the speedometer can be checked as follows Olnstall the meter unit ORaise the rear wheel off the ground using the stand OTurn on the ignition switch ORotate the rear wheel by hand OCheck that the speedometer shows the speed x If the speedometer does not work check the speed sen sor electric source voltage and speed sensor The electric source voltage and speed sensor are normal replace the meter assembly 16 70 ELECTRICAL SYSTEM Meter Gauge Indicator Unit Chec
247. clockwise position Usable range 0 4 turns out 2 turns out from the fully clockwise position Usable range 0 5 turns out Spring length 180 mm 7 09 in Spring length 175 185 mm 6 89 7 28 in weaker to stronger 980 kPa 10 0 kgf cm 142 psi non adjustable SUSPENSION 13 7 Special Tools Inside Circlip Pliers Fork Oil Level Gauge 57001 143 57001 1290 Oil Seal amp Bearing Remover Fork Piston Rod Puller M10 x 1 0 57001 1058 57001 1298 875710585 C 7571298ST C Bearing Driver Set Fork Spring Stopper 57001 1129 57001 1374 875713745 6 Bearing Remover Shaft 13 57001 1377 7571129ST C 57001 1238 7571238ST C ST5713778T C Fork Oil Seal Driver 41 Hook Wrench T 3 2 R37 57001 1288 57001 1539 7T5712888T C ST571539ST C 13 8 SUSPENSION Special Tools Swingarm Pivot Nut Wrench 57001 1597 875715975 C Jack Attachment 57001 1608 7 875716085 C Needle Bearing Driver 17 18 57001 1609 Q 875716095 C Stem Bearing Driver 28 57001 1610 50 T571610ST C Spacer 18 57001 1636 NULL 8757163697 Spacer 28 57001 1637 CO 875716375 Fork Spring Compressor 57001 1685 ST571685ST 6 SUSPENSION 13 9 Front Fork Rebound Damping Force Adjustment e To adjust the rebound damping force turn the rebound dampin
248. container B a few times e Keep the container in place for 20 minutes or more Don t remove the container from the battery until ts empty the battery requires all the electrolyte from the container for proper operation CAUTION Removal of the container before it is completely empty can shorten the service life of the battery Do not remove the electrolyte container until it is com pletely empty and 20 minutes have elapsed GPOS003BS1 C 8 09000851 C 8 09000851 C 16 24 ELECTRICAL SYSTEM Battery e Gently remove the container from the battery e Let the battery sit for 30 minutes prior to charging to allow the electrolyte to permeate into the plates for optimum performance NOTE OCharging the battery immediately after filling can shorten service life Let the battery sit for at least 30 minutes after filling Initial Charge e Place the strip A of caps loosely over the filler ports Newly activated sealed batteries require an initial charge Standard Charge 0 9 A x 5 10 hours x lf using a recommended battery charger follow the charger s instructions for newly activated sealed battery Kawasaki recommended chargers Optimate 111 8 08019851 C Yuasa 1 5 Amp Automatic Charger Battery Mate 150 9 x lf the above chargers are not available use equivalent one NOTE OCharging rates will vary depending on how long the battery has been stored temperature and
249. ct the input voltage see Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF GC17158BS1 C FUEL SYSTEM DFI 3 63 Speed Sensor Service Code 24 e Disconnect the speed sensor connector and connect the harness adapter A between the harness connector B and speed sensor connector C e Connect digital meter to the harness adapter leads Special Tool Throttle Sensor Setting Adapter 1 57001 1400 Speed Sensor Output Voltage Connections to Sensor Meter Y lead C Meter BK Y lead D e Measure the sensor output voltage with the engine stopped and with the connector joined e Turn the ignition switch ON Output Voltage at Sensor Standard About DC 0 05 0 07 V NOTE Olf you can rotate the drive shaft the output voltage will be raise x If the reading is out of the range check the speed sensor see Speed Sensor Inspection in the Electrical System chapter and the wiring to ECU see wiring diagram x If the reading speed sensor and wiring are good replace the ECU see ECU Removal Installation Speed Sensor Circuit 6GC17144BS1 C ae P BK Y Z 4 66178716 2 1 2 Meter Unit 3 Speed Sensor 4 Frame Ground 5 Battery 12 V 8 Ah 3 64 FUEL SYSTEM DFI Gear Position Switch Service Code 25 Gear Position Switch Removal Installation e Refer to th
250. ction explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts Especially note the following Battery Ground Before completing any service on the motorcycle discon nect the battery cables from the battery to prevent the en 9 S gine from accidentally turning over Disconnect the ground 2 qe AD cable first and then the positive When completed Wa with the service first connect the positive cable to the e 4 positive terminal of the battery then the negative ca A to negative terminal DISASSEMBLY ASSEMBLY 68020248 5 Edges of Parts Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts 6 020048 5 Solvent Use a high flush point solvent when cleaning parts High flush point solvent should be used according to directions of the solvent manufacturer 6 020058 5 Cleaning vehicle before disassembly Clean the vehicle thoroughly before disassembly Dirt or 0 otherforeign materials entering into sealed areas during ve hicle disassembly can cause excessive wear and decrease performance of the vehicle GENERAL INFORMATION 1 3 Before Servicing Arrangement and Cleaning of Removed Parts Disassembled parts are easy to confuse Arrange the parts according to the order the parts were disassembled and c
251. cture causing extensive engine damage e Apply molybdenum disulfide oil solution to the valve lifter surface and install the lifter e Install the camshafts see Camshaft Installation in the En gine Top End chapter Recheck the valve clearance and readjust if necessary Filling engine oil to all oil pockets front side of the cam lobes of the camshafts Inlet Side Oil Pockets A Exhaust Side Oil Pockets B Recheck the valve clearance and readjust if necessary e Install the removed parts Air Suction System Air Suction System Damage Inspection Set up the fuel tank see the Air Cleaner Element Re placement Pull the air switching valve hose A out of the air cleaner e Start the engine and run it at idle speed e Plug B the air switching valve hose end with your finger and feel vacuum pulsing in the hose xIf there is no vacuum pulsation check the hose line for leak If there is no leak check the air switching valve see Air Switching Valve Unit Test in the Electrical Sys tem chapter or air suction valve see Air Suction Valve Inspection in the Engine Top End chapter GE11231BS1 PERIODIC MAINTENANCE 2 25 Maintenance Procedure Cooling System Coolant Level Inspection NOTE OCheck the level when the engine is cold room or ambi ent temperature e Check the coolant level in the reserve tank A with the motorcycle held perpendicular Do not use the sid
252. d e With the ECU connectors connected check the following ground lead for continuity with the ignition switch OFF using a tester and needle adapter set Special Tool Needle Adapter Set 57001 1457 ECU Grounding Inspection ASTE Battery Terminal 0 Engine Ground lt Battery Terminal 0 6617940651 x lf no continuity check the connector the engine ground lead or main harness and repair or replace them if nec essary 3 100 FUEL SYSTEM DFI ECU e Check the ECU power source voltage with a tester A OPosition the terminal in accordance with terminal numbers of ECU connectors in this chapter figure Battery B ECU Power Source Inspection Tester Connections between 16 W Y Terminal and Battery Terminal between 17 W BK Terminal and Battery Terminal Ignition Switch OFF 16 W Y Terminal 0 V 17 W BK Terminal Battery Voltage 12 8 V or more Ignition Switch ON Battery Voltage 12 8 V or more xIf the tester does not read as specified check the follow ing Power Source Wiring Main Fuse 30 A see Fuse Inspection in the Electrical System chapter ECU Fuse 10 A see Fuse Inspection in Electrical Sys tem chapter ECU Main Relay see Relay Circuit Inspection in Elec trical System chapter ECU Power Source Circuit 6617941651 C JON PARK TaN TINIO TAIL 10 11 112
253. d start the engine and run it for several minutes at idle speed This fills the oil filter with oil Stop the engine then wait several minutes until the oil settles CAUTION Racing the engine before the oil reaches every part can cause engine seizure If the engine oil gets extremely low or if the oil pump or oil passages clog up or otherwise do not function properly the warning indicator light and oil pres sure warning symbol will blink If this blink stays on when the engine is running above idle speed stop the engine immediately and find the cause x If the oil level is too high remove the excess oil using a syring or some other suitable device x lf the oil level is too low add the correct amount of oil through the oil filler opening Use the same type and make of oil that is already in the engine NOTE Olf the engine oil type and make are unknown use any brand ofthe specified oil to top off the level in preference to running the engine with the oil level low Then at your earliest convenience change the oil completely Engine Oil Change e Refer to the Engine Oil Change in the Periodic Mainte nance chapter Oil Filter Replacement e Refer to the Oil Filter Replacement in the Periodic Main tenance chapter 6005010851 ENGINE LUBRICATION SYSTEM 7 9 Oil Pan Oil Pan Removal Drain the engine oil see Engine Oil Change in the Peri odic Maintenance chapter e Remove Fron
254. d without incurring an obligation to make such changes to products manufactured previously See your Motorcycle dealer for the latest information on product improvements incorporated after this publication All information contained in this publication is based on the latest product information available at the time of publication Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts 2007 Kawasaki Heavy Industries Ltd First Edition 1 Jan 30 2007 M LIST OF ABBREVIATIONS ampere s Ib pound s ABDC after bottom dead center m meter s AC alternating current min minute s ATDC after top dead center N newton s BBDC before bottom dead center Pa pascal s BDC bottom dead center PS horsepower BTDC before top dead center psi pound s per square inch C degree s Celsius r revolution DC direct current rpm revolution s per minute F farad s TDC top dead center F degree s Fahrenheit TIR total indicator reading ft foot feet V volt s g gram s W watt s h hour s ohm s L liter s COUNTRY AND AREA CODES AU Australia Malaysia CA Canada United States CAL California Whole Vehicle Type Approval FR France EMISSION CONTROL INFORMATION To protect the environment in which we all live Kawasaki has incorporated crankcase emis sion 1 and exhaust emission 2 control systems in compliance with applicable regulation
255. de Symptoms or Possible Causes Actions chapter Main throttle sensor trouble Inspect see chapter 3 Subthrottle sensor trouble Inspect see chapter 3 Subthrottle valve actuator trouble Inspect see chapter 3 Inlet air pressure sensor trouble Inspect see chapter 3 Atmospheric pressure sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Inlet air temperature sensor trouble Inspect see chapter 3 Inspect and replace see chapter 2 Inspect see chapter 16 2 inspect see chapter 3 inspect see chapter 3 inspect see chapter 3 inspect see chapter 3 inspect see chapter 3 inspect see chapter 3 inspect see chapter 3 inspect see chapter 3 Inlet air temperature sensor trouble Inspect see chapter 3 Surge Unstable fuel pressure Fuel pressure regulator trouble Inspect and replace fuel pump or kinked fuel line Inspect and replace fuel pump see chapter 3 Fuel Injector trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Inspect and replace see chapter 2 inspect see chapter 3 inspect see chapter 3 inspect see chapter 3 inspect see chapter 3 inspect see chapter 3 inspect see chapter 3 inspect see chapter 3 inspect see chapter 3 inspect see chapter 3 Air switching valve trouble Inspect and replace see chapter 1
256. de A BK Y r 1 IT Front Right Turn Signal Ss DM Light 12V21W Headlight 8 Exe 12 554 ll Headlight en 12V65W Front Left er Turn Signal n Light 12V21W Left Switch Housing Joint 1 Button 2 Passing Button Pin SLT ace Left Switch Housing Fuse Box Rekar Box 4 Dimmer Switch 1 Fuse 15 4 Weadlight Fuse 10A Starter Lockout Switch 2 ECU Fuse 10 5 Taillight Fuse 10A 6 Lap Time Button Turn Signal Relay 6 lgniton Fuse 10 Fuse 10 Horn Fuse 10 LEET HANDLEBAR SWITCH CONNECTIONS Horn Button Turn Signal ch Dimmer Switch Starter Lockout Switch Lap Time Button Passing Button Color color GY Color Color BK R Color W R Color BL YR BK HI Clutch Lever Released Push Push Pulled in 2102950 5 C ELECTRICAL SYSTEM 16 11 Wiring Diagram United States and Canada Gear Position Sensor Alternator Stand Nain Switch Subthrottle Throttle Sensor ensor Jorr Regulator TE 1 Rectifier Subthrottle water NRA NA Be Valve Temperature Actuator Ssi Eeh Camshaft L 1 L 3 Z Postion 1 Sensor 55 on Atmospheric SES Sza Pressure Crank LI peces Exhaust Butterfly Switch shaft BEE SERT Valve Actuator Sensor 2 Speed ius tales LI Oe x el Aic Bees 3 e Temperature Inle
257. de of the engine Throttle Position Sensor Lead Run the sensor lead up side the main harness and crankshaft sensor oil pressure switch lead Main Harness Stick Coils Align the connector portion of the coils and the lines of the cylinder head cover Subthrottle Valve Actuator Connector 17 6 APPENDIX Cable Wire and Hose Routing 9 G OQ 8 10 900494 42 9 OOOODOOWW GB09289CW3 C ON 11 12 Main Throttle Sensor Lead Connector 14 15 16 17 18 19 Clamps Insertion type Turn Signal Relay Fuse Box Clamp Relay Box Front Right Turn Signal Light Lead Con nector Right Switch Housing Lead Connectors Cylinder Head Cover Ground Main Harness Oxygen Sensor 1 Lead Connector Black Oxygen Sensor 2 Lead Connector Gray Inlet Air Pressure Sensor Lead Connector Subthrottle Throttle Sensor Lead Con nector Rear Brake Light Switch Lead Connector Crankshaft Sensor Lead Connector Gear Position Switch Lead Connector Engine Ground Cable Water Temperature Lead Sensor Con nector 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Speed Sensor Lead Connector Primary Fuel Injector Lead Connectors Left to Right 1 2 3 4 Secondary Fuel Injector Lead Connectors Left to Right 1 2 3 4 Inlet Air Temperature Sensor Lead Con nector Subthrottle Valve Actuator Lead
258. e Set up a dial gauge against the disc A as shown and measure disc runout while turning B the wheel by hand x If runout exceeds the service limit replace the disc CN 9108018851 C Disc Runout Standard TIR 0 15 mm 0 006 in or less Service Limit TIR 0 3 mm 0 01 in BRAKES 12 19 Brake Fluid Brake Fluid Level Inspection e Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter Brake Fluid Change Refer to the Brake Fluid Change in the Periodic Mainte nance chapter Brake Line Bleeding The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action Air however is easily compressed When air enters the brake lines brake lever or pedal movement will be partially used in compressing the air This will make the lever or pedal feel spongy and there will be a loss in braking power sure to bleed the air from the brake line ever brake lever or pedal action feels soft or spongy after the brake fluid is changed or when ever a brake line fitting has been loosened for any reason NOTE OThe procedure to bleed the front brake line is as follows Bleeding the rear brake line is the same as for the front brake e Remove Screw A Clamp B Front Brake Reservoir Cap C Diaphragm Plate Diaphragm e Fill the reservoir with fre
259. e Torque Engine Sprocket Nut 125 13 kgf m 92 ft Ib e Adjust the drive chain slack after installing the sprocket see Drive Chain Slack Adjustment in the Periodic Main tenance chapter FINAL DRIVE 11 11 Sprocket Coupling e Make sure that dowel pins A are in piace Install the engine sprocket cover e Install the clamp B as shown and tighten the cover bolts Torque Engine Sprocket Cover Bolts 6 9 N m 0 70 kgf m 61 in Ib e Install the speed sensor see Speed Sensor Installation in the Electrical System chapter e Bend the end of axle cotter pin surely after tightening the axle nut GK05069BS2 C Rear Sprocket Removal e Remove the rear wheel see Rear Wheel Removal in the Wheels Tires chapter CAUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground e Remove the rear sprocket nuts A e Remove the rear sprocket B Rear Sprocket Installation e Install the sprocket facing the tooth number marking A outward e Tighten the rear sprocket nuts Torque Rear Sprocket Nuts 59 N m 6 0 kgf m 43 ft Ib e Install the rear wheel see Rear Wheel Installation in the Wheels Tires chapter 11 12 FINAL DRIVE Sprocket Coupling Coupling Installation e Grease the following and install the coupling Coupling Grease Seal Lips A Cou
260. e B on the shaft OEngage the idle gear with the starter motor gear and idle gear starter clutch side OFitthe pin C into the groove D of the starter clutch cover e Install the dowel pin E and new gasket e Position the idle gear A to inside of the mating surface B of the cover e Install Idle Gear Cover A Idle Gear Cover Bolts B Idle Gear Cover Bolts C with Gaskets e Tighten Torque Idle Gear Cover Bolts 9 8 1 0 kgf m 87 in Ib e Install the removed parts see appropriate chapters CRANKSHAFT TRANSMISSION 9 33 Starter Idle Gear and Starter Clutch Starter Clutch Removal e Remove Alternator Cover see Alternator Cover Removal in the Electrical System chapter Starter Clutch Cover see Idle Gear Removal Idle Gear Starter Clutch Side see Idle Gear Removal e Unscrew the starter clutch bolt A while holding the al ternator rotor steady with the rotor holder see Alternator Rotor Removal in the Electrical System chapter Special Tools Grip 57001 1591 Stopper 57001 1679 Rotor Holder 57001 1666 e Remove Washer B Starter Clutch C Starter Clutch Installation e Install the starter clutch A while fitting the alignment notch B of the splines onto the alignment tooth C e Install the washer e Tighten the starter clutch bolt while holding the alternator rotor steady with the rotor holder see Alternator Rotor Installation in the Electrical System chapter S
261. e Valve clearance incorrect Valve spring broken or weak Camshaft bearing worn Valve lifter worn Other noise Connecting rod small end clearance exces sive Connecting rod big end clearance exces sive Piston ring groove clearance excessive Piston ring worn broken or stuck Piston ring groove worn Piston seizure damage APPENDIX 17 33 Troubleshooting Guide Cylinder head gasket leaking Exhaust pipe leaking at cylinder head con nection Crankshaft runout excessive Engine mount loose Crankshaft bearing worn Primary gear worn or chipped Camshaft chain tensioner trouble Camshaft chain sprocket guide worn Air suction valve damaged Air switching valve damaged Alternator rotor loose Catalytic converter melt down due to muffler overheating KLEEN Abnormal Drive Train Noise Clutch noise Clutch damper weak or damaged Clutch housing friction plate clearance ex cessive Clutch housing gear worn Wrong installation of outside friction plate Transmission noise Bearings worn Transmission gear worn or chipped Metal chips jammed in gear teeth Engine oil insufficient Drive line noise Drive chain adjusted improperly Drive chain worn Rear and or engine sprocket worn Chain lubrication insufficient Rear wheel misaligned Abnormal Frame Noise Front fork noise Oil insufficient or too thin Spring weak or broken Rear shock absorber noise Shock absorber damaged Disc brake noise Pad installed incorrectly Pad surf
262. e 17 1 7 13 Pressure Relief Valve 15 1 5 11 L Oil Pressure Switch 15 1 5 11 SS Oil Pressure Switch Terminal Bolt Hand tighten Water Hose Clamp Screws 2 0 0 20 17 in lb Water Pump Cover Bolts 12 1 2 104 in Ib L Engine Removal Installation Adjusting Collar Locknut 49 5 0 36 S Adjusting Collar 9 8 1 0 87 in lb S Lower Engine Mounting Nut 44 4 5 33 S Middle Engine Mounting Bracket Bolt 25 2 5 18 S Middle Engine Mounting Nut 44 4 5 33 S Upper Engine Mounting Bolts 44 4 5 33 S Crankshaft Transmission Breather Plate Bolts 9 8 1 0 87 L Connecting Rod Big End Nuts see the see the see the MO text text text Crankcase Bolts M8 Lower First 15 1 5 11 MO S Crankcase Bolts M8 Lower Final 31 3 2 23 MO S Crankcase Bolts M6 L 50 mm Lower 12 1 2 104 S Gear Position Switch Screws 2 9 0 30 26 in Ib L Crankcase Bolt M8 L 90 mm Upper 27 2 8 20 S Crankcase Bolts M8 L 75 mm Upper 27 2 8 20 S Crankcase Bolts M6 L 68 mm Upper 12 1 2 104 in Ib S Transmission Case Bolts M8 20 2 0 15 Transmission Case Bolts M6 9 8 1 0 87 Piston Oil Nozzles 2 9 0 30 26 in Ib Gear Positioning Lever Bolt 12 1 2 104 in Ib Oil Passage Plugs Taper Side 20 2 0 15 L Oil Passage Plug Left Side 17 1 7 13 Oil Pressure Switch 15 1 5 11 SS Fitting breather 15 1 5 11 L PERIODIC MAINTENANCE 2 9 Torque and Locking Agent Torque Fastener fb Remarks Oil Pa
263. e G Outside H About 6 mm 0 24 in I e Tighten Torque Rear Exhaust Pipe Mounting Bolt J 28 N m 2 8 kgf m 21 ft Ib Rear Exhaust Pipe Clamp Bolt 17 N m 1 7 kgf m 13 ft Ib e Install the muffler body see Muffler Body Installation GE18072BW3 C e Throughly warm up the engine wait until the engine cools down retighten all the bolts e Install the removed parts see appropriate chapters ENGINE TOP END 5 39 Muffler Front Exhaust Pipe Removal e Remove Radiator Lower Bolt A see Radiator and Radiator Fan Removal in the Cooling System chapter e Loosen the radiator upper bolts e Remove Oxygen Sensor Lead Connectors see Oxygen Sensor Removal Equipped Models in the Electrical System chapter Front Exhaust Pipe Holder Nuts B e Loosen the rear exhaust pipe clamp bolt A e Remove the front exhaust pipe mounting bolt B e Remove the front exhaust pipe C forward D 5 40 ENGINE TOP END Muffler Front Exhaust Pipe Installation e Replace the front exhaust pipe gaskets A with new ones e Replace the rear exhaust pipe gasket B with a new one Olnstall the rear exhaust pipe gasket until it is bottomed so that the chamfer side C faces to the rear exhaust pipe D e Install the front exhaust pipe E e Touch the gasket stoppers F of the rear exhaust pipe to the end of the gasket e Install the rear exhaust pipe clamp bolt as shown Upside H Outside I
264. e battery type This is to prevent overfilling of the electrolyte shorting the battery life and deteriora tion of the battery performance 8 08020451 C ELECTRICAL SYSTEM 16 23 Battery CAUTION Do not remove the aluminum sealing sheet A from the filler ports until just prior to use Be sure to use the dedicated electrolyte container for correct electrolyte volume e Place the battery on a level surface Check to see that the sealing sheet has no peeling tears or holes in it e Remove the sealing sheet NOTE OThe battery is vacuum sealed If the sealing sheet has leaked air into the battery it may require a longer initial charge e Remove the electrolyte container from the vinyl bag e Detach the strip of caps A from the container and set aside these will be used later to seal the battery NOTE ODo not pierce or otherwise open the sealed cells B of the electrolyte container Do not attempt to separate individual cells e Place the electrolyte container upside down with the six sealed cells into the filler ports of the battery Hold the container level push down to break the seals of all six cells You will see air bubbles rising into each cell as the ports fill NOTE ODo not tilt the electrolyte container e Check the electrolyte flow x If no air bubbles A are coming up from the filler ports or if the container cells have not emptied completely tap the
265. e check the crank shaft sensor Stick Coil Removal e Remove Air Cleaner Housing see Air Cleaner Housing Removal in the Fuel System DFI chapter e Disconnect the stick coil connectors A e Pull the stick coils B off the spark plugs CAUTION Do not pry the connector part of the coil while re moving the coil Stick Coil Installation e Apply grease to the stick coils A e Insert the stick coils B as shown being careful of the coil head directions OAlign the lines C of the cylinder head cover and coil head connectors OBe sure the stick coils are installed by pulling up A it lightly CAUTION Do not tap the coil head while installing the coil e Connect the connectors e Run the hoses and harness correctly see Cable Wire and Hose Routing section in the Appendix chapter e Install removed parts see appropriate chapters GP10422BS1 GI08578 P ELECTRICAL SYSTEM 16 39 Ignition System Stick Coil Inspection e Remove the stick coils see Stick Coil Removal Measure the primary winding resistance A as follows OConnect the hand tester between the coil terminals OSet the tester to the x 1 range and read the tester Measure the secondary winding resistance as follows OConnect the tester between the plug terminal and coil terminal OSet the tester to the x 1 range and read the tester Ignition Coil Winding Resistance P
266. e stand x If the coolant level is lower than the L level line B un screw the reserve tank cap and add coolant to the F level line C L low F full CAUTION For refilling add the specified mixture of coolant and soft water Adding water alone dilutes the coolant and degrades its anticorrosion properties The diluted coolant can attack the aluminum en gine parts In an emergency soft water alone can be added But the diluted coolant must be returned to the correct mixture ratio within a few days If coolant must be added often or the reservoir tank has run completely dry there is probably leakage in the cooling system Check the system for leaks Coolant ruins painted surfaces Immediately wash away any coolant that spills on the frame engine wheels or other painted parts Radiator Hose Damage and Installation Condition Inspection OThe high pressure inside the radiator hose can cause coolant to leak A or the hose to burst if the line is not properly maintained Visually inspect the hoses for signs of deterioration Squeeze the hoses A hose should not be hard and brittle nor should it be soft or swollen Replace the hose if any fraying cracks B or bulges C are noticed e Check that the hoses are securely connected and clamps are tightened correctly Torque Water Hose Clamp Screws 2 0 N m 0 20 kgf m 17 in lb 9506038851 C 2 26 PERIODIC MAINTENANCE
267. e Adjust the valve clearance Incorrect piston cylinder clearance Replace the piston and or cylinder Piston seizure Inspect the cylinder and replace repair the cylinder and or piston as necessary Bad condition of piston ring and or piston Replace the piston and or the piston ring grooves rings 5 24 ENGINE TOP END Cylinder Head Cylinder Head Removal Drain Coolant see Coolant Change in the Periodic Mainte nance chapter Engine Oil see Engine Oil Change in the Periodic Main tenance chapter e Remove Engine see Engine Removal in the Engine Removal In stallation chapter Cylinder Head Cover see Cylinder Head Cover Re moval Camshafts see Camshaft Removal Remove the front camshaft chain guide bolt upper A e Loosen the M6 and M9 cylinder head bolts as shown se quence 1 12 in the figure and remove them e Take off the cylinder head to upward Cylinder Head Installation NOTE OThe camshaft cap is machined with the cylinder head so if a new cylinder head is installed use the cap that is supplied with the new head Install a new cylinder head gasket and dowel pins e Apply molybdenum disulfide oil solution to both sides A of the washers and threads B of M9 bolts C GE14103BS1 ENGINE TOP END 5 25 Cylinder Head e Tighten the M9 cylinder head bolts following the tightening sequence 1 10 Torque Cylinder Head Bolts M9 First 1
268. e ECU If the stick coil 3 primary winding has failures no signal wiring short or open the ECU shuts off the injector 3 to stop fuel to the cylinder 3 though the engine keeps running Stick Coil 4 Radiator Fan Relay Subthrottle Valve Actuator The stick coil primary winding must send signals 20 or more times continuously to the ECU When the relay OFF condition the fan relay is open The actuator operates open and close of the subthrottle valve by the pulse signal from the ECU If the stick coil 4 primary winding has failures no signal wiring short or open the ECU shuts off the injector 4 to stop fuel to the cylinder 4 though the engine keeps running If the subthrottle actuator fails the signal is out to the usable range wiring short or open the ECU stops the current to the actuator 3 42 FUEL SYSTEM Self Diagnosis Service Output Signal Usable Codes Forts Range or Criteria Backups My ECU The opes If the exhaust butterfly valve actuator fails the Exhaust open and close of the signal is out to the usable range wiring short or open the ECU stops the current to the actuator 63 Butterfly Valve exhaust butterfly valve Actuator by the pulse signal from the ECU The air switching valve controls the flow of the secondary air by opening and shutting the solenoid valve The oxygen sensor Oxygen heater raise If the oxygen sensor heater fai
269. e ECU and meter unit connectors Wiring Connections ECU Connector A Meter Unit Connector B BRIR lead C x If the wiring is good check the meter unit see Electrical Combination Meter Unit Inspection in the Electrical Sys tem chapter x lf the meter unit is normal replace the ECU see ECU Removal Installation ECU Communication Line Circuit 9017913652 C D BR R N Je we O N 1 ECU 2 Meter Unit 3 Warning Indicator Light LED 4 Battery 12 V 8 Ah 5 Frame Ground BK Y BR R D 66179446 2 C FUEL SYSTEM DFI 3 83 Stick Coils 1 2 3 4 Service Code 51 52 53 54 Stick Coil 1 Service Code 51 Stick Coil 2 Service Code 52 Stick Coil 3 Service Code 53 Stick Coil 4 Service Code 54 Stick Coil Removal Installation CAUTION Never drop the stick coils especially on a hard sur face Such a shock to the stick coil can damage it e Refer to the Stick Coil Removal Installation in the Electri cal System chapter see Stick Coil Removal in the Elec trical System chapter Stick Coil Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Remove the ECU see ECU Removal Do not disconnect the ECU connector e Connect a digital voltmeter A to the connector of the ECU B with the needle adapter set Special Tool Needle Adapter Set
270. e Gear Position Switch Removal Installation in the Electrical System chapter see Gear Position Switch Removal Installation in the Electrical System chapter Gear Position Switch Inspection e Referto the Gear Position Switch Inspection in the Electri cal System chapter see Gear Position Switch Inspection in the Electrical System chapter Gear Position Switch Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Remove the ECU see ECU Removal ODo not disconnect the ECU connectors e Connect a digital meter A to the connector B with the needle adapter set Special Tool Needle Adapter Set 57001 1457 Gear Position Switch Input Voltage at 1 6 Gear Positions Connections to ECU Connector Meter W Y lead terminal 53 Meter Engine Ground e Measure the switch input voltage with the engine stopped and with the connector joined e Turn the ignition switch ON Input Voltage at 1 6 Gear Positions Standard 1st About 3 0 V 2nd About 2 5 V 3rd About 2 0 V 4th About 1 5 V 5th About 1 1 V 6th About 0 7 V e Turn the ignition switch OFF x If the reading is out of the range check the gear position switch see Gear Position Switch Inspection in the Elec trical System chapter xIf the switch is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal
271. e Inspection Measure the output voltage at the ECU in the same way as input voltage inspection Digital Voltmeter A Connectors B Special Tool Needle Adapter Set 57001 1457 Main Throttle Sensor Output Voltage Connections to ECU Meter Y W lead terminal 7 Meter BR BK lead terminal 28 e Start the engine and warm it up thoroughly e Check idle speed to ensure throttle opening is correct Idle Speed Standard 1 300 r min rpm x lf the idle speed is out of the specified range adjust the idle speed see Idle Speed Adjustment in the Periodic Maintenance chapter e Turn the ignition switch OFF e Measure the output voltage with the engine stopped and with the connector joined e Turn the ignition switch ON e Measure the output voltage when the throttle is fully opened or completely closed Output Voltage at ECU Standard DC 1 025 1 055 V at idle throttle opening Approximately DC 4 22 4 42 V full throttle opening 6617883651 FUEL SYSTEM DFI 3 45 Main Throttle Sensor Service Code 11 xIf the output voltage is within the standard range check the ECU for a good ground and power supply see ECU Power Supply Inspection If the ground and power sup ply are good replace the ECU x If the output voltage is far out of the standard range e g when the wiring is open the reading is O V check the output voltage again at the sensor connector e Disconnect the
272. e Tighten Torque Exhaust Butterfly Valve Cable Locknuts 6 9 N m 0 70 kgf m 61 in Ib e Install the grommet C to the exhaust butterfly valve cables and put the grommet into the notch of the rear fender e Install the exhaust butterfly valve cover D Tighten Torque Exhaust Butterfly Valve Cover Bolt 6 9 N m 0 70 kgf m 61 in Ib e Confirm whether it is an angle shown in the figure NOTE OCorrect the position electrically after confirming use is discontinued and there is no damage when differing from the angle of shown in the figure xIf the angle is wrong adjust the pulley see Exhaust But terfly Valve Actuator Installation in the Fuel System DFI chapter 41 7 7 E CAUTION Do not correct it with the tool forcibly The actuator damage will occur e Install the exhaust butterfly valve cable upper ends to the pulley of actuator Open Cable White F Close Cable Black Upside View H e Install the clamp I securely ENGINE END 5 43 Muffler Stretch the open cable white first by using the adjuster A OTurn the adjuster counterclockwise until the play of the open cable becomes no play CAUTION To keep the correct exhaust butterfly valve position adjust the open cable first Do not overstretch If the adjustment of the exhaust butterfly valve cables is incorrect the exhaust but terfly valve actuator does not operate correctly
273. e Using the hand tester measure the internal resistance of the sensor OThe sensor sends electric signals to the ECU Electronic Control Unit and coolant temperature gauge in the meter unit OMeasure the resistance across the terminals and the body for the gauge at the temperatures shown in the table x If the hand tester does not show the specified values re place the sensor Water Temperature Sensor Resistance for ECU C o Temperature n Terminal 1 3 0 115 20 68 F 246 80 176 F 0 32 0 011 110 230 F 0 1426 0 0041 Resistance for Water Temperature 0 Resistance Terminal 2 Body 50 C 122 F 210 40 120 C 248 F 21 2 1 5 Speed Sensor Removal Remove the front side bolts of the fuel tank Set up the fuel tank A using the suitable tool or bar OThe steering position is straight 8 18070352 ELECTRICAL SYSTEM 16 107 Switches and Sensors Disconnect the speed sensor lead connector eRemove the speed sensor bolt A Open the clamps Remove the speed sensor Speed Sensor Installation e Install the speed sensor e Apply a non permanent locking agent to the bolt Torque Speed Sensor Bolt 3 9 N m 0 40 kgf m 35 in Ib Speed Sensor Inspection e Remove Speed Sensor see Speed Sensor Removal e Connect
274. e chain e Apply grease to the link pins A and grease seals B C e Engage the drive chain on the rear sprocket through the swingarm e Insert the link pins in the drive chain ends e Install the grease seals C e Install the link plate so that the mark D faces out e Push the link plate by hand or plier to fix it e n case of grease seal chain be sure to set the grease seals correctly GK04020BS1 C 11 8 FINAL DRIVE Drive Chain e Set the plate holder a A and plate holder b B on the body GK04021BS1 C e Fit the plate holder a to link plate e Turn the pin holder by hand until plate holder b touches the other link plate e Turn the pin holder by wrench clockwise until two pins of link come into groove of plate holder a e Take off the plate holder a GK04023BS1 C e Set the plate holder b A and cutting and riveting pin B as shown e Turn the pin holder until riveting pin touches link pin GK04025BS1 C FINAL DRIVE 11 9 Drive Chain e Turn the wrench clockwise until tip of riveting pin hits of link pin Rivet it e Same work for the other link pin e After staking check the staked area of the link pin for cracks e Measure the outside diameter A of the link pin and link plates width B Link Pin Outside Diameter Standard 5 7 6 0 mm 0 22 0 24 in Link Plates Outside Width Standard 17 25 17 45 mm 0 679 0 687 in x
275. e feedback mode of the oxygen sensor Exhaust Butterfly Valve Actuator Sensor Output Voltage 0 1 4 8V If the exhaust butterfly valve sensor system fails the output voltage is out of the usable range wiring short or open the ECU locks the exhaust butterfly valve at full open position near and it stops the current to the exhaust butterfly valve actuator Immobilizer Amplifier If the immobilizer system fails no signal wiring short or open the vehicle is no start and run Master or User Key The user or master key must use register key The ECU send the data for gear position service code and key registration to the meter unit If the blank key or broken key is used the vehicle is no start and run Stick Coil 1 Stick Coil 2 The stick coil primary winding must send signals 20 or more times continuously to the ECU The stick coil primary winding must send signals 20 or more times continuously to the ECU If the stick coil 1 primary winding has failures no signal wiring short or open the ECU shuts off the injector 1 to stop fuel to the cylinder 1 though the engine keeps running If the stick coil 2 primary winding has failures no signal wiring short or open the ECU shuts off the injector 2 to stop fuel to the cylinder 2 though the engine keeps running Stick Coil 3 The stick coil primary winding must send signals 20 or more times continuously to th
276. e projections C face down ward 5 14 ENGINE TOP END Cylinder Head Cover e Replace the washer A with new ones e Install the new washer with the metal side faces upward e Install the cylinder head cover e Tighten Cylinder Head Cover Bolts A Torque Cylinder Head Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib e Install the ground terminal B and tighten the cylinder head cover ground bolt C e When installing the breather hose fitting D apply a non permanent locking agent to thread of the fitting and tighten it Torque Breather Hose Fitting 15 N m 1 5 kgf m 11 ft lb e Install the removed parts refer to appropriate chapters GE09033BS1 GE09083BS1 C Camshaft Chain Tensioner ENGINE TOP END 5 15 Camshaft Chain Tensioner Removal CAUTION This is a non return type camshaft chain tensioner The push rod does not return to its original position once it moves out to take up camshaft chain slack Observe all the rules listed below When removing the tensioner do not take out the mounting bolts only halfway Retightening the mounting bolts from this position could damage the tensioner and the camshaft chain Once the bolts are loosened the tensioner must be removed and reset as described in Camshaft Chain Ten sioner Installation Do not turn over the crankshaft while the tensioner is removed This could upset the camshaft chain timing and damage the valves e
277. e upper fork clamp bolts A first next the stem head nut B last the lower fork clamp bolts C and the handlebar bolts D OTighten the two lower fork clamp bolts alternately two times to ensure even tightening torque Torque Front Fork Clamp Bolts Upper 20 N m 2 0 kgf m 15 ft lb Steering Stem Head Nut 78 N m 8 0 kgf m 58 ft lb Front Fork Clamp Bolts Lower 25 N m 2 5 kgf m 18 ft Ib Handlebar Bolts 25 N m 2 5 kgf m 18 ft Ib A WARNING Do not impede the handlebar turning by routing the cables harnesses and hoses improperly see Ca ble Wire and Hose Routing section in the Appen dix chapter Steering Stem Bearing Lubrication e Refer to the Steering Stem Bearing Lubrication in the Pe riodic Maintenance chapter Steering Stem Warp e Whenever the steering stem is removed or if the steering can not be adjusted for smooth action check the steering stem for straightness x If the steering stem A is bent replace the steering stem GN05077BS1 Stem Cap Deterioration Damage Replace the stem cap if its oil seal A shows damage 14 10 STEERING Handlebar Handlebar Removal Loosen Front Fork Clamp Bolts A Right and Left Handlebar Bolts B Right and Left e Remove Clutch Lever Clamp Bolts A Clutch Lever Assembly B Left Switch Housing C Handlebar Weight D e Remove Front Brake Master Cylinder A see Front Master Cylin der Removal
278. e white paint faces upward 17 30 APPENDIX Troubleshooting Guide NOTE Stick coil trouble ORefer to the Fuel System chapter for most ECU trouble of DFI trouble shooting guide OThis is not an exhaustive list giving every possible cause for each problem listed It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties Camshaft position sensor trouble Gear position starter lockout or side stand switch trouble Crankshaft sensor trouble Ignition switch or engine stop switch shorted Starter system wiring shorted or open Engine Doesn t Start Starting Difficulty Starter motor not rotating Main 30A or ignition fuse blown Fuel air mixture incorrect Ignition and engine stop switch not ON Starter lockout switch or gear position switch trouble Starter motor trouble Battery voltage low Starter relay not contacting or operating Starter button not contacting Starter system wiring open or shorted Ignition switch trouble Engine stop switch trouble Main 30A or ignition fuse blown Starter motor rotating but engine doesn t turn over Vehicle down sensor DFI coming off Immobilizer system trouble Starter clutch trouble Starter idle gear trouble Engine won t turn over Valve seizure Valve lifter seizure Cylinder piston seizure Crankshaft seizure Connecting rod small end seizure Connecting rod big end seizure Transmission gear or bearing seizure C
279. ead of the switch bolt Torque Sidestand Switch Bolt F 8 8 N m 0 90 kgf m 78 in Ib 6020022BS1 ELECTRICAL SYSTEM 16 1 Electrical System Table of Contents Parts Exploded Wiring Diagram United States and Wiring Diagram Other than United States Canada Australia and Malaysia eere tt res Wiring Diagram Australia Wiring Diagram Malaysia Specifications Special Tools and Sealant Electrical Wiring Wiring Inspection Battery Battery Battery Installation Battery Activation Charging Condition Inspection Refreshing Charge Charging System Alternator Cover Remowval Alternator Cover Installation Stator Coil Removal Stator Coil Installation Alternator Rotor Removal Alternator Rotor Installation Alternator Inspection Regulator Rec
280. eappearance of problems and unstable operation of the DFI system xIf any wiring is deteriorated replace the wiring 9617572051 6017037351 3 26 FUEL SYSTEM Troubleshooting the DFI System e Pull each connector A apart and inspect it for corrosion dirt and damage x If the connector is corroded or dirty clean it carefully If it is damaged replace it Connect the connectors securely e Check the wiring for continuity OUse the wiring diagram to find the ends of the lead which is suspected of being a problem OConnect the hand tester between the ends of the leads OSet the tester to the x 1 range and read the tester x lf the tester does not read 0 the lead is defective Re place the lead or the main harness or the sub harness OIf both ends of a harness A are far apart ground B the one end C using a jumper lead D and check the con tinuity between the end E and the 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 co
281. earings by using the bearing driver set which does not contact the bearing inner race e Press in each right the bearing A until they are bottomed Special Tool Bearing Driver Set B 57001 1129 Replace the grease seals with new ones e Press in the grease seals A so that the seal surface is flush B with the end of the hole OApply high temperature grease to the grease seal lips Special Tool Bearing Driver Set C 57001 1129 Hub Bearing Inspection Since the hub bearings are made to extremely close tol erances the clearance can not normally be measured NOTE ODo not remove any bearings for inspection If any bear ings are removed they will need to be replaced with new ones e Turn each bearing in the hub back and forth A while checking for plays roughness or binding xIf bearing play roughness or binding is found replace the bearing e Examine the bearing seal B for tears or leakage x If the seal is torn or is leaking replace the bearing GJ06036BS1 6J06008BS1 C 6J06008BS1 C 6J06002BS1 C WHEELS TIRES 10 17 Hub Bearing Hub Bearing Lubrication NOTE OSince the hub bearings are packed with grease and sealed lubrication is not required FINAL DRIVE 11 1 Final Drive Table of Contents mee mi 222 dense 11 2 Specifica NS 11 4 Special OO c 11 5 BI 11 6
282. eat Cover see Seat Cover Removal in the Frame chapter Exhaust Butterfly Valve Actuator see Exhaust Butterfly Valve Actuator Removal e Disconnect the exhaust butterfly valve actuator sensor lead connector 3 pins connector A and connect the har ness adapter B between these connector Special Tool Throttle Sensor Setting Adapter 1 57001 1400 e Connect a digital meter to the harness adapter leads Exhaust Butterfly Valve Actuator Sensor Input Voltage Connections to Adapter Digital Meter Y W actuator W lead Digital Meter BK BL actuator BK lead e Measure the input voltage with the engine stopped and with the connector joined e Turn the ignition switch ON Input Voltage at Actuator Standard DC 4 75 5 25 V e Turn the ignition switch OFF x If the reading is within the standard check the output volt age see Exhaust Butterfly Valve Actuator Sensor Output Voltage Inspection x If the reading is out of the standard remove the ECU and check the wiring between these connectors ODisconnect the ECU and sensor connectors Wiring Connections ECU Connector A Exhaust Butterfly Valve Actuator Sensor Connector B BL lead ECU terminal 10 C BR BK lead ECU terminal 28 D xIf 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 6
283. ect or replace the follow ing item Engine Stop Switch see Switch Inspection in the Elec trical System chapter xIf the engine stop switch is good condition replace the ECU see ECU Removal Installation in the Fuel System DFI chapter PERIODIC MAINTENANCE 2 43 Maintenance Procedure Others Chassis Parts Lubrication Before lubricating each part clean off any rusty spots with rust remover and wipe off any grease oil dirt or grime Lubricate the points listed below with indicated lubricant NOTE OWhenever the vehicle has been operated under wet or rainy conditions or especially after using a high pressure water spray perform the general lubri cation Pivots Lubricate with Grease Brake Lever Brake Pedal Clutch Lever Rear Brake Joint Pin Side Stand Points Lubricate with Grease Clutch Inner Cable Upper and Lower Ends A Throttle Inner Cable Upper and Lower Ends 6004040381 C Cables Lubricate with Rust Inhibitor Clutch Cable Throttle Cables e Lubricate the cables by seeping the oil between the cable and housing OThe cable may be lubricated by using a commercially available pressure cable lubricator with an aerosol cable lubricant 6604011451 C 2 44 PERIODIC MAINTENANCE Maintenance Procedure e With the cable disconnected at both ends the inner cable should move freely A within the cable housing x If cable movement is not free after lubricating if the ca
284. ecting Rod Twist Service Limit TIR 0 2 100 mm 0 008 3 94 in Connecting Rod Big End Side Clearance Measure connecting rod big end side clearance Olnsert a thickness gauge A between the big end and ei ther crank web to determine clearance Connecting Rod Big End Side Clearance Standard 0 13 0 33 mm 0 0051 0 0130 in Service Limit 0 6 mm 0 024 in x If the clearance exceeds the service limit replace the con necting rod with new one and then check clearance again If clearance is too large after connecting rod replacement the crankshaft also must be replaced 6105040881 C 6105040781 CRANKSHAFT TRANSMISSION 9 23 Crankshaft and Connecting Rods Connecting Rod Big End Bearing Insert Crankpin Wear Measure the bearing insert crankpin clearance with plastigage A Tighten the big end nuts to the specified torque see Con necting Rod Installation NOTE ODo not move the connecting rod and crankshaft during clearance measurement CAUTION After measurement replace the connecting rod bolts Connecting Rod Big End Bearing Insert Crankpin Clearance Standard 0 044 0 081 mm 0 0017 0 0032 in Service Limit 0 12 mm 0 0047 in x If the clearance is within the standard no bearing replace ment is required xIf the clearance is between 0 082 mm 0 0032 in and the service limit 0 12 mm 0 0047 in replace the bear ing inserts A with insert
285. ection in the Electrical System chapter Ignition Fuse 10 A see Fuse Inspection in the Electrical System chapter Ignition Switch see Wiring Diagram in the Electrical Sys tem chapter Side Stand Switch see Switch Inspection in the Electri cal System chapter Engine Stop Switch see Switch Inspection in the Elec trical System chapter Starter Button see Wiring Diagram in the Electrical Sys tem chapter Gear Position Switch see Gear Position Switch Inspec tion in the Electrical System chapter Starter Relay see Starter Relay Inspection in the Elec trical System chapter Starter Circuit Relay see Relay Circuit Inspection in the Electrical System chapter Harness see Wiring Inspection in the Electrical System chapter x If the all parts are good condition replace the ECU Engine Stop Switch Operation Inspection First Step e Turn on the ignition switch Set the neutral position Turn the engine stop switch to stop position A e Push the starter button e The engine does not start x If the engine starts inspect or replace the following item Engine Stop Switch see Switch Inspection in the Elec trical System chapter Second Step e Turn on the ignition switch e Set the neutral position e Turn the engine stop switch to run position A e Push the starter button and run the engine e Turn the engine stop switch to stop position e Immediately the engine should be stop x If the engine does not stop insp
286. ee Drive Chain Wear Inspection in the Periodic Maintenance chapter Drive Chain Lubrication e Refer to the Drive Chain Lubrication Condition Inspec tion in the Periodic Maintenance chapter see Drive Chain Lubrication Condition Inspection in the Periodic Mainte nance chapter Drive Chain Removal NOTE OSince the drive chain is installed through the swingarm the chain cannot be removed other than by cutting it Prepare the new link pin link plate grease seals and tools for rejoining the chain e Using a suitable tool cut the drive chain by removing the link pins Recommended Tool EK Joint Tool 50 CAUTION Read the Tool Manual before removing Body A Handlebar B Cutting and Riveting Pin C For Cutting D For Riveting E Plate Holder a F Plate Holder b G Gauge H GKO4016BS1 FINAL DRIVE 11 7 Drive Chain e Grind A the pin head to make it flat e Set the cutting and riveting pin B as shown e Screw the pin holder until it touches chain pin e Be sure that the cutting pin hits center of chain pin GK04018BS1 C e Screw the handlebar A into body e Turn the pin holder with wrench B clockwise to extract chain pin GKO4019BS1 C Drive Chain Installation e Engage the new drive chain to the old drive chain and pull the end of the old drive chain until they are changing the position e Remove the old drive chain from the new driv
287. egger or a meter with a large capacity battery is used the regulator rectifier will be damaged Regulator Rectifier Resistance Unit Tester Lead Connection Ter BK BL BK1 BK2 Bk minal 20 20 20 300 300 300 300 750 20 20 20 20 20 300 750 20 20 300 750 T20 750 Tester Lead Connection e Install the regulator rectifier Torque Regulator Rectifier Bolts 6 9 N m 0 70 kgf m 61 in Ib BK1 BK BL BK W BK2 BK3 GP09201BS1 ELECTRICAL SYSTEM 16 33 Charging System Charging Voltage Inspection e Check the battery condition see Charging Condition In spection e Warm up the engine to obtain actual alternator operating conditions e Remove Front Seat see Front Seat Removal in the Frame chap ter Caps A e Check that the ignition switch is turned off and connect the hand tester B as shown in the table Special Tool Hand Tester 57001 1394 e Start the engine and note the voltage readings at vari ous engine speeds with the headlight turned on and then turned off Disconnect the headlight connector in the up per fairing The readings should show nearly battery volt age when the engine speed is low and as the engine speed rises the readings should also rise But they must be kept under
288. en tightening torque e Install the front brake calipers see Caliper Installation in the Brakes chapter e Check the front brake effectiveness see Brake Operation Inspection in the Periodic Maintenance chapter A WARNING Do not attempt to drive the motorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against the disc The brake will not function on the first application of the lever if this is not done Rear Wheel Removal e Raise the rear wheel off the ground with the stand A 10 8 WHEELS TIRES Wheels Rims e Remove Rear Caliper Mounting Bolts A Rear Caliper B e Remove Cotter Pin A Axle Nut B Axle C from Right Side Remove the drive chain A from the rear sprocket toward the left Move the rear wheel back and remove it CAUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground Rear Wheel Installation e Fit the collars on the both sides of the hub Right Side Collar A with Flange Left Side Collar B Olf the coupling A is removed from the rear wheel apply the grease as shown Wheel Flange Portion B O ring C WHEELS TIRES 10 9 Wheels Rims e Engage the drive chain with the rear sprocket e Install the caliper bracket A onto the swingarm stop B Oln
289. ening E as shown in the figure e Install the circlip A on the output shaft B so that the punch mark C faces the washer D and position the opening E as shown in the figure 81130302 5 6113040851 9113364851 C CRANKSHAFT TRANSMISSION 9 43 Transmission e The drive shaft gears can be recognized by size the gear with the smallest diameter is 1st gear and the largest one is 6th gear Be sure that all parts are put back in the cor rect sequence and all circlips and washers are properly in place e Install the 3rd 4th gear onto the drive shaft with their oil holes aligned e The output shaft gears can be recognized by size the gear with the largest diameter is 1st gear and the small est one is 6th gear Be sure that all parts are put back in the correct sequence and all circlips and washers are properly in place e Install the 5th and 6th gears onto the output shaft with their oil holes aligned e Fit the steel balls into the 5th gear holes in the output shaft aligning three oil holes 5th Gear A Output Shaft B Steel Balls C Oil Holes D CAUTION Do not apply grease to the balls to hold them in place This will cause the positive neutral finder 6113033BS1 C mechanism to malfunction OAfter assembling the 5th gear with steel balls in place on the output shaft check the ball locking effect that the 5th gear doesn t come out of the output shaft when movin
290. ening Temperature 58 62 C 136 144 F 6009000851 C 6009020252 C 4 20 COOLING SYSTEM Hoses and Pipes Hose Installation e Install the hoses and pipes being careful to follow bend ing direction Avoid sharp bending kinking flattening or twisting e Run the hoses in accordance with the Cable Wire and Hose Routing section in the Appendix chapter e Install the clamp A as near as possible to the hose end to clear the raised rib of the fitting This will prevent the hoses from working loose OThe clamp screws should be positioned correctly to pre vent the clamps from contacting the other parts Torque Water Hose Clamp Screws 2 0 N m 0 20 kgf m 17 in lb ZL SSS 6010020151 C Hose Inspection e Refer to the Water Hose and Pipe Inspection in the Peri odic Maintenance chapter COOLING SYSTEM 4 21 Water Temperature Sensor Water Temperature Sensor Removal e Refer to the Water Temperature Sensor Removal in the Fuel System DFI chapter Water Temperature Sensor Inspection e Refer to the Water Temperature Sensor Inspection in the Electrical System chapter ENGINE TOP END 5 1 Engine Top End Table of Contents Exploded Exhaust Specifications Special Tools and Sealant Clean Air System
291. epeat the same procedure for other bypass screws e Repeat the synchronization x If the vacuums are correct check the output voltage of the main throttle sensor see Output Voltage Inspection of the Main Throttle Sensor in the Fuel System DFI chapter Special Tool Throttle Sensor Setting Adapter 57001 1538 Main Throttle Sensor Output Voltage Connections to Sensor Meter Y W lead Meter BR BK lead Standard DC 1 025 1 055 V at idle throttle opening xIf the output voltage is out of the standard check the in put voltage of the main throttle sensor see Input Voltage Inspection of the Main Throttle Sensor in the Fuel System DFI chapter e Remove the vacuum gauge hoses and install the rubber caps on the original position e For the California Model install the vacuum hose ORoute the vacuum hose according to Cable Wire and Hose Routing section in the Appendix chapter Idle Speed Inspection e Start the engine and warm it up thoroughly e With the engine idling turn the handlebar to both sides A xIf handlebar movement changes the idle speed the throttle cables may be improperly adjusted or incorrectly routed or damaged Be sure to correct any of these conditions before riding see Idle Speed Inspection and Cable Wire and Hose Routing section in the Appendix chapter A WARNING Operation with improperly adjusted incorrectly routed or damaged cables could result in an un safe rid
292. er in the order listed as shown below 15535556 5 15 535 56 repeated 6GCc17905CW2 C Olf there is no problem or when the repair has been done Fl and or immobilizer symbols go off and service code is not displayed Service Code Erasing OWhen repair has been done Fl and or immobilizer warning symbols go off and service code is not displayed But the service codes stored in memory of the ECU are not erased to preserve the problem history In this model the problem history can not be erased FUEL SYSTEM DFI 3 39 Self Diagnosis Service Code Table 11 sensor malfunction wiring open 7742 inlet air pressure sensor malfunction wmngopenorshot 1 inlet air temperature sensor malfunction wiring open or sho 44 Water temperature sensor malfunction wiring open or short 45 pressure sensor malfunction wiring open or shot 21 Crankshaft sensor malfunction wiring open or short Camshaft position sensor malfunction wiring open or short Speed sensor malfunction wiring open or short Gear position switch malfunction wiring open or short Vehicle down sensor malfunction wiring open or short Subthrottle sensor malfunction wiring open or short Oxygen sensor 1 inactivation wiring open or short Equipped Models Exhaust butterfly valve actuator sensor malfunction wiring open or short Immobilizer amplifier malfunction Blank Key detection
293. erence valve x If the measurement is out of the range replace the sensor x If the measurement is within the specified replace the ECU see ECU Removal Installation Inlet Air Temperature Sensor Circuit Ld BR BK 66178776 1 C 1 ECU 2 Inlet Air Temperature Sensor 3 54 FUEL SYSTEM DFI Water Temperature Sensor Service Code 14 Water Temperature Sensor Removal Installation CAUTION Never drop the sensor especially on a hard surface Such a shock to the sensor can damage it e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Remove the throttle body assy see Throttle Body Assy Removal e Remove Connector Heat Insulation Rubber Plate Water Temperature Sensor A e Replace the gasket with new one e Apply silicone sealant to the threads of the water temper ature sensor and tighten it Sealant Kawasaki Bond Silicone Sealant 56019 120 Torque Water Temperature Sensor 25 N m 2 5 kgf m 18 ft Ib e Fill the engine with coolant and bleed the air from the cooling system see Coolant Filling in the Cooling System chapter Water Temperature Sensor Output Voltage Inspection NOTE OBe sure the battery is fully charged e Remove the ECU see ECU Removal Do not disconnect the connectors e Connect a digital voltmeter A to the ECU connectors B with the needle adapter set Special Tool Needle Adapter Set 57001 1457 Wate
294. ers Oil Filter Wrench 57001 143 57001 1249 7570143ST C 7571249ST C Steering Stem Nut Wrench Vacuum Gauge 57001 1100 57001 1369 875711005 C 7571369ST C Jack Extension Tube 57001 1238 57001 1578 7571238ST C Pilot Screw Adjuster A Jack Attachment 57001 1239 57001 1608 7571239ST C 7571608ST C 7571578ST C PERIODIC MAINTENANCE 2 15 Maintenance Procedure Fuel System DFI Throttle Control System Inspection e Check that the throttle grip A moves smoothly from full open to close and the throttle closes quickly and com pletely by the return spring in all steering positions x If the throttle grip does not return properly check the throt tle cables routing grip free play and cable damage Then lubricate the throttle cable e Check the throttle grip free play B x If the free play is incorrect adjust the throttle cables Throttle Grip Free Play Standard 2 3 mm 0 08 0 12 in xIf the free play is incorrect adjust the throttle cable as follows e Loosen the locknuts A B e Screw both throttle cable adjusters C D to give the throttle grip plenty of play e Turn the decelerator cable adjuster C until 2 3 mm 0 08 0 12 in of throttle grip play is obtained e Tighten the locknut A e Turn the accelerator cable adjuster D until 2 3 mm 0 08 0 12 in of throttle grip play is obtained e Tighten the locknut B xIf the free play c
295. ervice limit the fork must be replaced Shift Fork Guide Pin Diameter Standard 5 9 6 0 mm 0 232 0 236 in Service Limit 5 8 mm 0 228 in x If any shift drum groove is worn over the service limit the drum must be replaced Shift Drum Groove Width Standard 6 05 6 20 mm 0 238 0 244 in Service Limit 6 3 mm 0 248 in Gear Dog and Gear Dog Hole Damage 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 Gi 13387BS1 9113368851 C 9113369851 C WHEELS TIRES 10 1 Wheels Tires Table of Contents Exploded VIEW R E 10 2 SDpOeCcITICatlOriS 10 4 Special DoS 10 5 E 10 6 Eront Wheel Removals dee teca toe id duet rive tee wine nea Ma 10 6 Front Wheel Installation pp 10 6 Rear Wheel 10 7 Rear Wheel InistallatiQr 1 2 iiit ti et ee e le Lag ae e do p e A PER Lege dadas 10 8 Wheel Inspection nhanh rra nnne nnne rennen 10 10 AXle Irispectioni s dote e eee inea ta e n 10 10 Balance Inspection ie eer eR etn 10 11 Balarice Adjustment teet Mende poer da toe t
296. ery Terminal Connections to Injector 2 Meter lead Meter gt Battery Terminal Connections to Injector 3 Meter BL BK lead Meter gt Battery Terminal Connections to Injector 4 Meter BL Y lead Meter Battery Terminal 8017658 52 e Install the fuel tank see Fuel Tank Installation e Turn the ignition switch ON Output Voltage at Injector Connector Standard Battery Voltage 12 8 V or more NOTE OThe secondary fuel injectors operating with following conditions Engine speeds is over 8 000 rpm r min Throttle opening is over 30 xIf the output voltage is out of the standard replace the ECU see ECU Removal Installation 3 114 FUEL SYSTEM Fuel Injectors Injector Fuel Line Inspection Remove the nozzle assy see Nozzle Assy Removal Remove the throttle body assy see Throttle Body Assy e Check the injector fuel line for leakage as follows OConnect a commercially available vacuum pressure pump A to the nipple of the delivery pipe B with the fuel hose C both ends connected with the clamps D as shown soap and water solution to the areas E as shown OWatching the pressure gauge squeeze the pump lever F and build up the pressure until the pressure reaches the maximum pressure Fuel Line Maximum Pressure Standard 300 kPa 3 06 kgf cm 43 psi Bae Boe CAUT
297. especially on a hard sur face Such a shock to the injector can damage it Audible Inspection e Set up the fuel tank see Air Cleaner Housing Removal e Start the engine e Apply the tip of a screwdriver A to the injector B Put the grip end onto your ear and listen whether the injector is clicking or not A sound scope can also be used e Do the same for the other injector x If all the injectors click at a regular intervals the injectors are good OThe click interval becomes shorter as the engine speed rises x If either injector doesn t click perform the Injector Signal Test for injector operation NOTE OThe secondary fuel injectors operating with following conditions Engine speed is over 8 000 rpm r min Throttle opening is over 30 Injector Signal Test e Prepare two test light sets with male terminals as shown Rating of Bulb 12V x 3 4 W Terminal Width B 1 8 mm 0 07 in Terminal Thickness C 0 8 mm 0 03 in CAUTION Do not use larger terminals than specified above A larger terminal could damage the injector main har ness connector female leading to harness repair or replacement Be sure to connect bulbs in series The bulb works as a current limiter to protect the solenoid in the injector from excessive current e Remove connectors for injector A e Connect each test light set B to the injector sub harness connector C e Turn the ignition s
298. ess it only enough to install it and no more CAUTION Do not reuse snap rings as removal weakens and deforms them They could fall out and score the cylinder wall e The piston ring openings must be positioned as shown in the figure The openings of the oil ring steel rails must be about 30 40 of angle from the opening of the top ring Top Ring A Second Ring B Oil Ring Steel Rail C Upper Oil Ring Expander D Oil Ring Steel Rail E Lower Hollow F 40 50 6 GE16060BS1 C GE16061BS1 C 9105245851 9105246851 CRANKSHAFT TRANSMISSION 9 29 Pistons e Apply molybdenum disulfide oil solution to the cylinder bore piston skirt and piston rings e Install the piston with its marking hollow A facing exhaust side e Using the piston ring compressor assembly B to install the piston from the cylinder head side Special Tools Piston Ring Compressor Grip 57001 1095 Piston Ring Compressor Belt 67 79 57001 1097 e Install Crankshaft see Crankshaft Installation Connecting Rod Big End Cap see Connecting Rod In stallation Cylinder Wear Upper Crankcase Since there is a difference in cylinder wear upper crankcase in different directions take a side to side and a front to back measurement at each of the two locations total of four measurements shown in the figure xIf any of the cylinder inside diameter measurements e
299. etism A short or open in one of the coil wires will result in either a low output or no output at all A loss in rotor magnetism which may be caused by dropping or hitting the alternator by leaving it near an electromagnetic field or just by aging will result in low output e To check the alternator output voltage do the following procedures OTurn off the ignition switch OSet up the fuel tank see Speed Sensor Removal ODisconnect the alternator lead connector A OConnect the hand tester as shown in the table 1 OStart the engine ORun it at the rpm given in the table 1 ONote the voltage readings total 3 measurements Table 1 Alternator Output Voltage Tester Connections Reading Range Tester to Tester to 4 000 rpm 250 V AC One Black lead Another Black lead 42 V or more ELECTRICAL SYSTEM 16 31 Charging System x If the output voltage shows the value in the table the al ternator operates properly x If the output voltage shows a much higher than the value in the table the regulator rectifier is damaged A much lower reading than that given in the table indicates that the alternator is defective e Check the stator coil resistance as follows OStop the engine OConnect the commercially available tester as shown in the table 2 ONote the readings total 3 measurement Table 2 Stator Coil Resistance Tester Connections Range Tester to Tester
300. f Transmitting and Receiving Messages ECU confirms the following Immobilizer Amplfier Pattern 1 Master Key Collation Error Pattern 6 User Key is inserted 6 4 ECU confirms the following w 5 ECU confirms the following Immobilizer Amp fier Fa ure Pattern 1 User Key 1 Collation Error Pattern 6 User Key is inserted Pattern 2 6 ECU confirms the following Not Registered User Key 7 When the ECU registered key is turned OFF ECU keops the power for two seconds And then in two seconds after the key is OFF ECU turns the power 6302858 F 16 98 ELECTRICAL SYSTEM Immobilizer System Equipped Models Immobilizer System Parts Replacement Immobilizer Antenna e Remove Left Inner Cover see Inner Cover Removal in the Frame chapter e Disconnect the lead connectors A and clamp B e Remove Clutch Cable Upper End Throttle Cable Upper Ends Steering Stem Head and Handlebar see Handlebar Re moval in the Steering chapter e Using a small chisel or punch A turn out the Torx bolts e Cut the band A and tape B e Remove the screws C e Remove the antenna D with the cover E OPull the lower parts A of the cover outside to clear the projections B of the ignition switch e Install the rubber damper A around the top portion of the switch B OPut the grooves on the projections weit ELEC
301. ff spilled out fuel immediately Be sure to hold the measuring cylinder vertical e Close the fuel tank cap e With the engine stopped turn the ignition switch ON The fuel pump should operate for 3 seconds and then should stop CAUTION Do not drive the fuel pump 3 seconds or more with out the fuel in the fuel tank If the fuel pump is driven without the fuel it may be damaged e Measure the discharge for 3 seconds ORepeat this operation several times Amount of Fuel Flow Standard 67 mL 2 27 US oz or more for 3 seconds x If the fuel flow is much less than the specified check the following Battery Condition see Charging Condition Inspection in the Electrical System chapter e After inspection connect the fuel hoses see Fuel Tank Installation e Start the engine and check for fuel leakage 3 106 FUEL SYSTEM DFI Fuel Pump Fuel Pump Removal CAUTION Never drop the fuel pump especially on a hard sur face Such a shock to the pump can damage it A WARNING Gasoline is extremely flammable and can be explo sive under certain conditions Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Turn the ignition switch OFF Disconnect the battery terminal To make fuel spillage minimum draw the fuel out from the fuel tank when the engine is cold Be prepared for fuel spillage any sp
302. ft proof device by means of matching a code between the inbuilt key transponder and ECU Electronic Control Unit If the code does not match ignition system injectors subthrottle valve actuator and exhaust butterfly valve actuator will not operate and the engine will not start Abstract e Do not keep more than one immobilizer key of any system on a key ring Jamming of the key code signal may occur and the operation of the system may be affected The warning indicator light LED will flash for a period of 24 hours once the ignition switch has been switched OFF and the key removed This flashing can be set to on or off as desired by holding the Mode and Reset buttons down for two seconds within twenty seconds of switching the ignition off e f all coded keys master key and user keys are lost the ECU and ignition switch will have to be replaced e The immobilizer system can not function until the master key code is registered in the ECU e A total of six keys can be registered in the ECU at any one time one master key and five user keys e f the master key is lost it is not possible to register new user keys Operational Cautions Do not put two keys of any immobilizer system on the same key ring Do not submerge any key in water Do not expose any key to excessively high temperature Do not place any key close to magnet Do not place a heavy item on any key Do not grind any key or alter its shape Do not disassemble the plastic
303. function does not change replace the meter assembly NOTE OThe integrated value of the odometer cannot be reset Check 10 Water Temperature Meter Inspection e Connect the leads in the same circuit as Check 1 OThe indication in the display of the water temperature meter appears e Connect the terminal 4 to the battery terminal GP17873BS1 GP17878BS1 GP17874BS1 ELECTRICAL SYSTEM 16 71 Meter Gauge Indicator Unit e Check that the display of the water temperature meter A changes from to x If the water temperature meter does not work replace the meter assembly GP17875BS1 e Connect the resister A about 210 to the terminal 4 and the battery terminal e Check that the display of the water temperature meter A indicates approximately 50 122 F x If the water temperature meter does not indicate temper ature replace the meter assembly GP17877BS1 Check 11 Tachometer Inspection e Connect the leads in the same circuit as Check 1 e The revolutions per minute rpm equivalent to the input frequency is indicated in the oscillator A if the square wave illustrated as shown would be input into the termi nal 12 Olndicates approximately 4 000 rpm in case the input fre quency would be approximately 133 3 Hz x If the meter function does not work replace the meter assembly
304. g Holders Clutch Spring Plate B with Shim Bearing Pusher C Spring and Washer e Remove Friction Plates Steel Plates Spring Spring Seat e Hold the sub clutch hub A steady with the clutch holder B and remove the nut C Special Tool Clutch Holder 57001 1243 e Remove Torque Limiter Springs D Sub Clutch Hub Clutch Hub Spacer e Using the two 4 mm 0 16 in screws A pull out the sleeve B needle bearing C and clutch housing D e Remove the spacer Clutch Installation e Install the spacer A so that the stepped side B faces inward CLUTCH 6 11 Clutch e Install Clutch Housing A Needle Bearing B e Install the sleeve C so that holes D face outward OApply engine oil to the sleeve and needle bearing e Install the spacer A so that the stepped side B faces outward e Install the clutch hub A on the drive shaft e Align the damper cam B of the sub clutch hub C to the cam followers D of the clutch hub e Install the four torque limiter springs as shown OFirst Torque Limiter Spring A Tang B RL Ore OSecond Torque Limiter Spring A Tang B 8 06093851 C 6 12 CLUTCH Clutch OThird Torque Limiter Spring A Tang B OFourth Torque Limiter Spring A Tang B Replace the clutch hub nut with a new one Hold the sub clutch hub steady with the clutch holder and tighten the clutch hub nut Specia
305. g adjuster A on top of the right front fork leg to the desired position OThe standard adjuster setting for the average build rider of 68 kg 150 Ib with no passenger and no accessories is 1 1 2 turns out from the fully clockwise position OThe damping force can be left soft for average riding But it should be adjusted harder for high speed riding or riding with a passenger If the damping feels too soft or too stiff adjust it in accordance with the following table Rebound Damping Force Adjustment Adjuster Position Damping Force Spring Preload Adjustment e Turn the spring preload adjuster A to change spring preload setting OThe standard adjuster setting for the average build rider of 68 kg 150 Ib with no passenger and no accessories is 5 turns out from the fully clockwise position A WARNING If both adjusters are not adjusted equally handling may be impaired and a hazardous condition may result OThe spring preload can be left soft for average riding But it should be adjusted harder for high speed riding or riding with a passenger If the spring action feels too soft or too stiff adjust it in accordance with the following table Spring Action Counterclockwise Clockwise Sof ter Harder Seated position adjuster turned fully clockwise GM04431BS1 C T jd Setting Load Road Speed 15 Turns Out Weak Good Low T i
306. g it up and down by hand e Check that each gear spins or slides freely on the trans mission shafts after assembly x If it is not smooth replace the damaged parts 9 44 CRANKSHAFT TRANSMISSION Transmission Se OF 8 04 03 2 02 01 00 00 9 5 8 CD e nu ona L 254 TU L Y T IF 1st Gear 2nd Gear 3rd Gear 4th Gear 5th Gear 6th Top Gear Ball Bearing Bushing Washer 34 mm 1 34 in Circlip Toothed Washer 34 mm 1 34 in 12 13 14 Bushing Washer 32 mm 1 26 in Needle Bearing 68113365844 C Circlip Water 40 mm 1 57 in Bushing Toothed Washer 40 mm 1 57 in Circlip Steel Ball Bushing Spacer O ring Ball Bearing Collar Drive Shaft Output Shaft CRANKSHAFT TRANSMISSION 9 45 Transmission Shift Drum and Fork Removal e Remove the transmission assy see Transmission Assy Removal e Remove the shift forks A and shift drum B see Trans mission Assy Disassembly Shift Drum and Fork Installation e Refer to the Transmission Assy Assembly and Installa tion Shift Drum Disassembly e Remove the shift drum see Transmission Assy Disas sembly e While holding the shift drum with a vise remove the shift drum cam holder bolt A e Remove Shift Drum Cam B Dowel Pin C Ball Bearings D Shift Drum
307. g surfaces with water or coolant to prevent pressure leaks e Watching the pressure gauge pump the pressure tester to build up the pressure until the relief valve opens the gauge needle flicks downward Stop pumping and mea sure leak time at once The relief valve must open within the specified range in the table below and the gauge hand must remain within the same range at least 6 seconds Radiator Cap Relief Pressure Standard 93 123 kPa 0 95 1 25 kgf cm 13 18 psi x If the cap can not hold the specified pressure or if it holds too much pressure replace it with a new one 6007010451 C 6007013851 C GD07001BS1 C COOLING SYSTEM 4 17 Radiator Radiator Filler Neck Inspection e Remove the radiator cap see Pressure Testing Check the radiator filler neck for signs of damage e Check the condition of the top and bottom sealing seats A in the filler neck They must be smooth and clean for the radiator cap to function properly 4 18 COOLING SYSTEM Thermostat Thermostat Removal e Remove Oil Cooler see Oil Cooler Removal in the Engine Lubri cation System chapter Water Hose A e Remove Thermostat Housing Cover Bolts A Bracket B Thermostat Housing Cover C Thermostat Thermostat Installation e Install the thermostat A in the housing so that the air bleeder hole B is on top 6009007 1 C e Install the water hose A so that the white ma
308. gent Replacement Parts Follow the specified tightening sequence Apply silicone sealant Apply water Qo 5 0 2 4 4 COOLING SYSTEM Specifications Item Standard Coolant Provided when Shipping Type Recommended Permanent type of antifreeze soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators Color Green Mixed Ratio Soft water 50 coolant 50 Freezing Point 35 31 Total Amount 2 6 L 2 7 US qt Reserve tank full level including radiator and engine Radiator Cap Relief Pressure 93 123 kPa 0 95 1 25 kgf cm 13 18 psi Thermostat Valve Opening Temperature 58 62 C 136 144 F Valve Full Opening Lift 8 mm 0 31 in or more 75 C 167 F COOLING SYSTEM 4 5 Special Tools Bearing Driver 32 Bearing Driver Set 57001 382 57001 1129 875703825 C 875711295 C 4 6 COOLING SYSTEM Coolant Flow Chart 52 Radiator Cap Radiator TN e Hot Coolant Cold Coolant Reserve Tank Overflow Hose Reserve Tank 00040668 S COOLING SYSTEM 4 7 Coolant Flow Chart Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion When the engine starts the water pump turns and the coolant circulates The thermostat is a wax pellet type which opens or closes with coolant temperature changes The thermostat continuously change
309. get pinched or kinked Hose Inspection e Refer to the Evaporative Emission Control System In spection in the Periodic Maintenance chapter Separator Inspection e Refer to the Evaporative Emission Control System In spection in the Periodic Maintenance chapter Separator A FUEL SYSTEM DFI 3 133 Evaporative Emission Control System California Model Separator Operation Test A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Connect the hoses to the separator and install the sepa rator on the motorcycle e Disconnect the breather hose from the separator and in ject about 20 mL 0 68 US oz of gasoline A into the separator B through the hose fitting e Disconnect the fuel return hose C from the fuel tank D e Run the open end of the return hose into the container and hold it level with the tank top E e Start the engine and let it idle x If the gasoline in the separator comes out of the hose the separator works well If it does not replace the separator with a new one Canister Inspection e Refer to the Evaporative Emission Control System In spection in the Periodic Maintenance chapter NOTE OThe canister A is designed to work well through the motorcycle s life wi
310. ght LED Meter Light LED Shift Up Indicator Light LED 6 0dometer Trip Meter Stop Watch Indicator 5 Poy ovr oy 7 8ear Position Indicator 55 55 SS 8 Clock Tar mar 9 Water Temperature Gauge z Mrs 0 Tachometer cas 5 M c Usspeedame ter 3 Secondary Fue Injectors Ignition 1 2 Switch R 0 6 Antenna Immobilizer Amplifier 0 0 W R Meter Unit R E BL R R BK BR R BK LG Joint Connactor BKZY i i i BK AY SLED Light Emitting Diode A BK Y BK Y Front Right A Turn Signal Ss Light 12V21W Headlight eye 12 55 Headlight en 12V65W Front Left er 6 Turn Signal ae Light 12V21W Left Switch Housing Joint 1 Button 2 Passing Button Pin SLT ace Left Switch Housing Fuse Box Rekar Box 4 Dimmer Switch 1 Fuse 15 4 Weadlight Fuse 10A Starter Lockout Switch 2 ECU Fuse 10 5 Taillight Fuse 10A 6 Lap Time Button Turn Signal Relay 6 lgniton Fuse 10 Fuse 10 Horn Fuse 10 LEET HANDLEBAR SWITCH CONNECTIONS Horn Button Turn Signal ch Dimmer Switch Starter Lockout Switch Lap Time Button Passing auton pr leete E epe prx urere HI Clutch Lever eus Tul Pulled in
311. ghten the bleed valve and install the rubber cap Torque Bleed Valve 7 8 0 80 kgf m 69 in Ib e Check the fluid level see Brake Fluid Level Inspection in the Periodic Maintenance chapter e After bleeding is done check the brake for good braking power no brake drag and no fluid leakage Sd A NI a r 12 22 BRAKES Brake Fluid WARNING When working with the disc brake observe the cautions listed below 1 2 3 Never reuse old brake fluid Do not use fluid from a container that has been left unsealed or that has been open for a long time Do not mix two types and brands of fluid for use in the brake This lowers the brake fluid boiling point and could cause the brake to be ineffective It may also cause the rubber brake parts to deteriorate Don t leave the reservoir cap off for any length of time to avoid moisture contamination of the fluid Don t change the fluid in the rain or when a strong wind is blowing Except for the disc pads and disc use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning of the brake parts Do not use any other fluid for cleaning these parts Gasoline engine oil or any other petroleum distillate will cause deterio ration of the rubber parts Oil spilled on any part will be difficult to wash off completely and will eventually deteriorate the rubber used in the disc brake When handling t
312. h GP18342BS2 ELECTRICAL SYSTEM 16 105 Switches and Sensors Switch Inspection e Using a hand tester check to see that only the con nections shown in the table have continuity about zero ohms OFor the switch housings and the ignition switch refer to the tables in the Wiring Diagram xIf the switch has an open or short repair it or replace it with a new one Special Tool Hand Tester 57001 1394 Rear Brake Light Switch Connections When brake pedal is pushed down When brake pedal is released Side Stand Switch Connections _ amp MN X When side stand is up O When side stand is down Oil Pressure Switch Connections When engine is stopped When engine is running a Engine lubrication system is in good condition Tr 16 106 ELECTRICAL SYSTEM Switches and Sensors Water Temperature Sensor Inspection Remove the water temperature sensor see Water Tem perature Sensor Removal in the Fuel System DFI chap ter e Suspend the sensor A in a container of coolant so that the temperature sensing projection E and threaded por tion E are submerged e Suspend an accurate thermometer B in the coolant NOTE OThe sensor and thermometer must not touch the con tainer side or bottom e Place the container over a source of heat and gradu ally raise the temperature of the coolant while stirring the coolant gently
313. h with the surface of the crankcase as shown in the figure 9113362851 Install Gear Position Switch see Gear Position Switch Instal lation in the Electrical System chapter Removed Parts Transmission Shaft Removal e Remove the transmission assy see Transmission Assy Removal e Remove Shift Rods A Shift Forks B Drive Shaft C and Output Shaft D Transmission Shaft Installation Be sure that the spacer A is on the output shaft B e Install the transmission assy on the crankcase see Trans mission Assy Installation 9 42 CRANKSHAFT TRANSMISSION Transmission Transmission Shaft Disassembly e Remove the transmission shafts see Transmission Shaft Removal e Remove the circlips disassemble the transmission shafts Special Tool Outside Circlip Pliers 57001 144 e The 5th gear A on the output shaft has three steel balls assembled into it for the positive neutral finder mecha nism Remove the 5th gear OSet the output shaft in a vertical position holding the 3rd gear C OSpin the 5th gear quickly B and pull it off upward Transmission Shaft Assembly e Apply molybdenum disulfide oil to the sliding surfaces of the gears and shafts e Install the gear bushings A on the shaft with their holes B aligned e Replace any circlips removed with new ones e Install the circlip A on the drive shaft B so that the punch mark C faces the washer D and position the op
314. he disc pads or disc be careful that no disc brake fluid or any oil gets on them Clean off any fluid or oil that inadvertently gets on the pads or disc with a high flash point solvent Do not use one which will leave an oily residue Replace the pads with new ones if they cannot be cleaned satisfacto rily Brake fluid quickly ruins painted surfaces any spilled fluid should be completely wiped up imme diately If any of the brake line fittings or the bleed valve is opened at any time the AIR MUST BE BLED FROM THE BRAKE LINE BRAKES 12 23 Brake Hose Brake Hose Removal Installation e Refer to the Brake Hose and Pipe Replacement in the Periodic Maintenance chapter Brake Hose Inspection e Refer to the Brake Hose Damage and Installation Condi tion Inspection in the Periodic Maintenance chapter SUSPENSION 13 1 Suspension Table of Contents Exploded 13 2 Specifications eer 13 6 opeclal I00lS5 5 13 7 KOLI OA UTEM 13 9 Rebound Damping Force Adjustment 13 9 Spring Preload Adjustment pp 13 9 Compression Damping Force Adjustment pp 13 10 Front Fork Removal Each Fork Leg Ne 13 10 Eront Fork Installation ah adie ette y eee erede a aa y 13 11 Front Fork OIlChange eie aeta a 13 11 Fron
315. he hand tester A and 12 V battery to the starter relay C as shown Special Tool Hand Tester 57001 1394 xIf the relay does not work as specified the relay is defec tive Replace the relay Testing Relay Tester Range 1 range Criteria When battery is connected 0 GP11019BS1 C When battery is disconnected gt ELECTRICAL SYSTEM 16 51 Electric Starter System Electric Starter Circuit OOANDABRWDNDN Engine Stop Switch Starter Button Fuse Box Ignition Fuse 10 A Ignition Switch Cylinder Head Cover Ground Joint Connector C Joint Connector B Gear Position Switch Side Stand Switch GP11118BW3 C ECU Starter Lockout Switch Starter Circuit Relay Relay Box Starter Motor Main Fuse 30 A Starter Relay Battery 12 V 8 Ah Engine Ground Frame Ground 16 52 ELECTRICAL SYSTEM Lighting System This motorcycle adopt the daylight system and have a headlight relay in the relay box The headlight does not go on when the ignition switch and the engine stop switch are first turned on The headlight comes on after the starter button is released and stays on until the ignition switch is turned off The headlight will go out momentarily whenever the starter button is pressed and come back on when the button is released Headlight Beam Horizontal Adjustment Refer to the Headlight Aiming I
316. he locknut by using hook wrenches A with the rear shock absorber attached the frame Special Tools Hook Wrench T23 2 R37 57001 1539 x If the spring action feels too soft or too stiff adjust it Spring Adjustment Adjuster Damping Position Force 175 mm Weak 6 89 in Setting GM05270BS1 SUSPENSION 13 21 Rear Shock Absorber Rear Shock Absorber Removal e Remove Lower Fairings see Lower Fairings Removal in the Frame chapter Front Exhaust Pipe see Front Exhaust Removal in the Engine Top End chapter e Using the jack raise the rear wheel off the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1608 Squeeze the brake lever slowly and it with a band A Be sure to hold the front brake when removing the shock absorber or the motorcycle may fall over It could cause an accident and injury e Remove Lower Shock Absorber Nut and Bolt A Upper Tie Rod Nut and Bolt B Upper Shock Absorber Nut and Bolt C Remove the shock absorber downward Rear Shock Absorber Installation e While lifting up the rear wheel install the rear shock ab sorber Tighten Torque Rear Shock Absorber Nuts 34 N m 3 5 kgf m 25 16 Tie Rod Nuts 59 N m 6 0 kgf m 43 ft lb 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
317. head unit Camshaft Runout e Remove the camshaft see Camshaft Removal e Set the camshaft in a camshaft alignment jig or on V blocks e Measure runout with a dial gauge at the specified place as shown x If the runout exceeds the service limit replace the shaft Camshaft Runout Standard TIR 0 02 mm 0 0008 in or less Service Limit TIR 0 1 mm 0 004 in Cam Wear e Remove the camshaft see Camshaft Removal e Measure the height A of each cam with a micrometer x If the cams are worn down past the service limit replace the camshaft Cam Height Standard Exhaust 33 443 33 557 mm 1 3167 1 3211 in Inlet 34 243 34 357 mm 1 3481 1 3526 in Service Limit Exhaust 33 34 mm 1 313 in Inlet 34 14 mm 1 344 in Camshaft Chain Removal e Split the crankcase see Crankcase Splitting in the Crank shaft Transmission chapter e Remove the camshaft chain A from the crankshaft sprocket GE11040BS1 C GE11012281 ENGINE TOP END 5 23 Cylinder Head Cylinder Compression Measurement NOTE OUse the battery which is fully charged e Warm up the engine thoroughly e Stop the engine e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Air Cleaner Housing see Air Cleaner Housing Removal in the Fuel System DFI chapter Stick Coils see Stick Coil Ignition Coil together with Spark Plug Cap Removal in the Electrical System chap ter
318. hrust washer into the upper crankcase half e Move the crankshaft to the left or right and then slide the other washer into the upper crankcase half NOTE OSlide the thrust washers so that the oil grooves D face outward Make sure that the blue painted edges E positioned as shown in figure Front F 61052438W2 C NOTE OThere are two kinds of crankcase by the engine number Enaine No Crankcase Washer Washer 9 D Part No Part No Thickness 2 600 008560 14001 0112 92200 0383 29 mm 0 098 in 3 25 mm ZX600PE008561 14001 0113 92200 0385 0 128 in 9 18 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Removal Split the crankcase see Crankcase Splitting in this chap ter Remove the connecting rod nuts A and big end caps NOTE OMark and record the locations of the connecting rods and their big end caps so that they can be reassembled in their original positions e Remove Camshaft Chain C Crankshaft D Pistons E see Piston Removal CAUTION Discard the connecting rod bolts To prevent dam age to the crankpin surfaces do not allow the con necting rod bolts to bump against the crankpins Connecting Rod Installation CAUTION To minimize vibration the connecting rods should have the same weight mark Big End Cap A Connecting Rod B Weight Mark Alphabet C Diameter Mark D mark or no
319. ich requires tire removal It is generally under stood that higher running durability is obtained by perma nent internal repairs than by temporary external ones Also permanent internal repairs have the advantage of permitting a thorough examination for secondary damage not visible from external inspection of the tire For these reasons Kawasaki does not recommend temporary exter nal repair Only appropriate permanent internal repairs are recommended Repair methods may vary slightly from make to make Follow the repair methods indicated by the manufacturer of the repair tools and materials so that safe results can be obtained n 6J05042BS1 C 10 16 WHEELS TIRES Hub Bearing Hub Bearing Removal Remove the wheel see Front Rear Wheel Removal and take out the following Collars Coupling Out of rear hub Grease Seals e Use the bearing remover to remove the hub bearing A CAUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground Special Tools Bearing Remover Head 25 x 028 57001 1346 Bearing Remover Shaft 13 B 57001 1377 Hub Bearing Installation Before installing the hub bearings blow any dirt or foreign particles out of the hub with compressed air to prevent contamination of the bearings e Replace the bearings with new ones e Install the b
320. ign matter in fuel Throttle body assy holder loose Fuel to injector insufficient Fuel tank air vent obstructed Fuel line clogged Fuel pump trouble Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Knocking Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect ECU trouble Miscellaneous Throttle valve won t fully open Brake dragging Clutch slipping Engine overheating Engine oil level too high Engine oil viscosity too high Drive train trouble Camshaft cam worm Air suction valve trouble Air switching valve trouble Catalytic converter melt down due to muffler overheating KLEEN Overheating Firing incorrect Spark plug dirty broken or maladjusted Spark plug incorrect ECU trouble Muffler overheating For KLEEN do not run the engine even if with only one cylinder misfiring or poor running Request the nearest service fa cility to correct it For KLEEN do not push start with a dead battery Connect another full charged battery with jumper cables and start the engine using the electric starter For KLEEN do not start the engi
321. illed fuel must be completely wiped up immediately Draw the fuel out from the fuel tank with a commercially available electric pump 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 Unscrew the fuel pump bolts A and take out the fuel pump assembly B and gasket e Discard the fuel pump gasket CAUTION Do not pull the leads C of the fuel pump and fuel reserve switch If they are pulled the lead terminals may be damaged Fuel Pump Installation e Remove dirt or dust from the fuel pump A by lightly ap plying compressed air e Replace the fuel pump gasket with a new one is FUEL SYSTEM DFI 3 107 Fuel Pump e Check that the fuel pump terminals A fuel reserve switch terminal B and band C are in place Front D e Apply a non permanent locking agent to the threads of the fuel pump bolts e Tighten the fuel pump bolts to a snug fit following the tight ening sequence shown Following the tightening sequence tighten the fuel pump bolts to the specified torque Torque Fuel Pump Bolts 9 8 N m 1 0 87 in Ib e Tighten the fuel pump bolts again to check the tightness in the order shown Fuel Pump Operation Inspection NOTE OBe sure the battery is fully charged e Turn the
322. in or less 0 2 mm 0 01 in Wheel Balance 10 g 0 35 oz or less Balance Weights 10 g 0 35 oz 20 g 0 71 oz 30g 1 06 oz Rim Size Front 17 x 3 50 Rear 17 x 5 50 Tires Air Pressure when Cold Front Up to 180 kg 397 Ib load 250 kPa 2 5 kgf cm 36 psi Rear Up to 180 kg 397 Ib load 290 kPa 2 9 kgf cm 42 psi Tread Depth Front 3 6 mm 0 14 in 1 mm 0 04 AT CH DE 1 6 mm 0 06 in Rear 4 8 mm 0 19 in Up to 130 km h 80 mph 2 mm 0 08 in Over 130 km h 80 mph 3 mm 0 12 in Standard Tires Make Type Size Front BRIDGESTONE BATTLAX BT015F 120 70 ZR17 M C 58 W RADIAL J Rear BRIDGESTONE BATTLAX BT015R 180 55 ZR17 M C 73 W RADIAL J A WARNING Use the same manufacturer s tires on both front and rear wheels WHEELS TIRES 10 5 Special Tools Bearing Driver Set Bearing Remover Shaft 13 57001 1129 57001 1377 7571129ST C ST5713778T C Jack Jack Attachment 57001 1238 57001 1608 7571238ST C ST571608ST C Bearing Remover Head 25 x 028 57001 1346 8757134697 6 10 6 WHEELS TIRES Wheels Rims Front Wheel Removal e Remove Brake Caliper Mounting Bolts A Front Brake Calipers B e Loosen Axle Clamp Bolts A Left Side Axle Nut B Axle Clamp Bolts Right Side Remove the lower fairings see Lower Fairing Removal
323. in the cages and wipe the upper and lower outer races which are press fitted into the frame head pipe clean off grease and dirt e Visually check the outer races and the ball bearings Replace the bearing assemblies if they show wear or damage e Pack the upper and lower ball bearings A in the cages with grease and apply a light coat of grease to the upper and lower outer races e Install the steering stem see Stem Stem Bearing Instal lation in the Steering chapter e Adjust the steering see Steering Play Adjustment in this chapter Lights and Switches Operation Inspection First Step e Turn on the ignition switch e Thefollowing lights should go on according to below table City Light A goes on Taillight LED B goes on License Plate Light C goes on Meter Panel LCD D goes on Neutral Indicator Light LED E goes on Warning Indicator Light LED F goes on blinks Meter Panel Illumination Light LED G goes on x If the light does not go on inspect or replace the following item Battery see Charging Condition Inspection in the Elec trical System chapter Applicable Bulbs see Wiring Diagram in the Electrical System chapter Meter Unit see Electronic Combination Meter Unit In spection in the Electrical System chapter ECU see ECU Power Supply Inspection in the Fuel Sys tem DFI chapter Main Fuse 30 A and Taillight Fuse 10 A see Fuse In spection in the Electrica
324. ing Puller Adapter Steering Stem Bearing Driver 42 5 57001 136 57001 1344 ST570136ST Om Head Pipe Outer Race Press Shaft Steering Stem Bearing Driver Adapter 441 5 57001 1075 57001 1345 ST571075ST ST571345ST C Steering Stem Nut Wrench Head Pipe Outer Race Driver 55 57001 1100 57001 1446 875711005 C 875714465 C STEERING 14 5 Steering Steering Inspection e Refer to the Steering Play Inspection in the Periodic Main tenance chapter Steering Adjustment Refer to the Steering Play Adjustment the Periodic Maintenance chapter 14 6 STEERING Steering Stem Stem Stem Bearing Removal e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Front Wheel see Front Wheel Removal in the Wheels Tires chapter Front Fork see Front Fork Removal in the Suspension chapter Brake Hose Clamp Bolt A e Remove Steering Stem Head Nut A and Washer B Steering Stem Head Handlebars see Handlebar Removal Bend the claws A of lock washer straighten e Remove the steering stem locknut B Special Tool Steering Stem Nut Wrench 57001 1100 Remove the lock washer e Pushing up the stem base and remove the steering stem nut A with stem cap Special Tool Steering Stem Nut Wrench B 57001 1100 e Remove Steering Stem C Upper Ball Bearing Inner Race e To remove the bearing outer races A pressed into the head pipe B insert a bar into the recesses C
325. ing condition Check the idle speed Idle Speed Standard 1 300 50 r min rpm x If the idle speed is out of the specified range adjust it 6505015851 C PERIODIC MAINTENANCE 2 19 Maintenance Procedure Idle Speed Adjustment Start the engine and warm it up thoroughly Turn the adjusting screw A until the idle speed is correct OOpen and close the throttle a few times to make sure that the idle speed is within the specified range Readjust if necessary Fuel Hose Inspection fuel leak damage installation condition Olf the motorcycle is not properly handled the high pres sure inside the fuel line can cause fuel to leak A or the hose to burst Remove the fuel tank see Fuel Tank Re moval the Fuel System DFI chapter and check the fuel hose Replace the fuel hose if any fraying cracks B or bulges C are noticed GSO5090BS1 Check that the hose joints are securely connected e Check that the hoses are routed according to Cable Wire and Hose Routing section in the Appendix chapter Replace the hose if it has been sharply bent or kinked x If it does not locked reinstall the hose joint Evaporative Emission Control System California Model Evaporative Emission Control System Inspection e Inspect the canister as follows ORemove Left Inner Cover see Inner Cover Removal in the Frame chapter ORemove the canister A and disconnect
326. ion e Apply a non permanent locking agent to the threads of the stator coil bolts and tighten them Torque Stator Coil Bolts 12 N m 1 2 kgf m 106 in Ib e Apply silicone sealant to the circumference of the alter nator lead grommet and fit the grommet into the notch of the cover securely Sealant Kawasaki Bond Silicone Sealant 92104 0004 Secure the alternator lead with a holding plate and apply a non permanent locking agent to the threads of the plate bolts and tighten them Torque Alternator Lead Holding Plate Bolts 6 9 N m 0 70 kgf m 61 in Ib e Install the alternator cover see Alternator Cover Installa tion Alternator Rotor Removal e Remove Alternator Cover see Alternator Cover Removal Starter Idle Gear and Shaft e Wipe oil off the outer circumference of the rotor e Hold the alternator rotor steady with the rotor holder A and remove the rotor bolt B Special Tools Grip C 57001 1591 Rotor Holder 57001 1666 Stopper D 57001 1679 e Using the flywheel puller A remove the alternator rotor from the crankshaft Special Tool Flywheel Puller M38 x 1 5 57001 1405 CAUTION Do not attempt to strike the alternator rotor itself Striking the rotor can cause the magnets to lose their magnetism Alternator Rotor Installation e Using a cleaning fluid clean off any oil or dirt on the fol lowing portions and dry them with a clean cloth Crankshaft Tapered Portion A Alter
327. ion Replace spark plug Good DUST 1 No good 1 Stick coil winding resistance inspection Replace stick coil Good ME No good Voltage is less than Stick coil primary peak voltage inspection the specified value Good No good Stick coil is defective Voltage is zero Inspect Replace stick coil or almost zero 1 Lower resistance in a No good hand tester Use KAWASAKI Hand Tester Inspect Crankshaft sensor peak voltage 1 Adapter connection is Camshaft position sensor incorrect or adapter is peak voltage defective No good 2 Ignition switch and engine stop switch Crankshaft sensor peak voltage Camshaft position sensor peak voltage Replace bad parts ECU is defective Replace ECU Replace bad parts or inspect them with KAWASAKI Hand Tester 16 36 ELECTRICAL SYSTEM Ignition System WARNING The ignition system produces extremely high volt age Do not touch the spark plugs or stick coils while the engine is running or you could receive a severe electrical shock CAUTION Do not disconnect the battery leads or any other electrical connections when the ignition switch is on or while the engine is running This is to prevent IC igniter damage Do not install the battery backwards The negative side is grounded This is to prevent damage to the diodes and IC igniter Crankshaft Sensor Removal e Set up the Fuel Tank see Speed Sensor Removal Crankshaft Sensor Lead Connecto
328. ion and immo bilizer system parts are faulty and initiates fail safe func tion In case of serious troubles ECU stops the injection ig nition starter motor operation Dealer Mode The LCD Liquid Crystal Display display the service code s A to show the problem s which the DFI system ignition system and immobilizer system has at the moment of diagnosis Immobilizer Models B GP17880CS1 9017879652 C 3 36 FUEL SYSTEM DFI Self Diagnosis Self diagnosis Procedures OWhen a problem occurs with the DFI system and ignition system the warning indicator light LED A and FI warn ing symbol B blinks OFor models equipped with an immobilizer system when a problem occurs with the system the warning indicator light LED and immobilizer warning symbol C blinks NOTE OUse fully charged battery when conducting self diagnosis Otherwise the light LED and symbol blinks very slowly or do not blink e Turn the ignition switch ON e Push the MODE button A to display the odometer Immobilizer Models B 6017878082 C FUEL SYSTEM 3 37 Self Diagnosis e Push the MODE button A for more than two seconds e The service code B is displayed on the LCD by the num ber of two digits Immobilizer Models C e Any of the following procedures ends self diagnosis OWhen the service code is displayed on the LCD push the MODE button for more than two seconds OWhen the
329. it the projections A of the socket into the grooves of the city light housing Headlight Removal Installation e Remove Upper Fairing see Upper Fairing Removal in the Frame chapter Center Inner Fairing see Center Inner Fairing Removal in the Frame chapter e Remove Bolts A Screws B Refer to the Upper Fairing Assembly in the Frame chapter see Upper Fairing Assembly in the Frame chapter Tail Brake Light LED Removal e Remove Seat Cover see Seat Cover Removal in the Frame chapter e Disconnect Tail Brake Light LED Connector A e Remove Clamp B 16 54 ELECTRICAL SYSTEM Lighting System e Remove Left Muffler Side Cover A see Turn Signal Removal Rear Turn Signal Cover B Left Turn Signal Light C see Turn Signal Removal e Unscrew the mounting bolts A e Remove the tail brake light LED Tail Brake Light LED Installation e Fit the groove A of the light on the edge B of the turn signal cover License Plate Light Bulb Replacement e Remove Screws A License Plate Light Cover B Bulb e Insert the new bulb A by aligning its upper and lower pins B with the upper and lower grooves C in the socket and turn the bulb clockwise OTurn the bulb about 15 degrees ELECTRICAL SYSTEM 16 55 Lighting System Headlight Tail Light Circuit 1 LLi ur ie 9 QO 9 1 Ignition Switch 13 Fuse Box 2 High Beam Indicator
330. ixed with a flush ing compound CAUTION Do notuse a flushing compound which is harmful to the aluminum engine and radiator Carefully follow the instructions supplied by the manufacturer of the cleaning product e Warm up the engine and run it at normal operating tem perature for about ten minutes e Stop the engine and drain the cooling system e Fill the system with fresh water e Warm up the engine and drain the system e Repeat the previous two steps once more e Fill the system with a permanent type coolant and bleed the air from the system see Coolant Change in the Peri odic Maintenance chapter Coolant Reserve Tank Removal e Remove Left Middle Fairing see Middle Fairing Removal in the Frame chapter Coolant Reserve Tank Mounting Bolts A e Remove the cap B and poor the coolant into a container e Remove Radiator Overflow Hose C Reserve Tank Overflow Hose D Coolant Reserve Tank E 4 10 COOLING SYSTEM Coolant Coolant Reserve Tank Installation e Be sure that the pad A is in position on the coolant re serve tank B e Install the following to the coolant reserve tank Rubber Dampers C Collars D Gasket E Cap F e Tighten Torque Coolant Reserve Tank Mounting Bolts G 7 0 N m 0 70 kgf m 61 in Ib e Run the hoses correctly see Cable Wire and Hose Rout ing section in the Appendix chapter e Fill the coolant reserve tank with coolant see Coolant Change in the
331. k 7 Speed Sensor Electric Source Check e Connect the leads in the same circuit as Check 1 Set the hand tester A to the DC 25 V range and connect it to the terminals 18 and 19 Electric Source Voltage Standard Approximately 11 5 V at Battery Voltage 13 V x lf the voltage is not standard voltage replace the meter assembly Check 8 Odometer Inspection e Connect the leads in the same circuit as Check 6 e Set the ODO mode A by pushing the MODE button B e Raise the input frequency of the oscillator to see the result of this inspection OExample Indicates the increase of approximately 1 km h if the input frequency is approximately 525 Hz for one minute OExample Indicates the increase of approximately 1 mile if the input frequency is approximately 840 Hz for one minute xIf the value indicated by the odometer does not increase replace the meter assembly NOTE OThe integrated value of the odometer cannot be reset OWhen the figures come to 999999 they are stopped and locked Check 9 Trip Meter Inspection e Connect the leads in the same circuit as Check 6 e Set the TRIP mode A by pushing the MODE button B e Raise the input frequency of the oscillator to see the result of odometer inspection x If the value indicated by the trip meter does not increase replace the meter assembly e When pushing the RESET button C for more than two seconds check that the display changes 0 0 x If the display
332. k Coil 3 Ignite Signal Stick Coil 2 Ignite Signal Stick Coil 1 Ignite Signal Oxygen Sensor 2 Output Signal Equipped Models Gear Position Switch Output Signal Side Stand Switch Signal Unused External Communication Line Mode Switch Unused Power Supply to Oxygen Sensor Tachometer Output Signal Air Switching Valve Drive Signal Unused Secondary Fuel Injector 4 Drive Signal Secondary Fuel Injector 3 Drive Signal Primary Fuel Injector 4 Drive Signal Primary Fuel Injector 3 Output Signal Ground for Fuel System Ground for Ignition System Stick Coil 4 Ignite Signal FUEL SYSTEM DFI 3 21 DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system OThis DFI system is designed to be used with a 12 V sealed battery as its power source Do not use any other battery except for a 12 V sealed battery as a power source ODo not reverse the battery cable connections This will damage the ECU OTo prevent damage to the DFI parts do not disconnect the battery cables or any other electrical connections when the ignition switch is ON or while the engine is running OTake care not to short the leads that are directly con nected to the battery positive terminal to the chassis ground OWhen charging remove the battery from the motorcycle This is to prevent ECU damage by excessive voltage OWhenever the DFI e
333. ke any damping adjustments in small steps Clockwise Harder Counterclockwise Softer 25242322212019181716151413 F 23399 1211109 87654 32 1 Seated position adjuster turned fully clockwise 0M05287B 1 C Counterclockwise Clockwise Sof ter Harder STD 5 4 3 1 4 4 4 4 Seated position adjuster turned fully clockwise GMO5269BS1 C Counterclockwise Clockwise Softer Harder STD Seated position adjuster turned fully clockwise GMO5268BS1 C 13 20 SUSPENSION Rear Shock Absorber Spring Preload Adjustment e Loosen the locknut and turn out the adjusting nut to free the spring Special Tool Hook Wrench 3 2 R37 57001 1539 e To adjust the spring preload turn in the adjusting nut A to the desired position and tighten the locknut B Spring Length C Spring Preload Setting Standard Spring length 180 mm 7 09 in Usable Range Spring length 175 185 mm 6 89 7 28 in OThe standard adjusting nut setting for an average build rider of 68 kg 150 Ib with no passenger and no acces sories is 180 mm 7 09 in spring length e Remove the bolts A and left foot guard B for turning the hook wrench easily e To adjust the spring preload turn in the adjusting nut to the desired position and tighten t
334. kgf m 21 ft Ib e Check the gear positioning lever B and its spring for breaks or distortion xIf the lever or spring are damaged in any way replace them e Visually inspect the shift drum cam C x If they are badly worn or if they show any damage replace it Transmission Assy Removal e Remove Engine Sprocket see Engine Sprocket Removal in the Final Drive chapter Gear Position Switch see Gear Position Switch Re moval in the Electrical System chapter Collar A O ring B e Remove Clutch see Clutch Removal in the Clutch chapter Shift Shaft Assembly see External Shift Mechanism Re moval Transmission Case Bolts A x If the transmission assy is to be disassembed remove the following Gear Positioning Lever Bolt B Gear Positioning Lever C Spring and Collar Pull the transmission assy out of the crankcase Transmission Assy Disassembly e Remove the transmission assy see Transmission Assy Removal Remove the following from the transmission case A Shift Rods B Shift Forks C Drive Shaft D Output Shaft E CRANKSHAFT TRANSMISSION 9 39 Transmission e Remove Gear Positioning Lever A Bearing Holder Screws B Bearing Holder C Shift Drum Assembly D Transmission Assy Assembly e Press and insert the race A in the transmission case B so that the big stepped side C faces to transmission gears side until it is bottomed Special Tool Bearing Driver Set
335. l Inlet Air Temperature Sensor Connector A Inlet Air Pressure Sensor B Nozzle Assy Lead Connectors C e Remove Air Cleaner Housing Bolt A Plugs B FUEL SYSTEM DFI 3 125 Air Cleaner e Loosen Air Cleaner Housing Clamp Bolts A e Remove Clamp A Engine Breather Hose B Clamp C Drain Hose D e Remove the air switching valve hose A 0078291 Air Cleaner Housing Installation e Install the vacuum switch valve hose to the air cleaner housing e Install the air cleaner housing on the throttle body assy Olnstall the clamp bolt heads A outside as shown OPush in the ducts B touch the stopper C of the throttle body Torque Air Cleaner Housing Clamp Bolts 2 0 N m 0 20 kgf m 17 in Ib Air Cleaner Housing Mounting Bolt 6 9 N m 0 70 kgf m 61 in Ib GC07044BS2 C e Install Drain and Engine Breather Hoses Hose Joint see Nozzle Assy Installation 3 126 FUEL SYSTEM Air Cleaner Install Inlet Air Temperature Sensor Inlet Air Pressure Sensor B Hooks eRunthe harness and hose as shown Air Cleaner Housing Disassembly e Remove Air Cleaner Housing see Air Cleaner Housing Removal Inlet Air Temperature Sensor Nozzle Assy A see Nozzle Assy Removal Clamps B Ducts C e Remove the air filler see Air Filler Replacement in the Periodic Maintenance chapter Air Cleaner Housing Assembly e Fit the projections A of the d
336. l System chapter Ignition Switch see Wiring Diagram in the Electrical Sys tem chapter Gear Position Switch see Gear Position Switch Inspec tion in the Electrical System chapter Harness see Wiring Inspection in the Electrical System chapter e Turn off the ignition switch e The all lights should go off for the immobilizer model warning indicator light LED will blink see Abstract in the Electrical System chapter xIf the light does not go off replace the ignition switch 6514018851 C 9517091851 PERIODIC MAINTENANCE 2 39 Maintenance Procedure Second Step e Turn the ignition switch to P Park position e The city light tail orake light LED and license plate light should go on x lf the light does not go on inspect or replace the following item Ignition Switch see Wiring Diagram in the Electrical Sys tem chapter Third Step e Turn on the ignition switch e Turn on the turn signal switch A left or right position e The left or right turn signal lights B front and rear ac cording to the switch position should blink e The turn signal indicator light LED C in the meter unit should blink x If the each light does not blink inspect or replace the fol lowing item Turn Signal Light Bulb see Turn Signal Light Bulb Re placement in the Electrical System chapter Meter Unit for Turn Signal Light Indicator Light LED see Electronic Combination Meter Unit Inspection in the
337. l Tool Clutch Holder 57001 1243 Torque Clutch Hub Nut 135 N m 14 kgf m 100 ft Ib e Install the following as shown Friction Plate 36 lining blocks A Friction Plates 48 lining blocks B Steel Plates C Spring Seat D Spring E NOTE OThe lining blocks F of the friction plate A are larger than them of the friction plates B Olnstall the spring seat and spring between first steel plate and second steel plate CAUTION If new dry friction plates and steel plates are in stalled apply engine oil to the surfaces of each plate to avoid clutch plate seizure 8 06094851 GFO6O95BS1 C 8 06153 52 C CLUTCH 6 13 Clutch e Install the last friction plate 36 lining blocks A fitting the tangs in the grooves in the housing as shown e Apply molybdenum disulfide grease to the pusher ends A e Install the washer B spring C bearing D and shim E to the pusher e Install the pusher to the drive shaft F direction as shown e Align the projections A of the spring plate B to the grooves C of the sub clutch hub D to install the spring plate on the sub clutch hub e Install the springs and spring holders and tighten the clutch spring bolts Torque Clutch Spring Bolts 8 8 N m 0 90 kgf m 78 in Ib Install the clutch cover see Clutch Cover Installation in this chapter Spring Plate Free Play Measurement Insufficient clutch free play
338. l to all pockets front side of the cam lobes of the camshaft Inlet Side Oil Pockets A Exhaust Side Oil Pockets B 6507024851 9507132851 9507131851 GE11231BS1 2 22 PERIODIC MAINTENANCE Maintenance Procedure Valve Clearance Adjustment e To change the valve clearance remove the camshaft chain tensioner camshafts and valve lifters Replace the shim with one of a different thickness NOTE OMark and record the locations of the valve lifters and shims so that they can be reinstalled in their original positions Clean the shim to remove any dust or 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 0 Measured Valve Clearance c Specified Valve Clearance Mean Value 0 16 d Replace Shim Thickness Example 1 600 0 33 0 16 1 77 mm the shim for the 1 775 size shim CAUTION Don t use the shims for another models This could cause wear of the valve stem end and valve stem damage PERIODIC MAINTENANCE 2 23 Maintenance Procedure Adjustment Shims Thickness Part Number Mark 1 300 92180 0108 130 1 325 92180 0109 132 1 350 92180 0110 135 1 375 92180 0111 138 NS 1 400 92180 0112 140 1 425 92180 0113 142 ME 1 450 9
339. lace the meter assembly 8 17918 52 When terminal 16 is disconnected from IGN under changing the shift up indicator setting and it connected again check that pre set engine speed and light mode finish under setting x lf the display function does not work replace the meter assembly GP17917BS2 C ELECTRICAL SYSTEM 16 79 Meter Gauge Indicator Unit e The speed equivalent to the input frequency is indicated In the oscillator if the square wave illustrated as shown would be input into the terminal When inputting the signal of the oscillator with more than 1 km h mph or equivalent into 13 line under setting check to operate normally e When inputting the signal of the oscillator with more than 1 km h mph or equivalent into 13 line check the pre set engine speed and light mode does not move to the setting mode If the display function does not work replace the meter assembly e The revolutions per minute rpm equivalent to the input frequency is indicated in the oscillator A if the square wave illustrated as shown would be input into the termi nal 12 e When set the oscillator more than 550 Hz shift up indica tor light LED go on xIf each LED lights does not go on replace the meter as sembly Duty 50 BEES 8 17848 52 C Duty 50 GP17849BS2 16 80 ELECTRICAL SYSTEM Meter Gauge Indic
340. lant when the engine is still hot Wait until it cools down Coolant on tires will make them slippery and can cause an accident and injury Immediately wipe up or wash away any coolant that spills on the frame engine or other painted parts Since coolant is harmful to the human body do not use for drinking e Remove Right Inner Cover see Inner Cover Removal in the Frame chapter Radiator Cap A ORemove the radiator cap in two steps First turn the cap counterclockwise to the first stop Then push and turn it further in the same direction and remove the cap e Remove Left Middle Fairing see Middle Fairing Removal in the Frame chapter e Place a containers under the drain bolts A B of the wa ter pump cover and cylinder e Drain the coolant from the radiator and engine by remov ing the drain bolts Remove Coolant Reserve Tank A see Coolant Reserve Tank Removal in the Cooling System chapter e Remove the cap B and pour the coolant into a container e Install the coolant reserve tank see Coolant Reserve Tank Installation in the Cooling System chapter e Tighten the drain bolts with the washers OReplace the drain bolt washers with a new one if it is dam aged Torque Coolant Drain Bolt Water Pump 8 8 N m 0 90 kgf m 78 in lb Coolant Drain Bolt Cylinder 9 8 N m 1 0 kgf m 87 in Ib PERIODIC MAINTENANCE 2 51 Maintenance Procedure e Fill the radiator up to the radiator filler neck A
341. layer of engine oil before storing Marks Stamped on the Cutter The marks stamped on the back of the cutter A represent the following Cutter angle 031 5 Outer diameter of cutter Operating Procedures e Clean the seat area carefully Coat the seat with machinist s dye e Fit a 45 cutter into the holder and slide it into the valve guide Press down lightly on the handle and turn it right or left Grind the seating surface only until it is smooth CAUTION Do not grind the seat too much Overgrinding will reduce valve clearance by sinking the valve into the head If the valve sinks too far into the head it will be impossible to adjust the clearance and the cylin der head must be replaced 8 15011851 C ENGINE TOP END 5 31 Valves e Measure the outside diameter of the seating surface with vernier caliper x If the outside diameter of the seating surface is too small repeat the 45 grind until the diameter is within the spec ified range Widened Width A of engagement by machining with 45 cutter Ground Volume B by 32 cutter 32 C Correct Width D Ground Volume E by 60 cutter 60 F Measure the outside diameter of the seating surface with a vernier caliper x If the outside diameter of the seating surface is too small repeat the 45 grind A until the diameter is within the specified range Original Seating
342. lds the pressure in the system when the engine is running When the pressure exceeds 93 123 kPa 0 95 1 25 kgf cm 13 18 psi the pressure valve opens and releases the pressure to the reserve tank As soon as pressure escapes the valve closes and keeps the pressure at 93 123 kPa 0 95 1 25 kgf cm 13 18 psi When the engine cools down another small valve vacuum valve in the cap opens As the coolant cools the coolant contracts to form a vacuum in the system The vacuum valve opens and allows the coolant from the reserve tank to enter the radiator 4 8 COOLING SYSTEM Coolant Coolant Deterioration Inspection e Visually inspect the coolant the reserve tank x If whitish cotton like wafts are observed aluminum parts in the cooling system are corroded If the coolant is brown iron or steel parts are rusting In either case flush the cooling system xIf the coolant gives off an abnormal smell check for cooling system leak It may be caused by exhaust gas leaking into the cooling system Coolant Level Inspection e Refer to the Coolant Level Inspection in the Periodic Main tenance chapter Coolant Draining e Refer to the Coolant Change in the Periodic Maintenance chapter Coolant Filling e Refer to the Coolant Change in the Periodic Maintenance chapter Pressure Testing e Remove Right Inner Cover see Inner Cover Removal in the Frame chapter Radiator Cap A ORemove the radiator cap in two steps
343. le range replace the sensor Atmospheric Pressure Sensor Circuit BR BK BL G W 6C176288W2 C 1 ECU 2 Atmospheric Pressure Sensor x If you need to check the atmospheric pressure sensor for various altitudes other than sea level check the output voltage as follows ODetermine the local altitude Elevation FUEL SYSTEM DFI 3 59 Atmospheric Pressure Sensor Service Code 15 you know the local atmospheric pressure using a barometer substitute the atmospheric pressure for throt tle vacuum pressure in the inlet air pressure sensor chart see Inlet Air Pressure Sensor section And get the usable range of the atmospheric pressure sensor output voltage and check if output voltage is within the standard or not in the same way as Output Voltage Inspection of the inlet air pressure sensor If you know the local altitude use the following chart Atmospheric Pressure Altitude Relationship 750 P Atmospheric Pressure mmHg abs Z Altitude km Z _ 5 0 19026 760 1 44 51 700 E o 650 gt 7 o a o o B v o 600 lt 550 0 1 2 3 4 5 6 7 8 9 X1 000ft 0 0 2 0 4 0 6 08 1 1 2 1 4 1 6 1 8 2 2 2 2 4 2 6 2 8 X1 000m Altitude 6C17A435W4 C 3 60 FUEL SYSTEM DFI Crankshaft Sensor Service Code 21 Crankshaft Sensor Re
344. le valve is fully opened or completely closed Output Voltage at Sensor Standard DC 1 08 4 60 V at subthrottle valve full opening to closing CAUTION Do not remove or adjust the subthrottle sensor It has been adjusted and set with precision at the fac tory Never drop the throttle body assy especially on a hard surface A shock to the sensor can damage it e After subthrottle sensor voltage inspection remove the harness adapter xIf the reading is out of the standard range inspect the throttle sensor resistance x If the output voltage is normal check the wiring for conti nuity see wiring diagram FUEL SYSTEM DFI 3 73 Subthrottle Sensor Service Code 32 Resistance Inspection e Turn the ignition switch OFF e Disconnect the subthrottle sensor connector Connect a digital meter A to the subthrottle sensor con nector B Measure the subthrottle sensor resistance Subthrottle Sensor Resistance Connections BL lead C lt gt BR BK lead D Standard 4 6kQ x If the reading is out of the range replace the throttle body assy see Throttle Body Assy Removal Installation x lf the reading is within the range but the problem still exists replace the ECU see ECU Removal Installation GC17116BS1 C Subthrottle Sensor Circuit 66178846 2 1 ECU 2 Main Throttle Sensor 3 Subthrottle Sensor 3 74 FUEL SYSTEM Oxygen Sensor not ac
345. leaking replace the bearing Chain Guide Inspection e Refer to the Chain Guide Wear Inspection in the Periodic Maintenance chapter SUSPENSION 13 27 Tie Rod Rocker Arm Tie Rod Removal e Remove Lower Fairings see Lower Fairing Removal in the Frame chapter Front Exhaust Pipe see Front Exhaust Pipe Removal in the Engine Top End chapter Squeeze the brake lever slowly and hold it with a band e Using the jack raise the rear wheel off the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Remove Upper Tie Rod Bolt and Nut A Lower Tie Rod Bolt and Nut B Tie Rods C Tie Rod Installation e Apply grease to the inside of the grease seals e Install the tie rods so that the marked side faces A out side Tighten Torque Tie Rod Nuts 59 N m 6 0 kgf m 43 ft lb Rocker Arm Removal e Remove Lower Fairings see Lower Fairing Removal in the Frame chapter e Squeeze the brake lever slowly and hold it with a band A e Remove Front Exhaust Pipe see Front Exhaust Pipe Removal in the Engine Top End chapter e Remove the following nuts first A Lower Rear Shock Absorber Nut B Lower Tie Rod Nut C Rocker Arm Nut 13 28 SUSPENSION Tie Rod Rocker Arm e Using the jack raise the rear wheel off the ground Special Tools Jack A 57001 1238 Jack Attachment B 57001 1608 e Remove Lower Rear Shock Absorber Bolt A Lower Tie Rod Bolt B Rocke
346. lean the parts in order prior to assembly Storage of Removed Parts After all the parts including subassembly parts have been cleaned store the parts in a clean area Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re assembly 68020088 5 Inspection Reuse of worn or damaged parts may lead to serious ac cident Visually inspect removed parts for corrosion discol Sw N oration or other damage Refer to the appropriate sections N of this manual for service limits on individual parts Replace Yy W the parts if any damage has been found or if the part is be n yond its service limit a 68020098 5 Replacement Parts Replacement Parts must be KAWASAKI genuine or recommended by KAWASAKI Gaskets O rings oil seals grease seals circlips or cotter pins must be replaced with new ones whenever disassembled 68020108 5 Assembly Order In most cases assembly order is the reverse of disassem bly however if assembly order is provided in this Service c Manual follow the procedures given o gt M Rs 68020118 S 1 4 GENERAL INFORMATION Before Servicing Tightening Sequence Generally when installing a part with several bolts nuts or screws start them all in their holes and tighten them to a snug fit Then tighten them according to the specified se quence to prevent case warpage or deformation whi
347. leaning of the parts use only disc brake fluid isopropyl alcohol or ethyl alcohol e Install the bleed valve and rubber cap Torque Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib e Replace the fluid seal A with a new one OApply rubber grease to the fluid seal and install it into the cylinder by hand e Replace the dust seal B with a new one OApply rubber grease to the dust seal and install it into the cylinder by hand 6105040251 2 60 PERIODIC MAINTENANCE Maintenance Procedure e Install the pad spring A in the caliper as shown e Apply brake fluid to the outside of the piston B and push it into the cylinder by hand Replace the shaft rubber friction boot and dust boot D e Install the pad spring A on the caliper holder as shown e Apply a thin coat of PBC Poly Butyl Cuprysil grease to the caliper holder shafts B and holder holes PBC is a special high temperature water resistance grease e Install the pads see Rear Brake Pad Installation in the Brakes chapter e Wipe up any spilled brake fluid on the caliper with wet cloth Spark Plug Replacement e Remove Stick Coils see Stick Coil Removal in the Electrical Sys tem chapter e Remove the spark plug using the 16 mm 0 63 in plug wrench A vertically Owner s Tool Spark Plug Wrench 16 mm 92110 1132 e Replace the spark plug with a new one Standard Spark Plug Type NGK CR9E e Insert
348. lectrical connections are to be discon nected first turn off the ignition switch Conversely make sure that all the DFI electrical connections are firmly re connected before starting the engine OConnect there connectors until they click A ODo not turn the ignition switch ON while any of the DFI electrical connectors are disconnected The ECU memo rizes service codes not spray water on the electrical parts DFI parts con nectors leads and wiring Olf a transceiver is installed on the motorcycle make sure that the operation of the DFI system is not influenced by electric wave radiated from the antenna Check operation of the system with the engine at idle Locate the antenna as far as possible away from the ECU OWhen any fuel hose is disconnected do not turn on the ignition switch Otherwise the fuel pump will operate and fuel will spout from the fuel hose ODo not operate the fuel pump if the pump is completely dry This is to prevent pump seizure OBefore removing the fuel system parts blow the outer sur faces of these parts clean with compressed air OWhen any fuel hose is disconnected fuel may spout out by residual pressure in the fuel line Cover the hose joint with a piece of clean cloth to prevent fuel spillage OWhen installing the fuel hoses avoid sharp bending kink ing flattening or twisting and route the fuel hoses with a minimum of bending so that the fuel flow will not be ob structed ORoute
349. lf there is more resistance than the specified value the sensor coil has an open lead and must be replaced Much less than this resistance means the sensor coil is shorted and must be replaced Camshaft Position Sensor Resistance 400 460 GP10155BS1 C e Using the highest resistance range of the tester mea sure the resistance between the camshaft position sensor leads and chassis ground Any tester reading less than infinity gt indicates a short necessitating replacement of the camshaft position sen sor Camshaft Position Sensor Peak Voltage Inspection e Remove Camshaft Position Sensor Connector see Camshaft Position Sensor Removal Set the hand tester A to the 10 V DC range e Connect the peak voltage adapter B to the hand tester and camshaft position sensor leads in the terminals Special Tools Hand Taster 57001 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B GP10156BS1 C Connections Camshaft Position Sensor Terminal Adapter Hand Tester White Yellow C Red NS Yellow D Black e Turn the ignition switch and engine stop switch on e Pushing the starter button turn the engine 4 5 sec onds with the transmission gear in neutral to measure the camshaft position sensor peak voltage Repeat the measurement 5 or more times Camshaft Position Sensor Peak Voltage Standard 0 4 V or more x If the peak voltage is lower than the standard i
350. lief valve see Oil Pressure Relief Valve Removal e Check to see if the valve A slides smoothly when push ing it in with a wooden or other soft rod and see if it comes back to its seat by spring B pressure NOTE Olnspect the valve in its assembled state Disassembly and assembly may change the valve performance any rough spots are found during above inspection wash the valve clean with a high flash point solvent and blow out any foreign particles that may be in the valve with compressed air WARNING Clean the pressure relief valve well ventilated area and take care that there is no spark or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline or low flash point solvent x lf cleaning does not solve the problem replace the oil pressure relief valve as an assembly The oil pressure relief valve is precision made with no allowance for re placement of individual parts 6008060251 ENGINE LUBRICATION SYSTEM 7 13 Oil Pump Oil Pump Removal e Drain Coolant see Coolant Change in the Periodic Mainte nance chapter Engine Oil see Engine Oil Change in the Periodic Main tenance chapter e Remove Water Pump Cover Bolts A Water Pump Cover B Water Hose C e Remove Water Hose A Impeller Bolt B and Washer C Impeller D e Install the impeller bolt A temporary e Using the impeller bolt A
351. linder Mounting Bolts 25 N m 2 5 kgf m 18 ft lb Brake Hose Banjo Bolt 25 N m 2 5 kgf m 18 ft Ib Bleed the brake line see Brake Line Bleeding e Check the brake for good braking power no brake drag and no fluid leakage Front Master Cylinder Disassembly e Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter Rear Master Cylinder Disassembly e Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter Master Cylinder Inspection Visual Inspection e Remove the master cylinders see Front Rear Master Cylinder Removal e Disassemble the front and rear master cylinders see Master Cylinder Rubber Parts Replacement in the Peri odic Maintenance chapter e Check that there are no scratches rust or pitting on the inner wall A of each master cylinder and on the outside of each piston B x If a master cylinder or piston shows any damage replace them e Inspect the primary cup C and secondary cup D xIf a cup is worn damaged softened rotted or swollen the piston assembly should be replaced to renew the cups x If fluid leakage is noted at the brake lever the piston as sembly should be replaced to renew the cups Front Master Cylinder I 9107078851 BRAKES 12 17 Master Cylinder e Check the dust covers E for damage x If they are damaged replace them e Check the piston return spring F for any da
352. ling surfaces of the rim and tire and smooth the sealing surfaces of the rim with a fine emery cloth if necessary e Remove the air valve and discard it CAUTION Replace the air valve whenever the tire is replaced Do not reuse the air valve 6J05040BS1 C 10 14 WHEELS TIRES Tires e Install a new valve in the rim ORemove the valve cap lubricate the stem seal A with a soap and water solution or rubber lubricant and pull B the valve stem through the rim from the inside out until it snaps into place CAUTION Do not use engine oil or petroleum distillates to lu bricate the stem because they will deteriorate the rubber GJ05041BS1 OThe air valve is shown in the figure Valve Cap A Valve Core B Stem Seal C Valve Stem D Valve Seat E Valve Opened F 6J05030781 e Check the tire rotation mark on the front and rear tires and install them on the rim accordingly Tire Rotation Mark A Rotating Direction B 8 05051 51 C e Position the tire on the rim so that the valve A align with the tire balance mark B the chalk mark made during removal or the yellow paint mark on a new tire e Install the tire bead over the rim flange using a suitable commercially available tire changer e Lubricate the tire beads and rim flanges with a soap and water solution or rubber lubricant to help seat the tire beads in the sealing surfaces of the rim
353. ll GE15045BS1 C warp the cylinder head Soak the cylinder head in oil and heat the oil Special Tool Valve Guide Arbor 4 57001 1273 Valve Guide Installation e Apply engine oil to the valve guide outer surface before installation e Heat the area around the valve guide hole to about 120 150 C 248 302 F CAUTION Do not heat the cylinder head with a torch This will warp the cylinder head Soak the cylinder head and heat the oil e Using the valve guide driver and attachment A press and insert the valve guide in until the attachment surface B touches the head surface C 13 3 13 5 mm 0 52 0 53 in D Special Tools Valve Guide Driver 57001 1564 Attachment C 57001 1624 GE15041BS1 C e Ream the valve guide with valve guide reamer A even if the old guide is reused Special Tool Valve Guide Reamer 4 57001 1274 GE15046BS1 C 5 28 ENGINE TOP END Valves Valve to Guide Clearance Measurement Wobble Method If a small bore gauge is not available inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below e Insert a new valve A into the guide B and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface e Move the stem back and forth C to measure valve valve guide clearance e Repeat the measurement in a direc
354. ll Cam Lobes Journals and Thrust Journals e Apply engine oil B 1 4 Cam Lobes of EX and IN Camshafts Install O rings A Dowel Pins B O rings C Dowel Pins D e Install the camshaft caps and upper camshaft chain guide A as shown R Mark B L Mark C e First tighten the all camshaft cap bolts evenly to seat the camshaft in place then tighten all bolts following the spec ified tightening sequence Torque Camshaft Cap Bolts 1 20 First 5 9 0 6 kgf m 52 in lb Final 12 N m 1 2 kgf m 106 in Ib Upper Camshaft Chain Guide Bolts First 5 9 0 6 kgf m 52 in Ib Final 12 N m 1 2 kgf m 106 in Ib 25 z HC 6 t Qe SAGA PO z isl hi GE112238W2 ENGINE TOP END 5 21 Camshaft e Install the camshaft chain tensioner see Camshaft Chain Tensioner Installation Turn the crankshaft 2 turns clockwise to allow the ten sioner to expand and recheck the camshaft chain timing Check the valve clearance see Valve Clearance Inspec tion in the Periodic Maintenance chapter Fill the following oil pockets with engine oil A Oil Pockets of Inlet Camshaft B Oil Pockets of Exhaust Camshaft GE11231BS1 Replace the O ring of the timing inspection cap and starter clutch bolt cap e Apply grease to the new O rings e
355. low flash point solvents to clean them CAUTION Immediately dry the bolts and nuts with com pressed air after cleaning Clean and dry the bolts and nuts completely e Install new bolts in reused connecting rods e Dent both bolt head and bolt tip with a punch as shown e Before tightening use a point micrometer to measure the length of new connecting rod bolts and record the values to find the bolt stretch Connecting Rod A Dent here with a punch B Nuts C Fit micrometer pins into dents D e Apply a small amount of molybdenum disulfide oil solution to the following Threads of Nuts and Bolts Seating Surfaces of Nuts and Connecting rods e Tighten the big end nuts until the bolt elongation reaches the length specified in the table e Check the length of the connecting rod bolts x If the stretch is more than the usable range the bolt has stretched too much An overelongated bolt may break in use Bolt Length after _ Bolt Length before Stretch tightening tightening Usable Range of Connecting Rod Bolt Stretch 0 28 0 38 mm 0 0110 0 0150 in 6105040381 CRANKSHAFT TRANSMISSION 9 21 Crankshaft and Connecting Rods 2 Rotation Angle Method If you don t have a point micrometer you may tighten the nuts using the Rotation Angle Method e Be sure to clean the bolts nuts and connecting rods thor oughly with a high flash point solvent because the new connecting rods bol
356. lowing precisely the maximum charge current and time conditions indicated on the battery CAUTION This battery is designed to sustain no unusual deterioration if refresh charged according to the method specified above However the battery s performance may be reduced no ticeably if charged under conditions other than given above Never remove the seal cap during refresh charge If by chance an excessive amount of gas is generated due to overcharging the relief valve releases the gas to keep the battery normal 3 When you do not use the motorcycle for months Give a refresh charge before you store the motorcycle and store it with the negative cable re moved Give a refresh charge once a month during storage 4 Battery life If the battery will not start the engine even after several refresh charges the battery has ex ceeded its useful life Replace it Provided however the vehicle s starting system has no prob lem WARNING Keep the battery away from sparks and open flames during charging since the battery gives off an explosive gas mixture of hydrogen and oxygen When using a battery charger connect the battery to the charger before turning on the charger This procedure prevents sparks at the battery terminals which could ignite any battery gases No fire should be drawn near the battery or no terminals should have the tightening loos ened The electrolyte contains sulfuric acid Be careful
357. ls wiring short Sensor Heater temperature of the or open the ECU stops the current to the Equipped sensor for its earlier heater and it stops the feedback mode of the Models activation 12 V 3 6 W oxygen sensor 1 5 A The oxygen sensor 1 is active and sensor must send If the oxygen sensor is not activated the ECU signals output voltage stops the feedback mode of the oxygen sensor continuously to the ECU The oxygen sensor 1 must signals output voltage continuously to the ECU The oxygen sensor 1 must signals output voltage continuously to the ECU Air Switching Valve Oxygen Sensor 2 Equipped Models Oxygen Sensor 1 Equipped Models If the oxygen sensor 1 output voltage is incorrect the ECU stops oxygen sensor feed back mode of the oxygen sensor Oxygen Sensor 95 2 Equipped Models If the oxygen sensor 2 output voltage is incorrect the ECU stops oxygen sensor feed back mode of the oxygen sensor Note 1 a N Method the DFI control method from medium to heavy engine load When the engine load is light like at idling or low speed the ECU determines the injection quantity by calculating from the throttle vacuum inlet air pressure sensor output voltage and engine speed crankshaft sensor output voltage This method is called D J method As the engine speed increases and the engine load turns middle to heavy the ECU determines the injection quantity by calcul
358. lt in abnormal wear and may result in an unsafe riding condition Drive Chain Wear Inspection e Remove Chain Cover see Drive Chain Removal in the Final Drive chapter e Rotate the rear wheel to inspect the drive chain for dam aged rollers and loose pins and links xIf there is any irregularity replace the drive chain x Lubricate the drive chain if it appears dry e Stretch the chain taut by hanging a 98 N 10 kg 20 Ib weight A on the chain e Measure the length of 20 links B on the straight part C of the chain from the pin center of the 1st pin to the pin center of the 21st pin Since the chain may wear unevenly take measurements at several places x If any measurements exceed the service limit replace the chain Also replace the front and rear sprockets when the drive chain is replaced Drive Chain 20 link Length Standard 317 5 318 2 mm 12 50 12 53 in Service Limit 323 mm 12 7 in GK04060881 C A WARNING If the drive chain wear exceeds the service limit re place the chain or an unsafe riding condition may result A chain that breaks or jumps off the sprock ets could snag on the engine sprocket or lock the rear wheel severely damaging the motorcycle and causing it to go out of control For safety use only the standard chain It is an end less type and should not be cut for installation Standard Chain Make ENUMA Type EK520MVXL1 Link 112 links 2 3
359. lvent into the fuel tank and shake the tank to remove dirt and fuel deposits e Draw the solvent out of the fuel tank e Dry the tank with compressed air e Install the fuel pump see Fuel Pump Installation e Install the fuel tank see Fuel Tank Installation 3 132 FUEL SYSTEM Evaporative Emission Control System California Model The Evaporative Emission Control System routes fuel va pors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped Al though no adjustments are required a thorough visual in spection must be made at the intervals specified by the Pe riodic Maintenance Chart Parts Removal Installation A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light CAUTION If gasoline solvent water or any other liquid enters the canister the canister s vapor absorbing capac ity is greatly reduced If the canister does become contaminated replace it with a new one e To prevent the gasoline from flowing into or out of the canister hold the separator perpendicular to the ground e Connect the hoses according to the diagram of the sys tem see Cable Wire and Hose Routing section in the Appendix chapter Make sure they do not
360. ly 5 kO x If the reading is out of the range replace the throttle body assy see Throttle Body Assy Removal Installation xIf the reading is within the range but the problem still exists replace the ECU see ECU Removal Installation GC17116BS1 C 3 46 FUEL SYSTEM DFI Main Throttle Sensor Service Code 11 Main Throttle Sensor Circuit 66178846 2 1 ECU 2 Main Throttle Sensor 3 Subthrottle Sensor FUEL SYSTEM DFI 3 47 Inlet Air Pressure Sensor Service Code 12 CAUTION Never drop the sensor especially on a hard surface Such a shock to the part can damage it Inlet Air Pressure Sensor Removal e Turn the ignition switch OFF e Set up the fuel tank see Air Cleaner Housing Removal e Remove Inlet Air Pressure Sensor Connector A Inlet Air Pressure Sensor B Vacuum Hose C Inlet Air Pressure Sensor Installation e Install Vacuum Hose A e Put the rubber damper B of the inlet air pressure sensor C in the slot D of air cleaner housing e Connect the connector Inlet Air Pressure Sensor Input Voltage Inspection NOTE OBe sure the battery is fully charged OThe inspection is the same as Input Voltage Inspection ofthe throttle sensor and the atmospheric pressure sen sor e Turn the ignition switch OFF Remove the ECU see ECU Removal Do not disconnect the ECU connectors Connect a digital voltmeter A to the connector with
361. ly inspect the pistons A and cylinder surfaces B Replace the caliper if the cylinder and piston are badly Scores or rusty Rear Caliper Holder Shaft Wear 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 rubber friction boots are not damaged x If the rubber friction boot is damaged replace the rubber friction boot To replace the friction boot remove the pads and the caliper bracket xIf the caliper holder shaft is damage replace the caliper bracket GL05175BS1 C GL05172BS1 9105174851 9105176851 C BRAKES 12 13 Brake Pads Front Brake Pad Removal e Remove Pad Pins A Pad Springs B Brake Pads C Front Brake Pad Installation e Push the caliper pistons in by hand as far as they will go e Install the outside pad A and insert the pad pin B as shown 4 9 008161 Set Spring OPushing the holder to hole of the insert the pad pin D Torque Front Brake Pad Pins 17 1 7 kgf m 13 ft Ib A WARNING Do not attempt to drive the motorcycle until a full brake lever is obtained by pumping the brake
362. m the crankshaft clean them with a high flash point solvent Blow the crankshaft oil passages with compressed air to remove any foreign particles or residue that may have accumulated in the passages Connecting Rod Bend Remove the connecting rod big end bearing inserts and reinstall the connecting rod big end cap Select an arbor A of the same diameter as the connect ing rod big end and insert the arbor through the connect ing rod big end Select an arbor of the same diameter as the piston pin and at least 100 mm 3 94 in long and insert the arbor B through the connecting rod small end On a surface plate set the big end arbor on V block 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 x If connecting rod bend exceeds the service limit the con necting rod must be replaced Connecting Rod Bend Service Limit TIR 0 2 100 mm 0 008 3 94 in Connecting Rod Twist e With the big end arbor A still on V block C hold the connecting rod horizontally and measure the amount that the arbor B varies from being paralleled with the surface plate over a 100 mm 3 94 in length of the arbor to de termine the amount of connecting rod twist x If connecting rod twist exceeds the service limit the con necting rod must be replaced Conn
363. mage x If the springs are damaged replace them e Check that relief port G and supply port H are not plugged x lf the relief port becomes plugged the brake pads will drag on the disc Blow the ports clean with compressed air Rear Maser Cylinder J 9107079852 C Master Cylinder Assembly e Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter 12 18 BRAKES Brake Disc Brake Disc Removal Remove the wheel see Front Rear Wheel Removal in the Wheels Tires chapter e Unscrew the mounting bolts and take off the disc Brake Disc Installation e Install the brake disc on the wheel so that the marked side B faces out e Apply a non permanent locking agent to the threads of the rear brake disc mounting bolts A e Tighten Torque Brake Disc Mounting Bolts 27 N m 2 8 kgf m 20 ft Ib Brake Disc Wear Measure the thickness of each disc A at the point where it has worn the most x If the disc has worn past the service limit replace it Measuring Area B Brake Discs Thickness Standard Front 5 8 6 2 mm 0 23 0 24 in Rear 4 8 5 2 mm 0 19 0 20 in Service Limit Front 5 5 mm 0 22 in Rear 4 5 mm 0 18 in Brake Disc Warp e Jack up the motorcycle so that the wheel is off the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1608 OFor front disc inspection turn the handlebar fully to one sid
364. mage Inspection pp 2 24 Cooling Rc mcn 2 25 Coolant Level Inspection 2 25 Radiator Hose Damage and Installation Condition 2 25 TUE Dietas etl ta Mich 2 26 Clutch Operation Inspection 2 26 Wheels Tires 2 27 Air Pressure 2 27 Wheel Tire Damage Inspectiom tina 2 27 Tire Tread Wear Inspection e ERE DERI deed Re esd eles 2 27 Wheel Bearing Damage Inspection 18 2 28 IPIS Em 2 29 Drive Chain Lubrication Condition Inspection pp 2 29 Drive Chain Slack Inspection pp 2 29 Drive Chain Slack Adjustment 2 30 Wheel Alignment Inspection uei erronee ter 2 31 Drive Chain Wear Inspection pp 2 31 Chain Guide Wear Inspection pp 2 32 E 2 32 Brake Fluid Leak Brake Hose and Pipe Inspection 2 32 Brake Hose Damage and Installation Condition 2 32 Brake Operation Inspection 2 33 Brake Fluid Level Inspection pp 2 33 Brake Pad Wear Inspection pp 2 34 Brake Light Switch Operation
365. ment Refer to the Engine Vacuum Synchronization Inspection in the Periodic Maintenance chapter Throttle Body Assy Removal A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Disconnect the battery cable ter minal Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately e Remove Fuel Tank see Fuel Tank Removal Air Cleaner Housing see Air Cleaner Housing Removal in this chapter OBe sure to place a piece of cloth around the fuel supply pipe of the throttle body assy e Disconnect Subthrottle Valve Actuator Connector A Subthrottle Sensor Connector B Main Throttle Sensor Connector C Primary Injector Connectors D Water Temperature Sensor Connector E Clamp F e Remove Vacuum Switch Valve Vacuum Hose Vacuum Hose California Model e Loosen Clamp Bolts A Special Tool Carburetor Drain Plug Wrench Hex 57001 1269 B Olnsert the wrench from the outside of the frame Remove the throttle body assy from the holder CAUTION When removing the throttle body assy put the main throttle valves in the throttle bore be careful to damage to valves 3 118 FUEL SYSTEM DFI Throttle Body Assy e Remove the throttle case A to make a
366. moval Installation e Refer to the Crankshaft Sensor Removal Installation in the Electrical System chapter see Crankshaft Sensor Re moval Installation in the Electrical System chapter Crankshaft Sensor Inspection OThe crankshaft have no power source and when the en gine stops the crankshaft generates no signals e Crank the engine and measure the peak voltage of the crankshaft sensor see Crankshaft Sensor Peak Voltage Inspection in the Electrical System chapter in order to check the sensor e Check the wiring for continuity Crankshaft Sensor Circuit x an gt BK Y BK Y BK 80617632842 1 2 Crankshaft Sensor FUEL SYSTEM DFI 3 61 Camshaft Position Sensor Service Code 23 Camshaft Position Sensor Removal Installation The camshaft position sensor detects the position of the camshaft and distinguishes the cylinder e Refer to the Camshaft Position Sensor Removal Installa tion in the Electrical System chapter see Camshaft Posi tion Sensor Removal Installation in the Electrical System chapter Camshaft Position Sensor Inspection OThe camshaft position sensor have no power source and when the engine stops the camshaft position sensor gen erates no signal e Crank the engine and measure the peak voltage of the camshaft position sensor see Camshaft Position Sensor Peak Voltage Inspection in the Electrical System chapter in order to check the sensor
367. n not be removed Relay Box Removal e Remove Right Inner Cover see Inner Cover Removal in the Frame chapter Fuse Box A see Fuse Box Removal e Disconnect the connectors B and take out the relay box A Relay Circuit Inspection e Remove the relay box see Relay Box Removal e Check conductivity of the following numbered terminals by connecting the hand tester and one 12 V battery to the relay box as shown x If the tester does not read as specified replace the relay box ELECTRICAL SYSTEM 16 111 Relay Box Relay Circuit Inspection with the battery disconnected Tester Connection Tester Reading Q Headlight Relay 1 3 6 7 ECU Main Relay 4 5 Not 7 8 eo Fuel Pump Relay 9 10 Not m 11 16 oo Starter Circuit Relay 11 12 eo 17 20 Fan Relay 18 19 Not Relay Circuit Inspection with the battery connected Tester Tester Connection Reading O 0 ECU Main Relay Fuel Pump Relay 0 Fan Relay 0 Battery Tester Connection Tester Connection DC 25 V Range Reading V Starter Battery Circuit Relay Wg ete Voltage Diode Circuit Inspection e Remove the relay box see Relay Box Removal e Check conductivity of the following pairs of terminals see Relay Box Internal Circuit Diode Circuit Inspection 1 11 2 11 12 13 12 15 12 16 13 14 13 15 The resistance should be
368. nator Rotor Tapered Portion B e Install the washer C NOTE OConfirm the alternator rotor fit or not to the crankshaft before tightening it with specified torque e Install the rotor bolt D and tighten it with 70 N m 7 0 kgf m 52 ft lb of torque Remove the rotor bolt OHold the alternator rotor steady with the rotor holder Special Tools Grip 57001 1591 Rotor Holder 57001 1666 Stopper D 57001 1679 8 09200851 16 30 ELECTRICAL SYSTEM Charging System Check the tightening torque with flywheel puller Special Tool Flywheel Puller Assembly M38 x 1 5 M35 x 1 5 57001 1405 xIf the rotor is not pulled out with 20 N m 2 0 15 ft lb of drawing torque it is installed correctly x If the rotor is pulled out with under 20 N m 2 0 15 ft lb of drawing torque clean off any oil dirt or flaw of the crankshaft and rotor tapered portion and dry them with a clean cloth Then confirm that it is not pulled out with above torque Tighten the alternator rotor bolt while holding the alter nator rotor steadily with the holder A Special Tools Grip C 57001 1591 Rotor Holder 57001 1666 Stopper D 57001 1679 Torque Alternator Rotor Bolt 155 N m 16 kgf m 115 ft Ib e Install the alternator cover see Alternator Cover Installa tion Alternator Inspection There are three types of alternator failures short open wire burned out or loss in rotor magn
369. nd e Be sure to install the O rings e Tighten Torque Front Caliper Assembly Bolts 27 N m 2 8 kgf m 20 ft lb e Install the pads see Front Brake Pad Installation in the Brakes chapter e Wipe up any spilled brake fluid on the caliper with wet cloth 6105040251 C 9513154851 C PERIODIC MAINTENANCE 2 59 Maintenance Procedure Rear Caliper Disassembly e Remove the rear caliper see Rear Caliper Removal in the Brakes chapter e Remove the pads and pad springs see Rear Brake Pad Removal in the Brakes chapter 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 where the brake line fits into the caliper A WARNING To avoid serious injury never place your fingers or palm inside the caliper opening If you apply com pressed air into the caliper the piston may crush your hand or fingers Remove the dust seal and fluid seal Remove the bleed valve and rubber NOTE Olf compressed air is not available do as follows with the brake hose connected to the caliper OPrepare a container for brake fluid and perform the work above it ORemove the pads and pad spring see Rear Brake Pad Removal in the Brakes chapter OPump the brake pedal to remove the caliper piston Rear Caliper Assembly Clean the caliper parts except for the pads CAUTION For c
370. nd and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see ECU Re moval Installation FUEL SYSTEM DFI 3 57 Atmospheric Pressure Sensor Service Code 15 x If the reading is within the standard range check the input voltage again at the sensor connector e Remove the seat cover see Seat Cover Removal in the Frame chapter e Disconnect the atmospheric pressure sensor connector and connect the harness adapter A between the main harness connector and atmospheric pressure sensor con nector e Connect a digital meter to the harness adapter leads Atmospheric Pressure Sensor B Special Tool Sensor Harness Adapter 57001 1561 Atmospheric Pressure Sensor Input Voltage Connections to Sensor Meter BL lead C Meter BR BK lead D e Measure the input voltage with the engine stopped and with the connector joined e Turn the ignition switch ON Input Voltage at Sensor Connector Standard DC 4 75 5 25 V xIf the reading is out of the standard range check the wiring see wiring diagram x If the reading is good the input voltage is normal Check the output voltage e Turn the ignition switch OFF Atmospheric Pressure Sensor Output Voltage Inspection e Measure the output voltage at the ECU in the same way as input voltage inspection Digital Meter A ECU Connector B Atmospheric Pressure Sensor Output Voltage Connec
371. nd with the connectors joined e Turn the ignition switch ON 6617882651 Input Voltage at ECU Connector Standard DC 4 75 5 25 V e Turn the ignition switch OFF xIf the reading of input voltage is less than the standard check the ECU for its ground power supply and wiring shorted x If the input voltage is within the standard range check the input voltage at the main throttle sensor connector e Remove Air Cleaner Housing see Air Cleaner Housing Removal Fuel Pump Lead Connector see Fuel Tank Removal 3 44 FUEL SYSTEM DFI Main Throttle Sensor Service Code 11 Disconnect the main throttle sensor connector and con nect the harness adapter A between the harness con nector and main throttle sensor connector Connect a digital meter to the harness adapter leads Special Tool Throttle Sensor Setting Adapter 57001 1538 Main Throttle Sensor Input Voltage Connections to Sensor Meter BL lead Meter BR BK lead e Install the throttle body assy see Throttle Body Assy In stallation Measure the sensor input voltage with the engine stopped and with the connector joined e Turn the ignition switch ON Input Voltage at Sensor Standard DC 4 75 5 25 V e Turn the ignition switch OFF xIf the reading is out of the range check the wiring see wiring diagram x lf the reading is good check the output voltage of the sensor Main Throttle Sensor Output Voltag
372. nd Cap A Connecting Rod B Weight Mark Alphabet C Diameter Mark Around Weight Mark D O mark or no mark Select the proper bearing insert A in accordance with the combination of the connecting rod and crankshaft coding Size Color B Con rod Big Crankpin Bearing Insert End Inside Diameter Diameter Size Color Part Number Marking Marking None Brown 92139 0167 None None Black 92139 0166 Blue 92139 0165 e Install the new inserts in the connecting rod and check insert crankpin clearance with the plastigage x lf the insert crankpin clearance is less than the service limit replace the connecting rod bolts and nuts with new ones and measure the clearance again Crankshaft Side Clearance e Insert a thickness gauge A between the thrust washer on the crankcase and the crank web at the 3 main journal B to determine clearance the clearance exceeds the service limit replace the thrust washers as a set and check the width of the crank shaft 3 main journal Crankshaft Side Clearance Standard 0 05 0 25 mm 0 0020 0 0098 in Service Limit 0 45 mm 0 0177 in Measure the width A of the crankshaft 3 main journal f the measurement exceeds the standard replace the crankshaft Crankshaft 3 Main Journal Width Standard 21 09 21 14 mm 0 8303 0 8323 in 6105060181 6105041781
373. nder Head Removal Remove the valve lifter and shim OMark and record the valve lifter and shim locations so they can be installed in their original positions e Using the valve spring compressor assembly remove the valve Special Tools Valve Spring Compressor Assembly A 57001 241 Valve Spring Compressor Adapter 20 B 57001 1154 EX Valve Spring Compressor Adapter 24 B 57001 1586 IN GE15043BS1 C Valve Installation e Replace the oil seal with a new one e Apply a thin coat of molybdenum disulfide grease to the valve stem before valve installation e Install the springs so that the closed coil end faces down wards Valve Stem A Oil Seal B Spring Seat C Exhaust 22 1 mm 0 87 in aaa Inlet 23 5 mm 0 93 in Closed Coil End D Valve Spring E Exhaust Yellow Paint Inlet White Paint Retainer F Split Keepers G e After installing the valve tap the all retainers A and valve stem ends lightly for the split keepers fitting surely OFirst tap the top B of the retainer and then tap the valve stem end C GE15152BS1 ENGINE TOP END 5 27 Valves Valve Guide Removal e Remove Valve see Valve Removal Oil Seal Spring Seat Heat the area around the valve guide to 120 150 C 248 302 F and hammer lightly on the valve guide arbor A to remove the guide from the top of the head CAUTION Do not heat the cylinder head with a torch This wi
374. ne under misfire due to spark plug fouling or poor connection of the stick coil For KLEEN do not coast the motorcycle with the ignition switch off Turn the igni tion switch ON and run the engine ECU trouble Fuel air mixture incorrect Throttle body assy holder loose Air cleaner housing holder loose Air cleaner poorly sealed or missing 17 32 APPENDIX Troubleshooting Guide Air cleaner clogged Compression high Carbon built up in combustion chamber Engine load faulty Clutch slipping Engine oil level too high Engine oil viscosity too high Drive train trouble Brake dragging Lubrication inadequate Engine oil level too low Engine oil poor quality or incorrect Oil cooler incorrect Oil cooler clogged Water temperature meter incorrect Water temperature meter broken Water temperature sensor broken Coolant incorrect Coolant level too low Coolant deteriorated Wrong coolant mixed ratio Cooling system component incorrect Radiator fin damaged Radiator clogged Thermostat trouble Radiator cap trouble Radiator fan relay trouble Fan motor broken Fan blade damaged Water pump not turning Water pump impeller damaged Over Cooling Water temperature meter incorrect Water temperature meter broken Water temperature sensor broken Cooling system component incorrect Thermostat trouble Clutch Operation Faulty Clutch slipping Friction plate worn or warped Steel plate worn or warped Clutch spring
375. ness or binding is found replace the hub bearings see Hub Bearing Removal Installation e Inspect the wheel for small cracks dents bending or warp xIf there is any damage to the wheel replace the wheel e Remove the wheel and support it with the tire by the axle e Measure the rim runout axial A and radial B with a dial gauge x If rim runout exceeds the service limit check the hub bear ings see Hub Bearing Inspection xIf the problem is not due to the bearings replace the wheel Rim Runout with tire installed Standard Axial TIR 0 5 mm 0 02 in or less Radial TIR 0 8 mm 0 03 in or less Service Limit Axial TIR 1 0 mm 0 04 in Radial TIR 1 0 mm 0 04 in Never attempt to repair a damaged wheel If there is any damage besides wheel bearings the wheel must be replaced to insure safe operational condi tion Axle Inspection e Remove the front and rear axles see Front Rear Wheel Removal e Visually inspect the front and rear axle for damages xIf the axle is damaged or bent replace it e Place the axle in V blocks that are 100 mm 3 94 in A apart and set a dial gauge B on the axle at a point halfway between the blocks Turn C the axle to mea sure the runout The difference between the highest and lowest dial readings is the amount of runout x If axle runout exceeds the service limit replace the axle Axle Runout 100 mm 3 94 in Standard 0 05 mm 0 002 in or less Ser
376. ng Bearing Lubrication e Pack the bearing with good quality bearing grease A Turn the bearing around by hand a few times to make sure the grease is distributed uniformly inside the bearing Coupling Damper Inspection Remove the rear wheel coupling and inspect the rubber dampers A e Replace the damper if it appears damaged or deterio rated Sprocket Wear Inspection e Visually inspect the engine and rear sprocket teeth for wear and damage x If the teeth are worn as illustrated replace the sprocket and inspect the drive chain wear see Drive Chain Wear Inspection in the Periodic Maintenance chapter Worn Tooth Engine Sprocket A Worn Tooth Rear Sprocket B Direction of Rotation C NOTE Olfa sprocket requires replacement the chain is probably worn also When replacing a sprocket inspect the chain 6114010181 C GK05017BS1 C 11 14 FINAL DRIVE Sprocket Coupling Rear Sprocket Warp Inspection Raise the rear wheel off the ground so that it will turn freely e Set a dial gauge A against the rear sprocket B near the teeth as shown and rotate C the rear wheel to measure the sprocket runout warp The difference between the highest and lowest dial gauge readings is the amount of runout warp the runout exceeds the service limit replace the rear sprocket Rear Sprocket Warp Standard 0 4 mm 0 016 in or less Service Limit 0 5 mm 0 02 in GK0500
377. ng Removal in the Frame chapter Clutch Cable Lower End A see Cable Removal Clutch Cover Bolts B Bracket C e Turn the release lever A toward the rear as shown and remove the clutch cover B About 90 C Clutch Cover Installation e Apply silicone sealant to the area A where the mating surface of the crankcase touches the clutch cover gasket Sealant Kawasaki Bond Silicone Sealant 92104 0004 e Be sure that the dowel pins B are in position Replace the clutch cover gasket with a new one e Install the bracket A e Tighten the clutch cover bolts Torque Clutch Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib L 25 mm 0 98 in B L 40 mm 1 57 in C Release Shaft Removal CAUTION Do not remove the clutch release lever and shaft assembly unless it is absolutely necessary If re moved the oil seal replacement may be required e Remove the clutch cover see Clutch Cover Removal e Pull the lever and shaft assembly A straight out of the clutch cover 6 8 CLUTCH Clutch Cover Release Shaft Installation e Apply grease to the oil seal lips on the upper ridge of the clutch cover Apply engine oil to the needle bearings in the hole of the clutch cover e Apply molybdenum disulfide grease to the pusher holding portion A on the release shaft e Install the washer B and spring C e Insert the release shaft straight into the upper hole of the clutch cover C
378. ning what CAUSED the failure If the failure was caused by some other item or items they must be repaired or replaced or the new replacement will soon fail again OMake sure all connectors in the circuit are clean and tight and examine wires for signs of burning fraying etc Poor wires and bad connections will affect electrical system op eration OMeasure coil and winding resistance when the part is cold at room temperature OColor Codes BK Black G Green P Pink BL Blue GY Gray PU Purple BR Brown LB Light Blue R Red CH Chocolate LG Light Green W White DG Dark Green O Orange Y Yellow ELECTRICAL SYSTEM 16 21 Electrical Wiring Wiring Inspection e Visually inspect the wiring for signs of burning fraying etc If any wiring is poor replace the damaged wiring Pull each connector A apart and inspect it for corrosion dirt and damage x If the connector is corroded or dirty clean it carefully If it is damaged replace it e Check the wiring for continuity OUse the wiring diagram to find the ends of the lead which is suspected of being a problem OConnect the hand tester between the ends of the leads Special Tool Hand Tester 57001 1394 OSet the tester to the x 1 range and read the tester x If the tester does not read 0 the lead is defective Re place the lead or the wiring harness B if necessary 8 07002851 C 8 02325 52 16 22 ELECTRICAL SY
379. nnectors 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 xIf an abnormality is found replace the affected DFI part no abnormality is found in the wiring connectors and DFI parts replace the ECU OAfter inspection be sure to connect all the DFI electrical connectors Do not turn the ignition switch ON while the DFI electrical connectors and ignition system connectors are disconnected Otherwise the ECU memorizes ser vice codes as open circuit 9017904652 C 6017029281 FUEL SYSTEM DFI 3 27 Troubleshooting the DFI System OLead Color Codes BK Black G Green P Pink BL Blue GY Gray PU Purple BR Brown LB Light Blue R Red CH Chocolate LG Light Green W White DG Dark Green O Orange Y Yellow DFI Diagnosis Flow Chart Fl and or Immobilizer Warning indicator light Warning indicator light warning symbols do not LED and FI warning LED and Immobilizer blinks symbol blinks warning symbol blinks Conduct non self diagnosis inspection Conduct general fuel system inspection General fuel system throttle body assy air cleaner fuel tank etc Conduct self diagnosis Conduct self diagnosis inspection DFI system inspection immobilizer system 06172006 F Inquiries to Rider OEach rider reacts to problems in different ways so it
380. not done Front Caliper Disassembly e Refer to the Caliper Rubber Parts Replacement in the Pe riodic Maintenance chapter Front Caliper Assembly e Refer to the Caliper Rubber Parts Replacement in the Pe riodic Maintenance chapter Rear Caliper Disassembly e Refer to the Caliper Rubber Parts Replacement in the Pe riodic Maintenance chapter Rear Caliper Assembly e Refer to the Caliper Rubber Parts Replacement in the Pe riodic Maintenance chapter Caliper Fluid Seal Damage The fluid seal piston seal A is placed around the pis ton to maintain clearance between the pad and the disc If the seal is in a poor condition it could lead the pad to wear excessively or the brake to drag which may cause the tem perature of the discs or the brake fluid to increase Replace the fluid seal if it exhibits any of the conditions listed below OBrake fluid leakage around the pad OBrakes overheat OConsiderable difference in inner and outer pad wear OSeal and piston are stuck together x If the fluid seal is replaced replace the dust seal B as well Also replace all seals every other time the pads are changed GLO5171BS1 C 9105173851 C 12 12 BRAKES Calipers Rear Caliper Dust Boot and Friction Boot Damage Check that the dust boot A and friction boot are not cracked worn swollen or otherwise damaged xIf they show any damage replace it Caliper Piston and Cylinder Damage e Visual
381. nsions Overall Length Overall Width Overall Height Wheelbase Road Clearance Seat Height Dry Mass Curb Mass Front Rear Fuel Tank Capacity Performance Minimum Turning Radius 2 105 mm 82 9 in 720 mm 28 3 in 1 125 mm 44 3 in 1 405 mm 55 3 in 125 mm 4 7 in 820 mm 32 3 in 167 kg 368 Ib 101 kg 223 Ib 99 kg 218 Ib 17 L 4 5 US gal 3 4 m 11 2 ft Engine Type Cooling System Bore and Stroke Displacement Compression Ratio Maximum Horsepower Maximum Torque Carburetion System Starting System Ignition System Timing Advance Ignition Timing Spark Plug Cylinder Numbering Method Firing Order Valve Timing Inlet Open Close Duration Exhaust Open Close 4 stroke DOHC 4 cylinder Liquid cooled 67 0 x 42 5 mm 2 6 x 1 7 in 599 mL 36 6 cu in 13 3 1 91 9 kW 125 PS 14 000 r min rpm FR 78 2 kW 106 PS 914 000 r min rpm MY 80 0 kW 109 PS 12 000 r min rpm CA CAL US 66 0 6 7 kgf m 49 16 11 700 r min rpm FR 58 4 N m 6 0 kgf m 43 ft lb 11 700 r min rpm MY 64 Nm 6 5 kgf m 47 ft lb 12 000 r min rpm CA CAL 05 Fl Fuel injection Primary KEIHIN TTK 38 x 4 Secondary KEIHIN Multihole 8 holes x 4 Electric starter Battery and coil transistorized Electronically advanced digital igniter in ECU From 12 5 BTDC 1 300 r min rpm NGK CR9E Left to right 1 2 3 4 1 2 4 3 41 BTDC 67 A
382. nspect the camshaft position sensor ELECTRICAL SYSTEM 16 43 Ignition System Interlock Operation Inspection e Using the stand A raise the rear wheel off the ground 1st Check e Start the engine to the following conditions Condition Transmission Gear 1st Position Clutch Lever Release Side Stand Down or Up OTurn the ignition switch ON and push the starter button OThen the starter motor should not turn when the starter system circuit is normality x lf the engine is start inspect the starter lockout switch gear position switch and relay box x lf their parts are normality replace the ECU 2nd Check e Start the engine to the following conditions Condition Transmission Gear 1st Position Clutch Lever Pulled in Side Stand Up OTurn the ignition switch ON and push the starter button OThen the starter motor should turn when the starter sys tem circuit is normality If the starter motor is not turn inspect the starter lockout switch gear position switch and relay box x lf their parts are normality replace the ECU 3rd Check Inspect the engine for its secure stop after the following operations are completed e Run the engine to the following conditions Condition Transmission Gear 1st Position Clutch Lever Release Side Stand Up e Set the side stand on the ground then the engine will stop x If whichever may not be stopped inspect the gear position swi
383. nspection 6GC17931CW2 C 3 56 FUEL SYSTEM Atmospheric Pressure Sensor Service Code 15 CAUTION Never drop the sensor especially on hard surface Such a shock to the sensor can damage it Atmospheric Pressure Sensor Removal e Turn the ignition switch OFF e Remove Seat see Seat Removal in the Frame chapter Atmospheric Pressure Sensor Connector A Atmospheric Pressure Sensor B with Damper Atmospheric Pressure Sensor Installation e Put the damper A of the atmospheric pressure sensor in the hole B of the stay plate Atmospheric Pressure Sensor Input Voltage Inspection NOTE OBe sure the battery is fully charged OThe inspection is the same as Input Voltage Inspection of the throttle sensor and the inlet air pressure sensor Turn the ignition switch OFF Remove the ECU see ECU Removal Do not disconnect the ECU connectors pee e Connect a digital voltmeter A to the connector B with the needle adapter set Special Tool Needle Adapter Set 57001 1457 Atmospheric Pressure Sensor Input Voltage Connections to ECU Meter BL lead terminal 10 Meter BR BK lead terminal 28 e Measure the input voltage with the engine stopped and with the connectors joined e Turn the ignition switch ON Input Voltage at ECU Standard DC 4 75 5 25 V xIf the reading of input voltage is less than the standard range check the ECU for its grou
384. nspection in the Periodic Maintenance chapter Headlight Beam Vertical Adjustment Refer to the Headlight Aiming Inspection in the Periodic Maintenance chapter Headlight Bulb Replacement e Remove Right Inner Cover see Inner Cover Removal in the Frame chapter Headlight Connector A Turn the headlight bulb A counterclockwise CAUTION When handling the quartz halogen bulb never touch the glass portion with bare hands Always use clean cloth Oil contamination from hands or dirty rags can reduce bulb life or cause the bulb to explode NOTE OClean off any contamination that inadvertently gets on the bulb with alcohol or soap and water solution Replace the headlight bulb e Fit the projections A of the bulb in the hollows B of the headlight e Turn the bulb clockwise e After installation adjust the headlight aim see Headlight Aiming Inspection in the Periodic Maintenance chapter ELECTRICAL SYSTEM 16 53 Lighting System City Light Bulb Replacement e Remove Center Inner Fairing see Center Inner Fairing Removal in the Frame chapter e Turn the socket A counterclockwise and pull out the socket together with the bulb Pull the bulb A out of the socket CAUTION Do not turn the bulb Pull the bulb out to prevent damage to the bulb Do not use bulb rated for greater wattage than the specified value e Pushing the socket and turn it clockwise OF
385. nstallation e Be sure to install the new O rings A e Apply grease to the new O rings e Install the clamps B as shown e Apply a non permanent locking agent Throttle Body Assy Holder Bolts C e Tighten Torque Throttle Body Assy Holder Bolts 12 1 2 kgf m 106 in Ib Throttle Body Assy Holder Clamp Bolts D 2 9 N m 0 30 kgf m 26 e Fix the hole of clamp to the projection of holder E 10 F 25 G GE14102BS3 ENGINE TOP END 5 35 Muffler A WARNING To avoid a serious burn do not remove the muffler when the engine is still hot Wait until the muffler cool down Muffler Body Removal e Remove Seat Cover see Seat Cover Removal in the Frame chapter Flap see Flap and Rear Fender Removal in the Frame chapter Exhaust Butterfly Valve Cable Muffler Body Side see Exhaust Butterfly Valve Cable Removal Bolts A with Washers Remove the muffler body backward 5 36 ENGINE TOP END Muffler Muffler Body Installation x lf the muffler body covers were removed install them Muffler Body Upper Cover A Muffler Body Rear Cover B Dampers C OTighten Torque Muffler Body Upper Cover Bolts D 6 9 0 70 kgf m 61 in Ib Muffler Body Rear Cover Bolts E 6 9 N m 0 70 kgf m 61 in Ib Replace the muffler body gasket F with a new one e Install the muffler body gasket into the rear exhaust pipe G until it is bottomed so th
386. nted of the hose to the projection on the water pump cover 17 18 APPENDIX Cable Wire and Hose Routing 2 NO Z 5 Z Emma 25 o USC IER Xd 4 s c5 umm SEEN lj 92809974 9 0269 D 9 7 APPENDIX 17 19 Cable Wire and Hose Routing 5 Install the hose directions to backward Install the clamp so that the clamp screw head faces upward as shown Reserve Tank Overflow Hose Radiator Breather Hose Run the hose into the slit of heat insulation plate Air Bleeder Hose for Thermostat Housing Install the clamp so that the clamp bolt head faces right side as shown Install the clamp screw head direction backward and right side Insert the breather and overflow hoses to the clamp of the firing bracket Water Hose supply Water Hose return Water Hose for Oil Cooler return Water Hose for Oil Cooler supply Breather Hose Install the hose as shown in the figure Blowby Hose Install the hose as shown in the figure Install the clamp so that the claw side direction the rear side Install the hoses so that the white paint face the rear side About 45 Install the clamp so that the claw faces upward Align the white paint of the hose parallel to the mating surface of the thermostat cover
387. nterclock wise OThe position is original position of the pulley OTurn the ignition switch OFF x If the position is not within the specified angle above re place the exhaust butterfly valve actuator e Tighten Torque Exhaust Butterfly Valve Actuator Mounting Bolts 6 9 N m 0 70 kgf m 61 in Ib e Install the open cable first and then close cable see Ex haust Butterfly Valve Cable Installation in the Engine Top End chapter FUEL SYSTEM 3 91 Exhaust Butterfly Valve Actuator Service Code 63 Exhaust Butterfly Valve Actuator Inspection NOTE OBe sure to the battery in fully charged e Remove Seat Cover see Seat Cover Removal in the Frame chapter e Turn the ignition switch ON e Check to see the pulley A clockwise B and counter clockwise C smoothly OThe pulley turns clockwise and then counterclockwise and clockwise again x If the pulley does not operate check the exhaust butterfly valve actuator output voltage Exhaust Butterfly Valve Actuator Output Voltage Inspection e Remove Seat Cover see Seat Cover Removal in the Frame chapter Exhaust Butterfly Valve Actuator e Measure the output voltage at the 3 pins connector of the exhaust butterfly valve actuator A when the pulley is original position as follows e Disconnect 2 pins Connector B 3 pins Connector C e Connect the adapter D between the 3 pins connectors and digital voltmeter E Main Harness F Special Tool Throttle
388. nts Periodic Maintenance 2 2 2 860 00 00000000000000000000000000000000000000000000 nnn 2 3 Torque and Locking Agent iniri t iet pA enr sie bebe e e Eden 2 6 c 2 12 Special Iools cicero er er e Y e CR XXE EC ERR TIER ET EXT XR CHE ER RR EX RR n 2 14 Maintenance Procedure oe Fe ied anes ME e Ee eR nine tana 2 15 Fuel System 2 15 Throttle Control System INS Pe Cuan ives tati 2 15 Engine Vacuum Synchronization 2 15 he eed eT a a Meebo 2 18 Speed Adjustment 2 2 19 Fuel Hose Inspection fuel leak damage installation 2 19 Evaporative Emission Control System California Model 2 19 Evaporative Emission Control System Inspection pp 2 19 E gine OETA eme AM TK METRI VN 2 20 Valve Clearance 2 20 Valve Clearance ttal sana 2 22 AI Suction Systerm 2 24 Air Suction System Da
389. oasis odas shen ended 14 5 Steering 14 5 Steenng 14 6 Stem Stem Bearing Removal 14 6 Stem Stem Bearing Installation pp 14 7 Steering Stem Bearing Lubrication 14 9 Steering Stem Val decet eor queo 14 9 Stem Cap Deterioration Damage pp 14 9 Handlebar sis ten ene 14 10 Handlebar Removal 2 14 10 Handlebar Install amp tiOri Denia eee bueno erat D 14 11 14 2 STEERING Exploded View STEERING 14 3 Exploded View No Fastener Torque Remarks N m kgf m ft Ib 1 Front Fork Clamp Bolts Lower 25 2 5 18 AL 2 Front Fork Clamp Bolts Upper 20 2 0 15 3 Handlebar Bolts 25 2 5 18 4 Handlebar Position Bolts 9 8 1 0 87 L 5 Steering Stem Head Nut 78 8 0 58 6 Steering Stem Nut 20 2 0 15 7 Switch Housing Screws 3 5 0 36 31 in lb 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 14 4 STEERING Special Tools Bearing Puller Bearing Driver Set 57001 135 57001 1129 ST570158ST ST571129ST C Bear
390. oint Connector C Immobilizer Antenna Joint Connector B Meter Unit ECU Fuse 10 A 10 Ignition Fuse 10 A 11 Fuse Box 12 Relay Box 13 ECU Main Relay 14 Frame Ground 15 Main Fuse 30 A 16 Starter Relay 17 Battery 12 V 8 Ah 18 Immobilizer Kawasaki Self diagnostic System Connector 16 102 ELECTRICAL SYSTEM Switches and Sensors Brake Light Timing Inspection e Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance chapter see Brake Light Switch Operation Inspection in the Periodic Maintenance chapter Brake Light Timing Adjustment e Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance chapter see Brake Light Switch Operation Inspection in the Periodic Maintenance chapter Gear Position Switch Removal e Set up the fuel tank see Speed Sensor Removal e Disconnect Gear Position Switch Lead Connector A Clamp B e Open the clamps A e Remove Engine Sprocket Cover A see Engine Sprocket Re moval in the Final Drive chapter Speed Sensor see Speed Sensor Removal B e Disconnect the side stand switch lead connector C e Remove Screws A Holding Plate B Gear Position Switch ELECTRICAL SYSTEM 16 103 Switches and Sensors eRemove the pins and springs from the shift drum Gear Position Switch Installation e Securely place the springs A and pins B into the hole
391. ollowing items Wiring see Wiring Inspection ECU Communication Line Wiring Gear Position Switch see Gear Position Switch Inspec tion x If the above items are good replace the meter assembly and or ECU 8 17923 52 C GP17890BS1 ELECTRICAL SYSTEM 16 75 Meter Gauge Indicator Unit Check 14 Lights LED Inspection Connect the leads in the same circuit as Check 1 Neutral Indicator Light LED A Warning Indicator Light LED B Turn Signal Indicator Light LED C High Beam Indicator Light LED D Fuel Level Warning Indicator Light LED E Shift Up Indicator Light LED F Oil Symbol G Neutral Indicator Light LED Battery Negative Terminal To Terminal 1 GP17841BS1 Oil Symbol and Warning Indicator Light LED Battery Negative Terminal To Terminal 11 GP17842BS1 Right and Left Turn Signal Indicator Light LED Battery Positive Terminal to Terminal 2 Battery Positive Terminal to Terminal 10 GP17843BS1 High Beam Indicator Light LED Battery Positive Terminal to Terminal 3 GP17888BS1 C 16 76 ELECTRICAL SYSTEM Meter Gauge Indicator Unit Check 15 Fuel Level Warning Indicator Light LED and Fuel Symbol e Connect the leads in the same circuit as Check 1 OThe fuel segments flashes in the display e Connect a variable rheostat A to terminal 15 as shown Adjust the resist
392. on a flat surface e For California Model note the following CAUTION For California model if gasoline solvent water or any other liquid enters the canister the canister s vapor absorbing capacity is greatly reduced If the canister does become contaminated replace it with a new one OBe sure to plug the evaporative fuel return hose to prevent fuel spilling before fuel tank removal A WARNING For California model be careful not to spill the gasoline through the return hose Spilled fuel is hazardous x If liquid or gasoline flows into the breather hose remove the hose and blow it clean with compressed air careful of fuel spillage from the fuel tank since fuel still remains in the fuel tank and fuel pump A WARNING Store the fuel tank in an area which is well ventilated and free from any source of flame or sparks Do not smoke in this area Place the fuel tank on a flat surface and plug the fuel pipes to prevent fuel leakage 3 130 FUEL SYSTEM DFI Fuel Tank Fuel Tank Installation Note the above WARNING see Fuel Tank Removal e Route the hoses correctly see Cable Wire and Hose Routing section in the Appendix chapter For California Model note the following OTo prevent the gasoline from flowing into or out of the canister hold the separator perpendicular to the ground OConnect the hoses according to the diagram of the sys tem see Cable Wire and Hose Rou
393. ont Fork necessary measure the oil level as follows OHold the inner tube vertically in a vise OPump the inner tube several times to expel air bubbles OUsing the piston rod puller A move the piston rod B up and down more than ten times in order to expel all the air from the fork oil Special Tool Fork Piston Rod Puller M10 x 1 0 57001 1298 ORemove the piston rod puller OWait until the oil level settles OWith the fork fully compressed and the piston rod fully pushed in insert a tape measure or rod into the inner tube and measure the distance from the top of the outer tube to the oil Oil Level fully compressed without spring Standard 97 2 mm 3 8 0 08 in from the top of the outer tube NOTE OFork oil lever may also be measured using the fork oil level gauge Special Tool Fork Oil Level Gauge A 57001 1290 OWith the fork fully compressed and without fork spring insert the gauge tube into the inner tube B and position the stopper across the top end F of the outer tube C OSet the gauge stopper D so that its lower side shows the oil level distance specified E OPull the handle slowly to pump out the excess oil until the oil no longer comes out If no oil is pumped out there is insufficient oil in the inner tube Pour in enough oil then pump out the excess oil as shown above e Screw on the rod nut A fully to the piston rod B 6
394. onto the piston rod e Holding the spring preload adjuster A with a wrench B tighten the piston rod nut C Torque Piston Rod Nuts 20 N m 2 0 kgf m 15 ft Ib e While holding up the top plug A by one person push down B the fork spring compressor and pull out the fork spring stopper C e Remove the fork spring compressor Rise the outer tube and screw the top plug into it e Install the front fork see Front Fork Installation Front Fork Disassembly e Remove the front fork see Front Fork Removal e Drain the fork oil see Fork Oil Change e Hold the fork leg with a vise A e Unscrew the Allen bolt B then take the bolt and gasket out of the bottom of the inner tube e Take the cylinder unit A ODo not disassemble the cylinder unit 13 16 SUSPENSION Front Fork Separate the inner tube from the outer tube as follows OSlide up the dust seal A ORemove the retaining ring B from the outer tube GU OHolding the inner tube A by hand pull the outer tube several times to pull out the outer tube Remove the inner tube guide bushing A outer tube guide bushing B washer C oil seal D from the inner tube Front Fork Assembly e Replace the following parts with new one Oil Seal A Outer Tube Guide Bushing B Inner Tube Guide Bushing C Bottom Allen Bolt Gasket D Dust Seal E Retaining Ring F e Install the following parts onto the inner tube 8 Du
395. or Dent x If there is any damage to the rear shock absorber replace it e Visually inspect the bushing xIf it show any signs of damage replace it 13 22 SUSPENSION Rear Shock Absorber Rear Shock Absorber Scrapping A WARNING Since the reservoir tank of the rear shock absorber contains nitrogen gas do not incinerate the reser voir tank without first releasing the gas or it may explode Remove the valve cap A and release the nitrogen gas completely from the gas reservoir Remove the valve GM05271BS1 Since the high pressure gas is dangerous do not point the valve toward your face or body SUSPENSION 13 23 Swingarm Swingarm Removal e Remove Rear Wheel see Rear Wheel Removal the Wheels Tires chapter Engine Sprocket Cover see Engine Sprocket Removal in the Final Drive chapter Bolt A Brake Hose Clamp B Brake Pedal see Brake Pedal Removal in the Brakes chapter Rear Exhaust Pipe see Rear Exhaust Pipe Removal in the Engine Top End chapter Drive Chain see Drive Chain Removal in the Final Drive chapter e Remove Upper Tie Rod Nut and Bolt A Rear Shock Absorber B see Rear Shock Absorber Re moval e Unscrew the swingarm pivot shaft locknut A e Unscrew the swingarm pivot collar locknut A using the nut wrench B Special Tool Swingarm Pivot Nut Wrench 57001 1597 e Unscrew the swingarm pivot shaft C few times OTurn out the swingarm pi
396. ors B 15 20 FRAME Fenders e Remove Bolts A Both Side Turn Signal Lights B Both Side e Remove Bolts A Both Side Bracket B Both Side e Remove Bolts A Both Side Bracket B Flap C with Tail Brake Light Separate the flap and Light e Remove Muffler Body see Muffler Body Removal in the Engine Top End chapter Rear Exhaust Pipe see Rear Exhaust Pipe Removal in the Engine Top End chapter e Remove Bolt A Cover B e Remove Screws A Seat Lock Assy B Screw C Bolts D Exhaust Butterfly Valve Actuator E FRAME 15 21 Fenders e Remove Connectors A Grommet B e Remove Rear Footpeg Bracket Bolts A Both Side Rear Footpeg Bracket Assy B e Remove Band A Cables B Battery C e Remove Bolts A Battery Case B Starter Relay C pull out e Remove Regulator Rectifier Bracket Nuts A 15 22 FRAME Fenders e Remove Main Harness Clamp A Remove Quick Rivets A both side e Remove Screws A Rocks with Bracket B e Remove Bolts A Rear Fender B Flap and Rear Fender Installation e Install the removed parts see appropriate chapters e Install the harness clamp in accordance with Cable Wire and Hose Routing section in the Appendix chapter FRAME 15 23 Frame Rear Frame Removal e Remove Rear Fender see Rear Fender Removal Frame Bolts A and Nuts 900902
397. ose Routing Install the engine ground terminal touch the stopper Blowby Hose Water Temperature Sensor Lead Con nector Throttle Body 2 Install the heat insulation rubber plate so that the white painted faces upward Throttle Body 3 Alternator Lead Air Bleeder Hose for Thermostat Hous ing Gear Position Switch Sidestand Switch Lead 68093026 4 C Crankshaft Sensor Switch Oil Pressure Switch Lead Rivet Hold the heat insulation rubber plate to the frame Heat Insulation Rubber Plate Speed Sensor Lead Connector Speed Sensor Lead Connector Main Harness Side Clamp for Main Harness Hold the heat insulation rubber plate to the frame Run the starter motor cable and engine ground cable APPENDIX 17 17 Cable Wire and Hose Routing v q IN 9 D GB09298CW3 C gu X OY Air Bleeder Hose for Thermostat Hous ing Install the clamp direction as shown in the figure Water Hose for Oil Cooler Blowby Hose Breather Hose Oil Filter Water Hose Install the clamp so that the screw head faces to rearward 12 13 14 Install the hose so that white painted side faces left of the engine Install the hose so that white painted side faces left of the engine Install the hose so that white painted side faces upward Water Hose Water Hose Fitting Align the white pai
398. oval and if compressed air is not available disassemble the caliper before the brake hose is removed see Front Caliper Disassembly Rear Caliper Removal e Loosen the banjo bolt A at the brake hose lower end and tighten it loosely e Unscrew the caliper mounting bolts B and detach the caliper C from the disc e Unscrew the banjo bolt and remove the brake hose D from the caliper CAUTION Immediately wash away any brake fluid that spills NOTE Olf the caliper is to be disassembled after removal and if compressed air is not available disassemble the caliper before the brake hose is removed see Rear Caliper Disassembly Caliper Installation e Install the caliper and brake hose lower end OReplace the washers on each side of hose fitting with new ones e Tighten Torque Caliper Mounting Bolts Front 34 N m 3 5 kgf m 25 ft lb Rear 25 N m 2 5 kgf m 18 ft Ib Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft lb e Check the fluid level in the brake reservoirs e Bleed the brake line see Brake Line Bleeding e Check the brake for good braking power no brake drag and no fluid leakage 9 058171 P BRAKES 12 11 Calipers A WARNING Do not attempt to drive the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against the disc The brakes will not function on the first appli cation of the lever or pedal if this is
399. ow horizontal with the motorcycle on its wheels and the rider seated Adjust the headlight to the proper an gle according to local regulations 9517092851 65178245 PERIODIC MAINTENANCE 2 41 Maintenance Procedure NOTE OFor US model the proper angle is 0 4 degrees below horizontal This is 50 mm 2 drop at 7 6 m 25 ft measured from the center of the headlight with the motorcycle on its wheels and the rider seated 50 mm 2 in A Center of Brightest Spot B 7 6 m 25 ft C Height of Headlight Center D 9517093851 Side Stand Switch Operation Inspection Inspect the side stand switch A operation accordance to below table Side Stand Switch Operation Gear Clutch Engine Engine Sice stany Position Lever Start Run Up Neutral Released Starts Comune running Up Neutral Pulledin Starts Continue running Up In Gear Released Doshi start running Up In Gear Pulled in Starts Continue running Down Neutral Released Starts running Down Neutral Pulled in Starts eds running Down In Gear Released Dosen Stops start Down In Gear Pulled in Dosen Stops start 2 42 PERIODIC MAINTENANCE Maintenance Procedure x If the side stand switch operation does not work inspect or replace the following item Battery see Charging Condition Inspection in the Elec trical System chapter Main Fuse 30 A see Fuse Insp
400. passage clogged Air bleed pipe bleed holes clogged Pilot passage clogged Air cleaner clogged poorly sealed or miss ing Fuel tank air vent obstructed Fuel pump trouble Throttle body assy holder loose Air cleaner housing holder loose APPENDIX 17 31 Troubleshooting Guide Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Camshaft cam worm Run on dieseling Ignition switch trouble Engine stop switch trouble Fuel injector trouble Loosen terminal of battery cable or ECU ground lead Carbon accumulating on valve seating sur face Engine overheating Other ECU trouble Engine vacuum not synchronizing Engine oil viscosity too high Drive train trouble Brake dragging Clutch slipping Engine overheating Air suction valve trouble Air switching valve trouble Poor Running or No Power at High Speed Firing incorrect Spark plug dirty broken or maladjusted Spark plug incorrect Stick coil shorted or not in good contact trouble Stick coil trouble ECU trouble Fuel air mixture incorrect Air cleaner clogged poorly sealed or miss ing Air cleaner housing holder loose Water or fore
401. pecial Tools Grip 57001 1591 Stopper 57001 1679 Rotor Holder 57001 1666 Torque Starter Clutch Bolt 49 N m 5 0 kgf m 36 ft Ib e Install the removed parts see appropriate chapters Starter Clutch Disassembly e Remove Starter Clutch see Starter Clutch Removal e Pull the starter clutch gear A out of the starter clutch B e Remove Needle Bearing C e Remove Snap Ring A e Pull the one way clutch B out of the starter clutch case C GB 9 34 CRANKSHAFT TRANSMISSION Starter Idle Gear and Starter Clutch Starter Clutch Assembly e Install the one way clutch A so that its circlip side B faces in e Install the new snap ring e Push A the starter clutch gear B in and turn it counter clockwise C and install it e Apply molybdenum disulfide oil solution to the needle bearing A and install it Starter Clutch Inspection e Remove Starter Clutch Cover see Idle Gear Removal Idle Gear Starter clutch side see Idle Gear Removal e Turn the starter clutch gear A by hand The starter clutch gear should turn counterclockwise freely B but should not turn clockwise xIf the starter clutch does not operate as it should or if it makes noise go to the next step e Disassemble the starter clutch and visually inspect the clutch parts One way Clutch A Starter Clutch Case B x If there is any worn or damaged part replace it CRANKSHAFT TRANSMISSION 9 35
402. peller Bolt 9 8 1 0 87 in Ib 4 Oil Cooler Mounting Bolts 20 2 0 15 5 Oil Filter 31 3 2 23 G 6 Oil Filter Holder Bolt 25 2 5 18 L 7 Piston Oil Nozzles 2 9 0 30 26 in lb 8 Oil Pan Bolts 9 8 1 0 87 S 9 Oil Pump Gear Bolt 9 8 1 0 87 in lb L 10 Oil Passage Plugs Taper 20 11 Oil Passage Plug Left Side 7 e 12 Water Pump Cover Bolts 12 106 in lb 13 Oil Pressure Relief Valve 15 14 Oil Pressure Switch 15 15 Pressure Switch Terminal Bolt Hand tighten 16 Water Hose Clamp Screws 2 0 17 in lb Oi Passage Nozze 49 amb 15 AirBleed Bot J 98 10 ferme 21 Oil Filler Cap 2 0 inb Breather Plate Bolts 9 8 87 in lb Apply engine oil Apply grease Apply high temperature grease Apply a non permanent locking agent Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease a weight ratio 10 1 Replacement Parts Follow the specified tightening sequence Apply silicone sealant Apply water 7 4 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil Type Viscosity Capacity Level Oil Pressure Measurement Oil Pressure API SE SF or SG API SH SJ or SL with JASO MA SAE 10W 40 2 9 L 3 1 US gt when filter is not removed 3 2 L 3 4 US gt when filter is removed 3 8 L 4 0 US gt when engine is completely dry Between
403. perature e Remove the cylinder head cover see Cylinder Head Cover Removal in the Engine Top End chapter e Remove the timing inspection cap A and starter clutch bolt cap B on the starter clutch cover C e Using a wrench on the starter clutch bolt A turn the crankshaft clockwise until the line B TDC mark for 1 4 pistons on the starter clutch is aligned with the notches C in the edge of the timing inspection hole in the starter clutch cover PERIODIC MAINTENANCE 2 21 Maintenance Procedure e Using a thickness gauge A measure the valve clearance between the cam and the valve lifter Valve Clearance Standard Exhaust 0 24 0 31 mm 0 0094 0 0122 in Inlet 0 13 0 19 mm 0 0051 0 0075 in NOTE OThickness gauge is horizontally inserted on the valve lifter Appropriateness A Inadequacy B Thickness Gauge C Horizontally Inserts D Cam E Valve Lifter F Hits the Valve Lifter Ahead G OWhen positioning 1 piston TDC at the end of the compression stroke Inlet Valve Clearance of 1 and 3 Cylinders Exhaust Valve Clearance of 1 and 2 Cylinders Measuring Valve A OWhen positioning 4 piston TDC at the end of the compression stroke Inlet Valve Clearance of 2 and 4 Cylinders Exhaust Valve Clearance of 3 and 4 Cylinders Measuring Valve A x lf the valve clearance is not within the specified range first record the clearance and then adjust it Filling engine oi
404. pling Internal Surface B e Apply grease to the O ring A e Install the collar B Coupling Bearing Removal e Remove Coupling Grease Seal Circlip A discard Special Tool Inside Circlip Pliers B 57001 143 e Remove the bearing A by tapping from the wheel side Special Tool Bearing Driver Set B 57001 1129 Coupling Bearing Installation e Replace the bearing with a new one NOTE Olnstall the bearing so that the marked side faces out e Press in the bearing A until it is bottomed Special Tool Bearing Driver Set B 57001 1129 e Replace the circlip with a new one Special Tool Inside Circlip Pliers 57001 143 GK05072BS1 GK05070BS1 GK05071BS1 C FINAL DRIVE 11 13 Sprocket Coupling e Replace the grease seal with a new one e Press in the grease seal so that the seal surface is flush with the end of the hole OApply high temperature grease to the grease seal lips Special Tool Bearing Driver Set 57001 1129 Coupling Bearing Inspection Since the coupling bearing is made to extremely close tolerances the clearance can not normally be measured NOTE Olt is not necessary to remove the coupling bearing for inspection If the bearing is removed it will need to be replaced with a new one Spin A the bearing by hand to check its condition x lf it is noisy does not spin smoothly or has rough spots it must be replaced Coupli
405. put Voltage Stator Coil Resistance Charging Voltage Regulator rectifier Output Voltage Regulator Rectifier Resistance Ignition System Crankshaft Sensor Resistance Crankshaft Sensor Peak Voltage Camshaft Position Sensor Resistance Camshaft Position Sensor Peak Voltage Spark Plug Gap Stick Coil Primary Winding Resistance Secondary Winding Resistance Primary Peak Voltage Sealed battery 12 V 8 Ah 12 8 V or more Three phase AC 42 V or more 4 000 r min rpm 0 1 0 30 14 2 15 0 V in the text 380 5700 3 2 or more 400 4600 0 4 V or more 0 7 0 8 mm 0 028 0 032 in 1 2 1 6 0 8 5 11 5 80 V or more Electric Starter System Starter Brush Length Commutator Diameter 7 0 28 in Service Limit 3 5 mm 0 14 in 24 mm 0 94 in Service Limit 23 mm 0 91 in Air Switching Valve Air Switching Valve Resistance 12 22 Q at 20 C 68 F Switch and Sensor Rear Brake Light Switch Timing Engine Oil Pressure Switch Connections Water Temperature Sensor Resistance ON after about 10 mm 0 39 in pedal travel When engine is stopped ON When engine is running OFF In the text ELECTRICAL SYSTEM 16 19 Special Tools and Sealant Hand Tester Grip 57001 1394 57001 1591 4 7571394ST C 7571591ST C Flywheel Puller Assembly M38 x 1 5 M35 x 1 5 Rotor Holder 57001 1405 57001 1666 8888 875714055 C 8 5716665 Peak
406. r e Remove Air Cleaner Housing see Air Cleaner Housing Removal Fuel Pump Lead Connector see Fuel Tank Removal 6617882651 FUEL SYSTEM DFI 3 71 Subthrottle Sensor Service Code 32 e Disconnect the subthrottle sensor connector A and con nect the harness adapter B between the harness con nector and sub throttle sensor connector Connect a digital meter to the harness adapter leads Special Tool Throttle Sensor Setting Adapter 57001 1538 Subthrottle Sensor Input Voltage Connections to Sensor Meter BL lead Meter BR BK lead e Install the throttle body assy see Throttle Body Assy In stallation e Measure the sensor input voltage with the engine stopped and with the connector joined e Turn the ignition switch ON Input Voltage at Sensor Standard DC 4 75 5 25 V e Turn the ignition switch OFF xIf the reading is out of the range check the wiring see wiring diagram xIf the reading is good check the output voltage of the sensor Subthrottle Sensor Output Voltage Inspection e Measure the output voltage at the ECU in the same way as input voltage inspection Digital Voltmeter A Connectors B Special Tool Needle Adapter Set 57001 1457 Subthrottle Sensor Output Voltage Connections to ECU Meter BR lead terminal 24 Meter BR BK lead terminal 28 e Turn the ignition switch ON e Measure the output voltage when the subthrottle
407. r 6 Speed Sensor Output Signal 7 Main Throttle Sensor Output Signal 8 Inlet Air Pressure Sensor Output Signal 9 Water Temperature Sensor Output Signal 10 Power Supply to Sensors 11 Vehicle down Sensor Output Signal 12 Camshaft Position Sensor Output Signal 13 Crankshaft Sensor Output Signal 14 Immobilizer Communication Line Equipped Models 15 Immobilizer Communication Line Equipped Models 16 Power Supply to ECU from ECU Main Re lay 17 Power Supply to ECU from Battery 18 Subthrottle Valve Actuator Drive Signal 4 19 Subthrottle Valve Actuator Drive Signal 2 20 Unused 21 Unused 22 Unused 23 Unused 24 Subthrottle Sensor Output Signal 25 Atmospheric Pressure Sensor Output Sig nal 26 Inlet Air Temperature Sensor Output Signal 27 Unused 28 Ground to Sensors 29 Camshaft Position Sensor Output Signal 30 Crankshaft Sensor Output Signal 31 Immobilizer Communication Line 32 Unused 33 Unused 34 Ground to ECU 35 66177416 1 C Oxygen Sensor 1 Output Signal Equipped Models Unused Detect the Engine Stop Switch off Signal Starter Lockout Switch Output Signal Starter Button Output Signal Meter Communication Signal Ground Fuel Pump Relay Drive Signal Unused Radiator Fan Drive Signal Secondary Fuel Injector 2 Drive Signal Secondary Fuel Injector 1 Drive Signal Primary Fuel Injector 2 Drive Signal Primary Fuel Injector 1 Drive Signal Stic
408. r A e Remove Right Middle Fairing see Middle Fairing Removal in the Frame chapter Starter Idle Gear see Starter Idle Gear Removal Rubber Cap A Oil Pressure Switch Terminal B Bolts C Crankshaft Sensor D Clamp E e Pull out the grommet F Crankshaft Sensor Installation e Route the crankshaft sensor lead correctly see Cable Wire and Hose Routing section in the Appendix chapter e Tighten Torque Crankshaft Sensor Bolts 5 9 N m 0 60 kgf m 52 in Ib e Apply silicone sealant Crankshaft Sensor Lead Grommet Around A Crankcase Halves Mating Surfaces B Sealant Kawasaki Bond Silicone Sealant 92104 0004 e Install Clamp Starter Clutch Cover see Starter Idle Gear Installation in the Crankshaft Transmission chapter ELECTRICAL SYSTEM 16 37 Ignition System Connect Sensor Lead Connector Oil Pressure Switch Lead see Oil Pressure Switch In stallation in the Engine Lubrication System e Install the removed parts see appropriate chapters Crankshaft Sensor Inspection e Remove Crankshaft Sensor Lead Connector see Crankshaft Sensor Removal Set the hand tester A to the x 100 range and connect the lead to the black lead and lead to the black yel low lead in the connector B Special Tool Hand Tester 57001 1394 x 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 i
409. r Arm Bolt C Rocker Arm D Rocker Arm Installation e Apply grease to the inside of the grease seals Tighten Torque Uni Trak Rocker Arm Nut 34 N m 3 5 25 ft Ib Tie Rod Nuts 59 N m 6 0 kgf m 43 ft lb Rear Shock Absorber Nut Lower 34 N m 3 5 kgf m 25 ft lb SUSPENSION 13 29 Rocker Arm Tie Rod and Rocker Arm Bearing Removal e Remove Tie Rods see Tie Rod Removal in this chapter Rocker Arm see Rocker Arm Removal in this chapter Sleeves A Grease Seal B Swingarm C Needle Bearings D W 6 07066 2 OWhen remove the needle bearings A tap the bearings evenly with the bearing remover shaft B Special Tool Bearing Remover Shaft 613 57001 1377 GM07087BS1 C Tie Rod and Rocker Arm Bearing Installation e Replace the needle bearing and oil seals with new ones e Apply plenty of grease to the lips of the oil seals e Install the needle bearings and oil seals position as shown 13 30 SUSPENSION Tie Rod Rocker Arm OScrew the needle bearing driver A into the driver holder Olnsert the needle bearing driver into the needle bearing C and press the needle bearing into the housing until the driver contacts the end surface of the housing Bearing Pressing Depth 5 5 mm 0 22 in D 5 0 mm 0 20 in E NOTE OFor a bearing of inner diameter 18 select the pressing side of the needle bearing driver according to
410. r Cover see Inner Cove Removal in the Frame chapter e Disconnect Antenna Lead Connector A e Measure the resistance of the antenna coil in the ignition Switch as follows Antenna Resistance Connections to Antenna Meter R Lead Meter R Lead Standard About 0 6 0 9 O x If the resistance is out of the standard range replace the ignition switch Amplifier Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Remove Windshield see Windshield Removal in the Frame chapter Immobilizer Amplifier see Immobilizer System Parts Re placement in the Electrical System chapter e Connect a digital voltmeter to the connectors using the needle adapter set Special Tool Needle Adapter Set 57001 1457 Amplifier Input Voltage Connections to Connectors Meter BR W Lead A Meter BK Y Lead B e Measure the input voltage DC with the connectors joined e Turn the ignition switch ON Input Voltage Standard Battery Voltage 12 8 V or more e Turn the ignition switch OFF xIf the reading is out of the range check the wiring see Blank Key Detection Section xIf the reading and antenna resistance are good replace the amplifier see Immobilizer System Parts Replacement in the Electrical System chapter 3 80 FUEL SYSTEM DFI Blank Key Detection Service Code 36 This code appears in the following conditions OThe transponder
411. r Light LED e Connect the leads in the same circuit as check 1 e When pushing the MODE button A and RESET button B simultaneously for more than 2 seconds the shift up indicator C goes on at pre set light mode after 2 seconds passed TA meter needle D indicates the current pre set engine speed and check to move to the setting mode xIf the needle and light does not work replace the meter Assembly e When changing the pre set engine speed check that the TA meter needle moves change of pre set engine speed within the adjusting range by pushing the RESET button 15000 gt 15050 15100 16500 716450 16400 14950 gt 14100 14050 14000 66179426 3 e When changing the pre set engine speed check that the light mode of the shift up indicator changes at the MODE button released after MODE button is pushed in less than 2 seconds LIGHT OFF FLASH gt BRIGHT gt DIM GC17943CN3 xIf the display function does not work replace the meter assembly 555 0060606595958 GP17919BS2 C 16 78 ELECTRICAL SYSTEM Meter Gauge Indicator Unit e When changing the pre set engine speed push the MODE button A and RESET button B simultaneously for more than 2 seconds and engine speed and light mode setting complete after 2 seconds passed then check to go back to the mode before moving to this setting C mode xIf the needle and light does not work rep
412. r Position Switch Screws 2 9 0 30 26 L 3 Shift Drum Cam Holder Bolt 12 1 2 106 in Ib L 4 Shift Lever Bolt 6 9 0 70 61 in Ib 5 Shift Pedal Mounting Bolt 25 2 5 18 6 Shift Shaft Return Spring Pin 28 2 9 21 L 7 Shift Tie Rod Locknut 6 9 0 70 61 in Ib Lh 8 Shift Tie Rod Locknut 6 9 0 70 61 in Ib 9 Clutch Cap Hand tighten fining nspesion Gap PT itt T Starter Clutch Cover Bots 98 1 2 lee 11 713 Gear Cover Bos 98 12 EO Apply engine oil 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 9 6 CRANKSHAFT TRANSMISSION Specifications Item Standard Service Limit Crankcase Crankshaft Connecting Rods Connecting Rod Bend TIR 0 2 100 mm 0 008 3 94 in Connecting Rod Twist TIR 0 2 100 mm 0 008 3 94 in Connecting Rod Big End Side 0 13 0 33 mm 0 6 mm Clearance 0 0051 0 0130 in 0 024 in Connecting Rod Big End Bearing 0 044 0 081 mm 0 12 mm Insert Crankpin Clearance 0 0017 0 0032 in 0 0047 in Crankpin Diameter 29 987 30 000 mm 29 97 mm 1 1806 1 1811 in 1 1799 in Marking None 29 984 29 992 mm 1 1805 1 1808 in 29 993 30 000 1 1808 1 1811 in Connecting Rod Big End Inside 33 000 33 016 mm Diameter 1
413. r Temperature Sensor Output Voltage Connections to ECU Meter O lead terminal 9 Meter BR BK lead terminal 28 e Measure the sensor output voltage with the engine stopped and the connector joined e Turn the ignition switch ON Output Voltage at ECU Standard About 2 80 2 97 V at 20 C 68 F NOTE OThe output voltage changes according to the coolant temperature in the engine 80179070651 FUEL SYSTEM DFI 3 55 Water Temperature Sensor Service Code 14 e Turn the ignition switch OFF x If the output voltage is out of the specified check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see ECU Removal Installation x If the output voltage is far out of the specified e g when the wiring is open the voltage is about 5 V check the wiring x If the wiring is good check the water temperature sensor resistance e Remove the needle adapter set and apply silicone sealant to the seals of the connector for waterproofing Sealant Kawasaki Bond Silicone Sealant 56019 120 Water Temperature Sensor Circuit 1 ECU 2 Meter Unit 3 Water Temperature Sensor Water Temperature Sensor Resistance Inspection e Remove the water temperature sensor see Water Tem perature Sensor Removal Installation e Refer to the Electrical System chapter for water temper ature sensor i
414. r noise is found remove the front wheel and inspect the wheel bearing see Front Wheel Removal Hub Bearing Inspection in the Wheels Tires chapter e Using a stand raise the rear wheel off the ground see Rear Wheel Removal in the Wheels Tires chapter e Inspect the roughness of the rear wheel bearing by push ing and pulling A the wheel e Spin B the rear wheel lightly and check for smoothly turn roughness binding or noise x If roughness binding or noise is found remove the rear wheel and inspect the wheel bearing see Rear Wheel Re moval Hub Bearing Inspection in the Wheels Tires chap ter and coupling see Coupling Bearing Inspection in the Final Drive chapter 65118099 PERIODIC MAINTENANCE 2 29 Maintenance Procedure Drive Train Drive Chain Lubrication Condition Inspection e If a special lubricant is not available a heavy oil such as SAE 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication e f the chain appears especially dirty clean it before lubri cation CAUTION The O rings between the side plates seal in the lu bricant between the pin and the bushing To avoid damaging the O rings and resultant loss of lubri cant observe the following rules Use only kerosene or diesel oil for cleaning of the O ring of the drive chain Any other cleaning solution such as gasoline or trichloroethylene will cause deterioration and swelling of
415. ral law covering motor vehicle pollution contains what is commonly referred to as the Act s tampering provisions Sec 203 a The following acts and the causing thereof are prohibited 3 A for any person to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title prior to its sale and delivery to the ultimate purchaser or for any manufacturer or dealer knowingly to remove or render inoperative any such device or element of design after such sale and delivery to the ultimate purchaser 3 B for any person engaged in the business of repairing servicing selling leasing or trading motor vehicles or motor vehicle engines or who operates a fleet of motor vehicles know ingly to remove or render inoperative any device or element of design installed on or ina motor vehicle or motor vehicle engine in compliance with regulations under this title follow ing its sale and delivery to the ultimate purchaser NOTE OThe phrase remove or render inoperative any device or element of design has been generally interpreted as follows 1 Tampering does not include the temporary removal or rendering inoperative of de vices or elements of design in order to perform maintenance 2 Tampering could include a Maladjustment of vehicle components such that the emission standards are ex ceeded b Use of replacement parts or accesso
416. ries which adversely affect the performance or durability of the motorcycle c Addition of components or accessories that result in the vehicle exceeding the stan dards d Permanently removing disconnecting or rendering inoperative any component or element of design of the emission control systems WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING 10 000 PER VIOLATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below Replacement of the original exhaust system or muffler with a component not in compliance with Federal regulations Removal of the muffler s any internal portion of the muffler s Removal of the air box or air box cover Modifications to the muffler s or air inlet system by cutting drilling or other means if such modifications result in increased noise levels
417. rimary Windings 1 2 1 60 Secondary Windings 8 5 11 5 x If the tester does not read as specified replace the coil 8 10011952 C Stick Coil Primary Peak Voltage NOTE OBe sure the battery is fully charged e Remove the stick coils see Stick Coil Removal but do not remove the spark plugs e Measure the primary peak voltage as follows Olnstall the new spark plugs A into each stick coils B and ground them onto the engine OConnect peak voltage adapter C into the hand tester D which is set to the x 250 V DC range OConnect the adapter to the lead wire peak voltage adapter E which is connected between the stick coil connector and stick coil ECU F Special Tools Hand Tester 57001 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Lead Wire Peak Voltage Adapter 57001 1449 8 10154851 Primary Lead Connection Adapter R to lead wire peak voltage adapter Stick Coil 1 BK Stick Coil 42 BK G Stick Coil 43 BK W Stick Coil 44 BK O Adapter BK to lead wire peak voltage adapter R OTemporary install the air cleaner housing G see Air Cleaner Housing Installation in the Fuel System DFI chapter ORemove the fuel hose fitting of the fuel pump side OConnect the prepared fuel hose to the fuel supply pipe of the fuel pump Olnsert the fuel hose into the proper container 16 40 ELECTRICAL SYSTEM Ignition System A WARNING
418. rive the fuel pump 3 seconds or more with out the fuel in the fuel tank If the fuel pump is driven without the fuel it may be damaged Measure the fuel pressure with the engine stopped Fuel Pressure right after Ignition Switch ON with pump running Standard 294 kPa 3 0 kgf cm 43 psi after 3 seconds from Ignition Switch ON with pump stopped Standard 280 kPa 2 9 kgf cm 41 psi residual fuel pressure The system should hold the residual pressure about 30 seconds e Start the engine and let it idle e Measure the fuel pressure with the engine idling 3 104 FUEL SYSTEM Fuel Line Fuel Pressure ldling Standard 294 kPa 3 0 kgf cm 43 psi NOTE OThe gauge hand will fluctuate Read the pressure at the average of the maximum and minimum indications x If the fuel pressure is much higher than the specified re place the fuel pump see Fuel Pump Removal Installa tion xIf the fuel pressure is much lower than specified check the following Fuel Line Leakage Amount of Fuel Flow see Fuel Flow Rate Inspection xIf the fuel pressure is much lower than specified and if inspection above checks out good replace the throttle body assy nozzle assy or the fuel pump and measure the fuel pressure again see appropriate sections e Remove the fuel pressure gauge fuel hoses and adapter e Install the fuel tank see Fuel Tank Installation Fuel Flow Rate Inspection NOTE OBe sure the battery i
419. rk and the mating surface C of thermostat housing cover become parallel Replace the O ring A with a new one e Apply grease to the new O ring e Install a new O ring into the thermostat housing cover e Install the bracket C e Tighten Torque Thermostat Housing Cover Bolts D 5 9 Nm 0 60 kgf m 52 in Ib GD09017BS1 COOLING SYSTEM 4 19 Thermostat e Install the water hose clamp A as shown Upside View B Tighten Torque Water Hose Clamp Screw 2 0 0 20 kgf m 17 in Ib e Install the oil cooler see Oil Cooler Installation in the En gine Lubrication System chapter e Fill the radiator with coolant see Coolant Change in the Periodic Maintenance chapter Thermostat Inspection e Remove the thermostat see Thermostat Removal in this chapter e Inspect the thermostat valve A at room temperature x lf the valve is open replace the thermostat with a new one To check valve opening temperature suspend the ther mostat A in a container of water and raise the tempera ture of the water OThe thermostat must be completely submerged and must not touch the container sides or bottom Suspend an ac curate thermometer B in the water so that the heat sen sitive portions C are located in almost the same depth It must not touch the container either x If the measurement is out of the specified range replace the thermostat with a new one Thermostat Valve Op
420. rk Position eManifold A with Holes B for Oxygen Sensors Equipped Models Oxygen Sensor 1 Oxygen Sensor 2 D GE02339BS2 5 8 ENGINE TOP END Specifications Standard Service Limit Camshafts Cam Height Exhaust 33 443 33 557 mm 1 3167 1 3211 in 33 34 mm 1 313 in Inlet 34 243 34 357 mm 1 3481 1 3526 in 34 14 mm 1 344 Camshaft Journal Camshaft Cap Clearance Camshaft Journal Diameter Camshaft Bearing Inside Diameter Camshaft Runout 0 038 0 081 mm 0 0015 0 0032 in 23 940 23 962 mm 0 9425 0 9434 in 24 000 24 021 mm 0 9449 0 9457 in TIR 0 02 mm 0 0008 in or less 0 17 mm 0 0067 in 23 91 mm 0 941 in 24 08 mm 0 948 in TIR 0 1 mm 0 004 in Cylinder Head Cylinder Compression Cylinder Head Warp Usable Range 980 1 498 kPa 10 0 15 3 kgf cm 142 217 psi at 240 r min rpm 0 05 mm 0 002 in Valves Valve Clearance Exhaust Inlet Valve Head Thickness Exhaust Inlet Valve Stem Bend Valve Stem Diameter Exhaust Inlet Valve Guide Inside Diameter Exhaust Inlet Valve Valve Guide Clearance Wobble Method Exhaust Inlet Valve Seat Cutting Angle Valve Seating Surface Width Exhaust Inlet Outside Diameter Exhaust Inlet Valve Spring Free Length Exhaust Inlet 0 24 0 31 mm 0 0094 0 0122 in 0 13 0 19 mm 0 0051 0 0075 in 1 0 mm 0 03
421. rnator Lead Holding Plate Bolt 9 8 1 0 87 in lb L Alternator Rotor Bolt 155 16 115 Camshaft Position Sensor Bolt 9 8 1 0 87 Crankshaft Sensor Bolts 5 9 0 60 52 in Ib Cylinder Head Cover Ground Bolt 9 8 1 0 87 Front Brake Light Switch Screw 1 2 0 12 10 in Ib Front Turn Signal Light Mounting Screws 1 2 0 12 10 in Ib Headlight Mounting Screws 1 2 0 12 10 in Ib Licence Light Assembly Screws 0 9 0 09 8 in Ib Licence Light Mounting Screws 1 2 0 12 10 in Ib Meter Mounting Screws 1 2 0 12 10 in Ib PERIODIC MAINTENANCE 2 11 Torque and Locking Agent Fastener Torgus Remarks N m kgf m ft Ib Gear Position Switch Screws 2 9 0 30 26 in lb L Rear Turn Signal Light Lens Screws 1 0 0 10 9 Turn Signal Light Mounting Screws 1 2 0 12 10 in Ib Regulator Rectifier Bolts 6 9 0 70 61 in Ib Regulator Rectifier Bracket Nuts 6 9 0 70 61 in Ib Side Stand Switch Bolt 8 8 0 90 78 in Ib L Spark Plugs 13 1 3 113 in Ib Speed Sensor Bolt 6 9 0 70 61 in Ib L Stator Coil Bolts 12 1 2 106 in Ib L Starter Motor Cable Terminal Bolt 2 9 0 30 26 in lb Starter Clutch Bolt 49 5 0 36 Starter Motor Mounting Bolts 9 8 1 0 87 Starter Relay Cable Terminal Bolts 4 0 0 41 35 in Ib Switch Housing Screws 3 5 0 36 31 in Ib Tail Brake Light Mounting Bolts 4 0 0 40 35 in Ib Vehicle down Sensor Bolts 5 9 0 60 52 in lb Water Temperature Sensor 25 2 5 18 SS Idle Gear Cover Bolts 9 8 1 0 87 Starter Clutch Cover Bolts 9 8 1
422. rque No Fast R k astener kgfm ftlb emarks 1 Vehicle down Sensor Bolts 5 9 0 60 52 in lb 2 Air Inlet Duct Mounting Bolts 9 8 1 0 87 in lb L 3 Cleaner Housing Mounting Bolt 6 9 0 70 61 in Ib 4 Cleaner Housing Screws 1 1 0 11 9 7 in lb 5 Air Cleaner Housing Clamp Bolts 2 0 0 20 17 in Ib 6 Vehicle down Sensor 7 Immobilizer Amplifier 8 Air Switching Valve 9 Immobilizer Antenna 10 Air Cleaner Element 11 Catch Tank L Apply a non permanent locking agent R Replacement Parts 3 6 FUEL SYSTEM DFI Exploded View 6002294BW5 C FUEL SYSTEM DFI 3 7 Exploded View Torque No Fastener Nm kgfm ftlb Remarks 1 Delivery Pipe Mounting Screws Nozzle Assy 3 4 0 35 30 in Ib 2 Nozzle Assy Mounting Bolts 6 9 0 70 61 in Ib 3 Cable Holder Plate Bolt 3 9 0 40 35 in Ib L 4 Nozzle Assy Fuel Hose Screw 4 9 0 50 43 in lb 5 Delivery Pipe Mounting Screws Throttle Body 3 4 0 35 30 in Ib 6 Body Assembly Holder Clamp Bolts 3 0 0 30 27 in lb 7 Throttle Body Holder Bolts 12 1 2 104 in Ib L 8 Secondary Fuel Injectors 9 Inlet Air Pressure Sensor 10 Inlet Air Temperature Sensor 11 Subthrottle Sensor 12 Main Throttle Sensor 13 Subthrottle Valve Actuator 14 Primary Fuel Injectors 15 16 Bypass Screw Apply cable lubricant EO Apply grease Apply a non permanent locking agent Replacement Parts 17 Throttle Cable A
423. rvice codes stored in memory of the ECU are not erased to preserve the problem history The problem history can be referred using the KDS Kawasaki Diagnostic System when solving unstable problems When the motorcycle is down the vehicle down sensor is turned OFF and the ECU shuts off the fuel pump relay fuel injectors and ignition system The ignition switch is left ON If the starter button is pushed the electric starter turns but the engine does not start When the starter button is pushed the warning indicator light LED and Fl warn ing symbol blink but the service code is not displayed To start the engine again raise the motorcycle turn the igni tion switch OFF and then ON Much of the DFI system troubleshooting work consists of confirming continuity of the wiring The DFI parts are assembled and adjusted with precision and it is impossible to disassemble or repair them 80178700651 FUEL SYSTEM DFI 3 25 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 CAUTION Insert the needle adapter straight along the terminal in
424. s C of the shift drum e Apply grease to the new O ring A e Install Gear Position Switch B e Install Holding Plate A 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 Run the gear position switch and side stand switch lead correctly see Cable Wire and Hose Routing section in the Appendix chapter e Install the removed parts see appropriate chapters 16 104 ELECTRICAL SYSTEM Switches and Sensors Gear Position Switch Inspection NOTE OBe sure the transmission mechanism is good condition e Disconnect the connector A Clamp B Set the hand tester A to the 1 or x 100 range and connect it to the terminals in the oil pressure switch gear position switch lead connector B and ground C Internal Circuit 1 Light Green Lead 2 Green Red Lead 3 Black Lead Special Tool Hand Tester 57001 1394 Gear Position Switch Resistance Connections Gear Position 1 Ground 2 Ground 3 Ground Neutral about 0 1st 3 00 3 32 11 63 12 87 1 70 1 89 10 33 11 44 3rd 1 07 1 19 9 70 10 74 4th 0 695 0 769 9 32 10 32 5th 0 430 0 476 9 06 10 03 6th 0 248 0 274 8 89 9 81 xIf the tester reading is not as specified replace the gear position switch with a new one 1st 2nd 3rd 4th Sth 6t
425. s e Insert the fuel hose joint A straight onto the delivery pipe until the hose joint clicks e Push B the joint lock C until the hose joint clicks A WARNING Make sure the hose joint is installed correctly on the delivery pipe by sliding the joint or the fuel could leak 3 122 FUEL SYSTEM Nozzle Assy Nozzle Assy Disassembly e Remove the nozzle assy see Nozzle Assy Removal Remove the screws A to pull out the injector assys from the stay plate comp together with the delivery pipe assy NOTE ODo not damage the part of insert of the injectors when they are pulled out from the stay plate comp Remove the fuel hose Pull out the injectors from the delivery pipe assy NOTE ODo not damage the part of insert of the injectors when they are pulled out from the delivery pipe assy Nozzle Assy Assembly e Before assembling blow away dirt or dust from the nozzle and delivery pipes A by applying compressed air B e Apply engine oil to the new O rings A and the dust seals B of each injector NOTE OReplace the O ring and the dust seals of injectors to new one e Apply engine oil to the new O rings A Install the joint pipe to the delivery pipe 607029 6617918651 86617919651 C 80179200651 FUEL SYSTEM DFI 3 123 Nozzle Assy e Apply engine oil to the new O rings A e Fit the connector portion B of the injector
426. s 3 e Temperature Inlet Air om a Sansor Pressure 1 Sensor gt zx 5 exe Z zu Se re 555 25 53 zi License Plate ii Light 12V5N 1 9 Rear Might Turn Signal Lr 7 i Light 12VI0N 5 ae 5 58 455 EE a P Tail Brake Light LED 12V0 1 1 64 a ag doint T M Connector B S frane 5 dh amp 55 Rear Left 5 roun zz Turn Turn Signal Rear Vehicle Signal Light 12 10 Brake down Relay 5 59 Light Sensor 1 Starter Fuel rr Notor Reserve 55 Main Battery 4 Fri Fuss 12Y8Ab Switch Fuel u Relay Box 30 Tamobiliser i Fan Relay 4 Fuel Pump eel tee 2 Headlight Relay Relay 5 Starter System 3 ECU Wain Relay Circuit Relay Connector ight Blue IGNITION SWITCH CONNECTIONS L9 Orange RIGHT HANDLEBAR SWITCH CONNECTIONS P Pink IgnitionBattery Taili Tai l2 Front Brake Light Switch Engine Stop Switch Starter Button Stop Watch Button Color Color Y R Color BK RIBK R Color W B Brake Lever OFF Free W White Y Q Yellow wea M OFF Lock ON P PAR a 98052 03288 W2RO3288H5 C 16 18 ELECTRICAL SYSTEM Specifications Item Standard Battery Type Capacity Voltage Charging System Type Alternator Out
427. s fully charged WARNING Gasoline is extremely flammable be explo sive under certain conditions Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Turn the ignition switch OFF Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately e Turn the ignition switch and engine stop switch OFF e Wait until the engine cools down Prepare a measuring cylinder e Remove Front Seat see Front Seat Removal in the Frame chap ter Fuel Tank Bolts see Fuel Tank Removal Open the fuel tank cap A to lower the pressure in the tank e Be sure to place a piece of cloth around the fuel supply pipe of the fuel pump Remove the fuel hose from the fuel supply pipe of the fuel pump see Fuel Tank Removal A WARNING Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is disconnected fuel spills out from the hose and the pipe because of residual pressure Cover the hose connection with a piece of clean cloth to prevent fuel spillage 00098128 P FUEL SYSTEM DFI 3 105 Fuel Line e Connect the fuel hose A to the fuel supply pipe of the fuel pump Special Tool Fuel Hose 57001 1607 e Secure the fuel hose with a clamp e Insert the fuel hose into the measuring cylinder B A WARNING Wipe o
428. s its valve opening to keep the coolant temperature at the proper level When coolant temperature is less than 55 C 131 F the thermostat closes so that the coolant flow is restricted through the air bleeder hole causing the engine to warm up more quickly When coolant temperature is more than 58 62 C 136 144 F the thermostat opens and the coolant flows When the coolant temperature goes up beyond 100 C 212 F the radiator fan relay conducts to operate the radiator fan The radiator fan draws air through the radiator core when there is not suffi cient air flow such as at low speeds This increases up the cooling action of the radiator When the coolant temperature is below 97 C 207 F the fan relay opens and the radiator fan stops In this way this system controls the engine temperature within narrow limits where the engine op erates most efficiently even if the engine load varies The system is pressurized by the radiator cap to suppress boiling and the resultant air bubbles which can cause engine overheating As the engine warms up the coolant in the radiator and the water jacket expands The excess coolant flows through the radiator cap and hose to the reserve tank to be stored there temporarily Conversely as the engine cools down the coolant in the radiator and the water jacket contracts and the stored coolant flows back to the radiator from the reserve tank The radiator cap has two valves One is a pressure valve which ho
429. s key is turned off and removed otherwise registra tion mode will be ended and the warning indicator light 0 5second 0 5second LED goes off Arzt IGI OTo return to the registration mode start the master key 8030378851 verification procedure This applies to all user key reg istration e Insert the user key 2 to the ignition switch and turn it ON olf there is any problem in the registration the warning indicator light LED A blinks to display the collation error code Immobilizer Amplifier Failure 0 2second Gat GP30374BS1 ELECTRICAL SYSTEM 16 95 Immobilizer System Equipped Models When Registered User Key is Inserted 0 5second 0 5second A 8 Es ay GP30376BS1 C User Key Collation Error 0 3second A Be ULL GP30373BS1 C e The user key 2 is registered in the ECU OThe warning indicator light LED A blinks 3 times and stops for 1 second and then repeats this cycle to indicate successful registration of user key 2 e Turn OFF the ignition switch and wait for period more than 15 seconds e The registration mode automatically ends nm GP30371BS1 e FI indicator light goes off A GP30370BS1 NOTE OTurn the ignition switch ON with the registered user key OCheck that the engine can be started using all regis tered user keys Ca
430. s of the United States Environmental Protection Agency and California Air Resources Board Addi tionally Kawasaki has incorporated an evaporative emission control system 3 in compliance with applicable regulations of the California Air Resources Board on vehicles sold in California only 1 Crankcase Emission Control System This system eliminates the release of crankcase vapors into the atmosphere Instead the vapors are routed through an oil separator to the inlet side of the engine While the engine is operating the vapors are drawn into combustion chamber where they are burned along with the fuel and air supplied by the fuel injection system 2 Exhaust Emission Control System This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this motorcycle The fuel ignition and exhaust systems of this motorcycle have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels The exhaust system of this model motorcycle manufactured primarily for sale in California in cludes a catalytic converter system 3 Evaporative Emission Control System Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere In stead fuel vapors are routed into the running engine to be burned or stored in a canister when the engine is stopped Liquid fuel is caught by a vapor separator and returned to the fuel tank The Clean Air Act which is the Fede
431. s painted blue B Check in sert crankpin clearance with the plastigage The clear ance may exceed the standard slightly but it must not be less than the minimum in order to avoid bearing seizure xIf the clearance exceeds the service limit measure the diameter C of the crankpins Crankpin Diameter Standard 29 987 30 000 mm 1 1806 1 1811 in Service Limit 29 97 mm 1 1799 in x If any crankpin has worn past the service limit replace the crankshaft with a new one x If the measured crankpin diameters are not less than the service limit but do not coincide with the original diameter markings D on the crankshaft make new marks on it Crankpin Diameter Marks None 29 984 29 992 mm 1 1805 1 1808 in O 29 993 30 000 mm 1 1808 1 1811 in Crankpin Diameter Marks mark or no mark e Measure the connecting rod big end inside diameter and mark each connecting rod big end in accordance with the inside diameter e Tighten the connecting rod big end nuts to the specified torque see Connecting Rod Installation NOTE OThe mark already on the big end should almost coincide with the measurement 6105041851 6105041751 9105250851 9 24 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Big End Inside Diameter Marks None 33 000 33 008 mm 1 2992 1 2995 in 33 009 33 016 mm 1 2996 1 2998 Big E
432. s shorted and must be replaced Crankshaft Sensor Resistance 380 570 e Using the highest resistance range of the tester measure the resistance between the crankshaft sensor leads and chassis ground tester reading less than infinity indicates a short necessitating replacement of the crankshaft sensor as sembly Crankshaft Sensor Peak Voltage NOTE OBe sure the battery is fully charged OUsing the peak voltage adapter is a more reliable way to determine the condition of the crankshaft sensor than crankshaft sensor internal resistance measurements e Remove Crankshaft Sensor Lead Connector see Crankshaft Sensor Removal e Set the hand tester A to the x 10 V DC range and con nect it peak voltage adapter B e Using the auxiliary leads connect the black lead C of the adapter to black yellow lead and red lead D to black lead in the crankshaft sensor connector E e Turn the ignition switch on and engine stop switch on BK Y GP10421BS1 C 16 38 ELECTRICAL SYSTEM Ignition System e Pushing the starter button turn the engine 4 5 sec onds with the transmission gear in neutral to measure the crankshaft sensor peak voltage Repeat the measurement 5 or more times Crankshaft Sensor Peak Voltage Standard 3 2 V or more Special Tools Hand Tester 57001 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B x If the tester reading is not specified on
433. sc 13 Right Front Disc 80709 en up cm Mao 17 26 APPENDIX Cable Wire and Hose Routing GBO9327CH3 C White Viewed Rear Brake Reservoir Clamps Brake Hose Clamps Brake Hose Pad stick on Clamp Rear Caliper Rear Brake Master Cylinder Cotter Pin Bend the both side of the pin Viewed A Section C C Rear Disc APPENDIX 17 27 Cable Wire and Hose Routing California Model GB09325CW4 C 1 Clamp 8 Hose Green 2 Clamps 9 Hose Blue 3 Canister 10 Hose Red 4 Hose Blue 11 Fitting of the throttle body 1 5 Seporator 12 To the air cleaner housing 6 Clamp 13 To the air switching valve 7 Hose White 14 Fitting 17 28 APPENDIX Cable Wire and Hose Routing California Model 6809304095 C APPENDIX 17 29 Cable Wire and Hose Routing Left Middle Fairing Left Turn Signal Light Left Inner Cover Clamp Screws Run the hoses between the frame and rib of the heat insulation plate as shown To the air cleaner housing To the fitting of the throttle body 1 To the fuel tank Heat Insulation Plate Run the hoses 12 13 15 outside of the hose 17 as shown Hose Red Hose White To the air switching valve Hose Blue Hose Green Hose Blue Install the hose so that th
434. sc Mounting Bolts 27 2 8 20 L Rear Caliper Mounting Bolts 25 2 5 18 Rear Master Cylinder Mounting Bolts 25 2 5 18 Rear Master Cylinder Push Rod Locknut 18 1 8 13 Suspension Front Axle Clamp Bolts 2 10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Nem fb Remarks Front Fork Bottom Allen Bolts 35 3 5 26 Front Fork Clamp Bolts Lower 25 2 5 18 AL Front Fork Clamp Bolts Upper 20 2 0 15 Front Fork Top Plugs 35 3 5 26 Piston Rod Nuts 20 2 0 15 Rear Shock Absorber Bracket Nut 59 6 0 43 Rear Shock Absorber Nut Lower 34 3 5 25 Rear Shock Absorber Nut Upper 34 3 5 25 Swingarm Pivot Adjusting Collar 20 2 0 15 S Swingarm Pivot Adjusting Collar Locknut 98 10 72 S Swingarm Pivot Shaft Nut 108 11 81 S Tie Rod Nuts 59 6 0 43 Uni Trak Rocker Arm Nut 34 3 5 25 Steering Front Fork Clamp Bolts Lower 25 2 5 18 AL Front Fork Clamp Bolts Upper 20 2 0 15 Handlebar Bolts 25 2 5 18 Handlebar Position Bolts 9 8 1 0 87 L Steering Stem Head Nut 78 8 0 58 Steering Stem Nut 20 2 0 15 Switch Housing Screws 3 5 0 36 31 in Ib Frame Front Fender Mounting Bolts 3 9 0 40 35 in Ib Front Footpeg Bracket Bolts 25 2 5 18 Rear Footpeg Bracket Bolts 25 2 5 18 Rear Frame Bolts 44 4 5 32 L Sidestand Bolt 44 4 5 32 G Sidestand Bracket Bolts 49 5 0 36 L Sidestand Switch Bolt 8 8 0 90 78 L Windshield Mounting Bolts 0 4 0 04 4 in lb Electrical System Alternator Cover Bolts 9 8 1 0 87 Alte
435. scheduled maintenance e Use proper tools and genuine Kawasaki Mo torcycle parts Special tools gauges and testers that are necessary when servicing Kawasaki motorcycles are introduced by the Service Manual Genuine parts provided as spare parts are listed in the Parts Catalog e Follow the procedures in this manual care fully Don t take shortcuts e Remember to keep complete records of main tenance and repair with dates and any new parts installed How to Use This Manual In this manual the product is divided into its major systems and these systems make up the manual s chapters The Quick Reference Guide shows you all of the product s system and assists in locating their chapters Each chapter in turn has its own comprehensive Ta ble of Contents For example if you want 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 these WARNING and CAUTION symbols heed their instructions Always follow safe operating and maintenance practices A WARNING This warning symbol identifies special instructions or procedures which if not correctly followed could result in per sonal injury or loss of life CAUTION This caution symbol identifies special instructions or procedures which if not strictly observed could result in dam age to or destr
436. se 10 Starter Lockout Switch Fan Fuse 15 Taillight Fuse 10A 7 8 D Lap Time Button Fuse 10 1gniton Fuse 10 Turn Signal Relay 8 Horn Fuse 10 Fuse 10A LEFT HANDLEBAR SWITCH CONNECTIONS H Butt Signal Switch er Switch Starter Lockout ge olar PAR coter fiza faa oote HI Clutch Lever eee EI e Released R ulled in D Bom W2L0293DW5 C ELECTRICAL SYSTEM 16 13 Wiring Diagram Other than United States Canada Australia and Malaysia Gear Position Sensor LIT Side Alternator Stand aro Switch Nain Subthrottle Throttle Sensor ensor OFF ON Regulator TE 1 fRectifier Subthrottle water NRA NA Be Valve Temperature Actuator Ssi Eeh Camshaft L 1 L 3 2 Postion T oil Sensor So z Pressure Atmospheric u 2g Switch Crank bg ressurs Exhaust Butterfly shaft 3555 S55 ensor Val hetuat NS Sensor 59 Saeed H alve Actuator Sensor gt Inlet TEN x Aic Bees 3 e Temperature Inlet Air om Sansor Pressure Sensor Y R BR W BK BL ay G R R BK ECU Y Y w Y BL BL v a Y R Y BK BL W LA W BK P BK w BL BR Y BR BK M License Plate Light 12V5W Rear Right Turn Signal Light 12V10W Y R Tail Brake Light LED 12V0 1 1 68
437. se 4 When master key is faulty or lost The master key replacement is considered very rare case However if it is required the following is necessary NOTE OThe ECU must be replaced with a new one because the master key code that is registered in the current ECU can not be rewritten 16 96 ELECTRICAL SYSTEM Immobilizer System Equipped Models e Prepare a new ECU A new master key B and current user keys C NOTE OThe key registration unit is not required OThe key registration process is same as the electric con trol unit replacement Case 5 When replacing the antenna e Prepare a new antenna e Refer to the Immobilizer System Parts Replacement in this chapter NOTE ONo key registration is required GP30028BS1 C ELECTRICAL SYSTEM 16 97 Immobilizer System Equipped Models All Keys Initial Registration Flow Chart Blinking Patterns and Number 0 2second J gt 1 0 second 30 en ECU checks master D Jaecond Taenaod key NOTES gt 3 8 0 3 leecene gt e 93293093 Warning ight binkeg 5 52 Pattern 2 record Hhnnnnnnnnnn 6 8 Tum OFF and remove user key 1 ECU checks Warrsng indicator ight biring NOTE2 NOTES NOTE 1 Key Substitute Time Insert next key and turn ON within 15 seconds after ECU checks user previous key is turned OFF 1 NOTES 2 4 the f O Time o
438. se Banjo Bolts 25 2 5 18 Brake Pedal Bolt 78 x Rear Disc Meaning Bolts Ser sots 2s Rear Master Cylinder Mounting Bolts 7 Master Cylinder Push Rod Locknut T 3 B Apply brake fluid G Apply grease L Apply a non permanent locking agent R Replacement Parts Si Apply silicone grease 12 6 BRAKES Specifications Standard Service Limit Brake Lever Brake Pedal Brake Lever Position Brake Lever Free Play Pedal Free Play Pedal Position Brake Fluid Grade 6 way adjustable to suit rider Non adjustable Non adjustable About 78 mm 3 1 in below footpeg top DOT4 Brake Pads Pad Lining Thickness Front Rear 4 mm 0 16 in 5 mm 0 20 in 1 mm 0 04 in 1 mm 0 04 in Brake Discs Thickness Front Rear Runout 5 8 6 2 mm 0 23 0 24 in 4 8 5 2 mm 0 19 0 20 in TIR 0 15 mm 0 006 in or less 5 5 mm 0 22 in 4 5 mm 0 18 in 0 3 mm 0 01 in BRAKES 12 7 Special Tools Inside Circlip Pliers Jack Attachment 2 J L 57001 143 57001 1608 7570143ST C 7571608ST C Jack 57001 1238 7571238ST C 12 8 BRAKES Brake Lever Brake Pedal Brake Lever Position Adjustment The brake lever adjuster has 6 positions so that the brake lever position can be adjusted to suit the operator s hand e Push the lever forward and turn the adjuster A to align the num
439. see Air Suction Valve Re moval in this chapter e Visually inspect the reeds A for cracks folds warps heat damage or other damage x If there is any doubt as to the condition of the reed replace the air suction valve as an assembly e Check the reed contact areas B of the valve holder for grooves scratches any signs of separation from the holder or heat damage x If there is any doubt as to the condition of the reed contact areas replace the air suction valve as an assembly If any carbon or other foreign particles have accumulated between the reed and the reed contact area wash the valve assembly with a high flash point solvent CAUTION Do not scrape off the deposits with a scraper as this could damage the rubber requiring replacement of the suction valve assembly 5 12 ENGINE TOP END Clean Air System Air Switching Valve Removal e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Air Cleaner Housing see Air Cleaner Housing Removal in the Fuel System DFI chapter e Disconnect the connector A e Separate the hoses B from the air suction valve covers and air cleaner housing holder and remove the air switch ing valve C CAUTION Never drop the air switching valve especially on a hard surface Such a shock to the air switching valve can damaged it Air Switching Valve Installation e Route the hoses correctly see Cable Wire and Hose
440. sensor must send 1 signal to the ECU at the 2 crankings Speed sensor must send 8 signals to the ECU at the one rotation of the drive shaft If the camshaft position sensor system fails the signal is missing wiring short or open the ECU continues to ignite cylinders in the same sequence following the last good signal If the speed sensor system fails no signal wiring short or open the speedometer shows 0 Gear Position Switch Vehicle down 31 Sensor Subthrottle 32 Sensor Gear Position Switch Output Voltage signal Vd 0 2V 4 8V Output Voltage 0 65 4 45 V Output Voltage 0 15 4 85 V The ECU sets the top 6 gear position If the vehicle down sensor system has failures the output voltage is out of the usable range wiring short or open the ECU shuts off the fuel pump relay the fuel injectors and the ignition system If the subthrottle sensor system fails the output voltage is out of the usable range wiring short or open the ECU drive the subthrottle valve to the full closed position and it stops the current to the subthrottle valve actuator FUEL SYSTEM DFI 3 41 Self Diagnosis Service Codes Parts Oxygen Sensor 1 Equipped Models Output Signal Usable Range or Criteria The oxygen sensor 1 is active and sensor must send signals output voltage continuously to the ECU Backups by ECU If the oxygen sensor is not activated the ECU stops th
441. sert the axle from the right side of the wheel and tighten the axle nut Torque Rear Axle Nut 127 N m 13 kgf m 94 ft Ib e Adjust the drive chain slack after installation see Drive Chain Slack Inspection in the Periodic Maintenance chap ter Olnsert a new cotter pin A NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle tighten the nut clockwise B up to next alignment Olt should be within 30 OLoosen once and tighten again when the slot goes past the nearest hole 1 07000851 e Bend the cotter pin A over the nut A WARNING If the rear axle nut is not securely tightened or the cotter pin is not installed an unsafe riding condi tion may result GK04001BS1 C e Install the rear brake caliper see Caliper Installation in the Brakes chapter e Check the rear brake effectiveness see Brake Operation Inspection in the Periodic Maintenance chapter A WARNING Do not attempt to drive the motorcycle until a full brake pedal is obtained by pumping the brake pedal until the pads are against the disc The brake will not function on the first application of the pedal if this is not done 10 10 WHEELS TIRES Wheels Rims Wheel Inspection e Raise the front rear wheel off the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Spin the wheel lightly and check for roughness or binding x If rough
442. sh brake fluid to the upper level line in the reservoir e With the reservoir cap off slowly pump the brake lever several times until no air bubbles can be seen rising up through the fluid from the holes at the bottom of the reser voir OBleed the air completely from the master cylinder by this operation Remove the rubber from the bleed valve on the front master cylinder e Attach a clear plastic hose A to the bleed valve and run the other end of the hose into a container 12 20 BRAKES Brake Fluid e Bleed the brake line and the master cylinder ORepeat this operation until no more air can be seen com ing out into the plastic hose 1 Pump the brake lever until it becomes hard and apply the brake and hold it A 2 Quickly open and close B the bleed valve while hold ing the brake applied 3 Release the brake C NOTE OThe fluid level must be checked often during the bleed ing operation and replenished with fresh brake fluid as necessary If the fluid in the reservoir runs completely out any time during bleeding the bleeding operation must be done over again from the beginning since air will have entered the line Remove the clear plastic hose Tighten the bleed valve and install the rubber cap Torque Front Master Cylinder Bleed Valve 5 9 N m 0 60 kgf m 52 in lb e Remove the rubber cap from the bleed valve A on the caliper e Attach a clear plastic hose B to the bleed
443. sor 1 Oxygen Sensor 2 Ignition Switch Fuse Box Oxygen Sensor Fuse 10 A Main Fuse 30 A Starter Relay Battery Frame Ground OOANDABRWDN 3 96 FUEL SYSTEM DFI Oxygen Sensors Incorrect Output Voltage 1 2 Service Code 94 95 Equipped Models Oxygen Sensor 1 Service Code 94 Oxygen Sensor 2 Service Code 95 Oxygen Sensor Removal Installation e Refer to Oxygen Sensor Removal and Installation in the Electrical System chapter Oxygen Sensor Inspection NOTE OThe oxygen sensor itself is the same for 1 A and 2 B but wiring of the main harness side is different e Warm up the engine thoroughly e Turn the ignition switch OFF e Remove the right side cover see Right Side Cover Re moval in the Frame chapter e Connect a digital voltmeter A to the each oxygen sensor connector B sensor side using the needle adapter set Special Tool Needle Adapter Set 57001 1457 Oxygen Sensor Output Voltage Connections to Oxygen Sensor Connector Meter BK lead Meter lead e Remove the air switching valve hoses A both sides from the fittings e Install the suitable plugs A both sides on the fittings and shut off the secondary air e Turn the ignition switch ON e Start the engine and let it idle e Measure the output voltage of the sensor with the con nector joined Oxygen Sensor Output Voltage with Plugs Standard 0 45 2 5
444. ssage Nozzle 4 9 0 50 43 in Ib Oil Pressure Switch Terminal Bolt Hand tighten Bearing Holder Screws 4 9 0 50 43 in Ib L Shift Drum Cam Holder Bolt 12 1 2 104 in Ib L Shift Lever Bolt 6 9 0 70 61 Shift Pedal Mounting Bolt 25 2 5 18 Shift Shaft Return Spring Pin 28 2 9 21 L Shift Tie Rod Locknuts 6 9 0 70 61 Starter Clutch Bolt 49 5 0 36 Starter Clutch Bolt Cap Hand tighten Timing Inspection Cap Hand tighten Starter Clutch Cover Bolts 9 8 1 0 87 Idle Gear Cover Bolts 9 8 1 0 87 Wheels Tires Front Axle Clamp Bolts 20 2 0 15 AL Front Axle Nut 127 13 94 Rear Axle Nut 127 13 94 Final Drive Engine Sprocket Cover Bolts 9 8 1 0 87 Engine Sprocket Nut 125 13 92 MO Rear Sprocket Nuts 59 6 0 43 Chain Guide Bolts Front 9 8 1 0 87 L Chain Guide Bolt Rear 4 9 0 50 43 in Ib L Brakes Caliper Bleed Valves 7 8 0 80 69 Brake Hose Banjo Bolts 25 2 5 18 Brake Lever Pivot Bolt 1 0 0 10 9 Brake Lever Pivot Bolt Locknut 5 9 0 60 52 in lb Brake Pedal Bolt 8 8 0 90 78 Front Brake Light Switch Screw 1 2 0 12 10 in Ib Front Brake Reservoir Cap Stopper Screw 1 2 0 12 10 in Ib Front Brake Disc Mounting Bolts 27 2 8 20 E Front Brake Pad Pins 17 1 7 13 Front Caliper Assembly Bolts 27 2 8 20 Front Caliper Mounting Bolts 34 3 5 25 Front Master Cylinder Bleed Valve 5 9 0 60 52 in lb Front Master Cylinder Clamp Bolts 8 8 0 90 78 in Ib S Rear Brake Di
445. st Pipe Clamp Bolt 17 1 7 13 7 Front Exhaust Pipe Holder Nuts 13 8 Exhaust Pipe Mounting Bolts 21 Muffler Body Clamp Bolt 12 Muffler Body Mounting Bolts 21 Muffler Body Rear Cover Bolts 61 in lb Muffler Body Upper Cover Bolts Replacement Parts 61 in lb 5 6 ENGINE TOP END Exhaust System MANIFOLD MUFFLER BODY SPECIFICATION MARKETING CODE Honeycomb Type Catalyst 39178 0068 Mark KHI 106 Honeycomb Type Catalyst P No 39178 0070 Mark KHI M 107 Honeycomb Type Catalyst P No 39178 0075 Mark KHI M 108 Honeycomb Type Catalyst P No 39178 0078 Mark KHI M 112 Non Catalyst P No 18091 0329 Mark KHI K 510 EPA Noise Emission Control Information Non Catalyst P No 18091 0329 Mark KHI K 510 EPA Noise Emission Control Information Non Catalyst P No 18091 0329 Mark KHI K 510 EPA Noise Emission Control Information Non Catalyst P No 18091 0329 Mark KHI K 510 EPA Noise Emission Control Information WVTA FULL H UK WVTA FULL H WVTA 78 2 H U S A CANADA AUSTRALIA U S A CALIF MALAYSIA ZX600P7F ZX600P7F ZX600P7F ZX600P7F ZX600P7F ZX600P7F ZX600P7FL ZX600P7F 0 241608 F 78 2 Horse Power 78 2 kW 106 3 ps FULL Full Power H Honeycomb Type Catalyst WVTA Whole Vehicle Type Approval ENGINE TOP END 5 7 Exhaust System Manifold Mark Position Silencer Ma
446. st Seal 8 04429851 C Retaining Ring Oil Seal Washer Outer Tube Guide Bushing Inner Tube Guide Bushing SUSPENSION 13 17 Front Fork e Insert the inner tube to the outer tube e Fit the new outer tube guide bushing A into the outer tube NOTE OWhen assembling the new outer tube guide bushing hold the washer B against the new outer tube guide bushing and tap the washer with the fork oil seal driver C until it stops Special Tool Fork Oil Seal Driver 641 57001 1288 e Install the oil seal A Special Tool Fork Oil Seal Driver 41 57001 1288 e Install the retaining ring and dust seal into the outer tube e Insert the cylinder unit A into the inner tube B e Hold the front fork in a vise e Tighten Torque Front Fork Bottom Allen Bolt 35 N m 3 5 kgf m 26 ft lb e Pour in the specified type of the fork oil see Fork Oil Change Inner Tube Inspection e Visually inspect the inner tube A and repair any dam age Nicks or rust damage can sometimes be repaired by using a wet stone to remove sharp edges or raised areas which cause seal damage xIf the damage is not repairable replace the inner tube Since damage to the inner tube damages the oil seal replace the oil seal whenever the inner tube is repaired or replaced 6 04042051 C GM04430BS1 13 18 SUSPENSION Front Fork CAUTION If the inner tube is badly bent or creased replace it
447. stallation Throttle Body Assy Disassembly Throttle Body Assy Assembly Nozzle ASSy eri etr atoms Nozzle Assy Remowval Nozzle Assy Installation Nozzle Assy Disassembly Nozzle Assy Assembly Air Cleaner Element Removal Air Cleaner Element Installation Air Cleaner Element Inspection 3 116 3 117 3 117 3 117 3 117 3 117 3 118 3 119 3 120 3 121 3 121 3 121 3 122 3 122 3 124 3 124 3 124 3 124 Air Cleaner Housing Removal 3 124 Air Cleaner Housing Installation 3 125 Air Cleaner Housing Disassembly 3 126 Air Cleaner Housing Assembly 3 126 Oil Draining men 3 127 Fuel Tank ots 3 128 Fuel Tank Removal 3 128 Fuel Tank Installation 3 130 Fuel Tank and Cap Inspection 3 130 Fuel Tank Cleaning 3 131 Evaporative Emission Control System California Model 3 132 Parts Removal Installation 3 132 Hose Inspection 3 132 Separator Inspection 3 132 Separator Operation Test 3 133 Canister Inspection 3 133 3 4 FUEL SYSTEM Exploded View CAL 6002293BW5 C FUEL SYSTEM DFI 3 5 Exploded View To
448. stand for engine balance GH04076BS1 GHO4077BS1 ENGINE REMOVAL INSTALLATION 8 9 Engine Removal Installation e Install the engine mounting bolts and nuts following the specified installing sequence OFirth install the middle engine mounting bracket A and tighten the bracket bolts B temporally OSecond tighten the following bolts and nuts temporally C Lower Engine Mounting Bolt and Nut D Collar E Middle Engine Mounting Bolt and Nut F Left Upper Engine Mounting Bolt G Right Upper Engine Mounting Bolt 6GH040788W2 C OThird tighten the left upper engine mounting bolt A B Frame C Engine Torque Left Upper Engine Mounting Bolt 44 N m 4 5 kgf m 33 ft lb GH04079BS1 8 10 ENGINE REMOVAL INSTALLATION Engine Removal Installation OForth tighten the adjuster collar A with the lower engine mounting bolt B counterclockwise until the collar touches C the frame D Torque Lower Engine Mounting Bolt 9 8 N m 1 0 kgf m 87 in Ib OFifth tighten the lower and middle engine mounting bolt nuts following sequence Torque Lower Engine Mounting Nut E 44 N m 4 5 kgf m 33 ft Ib Middle Engine Mounting Nut F 44 N m 4 5 kgf m 33 ft lb OSixth tighten the middle engine mounting bracket bolts A Torque Middle Engine Mounting Bracket Bolts 25 N m 2 5 kgf m 18 ft Ib OSeventh remove the right upper engine mounting bolt A
449. sure Gauge 5 kgf cm 57001 125 875701255 C Carburetor Drain Plug Wrench Hex 3 57001 1269 875712695 Oil Level 57001 1290 ST571290ST C Hand Tester 57001 1394 7571394ST C Throttle Sensor Setting Adapter 1 57001 1400 875714005 C Needle Adapter Set Throttle Sensor Setting Adapter 57001 1538 57001 1457 8 5714578 C Sensor Harness Adapter 57001 1561 Fuel Pressure Gauge Adapter 57001 1593 Fuel Hose 57001 1607 8 5715615 C 7571593ST C 7571607ST C FUEL SYSTEM DFI 3 13 Special Tools and Sealant Kawasaki Bond Silicone Sealant 56019 120 875601205 C 3 14 FUEL SYSTEM DFI Parts Location Inlet Air Pressure Sensor A Inlet Air Temperature Sensor Nozzle Assy C Fuel Pump D Air Switching Valve A Subthrottle Valve Actuator B Stick Coils 1 2 3 4 C Throttle Body Assy D Subthrottle Sensor A Main Throttle Sensor B Water Temperature Sensor C Battery A Kawasaki Self Diagnosis System KDS Connector B Exhaust Butterfly Valve Actuator C Atmospheric Pressure Sensor D ECU Electronic Control Unit E Exhaust Butterfly Valve A amp ou FUEL SYSTEM DFI 3 15 DFI Parts Location Camshaft Position Sensor A Crankshaft Sensor B Gear Position Switch A Speed Sensor B Fuse Box with ECU M
450. sure Line Right after Ignition Switch ON with fuel pump running for 3 seconds with engine idling Fuel Pump Type Discharge Primary Fuel Injectors Type Nozzle Type Resistance Secondary Fuel Injectors Nozzle Type Resistance Main Throttle Sensor Input Voltage Output Voltage Resistance Inlet Air Pressure Sensor Atmo spheric Pressure Sensor Input Voltage Output Voltage Inlet Air Temperature Sensor Resistance Output Voltage at ECU Water Temperature Sensor Resistance Output Voltage at ECU Speed Sensor Input Voltage at Sensor Output Voltage at Sensor 1 300 50 r min rpm Oval type 38 mm 1 5 in 27 3 1 0 kPa 205 10 mmHg Denso Digital memory type with built in igniter sealed with resin 294 kPa 3 0 kgf cm 43 psi with fuel pump running 280 kPa 2 9 kgf cm 41 psi with fuel pump stopped In tank pump in fuel tank or Wesco pump friction pump 67 mL 2 27 US oz or more for 3 seconds INP 288 Fine atomizing type with 8 holes About 11 7 12 3 at 20 C 68 F Multihole type with 8 holes About 10 5 Q at 20 C 68 F Non adjustable and non removable DC 4 75 5 25 V between BL and BR BK leads DC 1 04 0 015 V between Y W and BR BK leads at idle throttle opening 4 6 DC 4 75 5 25 V between BL and BR BK leads DC 3 80 4 20 V at standard atmospheric pressure see this text for details 1 6 3 7 kQ at 20 C 68 F 0 24 0 43 at 80 C 176 F
451. sure Sensor Service Cote 2 Inlet Air Pressure Sensor Inlet Air Pressure Sensor Installation Inlet Air Pressure Sensor Input Voltage Inspection Inlet Air Pressure Sensor Output Voltage Inspection Inlet Air Temperature Sensor Service Code 13 e Des Inlet Air Temperature Sensor Remowval Installation Inlet Air Temperature Sensor Output Voltage Inspection Inlet Air Temperature Sensor Resistance Inspection Water Temperature Sensor Service Code T4 iiis eee Water Temperature Sensor Remowval Installation Water Temperature Sensor Output Voltage Inspection 3 4 3 10 3 12 3 14 3 16 3 21 3 23 3 23 3 27 3 30 3 35 3 35 3 36 3 38 3 38 3 40 3 43 3 43 3 43 3 44 3 45 3 47 3 47 3 47 3 47 3 48 3 52 3 52 3 52 3 53 3 54 3 54 3 54 Water Temperature Sensor Resistance Inspection Atmospheric Pressure Sensor Service Code 15 Atmospheric Pressure Sensor Atmospheric Installation Atmospheric Input Voltage Inspection Atmospheric Pressure Sensor Output Voltage Inspection Crankshaft Sensor Service
452. sure sensor Inspect and repair or replace see chapter 3 hose Atmospheric pressure sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Inlet air temperature sensor trouble nspect see chapter 3 Main throttle sensor trouble Inspect see chapter 3 Subthrottle sensor trouble Inspect see chapter 3 Subthrottle valve actuator trouble Inspect see chapter 3 Knocking Fuel poor quality or incorrect Fuel charge Use the gasoline recommended in the Owner s Manual Spark plug incorrect Replace it with the correct plug see chapter 2 Stick coil trouble Inspect see chapter 16 ECU trouble Inspect see chapter 3 Engine vacuum not synchronizing Inspect and adjust see chapter 2 Inlet air pressure sensor trouble Inspect see chapter 3 Atmospheric pressure sensor trouble Inspect see chapter 3 3 34 FUEL SYSTEM DFI DFI System Troubleshooting Guide Symptoms or Possible Causes Actions chapter Water temperature sensor trouble Inspect see chapter 3 Inlet air temperature sensor trouble Inspect see chapter 3 Miscellaneous Subthrottle sensor trouble Inspect see chapter 3 Subthrottle valve actuator trouble Inspect see chapter 3 Speed sensor trouble Inspect see chapter 3 Throttle valves will not fully open Engine overheating Water temperature sensor
453. t Fork Disassembly 13 15 13 16 Inner Tube 13 17 Dust Seal risDectiomts cct eoe edits 13 18 Spring Tension 13 18 Rear Shock Absorber e av ied ee antes 13 19 Rebound Damping Force 13 19 Compression Damping Force Adjustment pp 13 19 Spring Preload Adjustment 13 20 Rear Shock Absorber Removal ae 13 21 Rear Shock Absorber Installation 2 1211 13 21 Rear Shock Absorber Inspection 13 21 Rear Shock Absorber Scrapping RN 13 22 SWINGIN H Swingarm itis attrice Ree Ip oe Stoeb andes Swingarm Installation Swingarm Bearing REMOVAL ccs aci aei sav atest 13 25 Swingarm Bearing Installation pp 13 25 Swingarm Bearing Sleeve Inspection 2 2041 13 26 Chain Guide Inspectionm 13 26 13
454. t Air om Sansor Pressure I Sensor a Sz 2 3 License Plate i8 Light 12V5W Rear Right i8 Turn Signal Light 12V21W 5 ail Brake Light LED 12 0 1 1 69 denne 5 5 R Lef onnector 5 ear Left 3 Ground TUR d v1 Turn Signal Rear Vehicle Signal 1 52 Light 12V2iN Brake down Relay 5 59 Light Sensor Switch 1 Starter Fuel Notor Reserve Immobilizer Main Engine Switch Fuel Kawasaki Fuse Ground Pump Self Relay Box 30A diagnositic i Relay 4 Fuel Pump System 2 Headlight Relay Connector Relay Starter 3 ECU Wain Relay Circuit Relay LB Light Blue 0 Orange Pink IGNITION SWITCH CONNECTIONS Ignition Tailt a lgnition ignition BR BL GY PU Purple R Red w White Yellow 98052 02950 W2RO295D85 C 16 12 ELECTRICAL SYSTEM Wiring Diagram Other than United States Canada Australia and Malaysia Right Switch Housing 1 Front Brake 1 Engine Light Switch 7 Head Right Switch 2 Engine Stop Hom Housing witch xygen Oxygen Ground O O00 starter Button GH Gz Stop Watch br ed t Button Spack Plugs Meter Unit OOOO Mot XY e Turn Signal Indicator Light LED Horn die Primaly Fuel Injectors High Beam
455. t Exhaust Pipe see Front Exhaust Pipe Removal in the Engine Top End chapter Oil Pan Bolts A Clamp B Oil Pan C GG06033BS2 Oil Pan Installation Replace the oil pan gasket A with a new one e Install the dowel pins B e Install the clamp C as shown Rear View D GG06034BS2 C 7 10 ENGINE LUBRICATION SYSTEM Oil Pan Tighten the oil pan bolts as shown sequence 1 20 in the figure Torque Oil Pan Bolts 9 8 N m 1 0 kgf m 87 in Ib GG06035BS2 C ENGINE LUBRICATION SYSTEM 7 11 Oil Pressure Relief Valve Oil Pressure Relief Valve Removal e Remove Oil Pan see Oil Pan Removal Oil Screen A e Remove the oil pressure relief valve A Oil Pressure Relief Valve Installation e Apply a non permanent locking agent to the threads of the oil pressure relief valve A and tighten it CAUTION Do not apply too much non permanent locking agent to the threads This may block the oil pas sage Torque Oil Pressure Relief Valve 15 1 5 kgf m 11 ft lb e Clean the oil screen B e Install the O ring C and damper D to the oil screen e Install the oil screen so that the crankcase rib E and relief valve fits the oil screen e Install the oil pan see Oil Pan Installation GG08003BS2 C 7 12 ENGINE LUBRICATION SYSTEM Oil Pressure Relief Valve Oil Pressure Relief Valve Inspection e Remove the oil pressure re
456. t Manifold Holder Nuts 17 1 7 13 Exhaust Pipe Mounting Bolt 28 2 8 21 Exhaust Manifold Holder Studs stopped Front Camshaft Chain Guide Bolt Lower 12 1 2 106 in Ib Front Camshaft Chain Guide Bolt Upper 25 2 5 18 Muffler Body Clamp Bolt 17 1 7 12 Muffler Body Mounting Bolts 28 2 8 21 Muffler Rear Cover Bolts 6 9 0 70 61 in lb Muffler Slide Cover Bolts 6 9 0 70 61 in Ib Muffler Upper Cover Bolts 6 9 0 70 61 in Ib Upper Camshaft Chain Guide Bolt 25 2 5 18 Spark Plugs 13 1 3 113 in Ib Oxygen Sensors 25 2 5 18 Throttle Body Assy Holder Clamp Bolts 2 9 0 30 26 in Ib Throttle Body Holder Bolts 12 1 2 106 in Ib L Water Passage Plugs 20 2 0 15 L Clutch Clutch Cover Bolts M6 L 40 mm Clutch Cover Bolts M6 L 25 mm Clutch Hub Nut Clutch Lever Clamp Bolts Clutch Spring Bolts Sub Clutch Hub Bolts 4 Lubrication System Oil Filler 2 0 0 20 2 8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Nem kgfm Fib Remarks Air Bleed Bolt 9 8 1 0 87 Engine Oil Drain Bolt 29 3 0 22 Oil Cooler Oil Filter Case Mounting Bolts 20 2 0 15 L Oil Pump Gear Bolt 9 8 1 0 87 in Ib L Oil Cooler Mounting Bolts 20 2 0 15 Oil Filter 31 3 2 23 G R Oil Filter Guard Bolts 4 0 0 41 35 in lb L Oil Filter Holder Bolt 25 2 5 18 L Oil Pan Bolts 9 8 1 0 87 Oil Passage Nozzle 4 9 0 50 43 in lb Oil Passage Plugs Taper 20 2 0 15 L Oil Passage Plug Left Sid
457. t burns form hot engine oil that will drain through the oil passage when the gauge adapter is removed e Apply a non permanent locking agent to the oil passage plug and install it Torque Oil Passage Plug Taper 20 N m 2 0 kgf m 15 ft lb ENGINE LUBRICATION SYSTEM 7 21 Oil Pressure Switch Oil Pressure Switch Removal e Drain the engine oil see Engine Oil Change in the Peri odic Maintenance chapter Remove the right lower fairing see Lower Fairing Re moval in the Frame chapter e Slide out the rubber boot A e Loosen the oil pressure switch terminal bolt B and re move the switch lead C e Remove the oil pressure switch D Oil Pressure Switch Installation e Apply silicone sealant to the threads of the oil pressure Switch A and tighten it Sealant Kawasaki Bond Silicone Sealant 56019 120 Torque Oil Pressure Switch 15 N m 1 5 kgf m 11 ft Ib e Install the switch lead B direction as shown Front View C e Tighten Torque Oil Pressure Switch Terminal Bolt Hand tighten e Apply high temperature grease to the switch terminal D e Slide back the rubber boot to the original position GG13007BS1 NOTE OApply a small amount grease to the terminal so that grease should not close two breather holes A for switch diaphragm 9013004851 C ENGINE REMOVAL INSTALLATION 8 1 Engine Removal Installation Table of Contents Exploded
458. t fork oil level uneven Shock absorption unsatisfactory Too hard Front fork oil excessive Front fork oil viscosity too high Rear shock absorber adjustment too hard Tire air pressure too high Front fork bent 17 34 APPENDIX Troubleshooting Guide Too soft Tire air pressure too low Front fork oil insufficient and or leaking Front fork oil viscosity too low Rear shock adjustment too soft Front fork rear shock absorber spring weak Rear shock absorber oil leaking Brake Doesn t Hold Air in the brake line Pad or disc worn Brake fluid leakage Disc warped Contaminated pad Brake fluid deteriorated Primary or secondary cup damaged in master cylinder Master cylinder scratched inside Battery Trouble Battery discharged Charge insufficient Battery faulty too low terminal voltage Battery cable making poor contact Load excessive e g bulb of excessive wattage Ignition switch trouble Alternator trouble Wiring faulty Regulator rectifier trouble Battery overcharged Alternator trouble Regulator rectifier trouble Battery faulty MODEL APPLICATION Year Model Beginning Frame JKAZXAP107A000001 2007 ZX600P7F JKAZX600PPA000001 ZX600P 000001 O This digit in the frame number changes from one machine to another Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Consumer Products amp Machinery Company Part No 99924 1382 01 Printed in Japan
459. t rod I of the drive shaft side is shorter than the shift rod J of output shaft side e Apply molybdenum disulfide solution to the transmission gears x marks K e Install the spacer L on the output shaft e Apply grease to the O ring M and install it to its position on the output shaft g U Us d Hc F1 5 H ues CR UID m 6113361892 C Transmission Assy Installation e Assemble the transmission assy see Transmission Assy Assembly e Be sure that the dowel pins are in position e Install the transmission assy on the crankcase e Tighten the transmission case bolts Torque Transmission Case Bolts M8 A 20 N m 2 0 kgf m 15 ft Ib Transmission Case Bolts M6 B 9 8 N m 1 0 kgf m 87 in lb CRANKSHAFT TRANSMISSION 9 41 Transmission e Install the gear positioning lever see External Shift Mech anism Installation e Set the gear positioning lever to the neutral position A e Check that the drive and output shaft turn freely 9113344851 e Apply grease to the O ring A and install it to its position on the output shaft B e Install the collar C e When installing the oil seal D install it as follows OApply grease to the lip of the oil seal OApply oil to the outer circumference of the oil seal so that it will go into place smoothly OPress and insert the oil seal in the crankcase so that the surface of the oil seal is flus
460. tch starter lockout switch side stand switch and relay box x If their parts are normality replace the ECU GPIO0BSSS P 16 44 ELECTRICAL SYSTEM Ignition System IC Igniter Inspection OThe IC igniter is built in the ECU A e Refer to the Interlock Operation Inspection Ignition Sys tem Troubleshooting chart and Fuel System DFI chapter for ECU Power Supply Inspection ELECTRICAL SYSTEM 16 45 Ignition System Ignition System Circuit 9 9 BL Y R H Y 8k bm li i 68 10423844 1 Ignition Switch 14 Engine Stop Switch 2 Joint Connector 15 Cylinder Head Cover Ground 3 Starter Lockout Switch 16 Spark plugs 4 Fuse Box 17 Stick Coils 5 ECU Fuse 10 A 18 Camshaft Position Sensor 6 Ignition Fuse 10 A 19 Main Throttle Sensor 7 Relay Box 20 Gear Position Switch 8 ECU Main Relay 21 Side Stand Switch 9 Inter Lock Circuit 22 Crankshaft Sensor 10 Joint Connector B 23 ECU 11 Main Fuse 30 24 Vehicle down Sensor 12 Frame Ground 25 Immobilizer Antenna Equipped Models 13 Battery 12 V 8 Ah 26 Immobilizer Amplifier Equipped Models 16 46 ELECTRICAL SYSTEM Electric Starter System Starter Motor Removal e Remove Starter Clutch Cover A see Idle Gear Removal in the Crankshaft Transmission chapter e Slide back the rubber cap B e Remove Starter Motor Terminal Bolt
461. ted on the rim C and that the clip is hooked over the rib D Left Side E Right Side F 6J04074BS1 C 6J04088BS1 C WHEELS TIRES 10 13 Tires Air Pressure Inspection Adjustment e Refer to the Air Pressure Inspection in the Periodic Main tenance chapter see Air Pressure Inspection in the Peri odic Maintenance chapter Tire Inspection e Refer to the Wheel Tire Damage Inspection in the Peri odic Maintenance chapter see Wheel Tires Damage In spection in the Periodic Maintenance chapter Tire Removal e Remove Wheel see Front Rear Wheel Removal Valve Cap Valve Core Let out the air e To maintain wheel balance mark the valve stem position on the tire with chalk so that the tire can be reinstalled in the same position Chalk Mark or Yellow Mark A Air Valve B Align C e Lubricate the tire beads and rim flanges on both sides with a soap and water solution or rubber lubricant This helps the tire beads slip off the rim flanges CAUTION Never lubricate with engine oil or petroleum distil lates because they will deteriorate the tire e Remove the tire from the rim using a suitable commer cially available tire changer NOTE OThe tires cannot be removed with hand tools because they fit the rims too tightly Tire Installation A WARNING Use the same manufacture s on both front and rear wheels e Inspect the rim and tire and replace them if necessary e Clean the sea
462. the Fuel System chapter Alternator Lead Connector A Gear Position Sensor Lead Connector B Water Temperature Sensor Lead Crankshaft Sensor Lead Clamps C Heat Insulation Rubber Plate D 15 18 FRAME Engine Cover Heat Insulation Rubber Plate Installation e Install the heat insulation rubber plate A in throttle body 2 3 B so that the white paint face C up e Install Water Temperature Sensor Lead D Alternator Lead E Gear Position Sensor Lead F Crankshaft Sensor Lead G Coolant Hose H Breather Hose I Starter Motor Lead J Battery Negative Cable K Clamps with Main Harness L Clamp with Speed Sensor Lead of Main Harness M Clamp N 9012000851 FRAME 15 19 Fenders Front Fender Removal e Remove Brake Hose Clamps A Both Side Bolts B Both Side Remove the front fender assy e Remove Bolts A Separate the front fender cover and front fender G008010BS1 Front Fender Installation e Install the front fender assy to the front fork e Tighten Torque Front Fender Mounting Bolts 3 9 N m 0 40 kgf m 35 in Ib e Install the brake hose clamps to the front fender holes Flap and Rear Fender Removal e Remove Seats see Rear Front Seat Removal Seat Cover see Seat Cover Removal Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Bolts A Both Side Muffler Cover B e Remove Clamps A Connect
463. the O ring Immediately blow the chain dry with compressed air after cleaning Complete cleaning and drying the chain within 10 minutes e Apply oil to the sides of the rollers so that oil will penetrate to the rollers and bushings Apply the oil to the O rings so that the O rings will be coated with oil e Wipe off any excess oil Oil Applied Areas A O ring B Drive Chain Slack Inspection NOTE OCheck the slack with the motorcycle setting on its side stand OClean the chain if it is dirty and lubricate it if it appears dry e Check the wheel alignment see Wheel Alignment Inspec tion e Rotate the rear wheel to find the position where the chain is tightest e Measure the vertical movement chain slack A midway between the sprockets x If the chain slack exceeds the standard adjust it Chain Slack Standard 30 40 mm 1 2 1 6 in GK04060781 C 8812021 81 o 2 30 PERIODIC MAINTENANCE Maintenance Procedure Drive Chain Slack Adjustment Remove the cotter A and loosen the axle nut e Loosen the both chain adjuster locknuts C x If the chain is too loose turn out the left and right chain adjuster D evenly xIf the chain is too tight turn in the left and right chain adjusters evenly and kick the wheel forward e Turn both chain adjusters evenly until the drive chain has the correct amount of slack To keep the chain and wheel properly aligned the notch E on
464. the crankshaft main journal 6105041781 Crankshaft Main Journal Diameter Standard 30 984 31 000 mm 1 2198 1 2205 in Service Limit 30 96 mm 1 2189 in xIf any journal has worn past the service limit replace the crankshaft with a new one xIf the measured journal diameters are not less than the service limit but do not coincide with the original diameter markings D on the crankshaft make new marks on it 9105251851 C Crankshaft Main Journal Diameter Marks None 30 984 30 992 mm 1 2198 1 2202 in 1 30 993 31 000 mm 1 2202 1 2205 in Crankshaft Main Journal Diameter Marks 1 mark or no mark 9 26 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods e Measure the main bearing inside diameter and mark the upper crankcase half in accordance with the inside diam eter A Crankcase Main Bearing Inside Diameter Marks O mark or no mark Tighten the crankcase bolts to the specified torque see Crankcase Assembly in this chapter NOTE OThe mark already on the upper crankcase half should almost coincide with the measurement 9105242851 Main Bearing Inside Diameter O 34 000 34 008 mm 1 3386 1 3389 in None 34 009 34 016 mm 1 3390 1 3392 in e Select the proper bearing insert A in accordance with the combination of the crankcase and crankshaft coding Size Color B 6105041781
465. the hoses according to Cable Wire and Hose Routing section in the Appendix chapter 6017036881 3 22 FUEL SYSTEM DFI Servicing Precautions OReplace the fuel hose A if it has been sharply bent or kinked OThe motorcycle is not properly handled the high pressure inside the fuel line can cause fuel to leak or the hose to burst Bend and twist the fuel hose while examining it Replace the hose if any cracks or bulges are noticed OTo maintain the correct fuel air mixture F A there must be no inlet air leaks in the DFI system Be sure to install the oil filler plug A after filling the engine oil Torque Oil Filler Plug 1 5 N m 0 15 kgf m 13 in Ib FUEL SYSTEM 3 23 Troubleshooting the DFI System The warning indicator light LED A is used for the FI indicator immobilizer indicator immobilizer models and oil pressure warning indicator GP17880CS1 Outline When a problem occurs with DFI system the warning in dicator light LED A and Fl warning symbol B blinks to alert the rider In addition the condition of the problem is stored in the memory of the ECU For models equipped with an immobilizer system the warning indicator light LED and immobilizer warning symbol C blinks when a prob lem occurs in the system QU 123 9017902652 With the engine stopped and turned the self diagnosis mode the service code A is displa
466. the specified voltage Charging Voltage Connections Tester Range Reading Tester to Tester to 25 V DC Battery Battery 14 2 15 0 V e Turn off the ignition switch to stop the engine and discon nect the hand tester x If the charging voltage is kept between the values given in the table the charging system is considered to be working normally xIf the charging voltage is much higher than the values specified in the table the regulator rectifier is defective or the regulator rectifier leads are loose or open x If the charging voltage does not rise as the engine speed increases then the regulator rectifier is defective or the alternator output is insufficient for the loads Check the alternator and regulator rectifier to determine which part is defective 16 34 ELECTRICAL SYSTEM Charging System Charging System Circuit oe BR BR BATTERY GG OS w i GP092068W2 C Ignition Switch Load Main Fuse 30 A Starter Relay Battery 12 V 8 Ah Frame Ground Alternator Regulator rectifier ELECTRICAL SYSTEM 16 35 Ignition System Ignition System Troubleshooting Faulty ignition No spark Battery Inspection Charge or replace battery Good Ignition system wiring No good Repair or replace and connector inspection damaged part Good No good Spark plug inspect
467. the speed sensor connector A with the battery B 10 resistor C and hand tester D as shown e Set the tester to the DC 25 V range Special Tool Hand Tester 57001 1394 GP18032BS1 C e Trace A each side of the speed sensor surface with the Screw driver OThen the tester indicator should flick B x lf the tester indicator does not flick replace the speed sensor V 1 GP18078BS1 16 108 ELECTRICAL SYSTEM Switches and Sensors Fuel Reserve Switch Inspection e Remove Left Side Cover see Side Cover Removal in the Frame chapter Fuel Pump Lead Connector A e Fill the fuel tank with fuel Close the fuel tank cap surely e Connect the test light A 12 V 3 4 W bulb in a socket with leads and the 12 V battery B to the fuel pump connector C Connections Battery 12 V 3 4 W Bulb one side 12 V 3 4 W Bulb other side R BK Lead Terminal Battery BK W Lead Terminal BESTE IE x lf the test light turn on the reserve switch is defective Replace the fuel pump e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Fuel Pump see Fuel Pump Removal in the Fuel System DFI chapter e Connect the test light 12 V 3 4 W bulb in a socket with leads and the 12 V battery to the fuel pump connector as shown 12 V Battery A Test Light B Fuel Pump Connector C Fuel Reserve Switch D x lf the test light doesn t light repla
468. then repeats this cycle A Bee uio mmo GP30372BS1 e Turn the user key 1 OFF and remove off the user key 1 OThe warning indicator light LED A blinks to display the registration mode NOTE OTurn off the ignition switch and wait for the period of 15 seconds or more The registration mode automatically MS a ME finishes and the warning indicator light LED will switch ce na off OThis procedure registered the master key and one user GP30370B81 key OContinue with the procedure to register the second and later keys before the 15 seconds period has elapsed ELECTRICAL SYSTEM 16 85 Immobilizer System Equipped Models e Insert the user key 2 to the ignition switch and turn it ON OIf there is any problem in the registration the warning indicator light LED A blinks to display the collation error Immobilizer Amplifier Failure 0 2second GP30374BS1 C When Registered User Key is Inserted 0 5second 0 5second A 8 E xg GP30376BS1 User Key Collation Error 0 3second A Be ULL GP30373BS1 C e The user key 2 is registered in the ECU OThe warning indicator light LED A blinks 3 times and stops for 1 second and then repeats this cycle OThis procedure has registered the master key and 2 user keys e Continue with the procedure to register an additional 3
469. thout any maintenance if it is used under normal conditions COOLING SYSTEM 4 1 Cooling System Table of Contents Exploded Specifications e tete in Special Tools Coolant Flow Chart Coolant etie etd biete Coolant Deterioration Inspection Coolant Level Coolant Draining Coolant Filling acne teet ete Pressure Testing Cooling System Flushing Coolant Reserve Tank Removal Coolant Reserve Tank Installation Water Pump 4 Water Pump Removal Water Pump Installation Water Pump Impeller Disassembly Assembly pp Water Pump Impeller Inspection Water Pump Housing Disassembly Water Pump Housing Assembly Mechanical Seal Inspection PRRAGIALOR Radiator and Radiator Fan Removal Radiator and Radiator Fan Installation Radiator Inspection Radiator Cap Inspection Radiator Filler Neck Inspection Thermostat eti tete Thermostat Remowval Thermostat Installation Thermostat Inspection Hoses and Pipes
470. tifier Removal Regulator Rectifier Inspection Charging Voltage Inspection Ignition System Crankshaft Sensor Removal Crankshaft Sensor Installation Crankshaft Sensor Inspection Crankshaft Sensor Peak Voltage Stick Coil Removal Stick Coil Installation Stick Coil Stick Coil Primary Peak Voltage Spark Plug Removal Spark Plug Installation Spark Plug Clean and Inspection Camshaft Position Sensor Camshaft Position Sensor Installation Camshaft Position Sensor 16 41 Position Peak Voltage 16 42 Interlock Operation Inspection 16 43 IC Igniter Inspection 16 44 Electric Starter System 16 46 Starter Motor Remowval 16 46 Starter Motor Installation 16 46 Starter Motor Disassembly 16 47 Starter Motor Assembly 16 47 Brush Inspection 16 48 Commutator Cleaning and 16 48 Armature 16 49 Brush Lead Inspection 16 49 Right hand End Cover
471. ting section in the Appendix chapter Make sure they do not get pinched or kinked ORoute hoses with a minimum of bending so that the air or vapor will not be obstructed Set A the joint lock as shown e Insert the fuel hose joint A straight onto the delivery pipe B until the hose joint clicks e Push the joint lock C until the hose joint clicks e Connect the fuel pump connector and the battery cable terminal Fuel Tank and Cap Inspection e Visually inspect the gasket A on the tank cap for any damage Replace the gasket if it is damaged Check to see if the water drain pipe and fuel breather pipe C California Model in the tank are not clogged Check the tank cap breather also x If they are clogged remove the tank and drain it and then blow the breather free with compressed air CAUTION Do not apply compressed air to the air vent holes D in the tank cap This could cause damage and clogging of the labyrinth in the cap FUEL SYSTEM DFI 3 131 Fuel Tank Fuel Tank Cleaning A WARNING Clean the tank in a well ventilated area and take care that there are no sparks or flame anywhere near the working area Because of the danger or highly flammable liquids do not use gasoline or low flash point solvents to clean the tank e Remove the fuel tank see Fuel Tank Removal e Remove the fuel pump see Fuel Pump Removal e Pour some high flash point so
472. tion at a right angle to the first x If the reading exceeds the service limit replace the guide NOTE OThe reading is not actual valve valve guide clearance because the measuring point is above the guide Valve Valve Guide Clearance Wobble Method Standard Exhaust 0 09 0 17 mm 0 0035 0 0067 in Inlet 0 03 0 10 mm 0 0012 0 0039 in Service Limit Exhaust 0 38 mm 0 015 in Inlet 0 30 mm 0 012 in GE15007BS2 C ENGINE TOP END 5 29 Valves Valve Seat Inspection Remove the valve see Valve Removal in this chapter e Check the valve seating surface A between the valve B and valve seat C OMeasure the outside diameter D of the seating pattern on the valve seat x If the outside diameter is too large or too small repair the seat see Valve Seat Repair in this chapter Valve Seating Surface Outside Diameter Standard Exhaust 22 8 23 0 mm 0 898 0 906 in Inlet 26 9 27 1 mm 1 059 1 067 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 If the width is too wide too narrow or uneven J repair the seat see Valve Seat Repair in this chapter Valve Seating Surface Width GET8011782 C Standard Exhaust 0 8 1 2 mm 0 031 0 047 in Inlet 0 5 1 0 mm 0 020 0 039 in Valve Seat Repair e Repair the valve seat with the valve seat c
473. tions to ECU Meter G W lead terminal 25 8017808081 6 Meter BR BK lead terminal 28 Output Voltage Usable Range DC 3 80 4 20 V at the standard atmospheric pressure 101 32 kPa 76 cmHg abs NOTE OThe output voltage changes according to the local at mospheric pressure OThe atmospheric sensor output voltage is based on a nearly perfect vacuum in the small chamber of the sensor So the sensor indicates absolute atmospheric pressure x If the output voltage is within the usable range check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see ECU Removal Installation 3 58 FUEL SYSTEM Atmospheric Pressure Sensor Service Code 15 x If the output voltage is far out of the usable range check the output voltage at the sensor connector A when the wiring is open the output voltage is about 1 8 V Connect a digital meter to the harness adapter leads Atmospheric Pressure Sensor B Special Tool Sensor Harness Adapter 57001 1561 Atmospheric Pressure Sensor Output Voltage Connections to Sensor Meter G W lead C Meter BR BK lead D Output Voltage at Sensor Usable Range DC 3 80 4 20 V at the standard atmospheric pressure 101 32 kPa 76 cmHg abs x If the output voltage is normal check the wiring for conti nuity LI xIf the output voltage is out of the usab
474. tivated 1 2 Service Code 33 83 Equipped Models Oxygen Sensor 1 Service Code 33 Oxygen Sensor 2 Service Code 83 Oxygen Sensor Removal Installation e Refer to Oxygen Sensor Removal and Installation in the Electrical System chapter see Oxygen Sensor Removal in the Electrical System chapter Oxygen Sensor Inspection NOTE OThe oxygen sensor itself is the same for 1 A and 2 B but wiring of the main harness side is different e Warm up the engine thoroughly e Turn the ignition switch OFF e Remove the right middle fairing see Right Middle Fairing Removal in the Frame chapter e Connect a digital voltmeter A to the each oxygen sensor connector B sensor side using the needle adapter set Special Tool Needle Adapter Set 57001 1457 Oxygen Sensor Output Voltage Connections to Oxygen Sensor Connector Meter BK lead Meter lead e Remove the air cleaner housing see Air Cleaner Housing Removal e Remove the air switching valve hoses A both sides from the air suction valve cover e Insert the suitable plugs A both sides in the holes and shut off the secondary air e Reinstall the air cleaner housing see Air Cleaner Housing Installation e Turn the ignition switch ON e Start the engine and let it idle e Measure the output voltage of the sensor with the con nector joined Oxygen Sensor Output Voltage with Plugs Standard 0 45 2 5 V FUEL S
475. ton B e During the MODE button pushing the unit of the distance C and temperature D change every time the RESET button E is pushed within 2 seconds If the meter function does not work replace the meter assembly NOTE OMile Km Display can alternate between English and metric modes mile and km in the digital meter Make sure that km or mile according to local regulations is correctly displayed before riding GP17872BS1 Check 5 Clock Setting Check Connect the leads in the same circuit as Check 1 Set the ODO mode A by pushing the MODE button e Push the REST button C for more than two seconds OThe clock setting menu hour and minute D should flash e Push the RESET button OThe hour display A starts flashing e By pushing the MODE button each time check that the hour display changes alij GP17808BS1 ELECTRICAL SYSTEM 16 69 Meter Gauge Indicator Unit decides and minute display A starts flashing e By pushing the MODE button each time check that the e By pushing the RESET button check that the hour display XU minute display changes GP17809BS1 C e By pushing the RESET button check that the hour and minute display start flashing e By pushing the MODE button check that the hour and 70545 display decide 0 e When both hour and minute display is flashing by push 7779 ing the RESET button che
476. tor light LED does not go on inspect or replace the following item Headlight High Beam Bulb see Headlight Bulb Replace ment in the Electrical System chapter Dimmer Switch see Wiring Diagram in the Electrical System chapter Harness see Wiring Inspection in the Electrical System chapter Headlight Fuse 10 A see Fuse Inspection in the Electri cal System chapter Headlight Relay see Relay Circuit Inspection in the Electrical System chapter Turn off the engine stop switch e The low beam and high beam headlights should stay go ing on x lf the headlights and high beam indicator light LED does go off inspect or replace the following item Headlight Relay see Relay Circuit Inspection in the Electrical System chapter e Turn off the ignition switch The headlights and high beam indicator light LED should go off Headlight Aiming Inspection e Inspect the headlight beam for aiming x lf the headlight beam points to one side rather than straight ahead adjust the horizontal beam Headlight Beam Horizontal Adjustment Turn the horizontal adjuster A in both headlights in or out until the beam points straight ahead x lf the headlight beam points too low or high adjust the vertical beam Headlight Beam Vertical Adjustment e Turn the vertical adjuster B in both headlights in or out with a screwdriver to adjust the headlight vertically NOTE OON high beam the brightest points should be slightly bel
477. trical System Lights and switches operation inspect e Headlight aiming inspect e e Side stand switch operation inspect Engine stop switch operation inspect year e e Others Chassis parts lubricate year Bolts nuts tightness inspect For higher odometer readings repeat at the frequency interval established here Service more frequently when operating in severe conditions dusty wet muddy high speed or frequent starting stopping CAL California Model PERIODIC MAINTENANCE 2 5 Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY Whichever come first CHANGE REPLACE ITEM Every Air cleaner element Fuel hose 4 years Coolant 3 years Radiator hose and O ring 3 years Engine oil year Oil filter year Brake hose and pipe 4 years al Brake fluid 2 years Rubber parts of master cylinder and caliper 4 years Spark plug e e e e For higher odometer readings repeat at the frequency interval established here Service more frequently when operating in severe conditions dusty wet muddy high speed or frequent starting stopping 2 6 PERIODIC MAINTENANCE Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non permanent locking agent or silicone sealant etc Letters used in the Remarks column mean AL Tighten the
478. trouble Inspect see chapter 3 Subthrottle valve actuator trouble Inspect see chapter 3 Engine vacuum not synchronizing Inspect and adjust see chapter 2 Inlet air pressure sensor trouble Inspect see chapter 3 Atmospheric pressure sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Inlet air temperature sensor trouble Inspect see chapter 3 Engine stalls easily Spark plug dirty broken or gap maladjusted Inspect and replace see chapter 2 Stick coil trouble Inspect see chapter 16 Camshaft position sensor trouble Inspect see chapter 16 Main throttle sensor trouble Inspect see chapter 3 Subthrottle sensor trouble Inspect see chapter 3 Subthrottle valve actuator trouble Inspect see chapter 3 Fuel Injector rouble inspect see chapter 3 inspect see chapter 3 Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump see chapter 3 Fuel line clogged Inspect and repair see chapter 3 Poor acceleration Fuel pressure too low Inspect see chapter 3 Water or foreign matter in fuel Change fuel Inspect and clean fuel system see chapter 3 Fuel filter or pump screen clogged Inspect and replace fuel pump see chapter 3 Fuel pump trouble Inspect see chapter 3 Fuel Injector trouble Inspect see chapter 3 3 32 FUEL SYSTEM DFI DFI System Troubleshooting Gui
479. ts and nuts are treated with an anti rust solution Clean the bolts nuts and connecting rods well ventilated area and take care that there is no spark or flame anywhere near the working area This in cludes any appliance with a pilot light Because of the danger or highly flammable liquids do not use gasoline or low flash point solvents to clean them CAUTION Immediately dry the bolts and nuts with com pressed air after cleaning Clean and dry the bolts and nuts completely e Install new bolts in reused connecting rods e Apply a small amount of molybdenum disulfide oil solution to the following Threads A of Nuts and Bolts Seating Surfaces B of Nuts and Connecting Rods 6105040481 C e First tighten the nuts to the specified torque see table below e Next tighten the nuts 180 OMark A the connecting rod big end caps and nuts so that nuts can be turned 180 B properly Connecting Torque Angle Rod Assy PONU N m in Ib Use the bolts attached to new 11 8 1 2 104 180 6105235881 con rod Another new bolts ard nuls 11 8 1 2 104 180 Replace the bolts and nuts with 11 8 1 2 104 180 new ones CAUTION Be careful not to overtighten the nuts 9 22 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods Crankshaft Connecting Rod Cleaning e After removing the connecting rods fro
480. tton for more than 2 seconds e Check the following items OThe number 39 A and FI B in the display appear and flash OThe warning light LED C flashes e Push the MODE button for more than 2 seconds e Check the following items OThe display returns ODO mode from number 39 OThe FI in the display and warning light LED flash x If the meter unit does not work replace the meter assem bly NOTE OThe number 39 is service code of Self Diagnosis see Fuel System chapter It is the service code of the meter communication line error OThe number 39 and FI in the display disappear when the meter unit is connected to main harness of the normal motorcycle GP17888BS1 ELECTRICAL SYSTEM 16 67 Meter Gauge Indicator Unit Check 3 MODE BUTTON Operation Check the leads in the same circuit as Check 1 Check that the display A change to the ODO TRIP and STOP WATCH displays each time the mode selector but ton B is pressed Olf the fuel level warning indicator light LED blinked C display change to FUEL ODO TRIP and STOP WATCH x lf the display function does not work replace the meter assembly NE 008200 FUEL GP17889BS1 C Check 4 Unit Changing Check e Connect the leads in the same circuit as Check 1 GP17846BS1 16 68 ELECTRICAL SYSTEM Meter Gauge Indicator Unit e Set the ODO mode by pushing the MODE but
481. uartz halogen Low 12 V 55 W quartz halogen Tail Brake Light 12 V 0 1 1 6 W LED Alternator Type Three phase AC Rated Output 31 A 14 V 5 000 r min rpm Specifications subject to change without notice and may not apply to every country 1 12 GENERAL INFORMATION Unit Conversion Table Prefixes for Units Units of Length Prefix Bones km x 062144 mile mega x 1000 000 xa oa ccr Hi kilo 1 000 x 0 03937 in centi x 0 01 milli x 0 001 Units of Torque micro x 0 000001 N m x 01020 kgfm N m x 07376 ftlb Nm x 8 851 Units of Mass x 9 807 Nm kg x 2 205 z Ib kgfm X 7 233 TER g x 0 03527 oz kgfm x 86 80 inlb Units of Volume Units of Pressure L x 0 2642 gal US kPa x 0 01020 Kata L x 0 2200 gal imp kPa 0 1450 L x 1 057 qt US kPa 0 7501 cmHg L x 0879 te ee ee L x 2 113 pint US kgf cm 14 22 psi L x 1 816 pint imp cmHg x 1 333 kPa mL x 0 03381 oz US mL x 0 02816 oz imp Units of Speed mL x 0 06102 cu in km h x 0 6214 mph Units of Force Units of Power N x 0 1020 kg kW x 1 360 PS N x 02248 lb m URN NE LEE E kg x 9 807 N PS X 0 7355 kW kg x 2 205 Ib PS x 0 9863 HP Units of Temperature 9 C 40 5 F 40 SUUM cdd SUE AU 32 68 104 176 212 248 284 40 80 100 120 140 160 180 200 220 240 260 280 300 PERIODIC MAINTENANCE 2 1 Periodic Maintenance Table of Conte
482. uct into the slits B on the air cleaner housing e Do not twist the ducts C 9607042851 Install Air Cleaner Frame Gasket A Air Cleaner Case Gasket B Air Cleaner Air Element Gasket C Air Element D Upper Air Cleaner Housing E Screws F e Tighten Torque Air Cleaner Housing Screws 1 1 N m 0 11 kgf m 9 7 in lb e Install Air Cleaner Housing see Air Cleaner Housing Installa tion GC07043BS2 FUEL SYSTEM DFI 3 127 Air Cleaner Oil Draining A drain hose is connected to the bottom of the air cleaner part to drain water or oil accumulated in the cleaner part e Visually check the catch tank end if the water or oil accu mulates in the tank xIf any water or oil accumulates the hose remove the tank A from the drain hose and drain it A WARNING Be sure reinstall the tank in the drain hose after draining Oil on tires will make them slippery and can cause an accident and injury 3 128 FUEL SYSTEM Fuel Tank Fuel Tank Removal A WARNING Gasoline is extremely flammable and can be explo sive under certain conditions Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Turn the ignition switch OFF Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately e Turn the ignition switch OFF e Wait until the engine cools do
483. uction of equipment This manual contains four more symbols in addition to WARNING and CAUTION which will help you distinguish different types of informa tion NOTE OThis note symbol indicates points of par ticular interest for more efficient and con venient operation Indicates a procedural step or work to be done Olndicates a procedural sub step or how to do the work of the procedural step it follows It also precedes the text of a NOTE Indicates a conditional step or what action to take based on the results of the test or inspec tion in the procedural step or sub step it fol lows In most chapters an exploded view illustration of the system components follows the Table of Contents In these illustrations you will find the instructions indicating which parts require spec ified tightening torque oil grease or a locking agent during assembly GENERAL INFORMATION 1 1 General Information Table of Contents T Model IdentifICatiOn oi ep e e EE rte ren Gt er i agr ef e a General Specifications Unit Conversion Table 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 se
484. uel Pump Relay 17 Fuel Pump 9 Relay Box 18 Air Switching Valve 3 94 FUEL SYSTEM Oxygen Sensor Heaters 1 2 Service Code 67 Equipped Models Oxygen Sensor Heater Removal Installation The oxygen sensor heater is bult in the oxygen sensor So the heater itself can not be removed Remove the oxy gen sensor see Oxygen Sensor Removal in the Electrical System chapter Oxygen Sensor Heater Inspection e Remove Right Middle Fairing see Right Middle Fairing Removal in the Frame chapter e Disconnect the each oxygen sensor lead connectors A e Set the hand tester A to the x 1 O range and connect it to the terminals in the oxygen sensor lead connector B White Lead Terminal C White Lead Terminal D Special Tool Hand Tester 57001 1394 Oxygen Sensor Resistance Standard about 8 at 20 C 68 F x lf the tester reading is not as specified replace the oxygen sensor with a new one BCI79 6C 5 x lf he tester reading is specified check the power source voltage Inspection NOTE OBe sure the battery is fully charged Connect a digital meter A to each oxygen sensor con nector B using the needle adapter C Special Tool Needle Adapter Set 57001 1457 Oxygen Sensor Heaters Power Source Voltage Connections to Oxygen Sensor Connector Tester W main harness side P BK lead D Tester Battery Terminal E Oxygen Sensor 1 F
485. ure Absolute Pv 100 900 mmHg Backups by ECU If the main throttle sensor system fails the output voltage is out of the usable range wiring short or open the ECU locks ignition timing into the ignition timing at closed throttle position and sets the DFI in the D J method If the inlet air pressure sensor system fails the signal is out of the usable range wiring short or open the ECU sets the DFI in the a N method 1 Inlet Air Temperature Sensor Water Temperature Sensor Inlet Air Temperature 47 178 C Water Temperature Tw 30 120 C If the inlet air temperature sensor system fails the signal is out of the usable range wiring short or open the ECU sets Ta at 30 C If the water temperature sensor system fails the signal is out of the usable range wiring short or open the ECU sets Tw at 80 C When an radiator fan is turning on ECU sets Tw at 110 C Atmospheric Pressure Sensor Crankshaft Sensor Atmospheric Pressure Absolute Pa 100 900 mmHg Crankshaft sensor must send 22 signals to the ECU at the 1 cranking If the atmospheric pressure sensor system fails the signal is out of the usable range wiring short or open the ECU sets Pa at 760 mmHg the standard atmospheric pressure If the crankshaft sensor generates less than 22 or more signals the engine stops by itself Camshaft Position Sensor Speed Sensor Camshaft position
486. user keys 0 30 30 3 0 30 3 1second NOTE nm OThe ECU can store up the six key codes master key x 8030371881 1 and user key x 5 User Key Indicator Flashes Warning Warning Indicator Indicator Light LED Light LED Blinks Stop User Key 3 4 times 1 seconds Repeat User Key 4 1 seconds Repeat User Key 5 1 seconds Repeat e Turn OFF the ignition switch and wait for period of more than 15 seconds e The registration mode automatically ends 16 86 ELECTRICAL SYSTEM Immobilizer System Equipped Models e FI indicator light goes off A GP30370BS1 e Remove the key registration unit and connect the immo bilizer Kawasaki self diagnostic system connector NOTE the ignition switch ON with the registered user key OCheck that the engine can be started using all regis tered user keys ELECTRICAL SYSTEM 16 87 Immobilizer System Equipped Models Spare User Key Registration Flow Chart Repay faded parts in case of system lt Key registry pigment sort master and turn it ON pe mastar ECU checks Wiernng indicator light dE aps blinking NOTE2 OK Blinking Patterns and Number 0 2secon4 Hhinnnnnnnnnnannns 0 8 Verfies Seecerd 8 Seecond Warning indicator igh binkng Pattern 2 rm Repair tated parts in case 0 Jeecand teecend OFF and remove master Of entem adu
487. utters A Special Tools Valve Seat Cutter Holder Bar C 57001 1128 Valve Seat Cutter Holder 4 B 57001 1275 For Exhaust Valve Seat Valve Seat Cutter 45 524 5 57001 1113 Valve Seat Cutter 32 25 57001 1118 Valve Seat Cutter 60 525 57001 1328 For Inlet Valve Seat Valve Seat Cutter 45 530 57001 1187 Valve Seat Cutter 32 30 57001 1120 Valve Seat Cutter 60 527 57001 1409 If the manufacturer s instructions are not available use the following procedure GE15048BS1 C 5 30 ENGINE TOP END Valves Seat Cutter Operation Care 1 This valve seat cutter is developed to grind the valve for repair Therefore the cutter must not be used for other purposes than seat repair 2 Do not drop or shock the valve seat cutter or the dia mond particles may fall off 3 Do not fail to apply engine oil to the valve seat cutter before grinding the seat surface Also wash off ground particles sticking to the cutter with washing oil NOTE ODo not use a wire brush to remove the metal particles from the cutter It will take off the diamond particles 4 Setting the valve seat cutter holder in position operate the cutter in one hand Do not apply too much force to the diamond portion NOTE OPrior to grinding apply engine oil to the cutter and dur ing the operation wash off any ground particles sticking to the cutter with washing oil 5 After use wash it with washing oil and apply thin
488. valve and run the other end of the hose into a container e Bleed the brake line and the caliper ORepeat this operation until no more air can be seen com ing out into the plastic hose 1 Pump the brake lever until it becomes hard and apply the brake and hold it A 2 Quickly open and close B the bleed valve while hold ing the brake applied 3 Release the brake C NOTE OThe fluid level must be checked often during the bleed ing operation and replenished with fresh brake fluid as necessary If the fluid in the reservoir runs completely out any time during bleeding the bleeding operation must be done over again from the beginning since air will have entered the line OTap the brake hose lightly from the caliper to the reser voir for more complete bleeding OFront Brake First bleeding the right caliper then repeat the above steps for the left caliper e Remove the clear plastic hose GL09041BS2 C BRAKES 12 21 Brake Fluid e Install Diaphragm Diaphragm Plate B Front Brake Reservoir e Follow the procedure below to install the front rear brake fluid reservoir cap correctly OFirst tighten the brake fluid reservoir cap B clockwise C by hand until the resistance is felt fully then tighten the cap an additional 1 6 turn D while holding the brake fluid reservoir body A e Tighten Torque Front Brake Reservoir Cap Stopper Screw 1 2 N m 0 12 kgf m 11 in Ib e Ti
489. valve is fully opened or completely closed Output Voltage at ECU Standard DC 1 08 4 60 V at subthrottle valve full opening to closing CAUTION Do not remove or adjust the subthrottle sensor It has been adjusted and set with precision at the fac tory Never drop the throttle body assy can especially on a hard surface A shock to the sensor can damage it CC Gs 80179110651 C 3 72 FUEL SYSTEM DFI Subthrottle Sensor Service Code 32 xIf the output voltage is within the standard range check the ECU for a good ground and power supply see ECU Power Supply Inspection If the ground and power sup ply are good replace the ECU see ECU Removal Instal lation x If the output voltage is far out of the standard range e g when the wiring is open the reading is 0 V check the output voltage again at the sensor connector e Disconnect the subthrottle sensor connector A and con nect the harness adapter B between the harness con nector and subthrottle sensor connector Connect a digital meter to the harness adapter leads Special Tool Throttle Sensor Setting Adapter 57001 1538 Subthrottle Sensor Output Voltage Connections to Sensor Meter BR lead Meter lead Measure the sensor output voltage with the engine stopped and with the connector joined e Turn the ignition switch ON e Measure the output voltage when the subthrott
490. ve actuator D with bracket E e Remove Exhaust Butterfly Valve Actuator Pulley A OHold the pulley with a suitable tool B CAUTION If the pulley bolt is removed without holding the actuator damage will occur Exhaust Butterfly Valve Actuator Installation e Install the bracket on the actuator B Washers Nuts D 6617930651 3 90 FUEL SYSTEM Exhaust Butterfly Valve Actuator Service Code 63 e Fit the hole side A of the pulley to the groove side B of the actuator e Install the pulley A on the actuator e Hold the pulley with a suitable tool B and tighten the bolt Torque Exhaust Butterfly Valve Actuator Pulley Bolt 4 9 N m 0 50 kgf m 43 in Ib CAUTION If the pulley bolt is tightened without holding the actuator damage will occur e Confirm the pulley angle A 41 7 7 as shown It is original position of the pulley NOTE OCorrect the position electrically after confirming the use is discontinued and there is no damage when differing from the angle of shown in the figure CAUTION Do not correct the pulley position with the tool forcibly The actuator damage will occur 6617929651 xIf the angle is not within the specified angle adjust the actuator as follows OConnect the actuator connectors OTurn the ignition switch ON OConfirm the pulley turns clockwise and then cou
491. vel Engine Oil Change Oil Filter Replacement Table of Contents Oil Pressure Relief Valve Inspection pp Oll Pumps decet s Oil Pump Removal Oil Pump Installation Oil Pump Gear Removal Oil Pump Gear Installation Oil Pump Gear Shaft Removal Oil Pump Gear Shaft Installatiom nnne Oil Cooler enne Oil Cooler Remowval Oil Cooler Installation Oil Cooler Oil Filter Case Removal 8 8 8 Oil Cooler Oil Filter Case Oil Pressure Measurement Oil Pressure Measurement Oil Pressure Switch Oil Pressure Switch Removal Oil Pressure Switch Installation 7 2 7 4 7 5 7 6 7 8 7 8 7 8 7 9 7 9 7 9 7 11 7 11 7 11 7 12 7 13 7 13 7 14 7 15 7 15 7 16 7 16 7 17 7 17 7 17 7 18 7 19 7 20 7 20 7 21 7 21 7 21 7 2 ENGINE LUBRICATION SYSTEM Exploded View lt 27 Nd RN i ys VA A ST CE Ni 3 595 0 SA LS 5 08802101845 C ENGINE LUBRICATION SYSTEM 7 3 Exploded View No Fastener Torque Remarks Nm kgf m ft Ib 1 Coolant Drain Bolt Water Pump 8 8 0 90 78 2 Oil Drain Bolt 29 3 0 22 3 Im
492. vice Code 33 83 Equipped 5 222222 Oxygen Sensor Removal Installa Oxygen Sensor Inspection Exhaust Butterfly Valve Actuator Sensor Service Code 34 Exhaust Butterfly Valve Actuator Sensor Removal Installation Exhaust Butterfly Valve Actuator Sensor Input Voltage Inspection Exhaust Butterfly Valve Actuator Sensor Output Voltage 1 5 Exhaust Butterfly Valve Actuator Sensor Inspection Immobilizer Amplifier Service Code 35 Equipped Models Antenna Resistance Inspection Amplifier Input Voltage Inspection Blank Key Detection Service Code User Key Inspection ECU Communication Error Service Code 39 bos ipea ECU Communication Line 1 5 Stick Coils 1 2 3 4 Service Code 51 52 53 54 Stick Coil Removal Installation Stick Coil Input Voltage Radiator Fan Relay Service Code Radiator Fan Relay Removal Installation Radiator Fan Relay Inspection Subthrottle Valve Actuator Service Subthrottle Valve Actuator Removal pp Subthrottle Valve Actuator 1 5 Subthrottle Valve Actuator Resistance Inspection
493. vice Limit 0 2 mm 0 01 in GJ04130BS1 GJ04043BS1 C WHEELS TIRES 10 11 Wheels Rims Balance Inspection Remove the front and rear wheels see Front Rear Wheel Removal e Support the wheel so that it can be spun freely e Spin the wheel lightly and mark A the wheel at the top when the wheel stops ORepeat this procedure several times If the wheel stops of its own accord in various positions it is well balanced x If the wheel always stops in one position adjust the wheel balance see Balance Adjustment Balance Adjustment e f the wheel always stops in one position provisionally attach a balance weight A on the rim at the marking using adhesive tape e Rotate the wheel 1 4 turn B and see whether or not the wheel stops in this position If it does the correct balance weight is being used x If the wheel rotates and the weight goes up replace the weight with the next heavier size If the wheel rotates and the weight goes down replace the weight with the next lighter size Repeat these steps until the wheel remains at rest after being rotated 1 4 turn e Rotate the wheel another 1 4 turn and then another 1 4 turn to see if the wheel is correctly balanced e Repeat the entire procedure as many times as necessary to achieve correct wheel balance e Permanently install the balance weight Balance Weight Removal e Insert a regular tip screw drivers A B between the rib C
494. vot adjusting collar D Pull out the pivot shaft right side of the motorcycle and remove the swingarm 13 24 SUSPENSION Swingarm Swingarm Installation e Apply plenty of grease to the lip A of the grease seals Screw the adjusting collar A into the frame so that the collar does not project the swingarm mating surface C e Place the washer A between swingarm left end and frame mating surface e Insert the pivot shaft A into the frame from the right side e Tighten the pivot shaft so that the clearance between the adjusting collar B and the ball bearing C come to 0 mm 0 in D Torque Swingarm Pivot Adjusting Collar 20 N m 2 0 kgf m 15 ft Ib Tighten the adjusting collar locknut A with the swingarm pivot nut wrench Special Tool Swingarm Pivot Nut Wrench 57001 1597 Torque Swingarm Pivot Adjusting Collar Locknut 98 Nm 10 kgf m 72 ft Ib GM06134BS1 C GMO06136BS1 C 0008276 P SUSPENSION 13 25 Swingarm e Tighten the pivot shaft nut Torque Swingarm Pivot Shaft Nut 108 N m 11 kgf m 81 ft lb e Install the removed parts see appropriate chapters Swingarm Bearing Removal e Remove Swingarm see Swingarm Removal Washer A Grease Seals B Sleeve C Circlip D Right Side Special Tool Inside Circlip Pliers 57001 143 e Remove the ball bearing and needle bearings Special Tool Oil Seal
495. will cause the engine braking effect to be more sudden resulting in rear wheel hop On the other hand if the free play is excessive the clutch lever may feel spongy or pulsate when pulled e Hold an extra drive shaft in a vise and install the following clutch parts on the shaft see Clutch Installation Spacer A Needle Bearing B Sleeve C Clutch Housing D Spacer E Clutch Hub F Sub Clutch Hub G Friction Plates 36 lining blocks H Steel Plates I Spring Seat J Spring K Friction Plates 48 lining blocks L Spring Plate M GF06151BS2 C 6 14 CLUTCH Clutch e Engage the clutch hub with the sub clutch hub To measure the free play set a dial gauge A against the raised center B of the clutch spring plate Move the clutch housing gear back and forth The dif ference between the highest and lowest gauge readings is the amount of free play Drive Shaft D e Measure the spring plate free play Spring Plate Free Play Usable Range 0 05 0 70 mm 0 002 0 028 in x lf the free play is not within the usable range change all of the friction plate and measure the free play again x lf the free play is not within the usable range adjust the free play see Spring Plate Free Play Adjustment Spring Plate Free Play Adjustment NOTE OThe free play adjustment is performed by replacing the steel plate s e Measure the clutch spring plate free pl
496. witch ON e While cranking the engine with the starter motor watch the test lights xIf the test lights flicker at regular intervals the injector circuit in the ECU and the wiring are good Perform the Injector Resistance Inspection in this chapter 6017024281 6617024351 FUEL SYSTEM DFI 3 111 Fuel Injectors Olnjector signals can be also confirmed by connecting the hand tester AC 10 V instead of the test light set to the injector main harness female connector Crank the en gine with the starter motor and check to see if the hand oscillates at regular intervals Special Tool Hand Tester 57001 1394 xIf the test light doesn t flicker or the test hand doesn t oscillates check the wiring and connectors again If the wiring is good check the injector voltage see Injector Voltage Inspection Injector Resistance Inspection e Set up the fuel tank see Air Cleaner Housing Removal e Disconnect the connector from the injectors A OFor the primary fuel injector 3 B remove the hose joint of the nozzle assy see Nozzle Assy Removal e Measure the injector resistance with the hand tester Special Tool Hand Tester 57001 1394 Secondary Fuel Injector Resistance Connections to Injectors Meter Meter 1 WIR Terminal 2 WIR OIG Terminal 3 WIR OIBK Terminal 4 WIR Terminal Standard About 10 5 at 20 C 68 F
497. with coolant and install the radiator cap NOTE OPour in the coolant slowly so that it can expel the air from the engine and radiator e Fill the reserve tank up to the full level line with coolant and install the cap CAUTION Soft or distilled water must be used with the an tifreeze see below for antifreeze in the cooling sys tem If hard water is used in the system it causes scales accumulation in the water passages and consider ably reduces the efficiency of the cooling system Water and Coolant Mixture Ratio Recommended Soft Water 50 50 Freezing Point 35 31 F Total Amount 2 6 L 2 7 US qt NOTE OChoose a suitable mixture ratio by referring to the coolant manufacturer s directions Bleed the air from the cooling system as follows OStart the engine with the radiator cap removed and run it until no more air bubbles A can be seen in the coolant OTap the radiator hoses to force any air bubbles caught inside OStop the engine and add coolant up to the radiator filler neck e Install the radiator cap e Start the engine warm it up thoroughly until the radiator fan turns on and then stop the engine Check the coolant level in the reserve tank after the en gine cools down xIf the coolant level is lower than the low level line add coolant to the full level line CAUTION Do not add more coolant above the full level line 6D050109S1 C
498. wn e Remove Fuel Tank Bolts A e Remove Front Seat see Front Seat Removal in the Frame chap ter Battery Terminal A Fuel Tank Bolt B Drain Hose C Fuel Pump Connector D Fuel Return Hose Red California model only Fuel Tank Breather Hose Blue California model only e Open the fuel tank cap A to lower the pressure in the tank e Draw the fuel out from the fuel tank with a commercially available pump A OUse a soft plastic hose B as a pump inlet hose in order to insert the hose smoothly OPut the hose through the fill opening C into the tank and draw the fuel out Front D A WARNING The fuel could not be removed completely from the fuel tank Be careful for remained fuel spillage GCO9033BS1 C FUEL SYSTEM DFI 3 129 Fuel Tank e Be sure to place a piece of cloth A around the fuel hose joint e Insert the screw driver into the slot C of the joint lock e Pull the joint lock A as shown e Pull the fuel hose joint B out of the delivery pipe A WARNING Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is disconnected fuel spills out from the hose and the pipe because of residual pressure Cover the hose connection with a piece of clean cloth to prevent fuel spillage 7 609832 P e Close the fuel tank cap e Remove the fuel tank and place it
499. x ceeds the service limit replace the crankcase 10 mm 0 39 in A 60 mm 2 36 in B Cylinder Inside Diameter Standard 67 000 67 012 mm 2 6378 2 6383 in Service Limit 68 09 mm 2 64 in Piston Wear Measure the outside diameter A of each piston 5 mm 0 20 in B up from the bottom of the piston at a right angle to the direction of the piston pin x If the measurement is under service limit replace the pis ton Piston Diameter Standard 66 975 66 990 mm 2 6368 2 6374 in Service Limit 66 83 mm 2 631 in Piston Ring Piston Ring Groove Wear e Check for uneven groove wear by inspecting the ring seat ing The rings should fit perfectly parallel to groove surfaces If not replace the piston and all the piston rings e With the piston rings in their grooves make several mea surements with a thickness gauge A to determine piston ring groove clearance Piston Ring Groove Clearance Standard Top 0 05 0 09 mm 0 0020 0 0035 in Second 0 03 0 07 mm 0 0012 0 0028 in Service Limit Top 0 19 mm 0 0075 in Second 0 17 mm 0 0067 in b 9105247851 9105248851 GE16183BS1 C 9 30 CRANKSHAFT TRANSMISSION Pistons Piston Ring Groove Width e Measure the piston ring groove width OUse a vernier caliper at several points around the piston Piston Ring Groove Width Standard Top A 0 84 0 86 mm 0 0331 0 033
500. y charged e Turn the ignition switch OFF Connect the peak voltage adapter A and a digital meter B to the connector C using the needle adapter set D Special Tools Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Needle Adapter Set 57001 1457 Subthrottle Valve Actuator Input Voltage Connections to Harness Connector 1 Meter G lead 1 Meter W BL lead 3 Il Meter BK BL lead 2 Meter P BL lead 4 Measure the actuator input voltage with the engine stopped and with the connector joined e Turn the ignition switch ON 9017925052 C Input Voltage at Sensor Standard About DC 8 5 10 5 V x If the reading is out of the range check the wiring to ECU xIf the wiring is good replace the ECU see ECU Re moval Subthrottle Valve Actuator Circuit 68617949041 C 1 ECU 2 Subthrottle Valve Actuator FUEL SYSTEM DFI 3 89 Exhaust Butterfly Valve Actuator Service Code 63 Exhaust Butterfly Valve Actuator Removal e Remove Seat Cover see Seat Cover Removal in the Frame chapter Put off the rubber boots of exhaust butterfly valve cables e Loosen the locknuts A and adjuster nut B OScrew in both adjusters until no adjusting the adjuster e Remove Bolts A Screw B Pull out the exhaust butterfly valve actuator e Remove Clamp A Exhaust Butterfly Valve Cables B Connectors C e Remove the exhaust butterfly val
501. y crush your hand or fingers OPull out the pistons by hand Remove the dust seals A and fluid seals Remove the bleed valve and rubber D Repeat the previous step to remove the pistons from the other side of the caliper body 9513201851 9513153851 C 2 58 PERIODIC MAINTENANCE Maintenance Procedure NOTE Olf compressed air is not available do as follows for both calipers coincidentally with the brake hose connected to the caliper OPrepare a container for brake fluid and perform the work above it ORemove the pad spring and pads see Front Brake Pad Removal in the Brakes chapter OPump the brake lever until the pistons come out of the cylinders and then disassemble the caliper Front Caliper Assembly e Clean the caliper parts except for the pads CAUTION For cleaning the parts use only disc brake fluid isopropyl alcohol or ethyl alcohol e Install the bleed valve and rubber cap Torque Bleed Valve 7 8 0 80 kgf m 69 in Ib e Replace the fluid seals A with new ones OApply silicone grease to the fluid seals and install them into the cylinders by hand Replace the dust seals with new ones if they are dam aged OApply silicone grease to the dust seals and install them into the cylinders by hand e Replace the O ring A e Apply brake fluid to the outside of the pistons and push them into each cylinder by ha
502. yed on the LCD Liquid Crystal Display by the number of two digits If the problem is with the following parts the ECU can not recognize these problem Therefore the warning indicator light LED Fl and or immobilizer warning symbols do not blinks and service code is not displayed LCD for Meter Unit Fuel Pump Secondary Fuel Injectors Stick Coil Secondary Wiring and Ground Wiring ECU Power Source Wiring and Ground Wiring 9017903652 3 24 FUEL SYSTEM DFI Troubleshooting the DFI System When the service code A is displayed for first ask the rider about the conditions B of trouble and then start to determine the cause C of problem As a pre diagnosis inspection check the ECU for ground and power supply the fuel line for no fuel leaks and for correct pressure The pre diagnosis items are not indicated by the warning indicator light LED and Fl warning symbol Don t rely solely on the DFI self diagnosis function use common sense Even when the DFI system is operating normally the warning indicator light LED and Fl warning symbol may blink under strong electrical interference Additional mea sures are not required Turn the ignition switch OFF to stop the indicator light LED and symbol If the warning indicator light LED and Fl warning symbol of the motorcycle brought in for repair still blinks check the service code When the repair has been done the FI warning symbol goes off But the se

Kawasaki ZX6R ZX600P7F service manual

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