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Kawasaki Z750S Servi..

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1. Gl tchi Eever and Cable d tee on ote e e RR e HR PR UR da Clutch Lever Free Play Inspection pe Clutch Lever Free Play Adjustment 2 2 0 1 0210 107 04201514100 Cable Removal A Cable Installation xr He Cable EubriCatiori cerises etie ette eere opc Re Clutch Lever 99 Clutch Lever ACIS seo a hd tato teurer 6 7 E0 ire gk 0011 6 8 Ree ced 6 8 Clutch Cover 9 6 8 Release Shaft Removal diea ere LA RE 6 8 Release Shaft Installation pp 6 8 Clutch Cover Disassembly irri re 6 9 P H 6 9 MEE 6 10 Cl tchilsemiovalts tienes hee ether ep ex E Par re eee rab te 6 10 Clutch Installation rite re zoo rot te eh 6 10 Clutch Plate Assembly Inspectigom esee 6 12 Clutch Plate Assembly Adjustment pp 6 12 Clutch Plate Wear Damage Inspection
2. aa 9 24 Transmission Shaft Installation pp 9 24 TRANSMISSION Shaft Disassembly 9 24 Transmission Shaft Assembly pp 9 25 Shift Drum and Fork 9 28 Shift Drum and Fork Installatigom 9 28 Shift Drum Disassembly cic acini 9 28 Shift 9 28 Shift Fork Bending 9 29 Shift Fork Gear Groove Wear Ne 9 29 Shift Fork Guide Pin Drum Groove 9 29 Gear Dog and Gear Dog Hole Damage 9 29 9 2 CRANKSHAFT TRANSMISSION Exploded View 4 mm m im LO Ale CRANKSHAFT TRANSMISSION 9 3 Exploded View No Fastener Remarks Nm kgf m ft Ib 1 Breather Plate Bolts 9 8 1 0 87 in lb L 2 Bolts M9 L 81 mm 42 4 3 31 3 Bolts 9 L 95 mm 42 4 3 31 4 Bolts M8 27 2 8 20 5 Crankcase Bolts M7 20 2 0 14 S 6 Crankcase Bolts M6 12 1 2 104 in Ib S 7 Starter Motor Clutch Bolts 12 1 2 104 in Ib L 8 Oil Pipe Holder Bolts 13 1 3 113 in Ib L 9 Shift Drum Bearing Holder Screw 5 4 0 55 48 in lb L 10 Shift Drum Bearing Holder Bolt 13 1 3 113 in Ib L 11 Connecting Rod Big End Nuts see the text l
3. 3 74 Subthrottle Valve Actuator Service Code 62 3 76 Subthrottle Valve Actuator 9 3 76 A dible Inspection ek aetna 3 76 Visual 3 76 Resistance 3 76 Input Voltage Inspection ei e 3 77 Fl Indicator Eight LED irt reno 3 78 Fi Indicator Might LED Leo os ADR Ree dene DO e tun p doe noc cera Dodo 3 79 m Tur 3 80 EGU RemoValsssccocdtt teret 3 80 EGU Installatiors s iio ree ete rere 3 80 ECU Power Supply 3 80 DEI Power SOUFGO ie iine to AR HE CI E 3 83 ECU Fuse RemioVal ect ei Pr RR Er cre b pe epe i re ded 3 83 ECU Fuse mem 3 83 ECU F s Inspection ec 3 83 ECU Main Relay tese uta 3 83 ECU Main Relay Inspection ede dete ke khe aie t ede 3 83 Fuel LMC PAR HIE UR ADR EO EE Ree POR TR 3 84 Fuel Pressure 3 84 Fuel ElowRate Irispectlon tmt tti Rei ERE A ERE a cts 3 85 Fuel PUMP re e i E E EAR beds 3 87 Fuel Pu
4. 11 6 11 6 Drive Chain Installation 4 11 6 Drive Chain ene 11 7 jeofe aeree EUR 11 11 Engine Sprocket REMOVal n eere t bt Co ex ob luae eir i iai 11 11 Engine Sprocket Installation ee o erp ei ieu etre eoe earns 11 11 Rear Sprocket 8 Rear Sprocket Coupling Bearing Removal Coupling Bearing Installation Coupling Installation Coupling Bearing 21 1244002 000000000000000 11 13 Coupling Bearing Lubrication pp 11 13 Coupling Damper Inspectionm 4 11 13 Sprocket Wear Inspection Ne 11 14 Rear Sprocket Warp Inspection RN 11 14 11 2 FINAL DRIVE Exploded View FINAL DRIVE 11 3 Exploded View No Fastener Torque Remarks N m kgf m ft Ib 1 Engine Sprocket Cover Bolts 9 8 1 0 87 6 2 Engine Sprocket Nut 125 13 92 3 Sprocket Nuts 59 6 0 43 4 Speed Sensor Cover Bolts 6 9 0 70 61 in Ib L 5 Speed Sensor Bolt 6 9 0 70 61 in Ib L 6 Rear Axle Nut 108 11 80 G Apply 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 i
5. Front Fender Installation Rear Fender Flap Removal 15 15 Rear Fender Removal enhn enhn enne nnns ener sene annis ase 15 16 Rear Fender installation Seah cate wench NEA EN deine ute 15 16 Battery Case Removal ir c er teinte b gue 15 17 Battery Case 15 17 SIde Starid 15 18 eidecStand GO 15 18 Side Stand rastallatiaor 2 i 15 18 Frane 15 19 15 2 FRAME Exploded View FRAME 15 3 Exploded View Torque No Fastener Nm kgf m 1 Footpeg Bracket Bolts 34 3 5 25 2 Footpeg Holder Bolts 34 3 5 25 L 3 Side Stand Bracket Bolts 49 5 0 36 L 4 Side Stand Bolt 44 4 5 33 5 Side Stand Switch Bolt 8 8 0 90 78 L 6 Bank Sensor Bolts L 7 Footpeg Rubber Mounting Bolts L 8 Frame Cover Bolts 0 3 0 03 in Ib G Apply grease L Apply a non permanent locking agent R Replacement Parts 15 4 FRAME Exploded View FRAME 15 5 Exploded View Torque No Fastener Nm ftlb Remarks 1 Windshield Bolts 0 4 0 04 4 in lb 2 Front Fender Bracket Bolts 8 8 0 90 78 in Ib L Front Fender Bolts 3 9 040 35inb 4 United States and Canadian Models
6. 1 Measure the clearance when engine is cold 2 Check present shim size 3 Match clearance in vertical column with present shim size in horizontal column 4 Install the shim specified where the lines intersect This shim will give the proper clearance Example Present shim is 2 95 mm Measured clearance is 0 45 mm Replace 2 95 mm shim with 3 20 mm shim 5 Remeasure the valve clearance and readjust if necessary 2 28 PERIODIC MAINTENANCE Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE EXHAUST Part wo 92180 1014 1016 1018 1020 1022 1024 1028 108 1030 1032 1034 1036 1038 1040 1042 1044 1046 1048 1080 1052 1054 sol ssl eol 6 75 ss so os 0 5 25 MARK 75 80 8 10 90 THIOKNESS 2 50 2 55 2 60 2 65 2 70 2 15 2 80 2 85 2 90 2 95 3 00 3 05 3 10 3 15 2 50 2 55 2 60 2 65 2 70 2 75 2 80 2 85 2 90 2 95 2 00 3 15 2 601 2 65 2 70 2 15 2 80 3 00 2 95 3 00 3 05 3 10 3 15 3 20 3 25 3 30 3 35 3 40 3 45 3 50 aas oa o5 3 35 3 40 3 45 3 50 oso 0 54 2 75 2 80 2 85 2 90 2 95 3 00 3 05 3 10 3 15 3 20 3 25 3 30 3 35 3 40 3 45 3 50 0 55 0 59 229 2 85 2 90 2 95 3 00 2 05 2 10 3 15 2 20 ast 0 60 0 64 2 85 2 90 2 95 3 00 3 05 3 10 3 20 3 25 3 30 3 35 3 40 3 45 3 50 0 65 0 69 2 90 2 95 3 00 3
7. 6 12 Clutch Plate Warp INSpection ener nennen nennen nrnnn nns 6 13 Clutch Spring Free Length Measurement pp 6 13 Clutch Housing Finger Irispectlon iiit te 6 13 Clutch Housing Spline Inspection pp 6 13 6 2 CLUTCH Exploded View 6202058815 C CLUTCH 6 3 Exploded View Torque No Fastener Nem fb Remarks 1 Clutch Lever Clamp Bolts 7 8 0 80 69 in Ib S 2 Clutch Cover Mounting Bolts 11 1 1 95 in Ib 3 Filler Plug 1 5 0 15 13 in Ib 4 Clutch Spring Bolts 8 8 0 90 78 in lb 5 Clutch Hub Nut 135 14 100 R CL Apply cable lubricant m 5 amp Apply engine Apply grease Apply high temperature grease Apply molybdenum disulfide grease Replacement Parts Follow the specific tightening sequence Apply water 6 4 CLUTCH Specifications ltem Standard Service Limit Clutch Lever Free Play 2 3 mm 0 08 0 12 in Clutch Clutch Plate Assembly 37 7 38 3 mm 1 48 1 51 in Friction Plate Thickness 2 72 2 88 mm 0 107 0 113 in 2 4 mm 0 094 in Friction and Steel Plate Warp 0 2 mm 0 008 in or less 0 3 mm 0 012 in Clutch Spring Free Length 80 6 mm 3 17 in 76 6 mm 3 02 in CLUTCH 6 5 Special Tool Clutch Holder Kawasaki Bond Silicone Sealant 57001 1243 92104 0004 gt 7571243ST C 879200045 6 6 CLUTCH Clutch Lev
8. 5 28 Cylinder Head Cover Installation 5 12 Cylinder Remowval 5 28 Camshaft Chain Tensioner 5 14 Cylinder Installation 5 28 Camshaft Chain Tensioner Piston Remowval 5 29 5 14 Piston Installation 5 29 Camshaft Chain Cylinder Wear 5 30 Installation 5 14 Piston Wear 5 30 Camshaft Camshaft Chain 5 15 Piston Ring Piston Ring Groove Camshaft Removal 5 15 WY ST V 5 31 Camshaft Installation 5 15 Piston Ring Groove Width 5 31 Camshaft Camshaft Cap Wear 5 16 Piston Ring Thickness 5 31 Camshaft Runout 5 17 Piston Ring End Gap 5 32 Wear n 5 17 Throttle Body Holder 5 33 Camshaft Chain Removal 5 17 Throttle Body Holder Installation 5 33 Cylinder 5 18 i ioter ost eite te eat states 5 34 Cylinder Compression Muffler Body Remowval 5 34 5 18 Exhaust Pipe Removal 5 34 Cylinder Head Removal 5 19 Muffler Body and Exhaust Pipe Cylinder
9. 20W 40 SAE 10W 50 Capacity 3 1L US qt when filter is not ai removed 3 3 L 3 5 US qt when filter is removed SAE 10W 30 3 8 L 4 0 US qt when engine is pue uma ae completely dry 6s09011BS1 NOTE OAlthough 10W 40 engine oil is the recommended oil for most conditions the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area e Check the oil level see Engine Lubrication System chap ter PERIODIC MAINTENANCE 2 49 Periodic Maintenance Procedures 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 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 N m 3 2 kgf m 23 ft lb 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 Fuel Hose Replacement e Remove the fuel tank see Fuel System DFI chapter OBe sure to place a piece of cloth around the fuel hose joint e Remove Hose Joint A Fuel Hose B Clamps C Fuel Pump Inlet Hose D e Install the pump inlet hose clamps as shown OThe pinch A direction inside
10. FUEL SYSTEM DFI 3 93 Fuel Injectors Output Voltage Inspection e Turn the ignition switch OFF e Remove the ECU see ECU section e Connect a digital voltmeter A to the ECU connector B with the needle adapter set C Special Tool Needle Adapter Set 57001 1457 Injector Output Voltage Connections to Injector 1 Meter BL R lead terminal 36 Meter Battery Terminal Connections to Injector 2 Meter BL G lead terminal 35 Meter Battery Terminal Connections to Injector 3 Meter BL BK lead terminal 49 Meter Battery Terminal Connections to Injector 4 Meter BL Y lead terminal 48 Meter Battery Terminal e Turn the ignition switch ON Output Voltage at Injector Connector Standard Battery Voltage 12 6 V or more xIf the output voltage is normal perform Injector Signal Test the output voltage is out of the standard turn the ignition switch OFF remove the fuel tank and check the injector wiring for continuity Injector Wiring Inspection ECU Connector Injector Connectors Terminal 36 Injector 1 Terminal BL R Terminal 35 Injector 2 Terminal BL G Terminal 49 Injector 3 Terminal BL BK Terminal 48 Injector 4 Terminal BL Y x If the wiring is good inspect the resistance of the injectors see Injector Resistance Inspection e Remove the needle adapter e Apply silicone seal
11. Main Throttle Sensor Service Code 11 Main Throttle Sensor Removal Adjustment 4 Input Voltage Output Voltage Resistance Inlet Air Pressure Sensor Service Code 12 2222222 1 1 0001111 enne tenens FREIMOVAl teet exi bee te he tete eene te aile Input Voltage Inspection Output Voltage Rna a a a a i yi Inlet Air Temperature Sensor Service Code 13 Output Voltage Inspect Sensor Resistance Inspection 4 Water Temperature Sensor Service Code 14 2 44400000 Removal lnstallation Qutp t Voltage Inspect O o Rte Ete 3 2 FUEL SYSTEM DFI Sensor Resistance Inspection pp 3 57 Atmospheric Pressure Sensor Service Code 15 4 3 58 Removal 3 58 Input Voltage Inspection ice rrr te rei tete s E avenues 3 58 Output Voltage Inspection pp 3 59 Crankshaft Sensor Service Gode 21 ot eH eite pat Lei Ecc posed tinae des 3 62 Crankshaft Sensor Removallnstallation 4 3 62 Crankshaft Sensor Inspection pp 3 62 Camshaft Position Sensor Ser
12. Immobilizer System Parts Replacement Immobilizer System Inspection Switches and 16 59 16 59 16 59 16 59 16 60 16 63 16 63 16 63 16 64 16 64 Brake Light Timing Inspection 16 93 Brake Light Timing Adjustment 16 93 Switch Inspection 16 93 Speed Sensor Inspection 16 93 Fuel Level Sensor Inspection 16 95 Fuel Reserve Switch Inspection 16 95 Diode Rectifier Inspection 16 96 Junction BOX pp 16 97 Junction Box Fuse Circuit 16 97 Starter Circuit Headlight Relay 16 98 Diode Circuit Inspection 16 99 gi 16 100 30 A Main Fuse Remowval 16 100 Junction Box Fuse Removal 16 100 15 A ECU Fuse Remowval 16 100 Fuse Installation 16 100 Fuse 16 101 ELECTRICAL SYSTEM 16 3 Parts Location 1 Starter Lockout Switch 4 Py O Wie 5 mm A a gt gt 2 Water Temperature Sen SOT Starter Motor Battery 12 V 8 Ah Junction Box ECU Main Fuse 15 A Radiator Fan Switch Radiator Fan Alternator Speed Sensor 11 Neutral Switch 12 Side S
13. OMark and record the valve lifter and shim locations so they can be reinstalled in their original positions Olf there is no clearance select a shim which is several sizes smaller and then measure the clearance e To select a new shim which brings the valve clearance within the specified range refer to the Valve Clearance Adjustment Charts e Apply a thin coat of molybdenum disulfide grease to the valve lifters e Install the camshafts Be sure to time the camshafts prop erly see Engine Top End chapter e any valve clearance that was adjusted Readjust if necessary CAUTION Do not put shim stock under the shim This may cause the shim to pop out at high rpm causing ex tensive engine damage Do not grind the shim This may cause it to fracture causing extensive engine damage AT ENT 6507022851 C PERIODIC MAINTENANCE 2 27 Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART INLET VALVE PRESENT SHIM lt Exanple eg 5 1022 1024 1026 1028 1090 1092 1034 1036 1038 1040 1042 1044 1046 1048 1050 1082 1054 soj 85 os 5 10 15 2 so 35 sof asl IT Fr oh EE a il ws Cal asl 0 00 oo MER 2 50 2 55 2 60 2 65 2 70 2 15 2 80 2 85 2 90 2 95 3 00 3 06 3 10 a 15 3 20 3 28 3 30 ooa oor 2 55 2 60
14. 8 06010151 C ELECTRICAL SYSTEM 16 19 Precautions Male Connectors B 8 06010251 C 16 20 ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection e Visually inspect the wiring for signs of burning fraying etc If any wiring is poor replace the damaged wiring e Pull each connector A apart and inspect it for corrosion dirt and damage the connector is corroded or dirty clean it carefully If it is damaged replace it e Check the wiring for continuity OUse the wiring diagram to find the ends of the lead which is suspected of being a problem OConnect the hand tester between the ends of the leads Special Tool Hand Tester 57001 1394 OSet the tester to the x 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 C D if necessary 8 07002851 C GPO7014BS2 C ELECTRICAL SYSTEM 16 21 Battery Battery Removal CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition switch is ON as this could damage the ECU Electronic Con trol Unit Never reverse the connections of the battery this could damage the ECU e Remove Seats see Frame Chapter e Disconnect the negative cable A e Slide out the positive terminal cap B and then discon nect the positive cable CAUTION Be sure to di
15. BK Y BR W BK Y 6C17818BW2 C Ignition Switch Relay ECU Main Fuse 15 Vehicle down Fuse 30 Starter Relay H Battery 12 V 8 Ah Joint Connector FUEL SYSTEM DFI 3 69 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 sensor especially on a hard surface Such a shock to the sensor can damage it Subthrottle Sensor Connector Black B Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Disconnect the subthrottle sensor black connector and connect the harness adapter A between these connec tors Connect a digital meter to the harness adapter lead Special Tool Throttle Sensor Harness Adapter 57001 1538 Measure the sensor input voltage with the engine stopped and with the connector joined e Turn the ignition switch ON Subthrottle Sensor Input Voltage Connections to Adapter Meter R sensor BL lead Meter BK sensor BR BK lead Standard 4 75 5 25 V DC e Turn the ignition switch OFF xIf the input voltage is normal check the sensor output cw voltage the input voltage is less than the standard remove the ECU
16. Standard Service Limit Crankshaft Runout 0 02 mm 0 0008 in TIR 0 05 mm or less 0 0020 in Crankshaft Main Bearing Insert Journal Clearance 0 020 0 044 mm 0 07 mm 0 0008 0 0017 in 0 0028 in Crankshaft Main Journal Diameter 32 984 33 000 mm 32 96 mm 1 2986 1 2992 in 1 2976 in Marking None 32 984 32 992 mm 1 2986 1 2989 in 1 32 993 33 000 mm 1 2989 1 2992 in 36 000 36 016 mm Crankcase Bearing Inside Diameter 1 4173 1 4179 in Marking O 36 000 36 008 mm P 1 4173 1 4176 in None 36 009 36 016 mm m 1 4177 1 4179 in Crankshaft Main Bearing Insert Thickness Brown 1 490 1 494 mm 0 0587 0 0588 in Black 1 494 1 498 mm 0 0588 0 0590 in Blue 1 498 1 502 mm 0 0590 0 0591 in Crankshaft Main Bearing Insert Selection Crankcase Main Crankshaft Main Bearing Insert Bearing Inside Journal Diameter Diameter Marking Marking Size Color Part Number Journal Nos 92028 1868 92028 1829 1 2 4 None 1 92028 1867 3 5 Black 92028 1828 1 2 4 2028 1 None None Blue ore 92028 1827 1 2 4 The bearing inserts for Nos 1 2 and 4 journals have groove respectively 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 2
17. Control Unit R EGU BR R BL Y License Plate ud ain Light 125 rm Rear Right BK Y Turn Signal Light 12 10 BL R e ati LED 12V0 8 3 8W l R Kawasak i Self diagnasitic lt System t sk ge eer ie Y Y Sur Turn Signal SY EM vt T Light 12 108 PH 55 Yo Fuse ae 15 ss gelf diagnosis lad fret Ex Terminal Bkyy gt BK Y TD Starter 5 dh Set Circuit Rear Joint Brake Connector B Light Fuel Switch Pump Color Code Turn Vehicle Signal down VN ac ena Relay Sensor ue st Blue Pump er Brom Relay Starter Le Green Weser Wain Fuse 30A Light Blue ae SWITCH TTE cept eem RIGHT SWITCH HOUSING CONNECTIONS Front Brake Light Switch Engine Stop Switch Starter Button Brake Lever Tite sie ome ror eae roar oa 98052 01754 WDRO175AWS C ON 16 18 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems Learn and ob serve all the rules below ODo not reverse the battery lead connections This will burn out the diodes on the electrical parts OAlways check battery condition before condemning other parts of an electrical system A fully charged
18. 75 Nm 7 6 55 ft lb 98 200 r min rpm HR 73 7 4 kgf m 54 ft lb 08 200 r min rpm US FI Fuel Injection KEIHIN TTK34 x 4 Electric starter Battery and coil transistorized Electronically advanced digital igniter From 10 BTDC 91 100 r min rpm to 37 BTDC 5 800 r min rpm NGK CR9EK or ND U27ETR Left to right 1 2 3 4 1 2 4 3 38 BTDC 66 ABDC 284 57 BBDC 31 1 10 GENERAL INFORMATION General Specifications ltems Duration Lubrication System Engine Oil Type Viscosity Capacity Drive Train Primary Reduction System Type Reduction Ratio Clutch Type Transmission Type Gear Ratios 1st 2nd 3rd 4th 5th 6th Final Drive System Type Reduction Ratio Overall Drive Ratio ZR750 K1 268 Forced lubrication wet sump API SE SF or SG API SH or SJ with JASO MA SAE 10W 40 3 8 L 4 0 US qt Gear 1 714 84 49 Wet multi disc 6 speed constant mesh return shift 2 571 1 941 1 599 1 333 1 200 1 095 36 14 33 17 28 18 28 21 24 20 23 21 Chain drive 2 867 43 15 5 382 gear Caster Rake Angle Trail Front Tire Type Size Rear Tire Type Size Front Suspension Type Wheel Travel Rear Suspension Type Wheel Travel Brake Type Front Rear Tubular diamond 25 107 mm 4 2 in Tubeless 120 70 ZR17 M C 58W Tubele
19. ENGINE LUBRICATION SYSTEM 7 11 Oil Pump Oil Pump Removal e Drain Coolant see Periodic Maintenance chapter Engine Oil see Periodic Maintenance chapter e Remove Water Pipe Bolts A Water Pipes B pull out e Remove Neutral Switch Lead A Water Pump Cover Bolts B Clamp C Water Pump Cover D e Remove Impeller Bolt A Washer B Impeller C e Remove Water Pump Body A Oil Pump Cover B Oil Water Pump Shaft C Outer Rotor D Inner Rotor E Oil Pump Installation e Apply engine oil Inner Rotor Outer Rotor Oil water Pump Shaft e Install the outer rotor A into the crankcase e Install the pin B inner rotor C and oil water pump shaft D OTurn the pump shaft so that the slot E in its shaft fits onto the projection F of the pump drive gear shaft 6009029851 C 7 12 ENGINE LUBRICATION SYSTEM Oil Pump e Fit the pin A of the pump cover into the hole in the crankcase e Apply Grease O ring Install Pins A Water Pump Body B e Apply Coolant Mechanical Seal Surface Sealing Seat Surface Install Impeller A Washer and Bolt B Pins C Torque Water Pump Impeller Bolt 9 8 N m 1 0 kgf m 87 in Ib e Apply grease to the O ring A e Insert the water pump cover B to the water pipe C e Tighten the water pump cover bolts Torque Water Pump Cover Bolts 11 N m 1 1 kgf m 95 in Ib e Install Wate
20. GF04010BS1 C CLUTCH 6 7 Clutch Lever and Cable Clutch Lever Adjustment The adjuster has 5 positions so that the clutch lever posi tion can be adjusted to suit the operator s hand Push the lever forward and turn the adjuster A to align the number with the arrow mark B on the lever holder OThe distance from the grip to the lever is minimum at num ber 5 and maximum at number 1 6 8 CLUTCH Clutch Cover Clutch Cover Removal e Remove Engine Oil drain see Engine Oil Change in the Periodic Maintenance chapter Clutch Cable Lower End A Clutch Cover Mounting Bolts B e Turn the release lever A toward the rear as shown and remove the clutch cover B About 90 C Clutch Cover Installation e Apply silicone sealant to the area A where the mating surface of the crankcase touches the clutch cover gasket Sealant Kawasaki Bond Silicone Sealant 92104 0004 e Replace the clutch cover gasket with a new one e Tighten the clutch cover mounting bolts Torque Clutch Cover Mounting Bolts 11 N m 1 1 kgf m 95 in lb Release Shaft Removal CAUTION Do not remove the clutch release lever and shaft assembly unless it is absolutely necessary If re moved the oil seal replacement may be required e Remove the clutch cover see Clutch Cover Removal e Pull the lever and shaft assembly straight out of the clutch cover Release Shaft Installation e Apply high temp
21. Button Joint Connector 2 Hazard Button 3 Turn Signal Switch 4 Dimmer Switch 5 6 LEFT SWITCH HOUSING CONNECTIONS Hazard Button Turn Signal Switeh Dimmer Switch Starter Lockout Switch Passing Button cm cl EHE at EM E ee rem fret ft et to I omi Potted omimo Pulte in rusk oo LT eee Nain Relay Junction 1 ACC Fuse 2 Radiator 3 Headlight Fuse 4 Headlight Relay 5 6 Igniton Fuse 7 Fuse 8 Starter 9 Turn Signal Box 10 Fan 10 10 Taillight Fuse 10 10 10 Circuit Relay Relay Fuse 10 210175 5 C ELECTRICAL SYSTEM 16 17 Wiring Diagram Malaysia Water Sub Wain Speed Camshaft Inlet Air Temperature throttle Throttle Sensor Postion Temperature Atmospheric 598597 Inlet Air 1 2 3 4 Sensor Sensor Sensor Sensor Pressure ZY Pressure E Li Cy Sensor Sensor Q Q Qi g5 g5 ge g5 T T Pressure Crank Side n 1 2 Sag Switch shaft Stand zt 25 Sensor Switch E m 8 s Neutral Seiten 1 7 FRRERERSE BRyBK moet m BR BK H BR BK H BR BK 1 1 Meter Ground 3 z 2 Frame Ground 1 Joint See zx Connector D 2 55 3 _ Alternator BK BK BK BK Electronic
22. Caliper Rubber Parts Replacement Spark Plug Replacement 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 x 1 000 km x 1 000 mile 30 36 INSPECTION 20 24 Fuel System Air cleaner element clean Throttle control system play smooth return no drag inspect Choke operation inspection year 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 IAR year inspect Evaporative Emission Control System CAL 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 Air Suction System Air suction system damage inspect Engine Top End Clutch ssi Clutch operation play disengagement ee engagement inspect WheelsandTires Tire air pressure inspect year e 2 30 Wheel tire damage inspect P pun 2 30 e aan Wheel bearin
23. GNOS5015BS1 C 14 8 STEERING Steering Stem Settle the inner races in place as follows OTighten the steering stem nut with 39 N m 4 0 kgf m 29 ft lb of torque first and loosen it a fraction of a turn until it turns lightly Afterward tighten it again with specified torque using a stem nut wrench A in the direction shown OCheck that there is no play and the steering stem turns smoothly without rattles If not the steering stem bearings may be damaged Special Tool Steering Stem Nut Wrench 57001 1100 Torque Steering Stem Nut 27 N m 2 8 kgf m 20 ft lb e Install the claw washer 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 Install Front Fork A temporally Stem Head B Olnstall the fork so that the top end C of the outer tube is flush with the upper surface D of the steering stem head bracket e Install the washer E and tighten the stem head bolt F with specified torque NOTE OTighten the fork upper clamp bolts first next the stem head nut last the fork lower clamp bolts OTighten the two clamp bolts alternately two times to en sure even tightening torque Torque Steering Stem Head Bo
24. gt Kawasaki Z750S 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 gt 1 Appendix Kawasaki 2750 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 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 and without incurring an obligation to make such changes to p
25. 16 78 ELECTRICAL SYSTEM Immobilizer System Equipped Models Spare User Key Registration Flow Chart Blinking Patterns and Number mg 2 Saecend 0 Seecend 2g 350406 TPaecond 3 6193 23 Passend 4 P Anan 5 Se ECU checks user 1 NOTES 0 daecore OK Hhnnnnnnnnnn 6 2 indicator light blinking Panem 4 Immobikzer Amplifier Failure Pattern 1 Master Key Collation Error Patter 6 ECU confirms the following Master Key Code Matching Unique Code Key Registration Waiting Time Insert next key and turn ON within 15 seconds after previous key is tumed OFF ECU confirms the following Matching Unique Code Not Registered User Key User key or not ECU confirms the following Immobikzer Amplifier Failure 1 User Key 1 Collation Error Pattern 6 Registered User Key is inserted Pattem 2 ELECTRICAL SYSTEM 16 79 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 OThese parts are available as a set Prepare the current master key C GP30029BS1 e Remove Ignition Switch and Immobilizer Antenna see Immobi lizer System Parts Replacement Seat see Frame chapter e Disconnect the immobilizer Kawasaki self diagnostic sys tem connector e Connect the key registration unit A Spe
26. ties ome ro eae 98052 01734 W2RO173AWS C IGNITION SWITCH CONNECTIONS Tai Peni tion Color W BK ay arr Lock RIGHT SWITCH HOUSING CONNECTIONS ON eter 16 14 ELECTRICAL SYSTEM Wiring Diagram Other than United States Canada and Malaysia Subthrottle Valve Actuator Spark Plugs si Right Switch Housing l Front Brake Light Switch Engine Stop Switch Starter Ignition Switch Immobilizer Antenna BK Y aY eH BL R R BK BR R BK LG 18 Heter Unit zm a BR W wY Radiator SN Reserve Level Notor Switch Stick Switch Sensor Neter Unit 255 l High Beam Indicator Light 2 Left Turn Signal Indicator Light Ez Tiu 3 Right Turn Signal Indicator Light 4 Neutral Indicator Light ark 5 011 Pressure Warning Indicator Light S32 8 Tachometer Light 2 7 Tachometer rE Be r 8 Speedo Tachometer Light 5 aa 9 Speedometer 3 5 10 Speedometer Light if Water Temperature Warning Indicator Light LED 12 Indicator Light LED 13 0dometer Trip MeterA B Glock i4 Fuel Level Gauge Y 8 BK R Immobilizer R Amplifier ax Regulator Rectifier Button Front Right Turn Signal Light 2V10y ay Gity Light
27. 0 2second Gat GP30118BS1 C When Registered User Key is Inserted 0 5second 0 5second gt Ido 6230117851 C User Key Collation Error 0 3second gt ULL GP30119BS1 ELECTRICAL SYSTEM 16 77 Immobilizer System Equipped Models e The user key 2 is registered in the ECU OThe FI indicator light 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 user keys NOTE OThe ECU can store up the six key codes master key x 1 and user key x 5 User Key Indicator Flashes FI Indicator Indicator Remarks Light Blinks Light Stop User Key 3 4 times 1 seconds Repeat User Key 4 5 times 1 seconds Repeat User Key 5 6 times 1 seconds Repeat Turn OFF the ignition switch and wait for period of more than 15 seconds e The registration mode automatically ends e FI indicator light goes off A e Remove the key registration unit and connect the immo bilizer Kawasaki self diagnostic system connector NOTE the ignition switch with the registered user key OCheck that the engine can be started using all regis tered user keys 0 30 30 3 0 30 31second 6230121851 C 6230122851 C
28. Alternator BK BK BK BK BK dj Electronic Control Unit BK Y BK Y ECU Fuse 15 Joint Connector gaz Starter Circuit Relay Turn Vehicle Signal down Piei Relay Sensor Pump Relay Starter Rotor Wain Fuse 30A Immobilizer Kawasaki Self diagnositic System sConnector Bk Y S Self 85 diagnosis Indicator 28 Terninal Rear Brake Light Fuel Switch Pump Battery 12V8Ah Engine Ground TGNITION SHITCH CONNECTIONS DenitiosBattery Taini LA wy LA LA D BK Y BK Y BK Y BK Y BK Y doint Connector RIGHT SWITCH HOUSING License Plate na TEIE Light 125 Rear Right BK SY BK Y Turn Signal Light 12V10Ww Tail Brake Light LED 12V0 8 3 8W 1r all vets all Rear Left ud vIe Turn Signal Light 12 108 Color Code Black BL se BR Brown o6 bark Green e Green Lav eray LB Light Blue Light Green CONNECTIONS Starter Button Color BL OFF Lack G Front Brake Light Switch Engine Stop Switch Color color Y R eink Purple Color BK R BK R Red ite om o Brake Lever a o Pulled In Q a o a Y Yellow 98052 01744
29. G Apply grease L Apply a non permanent locking agent R Replacement Parts S Follow the specific tightening sequence EUR Europe Model MY Malaysia Model 14 4 STEERING Special Tools Steering Stem Nut Wrench Steering Stem Bearing Driver 42 5 57001 1100 57001 1344 875711005 C 7571344ST C Bearing Driver Set Steering Stem Bearing Driver Adapter 41 5 57001 1129 57001 1345 7571129ST C Jack 57001 1238 7571238ST C STEERING 14 5 Steering Steering Inspection e Refer to the Steering Play Inspection in the Periodic Main tenance chapter Steering Adjustment e Refer to the Steering Play Adjustment in the Periodic Maintenance chapter 14 6 STEERING Steering Stem Stem Stem Bearing Removal e Remove Front Wheel see Front Wheel Removal in the Wheels Tires chapter Handlebar see Handlebar Removal in the this chapter Steering Stem Head Bolt Plug Clamp Bolts A Upper Front Fork Clamp Bolts B Loosen Steering Stem Head Bolt C and Washer Steering Stem Head D e Remove Lower Front Fork Clamp Bolts A Loosen Front Fork B with Front Fender e Straighten the claws A of the claw washer e Remove the steering stem locknut B and claw washer C e Pushing up the stem base and remove the steering stem nut A with stem cap C Special Tool Steering Stem Nut Wrench 57001 1100 B e Remove the steering stem D under side e Remove th
30. No Fastener Remarks N m kgf m ft Ib 1 Front Axle Clamp Bolt 34 3 5 25 2 Front Axle 108 11 80 3 Axle Nut 108 11 80 G Apply grease R Replacement Parts WL Apply soap and water solution or rubber lubricant 10 4 WHEELS TIRES Specifications Axle Runout 100 mm 3 94 in Wheel Balance Balance Weights TIR 0 05 mm 0 0020 in or less 10 g 0 35 oz or less 10 0 35 oz 20 g 0 71 oz 30g 1 06 oz Item Standard Service Limit Wheels Rims Rim Runout Axial TIR 0 5 mm 0 020 in Radial TIR 0 8 mm 0 031 in TIR 0 2 mm 0 008 in Front Tires Air Pressure when Cold Rear 250 kPa n Up to 180 kg 2 5 kgf cm 36 psi 397 Ib load 290 kPa 2 9 kgf cm 42 psi Tread Depth Front BRIDGESTONE 3 4 0 13 in 1 mm 0 04 in AT CH DE 1 6 mm 0 06 in Rear BRIDGESTONE 5 8 mm 0 23 in Up to 130 km h 80 mph 2 mm 0 08 in Over 130 km h 80 mph 3 mm 0 12 in Standard Tires Make Type Size Front BRIDGESTONE BATTLAX BTO19F 120 70 ZR17 M C RADIAL N 58 W Rear BRIDGESTONE BATTLAX BT012R 180 55 ZR17 M C RADIAL E 73 W WARNING Use the same manufacturer s tires on both front and rear wheels AT Republic of Austria CH Swiss Confederation DE Federal Republic of Germany WHEELS TIRES 10 5 Special Tools Bearing Driver Set Bearing Remover Head 20 x 22 57001 1129 57001
31. Subthrottle Sensor Inlet Air Temperature Sensor Air Cleaner Housing Neutral Switch Speed Sensor Air Cleaner Element Vehicle down sensor Atmospheric Pressure Sensor ECU Electronic Control Unit Battery 12 V 8 Ah Fuel Flow Air Flow 3 10 FUEL SYSTEM DFI DFI System DFI System Wiring Diagram BR BK IGNITION QD BK Y de opu Le 6C17810BW5 C FUEL SYSTEM DFI 3 11 DFI System Part Name Engine Stop Switch Stick Coils 1 2 3 4 Stick Coils Subthrottle Valve Actuator Fuel Injectors 1 2 3 4 Subthrottle Sensor Main Throttle Sensor Speed Sensor Camshaft Position Sensor Inlet Air Temperature Sensor Atmospheric Pressure Sensor Water Temperature Sensor Crankshaft Sensor Inlet Air Pressure Sensor Joint Connector D Meter Ground Terminal Frame Ground Terminal Ignition Switch Fl Indicator Light LED vOEZrxXe roq4moour ODO T Tachometer U Speedometer V Ignition Fuse 10 A W X Junction Box ECU Main Relay Y Fuel Pump Relay DQAQK0T9 N ECU Main Fuse 15 Vehicle down Sensor Starter Relay Main Fuse 30 A Joint Connector C Battery 12 V 8Ah Fuel Pump Self diagnosis Terminal Joint Connector A
32. teeth are worn as illustrated replace the sprocket and inspect the drive chain wear see Periodic Mainte nance chapter Worn Tooth Engine Sprocket A Worn Tooth Rear Sprocket B Direction of Rotation C NOTE Olf a sprocket requires replacement the chain is proba bly worn also When replacing a sprocket inspect the chain Rear Sprocket Warp Inspection e Raise the rear wheel off the ground so that it will turn freely see Wheels Tires chapter 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 x If the runout exceeds the service limit replace the rear sprocket Rear Sprocket Warp Standard 0 4 mm 0 016 in or less Service Limit 0 5 mm 0 020 in GK05017B GK05000BS1 C BRAKES 12 1 Brakes Table of Contents Exploded Specifications Special Tools Brake Lever Brake Pedal Brake Lever Position Adjustment Brake Pedal Position Inspection Brake Pedal Position Adjustment Brake Pedal Removal Brake Pedal Installation GalipGrs iir mtt edad Front Caliper Removal Rear Caliper Remowval Caliper I
33. 12 2 BRAKES Exploded View BRAKES 12 3 Exploded View Torque No Fastener kar Remarks 1 Front Caliper Mounting Bolts 34 3 5 25 2 Brake Hose Banjo Bolts 34 35 25 3 Bleed Valve 7 8 0 80 69 in lb 4 Brake Lever Pivot Bolt 1 0 0 10 9 in Ib Si 5 Brake Lever Pivot Bolt Locknut 5 9 0 60 52 in Ib 9 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 specific tightening sequence Si Apply silicone grease ex PBC grease 12 4 BRAKES Exploded View 300 Q a gt 7 d M 15 152 eg M g Ge Z e 2 BRAKES 12 5 Exploded View Torque No Fastener kaim ftlb Remarks 1 Rear Master Cylinder Push Rod Locknut 18 1 8 13 2 Rear Caliper Mounting Bolts 25 2 5 18 3 Brake Hose Banjo Bolts 34 3 5 25 4 Bleed Valve 7 8 0 80 69 in Ib 5 Rear Master Cylinder Mounting Bolts 25 2 5 18 6 Rear Brake Disc Mounting Bolts 27 2 8 20 L B Apply brake fluid G Apply grease L Apply a non permanent locking agent R Replacement Parts Si Apply silicone grease ex PBC grease 12 6 BRAKES Specifications Standard Service Limit Brake Lever Brake Pedal Brake Lever Position 5 way adjustable to suit rider Brake Lever Free Play Non adjus
34. 7570221ST C 8 5711185 C Valve Spring Compressor Assembly Valve Seat Cutter 32 528 57001 241 57001 1119 7570241ST C ST571119ST C Piston Pin Puller Assembly Valve Seat Cutter Holder Bar 57001 910 57001 1128 7570910ST C 7571128ST C Valve Seat Cutter 45 24 5 Valve Spring Compressor Adapter 20 57001 1113 57001 1154 8 5711135 C 7571154ST C Valve Seat Cutter 45 527 5 Valve Guide Arbor 4 57001 1114 57001 1273 875711145 C ENGINE TOP END 5 9 Special Tools and Sealant Valve Guide Reamer 4 Valve Seat Cutter 60 627 57001 1274 57001 1409 EM Valve Seat Cutter Holder 4 Compression Gauge Adapter M10 x 1 0 57001 1275 57001 1458 ST571458ST C Fork Oil Level Gauge Kawasaki Bond Silicone Sealant 57001 1290 92104 0004 875712905 C 879200045 Valve Seat Cutter 60 525 57001 1328 7571328ST C 5 10 ENGINE TOP END Clean Air System Air Suction Valve Removal e Remove Fuel Tank see Fuel System DFI chapter Connector A from Clamp B Air Suction Valve Cover Bolts C and Clamp Air Suction Valve Cover D Air Suction Valve Air Suction Valve Installation e Install the air suction valve A so that its wider side B of the reed valve case faces the front Tighten Torque Air Suction Valve Cover Bolts 9 8 N m 1 0 kgf m 87 in lb Air Suction Valve Inspection e
35. GP17215BS1 C GP17216BS1 C GP17213BS1 C ELECTRICAL SYSTEM 16 69 Meter Gauge Indicator Unit Fuel Level Gauge Inspection eConnectthe 12 V battery and terminals in the same man ner as specified in the Liquid Crystal Display LCD Seg ments Check e Connect a variable rheostat A to terminal 4 and 9 as shown e Check that the number of segment B matches the resis tance value of the variable rheostat Resistance Q Number of Segments 0 16 5 F 6 11 5 34 5 26 5 52 5 41 5 70 5 71 5 above E x If this display function does not work replace the meter assembly w e Connect an other variable rheostat C to terminal 2 and 9 as shown e Set the hand tester D to the DC 10 V range and connect it to terminals of the variable rheostat as shown e When the 1 segment E appears adjust the variable rheostat C so that the terminal voltage is less than 5 2 V OThen the 1 and FUEL symbol segments should flush x If this display function does not flush replace the meter assembly Tachometer Check e Connect the 12 V battery and terminals in the same man ner as specified in the Liquid Crystal Display LCD Seg ments Check e The revolutions per minute rpm equivalent to the input frequency is indicated in the oscillator A if the square wave illustrated as shown would be input into the termi nal 7 Olndicates approximately 6
36. Handlebar Handlebar Installation e Install the handlebar lower holder A noting the letters L and e Tighten Torque Handlebar Lower Holder Nuts 34 N m 3 5 kgf m 25 ft lb Align the punch mark A on the handlebar and the corner edge B on the lower holder e Tighten the front holder bolts A first and then the rear holder bolts B There will be a gap C at the rear part of the holder after tightening Torque Handlebar Holder Bolts 25 2 5 kgf m 18 ft lb e Install the clutch lever A so that the mating surface B of the clutch lever clamps with punch mark C on the handlebar Torque Clutch Lever Clamp Bolts 7 8 N m 0 80 kgf m 69 in Ib e Apply adhesive cement to the inside of the left handlebar grip D e Apply a non permanent locking agent to the left handlebar weight E p GNOG023BS1 e Fit the choke lever A and choke cable end B into the switch housing 14 12 STEERING Handlebar e Install the left handlebar switch housings OFit the projection A into a small hole B in the handlebar Torque Handlebar Switch Housing Screws 3 5 N m 0 36 kgf m 31 in Ib e Install Throttle Grip Throttle Cable Tips A Right Handlebar Switch Housing OFit the projection B into a small hole C in the handlebar e Install Front Brake Master Cylinder see Brakes chapter e Tighten Right Handlebar Weight e Install
37. NOTE OTo enter the dealer mode 2 from the dealer mode 1 turn off the ignition switch once Service Code Clearing Procedures Service Code Clearing Procedures eEnter the self diagnosis dealer mode 2 see Self diagnosis Procedures in this chapter NOTE OMake sure to keep the grounding until the following opening and grounding starts e Pull the clutch lever in more than 5 seconds and then release it Repeat opening B and grounding A the lead self diagnosis terminal more than five times F within 2 seconds C after the lead is grounded and then keep it grounded continuously D for more than 2 seconds Auxiliary Lead E Self diagnosis Terminal G 2 lt 227 e 6C17072BS1 6C17072BS1 C 3 40 FUEL SYSTEM DFI Self Diagnosis Turn the ignition switch OFF Turn the ignition switch ON and self diagnosis mode starts using an auxiliary lead Dealer Dealer Y Y Dealer Mode 1 Dealer Mode 2 Ground the self diagnosis terminal Ground and open the self diagnosis for more than 2 seconds and then terminal more than five times within 2 keep it grounded seconds and then keep it grounded FI indicator light LED blinks to display the service code for more than 2 seconds Locate problem with service code table check repair DFI or ignition system accordi
38. SUSPENSION 13 5 Exploded View Torque No Fastener kgf m Remarks 1 Shock Absorber Nuts Upper and Lower 34 3 5 25 2 Swingarm Pivot Shaft Nut 108 11 80 3 Swingarm Pivot Shaft Locknut 98 10 72 4 Rocker Arm Nut 34 3 5 25 5 Tie rod Bolts 59 6 0 43 R Replacement Parts 2T Apply 2cycle Oil 13 6 SUSPENSION Specifications Standard Front Fork Per One Unit Fork Inner Tube Outside Diameter 41 mm 1 61 in Air Pressure Atmospheric pressure Non adjustable Fork Spring Setting Non adjustable Damper Setting Non adjustable Fork Oil Viscosity KAYABA KHL34 G10 or equivalent Fork Oil Capacity 465 4 mL 15 7 0 135 US oz Completely approx 395 mL 13 4 US oz when changing oil Fork Oil Level 105 2 mm 4 13 0 08 in below from inner tube top with fully compressed without fork spring Fork Spring Free Length 319 2 mm 12 57 in Service limit 313 mm 12 3 in Rear Shock Absorber Rebound Damping Force Number 2 Adjustable Range Number 1 4 Spring Preload Ath position Adjustable Range 1st 7th position Gas Pressure 980 kPa 10 kgf cm 142 psi Non adjustable SUSPENSION 13 7 Special Tools Inside Circlip Pliers Jack 57001 143 57001 1238 7570143ST C 7571238ST C Fork Cylinder Holder Handle Fork Oil Seal Driver 41 57001 183 57001 1288 Fork Cylinder Holder Adapter Fork Oil Level G
39. at 80 C 176 F x If the measurement is out of the range replace the sensor x If the measurement is within the specified replace the ECU Inlet Air Temperature Sensor Circuit 80171028 5 BR BK Y BR BK BR BK 6617826881 C mE BR BK Y 6617827BW1 C A ECU B Joint Connector D C Inlet Air Temperature Sensor 3 56 FUEL SYSTEM DFI Water Temperature Sensor Code 14 Removal Installation CAUTION Never drop the sensor especially on a hard surface Such a shock to the sensor can damage it e Remove the fuel tank see Fuel Tank Removal e Drain the coolant in the thermustot housing e Remove Meter Ground Bolt A e Disconnect the sensor connector B and unscrew the water temperature sensor C Silicone Sealant Kawasaki Bond 56019 120 Threads of Water Temperature Sensor Torque Water Temperature Sensor 25 N m 2 5 kgf m 18 16 e Fill the engine with coolant and bleed the air from the cool ing system see Coolant Change in the Periodic Mainte nance chapter Output Voltage Inspection NOTE OBe sure the battery is fully charged e Remove the ECU see ECU Removal Do not disconnect the connectors Connect a digital voltmeter A to the ECU connector with the needle adapter set Special Tool Needle Adapter Set 57001 1457 e Measure the sensor output voltage with the eng
40. e Insert the current master key into the ignition switch and turn it ON Olf there is any problem in the registration the Fl indicator light A blinks to display the collation error Immobilizer Amplifier Failure 0 2second d unnnnnnnnnnnui GP30118BS1 C Master Key Collation Error 0 3second gt UU GP30119BS1 16 84 ELECTRICAL SYSTEM Immobilizer System Equipped Models e The master key is registered in the ECU OThe FI indicator light A blinks 1 time and stops for 1 second and the repeats this cycle to indicate successful registration of the master key gt D Ole eee GP30123BS1 C e Turn of the master key and remove it OThe FI indicator light A blinks to display the registration mode NOTE Olnsert next key and turn ON within 15 seconds after pre vious key is turned off and removed otherwise registra tion mode will be ended and the indicator light goes off OTo return to the registration mode start the master key verification procedure This applies to all user key reg istration 0 5second 0 5second gt 6230117851 C 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 Fl indicator light A blinks to display the collation error Immobilizer Ampl
41. the Engine Lubrication System chapter Water Pump Installation e Refer to the Oil Pump Installation in the Engine Lubrica tion System chapter Water Pump Inspection e Check the drainage outlet passage A at the bottom of the water pump body for coolant leaks x lf the mechanical seal is damaged the coolant leaks through the seal and drains through the passage Re place the mechanical seal unit Water Pump Impeller Disassembly Assembly e The sealing seat and rubber seal may be removed easily by hand e Apply coolant around the surfaces of the rubber seal and sealing seat e Install the rubber seal A and sealing seat B into the impeller by pressing them by hand until the seat stops at the bottom of the hole e Tighten the water pump impeller bolt by special torque Torque Water Pump Impeller Bolt 9 8 1 0 kgf m 87 in Ib Water Pump Impeller Inspection e Visually inspect the water pump impeller A xIf the surface is corroded or if the blades are damaged replace the impeller Water Pump Housing Disassembly CAUTION Do not damage the hole wall of the water pump housing e Insert a bar A into the pump housing B and hammer evenly around the circumference of the mechanical seal bottom C 6006015851 C 4 10 COOLING SYSTEM Water Pump e Take the oil seal A out of the housing B with hook C 6006016851 C Water Pump Housing Assembly CAUTION
42. 3 110 POSE INS PO CUO Msi ett e en E e 3 110 Separator Inspection pp 3 110 Separator Operation 3 111 Canister Inspection m rtt etd ique rats 3 111 3 4 FUEL SYSTEM DFI Exploded View 82 6 AS GRANT es P 13 FUEL SYSTEM DFI 3 5 Exploded View No Fastener Torque Remarks Nm kgf m ft lb 1 Throttle Cable Plate Bolt 6 0 0 60 52 in lb 2 Throttle Body Assy Holder Clamp Bolts 2 0 0 20 17 in Ib 3 Choke Link Holder Screws 2 1 0 21 18 in Ib 4 Delivery Pipe Screws 3 4 0 35 30 in Ib 5 Fuel Pump Bolts 9 8 1 0 87 in lb L S 6 Fuel Level Sensor Bolts 6 9 0 70 62 in Ib L 7 Bypass Screws 0 2 0 02 1 7 in lb 8 California Model 9 FI Indicator LED Light 10 Throttle Cable Accelerator 11 Throttle Cable Decelerator 12 Choke Cable 13 Subthrottle Valve Actuator Connectors 14 Center Adjusting Screw 15 Injectors 16 Throttle Body Assy CL Apply cable lubricant EO Apply engine oil G Apply grease L Apply a non permanent locking agent R Replacement Parts S Follow the specified tightening sequence 3 6 FUEL SYSTEM DFI Exploded View FUEL SYSTEM DFI 3 7 Exploded View Torque No Fastener kgf m 1 nlet Air Pressure Sensor Bolt 12 1
43. 5 4 ENGINE TOP END Exploded View ENGINE TOP END 5 5 Exploded View Torque No Fastener Nem kgfm ftlb Remarks 1 Coolant Drain Plug Cylinder 9 8 1 0 87 2 Exhaust Pipe Manifold Holder Nuts 17 1 7 12 3 Muffler Body Clamp Bolt 17 1 7 12 4 Muffler Body Mounting Bolt 30 3 0 22 5 Crankshaft Sensor Cover Bolts 11 1 1 95 in Ib 6 1T marked side faces up 7 2T marked side faces up 8 Hollow mark faces forward MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts Exhaust System ZR750 K1 TOUT SENCER ITEM NAME ORG PRODUCT Honeycomb Type Catalyst US ZR750 K1 Canada ZR750 K1 Noise Emission WVTA FULLH 2 750 j WVTA 78 2 ZR750 K1H Control Information Non Catalyst P No 39178 0029 Mark KHI M 093 Honeycomb Type Catalyst P No 18091 0241 Malaysia ZR750 K1 Mark KHI K 476 GE02151B F 78 2 Horsepower 78 2 kW 106 3 ps Full Full Power H Honeycomb Type Catalyst GB United Kingdom Model US United States Model 5 6 ENGINE TOP END Specifications Item Standard Service Limit Clean Air System Vacuum Switch Valve Closing Pressure Open Close 41 49 kPa 310 370 mmHg 6 0 7 1 psi Camshafts Cam Height Exhaust Inlet Camshaft Journal Camshaft Cap Clearance Camshaft Journal D
44. Insert the fuel hose joint A straight onto the delivery pipe B until the hose joint clicks C Front D 6617183851 C 2 50 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Push and pull A the fuel hose joint B back and forth more than two times and make sure it is locked and doesn t come off x If it comes off reinstall the hose joint 2 9 42 a 55 gt e 599 OD 500 5 52 50506 52555 505006000 bee Make sure the fuel hose joint is installed correctly on the delivery pipe or the fuel could leak 6617182851 C e Run the fuel hose in accordance with the Cable Wire and Hose Routing section in the Appendix chapter e Install the removed part e Start the engine and check the fuel hose for leaks Coolant Change WARNING avoid burns do not remove the radiator try to change the coolant when the engine is still hot Wait until it cools down Coolant on tires will make them slippery and can cause an accident and injury Immediately wipe up or wash away any coolant that spills on the frame engine or other painted parts Since coolant is harmful to the human body do not use for drinking e Place a container under the water pump drain bolt A then remove the drain bolt e Remove Fuel Tank see Fuel System DFI chapter ORemove the radiator cap A in two steps First turn th
45. Switch Connector Crankshaft Sensor and Oil Pressure Switch Connector Starter Relay Band Rear Brake Switch Lead Connector Clamp Through the main harness Battery Negative Lead Connector Turn Signal Relay Fuel Pump Relay ECU Main Relay License Plate Light Lead Connector Tail Light Lead Connector Rear Right turn Signal Light Lead Con nector Gray Rear Left Turn Signal Light Lead Connec tor Black To Camshaft Clamp All Leads of this part Meter Connector Clamp Through the meter lead Clamp Ignition Switch Lead Run the main harness over the clutch ca ble Position Sensor Fan Switch Horn Frame Ground Water Temperature Sensor Connector Alternator Lead Connector Fuel Injector 4 Clamp Positioning Point of Main Harness Subthrottle Valve Actuator Connector Speed Sensor Lead Connector Neutral Switch Lead Connector Side Stand Switch Lead Connector Starter Motor Cable Battery Negative Cable Inlet Air Temperature Sensor Vehicle down Sensor Clamp Regulator Rectifier Battery Positive Cable ECU Run the lead of ECU under the upper sur face of battery case Junction Box ECU Fuse Immobilizer Kawasaki Self diagnositic System Connector Clamp Atmospheric Pressure Sensor Inside of Frame Outside of Frame Frame Pipe Viewed Section A A and B B 17 14 APPENDIX Cable
46. e Disconnect the diode B Set the hand tester to the x 100 range Special Tool Hand Tester 57001 1394 e Check the continuity between the diode terminals in both directions If there is continuity in one direction forward direction but no continuity infinity in the reverse direction the diode is normal The diode is defective if there is continuity after changing the direction or it if remains with no continuity 6P18040281 6 NOTE OThe actual resistance measurement in the forward direction varies with the tester used and the individual diodes Generally speaking it is acceptable if the tester s indicator swings approximately halfway ELECTRICAL SYSTEM 16 97 Junction Box The junction box has fuses relays and diodes The relays and diodes can not be removed Junction Box Fuse Circuit Inspection e Remove the seats see Frame chapter e Remove the junction box A Pull off the connectors A from the junction box Make sure all connector terminals are clean and tight and none of them have been bent Clean the dirty terminals and straighten slightly bent ter minals e Check conductivity of the numbered terminals with the hand tester ORefer to the Junction Box Internal Circuit x If the tester does not read as specified replace the junc tion box Special Tool Hand Tester 57001 1394 Fuse Circuit Inspection Tester Tester Tester Tester Conn
47. tena vera Re abre UR du iet n 4 10 Mechanical Seal Inspection pp 4 10 adlatg E 4 11 Radiator and Radiator Fan Removal pp 4 11 Radiator and Radiator Fan Installation pp 4 12 Radiator 4 12 Radiator o eet 4 13 Radiator Filler Neck Inspection RN 4 13 4 14 4 14 Thermostat Installation esses 4 14 Thermostat Inspection eode rre Pe 4 14 Hose and Pipes cre EP 4 16 Hose Installation soit e ee 4 16 Hose Inspection iei t E YE De e ER SEE RR EX lo ede ed b e da ds 4 16 Radiator Fan Switch Water Temperature Sensor pt 4 17 Radiator Fan Switch 4 17 Radiator Fan Switch Installation pp 4 17 Radiator Fan Switch 4 17 Water Temperature Sensor Removal Installation pp 4 17 Water Temperature Sensor Inspection pp 4 17 4 2 COOLING SYSTEM Exploded View COL O cm T 9f 8XL GD020438W5 C COOLING SYSTEM 4 3 Exploded View No Fastener Remarks N m kgf m ft Ib 1 Radiator Hose Clamp Screws 2 0 0 20 17 in lb 2 Radiator Fan Bolts 8 3 0 85 74 in lb 3 Water Pump Impeller Bolt 9 8 1 0 87 in lb 4 Water Pump Cover Bolts 1
48. 16 14 The resistance should be low in one direction and more than ten times as much in the other direction If any diode shows low or high in both directions the diode is defective and the junction box must be replaced NOTE OThe actual meter reading varies with the meter used and the individual diodes but generally speaking the lower reading should be from zero to one half the scale Junction Box Internal Circuit TOD 6219060112 C Fuse 10 Fan Fuse 10 Turn Signal Relay Fuse 10 A Horn Fuse 10 A Ignition Fuse 10 A Headlight Fuse 10 A Headlight Relay Headlight Diodes Starter Diode Starter Circuit Relay Interlock Diodes Taillight Fuse 10 A rTACc rIrO0Ommoour 16 100 ELECTRICAL SYSTEM Fuse 30 Fuse Removal e Remove Right Side Cover see Frame chapter 30 A Main Fuse Connector A Pull out the main fuse from the starter relay with needle nose pliers Junction Box Fuse Removal e Remove the seat see Frame chapter e Unlock the hook to lift up the lid A Pull the fuses straight out of the junction box with nee dle nose pliers 15 A ECU Fuse Removal e Remove Seat see Frame chapter e Unlock the hook to pull the lid A e Pull out the ECU Fuse from the fuse box Fuse Installation e fuse fails during operation inspect the electrical sys tem to determine the cause and then
49. 2 65 2 10 2 75 2 80 2 85 2 90 2 95 3 00 3 05 3 10 3 18 3 20 3 25 3 30 3 35 os o 12 2 50 2 55 2 60 2 68 2 70 2 75 2 80 2 85 2 90 2 95 3 00 3 05 3 10 3 15 3 20 9 25 3 30 3 351 3 40 0 13 0 14 2 55 2 60 2 65 2 70 2 75 2 80 2 85 2 90 2 95 3 00 3 05 3 10 3 15 3 20 3 25 2 20 3 35 3 40 3 45 SPECIFIED CLEARANCE NO CHANGE REQUIRED zost aan se aan aas xa Ls rae sas so aasta so 0 28 0 32 2 60 2 65 2 10 2 15 2 80 2 85 2 90 2 95 3 00 3 05 3 10 3 15 3 20 3 28 3 30 3 35 3 40 3 45 5 0 33 0 37 2 65 2 70 2 T5 2 80 2 90 2 95 3 00 3 20 8 25 3 30 3 50 3 25 3 30 3 35 0 38 0 42 2 70 2 T5 2 801 2 85 3 00 3 05 0 48 0 52 2 80 2 85 2 90 2 95 3 001 3 05 3 10 3 15 3 20 imam 3 30 3 35 E 3 50 ss 0 57 2 85 2 90 2 98 3 00 3 05 3 10 3 15 3 20 3 25 3 35 3 40 3 45 0 43 0 47 2 15 2 80 2 85 2 90 2 95 3 00 0 58 0 62 2 90 2 95 3 00 0 63 0 67 2 95 3 00 3 05 0 68 0 72 3 10 0 73 0 77 3 05 3 10 3 15 0 78 0 82 3 10 3 15 3 20 0 83 0 87 3 15 3 20 3 25 3 0 88 0 92 3 20 3 25 3 30 3 35 3 40 3 45 3 50 0 93 0 97 0 98 1 02 3 50 1 08 1 12 3 40 3 45 3 50 1 13 1 17 3 45 3 50 1 18 1 22 3 50 VALVE CLEARANCE MEASUREMENT mm Ezample N INSTALL THE SHIM OF THIS THICKNESS
50. 90 194 F e Stop the engine e Remove the oil pressure gauge and adapter A WARNING Take care against burns form hot engine oil that will drain through the oil passage when the gauge adapter is removed e Apply a non permanent locking agent to the oil passage plug and install it Torque Oil Passage Plug Right 20 N m 2 0 kgf m 14 ft Ib ENGINE LUBRICATION SYSTEM 7 15 Oil Pressure Switch Oil Pressure Switch Removal e Remove Engine Oil drain Periodic Maintenance chapter Switch Cover A Switch Terminal Bolt B Oil Pressure Switch C Oil Pressure Switch Installation e Apply silicone sealant to the threads of the oil pressure switch and tighten it Sealant Kawasaki Bond Silicone Sealant 56019 120 Torque Oil Pressure Switch 15 N m 1 5 kgf m 11 ft Ib e Install the switch lead A direction upward e Tighten the terminal bolt Torque Oil Pressure Switch Terminal Bolt 1 5 N m 0 15 kgf m 13 in Ib Apply grease to the terminal ENGINE REMOVAL INSTALLATION 8 1 Engine Removal Installation Table of Contents Exploded Views 8 2 leere 8 4 Engine Removal lnstallation Ne 8 5 Engine FROMIOVAL 2220 Em 8 5 E gin lnstalaton 8 7 8 2 ENGINE REMOVAL INSTALLATION Exploded View ENGINE REMOVAL INSTALLATION 8 3 Exploded View No Fastener Tordue Remarks N m kgf m ft Ib 1 Adjus
51. 92110 1146 e Attach the compression gauge A and adapter B firmly into the spark plug hole OUsing the starter motor turn the engine over with the throt tle fully open until the compression gauge stops rising the compression is the highest reading obtainable Special Tools Compression Gauge 20 kgf cm 57001 221 Compression Gauge Adapter M10 x 1 0 57001 1458 Cylinder Compression Usable Range 1 110 1 590 kPa 11 3 16 2 kgf cm 161 230 psi 300 r min rpm e Repeat the measurement for the other cylinders e Install the spark plugs Torque Spark Plugs 13 N m 1 3 kgf m 113 in Ib The following table should be consulted if the obtainable compression reading is not within the us able range Problem Diagnosis Remedy Action Cylinder compression Carbon accumulation on piston and in is higher than usable combustion chamber possibly due to Remove the carbon deposits range damaged valve stem oil seal and or and replace damaged parts if damaged piston oil rings This may be necessary indicated by white exhaust smoke Incorrect cylinder head gasket Replace the gasket with a standard thickness part Cylinder compression Replace damaged gasket and Gas leakage around cylinder head check cylinder head warp is lower than usable range Bad condition of valve seating Repair if necessary Incorrect valve clearance Adjust the valve clearance Incorrect piston cylinder clearance Rep
52. B up to next alignment Olt should be within 30 degree OLoosen once and tighten again when the slot goes past the nearest hole 1407000851 WHEELS TIRES 10 9 Wheels Rims e Bend the cotter pin A over the nut A WARNING If the rear axle nut is not securely tightened or the cotter pin is not installed an unsafe riding condi tion may result e Adjust the drive chain slack after installation see Drive Chain Slack Adjustment in the Periodic Maintenance chapter e Check the rear brake effectiveness WARNING Do not attempt to drive the motorcycle until a full brake pedal is obtained by pumping the brake pedal until the pads are against the disc The brake will not function on the first application of the pedal if this is not done Wheel Inspection e Raise the front rear wheel off the ground Special Tool Jack 57001 1238 e Spin the wheel lightly and check for roughness or binding x If roughness or binding is found replace the hub bearings e Inspect the wheel for small cracks dents bending or warp x If there is any damage to the wheel replace the wheel e Remove the wheel and support it without the tire by the axle e Measure the rim runout radial A and axial B with a dial gauge x If rim runout exceeds the service limit check the hub bear ings x If the problem is not due to the bearings replace the wheel Rim Runout Service Limit Axial TIR 0 5 mm 0 02
53. BRAKES 12 21 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 es 13 2 SPESCITICATIONS cbe cti t a eh ire be ema t e diede t ave d PN 13 6 Special Tools ett eee Pr bee de Fen a o M cte da e PO Peck ED RA Uv ed de e de Fe DUE LR eR 13 7 56 eem 13 9 Front Fork 13 9 Front Fork Installation dat ban 13 9 Front Fork 13 9 Front Fork Disassermbly xiu 13 11 gielsidgo qiiae 13 12 Inner Tube Outer Tube 13 13 Dust Seal Inspection pp 13 13 Fork Spring Inspection iet tet tee eeu e og e eua ere ug Dre eee es 13 14 Rear Shock ols e PER ra 13 15 Rebound Damping Force Adjustment pp 13 15 Spring Preload En dace d deeds 13 15 Rear Shock Absorber Removal pp 13 16 Rear Shock Absorber Installation pp 13 17 Rear Shock Absorber Inspection pp 13 17 SWinga mM ROMOV d MEE Swingarm Installation Swingarm Bearing R
54. Front Forks Rear Shock Absorber Oil Leak Inspection Rocker Arm Operation Inspection Tie rod Operation Inspection Steering System Steering Play Inspection Steering Play Adjustment Steering Stem Bearing Lubrication pp Electrical System Lights and Switches Operation Headlight Aiming Inspection Side Stand Switch Operation Engine Stop Switch Operation Bolts Nuts and Fasteners Tightness Inspection Replacement Parts Air Cleaner Element Replacement Engine Oil Change Oil Filter Replacement Fuel Hose Replacement Coolant Change Radiator Hose and O ring Replacement Brake Hose and Pipe Replacement 2 35 2 35 2 35 2 36 2 36 2 37 2 37 2 38 2 38 2 38 2 39 2 39 2 39 2 39 2 40 2 41 2 41 2 41 2 43 2 44 2 45 2 45 2 45 2 47 2 48 2 48 2 48 2 49 2 49 2 50 2 52 2 52 2 2 PERIODIC MAINTENANCE Brake Fluid Change Master Cylinder Rubber Parts Replacement
55. G e After tightening all crankcase bolts check the following items OCrankshaft and transmission shafts turn freely OWhile spinning the output shaft gears shift smoothly from the 1st to 6th gear and 6th to 1st OWhen the output shaft stays still the gear can not be shifted to 2nd gear or other higher gear positions 6104133851 C 9 12 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods Crankshaft Removal Split the crankcase see Crankcase Splitting e Remove the crankshaft A Crankshaft Installation CAUTION If the crankshaft bearing inserts or crankcase halves are replaced with new ones select the bear ing inserts and check clearance with a plastigage press gauge before assembling engine to be sure the correct bearing inserts are installed Apply molybdenum disulfide oil solution to the crankshaft main bearing inserts e Install the crankshaft with the camshaft chain A hanging on it Connecting Rod Removal Split the crankcase see Crankcase Splitting e Remove the connecting rod nuts A e Remove the crankshaft NOTE OMark and record the locations of the connecting rods and their big end caps so that they can be reassembled in their original positions e Remove the connecting rods from the crankshaft CAUTION Discard the connecting rod bolts To prevent dam age to the crankpin surfaces do not allow the con necting rod bolts to bump against
56. Injector stuck open Inspect see chapter 3 Water temperature sensor trouble Inspect and replace see chapter 3 Inlet air temperature sensor trouble Inspect and replace see chapter 3 Brown smoke Air cleaner duct loose Reinstall see chapter 3 Air cleaner O ring damaged Replace see chapter 3 Too low fuel pressure Inspect fuel line and fuel pump see chapter 3 Water temperature sensor trouble Inspect and replace see chapter 3 Inlet air temperature sensor trouble Inspect and replace see chapter 3 3 38 FUEL SYSTEM DFI Self Diagnosis Self diagnosis Outline Self diagnosis Outline The self diagnosis system has three modes and can be switched to another mode by grounding the self diagnosis terminal User Mode The ECU notifies the rider of troubles in DFI system and ignition system by lighting the FI indicator when DFI system and ignition system parts are faulty and initiates fail safe function In case of serious troubles the ECU stops the injection ignition starter motor operation Dealer Mode 1 The FI indicator light LED emits service code s to show the problem s which the DFI system Immobilizer system and ignition system has at the moment of diagnosis Dealer Mode 2 The FI indicator light LED emits service code s to show the problem s which the DFI system Immobilizer system and ignition system had in the past Self diagnosis Procedures Self diagnosis Procedures
57. L Apply a non permanent locking agent 15 6 FRAME Exploded View California Other than United States and Canada Other than United States and Canada FRAME 15 7 Seat Seat Removal e Insert the ignition switch key into the seat lock A turning the key clockwise pulling up B on the rear of the seat C and pulling the seat backward Seat Installation e Slip the front seat hooks A under the braces B on the fuel tank bracket and frame e Insert the seat latch C into the latch hole D e Push down the rear part of the seat until the lock clicks 15 8 FRAME Side Covers Side Cover Removal e Remove the bolt A e Pull the side cover B evenly outward to clear the stop pers Side Cover Installation e Insert the tabs A into the holes B e Install the bolt Frame Cover Removal e Remove Bolts A Frame Cover B both side FRAME 15 9 Fairings Inner Cover Removal e Remove Inner Cover Screw A and Washers e Push the central pin and then remove the quick rivet B OPull the cover evenly outward to clear the stopper C Inner Cover Installation e Fit the projection A on the inner cover B into the grom met C in the bracket e Reset the quick rivet A before installation it as shown e Temporary install the rivet and screw then install them e Push the central pin of the rivet Inner Cover Installation e Insta
58. M9 Bolts B e Tap lightly around the crankcase mating surface with a plastic mallet and split the crankcase Take care not to damage the crankcase 6104132851 C Crankcase Assembly CAUTION The upper and lower crankcase halves are ma chined at the factory in the assembled state so the crankcase halves must be replaced as a set e With a high flash point solvent clean off the mating sur faces of the crankcases halves and wipe dry e Using compressed air blow out the oil passages in the crankcase halves 9 10 CRANKSHAFT TRANSMISSION Crankcase Splitting e Apply liquid gasket to the breather plate mating surface A 1 to 1 5 mm 0 04 to 0 06 in thick and then install the breather plate Sealant Three Bond 1207B NOTE OMoreover fit the plate and tighten the bolts just after application of the silicone sealant e Apply a non permanent locking agent to the threads and tighten the bolts A Torque Breather Plate Bolts 9 8 N m 1 0 kgf m 87 in Ib e Install the breather hose A OAlign the white mark on the hose with the white mark on the pipe Olnstall the clamp B so that its head faces to clutch side Breather Plate C e Install Crankshaft and Connecting Rods Camshaft Chain A Transmission Shafts and Gears Dowel Pins B Shift Drum Shift Forks and Shift Rods e Before fitting the lower case on the upper case check the following OBe sure to hang the camshaft chain on the crank
59. One way to install inserts is as follows Installation D to Cap Installation E to Connecting Rod Push F Spare Dowel Pin G Connecting Rod Bolts H e Install the cap on the connecting rod aligning the weight and diameter marks e Remove debris and clean the surface of inserts e Apply molybdenum disulfide oil solution MO to the threads and seating surfaces of the big end nuts and bolts 9 14 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods e Install the crankshaft see Crankshaft Installation e Install each connecting rod on its original crankpin OThe connecting rod big end is bolted using the plastic region fastening method OThis method precisely achieves the needed clamping force without exceeding it unnecessarily allowing the use of thinner lighter bolts further decreasing connecting rod weight OThere are two types 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 fr
60. Shift Drum Bearing Holder Screw 5 4 0 55 48 in Ib L Connecting Rod Big End Nuts see the text Rotor 39 4 0 29 Oil Pressure Switch 15 1 5 11 SS Oil Pressure Switch Terminal Bolt 1 5 0 15 13 in Ib Oil Passage Plugs 20 2 0 14 L Crankshaft Sensor Cover Bolts 11 1 1 95 Shift Pedal Mounting Bolt 34 3 5 25 L Gear Positioning Lever Bolt 12 1 2 104 in Ib Shift Shaft Return Spring pin 29 3 0 22 L Shift Drum Cam Holder Bolt 12 1 2 104 in Ib L Footpeg Bracket Bolts 34 3 5 25 L Shift Lever Bolt 6 9 0 70 61 in Ib Tie rod Locknuts 6 9 0 70 61 in Ib Neutral Switch 15 1 5 11 Wheels Tires Front Axle Clamp Bolt 34 3 5 25 Front Axle 108 11 80 Rear Axle Nut 108 11 80 Final Drive Engine Sprocket Nut 125 13 92 MO Engine Sprocket Cover Bolts 9 8 1 0 87 in lb Speed Sensor Cover Bolts 6 9 0 70 61 in Ib L Rear Sprocket Nuts 59 6 0 43 PERIODIC MAINTENANCE 2 9 Torque and Locking Agent Torque Fastener Remarks SpedSewoBot 00 Brakes Bleed Valves 7 8 0 80 69 in Ib Brake Hose Banjo Bolts 34 3 5 25 Brake Lever Pivot Bolt 1 0 0 10 9 in lb Brake Lever Pivot Bolt Locknut 5 9 0 60 52 in lb Front Brake Reservoir Cap Screws 1 5 0 15 9 in Ib Front Brake Light Switch Screws 1 2 0 12 10 in Ib Front Master Cylinder Clamp Bolts 8 8 0 90 78 S Front Caliper Mounting Bolts 25 Front Brake Disc Mounting Bolts 20 L Rear Brake Disc Mounting Bolts 20 L Rear Caliper Mounting Bolts 18
61. Standard Position 4th position Adjustable Range 1st to 7th position e f the compression of the spring is not suited to the op erating conditions adjust it to an appropriate position by referring to the table below Spring Preload Adjustment Adjuster Damping Pian Load Road Driving Position Force Conditions Speed Hardness 1st Weak Soft Light Good Low 1 1 1 7th Strong Hard Heavy Bad Highway 13 16 SUSPENSION Rear Shock Absorber Rear Shock Absorber Removal e Remove the side stand bracket A e Using the jack B and attachment C raise the rear wheel off the ground Special Tool Jack 57001 1238 Jack Attachment 57001 1608 Squeeze the brake lever slowly and hold it with a band WARNING sure to hold the front brake when removing the shock absorber or the motorcycle may tall over It could cause an accident and injury e Remove Lower Shock Absorber Nut A Lower Shock Absorber Bolt B e Remove Upper Shock Absorber Nut A Upper Shock Absorber Bolt B e Remove the shock absorber A from upside GH04011081 C SUSPENSION 13 17 Rear Shock Absorber Rear Shock Absorber Installation 5 e Install the rear shock absorber so that the warning label and position marked A side faces backward B e Tighten OTemporary install the bolts and nuts OTouch the rear wheel on the ground OTighten the nu
62. Wire and Hose Routing p dy 05 sc je S ic ia WN Ny 125 2 ct WAS A lt y 7 N RS gt gD GHEE 6 6006 00 0 69 0 D o 6 t ee 63 1 6 69 APPENDIX 17 15 Cable Wire and Hose Routing 11 13 14 15 16 gt Immobilizer Kawasaki Clamp Viewed Front of Frame Clamp All Leads of this part ECU Main Relay Fuel Pump Relay Turn Signal Light Relay Junction Box Band Clamp the band near the bracket ECU Fuse Self diagnositic System Connector Band 12 Band Insert the band into the hole be tween the pipe and gusset Crankshaft Sensor and Oil Switch Lead Connector Fuel Pump Lead Connector Fuel Level Gauge and Fuel Reserve Switch Lead Connector To Inlet Air Temperature Sensor Connec tor Run the lead under the cross pipe Pressure Subthrottle Valve Actuator Connector Frame Ground with Thermostat Fuel Injector Connector 4 Clamp Clamp Fan Motor Connector Inlet Air Pressure Sensor Water Temperature Sensor Meter Ground Run the ground lead back ward Ignition Switch Lead Connector Frame Ground Ignition Switch Lead of Main Harness Left Switch Housing Lead Connector Front Left Turn Signal Light Connector City Light Lea
63. and Battery Terminal Ignition Switch OFF Terminal 11 W Y 0 V Terminal 43 W BK Battery Voltage 12 6 V or more Ignition Switch ON Both Battery Voltage 12 6 V or more x If the meter does not read as specified check the follow ing Main Fuse 30 A see Electrical System chapter ECU Fuse 15 A see DFI Power Source section ECU Main Relay see DFI Power Source section Power Source Wiring see wiring diagram below x If the inspection checks good the ECU is damaged Re place the ECU The ECU itself cannot be checked or ser viced GC17845BS1 C 3 82 FUEL SYSTEM ECU ECU Power Source Circuit BATTERY 6 6617848812 TON PARK eniT oo BR BATTERY SEE 1 80617847842 ECU Fuse 15 Fuse 30 Ignition Switch E Joint Connector C H Battery 12 V 8 Ah C ECU Relay Starter Relay Joint Connector FUEL SYSTEM DFI 3 83 DFI Power Source ECU Fuse Removal eRefer to the Electrical System chapter for the ECU fuse removal ECU Fuse Installation fuse fails during operation inspect the DFI system to determine the cause and then replace it with a new fuse of proper amperage e Refer to the Electrical System chapter for the ECU fuse installation ECU Fuse Inspection e Refer to the Electrical Sys
64. 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 6J05033BS1 C 10 14 WHEELS TIRES Tires e Install a new valve in the rim ORemove the valve cap lubricate the stem seal with a soap and water solution or rubber lubricant and pull B the valve stem A through the rim from the inside out until it snaps into place CAUTION Do not use engine oil or petroleum distillates to lu bricate the stem because they will deteriorate the rubber GJ05054BS1 C 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 Rotation Direction B GJO5055BS1 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 using a suitable commer cially available tire changer e Lubricate the tire beads and rim flanges with a soap and water solution or rubber lubricant to help seat the tire beads in the sealing surfaces of the rim while inflating the tire e Center the rim in the tire
65. 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 6006017851 C CAUTION Be careful not to damage the sealing surface of the mechanical seal e Press the new mechanical seal into the housing with bear ing driver A until its flange B touches the surface C of the housing Special Tool Bearing Driver 032 57001 382 Mechanical Seal Inspection e Visually inspect the mechanical seal x If 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 COOLING SYSTEM 4 11 Radiator Radiator and Radiator Fan Removal The radiator fan is connected directly to the bat tery The radiator fan may start even if the ignition switch is off NEVER TOUCH THE RADIATOR FAN UNTIL THE RADIATOR FAN CONNECTOR IS DIS CONNECTED TOUCHING THE FAN BEFORE THE CONNECTOR IS DISCONNECTED COULD CAUSE INJURY FROM THE FAN BLADES Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Remove Fuel Tank see Fuel System DFI chapter Radiator Fan Motor Connector A Disconnect e Remove Fan Switch Lead Connector A Radiator Lower Bolt B Hose Clamp Screw C Loosen Left Radiator Hose D e Remove Hose C
66. firmly pull down the outer tube a few times towards the direction of elongation 13 12 SUSPENSION Front Fork eRemove the following from the inner tube Guide Bushing inner A Guide Bushing outer B Washer C Oil Seal D e Remove the cylinder base A from the bottom of the outer tube Front Fork Assembly e Check the top plug O ring and replace it with a new one e Replace the following parts with new ones Retaining Ring A Dust Seal B Oil Seal C Inner Guide Bushing D Outer Guide Bushing E Fork Bottom Allen Bolt Gasket F e 008 e Install the guide bushing on the end of the inner tube e Insert the cylinder unit and the spring into the inner tube and install the cylinder base B onto the cylinder end A that protrudes from the bottom Olnstall the cylinder base starting with its stepped end e Insert the inner tube cylinder unit washer spring and cylinder base as a set into the outer tube e Install the guide bushing into the outer tube e After installing the washer install the oil seal A by using the fork oil seal driver B Special Tool Fork Oil Seal Driver 541 57001 1288 6 04042051 C OApply high temperature grease to the oil seal lips e Install the retaining ring into the outer tube e Install the dust seal by hand SUSPENSION 13 13 Front Fork eApply non permanent locking agent to the threads of the b
67. is opened quickly there is no hesitation or jerky response The subthrottle valves allow the fuel injection system to provide smooth throttle response similar to that of a constant velocity carburetor no matter how quickly the throttle is opened Throttle Body Carburetor gt Airflow mixture Fuel Flow GB06171BW3 C A Main Throttle Valve B Subthrottle Valve C Throttle Valve D Vacuum Piston E Inlet Air GENERAL INFORMATION 1 13 Technical Information Air Inlet System Operation The subthrottle control system consists of the subthrottle valve subthrottle valve actuator with stepping motor built in it ECU and subthrottle sensor The subthrottle valve is built in the each throttle body The subthrottle control system operates on the signal supplied from the ECU The open close oper ation of the subthrottle valve is performed by the subthrottle actuator which is controlled by the ECU to change the current direction into the motor of the subthrottle valve actuator The subthrottle sensor detects the subthrottle valve actuator movement by measuring voltage and the ECU determines the subthrottle valve angle based on the operation map When turning the ignition switch ON every time the ECU automatically drives the subthrottle valve from fully closed position to fully opened position The ECU memorizes these positions and turns back the subthrottle valve to the original point to confirm the subthrottle valve
68. or warped replace it 6009019851 C ELECTRICAL SYSTEM 16 1 Electrical System Table of Contents Parts Exploded Specifications Special Tools and Sealant Wiring Diagram United States and Wiring Diagram Other than United States Canada and Malaysia Wiring Diagram Malaysia 2 2222 Electrical Wiring Wiring Inspection Ini qe ER Battery Removal Battery Installation Battery Activation Interchange siiis cour iens 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 Starter Motor Clutch Removal Installation Starter Motor Clutch Inspection Starter Motor Clutch Disassembly Starter Motor Clutch Assembly Alternator Inspection Regulator Rectifier Inspection Charging Volta
69. the ECU cannot memorize these problems the Fl indicator light LED doesn t go on and no service codes can be displayed FI Indicator Light LED Fuel Pump Fuel Pump Relay DFI Main Relay ECU Power Source Wiring and Ground Wiring see ECU Inspection in the this chapter Fuel Injectors How to Erase Service Codes How to Erase Service Codes OEven if the ignition switch is turned OFF the battery or the ECU are disconnected or the problem is solved all service codes remain in the ECU ORefer to the Service Code Clearing Procedure for the service code erasure 3 42 FUEL SYSTEM DFI Self Diagnosis Service Code Table Service Code Table Service Code FI Indicator LED Light ON OFF Problems Main throttle sensor malfunction wiring open or short Inlet air pressure sensor malfunction wiring open or short Inlet air temperature sensor malfunction wiring open or short Water temperature sensor malfunction wiring open or short Atmospheric pressure sensor malfunction wiring open or short 5 N Crankshaft sensor malfunction wiring open or short Camshaft position sensor malfunction wiring open or short Speed sensor malfunction wiring open or short First 24 is displayed and then 25 repeatedly js Vehicle down sensor malfunction wiring open or short Subthrottle sensor malfunction wiring open or short Immobilizer amplifier malfunction K
70. the injector 1 to stop fuel to the cylinder 1 continuously to the ECU though the engine keeps running Stick Coil The stick coil primary If the ignition primary winding 2 has failures no 42 Ignition winding must send signal wiring short or open the ECU shuts off Coi signals output voltage the injector 2 to stop fuel to the cylinder 2 continuously to the ECU though the engine keeps running Stick Coil The stick coil primary If the ignition primary winding 3 has failures no 3 Ignition winding must send signal wiring short or open the ECU shuts off Coil signals output voltage the injector 3 to stop fuel to the cylinder 3 continuously to the ECU though the engine keeps running 4 The stick coil primary If the ignition primary winding 4 has failures no Stick Coil on 4 Ignition winding must send signal wiring short or open the ECU shuts off Coi signals output voltage the injector 4 to stop fuel to the cylinder 4 continuously to the ECU though the engine keeps running The actuator operates Subthrottle and close of the If the subthrottle valve actuator fails the signal is 62 Valve subthrottle valve by the out of the usable range wiring short or open the Actuator pulse signal from the ECU stops the current to the actuator ECU Note 1 D J Method and a N Method When the engine load is light like at idling or low speed the ECU determines the injection quantity by calculating f
71. with new ones OApply brake fluid to the fluid seals and install them into the cylinders by hand e Replace the dust seals B with new ones if they are dam aged OApply brake fluid to the dust seals and install them into the cylinders by hand GLO5067BS1 C 6105040251 C PERIODIC MAINTENANCE 2 57 Periodic Maintenance Procedures e Apply brake fluid to the outside of the pistons and push them into each cylinder by hand e Check the shaft rubber friction boot A and the dust cover B replace them with new ones if they are damaged e Apply a thin coat of PBC Poly Butyl Cuprysil grease to the caliper holder shafts C and holder holes D PBC is a special high temperature water resistance grease e Install the anti rattle spring A e Install the pads see Brakes chapter e Wipe up any spilled brake fluid on the caliper with wet cloth Rear Caliper Disassembly e Remove the rear caliper e Remove the pads and anti rattle spring see Brakes chap ter e Using compressed air remove the piston OCover the piston area with a clean thick cloth B OBlow compressed air A into the hole for the banjo bolt to remove the piston 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 e Remove the dust seal and fluid seal e Remove
72. 000 rpm in case the input fre quency would be approximately 200 Hz GP17221BS2 C d 10 15V ito 50 ov GP17048BS1 C 16 70 ELECTRICAL SYSTEM Meter Gauge Indicator Unit 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 wire quick open and connect the ter minal 1 to the terminal 7 repeatedly OThen the tachometer needle A should flick B x lf the needle does not flick replace the meter assembly Indicator Lights Inspection e Connect the 12 V battery and terminals in the same man ner as specified in the Liquid Crystal Display LCD Seg ments check Neutral Indicator Light A Fl Indicator Light LED B Oil Pressure Warning Indicator Light C Right Turn Signal Indicator Light D Left Turn Signal Indicator Light E High Beam Indicator Light F e Using the auxiliary leads connect a 12 V battery to the meter unit connector as follows Neutral Indicator Light Battery Negative Terminal To Terminal 5 FI Indicator Light LED Battery Negative Terminal To Terminal 6 Oil Pressure Warning Indicator Light Battery Negative Terminal To Terminal 11 GP17212BS1 C GP17052B
73. 12 V 8 Ah Taillight LED License Plate Light Joint Connector B ELECTRICAL SYSTEM 16 57 Lighting System Turn Signal Light Circuit GP12192BW3 C other than United States 6 Junction Box 13 Front Left Turn Signal Canada and Malaysia 7 Turn Signal Fuse 10 Light 1 Frame Ground 8 Ignition Switch 14 Joint Connector A 2 Meter Ground 9 Meter Unit 15 Main Fuse 30 3 Hazard Button United 10 Left Turn Signal Indicator 16 Battery 12 V 8 Ah States Canada Light 17 Rear Right Turn Signal Malaysia only 11 Right Turn Signal Indicator Light 4 Turn Signal Switch Light 18 Rear Left Turn Signal Light 5 Turn Signal Relay 12 Front Right Turn Signal 19 Joint Connector Light Turn Signal Light Bulb Replacement e Unscrew the screw A and remove the lens B 16 58 ELECTRICAL SYSTEM Lighting System e Push and turn the bulb A counterclockwise and remove it Insert the new bulb A by aligning its upper and lower pins B with the upper and lower grooves C in the socket and turn the bulb clockwise OTurn the bulb about 15 Turn Signal Relay Inspection e Remove Seat see Frame chapter Seat Cover see Frame chapter Turn Signal Relay A 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 Batte
74. 1293 7571129ST C 7571293ST C Jack Bearing Remover Shaft 13 57001 1238 57001 1377 7571238ST C ST5713778T C 10 6 WHEELS TIRES Wheels Rims Front Wheel Removal e Remove Brake Caliper Mounting Bolts A Front Brake Caliper B A AS b CN d e Using the stand A stay on the calipers B e Loosen the front axle clamp bolt A e Unscrew the front axle B e Raise the front wheel off the ground Special Tool Jack 57001 1238 Pull out the axle to the right and drop the front wheel out of the forks CAUTION Do not lay the wheel down on one of the discs This can damage or warp the disc Place blocks un der the wheel so that the disc does not touch the ground Front Wheel Installation NOTE OThe direction of the wheel rotation A is shown by an arrow B on the wheel hub e Check the wheel rotation mark on the front wheel and install it WHEELS TIRES 10 7 Wheels Rims e Fit the collars A on the both sides of the hub e Tighten the front axle Torque Front Axle 108 N m 11 kgf m 80 ft Ib e Before tightening the clamp bolt on the right front fork leg pump the front fork up and down 4 or 5 times to allow the right front fork leg to seat on the front axle NOTE OPut a block in front of the front wheel to stop moving e Tighten the axle clamp bolt A Torque Front Axle Clamp Bolt 34 3 5 kgf m 25 ft I
75. 13 Throttle Body Assy Immobilizer Neutral Switch ECU Main Relay Fuel Pump Relay DFI Self diagnosis Terminal Amplifier Equipped Models Immobilizer Subthrottle Sensor DFI Main Throttle Sensor DFI Ignition Switch and Immobilizer Antenna Immobilizer Equipped Models Fl Indicator Light LED DFI Vehicle down Sensor DFI Crankshaft Sensor FUEL SYSTEM DFI 3 17 Specifications Item Standard Digital Fuel Injection System Idle Speed 1 100 50 r min rpm Throttle Assy Type Four barrel type Bore 34 mm 1 34 in ECU Electronic Control Unit Make Denso Type Digital memory type with built in IC igniter sealed Usable Engine Speed Fuel Pressure High Pressure Line Right after Ignition Switch ON After 3 Seconds from Ignition Switch ON With Engine Idling Fuel Pump Type Discharge Fuel Injectors Type Nozzle Type Resistance Main Throttle Sensor Input Voltage Output Voltage at Idle Throttle Opening Output Voltage at Full Throttle Opening Resistance Inlet Air Pressure Sensor or Atmospheric Pressure Sensor Input Voltage Output Voltage Inlet Air Temperature Sensor Resistance Output Voltage at ECU Water Temperature Sensor Resistance Output Voltage at ECU Speed Sensor Input Voltage at Sensor Output Voltage at Sensor Vehicle down Sensor Detection Method Detection Angle with resin 100 12 240 r min rpm 3
76. 3 Release the brake C NOTE OThe fluid level must be checked often during the bleed ing operation and replenished with fresh brake fluid as necessary If the fluid in the reservoir runs completely out any time during bleeding the bleeding operation must be done over again from the beginning since air will have entered the line OTap the brake hose lightly from the caliper to the reser voir for more complete bleeding OFront Brake Repeat the above steps for the other caliper e Remove the clear plastic hose e Install the reservoir cap e Tighten Torque Front Brake Reservoir Cap Screws 1 0 0 10 kgf m 9 in Ib e Follow procedure below to rear brake fluid reservoir cap correctly OFirst tighten the rear brake fluid reservoir cap B clock wise C by hand until slight resistance is felt indicating that the cap is seated on the reservoir body then tighten the cap an additional 1 6 turn D while holding the brake fluid reservoir body A e Tighten the bleed valve and install the rubber cap Torque Bleed Valve 7 8 0 80 kgf m 69 in Ib e Check the fluid level e After bleeding is done check the brake for good braking power no brake drag and no fluid leakage 8813051 52 C 12 20 BRAKES Brake Fluid WARNING When working with the disc brake observe the pre cautions listed below 1 2 3 Never reuse old brake fluid Do not use fluid from a co
77. 3 113 in Ib 3 Alternator Lead Holding Plate Bolt 11 1 1 95 L 4 Starter Motor Mounting Bolts 11 1 1 95 5 Coil Bolts 11 1 1 95 in Ib 6 Alternator Rotor Bolt 110 11 81 7 Starter Motor Clutch Bolts 12 1 2 104 in Ib L 8 Alternator Cover Bolts 11 1 1 95 9 Crankshaft Sensor Bolts 5 9 0 60 52 10 Crankshaft Sensor Cover Bolts 11 1 1 95 in Ib 11 Timing Rotor Bolt 39 4 0 29 12 Camshaft Position Sensor Bolt 12 1 2 104 in Ib L 13 Radiator Fan Switch 18 1 8 13 14 Starter Relay Cable Terminal Bolts 3 9 0 40 35 in Ib L 15 Pressure Switch Terminal Bolt 1 5 0 15 13 in Ib G Oil Pressure Switch 17 Radiator Fan 18 Crankshaft Sensor 19 Camshaft Position Sensor 20 Starter Relay Main Fuse 21 Stick Coils 22 Ignition Switch 23 Ignition Switch Immobilizer Models 24 Amplifier Immobilizer Models G Apply Grease L Apply a non permanent locking agent M Apply molybdenum disulfide grease R Replacement Parts SS Apply silicone sealant 16 8 ELECTRICAL SYSTEM Exploded View ELECTRICAL SYSTEM 16 9 Exploded View No Fastener Tordue Remarks N m kgf m ft Ib 1 Regulator Rectifier Bolts 6 9 0 70 61 in Ib 2 Fuel Level Sensor Bolts 6 9 0 70 61 in Ib 3 Stand Switch Bolt 8 8 0 90 78 L 4 Neutral Switch 15 1 5 11 5 Speed Sensor Bolt 6 9 0 70 61 in Ib L 6 Speed Sensor Cover Bolts 6 9 0 70 61 in Ib L Regula
78. 3 86 FUEL SYSTEM Fuel Line e Open the fuel tank cap A to lower the pressure in the tank e Be sure to place a piece of cloth around the fuel pump outlet hose e Remove the fuel pump outlet hose A from the fuel pump B and the delivery pipe C see Fuel Pump Removal Front D A WARNING Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately GC17184BS1 C When the fuel hose is disconnected fuel spills out from the hose and the pipe because of residual pressure Cover the hose connection with a piece of clean cloth to prevent fuel spillage e Connect the plastic hose A to the fuel pump outlet pipe Secure the plastic hose with a clamp e Run the other side of the plastic hose into the measuring cylinder C Front D A WARNING Wipe off spilled out fuel immediately Be sure to hold the measuring cylinder vertical e Temporarily install the fuel tank and close the fuel tank cap e With the engine stopped turn the ignition switch ON The fuel pump should operate for 3 seconds and then should stop Repeat this several times until the plastic hose is filled with fuel CAUTION Do not drive the fuel pump without the fuel in the fuel tank Measure the discharge for 3 seconds with the plastic hose filled with fuel ORepeat this operation several times Amount of Fuel Flow Standard 67 mL or more for 3 seconds x If the
79. 4176 in None 36 009 36 016 mm 1 4177 1 4179 in Select the proper bearing insert A in accordance with the combination of the crankcase and crankshaft coding Size Color B 6105011451 C 45 44 3 2 1 6105011551 C 6105041781 Crankcase Crankshaft Bearing Insert Bearing Inside Journal Diameter Diameter Marking Marking Size Color Part Number Journal Nos 92028 1868 3 5 1 Brown 92028 1829 1 2 4 None 1 92028 1867 3 5 Black None 92028 1828 1 2 4 92028 1866 3 5 None None Blue 92028 1827 124 The bearing inserts for Nos 1 2 and 4 journals have an oil groove respectively e Install the new inserts in the crankcase halves and check insert journal clearance with the plastigage CRANKSHAFT TRANSMISSION 9 21 Transmission Shift Pedal Removal e Mark A the position of the shift lever B on the shift shaft so that it can be installed later in the same position e Remove Shift Lever Bolt C Shift Lever e Remove Footpeg Bracket Bolts A Footpeg Bracket B e Remove the bolt A footpeg B and shift pedal C Shift Pedal Installation e Apply grease to the oil seal lip e Press the oil seals A in the shift pedal housing B so that the oil seal surfaces are flush with the housing end C as shown Apply grease to the sliding surfaces A on the footpeg holder B e Apply a
80. 6 9 0 70 62 in Ib L Fuel Pump Bolts 9 8 1 0 87 in Ib L S Fuel Level Sensor Bolts 6 9 0 70 62 in Ib L TORX Screws 2 06 0 20 17 in Ib 17 in lb 74 87 in lb 95 95 in lb 95 61 in Ib 61 in Ib 61 in lb 61 in Ib 61 in Ib 61 in lb PERIODIC MAINTENANCE 2 7 Torque and Locking Agent Fastener Nm fb Remarks Radiator Fan Switch 18 1 8 13 IT Engine Top End Air Suction Valve Cover Bolts Cylinder Head Cover Bolts Camshaft Bolts Camshaft Chain Guide Bolts 87 87 104 in Ib 104 in Ib Cylinder Head Bolts M10 New Bolts 40 Cylinder Head Bolts M10 Used Bolts 36 Cylinder Head Bolts M6 104 in Ib Cylinder Head Water Jacket Plugs 16 Throttle Body Holder Bolts 13 1 3 113 in Ib Throttle Body Assy Holder Clamp Bolts 2 0 0 20 17 in lb Camshaft Position Sensor Bolt 12 1 2 104 in Ib Camshaft Position Sensor Rotor Bolt 12 1 2 104 in Ib L Front Camshaft Chain Guide Bolt Upper 25 2 5 18 Front Camshaft Chain Guide Bolt Lower 12 1 2 104 in Ib Rear Camshaft Chain Guide Bolt 25 2 5 18 Camshaft Chain Tensioner Mounting Bolts 11 1 1 95 in Ib Camshaft Chain Tensioner Cap Bolt 28 2 9 21 Spark Plugs 13 1 3 113 in Ib Coolant Drain Plug Cylinder 9 8 1 0 87 in lb Exhaust Pipe Manifold Holder Nuts 17 1 7 12 Muffler Body Clamp Bolt 17 1 7 12 Muffler Body Mounting Bolt 30 3 0 22 Crankshaft Sensor Cover Bolts 11 1 1 95 in Ib Clutch
81. A CAUTION Do not pinch the leads e Apply a non permanent locking agent to the threads and tighten the screws B ELECTRICAL SYSTEM 16 91 Immobilizer System Equipped Models Immobilizer Relational Parts Replacement Chart Failed or Lost Part Master Ignition An Ampli Key Switch tenna fier ERU Red Master Key Red User Key Black Ignition Switch e e ECU Replacement Part Main Replacement Part Additional Replacement Immobilizer System Inspection e Refer to the Immobilizer Amplifier and Blank Key Detec tion section in the Fuel System DFI chapter 16 92 ELECTRICAL SYSTEM Immobilizer System Equipped Models Immobilizer System Circuit 3 1 Ignition Switch 7 Meter Unit 14 Main Fuse 30A 2 Meter Ground 8 Immobilizer Antenna 15 Starter Relay 3 Frame Ground 9 Joint Connector A 16 Battery 12 V 8 Ah 4 Joint Connector B 10 Junction Box 17 Immobilizer Kawasaki Diag 5 Immobilizer Amplifier 11 Ignition Fuse 10 nostic System Connector 6 Fl Indicator Light LED 12 ECU Main Relay 18 ECU 13 ECU Fuse 15 A ELECTRICAL SYSTEM 16 93 Switches and Sensors Brake Light Timing Inspection e Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance chapter Brake Light Timing Adjustment e Refer to the Brake Light Switch Operation Inspection in th
82. A Guard Bracket Bolts B Guard Bracket C e Loosen the locknut A and turn the push rod with the hex head B to achieve the correct pedal position x If the length C shown is 70 1 mm 2 76 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 kgf m 13 ft Ib e Check the brake light switch operation see Periodic Maintenance chapter Brake Pedal Removal e Remove Reservoir Tank Bolt A Guard Bracket Bolts B Guard Bracket C 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 F with the front footpeg assy Brake Pedal Installation e Apply high temperature grease to the footpeg pivot shaft Install Brake Pedal Brake Pedal Bolt C Torque Brake Pedal Bolt 34 N m 3 5 kgf m 25 in lb e Hook the lower end of the rear brake light switch spring A on the pedal hook e Hook the upper end of the return spring B on the pedal hook e Replace the cotter pin with a new one Olnsert the cotter pin C and bend the pin ends D 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
83. Air Pressure Sensor Circuit 6617824 1 C ECU Joint Inlet Air Pressure Sensor 3 54 FUEL SYSTEM DFI Inlet Temperature Sensor Service Code 13 Removal Installation CAUTION Never drop the sensor especially on a hard surface Such a shock to the sensor can damage it e Remove the fuel tank see Fuel Tank Removal e Disconnect the connector A from the inlet air tempera ture sensor e Pull out the inlet air temperature sensor e Put the inlet air temperature sensor into the grommet Output Voltage Inspection NOTE OBe sure the battery is fully charged OThe output voltage changes according to the inlet air temperature e Remove the ECU see this chapter Do not disconnect the ECU connectors e Connect a digital voltmeter to the ECU connector using needle adapter set Special Tool Needle Adapter Set 57001 1457 e Measure the sensor output voltage with the engine stopped and the connector joined e Turn the ignition switch ON Inlet Air Temperature Sensor Output Voltage Connections to ECU Connector Meter Y lead terminal 18 Meter BR BK lead terminal 14 Connections to ECU Connector Immobilizer Equipped Models A Meter Y lead terminal 10 Meter BR BK lead terminal 20 Standard about 2 25 2 50 V at inlet air temperature 20 68 e Turn the ignition switch OFF x
84. Apply molybdenum disulfide grease to the pusher ends A and install the bearing B pusher C spring D and washer E in the clutch spring plate F OApply engine oil to the bearing e Install the clutch spring plate 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 e Install the clutch cover see Clutch Cover Installation GF06040181 C GFOGOSIBST1 C 6 12 CLUTCH Clutch Clutch Plate Assembly Inspection e Inspect the friction plate thickness see Clutch Plate Wear Damage Inspection e Measure the length A of the clutch plate assembly as shown OAssemble Clutch Hub B Spring Seat C Spring D Friction Plates E Steel Plates F Spring Plate G Springs H Spring Holders I Spring Bolts J Torque Clutch Spring Bolts 8 8 N m 0 90 kgf m 78 in Ib Clutch Plate Assembly Standard 37 7 38 3 mm 1 48 1 51 in xIf the length is not within the specified range adjust the length see Clutch Plate Assembly Adjustment Clutch Plate Assembly Adjustment e Inspect the clutch plate assembly length and then re place the steel plate s which brings the length within the specified range e Remove Spring Bolts Spring Holders Springs Spring Plate e Replace the following steel plate s Part No Thickness 13089 1126 1 4 mm 0 055 in 13089 013 1 6 mm 0 063 in STD 13089 1073 2 0 mm 0 079 in
85. Crankshaft Sensor Installation e Route the crankshaft sensor lead correctly see Cable Wire and Hose Routing in Appendix chapter e Tighten Torque Crankshaft Sensor Bolts 5 9 N m 0 60 kgf m 52 in Ib e Apply silicone sealant A to the crankshaft sensor lead grommet and crankcase halves mating surface on the front and rear sides of the crankshaft sensor cover mount Sealant Kawasaki Bond Silicone Sealant 92104 0004 e Install the clamps A direction as shown e Tighten Torque Crankshaft Sensor Cover Bolts 11 N m 1 1 kgf m 95 in Ib e Hold the sensor lead A with the clamp B Upper Crankcase C GP101189BS1 C e Install oil pressure switch lead terminal A securely Olnstall the lead terminal direction upward Torque Pressure Switch Terminal Bolt 1 5 0 15 kgf m 13 in Ib e Install the removed parts see appropriate chapters 16 38 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Inspection e Remove Right Frame Cover see Frame chapter Crankshaft Sensor Lead Connector A Set the hand tester to the x 100 range and connect lead to the yellow black lead and lead to the black lead in the connector 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 is shorted and must be replaced Cr
86. Disconnect the connector Fuel Pump Relay Inspection e Remove the fuel pump relay see above e Connect the hand tester A and one 12 V battery B to the relay connector C as shown Special Tool Hand Tester 57001 1394 Relay Coil Terminals 1 and 2 Relay Switch Terminals 3 and 4 Testing Relay Tester range 1 range Criteria When battery is connected 00 When battery is disconnected x If the relay does not work as specified replace the relay FUEL SYSTEM DFI 3 91 Fuel Pump Relay Fuel Pump Circuit on Par CT BATTERY 53 z 66178508182 ECU lgnition Switch Fuel Pump Relay for fuel pump and injectors Main Fuse 30 A Starter Relay Battery 12 V 8 Ah Fuel Pump Engine Stop Switch Ignition Fuse 10 Junction Box Joint Connector B Terminal 11 immobilizer Equipped Models power Supply 3 92 FUEL SYSTEM DFI Fuel Injectors Removal Installation e Refer to the Throttle Body Assy Disassembly Assembly Audible Inspection e Start the engine e Apply the tip of a screwdriver A to the injector C Put the grip end onto your ear and listen whether the injector is clicking or not OA sound scope B can also be used e Do the same for the other injectors x If all the injectors click at a regular intervals the injectors are good The trouble may be related to the fuel line
87. 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 layer of engine oil before storing Marks Stamped on the Cutter The marks stamped on the back of the cutter A represent the following ree ee dni Cutter angle B 0931 5 dete Outer diameter of cutter C Operating Procedures e Clean the seat area carefully e Coat the seat with machinist s dye e Fit a 45 cutter into the holder and slide it into the valve guide e Press down lightly on the handle and turn it right or left Grind the seating surface only until it is smooth CAUTION Do not grind the seat too much Over
88. F Pullout e Remove the cylinder head cover bolts A e Clear the cylinder head cover A to the coolant pipe B ORemove the head cover to left side Cylinder Head Cover Installation e Replace the head cover gasket with a new one e Apply silicone sealant A to the cylinder head as shown Sealant Kawasaki Bond Silicone Sealant 92104 0004 GEO9014BS1 C ENGINE TOP END 5 13 Cylinder Head Cover e Install Dowel Pins A Plug Hole Gaskets B as 2 EN lt lt i 24 aW e Install Washer A Bolts B Olnstall the washer with the metal side faces upward e Tighten the cover bolts following the specified tightening sequence ORetighten the two cover bolts 7 8 as shown Torque Cylinder Head Cover Bolts 9 8 1 0 kgf m 87 in Ib e Install the removed parts see appropriate chapters GE09035BS1 5 14 ENGINE TOP END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION This is a non return type camshaft chain tensioner The push rod does not return to its original position once it moves out to take up camshaft chain slack Observe all the rules listed below When removing the tensioner do not take out the mounting bolts only halfway Retightening the mounting bolts from this position could damage the tensioner and the camshaft chain Once the bolts are loosened the tensioner must be removed and reset as de
89. Head Installation 5 19 InistallatlOn tuere 5 34 5 2 ENGINE TOP END Exploded View GE021618W5 C ENGINE END 5 3 Exploded View No Fastener Remarks Nm kgf m ft Ib 1 Air Suction Valve Cover Bolts 9 8 1 0 87 2 Cylinder Head Cover Bolts 9 8 1 0 87 in lb S 3 Camshaft Cap Bolts 12 1 2 104 in Ib S 4 Camshaft Chain Guide Bolts 12 1 2 104 in Ib S 5 Cylinder Head Bolts M10 New Bolts 54 5 5 40 MO S Cylinder Head Bolts M10 Used Bolts 49 5 0 36 MO S 6 Cylinder Head Bolts M6 12 1 2 104 in Ib S 7 Cylinder Head Jacket Plugs 22 2 2 16 L 8 Throttle Body Holder Bolts 13 1 3 113 in Ib 9 Throttle Body Assy Holder Clamp Bolts 2 0 0 20 17 in lb 10 Camshaft Position Sensor Bolt 12 1 2 104 in Ib 11 Camshaft Position Sensor Rotor Bolt 12 1 2 104 in Ib L z FronCamshatChamGuieBot Uppe 25 25 18 18 FronCamshafChamGuideBot owe 12 12 14 Rear Camshaft Chain Guide Bolts 25 25 18 15 Camshaft Chain Tensioner Mounting Bos M 11 95m 16 CamshatChamTensonerCapBot 28 29 21 BekPus 13 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 specific tightening sequence SS Apply silicone sealant
90. Inspection First Step e Turn on the ignition switch e Set the neutral position e Turn the engine stop switch A to stop position 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 Electrical System chapter Second Step e Turn on the ignition switch e Set the neutral position e Turn the engine stop switch A to run position 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 inspect or replace the follow ing item Engine Stop Switch see Electrical System chapter the engine stop switch is good condition replace the ECU Others Chassis Parts Lubrication e Before lubricating each part clean off any rusty spots with rust remover and wipe off any grease oil dirt or grime e Lubricate the points listed below with indicated lubricant NOTE OWhenever the vehicle has been operated under wet or rainy conditions or especially after using a high pressure water spray perform the general lubri cation Pivots Lubricate with Motor Oil Rear Brake Rod Joint 2 46 PERIODIC MAINTENANCE Periodic Maintenance Procedures Points Lubricate with Grease Throttle and Choke Inner Cable Upper Ends A Clutch Lever Pivot Brake Lever Pivot Apply silicone grease Brake Pedal Pivot Side Stand Cables Lub
91. J Pressing the incorrect race can cause pressure between fe 5 At the inner and outer race and result in bearing damage gt 7 L 68020188 Seal Grease Seal Do not remove pressed oil or grease seals unless removal is with new whenever removed H Lt GS Press new oil seals with manufacture and size marks facing out Make sure the seal is aligned properly when installing Rss 68020198 Apply specified grease to the lip of seal before installing the seal Grease GBO2046BS1 C Circlips Cotter Pins Replace circlips or cotter pins that were removed with new ones Take care not to open the clip excessively when in stalling to prevent deformation 68020268 5 1 6 GENERAL INFORMATION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation Lubri cation points are called out throughout this manual apply the specific oil or grease as specified Direction of Engine Rotation When rotating the crankshaft by hand the free play amount of rotating direction will affect the adjustment Ro tate the crankshaft to positive direction clockwise viewed from output side Electrical Wires A two color wire is identified first by the primary color and then the stripe color Unless instructed otherwise electrical wires must be connected to th
92. NOTE ODo not use the steel plate of 1 4 mm 0 055 in and 2 0 mm 0 079 in thickness at the same time e Install the removed parts and inspect the clutch plate as sembly length Torque Clutch Spring Bolts 8 8 N m 0 90 kgf m 78 in Ib 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 x If any plates show signs of damage or if they have worn past the service limit replace them with new ones Friction Plate Thickness Standard 2 72 2 88 mm 0 107 0 113 in Service Limit 2 4 mm 0 094 in 6706012852 C GF06060281 CLUTCH 6 13 Clutch 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 2 mm 0 008 in or less Service Limit 0 3 mm 0 012 in Clutch Spring Free Length Measurement e Measure the free length of the clutch springs A If any spring is shorter than the service limit it must be replaced Clutch Spring Free Length Standard 80 6 mm 3 17 in Servic
93. OThe gauge needle will fluctuate Read the pressure at the average of the maximum and minimum indications x lf the fuel pressure is normal the fuel circulation system fuel pump pressure regulator and fuel passage is no faults Check the DFI electronic control system injectors sensors crankshaft sensor and ECU xIf the fuel pressure is much lower than specified check the following Fuel Pump Inlet Hose Clogging Fuel Line Leakage Fuel Pump Operation check the sound of the pump Amount of Fuel Flow see Fuel Flow Rate Inspection x If the fuel pressure is much higher than specified check the following Delivery Pipe Clogging Injector Clogging e Remove the fuel pressure gauge and adapter Install the fuel tank see Fuel Tank Installation Fuel Flow Rate Inspection NOTE OBe sure the battery is fully charged WARNING Gasoline is extremely flammable can 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 Wait until the engine cools down e Prepare a plastic hose of the inside diameter 7 5 mm 0 30 in and a measuring cylinder e Remove the fuel tank bolt see Fuel Tank Removal
94. OWhen problem occurs with the DFI system and ignition system the DFI indicator light LED A goes NOTE OUse a fuly charged battery when conducting self diagnosis Otherwise the light LED blinks very slowly or doesn t blink OKeep the self diagnosis terminal grounded during self diagnosis with an auxiliary lead e Remove the seat see Frame chapter e Ground A the self diagnosis terminal B yellow lead to the battery terminal C or battery lead connector using a wire e Turn on the ignition switch e Connect an auxiliary lead E to the self diagnosis terminal G for grounding e To enter the self diagnosis dealer mode 1 ground A the self diagnosis indicator terminal to the battery terminal for more than 2 seconds C and then keep it grounded continuously D OCount the blinks of the light LED to read the service code Keep the auxiliary lead ground until you finish read ing the service code 6C17071BS1 C FUEL SYSTEM DFI 3 39 Self Diagnosis e To enter the self diagnosis dealer mode 2 open and ground A the lead more than five times F within 2 sec onds C after the lead is first grounded and then keep it grounded continuously D for more than 2 seconds OCount the blinks of the light LED to read the service code Keep the auxiliary lead ground until you finish read ing the service code Auxiliary Lead E Self diagnosis Terminal G
95. Pliers Oil Filter Wrench 57001 144 57001 1249 7570144ST C 7571249ST C Oil Pressure Gauge 10 kgf cm Kawasaki Bond Silicone Sealant 57001 164 56019 120 7570164ST C 875601205 C Oil Pressure Gauge Adapter PT3 8 x 19 in 57001 1233 7 8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter A WARNING Motorcycle operation with insufficient deteri orated or contaminated engine oil will cause accelerated wear and may result in engine or trans mission seizure accident and injury Oil Level Inspection e Check that the engine oil level is between the upper A and lower B levels in the gauge NOTE OSituate the motorcycle so that it is perpendicular to the ground Olf the motorcycle has just been used wait several min utes for all the oil to drain down Olf the oil has just been changed start the engine and run it for several minutes at idle speed This fills the oil filter with oil Stop the engine then wait several minutes until the oil settles CAUTION Racing the engine before the oil reaches every part can cause engine seizure If the engine oil gets extremely low or if the oil pump or oil passages clog up or otherwise do not function properly the oil pressure warning light will light If this light stays on when the engine is running above idle speed stop the engine immediately and find the cause x lf the oil level is too high remove the excess oil u
96. Remove the air suction valve see Engine Top End chap ter e Visually inspect the reeds for cracks folds warps heat damage or other damage x If there is any doubt as to the condition of the reeds A replace the air suction valve as an assembly e Check the reed contact areas B of the valve holder for grooves scratches any signs of separation from the holder or heat damage e If there is any doubt as to the condition of the reed contact areas replace the air suction valve as an assembly e f any carbon or other foreign particles have accumulated between the reed and the reed contact area wash the valve assembly clean with a high flash point solvent CAUTION Do not scrape off the deposits with a scraper as this could damage the rubber requiring replacement of the suction valve assembly Vacuum Switch Valve Removal e Remove Fuel Tank see Fuel System DFI chapter Left Air Suction Valve Cover see Air Suction Valve Re moval Vacuum Switch Valve A ENGINE TOP END 5 11 Clean Air System Vacuum Switch Valve Installation e Install the vacuum switch valve so that the vacuum fitting A faces left side e Route the hoses correctly see Appendix chapter Vacuum Switch Valve Test e Remove Vacuum Switch Valve see Vacuum Switch Valve Re moval e Connect a vacuum gauge A and syringe B or fork oil level gauge to the vacuum hoses as shown Special Tool Fork Oil Level G
97. Technical Information Immobilizer System Equipped Models Immobilizer System Circuit 49 9 GP301258W2 C 10 Junction Box 11 Ignition Fuse 10 A 12 ECU Main Relay 13 ECU Fuse 15 A 14 Main Fuse 30 A 15 Starter Relay 16 Battery 12 V 8 Ah 17 Immobilizer Kawasaki Diagnostic System Connector 18 Electronic Control Unit ECU Ignition Switch Meter Ground Frame Ground Joint Connector B Immobilizer Amplifier Fl Indicator Light LED Meter Unit Immobilizer Antenna Joint Connector A 5 GENERAL INFORMATION 1 21 Unit Conversion Table Prefixes for Units Units of Length Prefix Symbol Power km 0 6214 1000 000 m x 3 281 ft kilo k x 1000 mm x 0 03937 in centi C x 0 01 milli m x 0 001 micro 0 000001 Units of Torque N m x 0 1020 kgf m N m x 0 7376 ft lb Units of Mass N m x 8 851 in Ib kg x 2 205 Ib kgf m x 9 807 N m g x 0 03527 oz kgf m x 7 233 ft lb kgf m x 86 80 in Ib Units of Volume L x 0 2642 05 Units of L x 0 2200 gal imp kPa x 0 01020 kgf cm L x 1 057 qt US kPa x 0 1450 psi L x 0 8799 qt imp kPa x 0 7501 cmHg L x 2 113 pint US kgf cm 98 07 L x 1 816 pint imp kgfcm x 1422 psi mL x 0 03381 gt 2 5 1 333 kPa mL 0 02816 oz imp mL x 0 06102 cu in Units o
98. Temperature Sensor Removatv Installation e Refer to the Fuel System DFI chapter Water Temperature Sensor A Water Temperature Sensor Inspection e Refer to the Electrical System chapter for the Water Tem perature Sensor Inspection ENGINE TOP END 5 1 Engine Top End Table of Contents Exploded 5 2 Cylinder Head 5 20 Specifications 5 6 VAIVES 5 21 Special Tools and Sealant 5 8 Valve Clearance Inspection 5 21 Clean Air System 5 10 Valve Clearance Adjustment 5 21 Air Suction Valve Remowval 5 10 Valve 5 21 Air Suction Valve Installation 5 10 Valve Installation 5 21 Air Suction Valve Inspection 5 10 Valve Guide Removal 5 21 Vacuum Switch Valve Removal 5 10 Valve Guide Installation 5 22 Vacuum Switch Valve Installation 5 11 Valve to Guide Clearance Vacuum Switch Valve Test 5 11 Measurement Wobble Clean Air System Hose Method 5 22 5 11 Valve Seat Inspection 5 23 Cylinder Head Cover 5 12 Valve Seat Repair 5 23 Cylinder Head Cover Removal 5 12 Cylinder Pistons
99. Tighten Torque Brake Disc Mounting Bolts 27 N m 2 8 kgf m 20 ft Ib Brake Disc Wear e Measure the thickness of each disc A at the point where it has worn the most x If the disk has worn past the service limit replace it Measuring Area B Front Disc Thickness Standard 4 3 4 5 mm 0 17 0 18 in Service Limit 4 0 mm 0 16 in 6108040151 C Rear Disc Thickness Standard 4 8 5 2 mm 0 19 0 20 in Service Limit 4 5 mm 0 18 in Brake Disc Warp e Jack up the motorcycle so that the wheel is off the ground see Wheels Tires chapter Special Tool Jack 57001 1238 OFor front disc inspection turn the handlebar fully to one side e Set up a dial gauge against the disc A as shown and measure disc runout while turning B the wheel by hand runout exceeds the service limit replace the disc aLdedbisesi Disc Runout Standard Not more than 0 2 0 008 in Service Limit 0 3 mm 0 012 in 12 18 BRAKES Brake Fluid Brake Fluid Level Inspection e Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter Brake Fluid Change e Refer to the Brake Fluid Change in the Periodic Mainte nance chapter Brake 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
100. Valve Seat Inspection e Remove the valve see Valve Removal e Check the valve seating surface A between the valve B and valve seat C 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 Seat Repair Valve Seating Surface Outside Diameter Standard Exhaust 21 6 21 8 mm 0 850 0 858 Inlet 26 4 26 6 mm 1 0276 1 0472 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 Valve Seating Surface Width GET8011782 C Standard Exhaust 0 5 1 0 mm 0 020 0 039 in Inlet 0 5 1 0 mm 0 020 0 039 in Valve Seat Repair e Repair the valve seat with the valve seat cutters A Special Tools Valve Seat Cutter Holder Bar 57001 1128 C Valve Seat Cutter Holder 4 57001 1275 B For Exhaust Valve Seat Valve Seat Cutter 45 524 5 57001 1113 Valve Seat Cutter 32 525 57001 1118 Valve Seat Cutter 60 525 57001 1328 For Inlet Valve Seat Valve Seat Cutter 45 527 5 57001 1114 Valve Seat Cutter 32 528 57001 1119 Valve Seat Cutter 60 527 57001 1409 If the manufacturer s instructions are not available use the following procedure GE15048BS1 C 5 24 ENGINE TOP
101. W2RO174AW5 C 16 16 ELECTRICAL SYSTEM Wiring Diagram Malaysia Subthrottle Valve Actuator Spark Plugs si YYYY Stick W BL P BL BK BL Radiator Fuel Fuel vam eserve Leve i Switch Sensor Motor Heter Unit 1 Beam Indicator Light 2 Left Turn Signal Indicator Light ea 3 Right Turn Signal Indicator Light 11 4 Neutral Indicator Light 4 5 5 011 Pressure Warning Indicator Light c 6 Tachometer Light 7 Tachometer z 8 Speedo Tachometer Light 5 aa 8 Speedometer irt i0 Speedometer Light 11 Water Temperature Warning Indicator Light LED 12 FI Indicator Light LED i3 0dometer Trip WeterA B Clock 14 Fuel Level Gauge 8 BK Immobilizer R Amplifier Right Switch Housing u x Brake Ignition aal Light Switch Switch Engine Stop Switch Starter Immobilizer Antenna BK Y ay BL R R BK BR R BK LG 18 Heter Unit a BR R wY Button Front Right Turn Signal Light 1210 Starter Lockout Switch Passing Button ay City Light 1 R 12v58 EUM BL Y 6 Headlight BK Y 12V55 Headlight Y tij 12V55Y Front Left Turn Signal Left Switeh Housing Light 12V10N 1
102. air enters the brake lines brake lever or pedal movement will be partially used in compressing the air This will make the lever or pedal feel spongy and there will be a loss in braking power A WARNING Be sure to bleed the air from the brake line when ever brake lever or pedal action feels soft or spongy after the brake fluid is changed or when ever a brake line fitting has been loosened for any reason NOTE OThe procedure to bleed the front brake line is as follows Bleeding the rear brake line is the same as for the front brake e Remove Screws A Reservoir Cap B Diaphragm Plate C Diaphragm D e Fill the reservoir with fresh brake fluid to the upper level line in the reservoir e Slowly pump the brake lever several times until no air bubbles can be seen rising up through the fluid from the holes A at the bottom of the reservoir OBleed the air completely from the master cylinder by this operation GL09029BS1 C BRAKES 12 19 Brake Fluid eRemove the rubber cap from the bleed valve e Attach a clear plastic hose B to the bleed 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
103. and check the wiring between these connectors mam ODisconnect the ECU and sensor connectors Wiring Connection ECU Connector A Subthrottle Sensor Connector B BL lead terminal 1 BR BK lead terminal 14 ECU Connector A Subthrottle Sensor Connector B Immobilizer Equipped Models C BL lead ECU terminal 7 BR BK lead ECU terminal 20 xIf the wiring is good check the ECU for its ground and power supply see ECU section 0617815852 C 3 70 FUEL SYSTEM DFI Subthrottle Sensor Service Code 32 Output Voltage Inspection e Remove the throttle body assy see Throttle Body Assy Removal e Measure the output voltage at the subthrottle sensor in the same way as input voltage inspection Note the fol lowing e Disconnect the subthrottle sensor black connector and black connect the harness adapter A between these connectors Special Tool Throttle Sensor Harness Adapter 57001 1538 Measure the output voltage of the sensor with the engine stopped and with the connector joined e Turn the ignition switch ON e Measure the output voltage when the subthrottle valve is fully opened or completely closed by hand Main Throttle Sensor Output Voltage Connections to Adapter Meter W sensor BR lead Meter BK sensor BR BK lead Standard 0 48 0 52 V DC at idle throttle opening 3 6 3 8 V DC at full throttle opening x lf the output
104. and replace see chapter 5 Air suction valve trouble Inspect and replace see chapter 5 Check that DFI connectors are clean and tight Intermittent any DFI fault and its recovery and examine wires for signs of burning or fraying see chapter 3 Engine overheating Poor Running or No Power at High Speed igniter trouble 3 36 FUEL SYSTEM DFI DFI System Troubleshooting Guide Symptoms or Possible Causes Actions chapter Stick coil trouble Inspect see chapter 16 Fuel air mixture incorrect Air cleaner clogged poorly sealed or missing Clean element or inspect sealing see chapter 3 Air cleaner duct loose Reinstall see chapter 3 Air cleaner O ring damaged Replace see chapter 3 Change fuel Inspect and clean fuel system see chapter 3 Throttle body assy loose Reinstall see chapter 3 Throttle body assy O ring damaged Replace see chapter 3 Fuel tank air vent obstructed Inspect and repair see chapter 3 Fuel line clogged Inspect and repair see chapter 3 Fuel pump operates intermittently and often DFI Pump bearings may wear Replace the pump fuse blows see chapter 3 Water or foreign matter in fuel Fuel pump trouble Inspect see chapter 3 Inlet air temperature sensor trouble Inspect see chapter 3 Main throttle sensor trouble Inspect see chapter 3 Atmospheric pressure sensor trouble Inspe
105. beads and inflate the tire with compressed air until the tire beads seat in the sealing surfaces 6J05036BS1 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 Tire Inspection e Adjust the wheel balance see Balance Adjustment e Install the air valve cap Tire Repair Currently two types of repair for tubeless tires have come into wide use One type is called a temporary external re pair which can be carried out without removing the tire from the rim and the other type is called permanent internal repair which requires tire removal It is generally under stood that higher running durability is obtained by perma nent internal repairs
106. damage Replace it if necessary 5 6 04062551 13 14 SUSPENSION Front Fork Fork Spring Inspection e Measure the free length B of the fork spring A x If the measured length is shorter than the service limit the spring must be replaced If the free length of the replace ment spring and that of the remaining spring vary greatly the remaining spring should also be replaced in order to keep the fork legs balanced to ensure stability Fork Spring Free Length Standard 319 2 mm 12 57 in Service Limit 313 mm 12 3 in 8 04041351 C SUSPENSION 13 15 Rear Shock Absorber Rebound Damping Force Adjustment e Turn the damper adjuster A to adjust the rebound damp ing OAlign the numbered mark B of the adjuster to the position mark C OThe standard adjuster setting for average build rider of 68 kg 150 Ib with no passenger and no accessories is position 2 x If the damper s effectiveness is not suited to the operating conditions adjust it to an appropriate position by referring to the table below Rebound Damping Adjustment Shock Adjuster Damping Absorber Position Force Driving Speed Spring Preload Adjustment e Using the hook wrench A turn the adjusting nut B to adjust the spring preload OThe standard adjuster setting for average build rider of 68 kg 150 Ib with no passenger and no accessories is 4th position Spring Preload Setting
107. 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 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 GE15012181 GE15012281 5 26 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
108. e Measure the resistance of the antenna coil in the ignition switch as follows Antenna Resistance Connections to Antenna Meter Black Lead Meter Black Lead Standard About 0 6 0 9 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 Right Side Cover see Frame chapter Amplifier A 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 Meter BK Y Lead e Measure the input voltage DC with the connectors joined e Turn the ignition switch ON Input Voltage Standard Battery Voltage e Turn the ignition Switch OFF xIf the reading is out of the range check the wiring see wiring diagram in next section x If the reading and antenna resistance are good replace the amplifier FUEL SYSTEM DFI 3 73 Blank Key Detection Immobilizer Equipped Models Service Code 36 This code appears in the following conditions OThe transponder 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 e Regi
109. e Tighten OTemporary install each bolts and nuts OTouch the rear wheel on the ground OTighten the nuts Torque Tie rod Nuts 59 N m 6 0 kgf m 43 ft Ib Rear Shock Absorber Nut 34 N m 3 5 kgfm 25 ft Ib Rocker Arm Removal e Using the jack and attachment raise the rear wheel off the ground see Rear Shock Absorber Removal Special Tool Jack 57001 1238 Jack Attachment 57001 1608 e Squeeze the brake lever slowly and hold it with a band e Remove Lower Rear Shock Absorber Nut and Bolt A Lower Tie rod Nut and Bolt B Rocker Arm Nut C and Bolt Rocker Arm D SUSPENSION 13 23 Tie rod Rocker Arm Rocker Arm Installation e Tighten OTemporary install each bolts and nuts OTouch the rear wheel on the ground OTighten the nuts Torque Rocker Arm Nut 34 N m 3 5 kgf m 25 ft Ib Tie rod Nut 59 N m 6 0 kgf m 43 ft Ib Rear Shock Absorber Nut 34 N m 3 5 kgf m 25 ft Ib Tie rod and Rocker Arm Bearing Removal e Remove Tie rods see Tie rod Removal Rocker Arm A see Rocker Arm Removal Sleeves B Oil Seal C e Remove the needle bearings D using the bearing re mover head and bearing remover shaft 6107032812 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 24 SUSPENSION Tie rod Rocker A
110. 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 certainly after air pressure inspec tion Torque Air Valve Cap 0 15 N m 0 015 kgf m 1 3 in Ib 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 If any damage is found replace the wheel if necessary Tire Tread Wear Abnormal 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 tread life 90 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 Wheels Tires chapter 6J05007BS
111. idling voltage 5 RE WW DEN EDU WIS Hy A SW WS 68B061748W2 C A Subthrottle Valves B Subthrottle Valve Actuator C Subthrottle Sensor D Main Throttle Sensor E ECU Electronic Control Unit F Air Cleaner Side G Crankshaft Sensor H Speed Sensor 1 14 GENERAL INFORMATION Technical Information New Ignition Interlock Side Stand Outline The New Ignition Interlock Side Stand System applied to ZR750 K models that cannot function if gears are engaged and or the side stand is not lifted upward even though clutch lever pulled in which differs from the traditional one Refer to the tables below as to the engine starts and or the driving at each condition New Ignition Interlock Side Stand System Side Stand Gear Position Clutch Lever Engine Start Engine Run A Up Neutral Released Starts Continue running B Up Neutral Pulled in Starts Continue running Up In Gear Released Doesn t start Continue running D Up In Gear Pulled in Starts Continue running Neutral Released Starts Continue running F Down Neutral Pulled in Starts Continue running G Down In Gear Released Doesn t start Stops Pulled in Doesn t start Current Ignition Interlock Side Stand System Side Stand Gear Position Clutch Lever Engine Start Run A Up Neutral Released Starts Continue running B Neut
112. lead Run the camshaft position sensor lead inside the connector bracket Ignition Harness Connector Alternator Lead Neutral Switch Side Stand Switch Lead Clamp Clamp Hold the side stand neutral switch and speed sensor leads Speed Sensor Run the sidestand neutral switch and speedsensor leads inside the coolant pipe Clamps Alternator Lead Connector Clamp Atmospheric Pressure Sensor 17 12 APPENDIX Cable Wire and Hose Routing 08809734845 C 19 69 29 9 89 69 09 9 69 G9 9 ED ED 9 69 69 CY CH GY 69 CD 0 9 OH 69 9 69 G9 p ees CDN ar 5 cc x oe 2 7 7 2 O er eX X 6 65 69 2 62 9 62 62 2262 2 69 6 6 DOD 9 9 D 9 9 oT Qa 6 gt APPENDIX 17 13 Cable Wire and Hose Routing Headlight Harness Connector 2 Clamp Through the headlight harness of the main harness Clamp Through the main harness Clamp Clutch Cable Main Harness Meter Ground Clamp Hold the ignition switch connec tor Ignition Switch Lead Connector Inlet Air Pressure Sensor To Ignition Harness Connector Fan Motor Connector Connect the con nector on the inlet air pressure sensor To the main throttle sensor Clamp To the subthrottle sensor To Fuel Pump Lead Connector Upper Lower Fuel Level Gauge and Fuel Reserve
113. lf the output voltage is out of the standard remove the fuel tank and check the wiring And if the output voltage is 4 8 V the ECU is normal x If the output voltage is within the standard check the ECU for its ground and power supply see ECU section in this chapter x lf the wiring is good check the sensor resistance e Remove the needle adapter set and apply silicone sealant to the seals of the connector for waterproofing Silicone Sealant Kawasaki Bond 56019 120 Seals of ECU Connectors 051782 6617118851 C 6617825851 C FUEL SYSTEM DFI 3 55 Inlet Air Temperature Sensor Service Code 13 Sensor Resistance Inspection e Remove the inlet air temperature sensor e Suspend the sensor A in a container of machine oil so that the heat sensitive portion is submerged Suspend a thermometer with the heat sensitive por tion C located in almost the same depth with the sensor NOTE OThe sensor and thermometer must not touch the con tainer side or bottom e Place the container over a source of heat and gradually raise the temperature of the oil while stirring the oil gently for even temperature e Using a digital meter measure the internal resistance of the sensor across the terminals at the temperatures shown in the table Inlet Air Temperature Sensor Resistance Standard 1 6 3 7 at 20 C 68 F 0 24 0 43
114. light does not turn on continue the test e Do the 2nd step regulator circuit test OConnect the test light and the 12 V battery in the same manner as specified in the Regulator Circuit Test 1st Step OApply 12 V to the voltage BR terminal OCheck BK1 BK2 and BK3 terminal respectively x If the test light turns on the regulator rectifier is defective Replace it x If the test light does not turn on continue the test e Do the 3rd step regulator circuit test OConnect the test light and the 12 V battery in the same manner as specified in the Regulator Circuit Test 1st Step OMomentarily apply 24 V to the voltage BR terminal by adding a 12 V battery OCheck BK1 BK2 and BK3 terminals respectively CAUTION Do not apply more than 24 volts If more than 24 volts is applied the regulator rectifier may be dam aged Do not apply 24 V more than a few seconds If 24 volts is applied for more than a few seconds the regulator rectifier may be damaged x lf the test light did not light when the 24 V was applied momentarily to the voltage monitoring terminal the regu lator rectifier is defective Replace it x lf the regulator rectifier passes all of the tests described it may still be defective If the charging system still does not work properly after checking all of the components and the battery test the regulator rectifier by replacing it with a known good unit 8 10000451 C 8
115. narrow the clutch may not engage fully In either case adjust it Clutch Lever Free Play Standard 2 3 mm 0 08 0 12 in A WARNING To avoid a serious burn never touch the engine or exhaust pipe during clutch adjustment Turn the adjuster A so that 5 6 mm 0 20 0 24 in of threads are 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 e Pull the clutch outer cable C tight and tighten the adjust ing nuts against the cover D e Slip the rubber dust cover back onto place e Turn the adjuster at the clutch lever until the free play is correct e Push the release lever A toward the front of the motor cycle until it becomes hard to turn OAt this time the release lever should have the proper an gle shown 60 B If the angle is wrong check the clutch and release parts for wear Be sure that the outer cable end at the clutch lever is fully seated in the adjuster at the clutch lever or it could slip into place later creating enough cable play to prevent clutch disengagement e After the adjustment start the engine and check that the clutch does not slip and that it releases properly 2 30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Wheels Tires Air Pressure Inspection e Remove the air valve cap e Measure the tire air pressure with an air pressure
116. non permanent locking agent to the shift pedal mounting bolt C e Tighten Torque Shift Pedal Mounting Bolt 34 N m 3 5 kgf m 25 ft Ib Footpeg Bracket D 46 Shift Pedal E 6113130851 C Oil Seals 9 22 CRANKSHAFT TRANSMISSION Transmission e Install the footpeg bracket e Tighten Torque Footpeg Bracket Bolts B 34 N m 3 5 kgf m 25 ft Ib e Install the shift lever A aligning the mark previously marked e Tighten Torque Shift Lever Bolt 6 9 N m 0 70 kgf m 61 in Ib e Install the shift pedal B as shown About 90 C OTo adjust the pedal position loosen the front locknut D left hand threads and rear locknut E and then turn the tie rod F e Tighten Torque Tie rod Locknuts 6 9 N m 0 70 kgf m 61 in Ib External Shift Mechanism Removal e Remove Engine Oil drain see Engine Oil Change in the Periodic Maintenance chapter Shift Pedal see Shift Pedal Removal Clutch see Clutch chapter Oil Pipe Holder Bolts A Oil Pipe Holders B Oil Pipe C and O rings e Remove the shift shaft assembly A while pulling the shift mechanism arm B to the direction of the arrow CRANKSHAFT TRANSMISSION 9 23 Transmission 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
117. replace it with a new fuse of proper amperage e Install the junction box fuses on the original position as specified on the lid ELECTRICAL SYSTEM 16 101 Fuse Fuse Inspection e Remove the fuse see Fuse Removal e Inspect the fuse element xIf 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 RU Terminals C Blown Element D NOTE OA mass current flows to the battery according to the state ofthe battery which needs refreshing charge when the engine is turned causing main fuse blown out CAUTION When replacing a fuse be sure the new fuse matches the specified fuse rating for that circuit Installation of a fuse with a higher rating may cause damage to wiring and components APPENDIX 17 1 Appendix Table of Contents Cable Wire and Hose Routing 17 2 Troubleshooting Guide 17 26 Cable Wire and Hose Routing 17 2 APPENDIX lt Eh e mw sr a MEN i pane e ES Sel a Fp uo AL AVN j wb 65 rd A eR CEN XS Ley E SS lt 21 Mu T X PZN a HY N
118. see this chapter e Disconnect the battery terminals CAUTION VS Be sure to disconnect the negative cable first as Measure the battery terminal voltage NOTE OMeasure with a digital voltmeter which can be read one decimal place voltage x lf the reading is 12 6 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 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 09001251 16 26 ELECTRICAL SYSTEM Battery Terminal Voltage 11 5 less than 12 8 V Standard Charge 0 9 5 101 see following chart Quick Charge 4Ax1h CAUTION possible do not quick charge If quick charge is done unavoidably do standard charge later on Terminal Voltage less than 11 5 V Charging Method 0 9 20h NOTE Olncrease the charging voltage to a maximum voltage of 25 V if the battery will not accept current initially Charge forno more th
119. spark weak Vehicle down sensor DFI coming off Ignition switch not ON Engine stop switch turned OFF Clutch lever not pulled in or gear not in neu tral Battery voltage low Spark plug dirty broken or gap malad justed Stick coil shorted or not in good contact Stick coil trouble Spark plug incorrect IC igniter in ECU trouble Camshaft position sensor trouble Neutral starter lockout or side stand switch trouble Crankshaft sensor trouble Ignition switch or engine stop switch shorted Wiring shorted or open Fuse blown Fuel air mixture incorrect Bypass screw and or idle adjusting screw maladjusted Air passage clogged Air cleaner clogged poorly sealed or miss ing 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 Poor Running at Low Speed Spark weak Battery voltage low Spark plug dirty broken or maladjusted Stick coil wiring trouble Stick coil not in good contact Spark plug incorrect IC igniter in ECU trouble Camshaft position sensor trouble Crankshaft sensor trouble Stick coil trouble Fuel air mixture incorrect Bypass screw maladjusted Air passage clogged Air
120. step above Correct Width B e Lap the valve to the seat once the seat width and outside diameter are within the ranges specified above 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 Adjustment in the Peri odic Maintenance chapter GE15012381 GE15012081 C ENGINE TOP END 5 27 Valves Valve Seat Repair START Tool Machinist s dye on seat 45 Grind 45 Cutter Purpose make seating area smooth and round Measure Seating Area O D Tool Vernier Caliper Purpose check seat O D Too small 45 Grind Tool 45 Cutter Purpose increase O D of seat area to spec against spec Machinist s dye on seat 32 Grind Tool 32 Cutter Purpose reduce O D of seat area to spec Measure S
121. than by temporary external ones Also permanent internal repairs have the advantage of permitting a thorough examination for secondary damage not visible from external inspection of the tire For these reasons Kawasaki does not recommend temporary exter nal repair Only appropriate permanent internal repairs are recommended Repair methods may vary slightly from make to make Follow the repair methods indicated by the manufacturer of the repair tools and materials so that safe results can be obtained 6J05037BS1 C 10 16 WHEELS TIRES Hub Bearing Hub Bearing Removal e Remove the wheel and take out the following Collars Coupling out of rear hub Grease Seals e Use the bearing remover to remove the hub bearings A CAUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Please blocks under the wheel so that the disc does not touch the ground Special Tools Bearing Remover Head 20 x 22 57001 1293 C Bearing Remover Shaft 513 57001 1377 B Hub Bearing Installation e Before installing the wheel bearings blow any dirt or for eign particles out of the hub with compressed air to pre vent contamination of the bearings e Replace the bearings with new ones NOTE Olnstall the bearings so that the marked side faces out e Install the bearings by using the bearing driver set which does not contact the bearing inner race e Pre
122. the bleed valve and rubber cap NOTE Olf compressed air is not available with the brake hose still attached apply the brake pedal to remove the pis ton The remaining process is as described above Rear Caliper Assembly e Clean the caliper parts except for the pads CAUTION For cleaning 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 0 80 kgf m 69 in Ib 2 58 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Replace the fluid seal A with a new one OApply brake fluid to the fluid seal and install it into the cylinder by hand e Replace the dust seal B with a new one if it is damaged OApply brake fluid to the dust seal and install it into the cylinder by hand 6105040251 e Apply brake fluid to the outside of the piston and push it into the cylinder by hand e Replace the shaft rubber friction boot A and dust cover B if they are damaged e Apply a thin coat of PBC Poly Butyl Cuprysil grease to the caliper holder shafts C and holder holes D PBC is a special high temperature water resistance grease e Install the anti rattle spring A in the caliper as shown e Install the pads see Brakes chapter e Wipe up any spilled brake fluid on the caliper with wet cloth Spark Plug Replacement e Remove Fuel Tank see Fuel System DFI chapter e If removing th
123. 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 O or no 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 6105060181 CRANKSHAFT TRANSMISSION 9 13 Crankshaft and Connecting Rods e Apply molybdenum disulfide grease to the outer sur face of the upper insert and the inner surface of the con necting rod big end Apply molybdenum disulfide to the inner surfaces of upper and lower bearing inserts OThe molybdenum disulfide oil is a mixture of engine oil and molybdenum disulfide grease with a weight ratio 10 1 ODo not apply any grease or oil C to the cap inside and cap insert outside Olnstall the inserts so that their nails D are on the same side and fit them into the recess of the connecting rod and 6105020881 CAUTION Wrong application of oil and grease could cause bearing damage OWhen installing the inserts A be careful not to damage the insert surface with the edge of the connecting rod B or the cap C
124. the front and rear master cylinders Re 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 x lf a master cylinder or piston shows any damage replace them e Inspect the primary cup C and secondary cup D 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 J e Check the dust covers E for damage x lf they are damaged replace them e Check the piston return springs F for any damage x If the springs are damaged replace them Check that relief port and supply port 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 Master Cylinder K 6513049851 C GS13050BS2 C BRAKES 12 17 Brake Disc Brake Disc Removal e Remove the wheel see Wheels Tires chapter e Unscrew the mounting bolts and take off the disc e Remove the gaskets Brake Disc Installation e Replace the gasket with new ones e Install the brake disc on the wheel so that the marked side A faces out e Apply a non permanent locking agent to the threads of the front and rear brake disc mounting bolts B e
125. to draw out the excess oil from fork into the gauge thus attaining the stan dard level Olf not oil is drawn out there is not enough oil in the fork Pour in some more oil and measure again e Repeat the same procedure for adjusting the other fork e Install the fork spring A fork spring seat B and collar C e Inspect the top plug O ring and replace it with a new one e Install the front fork see Front Fork Installation 6 04040551 C GM04040382 C 6 04040451 C SUSPENSION 13 11 Front Fork Front Fork Disassembly e Remove the front fork see Front Fork Removal e Remove the top plug A with O ring take out the collar B spring seat C and spring D e Drain the fork oil see Front Fork Oil Change 6M04040281 e Remove the Allen bolt C from the bottom of the fork Special Tools Fork Cylinder Holder Handle 57001 183 D Fork Cylinder Holder Adapter 57001 1057 E NOTE je BiS OHold the outer tube in a vise A stop the cylinder unit lef e B from turning by using the special tools and unscrew the Allen bolt 8 04013851 C e Remove the cylinder unit A washer and the spring B from the inner tube 0048147 P eRemove the following from the top of the outer tube Dust Seal A Retaining Ring B Separate the inner tube A from the outer tube NOTE OFrom the compressed state
126. voltage is out of the standard inspect the subthrottle sensor resistance x If the output voltage is normal check the wiring for conti nuity Wiring Connection ECU Connector A Subthrottle Sensor Connector B BR lead terminal 3 BR BK lead terminal 14 ECU Connector A Subthrottle Sensor Connector B For Immobilizer Models C BR lead terminal 19 BR BK lead terminal 20 xIf the wiring is good check the ECU for its ground and power supply see ECU section 8017838 52 C FUEL SYSTEM 3 71 Subthrottle Sensor Service Code 32 Resistance Inspection e Turn the ignition switch OFF e Disconnect the subthrottle sensor connector e Connect a digital meter A to the subthrottle sensor con nector B e Measure the subthrottle sensor resistance Throttle Sensor Resistance Connections BL lead C lt gt BR BK lead D Standard 4 6kQ x If the reading is out of the range replace the throttle body assy x lf the reading is within the range but the problem still exists replace the ECU see this chapter GC17116BS1 C Subthrottle Sensor Circuit 6617840 1 C ECU Subthrottle Sensor 3 72 FUEL SYSTEM Immobilizer Amplifier Immobilizer Equipped Models Service Code 35 Antenna Resistance Inspection e Remove Fuel Tank see this chapter e Disconnect Antenna Lead Connector A
127. 0 in Radial TIR 0 8 mm 0 031 in A WARNING Never attempt to repair a damaged wheel If there is any damage besides wheel bearings the wheel must be replaced to insure safe operational condi tion 6512013851 C lt 5 SS 999 5 ente S lt x 552 2555 9990 250 27 00 So CX 5 gt cece lt 55 55 52 55 090005 000 oS 5 2 o 0 RK tata 25244 555 59 9 52 757 55 90 o do ko po RS 256 6 A KR IL 9304115852 C 10 10 WHEELS TIRES Wheels Rims Axle Inspection e Remove the front and rear axles e Visually inspect the front and rear axle for damages x lf the axle is damaged or bent replace it e Place the axle in V blocks that are 100 mm 3 94 in A apart and set a dial gauge B on the axle at a point halfway between the blocks Turn C the axle to mea sure the runout The difference between the highest and lowest dial readings is the amount of runout x If axle runout exceeds the service limit replace the axle Axle Runout 100 mm 3 94 in Standard TIR 0 05 mm 0 0020 in or less Service Limit TIR 0 2 mm 0 008 in Balance Inspection e Remove the wheel e Support the wheel so that it can be spun freely e Spin the wheel lightly and mark A the whe
128. 05 3 10 3 15 3 20 3 25 3 30 3 351 3 40 3 45 3 50 0 70 0 74 3 00 3 05 3 10 3 15 3 20 3 25 3 30 3 35 3 40 3 45 3 50 N INSTALL THE SHIM OF THIS THICKNESS aa 3 25 3 30 3 35 3 40 3 45 3 50 0 0 84 205 3 10 3 15 3 20 3 25 3 30 3 35 3 40 3 45 3 50 0 85 0 89 3 10 3 15 3 20 3 25 3 30 3 35 3 40 3 45 3 50 0 90 0 94 3 15 3 20 3 25 3 30 3 35 3 40 3 45 oos 0 90 3 20 3 25 3 30 3 35 3 40 3 45 3 50 100 1 04 2226 3 30 3 35 3 40 3 45 2 50 1 05 1 09 3 35 50 1 10 1 14 3 40 1 15 1 19 3 401 3 45 3 50 1 20 1 24 3 45 3 50 nz 129 3 50 1 Measure the clearance when engine is cold 2 Check present shim size 3 Match clearance in vertical column with present shim size in horizontal column 4 Install the shim specified where the lines intersect This shim will give the proper clearance Example Present shim is 2 95 mm Measured clearance is 0 47 mm Replace 2 95 mm shim with 3 15 mm shim 5 Remeasure the valve clearance and readjust if necessary PERIODIC MAINTENANCE 2 29 Periodic Maintenance Procedures Clutch Clutch Operation Inspection e Pull the clutch lever just enough to take up the free play Measure the gap between the lever and the lever holder x lf the gap is too wide the clutch may not release fully If the gap is too
129. 1 1 1 95 in lb 5 Water Pump Drain Bolt 11 1 1 95 in lb 6 Water Pipe Bolts 11 1 1 7 Thermostat Housing Ground Bolt 7 0 0 70 T0 9 Radiator Upper Bolts 7 0 1 Radiator Lower Bolts 7 0 11 Radiator Screen Bolt 7 0 0 70 0 70 0 70 0 70 Radiator Fan Switch 18 1 8 0 1 70 13 4 14 Water Temperature Sensor 25 15 Mechanical Seal 16 Oil Pump Rotor 17 Thermostat 18 To Cylinder Head 19 To Cylinder G Apply grease R Replacement Parts SS Apply silicone sealant Kawasaki Bond 56019 120 2 5 4 4 COOLING SYSTEM Coolant Flow Chart 6004029812 C 1 Water Temperature Sensor 8 Reserve Tank 2 Thermostat Housing 9 Cylinder Jacket 3 Radiator Cap 10 Water Pump 4 Radiator 11 Drain Bolt 5 Radiator Fan Switch 12 Reserve Tank Overflow Hose 6 Radiator Fan 13 Reserve Tank 7 Cylinder Head Jacket 14 Hot Coolant 15 Cold Coolant Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corro sion When the engine starts the water pump turns and the coolant circulates The thermostat is a wax pellet type which opens or closes with coolant temperature changes The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level When coolant temperature is 55 C 131 F or more the thermostat closes so that the coolant flow is restricted through the air bleeder hole causing the engine to warm up
130. 1 C PERIODIC MAINTENANCE 2 31 Periodic Maintenance Procedures Tread Depth Front Standard 3 4 0 13 Service Limit 1 0 04 1 6 0 06 Rear Standard 5 8 mm 0 23 Service Limit 2 mm 0 08 Up to 130 km h 80 mph 3 mm 0 12 in Over 130 km h 80 mph A 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 Wheels Tires chapter e Turn the handlebar all the way to the right or left e Inspect the roughness of the front wheel bearing by push ing and pulling A the wheel e Spin B the front wheel lightly and check for smoothly turn roughness binding or noise x If roughness binding or noise is found remove the front wheel and inspect the wheel bearing see Wheels Tires chapter e Using a stand raise the rear wheel off the ground see Wheels Tires chapter e Inspect the roughness of the rear wheel bearing by push ing and pulling A the wheel e Spin B the rear wheel lightly and check for smoothly turn roughness binding or noise xIf roughness b
131. 10 kPa 3 2 kgf cm 46 psi with fuel pump running 290 kPa 2 9 kgf cm 43 psi with fuel pump stopped 310 kPa 3 2 kgf cm 46 psi with fuel pump running In tank friction pump 67 mL or more for 3 seconds INP 285 One spray type with 4 holes about 11 7 12 3 at 20 C 68 F Non adjustable and non removable 4 75 5 25 V DC between BL and BR BK leads 0 99 1 03 V DC between Y W and BR BK leads 4 19 4 39 V DC between Y W and BR BK leads 4 6 4 75 5 25 V DC between BL BR BK leads 3 74 4 26 V DC at standard atmospheric pressure see this text for details 1 6 3 7 kQ at 20 C 68 F 0 24 0 43 kQ at 80 C 176 F about 2 25 2 50 V 20 C 68 F see Electrical System chapter about 2 80 2 97 V 20 C 68 F about 9 11 V DC at Ignition Switch ON about 0 05 0 07 V DC at Ignition Switch ON and 0 km h Magnetic flux detection method more than 60 70 for each bank 3 18 FUEL SYSTEM DFI Specifications Item Standard Detection Time Output Voltage Subthrottle Sensor Input Voltage Output Voltage at Idle Throttle Opening Output Voltage at Full Throttle Opening Resistance Subthrottle Valve Actuator Resistance Input Voltage within 0 5 1 0 seconds with the sensor tilted 60 70 or more 3 7 4 4 V with sensor arrow mark pointed up 0 4 1 4 V Non adjustable and non removal 4 75 5 25 V DC between BL and BR BK leads 0 48 0 52 V DC between BR and BR BK
132. 10000551 C 8 10000851 C 16 34 ELECTRICAL SYSTEM Charging System Charging Voltage Inspection e Check the battery condition see Battery section e Warm up the engine to obtain actual alternator operating conditions e Remove the seat see Frame chapter e Check that the ignition switch is turned off and connect the hand tester A to the battery terminals B Special Tool Hand Tester 57001 1394 A e Start the engine and note the voltage readings at various engine speeds with the headlight turned on and then turned off To turn off the headlight disconnect the headlight connector on the headlight unit The readings should show nearly battery voltage when the engine speed is low and as the engine speed rises the read ings should also rise But they must be kept under the specified voltage Charging Voltage Tester Range Reading Tester to Tester to 25 V DC Battery Battery 14 2 15 2V 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 x If the charging voltage is much higher than the values specified in the table the regulator rectifier is defective or the regulator rectifier leads are loose or open x If the charging voltage does not rise as the engine speed increases then the regulator rectifier is
133. 16 Starter motor rotating but engine doesn t turn over inspect chapter 16 inspect see chapter 16 inspect and replace inspect and replace inspect and replace inspect and replace inspect and replace Crankshaft seizure Inspect and replace see chapter 5 see chapter 5 see chapter 5 see chapter 9 see chapter 9 see chapter 9 Transmission gear or bearing seizure Inspect and replace see chapter 9 Balancer bearing seizure Inspect and replace see chapter 9 No fuel flow No or little fuel in tank Supply fuel see Owner s Manual Fuel pump not rotating Inspect see chapter 3 Fuel injector trouble Inspect and replace see chapter 3 Fuel tank air vent obstructed Inspect and repair see chapter 3 Fuel filter or pump screen clogged Inspect and replace fuel pump see chapter 3 Fuel pressure regulator clogged Inspect and replace fuel pump see chapter 3 Fuel line clogged Inspect and repair see chapter 3 Engine flooded Spark plug dirty broken or gap maladjusted Replace see chapter 2 Starting technique faulty When flooded don t crank engine with throttle fully opened No spark or spark weak Ignition and engine stop switches not ON Turn both switches ON FUEL SYSTEM DFI 3 31 DFI System Troubleshooting Guide Symptoms or possible Causes Actions chapter Clutch lever not pu
134. 17 Fenders Battery Case Removal e Remove Seats see Seat Removal Seat Cover see Removal Side Covers see Side Cover Removal Rear Fender see Rear Fender Removal Battery A ECU Main Fuse 15 A B Fuse Box C with ECU Kawasaki Diagnostic System Connector D Starter Relay with Main Fuse E Immobilizer Amplifier F Equipped Model Clamp G Band H e Pull out the battery case backward Battery Case Installation e Put the battery case attachments A at the projections B on the frame 15 18 FRAME Side Stand Side Stand Removal e Raise the rear wheel off the ground with the stand e Remove Side Stand Switch Bolt A Side Stand Switch B Spring C Side Stand Nut D Side Stand Bolt E Side Stand F Side Stand Installation Apply grease to the sliding area B of the side stand A e Tighten the bolt and lock them with the nut Torque Side Stand Bolt 44 N m 4 5 33 ft Ib e Hook the spring e Install the side stand switch OApply a non permanent locking agent to the thread of the Switch bolt Torque Side Stand Switch Bolt 8 8 0 90 kgf m 78 802000045156 in Ib FRAME 15 19 Frame Frame Inspection e Visually inspect the frame for cracks dents bending or warp Olf 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
135. 2 104 in Ib 2 Water Temperature Sensor 25 2 5 18 3 Vehicle Down Sensor Bolts 2 0 0 20 17 in lb 4 Camshaft Position Sensor Bolt 12 1 2 104 in Ib 5 Camshaft Position Sensor Rotor Bolt 12 1 2 104 in Ib L 6 Air Cleaner Duct Holder Screws 3 8 0 39 34 in Ib 7 Air Cleaner Housing Mounting Bolts 9 8 1 0 87 in lb 8 Cleaner Duct Clamp Bolts 2 0 0 20 17 in lb 9 Air Cleaner Housing Screws 1 2 0 12 10 in Ib Air Cleaner Housing Tapping Screws 1 2 12 Inlet Air Pressure Sensor 13 Stick Coils 14 ECU 15 Fuel Pump Relay 16 ECU Main Relay 17 Atmospheric Pressure Sensor 18 Crankshaft Sensor 19 Inlet Air Temperature Sensor 20 Grommet 21 Immobilizer Antenna 22 Immobilizer Amplifier L Apply a non permanent locking agent R Replacement Parts SS Apply silicone sealant 3 8 FUEL SYSTEM DFI DFI System DFI System e 5 MO 12 FUEL SYSTEM DFI 3 9 DFI System gt Immobilizer Antenna Equipped Models Ignition Swich Starter Lockout Switch Starter Relay Tachometer Fl Indicator Light LED Immobilizer Amplifier Equipped Models Water Temperature Sensor Fuel Tank Fuel Filter Pressure Regulator Fuel Pump Delivery Pipe Fuel Injectors Inlet Air Pressure Sensor Camshaft position Sensor Spark Plug Crankshaft Sensor Main Throttle Valve Main Throttle Sensor Subthrottle Valve Subthrottle Valve Actuator
136. 3 0 0311 in Service Limit 0 70 mm 0 028 in x If 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 5 32 ENGINE TOP END Cylinder Pistons Piston Ring End Gap e Place the piston ring A inside the cylinder using the pis ton to locate the ring squarely in place Set it close to the bottom of the cylinder where cylinder wear is low Measure the gap between the ends of the ring with a thickness gauge Piston Ring End Gap Top Standard 0 30 0 40 mm 0 0118 0 0157 in Service Limit 0 7 mm 0 028 in Second Standard 0 45 0 55 mm 0 0177 0 0217 in Service Limit 0 8 mm 0 031 in x lf the end gap of either ring is greater than the service limit replace all the rings GE16066BS1 ENGINE TOP END 5 33 Throttle Body Holder Throttle Body Holder Installation e Be sure to install the O rings A e Install the clamps as shown and so that its hole fit on the projection C of the holder e Tighten Torque Throttle Body Holder Bolts D 13 N m 1 3 kgf m 113 in Ib Throttle Body Assy Holder Clamp Bolts E 2 0 N m 0 20 kgf m 17 in Ib GE17001BS2 C 5 34 ENGINE TOP END Muffler A WARNING To
137. 4 FUEL SYSTEM Speed Sensor Service Code 24 25 Speed Sensor Removal Installation e See the Switches and Sensors section in the Electrical System chapter Speed Sensor Inspection e See the Switches and Sensors section in the Electrical System chapter Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Disconnect the speed sensor connector A and connect the harness adapter B between the harness connector and speed sensor connector Engine Sprocket Cover C e Connect a digital meter to the harness adapter leads Special Tool Throttle Sensor Setting Adapter 1 57001 1400 e Measure the sensor input voltage with the engine stopped and with the connector joined e Turn the ignition switch ON 6C17262BS1 C Speed Sensor Input Voltage Connection to Adapter Meter BL sensor P lead C Meter BK BL sensor BK lead D 6617158851 C Standard About 9 11 V DC at Ignition Switch ON xIf the reading is out of the range check the wiring see wiring diagram in this section and meter see Electrical System chapter x If the reading is good check the output voltage e Turn the ignition switch OFF Output Voltage Inspection e Before this inspection inspect the input voltage see Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF FUEL SYSTEM DFI 3 65
138. 48 in TIR 0 1 mm 0 004 in 0 5 mm 0 020 in 0 25 mm 0 0098 in TIR 0 05 mm 0 002 in 3 94 mm 0 155 in 3 96 mm 0 156 in 4 08 mm 0 161 in 4 08 mm 0 161 in 0 40 mm 0 016 in 0 33 mm 0 013 in ENGINE TOP END 5 7 Specifications ltem Standard Service Limit Valve Spring Free Length Exhaust 40 7 mm 1 602 in 38 9 mm 1 531 in Inlet 40 7 mm 1 602 in 38 9 mm 1 531 in Cylinder Pistons Cylinder Inside Diameter 68 400 68 412 mm 2 6929 2 6934 in 68 50 mm 2 6969 in Piston Diameter 68 345 68 360 mm 2 6907 2 6913 in 68 21 mm 2 6854 in Piston Cylinder Clearance 0 040 0 067 mm 0 0016 0 0026 in Piston Ring Groove Clearance Top 0 04 0 10 mm 0 0016 0 00371 in 0 20 0 0071 in Second 0 02 0 08 mm 0 0008 0 0024 in 0 18 mm 0 0063 in Piston Ring Groove Width Top 0 83 0 85 mm 0 0327 0 0335 in 0 93 mm 0 037 in Second 0 81 0 83 mm 0 0319 0 0327 in 0 91 mm 0 036 in Piston Ring Thickness Top 0 75 0 79 mm 0 0303 0 0311 in 0 70 mm 0 028 in Second 0 75 0 79 mm 0 0303 0 0311 in 0 70 mm 0 028 in Piston Ring End Gap Top 0 30 0 40 mm 0 0118 0 0157 in 0 7 mm 0 028 in Second 0 45 0 55 mm 0 0177 0 0217 in 0 8 mm 0 031 in 5 8 ENGINE TOP END Special Tools and Sealant Compression Gauge 20 kgf cm Valve Seat Cutter 32 25 57001 221 57001 1118
139. 5 Ignition System 2nd Check e Raise the rear wheel off the ground with a stand e Inspect the engine for its secure stop after the following operations are completed e Run the engine to the following conditions Condition Transmission Gear 1st Position Clutch Lever Release Side Stand Up e Set the side stand to the down position then the engine will stop x If whichever may not be stopped inspect the starter lock out switch side stand switch and junction box x If their parts are normality replace the ECU IC Igniter Inspection OThe IC Igniter is built in the ECU A e Refer to the Interlock Operation Inspection Ignition Sys tem Troubleshooting table and Fuel System DFI chapter for ECU Inspection 16 46 ELECTRICAL SYSTEM Ignition System Ignition System Troubleshooting Faulty ignition No spark Battery Inspection Charge or replace battery Ignition system wiring Repair or replace and connector inspection damaged part Good Spark plug inspection gt Replace spark plug Good iubes No good Stick coil winding resistance inspection Replace stick coil Good No good Voltage is less than the specified value Stick coil primary peak voltage inspection Good No good Stick coil is defective Voltage is zero Replace stick coil or almost zero Inspect 1 Lower resist
140. 5 mm 0 238 0 242 in 0 246 in Shift Fork Guide Pin Diameter 6 9 7 0 mm 6 8 mm 0 272 0 276 in 0 268 in Shift Drum Groove Width 7 05 7 20 mm 7 3 mm 0 278 0 283 in 0 287 in 9 8 CRANKSHAFT TRANSMISSION Special Tools and Sealant Bearing Puller 57001 135 875701355 C Outside Circlip Pliers 57001 144 7570144ST C Bearing Puller Adapter 57001 317 o lt 2 Kawasaki Bond Liquid Gasket Black 92104 1062 CRANKSHAFT TRANSMISSION 9 9 Crankcase Splitting Crankcase Splitting e Remove the engine see Engine Removal Installation chapter e Set the engine on a clean surface and hold the engine steady while parts are being removed e Remove Crankshaft Sensor see Electrical System chapter Clutch see Clutch chapter External Shift Mechanism see External Shift Mecha nism Removal Starter Motor see Electrical System chapter Oil Pump see Engine Lubrication System chapter Alternator Rotor see Electrical System chapter Oil Filter see Engine Lubrication System chapter xlIf the crankshaft is to be removed remove the pistons see Engine Top End chapter e Remove the upper crankcase bolts OFirst loosen the M6 bolts M6 Bolts A M7 Bolts B 8 Bolts C 6104055851 C e Remove the oil pan relief valve oil screen and oil pipes see Engine Lubrication System chapter e Remove the lower crankcase bolts OFirst loosen the M7 bolts M7 Bolts A
141. 80 52 69 1 4 1 9 10 0 13 5 2 6 3 5 19 0 25 4 5 6 2 33 45 14 73 98 7 4 10 0 54 72 16 115 155 11 5 16 0 83 115 18 165 225 17 0 23 0 125 165 20 225 325 23 0 33 0 165 240 2 12 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Fuel System Throttle Grip Free Play 2 3 mm 0 08 0 12 in Idle Speed 1 100 50 r min rpm Bypass Screws Turn Out 0 1 1 2 for reference Engine Vacuum 29 7 1 333 kPa 225 10 mmHg Air Cleaner Element Paper filter Cooling System Coolant Type recommended Permanent type of antifreeze Color Green Mixed Ratio Soft water 50 Coolant 50 Freezing Point 35 31 Total Amount 2 9 L 3 1 US qt Engine Top End Valve Clearance Exhaust 0 22 0 31 mm 0 0087 0 0122 in Inlet 0 15 0 24 mm 0 0059 0 0094 in Clutch Clutch Lever Free Play 2 3 0 08 0 12 in Engine Lubrication System Engine Oil Type API SE SF or SG API SH or SJ with JASO MA Viscosity SAE 10W 40 Capacity 3 1 3 3 US qt when filter is not removed 3 3 L 3 5 US qt when filter is removed 3 8 L 4 0 US qt when engine is completely dry Between upper and lower level lines after idling or running Wheels Tires Tread Depth Front BRIDGESTONE 3 4 mm 0 13 in Rear BRIDGESTONE 5 8 mm 0 23 in A
142. A R 25 BL Y amp Headlight on H1 ik 120588 5 5 Headlight m L0 E 0 12 55 sr BXZY BK Y BX Y Front Left Turn Signal sur Left Switch Housing Light 12V10N Button Joint Connector Turn ignal Switch Starter Lockout Switch 1 2 3 Dimmer Switch 4 5 Passing Button LEFT SWITCH HOUSING CONNECTIONS Turn Signal Switch Dimmer Switch Starter Lockout Switch ee e e I Puen Junction 1 ACG Fuse 2 Radiator 3 Headlight Fuse 4 Headlight Relay Passing Button 5 6 Igniton Fuse 7 Fuse 8 Starter 9 Turn Signal Box 10A Fan Fuse 10 10 Taillight Fuse 10 10 10 Circuit Relay Relay Fuse 10 W2L0174AW5 C ELECTRICAL SYSTEM 16 15 Wiring Diagram Other than United States Canada and Malaysia Sub Main Fuel Injectors throttle Throttle 1 2 3 4 Sensor Sensor BR BK Water Speed Camshaft Inlet Air Sensor Postion Temperature Atmospheric Sensor Sensor Sensor Pressure 2 Sensor BR EK BR BK BR EK Joint Connector D Temperature Inlet Air Pressure Sensor eil Pressure Crank Side switch shaft Stand z Sensor Switch Neutral witch 1 Meter Ground 2 Frame Ground
143. B Special Tool Needle Adapter Set 57001 1457 Vehicle down Sensor Output Voltage Connections to Sensor Meter Y G lead D Meter gt lead E e Hold the sensor vertically e Turn the ignition switch ON and measure the output volt age with the connector joined OTilt the sensor 60 70 or more C right or left then hold the sensor almost vertical with the arrow mark pointed up and measure the output voltage Output Voltage at Sensor Standard with sensor tilted 60 70 or more right or left 3 7 4 4 V with sensor arrow mark pointed up 0 4 1 4 V NOTE Olf you need to 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 Silicone Sealant Kawasaki Bond 56019 120 Seals of Vehicle down Sensor Connector the output voltage is normal the wiring is suspect Check the wiring xIf the wiring is good check the ECU for its ground and power supply see ECU section xIf the output voltage is out of the specified replace the vehicle down sensor 6017126852 C 3 68 FUEL SYSTEM DFI Vehicle down Sensor Service Code 31 Vehicle down Sensor Circuit BATTERY 105 1 6P 6C17817BW2 mos 2021 iE 6P
144. 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 Left Frame Cover see Frame chapter Left and Right Side Covers see Frame chapter e Disconnect Main Throttle Sensor Connector A Subthrottle Sensor Connector B 4 Injector Connector C 3 Injector Connector D Subthrottle Sensor Actuator Connector E e Discommect 1 2 Injector Connector A e Remove the vacuum switch valve vacuum hose and vac uum hoses from the positions B shown e Remove Choke Cable Lower End C loosen Holder and Duct Clamp Bolts D FUEL SYSTEM DFI 3 101 Throttle Body Assy e Remove Bolts A Throttle Cable Plate B e Remove Immobilizer Amplifier A Immobilizer Equipped Models Bolt and Bracket B Immobilizer Equipped Models Starter Relay C Bolt D e Remove Coolant Reserve Tank see Coolant Change in the Peri odic Maintenance chapter Crankcase Breather Hose see Engine Removal in the Engine Removal Installation chapter Left Air Cleaner Housing Mounting Bolts A Clamp B Open Alternato
145. C BK BL G P BL B W BL 80617842841 C A ECU B Subthrottle Valve Actuator 3 78 FUEL SYSTEM DFI Fl Indicator Light LED Inspection Flow Chart Turn the ignition SW ON Repair or replace the meter or wiring NG No Flashes once then oes off or unlit i Does the light LED goes on 2 light wiring Yes goes on Good Does the light LED go off after Yes goes off DFI and ignition systems are 1 2 seconds considered to be normal No stays on DFI and ignition systems abnormal the ignition SW OFF End of inspection Go to self diagnosis Does the light LED go off after No stays on 10 20 seconds Run the engine with idling Turn the ignition SW OFF DFI and ignition systems Ask the rider if the problem are normal occurs again Yes occurs Replace the ECU GC17852B F FUEL SYSTEM DFI 3 79 Fl Indicator Light LED FI Indicator Light LED Inspection e Remove the meter unit see Electrical System chapter e Using two auxiliary leads supply battery power to the FI indicator light LED A 12 V Battery B Fl Indicator Light LED Check aee Connector Meter Connector C disconnected 00000000 Connection BR W Lead Terminal 1 of the Meter Battery Terminal GC17779BS1 C BR R Lead Terminal 6 of the Meter Battery Terminal C
146. Clutch Lever Clamp Bolts 7 8 0 80 69 in Ib Clutch Cover Mounting Bolts 11 1 1 95 in Ib Oil Filler Plug 1 5 0 15 13 in Ib Clutch Spring Bolts 8 8 0 90 78 Clutch Hub Nut 135 14 100 R Engine Lubrication Oil Filler Plug 1 5 0 15 13 in Ib Engine Oil Drain Bolt 29 3 0 21 Oil Filter 31 3 2 23 Holder Mounting 76 7 8 56 EO Oil Pan Bolts 11 1 1 95 Oil Pipe Holder Bolts 13 1 3 113 in Ib L Oil Pressure Relief Valve 15 1 5 11 L Oil Pressure Switch 15 1 5 11 SS Oil Pressure Switch Terminal Bolt 1 5 0 15 13 in Ib Water Pump Cover Bolts 11 1 1 95 in Ib 2 8 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Remarks N m kgf m ft Ib Water Pump Impeller Bolt 9 8 1 0 87 in lb Coolant Drain Plug Water Pump 11 1 1 95 1 Oil Passage Plugs 20 2 0 14 L Engine Removal Installation Adjusting Collar Locknut 49 5 0 36 S Engine Mounting Bolts and Nuts 44 4 5 33 S Front Engine Bracket Bolts 44 4 5 33 S Rear Engine Bracket Bolts 25 2 5 18 S Engine Ground Cable Terminal Bolt 9 8 1 0 87 in lb Crankshaft Transmission Breather Plate Bolts 9 8 1 0 87 in lb L Crankcase Bolts M9 L 95 mm 42 4 3 31 MO S Crankcase Bolts M9 L 81 mm 42 4 3 31 MO S Crankcase Bolts M8 27 2 8 20 S Crankcase Bolts M7 20 2 0 14 S Crankcase Bolts M6 12 1 2 104 in Ib S Starter Motor Clutch Bolts 12 1 2 104 in Ib L Oil Pipe Holder Bolts 13 1 3 113 in Ib L Shift Drum Bearing Holder Bolt 13 1 3 113 in Ib L
147. Equipped Models Immobilizer System Parts Replacement Immobilizer Antenna e Remove Fuel Tank see Fuel System DFI chapter e Disconnect the lead connectors A e Remove Handlebar see Steering chapter Steering Stem Head see Steering chapter e Using a small chisel or punch A turn out the Torx bolts e Cut the band A e Remove the screw B e Remove the antenna C with the cover D OPull the lower parts E of the cover outside to clear the projection F of the ignition switch e Tighten a new Torx bolt A until the bolt head B is broken C e Run the leads correctly see General Information chap ter Immobilizer Amplifier Replacement e Remove Right Side Cover see Frame chapter e Disconnect the connector A e Pullout the amplifier B from the bracket 16 90 ELECTRICAL SYSTEM Immobilizer System Equipped Models ECU Electronic Control Unit Replacement for Euro pean Model e Remove Seat see Frame chapter Junction Box see this chapter Battery see this chapter ECU A e Set the hard stand A onto the frame OBe sure to place a piece of cloth B under the hard stand e Using a small chisel C or other suitable tool turn the screw head and remove the upper D and lover bracket e Disconnect the connectors e Connect the connectors A e Install the damper B to the ECU C e Set the under guard bracket to the ECU e Install Upper Guard Bracket
148. FI chapter e Remove the thermostat bracket bolt A Olf removing the stick coil 3 e Disconnect the stick coil 1 and 2 connectors A e Pull the stick coil 1 B off the spark plug e Take out the camshaft position sensor connector C from the bracket see Camshaft Position Sensor Removal e Pull the stick coil 2 D off the spark plug CAUTION Do not pry the connector part of the coil while re moving the coil e Remove the ignition harness A from the bracket e Remove Stick Coil Connector 4 B Disconnect Stick Coil 4 C Stick Coil Connector 3 D Disconnect e Pull the stick coil 3 A upward and take out the lower end from the plug hole Stick Coil Ignition Coil together with Spark Plug Cap Installation e Install the coil using the following steps Olnsert the as shown being careful of the coil heads A direction ui M GP10120BS1 C 16 42 ELECTRICAL SYSTEM Ignition System OBe sure the stick coils are installed by pulling up A it lightly OConnect the connectors CAUTION Do not tap the coil head while installing the coil e Install the removed parts see appropriate chapters Stick Coil Ignition Coil together with Spark Plug Cap Inspection e Remove the stick coils see this chapter e Measure the primary winding resistance A as follows OConnect the hand tester between the coil te
149. Fuel pump trouble Inspect see chapter 3 Main throttle sensor trouble Inspect see chapter 3 Inlet air temperature sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Atmospheric pressure sensor trouble Inspect see chapter 3 FUEL SYSTEM DFI 3 35 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions chapter Inlet air pressure sensor trouble Inspect see chapter 3 Vacuum switch valve broken Inspect and replace see chapter 5 Air suction valve trouble Inspect and replace see chapter 5 After fire Crankshaft sensor rouble inspect see chapter 16 inspect see chapter 3 Runon diesen S Loose terminal of battery lead or ECU ground lead Inspect and repair See chapter 16 Carbon accumulating on valve seating surface Repair see chapter 5 see Overheating of Troubleshooting Guide see Engine overheating chapter 17 Other Engine oil viscosity too high Change see chapter 2 Dire trouble Inspect drive chain see chapter 2 and sprocket see chapter 11 Inspect caliper fluid seal damage or clogging Brake dragging of master cylinder relief and supply ports see chapter 12 Clutch slipping Inspect friction plates for wear see chapter 6 see Overheating of Troubleshooting Guide see chapter 17 Vacuum switch valve trouble Inspect
150. Gear Positioning Lever Bolt 12 N m 1 2 kgf m 104 in Ib e Apply grease to the O rings on the oil pipe ends Apply anon permanent locking agent to the oil pipe holder bolts and tighten them Torque Oil Pipe Holder Bolts 13 N m 1 3 kgf m 113 in Ib External Shift Mechanism Inspection e Examine the shift shaft A for any damage the shaft is bent straighten or replace it x lf the serration B are damaged replace the shaft x If the springs C are damaged in any way replace them x lf the shift mechanism arm D is damaged in any way replace the arm e Check the return spring pin A is not loose is loose unscrew it apply a non permanent locking agent to the threads and tighten it Torque Shift Shaft Return Spring Pin 29 3 0 kgf m 22 ft lb e Check the gear positioning lever B and its spring for breaks or distortion x lf 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 Us 6113131851 9 24 CRANKSHAFT TRANSMISSION Transmission Transmission Shaft Removal Split the crankcase see Crankcase Splitting e Remove the drive shaft A and output shaft B Transmission Shaft Installation e Check to see that the set pins A and set rings B are in place e Install the drive shaft and output shaft into the upper crankcase
151. INE TOP END 5 31 Cylinder Pistons Piston Ring Piston Ring Groove Wear e Check for uneven groove wear by inspecting the ring seat ing x The rings should fit perfectly parallel to groove surfaces If not replace the piston and all 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 GE16065BS1 C Top Standard 0 04 0 10 mm 0 0016 0 0031 in Service Limit 0 20 mm 0 0071 in Second Standard 0 02 0 08 mm 0 0008 0 0024 in Service Limit 0 08 mm 0 0063 in Piston Ring Groove Width e Measure the piston ring groove width OUse a vernier caliper at several points around the piston Piston Ring Groove Width Top A Standard 0 83 0 85 mm 0 0327 0 0335 Service Limit 0 93 mm 0 037 in Second B TTE Standard 0 81 0 83 mm 0 0319 0 0327 in Service Limit 0 91 mm 0 036 in xIf the width of any of the two grooves is wider than the service limit at any point replace the piston Piston Ring Thickness e Measure the piston ring thickness OUse the micrometer to at several points around Y A the ring Piston Ring Thickness Top A Standard 0 75 0 79 0 0303 0 0311 1 Service Limit 0 70 mm 0 028 in GE16103BS1 Second B Standard 0 75 0 79 mm 0 030
152. Install the hoses and pipes being careful to follow bend ing direction Avoid sharp bending kinking flattening or twisting e Run the hoses see Cable Wire and Hose Routing sec tion in the Appendix chapter e Install the clamp A as near as possible to the hose end to clear the raised rib of the fitting This will prevent the hoses from working loose OThe clamp screws should be positioned correctly to pre vent the clamps from contacting the other parts Torque Radiator Hose Clamp Screws 2 0 N m 0 20 kgf m 17 in Ib 6010020151 C Hose Inspection e Refer to the Cooling Hose and Connection Inspection in the Periodic Maintenance chapter COOLING SYSTEM 4 17 Radiator Fan Switch Water Temperature Sensor CAUTION The fan switch or the water temperature sensor should never be allowed to fall on hard surface Such a shock to their parts can damage them Radiator Fan Switch Removal e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Remove Radiator Fan Switch Lead Connector A Rubber Cap B Radiator Fan Switch C Radiator Fan Switch Installation e Tighten Torque Radiator Fan Switch 18 N m 1 8 kgf m 13 ft Ib e Fill the coolant see Coolant Change in the Periodic Main tenance chapter Radiator Fan Switch Inspection e Refer to the Electrical System chapter for the Radiator Fan Switch Inspection Water
153. Joint Connector B ECU Electronic Control Unit see Electrical System chapter 3 12 FUEL SYSTEM DFI DFI System DFI System Wiring Diagram Immobilizer Equipped Models Cr BR IGNITION 6221 SS E EL Y R BK BL nu YR Y BK P BL wey BR BK 2 Y BL Y W BL P BR W B HEHH TERN ee V H E i ww wit w v BK Y BK Y BK Y BK Y BK Y BK Y BK Y RM LITT ss 5 ge gt gt sz di 5 2 7 BL BK 80178118485 C FUEL SYSTEM DFI 3 13 DFI Part System Name Immobilizer Equipped Models Engine Stop Switch B Ignition Coils 1 2 3 4 Q R S POEZrAc _ LOAMIVIO Stick Coils Subthrottle Valve Actuator Subthrottle Sensor Fuel Injectors 1 2 3 4 Main Throttle Sensor Speed Sensor Camshaft Position Sensor Inlet Air Temperature Sensor Atmospheric Pressure Sensor Water Temperature Sensor Crankshaft Sensor Inlet Air Pressure Sensor Joint Connector D Meter Ground Terminal Frame Ground Terminal Ignition Switch Fl Indicator Light LED T Tachometer U Speedometer V Ignition Fuse 10 A W X Junction Box ECU Main R
154. KI Gaskets O rings oil seals grease seals circlips or cotter pins must be replaced with new ones whenever disassembled Assembly Order In most cases assembly order is the reverse of disassem bly however if assembly order is provided in this Service Manual follow the procedures given 68020088 68020098 68020108 E i EO om poA oL S 22 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 which can lead to malfunction Conversely when loosening the bolts nuts or screws first loosen all of them by about a quar ter turn and then remove them If the specified tightening sequence is not indicated tighten the fasteners alternating diagonally Tightening Torque Incorrect torque applied to a bolt nut or screw may lead to serious damage Tighten fasteners to the specified torque using a good quality torque wrench Often the tightening sequence is followed twice initial tightening and final tightening with torque wrench Force Use common sense during disassembly and assembly excessive force can cause expensive or hard to repair dam age When necessary remove screws that have a non permanent locking ag
155. L lead terminal 7 Meter BR BK lead terminal 20 9617821851 Standard 4 75 5 25 V DC x If the reading is within the standard range check the sen sor output voltage xIf the reading of input voltage is less than the standard range remove the ECU and check the wiring between these connections xIf the wiring is good check the ECU for its ground and power supply see ECU section FUEL SYSTEM DFI 3 59 Atmospheric Pressure Sensor Service Code 15 Output Voltage Inspection e Measure the output voltage at the ECU in the same way as input voltage inspection Note the following Digital Meter A ECU Connector B Atmospheric Pressure Sensor Output Voltage Connections to ECU Meter G W lead terminal 4 Meter BR BK lead terminal 14 Connections to ECU Immobilizer Equipped Models C Meter G W lead terminal 21 Meter BR BK lead terminal 20 Usable Range 3 74 4 26 V DC at the standard atmospheric pressure 101 32 kPa 76 cmHg abs NOTE 9017831851 OThe output voltage changes according to the local at mospheric pressure e Turn the ignition switch OFF x If the output voltage is within the usable range check the ECU for its ground and power supply see ECU section x lf the output voltage is out of the standard remove the seat cover and check the wiring And if the output voltag
156. N 6809729815 C APPENDIX 17 3 Cable Wire and Hose Routing 12 Clamp 14 15 16 17 18 19 20 21 Main Harness Clamp Through the Throttle Cables Throttle Cable Accelerator Throttle Cable Decelerator Choke Cable Clutch Cable Right Switch Housing Lead Brake Hose To Right Front Caliper Run the ignition switch lead in front of clutch and starter cable Ignition Switch Lead Run the leads for the clutch starter and the ignition switch in order from the head pipe and in front of these run the both throttle cables with accelerating one placed outside Clamp Through the right switch housing lead Right Switch Housing Lead Left Switch Housing Lead Clamp Run the Clutch Cable and the Starter Cable through of the Clamp Clamp Through the left switch housing lead Run the starter cable through under the throttle cables Run the clutch cable between the water hose and the main harness Throttle Cable Holder 17 4 APPENDIX Cable Wire and Hose Routing 68809731844 C Throttle Cable Accelerator Throttle Cable Decelerator Clutch Cable Clamp Through the throttle cables Run the clutch cable inside the chain tensioner Clamp Through the chock and clutch cables Chock Cable Insert the chock cable in the hole of the throttle body ONDA RONS gt APPENDIX 17 5 Cable Wire and Hose
157. N 9 29 Transmission Shift Fork Bending e Visually inspect the shift forks and replace any fork that is bent A bent fork could cause difficulty in shifting or allow the transmission to jump out of gear when under power 90 A A 6113014581 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 x If 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 6113133851 C 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 guide on any shift fork is less than the service limit the fork must be replaced Shift Fork Guide Pin Diameter Standard 6 9 7 0 mm 0 272 0 276 in Service Limit 6 8 mm 0 268 in x If any shift drum groove is worn over the service limit the drum must be replaced Shift Drum Groove Width Standard 7 05 7 20 mm 0 278 0 283 in Service Limit 7 3 mm 0 287 in 6113134851 C Gear Dog and Gear Dog Hole Damage e Visually inspect the gear dogs A and ge
158. NDIX 17 25 Cable Wire and Hose Routing California Model Coolant Breather Hose Radiator Cap Coolant Reservoir Thermostat Housing Run the tube White between the throttle cables Canister Holder Band Canister Throttle Cables Canister Purge Joint Tube Fitting Throttle Body 2 Right Vacuum Pipe Fitting Subthrottle Valve Actuator Lead Main Harness Side Canister Purge Tube Green Tube White Separator Throttle Body 3 Right Vacuum Pipe Separate Tube Blue Separator Canister Tube Blue Separator Fuel Tank Alternator Lead Main Harness Side Clips Tube Red Separator Fuel Tank Coolant Reservoir Over Flow Tube Run the tube backward the cross pipe Clamp Hold the sensor lead and tubes Atmospheric Pressure Sensor Alternator Connector Tube 12 Run the tube inside the separator bracket Viewed Over the Separator Chock Cable Run the cable into the hole of the throttle body Run the tubes inside the rib Clamp Install the clamp inside the tubes To the fuel tank Run the tubes 11 13 outside the frame Clamp Holding the tubes near the frame Viewed A Vacuum Balance Tubes Run the tubes forward the tubes 8 12 Viewed B Separator Bracket Clip Separator Cross Pipe Air Cleaner Housing Drain Hose Run the hose backward the cross pipe Fuel Tank Drain Hose Clamp Install the purge tube 11 unde
159. None 34 984 34 992 mm 1 3773 1 3776 in 34 993 35 000 1 3777 1 3780 Crankpin Diameter Marks or no mark Measure the connecting rod big end inside diameter and mark each connecting rod big end in accordance with the inside diameter e Tighten the connecting rod big end nuts to the specified torque see Connecting Rod Installation NOTE OThe mark already on the big end should almost coincide with the measurement Connecting Rod Big End Inside Diameter Marks None 38 000 38 008 mm 1 4961 1 4964 in 38 009 38 016 mm 1 4964 1 4967 Big End Cap A Connecting Rod B Weight Mark Alphabet C Diameter Mark Around Weight Mark D O or no mark Select the proper bearing insert A in accordance with the combination of the connecting rod and crankshaft coding Size Color B 6105040851 6105060181 Con rod Big End Crankpin Bearing Insert Inside Diameter Diameter Marking Size Color Part Number None Brown 92139 1110 None None Black 92139 1109 Blue 92139 1108 e Install the new inserts in the connecting rod and check insert crankpin clearance with the plastigage 6105041781 CRANKSHAFT TRANSMISSION 9 19 Crankshaft and Connecting Rods Crankshaft Side Clearance e Insert a thickness gauge A between the crankcase main bearing and the crank web at the N
160. Reading 4 Range Tester to Tester to 000 rpm 250 V AC One Black lead 42 V or more 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 hand tester as shown in the table 2 ONote the readings total 3 measurement Table 2 Stator Coil Resistance Reading Range Tester to Tester to One Black lead Another Black lead 0 3 0 4 Q 16 32 ELECTRICAL SYSTEM Charging System x If there is more resistance than shown in the table or no hand tester reading infinity for any two leads the stator has an open lead and must be replaced Much less than this resistance means the stator is shorted and must be replaced e Using the highest resistance range of the hand tester measure the resistance between each of the black leads and chassis ground Any hand tester reading less than infinity 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 Regula
161. Rear Master Cylinder Mounting Bolts 18 Rear Master Cylinder Push Rod Locknut 13 Suspension Front Fork Clamp Bolts Upper 14 Front Fork Clamp Bolts Lower 14 Front Fork Plugs 18 Front Fork Bottom Allen Bolts 22 Front Axle Clamp Bolt 25 Rear Shock Absorber Nuts Upper and Lower 25 Swingarm Pivot Shaft Nut 80 Swingarm Pivot Shaft Locknut 72 Uni trak Rocker Arm Nut 5 25 Tie rod Nuts 43 Steering Steering Stem Head Bolt 80 Steering Stem Nut 20 Handlebar Holder Bolts 18 Handlebar Lower Holder Nuts 25 Switch Housing Screws 31 in Ib Front Fork Clamp Bolts Upper 14 Front Fork Clamp Bolts Lower 14 Windshield Screws Footpeg Bracket Bolts 25 Footpeg Holder Bolts 25 Side Stand Bolt 33 Bolts in lb Side Stand Switch Bolt 78 in lb 2 10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Nam kgf m ftlb Remarks Front Fender Bracket Bolts 8 8 0 90 78 in lb L Front Fender Bolts 3 9 0 40 35 in Ib L Side Stand Bracket Bolts 49 5 0 36 Electrical System Spark Plugs 13 1 3 113 in Ib Alternator Rotor Bolt 110 11 81 Stator Coil Bolts 12 1 2 104 in Ib L Alternator Lead Holding Plate Bolt 12 1 2 104 in Ib L Engine Ground Cable Terminal Bolt 9 8 1 0 87 in lb Alternator Cover Bolts 11 1 1 95 in lb Crankshaft Sensor Cover Bolts 11 1 1 95 in Ib Crankshaft Sensor Bolts 5 9 0 60 52 in lb Camshaft Position Sensor Bolt 12 1 2 104 in Ib L Timing
162. Rotor Bolt 39 4 0 29 Starter Motor Mounting Bolts 11 1 1 95 in Ib Switch Housing Screws 3 5 0 36 31 in Ib Radiator Fan Switch 18 1 8 13 Water Temperature Sensor 25 2 5 18 Oil Pressure Switch 15 1 5 11 SS Oil Pressure Switch Terminal Bolt 1 5 0 15 13 in Ib G Neutral Switch 15 1 5 11 Speed Sensor Bolt 6 9 0 70 61 in Ib L Fuel Level Sensor Bolts 6 9 0 70 61 in Ib L Front Brake Light Switch Screw 1 2 0 12 10 in Ib Meter Mounting Screws 1 2 0 12 10 in Ib Tail Brake Light Mounting Screws 1 2 0 12 10 in Ib License Plate Light Mounting Screws 1 2 0 12 10 in Ib Turn Signal Light Screws 1 2 0 12 10 in Ib Headlight Mounting Bolts 5 9 0 60 52 Starter Lockout Switch Screws L Starter Motor Clutch Bolts 12 1 2 104 in Ib L Starter Relay Cable Terminal Bolts 3 9 0 40 35 L Regulator Rectifier Bolts 6 9 0 70 61 in Ib Regulator Rectifier Bracket Bolts 6 9 0 70 61 in Ib Speed Sensor Cover Bolts 6 9 0 70 61 in Ib L Side Stand Switch Bolt 8 8 0 90 78 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 PERIODIC MAINTENANCE 2 11 Torque and Locking Agent Threads Diameter Torque mm kgf m ft Ib 0 35 0 50 30 43 in lb 0 60 0
163. Routing GB09732BW3 C Front Clamp Bolt head direction as shown Viewed A Align the paint mark with the projection Clamp Bolt head direction upward Radiator Hose Thermostat Housing Clamp Bolt head direction forward Align the pain mark with the rib 10 Coolant Hose 11 Clamp Bolt head direction right side 12 Coolant Pipe 13 O ring 14 Paint mark side upper 15 Clamp 16 Coolant Hose 17 Clamp 18 Coolant Pipe 19 O rings 20 Radiator 21 Clamp 22 Radiator Hose 23 Clamp 24 Coolant Pipe 25 Viewed Section A A po 17 6 APPENDIX Cable Wire and Hose Routing P 2427 08809741845 C APPENDIX 17 7 Fixes by the left side clamp of the tank Run the tank drain hose under the bracket for the side cover Air Cleaner Drain Hose Cooling Reserve Tank Hose Run the hose inside the under ring Fuel Tank Drain Hose Fixes by the swingarm clamp Fuel Level Sensor Fixes by the right side clamps two places of the tank Run the lead outside the frame Fuel Level Sensor Lead Cable Wire and Hose Routing 17 8 APPENDIX Cable Wire and Hose Routing 5 Woe C Xy 6809733885 C APPENDIX 17 9 Cable Wire and Hose Routing Discrimination Tape Connect green tape side to left head lamp Green United Kingdom White other Instal
164. S1 C GP17053BS1 C ELECTRICAL SYSTEM 16 71 Meter Gauge Indicator Unit Right and Left Turn Signal Indicator Light For Right Turn Signal Indicator Light Battery Positive Terminal to Terminal 13 2 Left Turn Signal Indicator Light Battery Positive Terminal to Terminal 14 GP17051BS1 C High Beam Indicator Light Battery Positive Terminal to Terminal 15 GP17050BS1 e f each indicator lights does not go on replace the bulb NOTE OThe FI indicator light LED does not go on replace the meter assembly 16 72 ELECTRICAL SYSTEM Meter Gauge Indicator Unit Meter Circuit 12 13 High Beam Indicator Light Left Turn Signal Indicator Light Right Turn Signal Indicator Light Neutral Indicator Light Oil Pressure Warning Indicator Light Meter Light Tachometer Speedometer Water Temperature Warning Indicator Light LED Fl Indicator Light LED Odometer Trip A B Meters Clock Fuel Indi cator Fuel Level Gauge Meter Unit Joint Connector A Frame Ground Meter Ground Speed Sensor Fuel Reserve Switch Fuel Level Sensor Water Temperature Sensor Oil Pressure Switch Neutral Switch Ignition Switch Junction Box ACC Fuse 10 A Ignition Fuse 10 Main Fuse 30 A Battery 12 V 8 Ah ECU Joint Connector B J
165. Speed Sensor Service Code 24 25 e Disconnect the speed sensor connector A and connect the harness adapter B between the harness connector and speed sensor connector Engine Sprocket Cover C e Connect a digital meter to the harness adapter leads Special Tool Throttle Sensor Setting Adapter 1 57001 1400 e Measure the sensor output voltage with the engine stopped and with the connector joined e Turn the ignition switch ON Speed Sensor Output Voltage at Sensor Connections to Adapter Meter Y W sensor Y lead C Meter BK BL sensor BK lead D Standard About 0 05 0 07 V DC NOTE Olf you rotate the engine sprocket the output voltage will be increased x lf the reading is out of the range check the speed sensor operation see Electrical System chapter and the wiring to ECU see wiring diagram in this section the reading speed sensor operation and wiring are good check the ECU for its ground and power supply see ECU section Speed Sensor Circuit 6C17262BS1 6617144851 C A ECU B Speed Sensor 6Cc17835BWi C 6C17836BWi C C Speedometer Unit 3 66 FUEL SYSTEM Vehicle down Sensor Service Code 31 CAUTION Never drop the down sensor especially a hard surface Such a shock to the sensor can damage it e Remove Bolts A Connection and Vehicle down Sen
166. Suction System Damage Engine End Valve Clearance Inspection Clutch Operation Inspection Air Pressure Wheel Tire Damage Inspection Tire Tread Wear Abnormal Wear Wheel Bearing Damage Drive Train Drive Chain Lubrication Condition Inspection pp Drive Chain Slack Inspection Drive Chain Slack Adjustment Wheel Alignment Inspection Drive Chain Wear Inspection Chain Guide Inspection 2 15 2 16 2 17 2 17 2 17 2 18 2 19 2 22 2 23 2 23 2 24 2 24 2 24 2 24 2 24 2 25 2 29 2 29 2 30 2 30 2 30 2 30 2 31 2 32 2 32 2 32 2 33 2 34 2 34 2 35 Brake System Brake Fluid Leak Brake Hose and Pipe Inspection Brake Hose Damage and Installation Condition Brake Operation Inspection Brake Fluid Level Inspection Brake Pad Wear Inspection Brake Light Switch Operation Suspensions Front Forks Rear Shock Absorber Operation Inspection
167. Symptoms or Possible Causes Actions chapter Speed sensor trouble Inspect see chapter 3 Inspect throttle cable and lever linkage see Throttle valves won t fully open chapter 3 Inspect caliper fluid seal damage or clogging Brake dragging of 2 relief ports see chapter 12 Clutch slipping Inspect friction plates for wear see chapter 6 Engine overheating Water temperature sensor See Overheating of Troubleshooting Guide crankshaft sensor or speed sensor trouble chapter 17 Engine oil level too high Repair see chapter 7 Engine oil viscosity too high Change see chapter 2 Inspect drive chain see chapter 2 and sprockets see chapter 11 Camshaft cam worn Inspect and replace see chapter 5 Vacuum switch valve trouble Inspect and replace see chapter 5 Air suction valve trouble Inspect and replace see chapter 5 Catalytic converters melt down due to muffler overheating KLEEN Exhaust Smokes Excessively n White smokes 7 Piston oil ring worn Inspect and replace see chapter 5 Cylinder worn Inspect and replace see chapter 5 Valve oil seal damaged Replace see chapter 5 Valve guide worn Replace the guide see chapter 5 Engine oil level too high Repair see chapter 7 Drive train trouble Replace muffler see chapter 5 Black smoke Air cleaner clogged Clean see chapter 3 Too high fuel pressure Inspect see chapter 3
168. TEM Electric Starter System e Align the line A marked on the yoke with the through bolt hole B Brush Inspection e Measure the length A of each brush x If any is worn down to the service limit replace the carbon brush holder assembly B and the terminal bolt assembly C Starter Motor Brush Length Standard 12 mm 0 47 in Service Limit 8 5 mm 0 33 in Commutator Cleaning and Inspection e Smooth the commutator surface A if necessary with fine emery cloth B and clean out the grooves e Measure the diameter A of the commutator B x If the commutator diameter is less than the service limit replace the starter motor with a new one Commutator Diameter Standard 28 mm 1 10 in Service Limit 27 mm 1 06 in Armature Inspection e Using the x 1 hand tester range measure the resis tance between any two commutator segments A Special Tool Hand Tester 57001 1394 lf there is a high resistance or no reading gt between any 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 lf there is any reading at all the armature has a short and the starter motor must be replaced 8 11061051 C 8 11080851 C ELECTRICAL SYSTEM 16 51 Electric Starter System NOTE OEven if the foregoing checks show the armature to be good it ma
169. Upper 20 N m 2 0 kgf m 14 ft lb e Install the removed parts see appropriate chapters Front Fork Oil Change e Remove the front fork see Front Fork Removal e Remove Top Plug A Collar B Fork Spring Seat C Fork Spring D D gt 0 6 04040251 13 10 SUSPENSION Front Fork e Compress the fork A upside down to draw out the into the suitable container C e Pour in the specified amount of oil Fork Oil Viscosity KAYABA KHL34 G10 or equivalent Capacity when 395 mL 13 4 US oz changing oil NOTE OMove the outer tube up and down a few times to remove the air that is trapped in the fork oil in order to stabilize the oil level e Hold the outer tube vertically in a vise and compress the fork completely e Wait until the oil level stabilizes e Use the fork oil level gauge A to measure the distance between the top of the inner tube to the oil level Special Tool Fork Oil Level Gauge 57001 1290 OSet the oil level gauge stopper B so that the distance C from the bottom of the stopper to the lower end of the pipe is the standard oil level distance OA correct measurement can not be obtained unless the level gauge pipe is placed in the center of the inner tube Oil Level fully compressed without spring Standard 105 2 mm 4 13 0 08 in OPlace the stopper of the level gauge at the top E of the inner tube D and pull the handle slowly
170. Y When the fuel hose is disconnected fuel spills out Vr 9 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 between the fuel pump outlet pipe B and the delivery e Connect the pressure gauge D to the fuel pressure gauge adapter right side view Special Tools Oil Pressure Gauge 5 kgf cm 57001 125 Fuel Pressure Gauge Adapter 57001 1593 Fuel Hose 57001 1607 GC17180BS1 C A WARNING Do not try to start the engine with the fuel hoses disconnected e Temporarily install the fuel tank E Clamps F e Turn the ignition switch ON The fuel pump will turn for 3 seconds and then stop CAUTION Do not drive the fuel pump without the fuel in the fuel tank e Measure the fuel pressure with the engine stopped Fuel Pressure Right after Ignition Switch ON with pump running Standard 310 kPa 3 2 kgf cm 44 psi After 3 seconds from Ignition Switch ON with pump stopped Standard 290 kPa 3 0 kgf cm 43 psi residual fuel pressure The system should hold the residual pressure about 30 seconds FUEL SYSTEM DFI 3 85 Fuel Line e Start the engine and let it idle e Measure the fuel pressure with the engine idling Fuel Pressure Idling Standard 310 kPa 3 2 kgf cm 46 psi NOTE
171. a transmits a radio wave to excite the transponder receives the code from the transpon der and then transmits the code to the ECU through the amplifier Ignition Switch The ignition switch turns the main circuit ON and OFF Amplifier The amplifier which is approximately the same size as a match box amplifies signals from the antenna and the ECU ECU The ECU has the capacity to store a maximum of six key code memories one master and five user keys The owner can have a total of five user keys at any one time The master key memory can not be rewritten after initial registration whereas the user key memories can be rewritten as necessary When the ECU communicates with the transponder a cipher generator changes the code every time it is used to avoid cloning FI Indicator Light The condition or the failure of the immobilizer system is indicated by various patterns of the indi cator light blinking Sequence of Operation 1 Turn ON the ignition switch the ECU amplifier and antenna start working and the meter assembly Fl indicator lights up 2 The transponder excited by radio waves transmitted from the antenna receives the ciphered code from the ECU 3 The transponder transmits the calculated result from the key s unique code to the ECU 4 The ECU compares this with its memorized code and if they match the engine can start At this time the FI indicator in the meter assembly is switched off 1 20 GENERAL INFORMATION
172. ad between the convex area of cap center and bolt head to secure the coupler Fan Switch and Horn Lead Air Suction Valve Cap Clutch Cable Run the cable through forward the water hose Vacuum Switch Valve Radiator Hose Thermostat Housing Radiator Coolant Hose Head Thermostat Housing Inlet Air Pressure Sensor Vacuum Hose Run the vacuum hose under the throttle cables to connect with the inlet air pres sure sensor Throttle Cable Decelerator Throttle Cable Accelerator Vacuum Balance Tube Choke Cable Run the cable through left side of vacuum switch valve hose Hose Vacuum Switch Valve Air Cleaner Stick Coil Vacuum Switch Valve Tube Clamp Radiator Fan Lead Run the lead through forward the coolant hose and over the air pressure sensor connector Ignition Harness To inlet air pressure sensor Fuel Hose Fuel Pump To vacuum switch valve Throttle Cable Holder Subthrottle Valve actuator 17 18 APPENDIX Cable Wire and Hose Routing 6809730 5 C APPENDIX 17 19 Cable Wire and Hose Routing Battery Negative Cable Install the exterior of the cable with staking area facing downward Starter Motor Cable Crankshaft Sensor and Oil Pressure Switch Lead Run the lead inner side the starter lead Run the starter motor cable on the crankshaft sensor and oil pressure switc
173. ake Pad Wear Inspection Refer to the Brake Pad Wear in the Periodic Maintenance chapter 12 14 BRAKES Master Cylinder Front Master Cylinder Removal e Disconnect the front brake light switch connectors A e Remove the banjo bolt B to disconnect the brake hose from the master cylinder 0 see Brake Hose Re moval Installation e Unscrew the clamp bolts A and take off the master cylin der as an assembly with the reservoir brake lever and brake switch installed Front Master Cylinder Installation e Install the front master cylinder so that the punch mark A of the handlebar is aligned with the mating surface B of the master cylinder clamp to level the reservoir e The master cylinder clamp must be installed with the ar row mark A upward e Tighten the upper clamp bolt B first and then the lower clamp bolt C There will be a gap at the lower part of the clamp after tightening Torque Front Master Cylinder Clamp Bolts 8 8 0 90 kgf m 78 in lb e Replace the washers on each side of the hose fitting with new ones e Tighten the brake hose banjo bolt Torque Brake Hose Banjo Bolt 34 N m 3 5 kgf m 25 ft Ib e Bleed the brake line see Brake Line Bleeding e Check the brake for good braking power no brake drag and no fluid leakage BRAKES 12 15 Master Cylinder Rear Master Cylinder Removal e Unscrew the brake hose banjo bolt A ODrain the brake fluid into a con
174. an 5 minutes at the increased voltage then check if the battery is drawing current If the battery will accept current decrease the voltage and charge by the standard charging method described on the battery case If the battery will not accept current after 5 min utes replace the battery Battery A Battery Charger B Standard Value C Current starts to flow D e Determine 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 0 lower than 12 8 V Charge insufficient Recharge lower than 12 0 V Unserviceable Replace Charge Time h 11 6 11 8 12 0 12 2 12 4 12 6 12 8 13 0 Battery Terminal Voltage V 6208011151 8 08011451 C ELECTRICAL SYSTEM 16 27 Charging System Alternator Cover Removal e Remove Left Frame Cover see Frame chapter Separator A California Model Clamp Open B Alternator Lead Connector C e Place a suitable container under the alternator cover A and remove the cover bolts B e Pull the alternator cover outside Alternator Cover Installation e Apply silicone sealant to the alternator lead grommet and crankcase halves mating surface A on the front and rear sides of the cover mount Sealant Kawasaki Bond Silicone Sealant 92104 0004 e Chec
175. ance in a hand tester Use KAWASAKI Hand Tester 2 Crankshaft sensor peak voltage 3 Camshaft position sensor peak voltage Good Inspect 1 Adapter connection is incorrect or Replace bad parts adapter is defective or inspect them with Ignition Switch and engine stop switch KAWASAKI Hand Crankshaft peak voltage Tester Camshaft position sensor peak voltage Good Replace bad parts Inspect the ECU Power Supply V Inspect the wiring ECU is defective Replace ECU Connection and related parts GP10058B ELECTRICAL SYSTEM 16 47 Ignition System Ignition System Circuit 1 1 gt lt 1 1 L GP10233BW4 United States and Canada 9 Frame Ground 18 Diode Immobilizer Models 10 Crankshaft Sensor 19 ECU Main Relay 1 Immobilizer Antenna 11 Camshaft Position Sensor 20 ECU Fuse 15A 2 Ignition Switch 12 Neutral Switch 21 Vehicle down Sensor 3 Engine Stop Switch 13 Joint Connector A 22 Main Fuse 30 4 Starter Button 14 Immobilizer Amplifier 23 Joint Connector C 5 Spark Plugs 15 Ignition Fuse 10 A 24 Battery 12 V 8 Ah 6 Stick Coils 16 Junction Box 25 Joint Connector B 7 Side Stand Switch 17 Starter Lockout Switch 26 ECU 8 Meter Ground Electronic Control Unit 16 48 ELECTRICAL SYSTEM Electric Starter System Starter Mot
176. ankshaft Sensor Resistance 376 564 e Using the highest resistance range of the tester measure the resistance between the crankshaft sensor leads and chassis ground Any tester reading less than infinity lt indicates a short necessitating replacement of the crankshaft sensor as sembly Crankshaft Sensor Peak Voltage Inspection NOTE OBe sure the battery is fully charged OUsing the peak voltage adapter is a more reliable way to determine the condition of the crankshaft sensor than crankshaft sensor internal resistance measurements e Remove Right Frame Cover see Frame chapter Crankshaft Sensor Lead Connector see Crankshaft Sensor Removal e Set the hand tester B to the x 10 V DC range and con nect it the peak voltage adapter A as shown in the dia gram e Connect the black lead of the adapter to black lead and red lead to yellow lead in the crankshaft sensor connector e Turn the ignition switch and engine stop switch on e Pushing the starter button turn the engine 4 5 sec onds with the transmission gear in neutral to measure the crankshaft sensor peak voltage e Repeat the measurement 5 or more times Crankshaft Sensor Peak Voltage Standard 1 9 V or more Special Tools Hand Tester 57001 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B x If the tester reading is not specified one check the crank shaft sensor ELECTRICAL SYSTEM 16 39 Ignition System Timing Rotor Rem
177. ant to the seals of the ECU connector for waterproofing Silicone Sealant Kawasaki Bond 56019 120 Seals of ECU Connectors GC17267BS1 3 94 FUEL SYSTEM DFI Fuel Injectors Injector Signal Test e Prepare two test light sets with male terminals as shown Rating of Bulb A 12 V x 3 4 W Terminal Width B 1 8 mm 0 071 in Terminal Thickness C 0 8 mm 0 031 in CAUTION Do not use larger terminals than specified above A larger terminal could damage the injector main har ness connector female leading to harness repair or replacement Be sure to connect bulbs in series The bulb works as a current limiter to protect the solenoid in the injector from excessive current e Remove the fuel tank see Fuel Tank Removal e Remove connectors for injector A e Connect each test light set B to the injector sub harness connector C e Turn the ignition switch ON e While cranking the engine with the starter motor watch the test lights xIf the test lights flicker at regular intervals the injector circuit in the ECU and the wiring are good Perform the Injector Resistance Inspection Olnjector signals can be also confirmed by connecting the hand tester x 10 V AC instead of the test light set to the injector main harness female connector Crank the engine with the starter motor and check to see if the hand oscillates at regular intervals Special Tool Ha
178. ar dog holes B Replace any damaged gears or gears with excessively worn dogs or dog holes 6113135851 C WHEELS TIRES 10 1 Wheels Tires Table of Contents EXplodegd NMVIeW aa Fiere 10 2 Specifications m 10 4 Special Tools scere Y OO e RR EX RR E PRAE HERR CR EU Ee 10 5 Wheels RIMS eme UT De 10 6 Front Wheel Removal 2 10 6 Front Wheel Installation 10 6 Rear Wheel Rear Wheel Installation Wheel Inspection thanh Balance Inspection c cre eadem Balance Air Pressure Inspection o crt ed e teme Tire Removalue these er rr e Tire ne iat hee Ee RR H b e D m Hub Bearing Removal cues cao Ape Hub Bearing Installation pp 10 16 Hub Bearirig Inspection ernen tubs Pap EAEE TEU AAA 10 16 10 2 WHEELS TIRES Exploded View WHEELS TIRES 10 3 Exploded View
179. are not indicated by the Fl indicator LED light Don t rely solely on the DFI self diagnosis function use common sense Even when the DFI system is operating normally the FI indicator LED light A may light up under strong electrical interference No repair needed Turn the ignition switch OFF to stop the indicator light When the FI indicator LED light goes on and the motor cycle is brought in for repair check the service codes Olf the Fl indicator LED light blinks when the ignition switch is turned to the ON position this shows the immobilizer system has a foult Check the service codes When the repair has been done the LED light doesn t go on But the service codes stored in memory are not erased to preserve the problem history and the LED light can display the codes in the self diagnosis mode The problem history is referred when solving unstable problems When the motorcycle is down the vehicle down sensor is turned OFF and the ECU shuts off the fuel injectors and ignition system The FI indicator LED light blinks but the service code cannot be displayed 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 The vehicle down sensor is turned ON and the LED light goes OFF MG GC17680BS1 3 24 FUEL SYSTEM DFI Troub
180. arter Relay 2 Master Key 9 Battery 3 User Keys 10 Electronic Control Unit ECU 4 Fl Indicator Light 11 Junction Box 5 Immobilizer Antenna 12 Immobilizer Kawasaki Diagnostic System 6 Ignition Switch Connector 7 Immobilizer Amplifier Master Key 1 piece The master key colored red has an inbuilt transponder containing a master key code These codes are unique to each key This code and an additional two user key codes must be registered in the ECU for the system to operate The master key is necessary when registering user keys and should not be used as the main key to start the motorcycle except in emergencies loss or damage of user keys It should be kept in a safe place GENERAL INFORMATION 1 19 Technical Information Immobilizer System Equipped Models Transponder in Keys The transponder made by Texas Instruments Inc has an integrated circuit with a unique code that also calculates data sent by the ECU When the ignition switch is turned ON the transponder is excited by the radio wave transmitted from the antenna and then transmits a unique code to the antenna User Key 2 pieces The user keys colored black should be used when riding the motorcycle These keys have unique codes which differ from the master key Up to a maximum of five user key codes can be stored by the ECU at any one time These codes can not be registered to the ECU without firstly registering the master key code Antenna The antenn
181. as sembly GP17218BS1 C GP17225BS1 C 16 66 ELECTRICAL SYSTEM Meter Gauge Indicator Unit MODE AND RESET BUTTON Operation Check eConnectthe 12 V battery and terminals in the same man ner as specified in the Liquid Crystal Display LCD Seg ments Check e Check that the display change to the ODO TRIP A TRIP B and CLOCK displays each time the MODE button A is pressed xIf the display function does not work replace the meter assembly e Indicate the clock mode e Check that when the RESET button in CLOCK mode is pushed for more than two seconds the meter display turns to the clock set mode OBoth the hour and minute display start flashing e the HOUR MINUTE setting mode press the RESET button again to effect the HOUR setting mode OThe hour display flashes on the display e Press the MODE button to set the hour CLOCK TRIP B 138 9 93 CLOCK TRIP AB HEBREE GP17217BS1 C 8 17223 52 C CLOCK CLOCK GP17062BS1 C ELECTRICAL SYSTEM 16 67 Meter Gauge Indicator Unit e In the HOUR setting mode press the RESET button to effect the MINUTE setting mode CLOCK E 4 minute display flashes display 7 Press MODE button to set the minute 219 CLOCK via e In the MINUTE setting mode press the RESET button to ete return to the HOUR MINUTE setting mode EORR 1224
182. asure the input voltage with the engine stopped and with the connectors joined e Turn the ignition switch ON Inlet Air Pressure Sensor Input Voltage Connections to ECU Meter BL lead terminal 1 Meter gt BR BK lead terminal 14 Connections to ECU Immobilizer Equipped Models C Meter BL lead terminal 7 Meter BR BK lead terminal 20 Standard 4 75 5 25 V DC reading is within the standard range check the sen sor output voltage x lf the reading is less than the standard range remove the ECU and check the wiring between these connectors xIf the wiring is good check the ECU for its ground and power supply see ECU section Output Voltage Inspection NOTE OThe output voltage changes according to the local at mospheric pressure e Measure the output voltage at the ECU in the same way as input voltage inspection Note the following Inlet Air Pressure Sensor Output Voltage Connections to ECU Meter Y BL lead terminal 17 Meter BR BK lead terminal 14 Connections to ECU Immobilizer Equipped Models A Meter Y BL lead terminal 8 Meter BR BK lead terminal 20 Usable Range 3 74 4 26 V DC at the standard atmospheric pressure 101 32 kPa 76 cmHg abs e Turn the ignition switch OFF x If the output voltage is within the usable range check the ECU for its ground and power supply see this chapter x lf the output voltage is
183. auge 57001 1057 57001 1290 75712908T C Oil Seal amp Bearing Remover Hook Wrench 3 2 R37 57001 1058 57001 1539 7571058ST C 875715395 C Bearing Driver Set Swingarm Pivot Nut Wrench 57001 1129 57001 1597 7571129ST C 875715975 C 13 8 SUSPENSION Special Tools Jack Attachment Stem Bearing Driver 528 57001 1608 57001 1610 7 875716085 C 8 5716105 C Needle Bearing Driver 517 6018 57001 1609 Q 875716095 C SUSPENSION 13 9 Front Fork Front Fork Removal e Remove Front Wheel see Tires Wheels chapter Front Fender see Frame chapter x Loosen the upper fork clamp bolt A and fork top plug before hand if the fork leg is to be disassembled NOTE OLoosen the top plug B after loosening the upper fork clamp bolt e Loosen the upper fork clamp bolt A and lower fork clamp bolts B e With a twisting motion work the fork leg down and out Front Fork Installation e Install the fork with the upper end of the inner tube flush A against the top surface of the stem head B e Tighten Torque Front Fork Clamp Bolts Lower 20 N m 2 0 kgf m 14 ft Ib Front Fork Top Plug 25 N m 2 5 kgf m 18 ft Ib NOTE OTighten the top plug before tightening the upper fork clamp bolt OTighten the two clamp bolts alternately two times to en sure even tightening torque 6 04040751 e Tighten Torque Front Fork Clamp Bolt
184. auge 57001 1290 Air Flow C e Gradually raise the vacuum lower the pressure applied to the vacuum switch valve and check the valve opera tion When the vacuum is low the vacuum switch valve should permit air to flow When the vacuum raises to valve closing pressure it should stop air flow Spring A Diaphragm B Valve C Low Vacuum D Secondary Air Flow E x If the vacuum switch valve does not operate as described replace it with a new one NOTE OTo check air flow through the vacuum switch valve just blow through the air cleaner hose Vacuum Switch Valve Closing Pressure Open Close Standard 41 49 kPa 310 370 mmHg 6 0 7 1 psi High Vacuum A Secondary air cannot flow B Clean Air System Hose Inspection e Be certain that all the hoses are routed without being flat tened or kinked and are connected correctly to the air cleaner housing vacuum switch valve 1 and 4 carbu retor holders and air suction valve covers xIf they are not correct them Replace them if they are damaged 8 04010451 C 8 04010851 C 5 12 ENGINE TOP END Cylinder Head Cover Cylinder Head Cover Removal e Remove ODrain the coolant in the cylinder Drain Bolt A e Remove Fuel Tank see Fuel System DFI chapter Vacuum Switch Valve and Hoses A Stick Coils B see Electrical System chapter Air Suction Valve Covers C Ignition Harness D Clamp Screw E Loosen Radiator Hose
185. 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 Muffler Body Clamp Bolt A Muffler Body Mounting Bolt B Pull the muffler body backward Exhaust Pipe Removal e Remove Radiator Lower Bolt see Cooling System chapter Muffler Body Clamp Bolt A Exhaust Pipe Manifold Holder Nuts B Exhaust Pipe C Gaskets D Muffler Body and Exhaust Pipe Installation e Replace the exhaust pipe gaskets A and muffler body connection gasket B with new ones and install them Olnstall the muffler body connection gasket until it is bot tomed so that the chamfer side feces muffler body C Install Muffler Body Exhaust Pipe D e Tighten Torque Exhaust Pipe Manifold Holder Nuts E 17 N m 1 7 kgf m 12 ft lb Muffler Body Mounting Bolt 30 N m 3 0 kgf m 22 ft lb Muffler Body Clamp Bolt 17 N m 1 7 kgf m 12 ft lb GE18012BS1 C ENGINE TOP END 5 35 Muffler Olnstall the muffler body clamp bolt as shown Upper Side H Outside I 7174 ja 18013 2 e Thoroughly warm up the engine wait until the engine cools down and retighten all the bolts and nuts CLUTCH 6 1 Clutch Table of Contents Exploded Vie W 6 2 Specifications 2 6 4 Special TOO
186. b e Install the front brake calipers see Brakes chapter e Check the front brake effectiveness see Brakes chapter WARNING Do not attempt to drive the motorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against the disc The brake will not function on the first application of the lever if this is not done Rear Wheel Removal e Using the stand A raise the rear wheel off the ground 6 048249 10 8 WHEELS TIRES Wheels Rims e Loosen Chain Adjuster lock nut A Chain Adjuster Nut B e Remove Cotter Pin C Axle Nut D Axle E e Remove the drive chain A from the rear sprocket toward the left e Move the rear wheel back and remove the rear caliper A from the wheel e Remove the rear wheel CAUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground Rear Wheel Installation e Install the groove A of the caliper bracket onto the swingarm stop B e Engage the drive chain with the rear sprocket e Insert the axle from the right side of the wheel and tighten the axle nut Torque Rear Axle Nut 108 N m 11 kgf m 80 ft Ib e Insert a new cotter pin A NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle tighten the nut clockwise
187. battery is a must for conducting accurate electrical system tests OThe electrical parts should never be struck sharply as with a hammer or allowed to fall on a hard surface Such a shock to the parts can damage them OTo prevent damage to electrical parts do not disconnect the battery leads or any other electrical connections when the ignition switch is on or while the engine is running OBecause of the large amount of current never keep the starter button pushed when the starter motor will not turn over or the current may burn out the starter motor wind ings OTake care not to short the leads that are directly con nected to the battery positive terminal to the chassis ground OTroubles may involve one or in some cases all items Never replace a defective part without determining what CAUSED the failure If the failure was caused by some other item or items they must be repaired or replaced or the new replacement will soon fail again 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 White DG Dark green Yellow OElectrical Connectors Female Connectors A
188. beam indicator light does go off inspect or replace the following item Headlight Relay in Junction Box see Electrical System chapter e Turn off the ignition switch e The headlights and high beam indicator light should go off Headlight Aiming Inspection e Inspect the headlight beam for aiming x lf the headlight beam points to one side rather than straight ahead adjust the horizontal beam Headlight Beam Horizontal Adjustment e Turn the horizontal adjuster A on the headlight with the screwdriver in or out until the beam points straight ahead xIf the headlight beam points too low or high adjust the vertical beam Headlight Beam Vertical Adjustment e Turn the vertical adjuster A on the headlight with the screwdriver in or out to adjust the headlight vertically 9517041851 2 44 PERIODIC MAINTENANCE Periodic Maintenance Procedures horizontal NOTE OON high beam the brightest points should be slightly below horizontal with the motorcycle on its wheels and the rider seated Adjust the headlight to the proper an gle according to local regulations OFor US model the proper angle is 0 4 degrees below This is 50 mm 2 drop at 7 6 25 ft measured from the center of the headlight with the motorcycle on its wheels and the rider seated 50 mm 2 in A Center of Brightest Spot B 7 6 m 25 ft C Low Beam D Height of Headlight Center E High Beam F Side Stan
189. ble with the rubber cap is connected directly to the battery positive termi nal even when the ignition switch off so take care not to short the removed cable to chassis ground 118007 P 16 52 ELECTRICAL SYSTEM Electric Starter System e Connect the hand tester Al and 12 V battery B to the starter relay as shown Special Tool Hand Tester 57001 1394 lf the relay does not work as specified the relay is defec tive Replace the relay Testing Relay Tester Range x 1 range Criteria When battery is connected 00 When battery is disconnected gt lt GP11010781 C Electric Starter Circuit G W G BK gt 2 c lt 2 GPilO65BW3 C 1 Joint Connector A 7 Junction Box 14 Starter Motor 2 Meter Ground 8 Ignition Fuse 10 15 Starter Relay 3 Frame Ground 9 Ignition Switch 16 Main Fuse 30 A 4 Engine Stop Switch 10 Side Stand Switch 17 Battery 12 V 8 Ah 5 Starter Button 11 Starter Lockout Switch 18 Joint Connector B 6 Starter Circuit Relay 12 Neutral Switch 19 ECU 13 Diode ELECTRICAL SYSTEM 16 53 Lighting System This models adopt the daylight system and have a head light relay in the junction box In these models the head light does not go on when the ignition switch and the engine stop switch are first turned on The headlight comes on after the starter button is released and stays on until
190. bleed pipe bleed holes clogged Pilot passage clogged Air cleaner clogged poorly sealed or miss ing Fuel tank air vent obstructed Fuel pump trouble APPENDIX 17 27 Troubleshooting Guide Throttle body assy holder loose Air cleaner duct loose Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head warped Cylinder head gasket damaged Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Other IC igniter in ECU trouble Throttle body assy not synchronizing Engine oil viscosity too high Drive train trouble Brake dragging Air suction valve trouble Vacuum switch valve trouble Engine overheating Clutch slipping Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Knocking Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect IC igniter in ECU trouble Camshaft position sensor trouble Crankshaft sensor trouble Miscellaneous Throttle valve won t fully open Brake dragging Clutch slipping Engine overheating Eng
191. c Pressure Sensor Output Voltage v H Altitude m or feet ST Standard of Sensor Output Voltage v UR Usable Range of Sensor Output Voltage v FUEL SYSTEM DFI 3 61 Atmospheric Pressure Sensor Service Code 15 Atmospheric Pressure Sensor Circuit 4 1 BL cepe 14 HH B BR BK G W 8617833881 Atmospheric Pressure Sensor Circuit Immobilizer Equipped Models G W BR BK G W BR BK BL ABC 6C17832BW1 C Atmospheric Pressure Sensor 3 62 FUEL SYSTEM DFI Crankshaft Sensor Service Code 21 Start the engine and switch the diagnosis mode to Dealer 1 mode to know all the problem that the DFI system has at the time of self diagnosis If the engine cannot be started the self diagnosis system does not detect dynamic condi tion of the crankshaft sensor In this case turn off the igni tion switch and turn it on again to enter the Dealer 2 mode In this mode the system tells all the troubles which the DFI system had in both static and dynamic conditions Crankshaft Sensor Removal Installation e See the Ignition System section in the Electrical System chapter Crankshaft Sensor Inspection OThe crankshaft sensor has no power source and when the engine stops the crankshaft sensor generates no sig nals e Crank the engine and measure the peak voltage of the crankshaft sensor see Electrical Syst
192. c Pressure Sensor Signal Camshaft Position Sensor Signal Water Temperature Sensor Signal Speed Sensor Signal ECU Power Source Circuit Ground to Bat tery Terminal Crankshaft Sensor Signal 27 DFI System Ground 28 Electric Starter Button Signal Fuel Pump Relay Signal Engine Stop Switch Signal Immobilizer Communication Signal Unused Tachometer Signal Injector 2 Signal Injector 1 Signal Stick Coil 3 Signal Stick Coil 2 Signal Stick Coil 1 Signal Interlock Circuit Signal Self diagnosis Signal Starter Lockout Switch Signal generated by grounding this terminal and shown by Fl indicator LED light Unused Battery Power ON OFF Signal Immobilizer Communication Signal Immobilizer Communication Signal External Diagnosis System Signal Fl Indicator LED Light Signal Injector 4 Signal Injector 3 Signal Unused Ignition System Ground Stick Coil 4 Signal 3 16 FUEL SYSTEM DFI DFI Parts Location 6017777BW2 C 23 a mv SS GC17778BW2 C 1 Digital Fuel Injection Parts Water Temperature Sensor DFI Inlet Air Pressure Sensor DFI Injectors DFI Fuel Pump DFI Inlet Air Temperature Sensor DFI Sealed Battery Junction Box ECU DFI ECU Fuse 15 10 Atmospheric Pressure Sensor DFI 11 Stick Coils 12 Camshaft Position Sensor
193. caliper mounting bolts B and detach the caliper C from the disc e Unscrew the banjo bolt and remove the brake hoses D from the caliper see Brake Hose Removal Installation CAUTION Immediately wash away any brake fluid that spills NOTE OAfter the caliper removal if compressed air will not be available for disassembling the caliper remove the pis ton before detaching the brake hose see Front Caliper Disassembly Rear Caliper Removal e Loosen the banjo bolt A at the brake hose lower end and tighten it loosely e Unscrew the caliper mounting bolts B and detach the caliper C from the disc e Unscrew the banjo bolt and remove the brake hose D from the caliper see Brake Hose Removal Installation CAUTION Immediately wash away any brake fluid that spills NOTE OAfter the caliper removal if compressed air will not be available for disassembling the caliper remove the pis ton before detaching the brake hose see Rear Caliper Disassembly Caliper Installation e Install the caliper and brake hose lower end OReplace the washers on each side of hose fitting with new ones e Tighten Torque Caliper Mounting Bolts Front 34 N m 3 5 kgf m 25 ft lb Caliper Mounting Bolts Rear 25 N m 2 5 kgf m 18 ft Ib Brake Hose Banjo Bolt 34 N m 3 5 kgf m 25 ft lb e Check the fluid level in the brake reservoirs e Bleed the brake line see Bleeding the Brake Line e Check
194. cial 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 FI indicator light A blinks to display the ECU is in the registration mode go to the next step 0 5second 0 5second gt ep es GP30117BS1 C 16 80 ELECTRICAL SYSTEM Immobilizer System Equipped Models Not Verified OThe FI indicator light A blinks to display the collation er ror Immobilizer Amplifier Failure GP30118BS1 Master Key Collation Error 0 3second GO eL LELTUFLTUFLELTELTLTUTUTUT GP301189BS1 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 FI indicator light 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 a
195. cked bent or otherwise damaged FUEL SYSTEM DFI 3 81 ECU e With the ECU connectors A connected check the fol lowing ground lead for continuity with the ignition switch OFF using a tester and needle adapter set Battery B Tester C Special Tool Needle Adapter Set 57001 1457 ECU Grounding Inspection 26 50 or 51 BK Y Terminal Engine Ground Battery Terminal 0 lt Battery Terminal 0 Immobilizer Equipped Models 25 27 or 51 BK Y lt Battery Terminal 0 Engine Ground lt Battery Terminal 0 no continuity check the connector the engine ground lead or main harness and repair or replace them if nec essary GC17844BS1 e Check the ECU power source voltage with a digital meter A OPosition the terminal in accordance with terminal numbers of ECU connectors B in this chapter figure Battery C ECU Power Source Inspection Meter Connections Between Terminal 13 W Y and Battery Terminal Between Terminal 43 W BK and Battery Terminal Ignition Switch OFF Terminal 13 W Y 0 V Terminal 43 W BK Battery Voltage 12 6 V or more Ignition Switch ON Both Battery Voltage 12 6 V or more Meter Connections Immobilizer Equipped Models Between Terminal 11 W Y and Battery Terminal Between Terminal 43 W BK
196. clearance with plastigage A e Tighten the big end nuts to the specified torque see Con necting Rod Installation NOTE ODo not move the connecting rod and crankshaft during clearance measurement 9105041881 CAUTION After measurement replace the connecting rod bolts Connecting Rod Big End Bearing Insert Crankpin Clearance Standard 0 041 0 071 mm 0 0016 0 0028 in Service Limit 0 11 mm 0 0043 in x If the clearance is within the standard no bearing replace ment is required the clearance is between 0 072 mm 0 00284 the service limit 0 11 mm 0 0043 in replace the bear ing inserts A with inserts painted blue B Check in sert crankpin clearance with the plastigage The clear ance may exceed the standard slightly but it must not be less than the minimum in order to avoid bearing seizure x lf the clearance exceeds the service limit measure the diameter of the crankpins 6105041781 Crankpin Diameter Standard 34 984 35 000 mm 1 3773 1 3780 in Service Limit 34 97 1 3768 9 18 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods x If any crankpin has worn the service limit replace the crankshaft with a new one the measured crankpin diameters not less than the service limit but do not coincide with the original diameter markings on the crankshaft make new marks on it Crankpin Diameter Marks
197. come 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 Make sure they do not 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 A Separator FUEL SYSTEM DFI 3 111 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 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 re
198. connection of the stick coil For KLEEN do not coast the motorcycle with the ignition switch off Turn the igni tion switch ON and run the engine IC igniter in ECU trouble Fuel air mixture incorrect Throttle body assy holder loose Air cleaner duct loose Air cleaner poorly sealed or missing Air cleaner O ring damaged Air cleaner clogged 17 28 APPENDIX Troubleshooting Guide 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 Gauge incorrect Water temperature gauge broken Water temperature sensor broken Coolant incorrect Coolant level too low Coolant deteriorated Wrong coolant mixed ratio Cooling system component incorrect Radiator fin damaged Radiator clogged Thermostat trouble Radiator cap trouble Radiator fan switch trouble Radiator fan relay trouble Fan motor broken Fan blade damaged Water pump not turning Water pump impeller damaged Over Cooling Gauge incorrect Water temperature gauge broken Water temperature sensor broken Cooling system component incorrect Radiator fan switch trouble Thermostat trouble Clutch Operation Faulty Clutch slipping Friction plate worn or warped Steel plate worn or warped Clutch spring broken or weak Clutch hub or housing une
199. ct see chapter 3 Inlet air trouble Inspect chapter 3 Cracked or obstructed inlet air pressure sensor Hase Inspect and repair or replace see chapter 3 Injector clogged Visually inspect and replace see chapter 3 Compression low Spark plug loose Reinstall see chapter 16 Tighten see chapter 5 Adjust see chapter 2 Inspect and replace see chapter 5 Inspect and replace see chapter 5 Inspect and replace see chapter 5 Replace see chapter 5 Inspect and replace see chapter 5 Inspect and replace see chapter 5 Valve not seating properly valve bent worn or carbon accumulating on the seating surface opo Knocking Carbon built up in combustion chamber Repair see chapter 5 Fuel poor quality or incorrect Use the gasoline recommended in the Owner s Manual ange uel See Spark plug incorrect Replace it with the correct plug see chapter 16 Stick coil trouble Inspect see chapter 16 IC igniter in ECU trouble Inspect see chapter 16 Inlet air temperature sensor trouble Inspect see chapter 3 Atmospheric pressure sensor trouble Inspect see chapter 3 Miscellaneous Subthrottle sensor trouble Inspect see chapter 3 Subthrottle valve actuator trouble Inspect see chapter 3 FUEL SYSTEM DFI 3 37 DFI System Troubleshooting Guide
200. d Connector Headlight Lead Connectors Front Right Turn Signal Light Lead Con nector Headlight Harness Right Switch Housing Lead Connector Meter Connector Clamp Tail Brake Light Rear Left Turn Signal Light Connector Black Rear Right Turn Signal Light Connector Gray License Plate Light Connector ECU Battery Negative Cable Battery Battery Negative Lead Connector Battery Positive Cable Regulator Rectifier Clamp Starter Relay Rear Brake Switch Lead Connector Vehicle down Sensor Regulator Rectifier Lead Vehicle down Sensor Lead Clamp Viewed Back of Frame Upper Front Viewed from Right of Frame Battery Negative Cable Run the cable under the cross pipe Subthrottle Sensor Connector Main Throttle Sensor Connector Ignition Harness Connector To Fun Motor 17 16 APPENDIX Cable Wire and Hose Routing 4 Ao A E TT FAL me A ms sr LT ie ie E oa O RE I E 9C 9 rp ji Loos N 93 BE 11 52 tras UA ISS a gt 2 atl gi Y 2 i rece FT ja 1 Y lt OO S lt J 6809727 5 C APPENDIX 17 17 Cable Wire and Hose Routing 1 Camshaft Position Sensor Lead Run the le
201. d Muffler Body see Engine Top End chapter Throttle Body Assy D see Fuel System DFI chapter Radiator E see Cooling System chapter Radiator Hose F Crankshaft Sensor Lead Connector G Disconnect e Disconnect Ignition Harness Connector A e Disconnect Starter Motor Lead A see Electrical System chapter Alternator Lead Connector B see Electrical System chapter Neutral Switch Lead Connector see Electrical system chapter Side Stand Switch Lead Connector C Speed Sensor Connector D e Remove Engine Sprocket see Final Drive chapter 8 6 ENGINE REMOVAL INSTALLATION Engine Removal Installation e Remove Camshaft Position Sensor Connector A Camshaft Position Sensor B e Remove the vacuum switch valve hose from the air cleaner housing e Remove Breather Hose End A Engine Ground Cable Terminal Bolt B e Support the engine with a suitable stand A OPut a plank B onto the suitable stand for engine balance e Remove Right and Left Upper Engine Mounting Bolts A Front Engine Bracket Bolts B Front Engine Bracket C Heat Insulation Plate ENGINE REMOVAL INSTALLATION 8 7 Engine Removal Installation e Remove the middle and lower engine mounting nuts A and bolts e Remove Rear Engine Bracket Bolts B Rear Engine Bracket C e Using the nut wrench A loosen the locknut B Special Tool Engine Mount Nut Wrench 57001 1450 e Using the Hexagon Wr
202. d Switch Operation Inspection e Inspect the side stand switch A operation accordance to below table Side Stand Switch Operation 9517042851 9517043851 Clutch Engine Engine Sige Stang Position Lever Start Run Up Neutral Released Starts running Up Neutral Pulledin Starts Continue running Up In Gear Released Doesnt start running Up In Gear Pulled in Starts running Down Neutral Released Starts running Down Neutral Pulled in Starts Continue running Down In Gear Released pacon Stops 52 Start Down In Gear Pulled in Starts Continue running PERIODIC MAINTENANCE 2 45 Periodic Maintenance Procedures x If the side stand switch operation does not work inspect or replace the following item Battery see Electrical System chapter Main Fuse 30 A see Electrical System chapter Ignition Fuse 10 A see Electrical System chapter Ignition Switch see Electrical System chapter Side Stand Switch see Electrical System chapter Engine Stop Switch see Electrical System chapter Starter Button see Electrical System chapter Neutral Switch see Electrical System chapter Starter Circuit Relay see Electrical System chapter Junction Box see Electrical System chapter Harness see Wiring Inspection in the Electrical System chapter x lf the all parts are good condition replace the ECU Engine Stop Switch Operation
203. d and adjusted when the engine is cold at room temperature e Remove Crankshaft Sensor Cover see Electrical System chap ter Cylinder Head Cover see Engine Top End chapter 6506005851 C PERIODIC MAINTENANCE 2 25 Periodic Maintenance Procedures e Position the crankshaft at 1 4 piston TDC TDC Mark A for 1 4 Pistons Timing Mark Crankcase halves mating surface B 6507004851 C e Using the thickness gauge A measure the valve clear ance between the cam and the valve lifter Valve Clearance Standard Exhaust 0 22 0 31 mm 0 0087 0 0122 in Inlet 0 15 0 24 mm 0 0059 0 0094 in 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 GSO7015BS1 C OWhen positioning 1 piston TDC at the end of the compression stroke 2 8 e Inlet Valve Clearance of 1 3 Cylinders Exhaust Valve Clearance of 1 and 2 Cylinders Measuring Valve A Q9 S IN 6507016851 x lf the valve clearance is within the specified range first record the clearance and then adjust it 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 2 26 PERIODIC MAINTENANCE Periodic Maintenance Procedures
204. decimal places voltage or resistance Resistance Check Method OThis method is simple No need for a fully charged battery and the needle adapter Just do the following especially when a sensor A is suspect e Turn the ignition switch OFF and disconnect the connec tors e Inspect the sensor resistance using a digital meter see each sensor inspection in this chapter e Inspect the wiring and connectors B for continuity using the hand tester C analog tester rather than a digital meter Special Tool Hand Tester 57001 1394 x If the sensor the wiring and connections are good in spect the ECU for its ground and power supply see this chapter If the ground and power supply are good the ECU is suspect Replace the ECU 6017134852 C 6617135852 C FUEL SYSTEM DFI 3 27 Troubleshooting the DFI System DFI Diagnosis Flow Chart Problem occurs Confirm problems Gather information from rider The ignition switch is turned on and the state of the FI indicator light LED is seen Conduct non self diagnosis Conduct immobilizer Conduct self diagnosis inspection system inspection inspection Conduct general fuel system inspection General fuel system throttle assy air cleaner fuel tank etc GC17323B F Inquiries to Rider Inquiries to Rider OEach rider reacts to problems in different ways so it is important to confirm what
205. ded 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 2 24 PERIODIC MAINTENANCE Periodic Maintenance Procedures Radiator Hose and Pipe Inspection coolant leak damage installation condition OThe high pressure inside the radiator hose and pipe can cause coolant to leak A or the hose to burst if the line is not properly maintained e Visually inspect the hoses for signs of deterioration Squeeze the hoses A hose should not be hard and brittle nor should it be soft or swollen Replace the hose if any fraying cracks B or bulges C are noticed e Check that the hoses are securely connected and clamps are tightened correctly Torque Radiator Hose Clamp Screws 2 0 N m 0 20 kgf m 17 in Ib Air Suction System Air Suction System Damage Inspection e Pull the vacuum switch valve hose A out of the air cleaner e Start the engine and run it at idle speed e Plug A the vacuum switch valve hose end with your fin ger 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 vacuum switch valve or air suction valve see Engine Top End chapter Engine Top End Valve Clearance Inspection NOTE OValve clearance must be checke
206. defective or the alternator output is insufficient for the loads Check the alternator and regulator rectifier to determine which part is defective ELECTRICAL SYSTEM 16 35 Charging System Charging System Circuit GPO9131BW2 C Ignition Switch Meter Ground Frame Ground Alternator Regulator Rectifier Joint Connector A Joint Connector B Battery 12 V 8 Ah Main Fuse 30 A Load gt 16 36 ELECTRICAL SYSTEM Ignition System A WARNING The ignition system produces extremely high volt age Do not touch the spark plugs or stick coils while the engine is running or you could receive a severe electrical shock CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition switch is on or while the engine is running This is to prevent ECU Electronic Control Unit damage Do not install the battery backwards The negative side is grounded This is to prevent damage to the diodes and ECU Crankshaft Sensor Removal e Remove Right Frame Cover see Frame chapter Crankshaft Sensor Lead Connector A e Remove Rubber Boot Slide Out A Oil Pressure Switch Lead Terminal B Crankshaft Sensor Cover Bolts C with Clamps Crankshaft Sensor Cover D e Remove the crankshaft sensor A by taking off the crank shaft sensor bolts B ELECTRICAL SYSTEM 16 37 Ignition System
207. ds 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 e Replacement of the original exhaust system or muffler with a component not in compliance with Federal regulations e Removal of the muffler s or any internal portion of the muffler s e Removal of the air box or air box cover e Modifications to the muffler s or air inlet system by cutting drilling or other means if such modifications result in increased noise levels Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop However it contains enough detail and basic in formation to mak
208. e near the working area Because of the danger or highly flammable liquids do not use gasoline or low flash point solvents to clean the tank e Remove the fuel tank see Fuel Tank Removal e Remove the fuel pump inlet hose and the fuel pump see Fuel Pump section in this chapter e Pour some high flash point solvent into the fuel tank and shake the tank to remove dirt and fuel deposits e Draw the solvent out of the fuel tank e Dry the tank with compressed air e Install the fuel pump see Fuel Pump Installation e Install the fuel tank see Fuel Tank Installation 3 110 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 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 be
209. e cap counterclockwise to the first stop Then push and turn it further in the same direction and remove the cap OThe coolant will drain from the radiator and engine PERIODIC MAINTENANCE 2 51 Periodic Maintenance Procedures e Remove Left Side Cover see Frame chapter Reserve Tank Screws A e Turn over B the reserve tank remove the cap C and pour the coolant into a suitable container e Install the reserve tank Torque Coolant Reserve Tank Screws 7 0 Nm 0 70 kgf m 61 in Ib e Tighten the drain bolt with the gasket OReplace the drain bolt gasket with a new one Torque Water Pump Drain Bolt 11 N m 1 1 kgf m 95 in Ib e When filling the coolant choose a suitable mixture ratio by referring to the coolant manufacturer s directions CAUTION Soft or distilled water must be used with the an tifreeze in the cooling system If hard water is used in the system it causes scales accumulation in the water passages and consider ably reduces the efficiency of the cooling system Water and Coolant Mixture Ratio Recommended Soft Water 50 Coolant 50 Freezing Point 35 31 F Total Amount 2 9 L 3 1 US qt e Fill the radiator up to the filler neck A with coolant NOTE OPour in the coolant slowly so that it can expel the air from the engine and radiator e Check the cooling system for leaks e Tap the radiator hoses to force any air bubbles caught inside e Fill the radia
210. e frequently than the recommended interval OAfter riding through rain or on muddily roads the ele ment should be cleaned immediately If dirt or dust is allowed to pass through into the throttle assy the throttle may become stuck possi bly causing accident CAUTION If dirt gets through into the engine excessive en gine wear and possibly engine damage will occur e Remove the fuel tank see Fuel System DFI chapter e Remove the fuel tank bracket A Front B e Remove Screws A Air Cleaner Duct Holder B e Pull it out C backwards Front D PERIODIC MAINTENANCE 2 19 Periodic Maintenance Procedures e Clean the element by tapping it lightly to loosen dust e Blow away the remaining dust by applying compressed air A from the outside to the inside from the clean side to the dirty side e Visually inspect the element for no tears or no breaks and inspect the sponge gaskets B also x lf the element or gasket has any tears or breaks replace the element e Install the element A with the flat side B facing for wards e Fit the tongue C of the air cleaner duct holder into the slot of the housing Front D Torque Air Cleaner Duct Holder Screws 3 8 N m 0 39 kgf m 34 in lb Engine Vacuum Synchronization Inspection NOTE These procedures are explained on the assumption that the inlet and exhaust systems of the engine are in good condition e Situat
211. e is 4 8 V the ECU is normal x If the wiring is good check the sensor for various vacuum x If the output voltage for various vacuum is normal check the ECU for its ground and power supply see ECU sec tion ODetermine the local altitude elevation x lf you know the local atmospheric pressure using a barometer substitute the atmospheric pressure for Pv throttle vacuum in the vacuum sensor chart see Inlet Air Pressure Sensor section OGet the usable range of the atmospheric pressure sensor output voltage in the same way as Output Voltage Inspec tion of the inlet air pressure sensor and check if Va output voltage is within the usable range or not If you know the local altitude use the following chart For example Suppose the local altitude is 1 300 m 4 200 ft and the sensor output voltage Va is 3 3 V Plot this 1 300 m at a point 1 on the following chart and draw a vertical line through the point Then you can get the usable range 2 of the sensor output voltage Usable Range 3 2 3 64 V Plot Va 3 3 V on the vertical line Point 3 Results In the chart Va is within the usable range and the sensor is normal 3 60 FUEL SYSTEM Atmospheric Pressure Sensor Service Code 15 1000 1500 2000 1 400 0 500 2500 3000 1 ae 1 J 1310 0 2000 4000 6000 8000 10000 aes Ft 66170351 3 Va Atmospheri
212. 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 8 09000851 C 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 xIf no air bubbles A are coming up from the filler ports or if the container cells have not emptied completely tap the container B a few times e Keep the container in place for 30 minutes or more Don t remove the container from the battery until it s empty the battery requires all the electrolyte from the container for proper operation CAUTION 8 09000851 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 ELECTRICAL SYSTEM 16 23 Battery e Gently remove the container from the battery eLetthe battery sitfor 60 minutes priorto charging to allow the electrolyte to permeate into the plates for optimum performance NOTE OCharging the battery immediately aft
213. e Limit 76 6 mm 3 02 in Clutch Housing Finger Inspection e Visually inspect the clutch housing fingers A where the friction plate tangs B hit them x If they are badly worn or if there are groove cuts where the tangs hit replace the housing Also replace the friction plates if their tangs are damaged Clutch Housing Spline Inspection e Visually inspect where the teeth B on the steel plates wear against the clutch hub splines A x If there are notches worn into the splines replace the clutch hub Also replace the steel plates if their teeth are damaged GF06060381 C GF06105BS1 C GF06104BS1 C ENGINE LUBRICATION SYSTEM 7 1 Engine Lubrication System Table of Contents Exploded Vigw ELE 7 2 Engine Qil 7 4 SD6ecIfICatlOris doi tete 7 6 Special Tools and 7 7 E gin Oil ang 7 8 Oil Level 9 7 8 m ET 7 8 Oil Filter Replacement pp 7 8 EE 7 9 24 Deren oce ERE FE AERE e ae E Re ERN 7 9 RR tee Tu
214. e Periodic Maintenance chapter Switch Inspection e Using a hand tester check to see that only the connec tions shown in the table have continuity about 0 ohms OFor the handlebar switches and the ignition switch refer to the tables in the Wiring Diagram x lf the switch has an open or short repair it or replace it with a new one Special Tool Hand Tester 57001 1394 Rear Brake Light Switch Connections LEN When brake is pushed down When brake pedal is released Side Stand Switch Connections When side stand is up When side stand is down Neutral Switch Connections When transmission is in neutral When transmission is not in neutral a Oil Pressure Switch Connections When engine is stopped When engine is running i Engine lubrication system is in good condition Tr Speed Sensor Inspection e Disconnect Speed Sensor Connector A e Remove Engine Sprocket Cover B see Final Drive chapter 16 94 ELECTRICAL SYSTEM Switches and Sensors e Remove Bolts A Speed Sensor Cover e Remove Bolt A Take out the speed sensor e Connect the speed sensor connector A with the battery B 10 kQ resistor C and hand tester D as shown e Set the tester to the DC 25 V range Special Tool Hand Tester 57001 1394 e Trace A each side of the speed sensor surface with the scre
215. e Press the MODE button to complete the time setting process d ud OThe clock starts counting the seconds as soon as the 1 MODE button is pressed sek GP17064BS1 x lf the display function does not work and adjust replace the meter assembly Speedometer Check e Connect the 12 V battery and terminals in the same man ner as specified in the Liquid Crystal Display LCD Seg ments Check e The speed equivalent to the input frequency is indicated in the oscillator A if the square wave illustrated as shown would be input into the terminal 16 Olndicates approximately 60 mph in case the input fre LL quency would be approximately 56 Hz Olndicates approximately 60 km h case the input fre quency would be approximately 97 Hz OQOOOOOOO 10 15 GP17049BS1 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 jack on the ignition switch ORotate the rear wheel by hand OCheck that the speedometer shows the speed 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 68 ELECTRICAL SYSTEM Meter Gauge Indicator Unit Speed Sensor Electric Source Check eConnectthe 12 V battery and te
216. e 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 OTo prevent corrosion and deposits in the fuel system do not add to fuel any fuel antifreeze chemicals 6617036851 3 22 FUEL SYSTEM DFI Servicing Precautions OTo maintain the correct fuel air mixture F A there must be no inlet air leaks in the DFI system Be sure to install the oil filler plug A after filling the engine oil Clutch Cover B Torque Oil Filler Plug 1 5 N m 0 15 kgf m 13 in Ib FUEL SYSTEM DFI 3 23 Troubleshooting the DFI System Outline Outline When an abnormality in the system occurs the FI indica tor LED Light Emitting Diode light goes on to alert the rider on the meter panel In addition the condition of the problem is stored in the memory of the ECU electronic control unit With the engine stopped and turned in the self diagnosis mode the service code A is indicated by the number of times the FI indicator LED light blinks When due to a malfunction the FI indicator LED light re mains lit ask the rider about the conditions B under which the problem occurred and try to determine the cause C e First conduct a self diagnosis inspection and then a non self diagnosis inspection The non self diagnosis items
217. e body assy x If the reading is within the range check the input voltage see Input Voltage Inspection GC17168BS1 C FUEL SYSTEM DFI 3 77 Subthrottle Valve Actuator Service Code 62 Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Remove the throttle body assy see Throttle Body Assy Removal e 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 Brand KOWA SEIKI Needle Adapter Set 57001 1457 Subthrottle Valve Actuator Input Voltage d es Connections to Harness m I Meter BK BL lead 1 Meter P BL lead 2 M Meter G lead 3 Meter W BL lead 4 6c17167B32 C e Measure the actuator input voltage with the engine stopped and with the connector joined e Turn the ignition switch ON Input Voltage at Actuator Standard about 8 5 10 5 V DC the reading is within the standard but the actuator doesn t operate replace it x If the reading is out of the range check the wiring to ECU see wiring diagram in this section xIf the wiring is good check the ECU for its ground and power supply see ECU section Subthrottle Sensor Circuit BK BL i B P BL n W BL 80617841841
218. e clearance again x If the clearance still remains out of the limit replace the cylinder head unit Camshaft Runout e Remove the camshaft see Camshaft Removal e Set the camshaft in a camshaft alignment jig or on V blocks e Measure runout with a dial gauge at the specified place as shown 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 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 36 146 36 254 mm 1 4231 1 4273 in Inlet 36 746 36 854 mm 1 4467 1 4509 in Service Limit Exhaust 36 05 mm 1 419 in Inlet 36 65 mm 1 443 in Camshaft Chain Removal e Split the crankcase see Crankshaft Transmission chap ter e Remove the camshaft chain A from the crankshaft sprocket GE11073BS1 C GE11012281 5 18 ENGINE TOP END Cylinder Head Cylinder Compression Measurement NOTE OUse the battery which is fully charged e Warm up the engine thoroughly e Stop the engine e Remove Seats see Frame chapter Fuel Tank see Fuel System DFI chapter Stick Coils see Electrical System chapter Spark Plugs see Electrical System chapter Owner s Tool Spark Plug Wrench 16 mm
219. e correct plug see chapter 16 inspect see chapter 16 inspect see chapter 16 inspect see chapter 16 Supply fuel see Owner s Manual Clean element or inspect sealing see chapter 2 3 Air cleaner duct loose Reinstall see chapter 3 Air cleaner O ring damaged Replace see chapter 3 Fuel tank air vent obstructed Inspect and repair see chapter 3 Throttle body assy loose Reinstall see chapter 3 Throttle body assy O ring damage Replace see chapter 3 Fuel filter or pump screen clogged Inspect and replace fuel pump see chapter 3 Inspect fuel pressure and replace fuel pump see chapter 3 Inspect and repair see chapter 3 inspect see chapter 3 inspect see chapter 3 Inspect and replace see chapter 4 inspect see chapter 3 inspect see chapter 3 inspect see chapter 3 inspect see chapter 2 Air cleaner clogged poorly sealed or missing Fuel pressure regulator clogged Inlet air temperature sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Atmospheric pressure sensor trouble Inspect see chapter 3 Fuel pressure too low or too high Inspect see chapter 3 Battery voltage low Inspect and charge see chapter 16 FUEL SYSTEM DFI 3 33 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions chapter Incorrect idle speed Water temperature se
220. e fails the ECU locks ignition timing into the ignition timing at closed throttle position and sets the DFI the a N method If the inlet air pressure sensor system fails the signal Pv is out of the usable range wiring short or open the ECU sets the DFI in the method Inlet Air Tempera ture Sensor Water Tem perature Sensor Inlet Air Temperature Ta A7 C 178 Water Temperature Tw 30C 120 C If the inlet air temperature sensor fails the signal is out of the usable range wiring short or open the ECU sets Ta at 40 C 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 Atmo spheric Pressure Sensor Crankshaft Sensor Absolute Atmospheric Pressure Pa 100 mmHg 900 mmHg Crankshaft sensor must send 23 signals output signal to the ECU at the one 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 crankshaft sensor generates other than 23 signals the engine stops by itself 31 Camshaft Position Sensor Speed Sensor Vehicle down Sensor Cam sensor must send one signal output signal to the ECU at the two cranking Speed sensor must send 4 signals output signal to the ECU at the one rotation of the engine sprocket The g
221. e flows into the breather hose remove the hose and blow it clean with compressed air California model careful of fuel spillage from the fuel tank since fuel still remains in the fuel tank and fuel pump 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 CY 3 5 e lt lt Z 25090 555 d 00 504050 5550 4 005 Co 10565 1252 9 26 5025 5550 855502 00500 BS x GC17182BS1 C FUEL SYSTEM DFI 3 109 Fuel Tank Fuel Tank and Cap Inspection e Visually inspect the gasket A on the tank cap for any damage Replace the gasket if it is damaged e Check to see if the water drain pipe B and fuel breather pipe C 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 Tank Cleaning A WARNING Clean the tank in a well ventilated area and take care that there are no sparks or flame anywher
222. e gap is incorrect carefully bend the side electrode with a tool to obtain the correct gap Spark Plug Gap 0 7 0 8 mm 0 028 0 031 in e Install the spark plug see Periodic Maintenance chapter Interlock Operation Inspection e Remove Seat see Frame chapter Junction Box see this chapter ODo not disconnect the connectors 1st Check e Measure the terminal voltage of the G BK lead in the junc tion box connector A in accordance with the following procedure Olnsert the tester probe B in the Green Black lead termi nal OSet the tester C to the 25 V DC range connect it to the frame ground D Connection Tester Terminal G BK Lead Terminal Tester Terminal Frame Ground Condition Transmission Gear 1st Position Clutch Lever Release or Pulled In Side Stand gt Down OTurn the ignition switch on ORead the voltage Interlock Operation Voltage Standard 4 V or x If the voltage is lower than the standard inspect the side stand switch starter lockout switch and junction box And their parts are normality replace the ECU If the voltage is standard push the starter button to check as follows Olf the starter motor does not turn the ECU is good and check the starter system circuit Olf the starter motor turned ECU is defective Replace the ECU lt SN N SS 22222 RK ANN lt 2 N GS17005BS1 C ELECTRICAL SYSTEM 16 4
223. e it useful to the owner who de sires to perform his own basic maintenance and repair work A basic knowledge of mechanics the proper use of tools and workshop proce dures must be understood in order to carry out maintenance and repair satisfactorily When ever the owner has insufficient experience or doubts his ability to do the work all adjust ments maintenance and repair should be car ried out only by qualified mechanics In order to perform the work efficiently and to avoid costly mistakes read the text thor oughly familiarize yourself with the procedures before starting work and then do the work care fully in a clean area Whenever special tools or equipment are specified do not use makeshift tools or equipment Precision measurements can only be made if the proper instruments are used and the use of substitute tools may ad versely affect safe operation For the duration of the warranty period we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty To get the longest life out of your vehicle Follow the Periodic Maintenance Chart in the Service Manual eBe alert for problems and non scheduled maintenance e Use proper tools and genuine Kawasaki Mo torcycle parts Special tools gauges and testers that are necessary when servicing Kawasaki motorcycl
224. e socket A together with the bulb e Pull the bulb A out of the socket CAUTION Do not turn the bulb Pull the bulb out to prevent damage to the bulb Do not use bulb rated for greater wattage then the specified valve e Replace the bulb with a new one ELECTRICAL SYSTEM 16 55 Lighting System Tail Brake Light LED Removal e Remove Seat see Frame chapter e Disconnect the tail brake light LED connector A e Remove the seat cover see Frame chapter e Unscrew the bolts A e Remove the tail brake light LED B Tail Brake Light LED Installation e Insert the slots A into the tongues B e Tighten the tail brake light mounting bolts Torque Tail Brake Light Mounting Bolts 1 2 0 12 kgf m 10 in Ib e Install Seat Cover see Frame chapter 16 56 ELECTRICAL SYSTEM Lighting System Headlight Tail Light Circuit Park lieni ionoj BATTERY G3 o TAIL Oat TAIL2 Headlight Fuse 10 A 1 Ignition Switch 9 2 Meter Ground 10 3 Frame Ground 11 4 Alternator 12 5 Headlight Diodes 13 6 Headlight Circuit Relay 14 7 Taillight Fuse 10 A 15 8 Junction High Beam Indicator Light Joint Connector A City Light Headlight High Headlight Low Dimmer Switch 16 6 121918 2 Passing Button other than United States and Canada Main Fuse 30 Battery
225. e spark plug 3 unscrew the thermostat bracket bolt A e Disconnect Stick Coil Connectors A Pull out the stick coil 1 B e Take out the camshaft position sensor connector C from the bracket e Pull out the stick coil 2 D CAUTION Do not pry the connector part of the coil while re moving the coil PERIODIC MAINTENANCE 2 59 Periodic Maintenance Procedures eRemove the ignition harness connector from the bracket e Remove Stick Coil Connector 4 B Disconnect Stick Coil 4 C Stick Coil Connector 3 D Disconnect e Pull the main harness upward and remove the stick coil 3 e Remove the spark plugs using the 16 mm plug wrench A Owner s Tool Spark Plug Wrench 16 mm 92110 1146 e Insert the spark plug vertically into the plug hole with the spark plug installed in the plug wrench A Owner s Tool Spark Plug Wrench 16 mm 92110 1146 Tighten Torque Spark Plugs 13 N m 1 3 kgf m 113 in Ib e Insert the coils as shown being careful of the coil heads A direction OFit the coils securely CAUTION Do not tap the coil head while installing the coil OBe sure the stick coils are installed by pulling up A it lightly e Connect the connectors Install Thermostat Bracket Bolt see Cooling System chapter Fuel Tank see Fuel System DFI chapter GP10120BS1 C FUEL SYSTEM DFI 3 1 Fuel System DFI Table of Conten
226. e swingarm OThe rollers and ball in bearing normally wear very little and wear is difficult to measure Instead of measuring visually inspect the bearing for abrasion discoloration or other damage x If the needle bearings and sleeve show any sings of ab normal wear discoloration or damage replace them as a set e Turn the ball bearing in the swingarm back and forth A while checking for plays roughness or binding x lf the ball 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 Chain Guide Inspection e Refer to the Chain Guide Wear Inspection in the Periodic Maintenance chapter GM06076BS1 C 6J06002BS1 C SUSPENSION 13 21 Swingarm Swingarm Bearing Lubrication NOTE OSince the bearings are packed with grease lubrication is not required 13 22 SUSPENSION Tie rod Rocker Arm Tie rod Removal e Using the jack and attachment raise the rear wheel off the ground see Rear Shock Absorber Removal Special Tool Jack 57001 1238 Jack Attachment 57001 1608 e Squeeze the brake lever slowly and hold it with a band A GH04011081 C e Remove Lower Rear Shock Absorber Bolt and Nut A Upper and Lower Tie rod Nuts and Bolts B Tie rods C Tie rod Installation e Install the tie rods so that the marked A side faces the bolts and nuts
227. e the motorcycle so that it is vertical e Remove the fuel tank see Fuel System DFI chapter e Pull off the vacuum hoses and the rubber cap s from the right fitting of each throttle body Pull off the vacuum switch valve hose thick A from the air cleaner housing B Front C CAUTION Do not remove the inlet air pressure sensor hoses on the left fitting of each throttle body e Connect a commercially available vacuum gauge A to these right fittings of the throttle body as shown Front B e Connect a highly accurate tachometer to one of the stick coil primary leads e Plug Vacuum Switch Valve Hose Thick and its Air Cleaner Housing Hole Vacuum Switch Valve Vacuum Hose Ends C 6505039851 C 2 20 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Connect Fuel Pump Lead Connector A Extension Tube Special Tool Extension Tube 57001 1578 e Start the engine and warm it up thoroughly e Check the idle speed Tachometer A e Open and close the throttle x If the idle speed is out of the specified range adjust it CAUTION Do not measure the idle speed by the tachometer of the meter unit e While idling the engine inspect the engine vacuum using the vacuum gauge B Engine Vacuum Standard 29 7 1 333 kPa 225 10 mmHg at Idle Speed 1 100 50 r min rpm any vacuum is not within the specifications firs
228. e upper stem bearing inner race and bearing e To remove the bearing outer races C pressed into the head pipe B insert a bar A into the recesses of head pipe and applying it to both recess alternately hammer it to drive the race out NOTE Olf either steering stem bearing is damaged it is recom mended that both the upper and lower bearings includ ing outer races should be replaced with new ones GNO5010381 C STEERING 14 7 Steering Stem eRemovethelowerbearing inner race which is pressed onto the steering stem with a suitable commercially avail able chisel B Stem Stem Bearing Installation e Replace the bearing outer races with new ones e Apply grease to the outer races and drive them into the head pipe at the same time Special Tool Bearing Driver Set 57001 1129 A e Replace the bearing inner races and oil seal with new ones e Apply grease to the oil seal e Drive the lower ball bearing inner race applied the grease onto the stem Special Tools Steering Stem Bearing Driver 542 5 57001 1344 A Steering Stem Bearing Driver Adapter 41 5 57001 1345 B e Apply grease the lower ball bearing A and install it onto the stem e Apply grease to the upper ball bearing B and inner race C e Install the stem A through the head pipe and install the ball bearing B and inner race C on it e Install the stem cap D and steering stem nut E
229. e weight has any play on the rim the clip of the weight has been stretched Replace the loose balance weight Do not reuse balance weight Unbalanced wheels can create an unsafe riding condition 6J04075BS1 C WHEELS TIRES 10 13 Tires Air Pressure Inspection e Refer to the Air Pressure Inspection in the Periodic Main tenance chapter Tire Inspection e Refer to the Wheels Tires Damage and Tire Tread Wear Inspection in the Periodic Maintenance chapter Tire Removal e Remove Wheel see Front Rear Wheel Removal 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 Lubricate the tire beads and rim flanges on both sides with a soap and water solution or rubber lubricant This helps the tire beads slip off the rim flanges CAUTION Never lubricate with engine oil or petroleum distil lates because they will deteriorate the tire e Remove the tire from the rim using a suitable commer cially available tire changer NOTE OThe tires cannot be removed with hand tools because they fit the rims too tightly Tire Installation A WARNING Use the same manufacturer s tires on both front and rear wheels e Inspect the rim and tire and replace them if necessary e Clean the sealing surfaces of the rim and tire
230. ear position is decided by the signal of the speed sensor Vehicle down Sensor Output Voltage signal VWd 0 4V 44V 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 and the ECU sets the top 6 gear position If the vehicle down sensor system has failures the output voltage Vd is more than usable range wiring open the ECU shuts off the fuel pump the fuel injectors and the ignition system 3 44 FUEL SYSTEM DFI Self Diagnosis Service Output Signal Usable Codes pans Range or Criteria Backups Dy 2697 If the subthrottle sensor system fails the signal Subthrottle Rs is out of the usable range wiring short or open 32 Output Voltage Sensor the actuator locks sub throttle valve at full open 0 15 4 85 V a position Immobilizer _ If the immobilizer system fails no signal wiring Amplifier shortor open the vehicle is no start and run Master or The user or master key If the blank key or broken key is used the User Key must use register key vehicles is no start and run Stick Coil The stick coil primary If the ignition primary winding 1 has failures no 1 Ignition winding must send signal wiring short or open the ECU shuts off Coi signals output voltage
231. eat Width Tool Vernier Caliper Purpose check seat width Too narrow 45 Grind Tool 45 Cutter Purpose increase width of seat area beyond spec to increase O D against spec Machinist s dye on seat 60 Grind Tool 60 Cutter Purpose reduce seat width to specification Lap Valve Tools Purpose Valve Lapper Grinding Compound perfectly match valve and seat area check valve head for damage FINISHED 5 28 ENGINE TOP END Cylinder Pistons Cylinder Removal e Remove Cylinder Head see Cylinder Head Removal Water Hose A e Remove the cylinder Cylinder Installation NOTE Olf a new cylinder is used use new piston ring e Install the dowel pins A and new cylinder gasket e The piston ring openings must be positioned as shown in the figure The openings of the oil ring steel rails must be about 30 40 of angle from the opening of the top ring Top Ring A Second Ring B Oil Ring Steel Rails C Oil Ring Expander D Hollow E 30 40 F e Apply molybdenum disulfide oil solution to the cylinder bore piston rings and piston e Position the crankshaft at 2 3 piston TDC e Prepare two auxiliary head bolts with their head cut Olnstall the two cylinder head bolts A diagonally in the crankcase e Install the cylinder block B Pistons C OFirst insert the 2 3 pistons and then rotate the crank shaft at 90 angle Olnsert the p
232. ection Reading Q Connection Reading Q 1 1A 0 1A 8 eo 16 98 ELECTRICAL SYSTEM Junction Starter Circuit Headlight Relay Inspection e Remove the junction box see Junction Box Fuse Circuit Inspection e Check conductivity of the following numbered terminals by connecting the hand tester and one 12 V battery to the junction box as shown ORefer to the Junction Box Internal Circuit x If the tester does not read as specified replace the junc tion box Special Tool Hand Tester 57001 1394 Relay Circuit Inspection with the battery disconnected Tester Connection Tester Reading Q Headlight 7 13 Relay Starter C Circuit Relay 13 11 12 11 The actual reading varies with the hand tester used Apply tester positive lead Apply tester negative lead Relay Circuit Inspection with the battery connected Battery Connection Tester Tester Connection Reading Headlight 9 13 78 5 Relay Starter Circuit 11 12 9 Not 13 11 Relay The actual reading varies with the hand tester used Apply tester positive lead Apply tester negative lead ELECTRICAL SYSTEM 16 99 Junction Box Diode Circuit Inspection e Remove the junction box e Check conductivity of the following pairs of terminals Diode Circuit Inspection Tester Connection 13 8 13 9 12 11 12 14 15 14
233. ed 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 x lf it does discard it A WARNING If the balance weight has any play on the rim the clip of the weight have been stretched Replace the loose balance weight Do not reuse used balance weight Unbalanced wheels can create an unsafe riding condition Balance Weight Part Number Weight 41075 0007 10 g 0 35 oz 41075 0008 20 g 0 71 oz 41075 0009 30 g 1 06 oz NOTE OBalance weights are available from Kawasaki dealers in 10 20 and 30 grams 0 35 0 71 and 1 06 oz sizes An imbalance of less than 10 grams 0 35 oz will not usually affect running stability ODo not use four or more balance weight more than 90 gram 3 17 oz If the wheel requires an excess balance weight disassemble the wheel to find the cause e Slip the balance weight A onto the rib B by pushing or lightly hammering C the clip D D Left Side Right Side CAUTION When installing the balance weight do not touch the brake disc The disc could be damaged B 6J04074BS1 C 10 12 WHEELS TIRES Wheels Rims e Check that the weight A and clip B are fully seated on the rim C and that the clip is hooked over the rib D Left Side E Right Side F A WARNING If the balanc
234. eep the other user key away from the immobilizer an tenna Olf there is any problem in the registration the Fl indicator light A blinks to display the collation error Immobilizer Amplifier Failure gt GP30118BS1 When Registered User Key is Inserted 0 5second 0 5second gt 13 GP30117BS1 C User Key Collation Error 0 3second QOO UU GP30119BS1 C e The user key 1 is successfully registered in the ECU OThe FI indicator light A blinks 2 times and stops for 1 second and then repeats this cycle gt ON GP30120BS1 C 16 76 ELECTRICAL SYSTEM Immobilizer System Equipped Models e Turn the user key 1 OFF and remove off the user key 1 OThe FI indicator light 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 finishes and the FI indicator light will switch off OThis procedure registered the master key and one user key OContinue with the procedure to register the second and later keys before the 15 seconds period has elapsed 0 5second 0 5second gt GP30117BS1 C e Insert the user key 2 to the ignition switch and turn it ON Olf there is any problem in the registration the Fl indicator light A blinks to display the collation error Immobilizer Amplifier Failure
235. el 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 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 standard screwdrivers A B between the rib C and the weight D as shown e Pry the weight with two screwdrivers and remove the bal ance weight 6J04043BS1 C 6J04076BS1 C 6J04077BS1 6J04073BS1 C WHEELS TIRES 10 11 Wheels Rims CAUTION When removing the balance weight do not touch the brake disc The disc could be damag
236. elay Y Fuel Pump Relay od dx SO 4 Ao ECU Main Fuse 15A Vehicle down Sensor Starter Relay Main Fuse 30 A Joint Connector C Battery 12 V 8Ah Fuel Pump Self diagnosis Terminal Joint Connector A Joint Connector B ECU Electronic Control Unit see Electrical System chapter Immobilizer Antenna Immobilizer Amplifier 3 14 FUEL SYSTEM DFI DFI System v 2625124123122 1211201191118 1171116115114 Terminal Nambers of ECU Connectors Power Supply to Sensors Main Throttle Sensor Signal Subthrottle Sensor Signal Atmospheric Pressure Sensor Signal Water Temperature Sensor Signal Unused Ignition Switch Signal Unused Camshaft Position Sensor Signal Unused Crankshaft Sensor Signal Unused Power Supply to ECU Injectors and Fuel Pump Ground to Sensors Unused Vehicle down Sensor Signal Inlet Air Pressure Sensor Signal Inlet Air Temperature Sensor Signal Unused Speed Sensor Signal Unused Camshaft Position Sensor Signal Unused Crankshaft Sensor Signal Unused ECU Power Source Circuit Ground to Bat tery Terminal GCi7713BWi C Engine Stop Switch Signal Starter Lockout Switch Signal Electric Starter Button Signal Fuel Pump Relay Signal Subthrottle Valve Actuator Drive Signal Subthrottle Valve Actuator Drive Signal Unused Tachometer Sig
237. em chapter in or der to check the sensor e Check the wiring for continuity using the following dia gram Crankshaft Sensor Circuit 6617261881 6C17834BW1 C ECU Crankshaft Sensor FUEL SYSTEM DFI 3 63 Camshaft Position Sensor Service Code 23 Start the engine and switch the diagnosis mode to Dealer 1 mode to know all the problem that the DFI system has at the time of self diagnosis If the engine cannot be started the self diagnosis system does not detect dynamic condi tion of the camshaft position sensor In this case turn off the ignition switch and turn it on again to enter the Dealer 2 mode In this mode the system tells all the troubles which the DFI system had in both static and dynamic conditions Camshaft Position Sensor Removal Installation The camshaft position sensor detects the position of the camshaft and distinguishes the cylinder e See the Ignition system section in the Electric System chapter Camshaft Position Sensor Inspection OThe camshaft position sensor has no power source and when the engine stops the camshaft position sensor gen erates no signal e Crank the engine and measure the peak voltage of the camshaft position sensor see Electrical System chapter in order to check the sensor e Check the wiring for continuity using the following dia gram A ECU G Camshaft Position Sensor GCITI7IBWi 3 6
238. emoval Swingarm Bearing Installation pp 13 20 Swingarm Bearing Sleeve Inspection pp 13 20 Chain Guide 13 20 Swingarm Bearing Lubrication pp 13 21 Tiesrod Rocker 13 22 Tieerd Removal tende Cane de Et e ag E De De aea 13 22 Tie rod IristallatiOnz in o Rm e tl e FR b ke 13 22 Rocker Arm Removal 2 12d te Td 13 22 Rocker Arm Installation pp 13 23 Tie rod and Rocker Arm Bearing Removal een 13 23 Tie rod and Rocker Arm Bearing Installation pp 13 23 Rocker Arm Tie rod Bearing Sleeve Inspection pp 13 25 Rocker Arm Tie rod Bearing 13 25 13 2 SUSPENSION Exploded View OD 00 gt 9 1 6002085815 SUSPENSION 13 3 Exploded View Torque No Fastener Nan kgf m ftlb Remarks 1 Front Fork Clamp Bolts Upper 20 2 0 14 2 Front Fork Clamp Bolts Lower 20 2 0 14 AL Front Fork Top Plugs 25 2 5 18 4 Front Fork Bottom Allen Bolts 30 3 1 22 L 5 Front Axle Clamp Bolt 34 3 5 25 6 Right Fork Leg 7 Left Fork Leg AL Tighten the two clamp bolts alternately two times to ensure even tightening torque G Apply grease L Apply a non permanent locking agent R Replacement Parts 13 4 SUSPENSION Exploded View adu A
239. enance However if the motorcycle is not properly handled the high pressure in side the fuel line can cause fuel to leak A or the hose to burst Remove the fuel tank see Fuel System DFI chapter and check the fuel hose Replace the fuel hose if any fraying cracks B or bulges C are noticed 6505012851 e Check that the hoses routed according to Cable Wire and Hose Routing section in the Appendix chapter Replace the hose if it has been sharply bent or kinked Hose Joints A Pump Outlet Hose B Pump Inlet Hose C Front D 6505013851 C e Check that the hose joints are securely connected OPush and pull A the hose joint B back and forth more than two times and make sure it is locked and doesn t come off When the hose joint is correctly installed it should slide on the delivery pipe about 5 mm 0 2 in x lf it does not slide reinstall the hose joint WARNING Make sure the hose joint is installed correctly on the delivery pipe by sliding the joint or the fuel could leak 6617182851 C OCheck that the inlet hose A is onto the pipe fully and the plate clamps B are installed beyond the raised rib C 1 2 mm 0 039 0 079 D 6617054851 C 2 16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Throttle Control System Inspection e Check that the throttle grip moves smoothly from full open to close A and the throt
240. ench turn the adjusting collar A counter clockwise to make the gap between the engine and adjusting collar e Remove the drive chain A from the output shaft B e Using the stand take out the engine Engine Installation e Support the engine A with a suitable stand B OPut a plank onto the suitable stand for engine balance e Screw the adjusting collar fully by hand e Install the engine ground cable Torque Engine Ground Cable Terminal Bolt 9 8 1 0 kgf m 87 in lb 8 8 ENGINE REMOVAL INSTALLATION Engine Removal Installation e Install the engine mounting bolts and nuts following the specified installing sequence OFirst hang the drive chain over the output shaft just before moving the engine into its final position in the frame OSecondly insert the lower engine mounting bolt A OThirdly insert the middle engine mounting bolt B OFourthly install the rear engine bracket C temporarily OFifthly install the left upper engine mounting bolt A and tighten it Torque Left Upper Engine Mounting Bolt 44 Nm 4 5 kgf m 33 ft lb OSixthly tighten the adjusting collar A until the clearance between the crankcase B and frame bracket C comes to 0 mm D OSeventhly tighten the collar locknut E Torque Adjusting Collar Locknut 49 N m 5 0 kgf m 36 ft lb Special Tool Engine Mount Nut Wrench 57001 1450 OEighthly tighten the rear bracket bolts Torque Rear Engine Brac
241. ent applied using an impact driver Use a plastic faced mallet whenever tapping is necessary Gasket O ring Hardening shrinkage or damage of both gaskets and O rings after disassembly can reduce sealing per formance Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains Install new gaskets and replace used O rings when re assembling Liquid Gasket Non permanent Locking Agent For applications that require Liquid Gasket or a Non permanent Locking Agent clean the surfaces so that no oil residue remains before applying liquid gasket or non permanent locking agent Do not apply them exces sively Excessive application can clog oil passages and cause serious damage 68020148 68020158 68020168 GENERAL INFORMATION 1 5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place apply small amount of oil to the con lt NE tact area Be sure to maintain proper alignment and use d fr n smooth movements when installing CA gt gt Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary Replace with new ones whenever removed Press bearings with the manufacturer and size A pa marks facing out Press the bearing into place by putting NN S A pressure on the correct bearing race as shown Gh
242. eplace circlips removed with new ones e Install the circlips A so that the opening B is aligned with a spline groove C 6113010251 e The drive shaft gears can be recognized by size the gear with the smallest diameter is 1st gear and the largest one is 6th gear Be sure that all parts are put back in the cor rect sequence and all circlips and washers are properly in place e Install the 3rd 4th gear onto the drive shaft with their oil holes aligned e Install the 6th gear bushing onto the drive shaft with their oil holes aligned e The output shaft gears can be recognized by size the gear with the largest diameter is 1st gear and the small est one is 6th gear Be sure that all parts are put back in the correct sequence and all circlips and washers are properly in place e Install the 5th and 6th gears onto the output shaft with their oil holes aligned e Install the 3rd 4th gear bushings onto the output shaft with their oil holes aligned 9 26 CRANKSHAFT TRANSMISSION Transmission NOTE OWhen the toothed washers 28 29 are assembled onto the output shaft note the following OWhen the tangs A of the toothed washer 29 shall be assembled they should be installed into the notch B of the toothed washer 28 see Page 9 29 e Fit the steel balls into the 5th gear holes in the output shaft aligning three oil holes D 5th Gear A Output Shaft B Steel Balls C CAUTION Do not app
243. eplacement NOTE ONo key registration is required 16 88 ELECTRICAL SYSTEM Immobilizer System Equipped Models All Keys Initial Registration Flow Chart OK FI indicator blinking Pattern 4 NOTES OK Temporary registry of use key 2 Fi indicator ight blinking Pattern 5 Registered keys in ECU m Blinking Patterns and Number 0 2second 0 gp 0 Ssecond 0 Seacend 2 0 Jeecond tsecond 3 8f 4 BF 032303 03831 5 5 6 ffe NOTE 1 Key Substitute Time Insert next key and turn ON within 15 seconds after key is turned OFF 2 ECU confirms the following O Power Supply of Amplifier O Connection of Amplifier Time of Transmitting and Receiving Messages 3 ECU confirms the following tmmobilizer Amplifier Failure Pattern 1 Master Key Collation Error Pattern 6 User Key is inserted 4 ECU confirms the following Master Key or Not Match the Unique Code 5 ECU confirms the following Immobilizer Amplifier Failure Pattern 1 User Key 1 Collation Error Pattern 6 Rogistered User Key is Inserted Pattern 2 6 ECU confirms the following User Key or Not Match the Unique Code Not Registered User Key 7 When the ECU registered key is turned OFF ECU keeps the power ON for two seconds And then in two seconds after the key is OFF ECU turns the power OFF ELECTRICAL SYSTEM 16 89 Immobilizer System
244. er 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 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 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 There will be a gap at the lower part of the clamp after tightening Torque Clutch Lever Clamp Bolts 7 8 0 80 kgf m 69 in Ib
245. er filling can shorten service life Let the battery sit for at least 60 minutes after filling Initial Charge e Place the strip A of caps loosely over the filler ports 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 6 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 the type of charger used Let battery sit 30 minutes after initial charge then check voltage using a voltmeter If it is not at least 12 6 volts repeat charging cycle e After charging is completed press down firmly with both hands to seat the strip of caps A into the battery don t pound or hammer When properly installed the strip of the caps will be level with the top of the battery CAUTION Once the strip of the caps A is installed onto the battery never remove the caps nor add water or electrolyte to the battery H Hm LJ LJ LJ L3 GPO8012BS1 C GPOSO10BS1 C 16 24 ELECTRICAL SYSTEM Battery NOTE OTo ensure maximum battery life and customer satisfac tion it is recommended the battery be l
246. er on some kind of stand so that it doesn t dangle e Remove Front Fender Bracket Bolts A both side Bolts B both side e Remove the front fender C Front Fender Installation e Apply a non permanent locking agent to the threads of the bracket bolts e Tighten Torque Front Fender Bracket Bolts 8 8 0 90 kgf m 78 in Ib Front Fender Bolts 3 9 N m 0 40 kgf m 35 in Ib e Install the brake hose clamps to the front fender holes e Install the front wheel see Wheels Tires chapter Rear Fender Flap Removal e Remove Seat see Seat Removal Seat Cover see Seat Cover Removal e Disconnect Clamp A open Turn Signal Light Lead Connectors B License Plate Light Lead Connector C e Remove Bolts A with clamp B Caps C Nuts D Rear Fender Flap 15 16 FRAME Fenders e For California Model Caps Nuts A Canister Holding Plate B Canister C e Remove Flap Brackets A Left and Right Turn Signal Light B Bolts C License Plate Light License Plate Reflector Rear Fender Removal e Remove Seat see Seat Removal Seat Cover see Seat Cover Removal Screws A Seat Lock Bracket with Cable B Rear Fender Flap see Rear Fender Flap Removal e Remove ECU Main Relay A Fuel Pump Relay B Turn Signal Light Relay C Mounting Bolts D Rear Fender Rear E Rear Fender installation e Insert the band A into the slot B of the rear fender FRAME 15
247. erature grease to the oil seal lips on the upper ridge of the clutch cover e 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 CAUTION When inserting the release shaft be careful not to remove the spring of the oil seal GF05025BS1 C CLUTCH 6 9 Clutch Cover e Fit the spring as shown Viewed from Rear B Release Shaft C Clutch Cover D Clutch Cover Disassembly e Remove Oil Seal A Needle Bearings e Remove Circlip A Oil Level Gauge B Clutch Cover Assembly e Replace the needle bearings and oil seal with new ones NOTE Olnstall the needle bearings so that the manufacture s mark face out e Install the needle bearings A and oil seal B position as shown Press the bearing until the bottom C Press the bearing so that the bearing surface D is flush with the housing end of clutch cover E 6205018851 C Apply water to the rubber of the oil gauge A and press it so that the projections B face inside e Install a new circlip so that the circlip ends C do not warp over the projection D 6205019851 C 6 10 CLUTCH Clutch Clutch Removal e Remove Engine Oil drain see Engine Oil Change in
248. es are introduced by the Special Tool Catalog or Manual Genuine parts provided as spare parts are listed in the Parts Catalog e Follow the procedures in this manual fully Don t take shortcuts e Remember to keep complete records of main tenance and repair with dates and any new parts installed How to Use This Manual In preparing this manual we divided the prod uct into its major systems These systems be came the manual s chapters All information for a particular system from adjustment through disassembly and inspection is located in a sin gle chapter The Quick Reference Guide shows you all of the product s system and assists in locating their chapters Each chapter in turn has its own comprehensive Table of Contents The Periodic Maintenance Chart is located in the Periodic Maintenance chapter The chart gives a time schedule for required maintenance operations If you want spark plug information for exam ple go to the Periodic Maintenance Chart first The chart tells you how frequently to clean and gap the plug Next use the Quick Reference Guide to locate the Periodic Maintenance chap ter Then use the Table of Contents on the first page of the chapter to find the Spark Plug sec tion Whenever you see these WARNING and CAUTION symbols heed their instructions Always follow safe operating and maintenance practices A WARNING This warning symbol identifies special instructions or proced
249. ey collation error Stick Ignition coil 1 malfunction wiring open or short Stick Ignition coil 2 malfunction wiring open or short N 1 Stick Ignition 3 malfunction wiring open or short Stick Ignition coil 4 malfunction wiring open or short Subthrottle valve actuator malfunction wiring open or short Notes OThe ECU may be involved in these problems If all the parts and circuits checked out good be sure to check the ECU for ground and power supply If the ground and power supply are checked good replace the ECU OWhen no service code is displayed the electrical parts of the DFI system has no fault and the mechanical parts of the DFI system and the engine are suspect FUEL SYSTEM 3 43 Self Diagnosis Backups Backups OThe ECU takes the following measures to prevent engine damage when the DFI or the ignition system parts have troubles Service Output Signal Usable Codes Baits Range or Criteria Back ps By EGU If the main throttle sensor system fails the signal is out of the usable range wiring short or open the ECU locks ignition timing into the ignition Main Main Throttle Sensor timing at closed throttle position and sets the DFI 11 Throttle Output Voltage in the D J method Sensor 0 20 4 79 V Also the main throttle sensor system and inlet air Inlet Air Pressure Sensor Inlet Air Pressure absolute Pv 100 mmHg 900 mmHg pressur
250. f Speed km h x 0 6214 mph Units of Force N x 0 1020 kg N x 0 2248 Ib Units of Power kg x 9 807 N kW x 1 360 PS kg x 2 205 Ib kW x 1 341 HP PS x 0 7355 kw PS x 0 9863 HP Units of Temperature 29110002 oF _ oF oF 4 32 68 104 176 212 248 284 40 20 0 20 i40 60 80 100 120 140 160 1180 200 1220 240 260 280 300 320 40 20 0 20 1 6 80 10 i 420 1140 160 17 8 4 4 267 48 9 71 1 933 116 138 PERIODIC MAINTENANCE 2 1 Periodic Maintenance Table of Contents Periodic Maintenance Chart Torque and Locking Specifications Special Tools Periodic Maintenance Procedures Fuel System DFl Fuel Hose Inspection fuel leak damage installation condition Throttle Control System Idle Speed Inspection Idle Speed Adjustment Choke Operation Inspection Air Cleaner Element Cleaning Engine Vacuum Synchronization Evaporative Emission Control System Inspection CAL Cooling Coolant Level Inspection Radiator Hose and Pipe Inspection coolant leak damage installation condition Air Suction System Air
251. f m 80 ft lb e Tighten the pivot locknut using the socket wrench Special Tool Swingarm Pivot Nut Wrench 57001 1597 6 06036851 C Torque Swingarm Pivot Shaft Locknut 98 N m 10 kgf m 72 ft lb e Install the removed parts see appropriate chapters Swingarm Bearing Removal e Remove Swingarm Collar A Grease Seals B Sleeve C Circlip right side D Ball Bearing E Needle Bearings F Special Tool Inside Circlip Pliers 57001 143 GM06077BS2 C ORemove the ball bearing and needle bearings Special Tool Oil Seal amp Bearing Remover 57001 1058 A 6 06060351 C 13 20 SUSPENSION Swingarm Swingarm Bearing Installation e Replace the ball and needle bearings with new ones e Install the needle bearings so that the manufacturer s marks face out e Install the ball bearing so that the manufacturer s marks faces out e Apply Grease Grease Seal Lip Special Tool Bearing Driver Set 57001 1129 Needle Bearing Driver 28 57001 1610 A e Install the needle bearings A ball bearing B and grease seals C position as shown Circlip D GM06075BS1 5 5 0 4mm 23 510 4mm 23 5 0 4mm 6 06078 1 Swingarm Bearing Sleeve Inspection CAUTION Do not remove the bearings for inspection Remove may damage them e Inspect the needle bearings A and ball bearing B in stalled in th
252. f 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 39 Meter BK Y lead terminal 51 Connections for Stick Coil 2 Meter BK G lead terminal 38 Meter BK Y lead terminal 51 Connections for Stick Coil 3 Meter BK W lead terminal 37 Meter BK Y lead terminal 51 Connections for Stick Coil 4 Meter BK O lead terminal 52 Meter BK Y lead terminal 51 6617129851 C Input Voltage at ECU Standard Battery Voltage 12 6 V or more x If the reading is out of the standard check the wiring see next 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 Electrical System chapter in order to check the pri mary coils FUEL SYSTEM 3 75 Stick Coils 1 2 3 4 Service Code 51 52 53 54 Stick Coil Circuit A ECU B Stick Coils C Engine Stop Switch D Ignition Switch 6C178438W2 E Junction Box Starter Relay F Ignition Fuse 10 J Battery 12 V 8 G Main Fuse 30 A H Joint Connector C 3 76 FUEL SYSTEM DFI Subthrottle Valve Actuator Service Code 62 Subthrottle Valve Actuator Removal CAUTION Do not remove the subthrott
253. formula and chart Suppose Pg Vacuum Pressure gauge to Sensor PI Local Atmospheric Pressure absolute measured by a barometer Pv Vacuum Pressure absolute to Sensor 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 Varometer 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 04 3 49 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 FUEL SYSTEM DFI 3 51 Inlet Air Pressure Sensor Service Code 12 Pv 24 55 cmHg cmHg kPa 60 73 gt Pv abs 68017034983 3 52 FUEL SYSTEM DFI Inlet Air Pressure Sensor Service Code 12 Pv 55 86 cmHg a Pv abs 115 66170350 3 Vv Inlet Air Pressure Sensor Output Voltage V Digital Meter Reading Pv Throttle Vacuum Pressure Absolute Ps Standard Atmospheric Pressure Absolute ID Idling TO Throttle Full Open ST Standard of Sensor Output Voltage v UR Usable Range of Sensor Output Voltage v FUEL SYSTEM DFI 3 53 Inlet Air Pressure Sensor Service Code 12 Inlet
254. fuel flow is much less than the specified check the battery condition see Electrical System chapter If the battery is good replace the fuel pump e After inspection install the fuel tank see Fuel Tank In stallation e Start the engine and check for fuel leakage FUEL SYSTEM 3 87 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 Gasoline is extremely flammable and can be explo sive under certain conditions Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Turn the ignition switch OFF Disconnect the battery terminal To make fuel spillage minimum draw the fuel out from the fuel tank when the engine is cold Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately e Draw the fuel out from the fuel tank with a commercially available electric pump e Remove the fuel tank see Fuel Tank Removal OBe careful of fuel spillage from the fuel tank since fuel still remains in the fuel tank and fuel pump Plug the fuel pipe of the fuel tank e Turn the fuel tank upside down e Remove Fuel Pump Inlet Hose A Fuel Hose B Fuel Pump Bolts C Fuel Pump D and gasket e Discard the fuel pump gasket CAUTION Do not pull the lead of the fuel pump If they are pulled t
255. g eae inspect 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 x 1 000 km first x 1 000 mile See 11 6 24 30 36 Page INSPECTION Every 0 6 4 7 5 12 15 20 24 Drive chain wear inspect e e e 2 34 Chain guide wear inspect e e e 2 35 Brake System Sa leak brake hose and pipe year acus a Mage ee a Brake hose and pipe damage inspect year e 2 35 Brake hose installation condition inspect year e 2 35 2 effectiveness play Dye jejeje 2 36 Brake fuid e Brake pad wear inspect 2 37 Brake light switch operation inspect 2 37 Suspensions Front forks rear shock absorber operation damping and smooth stroke inspect 2298 Front forks rear shock absorber oil leak inspect dal 238 Rocker arm operation inspect 2 39 Tie rods operation inspect e 2 39 Steering System Steering play inspect year e e e e 2 39 Steering stem bearings lubricate 2 years e 2 41 Lights and switches operation inspect year 2 41 Headlight aiming inspect year 2 43 Side stand switch operation inspect year 2 44 Engine stop swi
256. ge Inspection Ignition System Crankshaft Sensor Removal Crankshaft Sensor Installation Crankshaft Sensor Inspection Crankshaft Sensor Peak Voltage Timing Rotor Removal Timing Rotor Installation Camshaft Position Sensor Camshaft Position Installation 16 39 Camshaft Position Sensor 16 40 Camshaft Position Sensor Peak Voltage Inspection 16 40 Stick Coil Ignition Coil together with Spark Plug Cap Removal 16 41 Stick Coil Ignition Coil together with Spark Plug Cap Installation soo etes 16 41 Stick Coil Ignition Coil together with Spark Plug Cap Inspection 16 42 Stick Coil Primary Peak Voltage 16 42 Spark Plug Removal 16 43 Spark Plug Installation 16 43 Spark Plug Cleaning and 16 44 Interlock Operation Inspection 16 44 IC Igniter Inspection Electric Starter System Starter Motor Removal Starter Motor Installation Starter Motor Disassembly Starter Motor Assembly Brush Inspection Comm
257. ghten all bolts following the specified tightening sequence Torque Camshaft Cap Bolts 1 16 19 20 12 N m 1 2 kgf m 104 in Ib Camshaft Chain Guide Bolts 17 18 12 N m 1 2 kgf m 104 in Ib e Install Camshaft Chain Tensioner see this chapter Cylinder Head Cover see this chapter Camshaft Camshaft Cap Wear e Remove Camshaft Chain Guide Camshaft Cap e Cut strips of plastigage to journal width Place a strip on each journal parallel to the camshaft installed in the correct position e Measure each clearance between the camshaft journal and the camshaft cap using plastigage press gauge A e Tighten Torque Camshaft Cap Bolts 12 N m 1 2 kgf m 104 in Ib Camshaft Chain Guide Bolts 12 N m 1 2 kgf m 104 in Ib NOTE ODo not turn the camshaft when the plastigage is be tween the journal and camshaft cap Camshaft Journal Camshaft Cap Clearance Standard 0 028 0 071 mm 0 0011 0 0028 in Service Limit 0 16 mm 0 0063 in GE11142BS2 C GE11046BS1 C GE11072BS1 C ENGINE TOP END 5 17 Camshaft Camshaft Chain xIf any clearance exceeds the service limit measure the diameter of each camshaft journal with a micrometer Camshaft Journal Diameter Standard 23 950 23 972 mm 0 9429 0 9438 in Service Limit 23 92 mm 0 942 in lf the camshaft journal diameter is less than the service limit replace the camshaft with a new one and measure th
258. gine sprocket B and take it off the chassis Drive Chain Installation e Engage the drive chain to the engine sprocket e Install Swingarm see Suspension chapter Rear Wheel see Wheels Tires chapter Engine Sprocket Cover see this chapter Chain Cover e Adjust the chain slack after installing the chain see Peri odic Maintenance chapter FINAL DRIVE 11 7 Drive Chain Drive Chain Replacement 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 amp Riveting Pin C For Cutting D For Riveting E Plate Holder A F Plate Holder B G Gauge H GKO4016BS1 e Grind A the pin head to make it flat Set the cutting amp riveting as shown e Screw the pin holder until it touches the chain pin e Be sure that the cutting pin hits center of the chain pin GK04018BS1 C 11 8 FINAL DRIVE Drive Chain Screw the handlebar into body e Turn the pin holder with the wrench B clockwise to the extract chain pin e Engage the new drive chain to the old drive chain and pull the end of the old drive chain until they are changi
259. grinding 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 25 Valves e Measure the outside diameter of the seating surface with vernier caliper the outside diameter of the seating surface is too small repeat the 45 grind until the diameter is within the spec ified range Widened Width A of engagement by machining with 45 cutter Ground Volume B by 32 cutter 32 C Correct Width D Ground Volume E by 60 cutter 60 F e Measure the outside diameter of the seating surface with a vernier caliper 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 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 x lf the outside diameter A of the seating surface is too large make the 32 grind described below the outside diameter of the seating surface is within the specified range measure the seat width as
260. h lead Clamp Clamp the lead then bend the bracket as shown to secure the lead Cross Pipe Run the cable under the cross pipe Clamps Bend the claw Run the lead outside of engine bracket and under the cross pipe Install the oil pressure switch lead terminal upward 17 20 APPENDIX Cable Wire and Hose Routing APPENDIX 17 21 Cable Wire and Hose Routing Clamp Clamp the alternator lead Side Stand Switch Lead Neutral Switch Lead Speed Sensor Lead Speed Sensor Push the speed sensor lead to the inside of pipe Bend the clamp securely Run the alternator lead inside of pipe Viewed Back of Frame Run the alternator lead speed sensor lead neutral switch lead and side stand switch lead through the clamp Bend the clamp and insert the clamp to the hole 17 22 APPENDIX Cable Wire and Hose Routing 08809740845 C APPENDIX 17 23 Cable Wire and Hose Routing Seat Lock Seat Lock Cable Tighten the bolt to the specified torque with the stopper for turning prevention applied Brake Hose Clamp Grommet Viewed A Clamps Run the brake hose inside of the reservoir hose Clamp 17 24 APPENDIX Cable Wire and Hose Routing WA 2 RN E 22 3 fe California Model APPE
261. h the holder D towards the piston and remove the pad of the other side E from the holder shaft F Front Brake Pad Installation e Push the caliper pistons in by hand as far as they will go e Install the anti rattle spring in its correct position e Install the pad on the piston side first then install the other pad on the holder e Install the caliper see Caliper Installation A WARNING Do not attempt to drive the motorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against the disc The brake will not function on the first application of the lever if this is not done Rear Brake Pad Removal e Remove the caliper with the hose installed e Draw out the clip A and take off the pad pin B e Remove the pad C on the piston side e Push the holder D towards the piston and remove the pad of the other side E from the holder shaft F Rear Brake Pad Installation e Push the caliper piston in by hand as far as it will go e Install the anti rattle spring in its correct position e Install the pad on the piston side first then install the other pad on the holder e Install the caliper see Caliper Installation 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 Br
262. half e Apply engine oil to the bearings OThe bearing set pins and rings must match properly with the holes or grooves in the bearing outer races When they are properly matched there is no clearance A be tween the crankcase and the bearing outer races e Assemble the crankcase e Press in the oil seal A onto collar B so that the surface of the oil seal is flush with the counterbore bottom surface C of the crankcase Transmission Shaft Disassembly e Remove the transmission shafts see Transmission Shaft Removal e Remove the circlips disassemble the transmission shafts Special Tool Outside Circlip Pliers 57001 144 e The 5th gear A on the output shaft has three steel balls e assembled into it for the positive neutral finder mecha nism Remove the 5th gear OSet the output shaft in a vertical position holding the 3rd gear B OSpin the 5th gear quickly C and pull it off upward PR ay A Ses 0 PLUA SEs Ya En gt ATE 1 61130828 5 CRANKSHAFT TRANSMISSION 9 25 Transmission e Remove the ball bearing A from each shafts Special Tools Bearing Puller 57001 135 B Bearing Puller Adapter 57001 317 C e Discard the bearing 6113048BS1 C Transmission Shaft Assembly e Apply engine oil to the bushings ball bearings and shafts e Install the gear bushings A on the shaft with their holes B aligned 6113040851 e R
263. hapter Meter Unit for Neutral Indicator Light see Electrical Sys tem chapter Meter Unit for Oil Pressure Warning Indicator Light see Electrical System chapter Meter Unit and ECU for FI Indicator Light LED see Elec trical System chapter Main Fuse 30 A and Taillight Fuse 10 A see Electrical System chapter Ignition Switch see Electrical System chapter Neutral Switch see Electrical System chapter Harness see Electrical System chapter ddp ES e Turn off the ignition switch e The all lights should go off x lf the light does not go off replace the ignition switch Second Step e Turn the ignition switch to P Park position e The city light taillight and license plate light should go on x If the light does not go on inspect or replace the following item Ignition Switch see Electrical System chapter 2 42 PERIODIC MAINTENANCE Periodic Maintenance Procedures Third Step 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 flash e The turn signal indicator light C in the meter unit should flash the each light does not flash inspect or replace the following item Turn Signal Light Bulb see Electrical System chapter Meter Unit for Turn Signal Indicator Light see Electrical System chapter Turn Signal Relay Fuse 10 A see Electrical System chapter Turn Signal Switch see Electrical Sy
264. he 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 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 ELECTRICAL SYSTEM 16 25 Battery Charging Condition Inspection OBattery charging condition can be checked by measuring battery terminal voltage with a digital voltmeter A e Remove Seats see Frame chapter Battery Cable Caps
265. he end of the lead to the battery terminal repeatedly The injector should click x If the injector does not click replace the injector xIf the injector clicks check the wiring again If the wiring is good replace the injector may be clogged or ECU Injector Fuel Line Inspection e Remove Fuel Tank see Fuel Removal in the this chapter OWhile pinching the fuel pump outlet hose joint locks A with fingers pull the joint out along the delivery pipe see Fuel Tank Removal Cloth B Pump Outlet Hose Joint C 6017024481 3 96 FUEL SYSTEM DFI Fuel Injectors e Check the injector fuel line for leakage as follows OConnect a commercially available vacuum pressure pump A to the nipple of the delivery pipe B with a high pressure fuel hose C both ends connected with the clamps D as shown Torque Fuel Hose Clamp Screws 1 5 N m 0 15 kgf m 13 in Ib OApply 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 Injector Fuel Line Maximum Pressure Standard 300 kPa 3 06 kgf cm 43 psi CAUTION During pressure testing do not exceed the maxi mum pressure for which the system is designed e Watch the gauge for at least 6 seconds x If the pressure holds steady the system is good x If the pressure drops at once or if bubbles are found
266. he lead terminals may be damaged Fuel Pump Installation e Remove dirt or dust from the fuel pump A by lightly ap plying compressed air 3 88 FUEL SYSTEM DFI Fuel Pump eReplace the fuel pump gasket with new e Checkthat the fuel terminal and band are place Front C e Apply non permanent locking agent to the threads of the fuel pump bolts Tighten the fuel pump bolts to a snug fit following the tightening sequence shown e Following the tightening sequence tighten the fuel pump bolts to the specified torque Torque Fuel Pump Bolts 9 8 N m 1 0 kgf m 87 in Ib e Tighten the pump bolts again to check the tightness in the order shown Operation Inspection NOTE OBe sure the battery is fully charged OJust listen to the pump sound in the fuel tank to confirm pump operation e Turn the ignition switch ON and make sure that the fuel pump operates make light sounds for 3 seconds and then stops e Turn the ignition switch OFF x lf the pump does not work as described above inspect the operating voltage Operating Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Remove the frame cover bolts and frame cover 65178169 P 6C17170BS1 FUEL SYSTEM DFI 3 89 Fuel Pump e Connect the hand tester 25 V DC to the fuel pump con nector A with needle adapter se
267. he secondary cup from the piston since removal will damage it 9513111851 C PERIODIC MAINTENANCE 2 55 Periodic Maintenance Procedures Rear Master Cylinder Disassembly NOTE not remove the push rod clevis for master cylinder disassembly since removal reguires brake position ad justment e Remove the rear master cylinder see Brakes chapter e Slide the dust cover on the push rod out of place and remove the circlip Special Tool Inside Circlip Pliers 57001 143 e Pull out the push rod with the piston stop e Take off the piston A secondary cup B primary cup C and return spring D CAUTION Do not remove the secondary cup from the piston since removal will damage it 9107011052 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 e Apply brake fluid to the new parts and to the inner wall of the cylinder e Take care not to scratch the piston or the inne
268. ht and left inner cover Screw A Quick Rivets B Meter Cover C e Slide the dust cover A and remove the wiring connector e Remove Nuts with the Washers C Meter Unit 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 Separate the upper meter cover A meter assembly and lower meter cover C 16 64 ELECTRICAL SYSTEM Meter Gauge Indicator Unit Bulb Replacement e Disassembly Meter Unit see Meter Unit Disassembly e Turn the bulb socket A counterclockwise to remove NOTE OThe water temperature warning indicator light LED and FI indicator light LED and can not be exchanged CAUTION Do not use bulb rated for greater wattage than the specified value refer to the wiring diagram Electronic Combination Meter Unit Inspection e Remove the meter unit A 1 Ignition 2 Fuel Reserve Switch 3 Unused 4 Fuel Level Sensor 5 Neutral Indicator Light Ground 6 FI Indicator Light LED Ground 7 Tachometer Pulse 8 Water Temperature Warning Indicator Light LED Ground 9 Ground 10 Battery 11 Oil Pressure Warning Indicator Light Ground 12 Speed Sensor Supply Voltage 13 Right Turn Signal Light 14 Left Turn Signal Indicator Light 15 H
269. iameter Camshaft Bearing Inside Diameter Camshaft Runout Cylinder Head Cylinder Compression Cylinder Head Warp Valves Valve Clearance Exhaust Inlet Valve Head Thickness Exhaust Inlet Valve Stem Bend Valve Stem Diameter Exhaust Inlet 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 36 146 36 254 mm 1 4231 1 4273 in 36 746 36 854 mm 1 4467 1 4509 in 0 028 0 071 mm 0 0011 0 0028 in 23 950 23 972 mm 0 9429 0 9438 in 24 000 24 021 mm 0 9449 0 9457 in TIR 0 02 mm 0 0008 in or less Usable Range 1 110 1 590 kPa 11 3 16 2 kgf cm 161 230 psi 300 r min rpm 0 22 0 31 mm 0 0087 0 0122 in 0 15 0 24 mm 0 0059 0 0094 in 1 0 mm 0 039 in 0 5 mm 0 020 in TIR 0 01 mm 0 0004 in or less 3 955 3 970 mm 0 1557 0 1563 in 3 975 3 990 mm 0 1565 0 1571 in 4 000 4 012 mm 0 1575 0 1580 in 4 000 4 012 mm 0 1575 0 1580 in 0 09 0 18 mm 0 0035 0 0071 in 0 03 0 12 mm 0 0012 0 0047 in 45 32 60 0 5 1 0 mm 0 020 0 039 in 0 5 1 0 mm 0 020 0 039 in 21 6 21 8 mm 0 850 0 858 in 26 4 26 6 mm 1 0276 1 0472 in 36 05 mm 1 419 in 36 65 mm 1 443 in 0 16 mm 0 0063 in 23 92 mm 0 942 in 24 08 mm 0 9
270. ication NOTE OSince the bearings are packed with grease lubrication is not required GMO7016BS1 C STEERING 14 1 Steering Table of Contents AE EA EE 14 2 SPeClal lO0 S E 14 4 14 5 Steering INSpEcti N Wet eed eh Tea Th an a ante ended 14 5 14 5 Steering Stemi E 14 6 Stem Stem Bearing 14 6 Stem Stem Bearing Installation pp 14 7 adis tas tained uds 14 8 Steering Stem T 14 9 Stem Cap Deterioration Damage pp 14 9 keo orit ETIAM MILITE 14 10 Handlebar Removal reed rt dese a 14 10 Hatndlebar InstallatiOFis AE CS eee tee e eR bee E Pe ERG 14 11 14 2 STEERING Exploded View STEERING 14 3 Exploded View No Fastener pales Remarks N m kgf m ft Ib 1 Steering Stem Nut 27 2 8 20 2 Steering Stem Head Bolt 108 11 80 Front Fork Clamp Bolts Upper 20 2 0 14 4 Front Fork Clamp Bolts Lower 20 2 0 14 AL 5 Handlebar Clamp Bolts 25 2 5 18 S 6 Handlebar Lower Clamp Nuts 34 3 5 25 7 Switch Housing Screws 3 5 0 36 31 in Ib 8 Steering Stem Head Bolt Plug AD Apply adhesive AL Tighten the two clamp bolts alternately two times to ensure even tighten torque
271. ifier Failure 0 2second Gat GP30118BS1 C When Registered User Key is Inserted 0 5second 0 5second gt E LIVlIVITITYiJI GP30117BS1 C ELECTRICAL SYSTEM 16 85 Immobilizer System Equipped Models User Key Collation Error 0 3second ULL 6230119851 C e The user key 1 is registered the ECU OThe FI indicator light A blinks 2 times and stops for 1 second and then repeats this cycle to indicate successful registration of user key gt Esc s 1 GP30120BS1 C e Turn off and remove the user key 1 OThe FI indicator light A blinks to display the registration mode codes NOTE Olnsert next 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 indicator light goes off QN Lu mm a OTo return to the registration mode start the master key 9230117851 6 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 Fl indicator light A blinks to display the collation error code Immobilizer Amplifier Failure 0 2second ON On GP30118BS1 C 16 86 ELECTRICAL SYSTEM Immobilizer System Equipped Models When Registered User Key is In
272. igh Beam Indicator 16 Speed Sensor Pulse 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 GP17220BS2 C Liquid Crystal Display LCD Segments Check e Use the harness adapter for meter inspection Special Tool Harness Adapter 57001 1542 e Using the auxiliary wires connect the 12 V battery to the meter unit connector as follows OConnect the battery positive terminal to the terminal 10 OConnect the battery negative terminal to the terminal 9 OOOOOOOO 422227 GP17040BS1 C ELECTRICAL SYSTEM 16 65 Meter Gauge Indicator Unit OThe speedometer and tachometer needles Al momentar ily point their last readings x If the meters do not work replace the meter assembly e Connect the terminal 1 to the terminal 10 OThe speedometer and tachometer needles momentarily point to their last readings OWhen the terminals are connected all the LCD segments A and LED warning lights B appear for three seconds the meter needles to not work replace the meter as sembly xIf the LCD segments and LED warning light will not ap pear replace the meter assembly e Disconnect the terminal 1 the LCD segments and LED warning light disappear xIf the segments do not disappear replace the meter
273. ight Connector B City Light Connector C e Remove Bolts D Headlight Assy E e Remove Screws A Front Turn Signal Lights B Screws C Right Fairing D Middle Fairing E Left Fairing F 15 12 FRAME Fairings Fairing Assembly e Temporary install all fairing mounting screws and then tighten them e Run the headlight harness connector A through the bracket hole B e Install the pad A and trim B as shown illustration Left Fairing C Right Fairing D Upside Down E Fairing Bracket Removal e Remove Fairing see Fairing Removal e Disconnect Right and Left Switch Housing Connectors A e Remove Clamps B FRAME 15 13 Fairings e Remove Bolts A Fairing Bracket B 15 14 FRAME Seat Covers Seat Cover Removal e Remove Seat see Seat Removal e Push the central pin and then remove the quick rivets A e Remove Screws with Washers A Bolts B Grab Rails C Tail Brake Light Connector D e Pull the front portions A of the seat cover outside B and then remove the seat cover backward Seat Cover Installation e Installation is reverse of removal e Put the projections A into the grommets B on the frame e Fit the recess A of the cover under the tab B of the fender FRAME 15 15 Fenders Front Fender Removal e Remove Front Wheel see Wheels Tires chapter Brake Hose Clamps A NOTE ORest the calip
274. il G Apply grease to the threads L Apply a non permanent locking agent to the threads MO Apply molybdenum disulfide oil solution R Replacement Parts S Tighten the fasteners following the specified sequence Si Apply silicone grease ex PBC grease SS Apply silicone sealant Cooling System Radiator Hose Clamp Screws Radiator Fan Bolts Water Pump Impeller Bolt Water Pump Cover Bolts Coolant Drain Bolt Water Pump Water Pipe Bolts Thermostat Housing Ground Bolt Thermostat Bracket Bolt Radiator Upper Bolts Radiator Lower Bolts Radiator Screen Bolt Coolant Reserve Tank Screws 2 0 8 3 9 8 11 11 11 7 0 7 0 7 0 7 0 7 0 7 0 0 20 0 85 1 0 1 1 1 1 1 1 0 70 0 70 0 70 0 70 0 70 0 70 Torque Fastener ft lb Remarks Fuel System Inlet Air Pressure Sensor Bolt 12 1 2 104 in Ib Water Temperature Sensor 25 2 5 18 Vehicle down Sensor Bolts 2 0 0 20 17 Camshaft Position Sensor Bolt 12 1 2 104 in Ib Camshaft Position Sensor Rotor Bolt 12 1 2 104 in Ib L Throttle Cable Plate Bolt 6 0 0 60 52 Throttle Body Assy Holder Clamp Bolts 2 0 0 20 17 in Ib Choke Link Holder Screws 2 1 0 21 18 in Ib Delivery Pipe Screws 3 4 0 35 30 in Ib Bypass Screws 0 2 0 02 1 7 Air Cleaner Duct Holder Screws 3 8 0 39 34 in Ib Air Cleaner Duct Clamp Bolts 2 0 0 20 17 in lb Air Cleaner Housing Screws 1 2 0 12 10 in Ib Air Cleaner Housing Tapping Screws 1 2 0 12 10 in Ib Speed Sensor Bolt
275. il solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts SS Apply silicone sealant Kawasaki Bond 56019 120 W Apply water 7 4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart ENGINE LUBRICATION SYSTEM 7 5 Engine Oil Flow Chart Camshaft Oil Oil Passage Hole in Alternator Rotor Bolt Starter Clutch Oil Passage Hole Main Oil Passage Crankshaft Oil Passage Oil Filter Oil Pressure Switch Oil Pipe Oil Pump To Drive Shaft Oil Pipe To Output Shaft Drive Shaft Oil Passage Hole Output Shaft Oil Passage Hole Inlet Camshaft Exhaust Camshaft To Air Cleaner Drive Shaft Relief Valve Oil Screen Engine Oil Drain Bolt Output Shaft 7 6 ENGINE LUBRICATION SYSTEM Specifications Standard Engine Oil Type Viscosity Capacity Level Oil Pressure Measurement Oil Pressure 4 000 r min rpm Oil Temperature 90 C 194 F API SE SF or SG API SH or SJ with JASO MA SAE 10W 40 3 1 L 3 3 US gt when filter is not removed 3 3 L 3 5 US gt when filter is removed 3 8 L 4 0 US gt when engine is completely dry Between upper and lower level lines 255 314 kPa 2 6 3 2 kgf cm 37 46 psi ENGINE LUBRICATION SYSTEM 7 7 Special Tools and Sealant Outside Circlip
276. ill too tight or too loose repeat the ad justment e Install the removed parts 65158104 PERIODIC MAINTENANCE 2 41 Periodic Maintenance Procedures Steering Stem Bearing Lubrication e Remove the steering stem see Steering chapter e Using a high flash point solvent wash the upper and lower ball bearings in the cages and wipe the upper and lower outer races which are press fitted into the frame head pipe clean off grease and dirt e Visually check the outer races and the ball bearings Replace the bearing assemblies if they show wear or damage e Pack the upper and lower ball bearings A in the cages with grease and apply a light coat of grease to the upper and lower outer races e Install the steering stem and adjust the steering Electrical System 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 B goes on License Plate Light C goes on Meter Panel LCD D goes on Neutral Indicator Light E goes on Oil Pressure Warning Indicator Light F goes on FI Indicator Light LED G goes on about 2 seconds x the light does not go on inspect or replace the following item Battery see Electrical System chapter Applicable Bulb see Electrical System chapter Meter Unit for Meter Panel LCD see Electrical System c
277. in the area the line is leaking Replace the delivery pipe injectors and related parts ORepeat the leak test and check the fuel line for no leak age e Install the pump outlet hose see Fuel Tank Installation e Run the hoses correctly see Cable Wire and Hose Rout ing section in the Appendix chapter FUEL SYSTEM DFI 3 97 Fuel Injectors fv Dei ET BLZY BL Y BL BK BL BK BL G BL G BL R BL R W R W R YE 6017851883 C ECU Fuel Injectors Ignition Switch Fuel Pump Relay for fuel pump an injectors Main Fuse 30 A F Joint Connector C Starter Relay Battery 12 V 8 Ah Engine Stop Switch Ignition Fuse 10 Junction Box Joint Connector B Terminal 11 Immobilizer Equipped Models Power Supply 2 3 98 FUEL SYSTEM DFI Throttle Grip and Cables Free Play Inspection e Refer to the Throttle Control System Inspection in the Pe riodic Maintenance chapter Free Play Adjustment e Refer to the Throttle Control System Inspection in the Pe riodic 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 assy after installing the upper ends of the throttle cables in the grip e After installation ad
278. inding or noise is found remove the rear wheel and inspect the wheel bearing see Wheels Tires chapter and coupling see Final Drive chapter 2 32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Drive Train Drive Chain Lubrication Condition Inspection e special lubricant is not available a heavy oil such as SAE 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication e f the chain appears especially dirty clean it before lubri cation CAUTION The O rings between the side plates seal in the lu bricant between the pin and the bushing To avoid damaging the O rings and resultant loss of lubri cant observe the following rules Use only kerosene or diesel oil for cleaning an O ring drive chain Any other cleaning solution such as gasoline or trichloroethylene will cause deterio ration and swelling of the O ring Immediately blow the chain dry with compressed air after cleaning Complete cleaning and drying the chain within 10 minutes e Apply oil to the sides of the rollers so that oil will penetrate to the rollers and bushings Apply the oil to the O rings so that the O rings will be coated with oil e Wipe off any excess oil Oil Applied Areas A O rings B GK04060781 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
279. ine stopped and the connector joined e Turn the ignition switch ON Water Temperature Sensor Output Voltage Connections to ECU Meter O lead terminal 5 Meter BR BK lead terminal 14 Connections to ECU Immobilizer Equipped Models C Meter O lead terminal 23 Meter BR BK lead terminal 20 Standard about 2 80 2 97 V at 20 C 68 F NOTE OThe output voltage changes according to the coolant temperature in the engine e Turn the ignition switch OFF x If the output voltage is within the standard check the ECU for its ground and power supply see ECU section x lf the output voltage is out of the standard remove the fuel tank and check the wiring And if the output voltage is 4 8 V the ECU is normal GC17828BS1 FUEL SYSTEM DFI 3 57 Water Temperature Sensor Service Code 14 x If the wiring is good check the water temperature sensor resistance e Remove the needle adapter set and apply silicone sealant to the seals of the connector for waterproofing Silicone Sealant Kawasaki Bond 56019 120 Seals of ECU Connectors Water Temperature Sensor Circuit 6617830 1 C 80617829841 C A ECU B Joint Connector D C Water Temperature Sensor D Water Temperature Warning Light LED Sensor Resistance Inspection e Remove the water temperature sensor see this sec
280. ine oil level too high Engine oil viscosity too high Drive train trouble Air suction valve trouble Vacuum switch valve trouble Catalytic converter melt down due to muffler overheating KLEEN Poor Running or No Power at High Speed Overheating Firing incorrect Firing incorrect Spark plug dirty broken or maladjusted Stick coil wiring trouble Stick coil not in good contact Spark plug incorrect Camshaft position trouble IC igniter in ECU trouble Crankshaft sensor trouble Stick coil trouble Fuel air mixture incorrect Air cleaner clogged poorly sealed or miss ing Air cleaner O ring damaged Air cleaner duct loose Water or foreign matter in fuel Throttle body assy holder loose Fuel to injector insufficient DFI Fuel tank air vent obstructed Fuel line clogged Fuel pump trouble DFI Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Spark plug dirty broken or maladjusted Spark plug incorrect IC igniter in ECU trouble Muffler overheating For KLEEN do not run the engine even if with only one cylinder misfiring or poor running Request the nearest service fa cility to correct it For KLEEN do not push start with a dead battery Connect another full charged battery with jumper cables and start the engine using the electric starter For KLEEN do not start the engine under misfire due to spark plug fouling or poor
281. ine the starter motor clutch gear as well Replace it if it is worn or damaged Starter Motor Clutch Disassembly e Remove Alternator Rotor see Electrical System chapter Starter Motor Clutch Bolts A and Starter Motor Clutch Starter Motor Clutch Assembly e Be sure to install the one way clutch A so that its flange B fits in the holder recess C e Apply a non permanent locking agent to the threads of the starter motor clutch bolts and tighten them Torque Starter Motor Clutch Bolts 12 N m 1 2 kgf m 104 in Ib ELECTRICAL SYSTEM 16 31 Charging System Alternator Inspection There are three types of alternator failures short open wire burned out or loss in rotor magnetism A short or open in one of the coil wires will result in either a low output or no output at all A loss in rotor magnetism which may be caused by dropping or hitting the alternator by leaving it near an electromagnetic field or just by aging will result in low output e To check the alternator output voltage do the following procedures OTurn off the ignition switch ORemove Left Frame Cover see Alternator Cover Removal Separator California Model 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
282. ion switch and the engine stop switch ON e Pushing the starter button turn the engine 4 5 seconds with the transmission in neutral to measure the primary peak voltage e Repeat the measurements 5 times for one stick coil Stick Coil Primary Peak Voltage Standard 88 V or more e Repeat the test for the other stick coil x lf the reading is less than the specified value check the following Stick Coils see Stick Coil Inspection Crankshaft Sensor see Crankshaft Sensor Inspection x If the stick coils and crankshaft sensor are normal check the ECU see Fuel System DFI chapter Spark Plug Removal e Refer to the Spark Plug Replacement in the Periodic Maintenance chapter Spark Plug Installation e Refer to the Spark Plug Replacement in the Periodic Maintenance chapter GP10070281 16 44 ELECTRICAL SYSTEM Ignition System Spark Plug Cleaning and Inspection e Remove the spark plug see Periodic Maintenance chap ter e Clean the spark plug preferably in a sandblasting device and then clean off any abrasive particles The plug may also be cleaned using a high flash point solvent and a wire brush or other suitable tool If the spark plug center electrode A and or side electrode B are corrected or damaged or if the insulator C is cracked replace the plug Use the standard spark plug or its equivalent Measure the gaps with a wire type thickness gauge xIf th
283. ir Pressure When Cold Front Up to 180 kg 397 Ib load 250 kPa 2 5 kgf cm 36 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 Rear Final Drive Drive Chain Slack Drive Chain 20 link Length Brakes Brake Fluid Grade Brake Pad Lining Thickness Front Rear Brake Light Timing Front Rear Up to 180 kg 397 Ib load E 290 kPa 2 9 kgf cm 42 psi 25 35 mm 1 0 1 4 in 317 5 318 2 mm 12 50 12 53 in 4 5 mm 0 18 in 1 mm 0 04 in 5 0 mm 0 20 in 1 mm 0 04 in Pulled ON ON after about 10 mm 0 39 in of pedal travel Electrical System Spark Plug Gap 0 7 0 8 mm 0 028 0 031 in AT Republic of Austria CH Swiss Confederation DE Federal Republic of Germany 2 14 PERIODIC MAINTENANCE Special Tools Inside Circlip Pliers Oil Filter Wrench 57001 143 57001 1249 7570143ST C 7571249ST C Steering Stem Nut Wrench Extension Tube 57001 1100 57001 1578 7571578ST C 875711005 C Jack 57001 1238 7571238ST C PERIODIC MAINTENANCE 2 15 Periodic Maintenance Procedures Fuel System DFI Fuel Hose Inspection fuel leak damage installation condition OThe fuel hose is designed to be used throughout the mo torcycle s life without any maint
284. is sys tem connector A 16 74 ELECTRICAL SYSTEM Immobilizer System Equipped Models e Connect the key registration unit A Special Tool Key Registration Unit 57001 1582 e Insert the master key to the ignition switch and turn it ON Verified OThe FI indicator light A blinks to display the registration mode go to the next step Not Verified OThe Fl indicator light A blinks to display the collation error refer to the following failure illustrations Immobilizer Amplifier Failure Master Key Collation Error e Turn the master key OFF and remove the master key OThe Fl indicator light 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 vious key is turned off and removed otherwise registra tion mode will be ended and the indicator light stops flashing OTo return to the registration mode start the master key verification procedure This applies to all user key reg istration 0 5second 0 5second QN OFF gt LILI LILI LJ GP30117BS1 GP30118BS1 0 3second am UU UU UU UU UU GP30119BS1 0 5second 0 5second ON OFF gt Le EE E GP30117BS1 C ELECTRICAL SYSTEM 16 75 Immobilizer System Equipped Models e Insert the user key 1 to the ignition switch and turn it ON NOTE OK
285. ission 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 intake 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 includes a catalytic converter system 3 Evaporative Emission Control System Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere In stead fuel vapors are routed into the running engine to be burned or stored in a canister when the engine is stopped Liquid fuel is caught by a vapor separator and returned to the fuel tank The Clean Air Act which is the Federal law covering motor vehicle pollution contains what is commonly referred to as the Act s tampering provisions Sec 203 a The following acts and
286. iston rings with your thumbs or the thin screwdriver GE16057BS1 C ENGINE TOP END 5 29 Cylinder Pistons Piston Removal e Remove the cylinder see Cylinder Removal e Place a clean cloth under the pistons and remove the pis ton pin snap ring A from the outside of each piston e Remove the piston pins Special Tool Piston Pin Puller Assembly 57001 910 A e Remove the pistons e Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring A to remove it e Remove the 3 piece oil ring with your thumbs in the same manner GE16059BS1 C Piston Installation e Install the oil ring expander A in the bottom piston ring groove so the ends B butt together e Install the oil ring steel rails one above the expander and one below it B 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 GET16060BS1 C OThe oil ring rails have no top or bottom e Do not mix up the top and second ring A e Install the top ring A so that the 1T mark B faces up e Install the second ring C so that the 2T mark D faces B up C D GE16102BS1 5 30 ENGINE TOP END Cylinder Pistons NOTE Olf a new piston is used use new piston ring e Install the piston with its marking hollow facing forward e Fit a ne
287. 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 6512020851 is tightest e Measure the vertical movement chain slack midway between the sprockets the chain slack exceeds the standard adjust it Chain Slack Standard 25 35 1 0 1 4 in PERIODIC MAINTENANCE 2 33 Periodic Maintenance Procedures Drive Chain Slack Adjustment e Remove the cotter pin A and loosen the axle nut B e Loosen the both chain adjuster locknuts C x If the chain is too loose turn out the left and right chain adjuster nut 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 the left wheel alignment indicator F should align with the same swingarm mark G or position that the right indicator notch aligns with A WARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition e Tighten both chain adjuster locknuts securely e Tighten the axle nut Torque Rear Axle Nut 108 N m 11 kgf m 80 ft lb Turn the wheel measure the chain slack again at the tight est position and readjust if necessary e Insert a new cotter pin A NOTE OWhen i
288. just each cable properly A WARNING Operation with incorrectly routed or improperly ad justed cables could result in an unsafe riding con dition Cable Lubrication Refer to the Chassis Parts Lubrication in the Periodic Maintenance chapter FUEL SYSTEM DFI 3 99 Choke Cable Free Play Inspection e Refer to the Choke Operation Inspection in the Periodic Maintenance chapter Free Play Adjustment e Refer to the Choke Operation Inspection in the Periodic Maintenance chapter Choke Cable Installation e Install the choke cable in accordance with the Cable Wire and Hose Routing section in the Appendix chapter e After installation adjust the cable properly A WARNING Operation with an incorrectly routed or improperly adjusted cable could result in an unsafe riding con dition Cable Lubrication e Refer to the Chassis Parts Lubrication in the Periodic Maintenance chapter 3 100 FUEL SYSTEM DFI Throttle Body Assy Idle Speed Inspection e Refer to the Idle Speed Inspection in the Periodic Main tenance chapter Engine Vacuum Synchronization Inspection Adjustment e Refer to the Engine Vacuum Synchronization Inspection in the Periodic Maintenance chapter High Altitude Performance Adjustment e Any modification is not necessary in this model since the atmospheric pressure sensor senses atmospheric pres sure change due to high altitude and the ECU compen sates the change Throttle
289. k Pin Outside Diameter Standard 5 6 6 0 mm 0 22 0 24 in Link Plates Outside Width Standard 17 45 17 60 mm 0 687 0 693 in x If the reading exceeds the specified length cut and rejoin the chain again e Check Movement of the Rollers Adjust the drive chain slack after installing the chain see Periodic Maintenance chapter GK04028BS1 FINAL DRIVE 11 11 Sprocket Coupling Engine Sprocket Removal e Remove Clamps A Open Speed Sensor Connector B Engine Sprocket Cover Bolts C Engine Sprocket Cover D with Speed Sensor e Flatten out the bended washer A e Remove the engine sprocket nut B and washer NOTE OWhen loosening the engine sprocket nut hold the rear brake on e Using the stand raise the rear wheel off the ground e Loosen the drive chain see Periodic Maintenance chap e the drive chain from the rear sprocket toward the e the drive the sprocket E the engine sprocket off the output shaft C Engine Sprocket Installation e Replace the sprocket washer and axle cotter pin e Install the engine sprocket so that OUTSIDE letters A face outward e Apply molybdenum disulfide oil 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 of the washer over the nut NOTE OTighten the nut while applying the rear b
290. k that knock pins B are in place on the crankcase Install a new gasket and the alternator cover e Tighten Torque Alternator Cover Bolts 11 N m 1 1 kgf m 95 in Ib Stator Coil Removal e Remove Alternator Cover see Alternator Cover Removal Holding Plate Bolt A and Plate Alternator Lead Grommet B Stator Coil Bolts C e Remove the stator coil D from the alternator cover 16 28 ELECTRICAL SYSTEM Charging System Stator Coil Installation e Apply a non permanent locking agent to the threads of the stator coil bolts and tighten them Torque Stator Coil Bolts 11 N m 1 1 kgf m 95 in Ib e Secure the alternator lead with a holding plate and tighten the bolt OApply a non permanent locking agent to the threads of the plate bolt Torque Alternator Lead Holding Plate Bolt 11 N m 1 1 kgf m 95 in lb 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 e Install the alternator cover see Alternator Cover Installa tion Alternator Rotor Removal e Remove Alternator Cover see Alternator Cover Removal e Wipe oil off the outer circumference of the rotor e Hold the alternator rotor steady with the rotor holder A and remove the rotor bolt B and washer Special Tool Rotor Holder 57001 1543 e Using the flywheel puller A remove the alternator rot
291. ket Bolts 25 N m 2 5 kgf m 18 ft lb ONinthly tighten securely Middle Engine Mounting Nut Lower Engine Mounting Nut Torque Engine Mounting Nuts 44 N m 4 5 kgf m 33 ft Ib GHO4016BS1 C ENGINE REMOVAL INSTALLATION 8 9 Engine Removal Installation e Fit the holes A of the bracket B onto the projections C of the heat insulation plate D OTenthly temporarily install Right Upper Engine Mounting Bolt A Front Engine Bracket Bolts B Front Engine Bracket C OEleventhly tighten the right upper engine mounting bolt OLastly tighten the front engine bracket bolts Torque Right Upper Engine Mounting Bolt 44 N m 4 5 kgf m 33 ft lb Front Engine Bracket Bolts 44 N m 4 5 kgf m 33 ft Ib e Run the leads cables and hoses correctly see Cable Wire and Hose Routing section in Appendix chapter e Install the removed parts see appropriate chapters e Adjust Throttle Cables see Fuel System DFI chapter Choke Cable see Fuel System DFI chapter Clutch Cable see Clutch chapter Drive Chain see Final Drive chapter e Fill the engine with engine oil see Engine Oil Change in the Periodic Maintenance chapter e Fill the engine with coolant see Coolant Change in the Periodic Maintenance chapter CRANKSHAFT TRANSMISSION 9 1 Crankshaft Transmission Table of Contents Exploded VieW iater Meere eda 9 2 Specifications see
292. 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 Model EngmeNo No Date problem occurred Mileage Environment when problem occurred Weather Ofine Ocloudy Orain Osnow Dalways Oother Temperature Ohot Owarm Ocold Overy cold Dalways Problem chronic frequency Ostreet Ohighway Omountain road Ouphill downhill Obumpy pebble Altitude Ohigh about 1 000 m or more Motorcycle conditions when problem occurred Fl indicator Olight up immediately after ignition switch ON and goes off after 1 2 seconds light LED normal lights blinks immediately after ignition switch ON and stays on DFI problem Olights up immediately after ignition switch ON but goes off after about 10 seconds DFI problem Ounlights light LED ECU or its wiring fault Sometimes lights up probably wiring fault Starting Ostarter motor not rotating difficulty Ostarter motor rotati
293. l Pressure Relief Valve 15 1 5 11 ft Ib e Install the clamp A at an angle of within 45 as shown e Replace the oil pan gasket with a new one e Tighten Torque Oil Pan Bolts C 11 1 1 95 in Ib GG06008BS1 C 7 10 ENGINE LUBRICATION SYSTEM Oil Pressure Relief Valve Oil Pressure Relief Valve Removal See Oil Pan Removal Oil Pressure Relief Valve Installation See Oil Pan Installation Oil Pressure Relief Valve Inspection 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 x If any rough spots are found during above inspection wash the valve clean with a high flash point solvent and blow out any foreign particles that may be in the valve with compressed air A WARNING Clean the oil pressure relief valve in 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
294. l the connector with its lead side facing inward Clamp Headlight Harness City Light Connector Right Turn Signal Light Connector White Tape Main Harness Right Switch Housing Connector Left Switch Housing Connector Clamp Left Turn Signal Light Connector Headlight Connector High and Low To Right Switch Housing To Left Switch Housing Meter Connector Discrimination Tape Green U S A Canada Red Malaysia Blue other 17 10 APPENDIX Cable Wire and Hose Routing 63 0 60 9 9 9 49 9 2 69 2 9 6809738885 C APPENDIX 17 11 Cable Wire and Hose Routing 5 Meter Lead Band Hold the ignition switch lead to the upper bracket Ignition Switch Lead Run the main harness under and right side of the thermostat Frame Ground with Thermostat Bracket Ignition Switch Connector Meter Ground Water Temperature Sensor Inlet Air Pressure Sensor Clamp Fuel Injector Connector 1 Subthrottle Valve Actuator Crankshaft Sensor and Oil Pressure Switch Connector Fuel Level Sensor and Fuel Reserve Switch Connector Fuel Pump Connector Radiator Fan Switch Clamp Hold the fan switch lead Run the camshaft position sensor lead between the engine bracket and heat insulation plate Camshaft Position Sensor Lead Connector Horn Run the camshaft position sensor lead inside the horn
295. lace the ele ment Air Cleaner Oil Draining A drain hose is connected to the bottom of the air cleaner to drain water or oil accumulated in the cleaner part e Visually check the drain hose A if the water or oil accu mulates xIf any water or oil accumulates the hose remove the plug B from the drain hose and drain it A WARNING Be sure to reinstall the plug in the drain hose after draining Oil on tires will make them slippery and can cause an accident and injury Air Cleaner Housing Removal e Remove the engine see Engine Removal Installation chapter OThe throttle body assy is removed during engine removal e Remove the right and left air cleaner housing bolts e Move the air cleaner housing A forwards and remove it from the right side of the frame 3 106 FUEL SYSTEM DFI 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 Remove Seat see Seat Removal in the Frame chapter Fuel Tank Bolt A Fuel Tank Drain Hose Tubes B california Model e Turn the ignition switch and engine stop switch OFF e Wait until the engine cools down e Open the f
296. lace the piston and or cylinder Inspect the cylinder and Piston seizure replace repair the cylinder and or piston as necessary Bad condition of piston ring and or Replace the piston and or the piston ring grooves piston rings ENGINE TOP END 5 19 Cylinder Head Cylinder Head Removal e Remove Exhaust Pipes see Exhaust Pipe Removal Cylinder Head Cover see Cylinder Head Cover Re moval Camshaft Position Sensor see Electrical System chap ter Camshafts see Camshaft Removal Throttle Body Assy see Fuel System DFI chapter Water Hose Upper Engine Mounting Bolts both side A Front Camshaft Chain Guide e Remove the M6 cylinder head bolts B and then the M10 cylinder head bolts A e Take off the cylinder head GE14036BS1 C Cylinder Head Installation 9 SP OThe camshaft cap is machined with the cylinder head so if a new cylinder head is installed use the cap that is supplied with the new head e Install a new cylinder head gasket and dowel pins 8 S A e Apply molybdenum disulfide oil solution to both sides A of the cylinder head bolt washers B and the thread of M10 head bolts C GE14070281 C e Tighten the M10 cylinder head bolts following the tighten ing sequence 1 10 Torque Cylinder Head Bolts M10 First 20 N m 2 0 kgf m 14 5 ft Ib Final Used Bolts 49 N m 5 0 kgf m 36 ft Ib New Bolts 54 5 5 kgf m 40 ft Ib e Tighten the M6 cyli
297. lamp A Loosen Right Radiator Hose B e Remove Radiator Bolts A e Remove the radiator CAUTION Do not touch the radiator core This could damage the radiator fins resulting in loss of cooling effi ciency 4 12 COOLING SYSTEM Radiator e If necessary remove Radiator Fan Mounting Bolts A Radiator Fan B Radiator and Radiator Fan Installation e Installation is the reverse of removal e Install the radiator bracket collars A as shown Rubber Damper B 30 40 C Radiator D Bracket E e Tighten Torque Radiator Lower Bolts 7 0 N m 0 70 kgf m 61 in Ib Radiator Upper Bolts 7 0 0 70 kgf m 61 in Ib Radiator Inspection e Check the radiator core x If there are obstructions to air flow remove them the corrugated fins A are deformed carefully straighten them x lf the air passages of the radiator core are blocked more than 20 by unremovable obstructions or irreparably de formed fins replace the radiator with a new one CAUTION When cleaning the radiator with steam cleaner be careful of the following to prevent radiator damage Keep the steam gun A away more than 0 5 m 1 6 ft B from the radiator core Hold the steam gun perpendicular C not oblique D to the core surface Run the steam gun following the core fin direction 6007010451 C 6007020151 C COOLING SYSTEM 4 13 Radiator Radiato
298. le opening x If the output voltage is out of the range check the throttle input voltage see Input Voltage Inspection of Main Throt tle Sensor in the Fuel System DFI chapter 2 22 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Remove the vacuum gauge hoses and install the vacuum hoses A and rubber caps B on the original position as shown Front C Evaporative Emission Control System Inspection CAL e Inspect the canister as follows ORemove the seat cover see Frame chapter ORemove the band A and hoses and take out the canister B OVisually inspect the canister for cracks and other damage xIf 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 OConnect the purge hose white C and the canister breather hose blue D to the canister as shown Olnstall the canister with the inlet E down and the seat see Frame chapter Clamps F e Check the liquid vapor separator as follows e Remove Bolts A with Washer Left Frame Cover B 0805068852 C PERIODIC MAINTENANCE 2 23 Periodic Maintenance Procedures 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 c
299. le range the bolt has stretched too much An overelongated bolt may break in use Bolt Length _ Bolt Length after tightening before tightening Bolt otelch Connect Usable Range of ing Rod Bolt Nut Connecting Rod Assy Bolt Stretch Use the bolts Attached to New lattached to new con rod 0 24 0 36 mm 0 0094 0 0142 in new con rod New Replace the Used Used bolts with new 0 20 OA mm ones New 0 0079 0 0126 in 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 and nuts thoroughly with a high flash point solvent because the new bolts and nuts are treated with an anti rust solution A WARNING Clean the bolts and nuts in a well ventilated area and take care that there is no spark or flame any where near the working area This includes any ap pliance with a pilot light Because of the danger or highly flammable liquids do not use gasoline or low flash point solvents to clean them CAUTION Immediately dry the bolts and nuts with com pressed air after cleaning Clean and dry the bolts and nuts completely 9 16 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods e Install new bolts in reused connecting rods e Apply a small amount of molybdenum disulfide oil to the following Threads A of Nuts and Bolts Seating Surfaces B of Nuts and Con
300. le valve actuator A since it has been adjusted and set with precision at the factory Never drop the actuator especially on a hard sur face Such a shock to the actuator can damage it Audible Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch ON and ensure that the actuator valves open and close make light sounds several times within seconds and then close at the idle throttle opening position e Turn the ignition switch OFF x If the actuator does not work as described above do the visual inspection Visual Inspection e Remove the throttle body assy see Throttle Body Assy Removal e Turn the ignition switch ON e Check to see that all the subthrottle valves A open and close smoothly x If the subthrottle valves do not operate check the actuator internal resistance see Resistance Inspection Resistance Inspection e Turn the ignition switch OFF e Remove the throttle body assy see Throttle Body Assy Removal e Disconnect the subthrottle valve actuator connector A e Connect a digital meter to the subthrottle valve actuator connector A e Measure the subthrottle valve actuator resistance Subthrottle Valve Actuator Resistance Connections BK BL lead 1 P BL lead 2 lead 3 lt gt W BL lead 4 Standard About 5 7 kQ Special Tool Hand Tester 57001 1394 xIf the reading is out of the range replace the actuator along with the throttl
301. leads 3 6 3 8 V DC between BR and BR BK leads 4 6 about 5 7 about 8 5 10 5 V DC Throttle Grip and Cables Throttle Grip Free Play Choke Cable Choke Cable Free Play 2 3 mm 0 08 0 12 in 0 0 5 mm 0 0 02 in FUEL SYSTEM DFI 3 19 Special Tools and Sealant Oil Pressure Gauge 5 kgf cm 57001 125 875701255 C Fork Oil Level Gauge 57001 1290 875712905 C Needle Adapter Set 57001 1457 T571457ST C Throttle Sensor Setting Adapter 57001 1538 Hand Tester 57001 1394 Sensor Harness Adapter 57001 1561 7571394ST C Throttle Sensor Setting Adapter 1 57001 1400 875714005 C Peak Voltage Adapter 57001 1415 875714155 C Fuel Pressure Gauge Adapter 57001 1593 E Fuel Hose 57001 1607 ST571607ST 3 20 FUEL SYSTEM DFI Special Tools and Sealant Kawasaki Bond Silicone Sealant 56019 120 875601205 C FUEL SYSTEM DFI 3 21 DFI Servicing Precautions DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system 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 cable
302. leshooting the DFI System DFI part connectors have seals including the ECU e Join the connector and insert the needle adapters C inside the seals B from behind the connector until the adapter reaches the terminal Special Tool Needle Adapter Set 57001 1457 CAUTION Insert the needle adapter straight along the terminal in the connector to prevent short circuit between terminals e Make sure that measuring points are correct in the con nector noting the position of the lock D and the lead color before measurement Do not reverse connections of the hand tester or a digital meter e Be careful not to short circuit the leads of the DFI or elec trical system parts by contact between adapters e Turn the ignition 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 Silicone Sealant Kawasaki Bond 56019 120 Seals of Connector e Always check battery condition before replacing the parts A fully charged battery is a must for conducting accurate tests of the DFI system e Trouble may involve one or in some cases all items Never replace a defective part without determining what CAUSED the problem If the problem
303. ll 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 2 40 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering Play Adjustment e Remove Handlebar see Steering chapter Upper Fork Clamp Bolts A Steering Stem Head Bolt Plug Stem Head Bolt B Clamp Bolts C with Clamp e Remove the steering stem head D e Straighten the claw A of the claw washer e Remove the steering stem locknut B and claw washer C e Adjust the steering Special Tool Steering Stem Nut Wrench 57001 1100 B If the steering is too tight loosen the stem nut A a fraction of a turn the steering is too loose tighten the stem nut a fraction of a turn NOTE OTurn the stem nut 1 8 turn at time maximum e Install the claw washer A so that its bent side B faces upward and engage the bent claws with the grooves of stem locknut C e Hand tighten the stem locknut until it touches the claw washer e Tighten the stem locknut clockwise until the claws are aligned with the grooves ranging from 2nd to 4th of stem nut D and bend the 2 claws downward E e Tighten Torque Steering Stem Head Bolt 108 N m 11 80 ft lb Front Fork Clamp Bolts Upper 20 N m 2 0 kgf m 14 ft lb e Check the steering again x If the steering is st
304. ll the radiator cap 6005015851 C 4 8 COOLING SYSTEM Coolant Cooling System Flushing Over a period of time the cooling system accumulates rust scale and lime in the water jacket and radiator When this accumulation is suspected or observed flush the cool ing system If this accumulation is not removed it will clog up the water passage and considerable reduce the effi ciency of the cooling system e Drain the cooling system see Coolant Change in the Pe riodic Maintenance chapter e Fill the cooling system with fresh water mixed with a flush ing compound CAUTION Do not use a flushing compound which is harmful to the aluminum engine and radiator Carefully follow the instructions supplied by the manufacturer of the cleaning product 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 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 Installation e The coolant reserve tank is removed and installed dur ing coolant change see Coolant Change in the Periodic Maintenance chapter COOLING SYSTEM 4 9 Water Pump Water Pump Removal e Refer to the Oil Pump Removal
305. ll the trim A as shown illustration Left Inner Cover B Right Inner Cover C Meter Cover Removal e Remove Right and Left Inner Cover Screw with Washer A e Push the central pin and then remove the quick rivets B e Remove the meter cover C G005001BS1 C 15 10 FRAME Fairings Meter Cover Installation e Install the lower portion A of the meter cover under the air duct B of the fairing e Reset the quick rivets see Inner Cover Installation e Temporary install the screws and quick rivets and then install them Windshield Removal e Remove Bolts with Washers A Bolts with Washers and Nuts with Washers B Windshield C Windshield Installation e Tighten Torque Windshield Bolts 0 4 N m 0 04 kgf m 4 in Ib Fairing Removal e Remove Fairing Mounting Bolts A both side e Remove Windshield see Windshield Removal Inner Covers see Inner Cover Removal Meter Cover see Meter Cover Removal Meter Connector A disconnect Headlight Harness Connector B disconnect FRAME 15 11 Fairings e Remove Bolts A Pull out the fairing forward Fairing Installation e Temporary install all fairing mounting bolts and tighten them Fairing Disassembly e Remove Fairing see Fairing Removal Nuts A Right and Left Rear View Mirrors B Meter Bracket with Meter Unit C e Disconnect Front Turn Signal Light Connectors A Headl
306. lled in and gear not in neutral whether sidestand up or not gear not in neutral whether gear in neutral or not inspect see chapter 3 inspect see chapter 3 Inspect and charge see chapter 16 Spark plug cap trouble Inspect stick coil see chapter 16 Spark plug cap shorted or not in good contact Reinstall or inspect stick coil see chapter 16 Spark plug incorrect Replace it with the correct plug see chapter 16 IC igniter in ECU trouble Inspect see chapter 16 Neutral starter lockout or sidestand switch trouble Crankshaft sensor trouble Inspect see chapter 16 Stick coil trouble Inspect see chapter 16 Ignition switch shorted Inspect and replace see chapter 16 Engine stop switch shorted Inspect and repair or replace see chapter 2 Starter system wiring shorted or open Inspect and repair or replace see chapter 16 Main 30A or ignition fuse blown Inspect and replace see chapter 16 Fuel air mixture incorrect Air cleaner clogged poorly sealed or missing Clean or reinstall see chapter 3 Leak from oil filler cap crankcase breather hose or air cleaner drain hose Water or foreign matter in fuel Change fuel Inspect and clean fuel system see chapter 3 Inspect fuel pressure and replace fuel pump see chapter 3 Main throttle sensor trouble Inspect see chapter 3 Fuel pressure may be low Inspect see chapter 3 Fuel pump trouble Inspect see chapter 3 Fuel injector trouble Inspect see cha
307. lled 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 e Tighten the alternator rotor bolt while holding the alterna tor rotor steady with the rotor holder Special Tool Rotor Holder 57001 1543 Torque Alternator Rotor Bolt 110 N m 11 kgf m 81 ft Ib GP09133BS1 C 16 30 ELECTRICAL SYSTEM Charging System e Apply a thin coat of molybdenum disulfide grease to the shaft A and install it and starter idle gear B e Install the alternator cover see Alternator Cover Installa tion Starter Motor Clutch Removal Installation e Refer to the Alternator Rotor Removal and Installation in the Electrical System chapter Starter Motor Clutch Inspection e Remove Alternator Cover see Electrical System chapter Starter Idle Gear e Turn the starter motor clutch gear A by hand The starter motor clutch gear should turn clockwise B freely but should not turn counterclockwise C x If the clutch does not operate as it should or if it makes noise go to the next step e Remove and disassemble the starter motor clutch and visually inspect the clutch parts x If there is any worn or damaged part replace it NOTE OExam
308. lt 108 N m 11 kgf m 80 ft lb Front Fork Clamp Bolts Upper 20 N m 2 0 kgf m 14 ft lb Front Fork Clamp Bolts Lower 20 N m 2 0 kgf m 14 ft lb e Install the steering stem head bolt plug Do not impede the handlebar turning by routing the cables harnesses and hoses improperly see Ap pendix chapter e Install the removed parts see appropriate chapters Stem Bearing Lubrication e Refer to the Steering Stem Bearing Lubrication in the Pe riodic Maintenance chapter 6 05060451 C STEERING 14 9 Steering Stem Steering Stem Warp e Whenever the steering stem is removed or if the steering cannot be adjusted for smooth action check the steering stem for straightness x lf the steering stem A is bent replace the steering stem Stem Cap Deterioration Damage Replace the stem cap if its grease seal A shows dam age GNO5025BS1 C 14 10 STEERING Handlebar e Remove Handlebar Holder Plugs A Clamps B e Remove Clutch Lever Assembly A Left Switch Housing B Front Brake Master Cylinder C Right Switch Housing D e Remove Left and Right Handlebar Weights A Throttle Grip B e Remove Handlebar Holder Bolts A Handlebar Holder B Handlebar C e Remove the cotter pins e Remove the mounting nuts B washers and handlebar lower holders C STEERING 14 11
309. ly grease to the balls to hold them in place This will cause the positive neutral finder mechanism to malfunction OAfter assembling the 5th gear with steel balls in place on the output shaft check the ball locking effect that the 5th gear doesn t come out of the output shaft when moving it up and down by hand Check that each gear spins or slides freely on the trans mission shafts without binding after assembly 6113132851 C 6113033851 C CRANKSHAFT TRANSMISSION 9 27 Transmission Drive Shaft Output Shaft 5 AVENINEMOQOUMIOVOPOMOOD SIMD JASA TE IM no ILLA 1 A Eur Jb E TES 5 WOS CX XT 24m TUM SEN 763626990469 2 09 4 696909 69 9 5 00690950 99929 299 es 1st Gear 2 Gear 3rd Gear 4th Gear 5th Gear 6th Top Gear Toothed Washer 31 mm 1 22 in Thrust Washer 30 mm 1 18 in Circlip Circlip Bushing Bushing Needle Bearing Needle Bearing Bearing Outer Race 6113080183 C Steel Ball Bushing Bushing Circlip Ball Bearing Collar Washer Toothed Washer Oil Seal Thrust Washer 31 mm 1 22 in Thrust Washer 33 mm 1 30 in Toothed Washer Toothed Washer Toothed Washer 35 mm 1 38 in 9 28 CRANKSHAFT TRANSMISSION Tran
310. 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 95 101 C 203 214 F the radiator fan switch conducts to operate the radiator fan The radiator fan draws air through the radiator core when there is not sufficient air flow such as at low speeds This increases up the cooling action of the radiator When the coolant temperature goes down from the operation temperature by 3 8 C 37 46 F the fan switch opens and the radiator fan stops In this way this system controls the engine temperature within narrow limits where the engine op erates most efficiently even if the engine load varies The system is pressurized by the radiator cap to suppress boiling and the resultant air bubbles which can cause engine overheating As the engine warms up the coolant in the radiator and the water jacket expands The excess coolant flows through the radiator cap and hose to the reserve tank to be stored there temporarily Conversely as the engine cools down the coolant in the radiator and the water jacket contracts and the stored coolant flows back to the radiator from the reserve tank The radiator cap has two valves One is a pressure valve which holds the pressure in the system when the engine is running When the pressure exceeds 93 123 kPa 0 95 1 25 kgf cm 14 17 8 psi the pressure valve opens and releases the pressure to the
311. n tenna Olf there is any problem in the registration the Fl indicator light A blinks to display the collation error Immobilizer Amplifier Failure 0 2second Gat GP30118BS1 C ELECTRICAL SYSTEM 16 81 Immobilizer System Equipped Models When Registered User Key is Inserted User Key Collation Error e The user key 1 is successfully registered in the ECU OThe FI indicator light A blinks 2 times and stops for 1 second and then repeats this cycle to indicate successful registering of user key 1 Turn off and remove user key 1 OThe FI indicator light 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 ends and FI indicator light goes off OThis procedure has registered the master key and one user key OContinue the procedure to program the second and later keys e Insert the user key 2 to the ignition switch and turn it ON 0 5second 0 5second gt ee GP30117BS1 C 0 3second BE OHS LLU UU UU uu GP30119BS1 gt LIS LL GP30120BS1 C 0 5second 0 5second GP30117BS1 C 16 82 ELECTRICAL SYSTEM Immobilizer System Equipped Models Olf there is any problem in the registration the Fl indicator light A blinks
312. n Interlock Side Stand 1 14 Technical Information Tail Brake Lights Employing LED pp 1 15 Technical Information KAWASAKI LOW EXHAUST EMISSION SYSTEM 1 17 Technical Information Immobilizer System Equipped 1 18 Unit C nv rsion Table EET 1 21 1 2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera tion on a motorcycle read the precautions given below To facilitate actual operations notes illustra tions photographs cautions and detailed descriptions have been included in each chapter wherever necessary This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts Especially note the following Battery Ground Before completing any service on the motorcycle discon e nect the battery wires from the battery to prevent the engine by gt Sim from accidentally turning over Disconnect the ground wire E wo NU gt first and then the positive When completed with the wal Ie service first connect the positive wire to the positive 8 3 PN Pd terminal of the battery then the negative wire to the neg ative terminal DISASSEMBLY ASSEMBLY 68020248 Edges of Parts Lift large or hea
313. n a weight ratio 10 1 R Replacement Parts 11 4 FINAL DRIVE Specifications Standard Service Limit Drive Chain Chain Slack 25 35 mm 1 0 1 4 in 20 link Length 317 5 318 2 mm 12 50 12 53 in 323 mm 12 7 in Standard Chain Make ENUMA Type EK520MVXL Link 112 links Sprockets Rear Sprocket Warp 0 4 mm 0 016 in or less 0 5 mm 0 020 in FINAL DRIVE 11 5 Special Tools Inside Circlip Pliers Jack 57001 143 57001 1238 7570143ST C i 7571238ST C Bearing Driver Set 57001 1129 875711295 C 11 6 FINAL DRIVE Drive Chain Drive Chain Slack Inspection e Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter Drive Chain Slack Adjustment e Refer to the Drive Chain Slack Adjustment in the Periodic Maintenance chapter Wheel Alignment Inspection Adjustment e Refer to the 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 Drive Chain Lubrication e Refer to the Drive Chain Lubrication Condition Inspection in the Periodic Maintenance chapter Drive Chain Removal e Remove Rear Wheel see Wheels Tires chapter Chain Cover Screws A Chain Cover B Swingarm see Suspension chapter Engine Sprocket Cover see this chapter e Disengage the drive chain A from the en
314. nal Injector 2 Signal Injector 1 Signal Stick Coil 3 Signal Stick Coil 2 Signal Stick Coil 1 Signal Interlock Circuit Signal Self diagnosis Signal generated by grounding this terminal and shown by Fl indicator light Unused Battery Power ON OFF Signal Subthrottle Valve Actuator Drive Signal Subthrottle Valve Actuator Drive Signal External Diagnosis System Signal Fl Indicator Light LED Signal Injector 4 Signal Injector 3 Signal DFI System Ground Ignition System Ground Stick Coil 4 Signal FUEL SYSTEM 3 15 DFI System 34 83 32 ot jon 28 26127 op of a e sp af 26 25 24 23 22 121 20119118117116115 14 6C17713BW1 C Terminal Nambers of ECU Connectors Immobilizer Equipped Models Exes ee ee NOOB Subthrottle Valve Actuator Drive Signal Subthrottle Valve Actuator Drive Signal Unused Unused Unused Main Throttle Sensor Signal Power Supply to Sensor Inlet Air Pressure Sensor Signal Camshaft Position Sensor Signal Inlet Air Temperature Sensor Signal Power Supply to ECU Injectors and Fuel Pump Vehicle Down Sensor Signal Crankshaft Sensor Signal Subthrottle Valve Actuator Drive Signal Subthrottle Valve Actuator Drive Signal Unused Unused Unused Subthrottle Sensor Signal Ground to Sensor Atmospheri
315. nd Tester 57001 1394 x If the test light doesn t flicker or the tester needle doesn t oscillates check the wiring and connectors again If the wiring is good check the injector voltage If the wiring is good inspect the ECU for its ground and power supply see ECU section 6017024281 6017024381 FUEL SYSTEM DFI 3 95 Fuel Injectors Injector Resistance Inspection e Remove the fuel tank see Fuel Tank Removal e Disconnect the connector from the injector A see Throt tle Body Assy Disassembly Assembly e Measure the injector resistance with the hand tester B Special Tool Hand Tester 57001 1394 Injector Resistance Connections to Injector Meter Meter 1 W R BL R Terminal 2 WIR BL G Terminal 3 WIR BL BK Terminal 4 WIR BL Y Terminal Standard about 11 7 12 3 20 68 F x If the reading is out of the range perform the Injector Unit Test x lf the reading is normal perform the Injector Unit Test for confirmation Injector Unit Test e Use two leads A and the same test light set B as in Injector Signal Test Rating of Bulb C 12 V x 3 3 4 W 12 V Battery D CAUTION Be sure to connect the bulb in series The bulb works as a current limiter to protect the solenoid in the injector from excessive current e Connect the test light set to the injector E as shown e Open and connect t
316. nder head bolts 11 12 OP c Torque Cylinder Head Bolts 6 12 1 2 kgf m 104 in Ib 5 20 ENGINE TOP END Cylinder Head Install Front Camshaft Chain Guide O ring Collar e Tighten Torque Front Camshaft Chain Guide Bolt Upper D 25 N m 2 5 kgf m 18 ft Ib Front Camshaft Chain Guide Bolt Lower E 12 N m 1 2 kgf m 104 in Ib e Install the removed parts see appropriate chapters Cylinder Head Warp e Clean the cylinder head Lay astraightedge across the lower surface of the cylinder head at several positions e Use a thickness gauge A to measure the space between the straightedge B and the head Cylinder Head Warp Standard Service Limit 0 05 mm 0 002 in x If the cylinder head is warped more than the service limit replace it x If the cylinder head is warped less than the service limit repair the head by rubbing the lower surface on emery paper secured to a surface plate first No 200 then No 400 GE14039BS2 C GE14038BS1 C ENGINE TOP END 5 21 Valves Valve Clearance Inspection e Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter Valve Clearance Adjustment e Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter Valve Removal e Remove the cylinder head see Cylinder Head Removal e Remove the valve lifter and shim OMark and record the valve lifte
317. ne is running OFF Fan Switch Connections Rising Temperature From OFF to ON 93 103 C 199 217 F Falling Temperature Fan stops with the temperature 3 8 C 38 46 F lower than the operation temperature range ON Less than 0 5 OFF More than 10 MQ Water Temperature Sensor Resistance in the text Fuel Level Sensor Resistance Fuel Position 4 100 Empty Position 90 1000 ELECTRICAL SYSTEM 16 11 Special Tools and Sealant Hand Tester Harness Adapter 57001 1394 57001 1542 7571394ST C 875715425 C Flywheel Puller Assembly M38 x 1 5 M35 x 1 5 Rotor Holder Hex 34 57001 1405 57001 1543 T 875714055 C 1571543 Peak Voltage Adapter Flywheel amp Pulley Holder 57001 1415 57001 1605 875714155 C 7571605ST C Lead Wire Peak Voltage Adapter Kawasaki Bond Silicone Sealant 57001 1449 92104 0004 7571449ST C 879200045 Needle Adapter Set 57001 1457 1571457 C 16 12 ELECTRICAL SYSTEM Wiring Diagram United States and Subthrottle Valve Actuator Spark Plugs LENITION jl Heter Unit di 42 43 34 Radiator X Fuel Fuel F Horn Fan an Resorte Level 12V2 Notor Switch Stick Switch Sensor sin The 868 4 YY uf OFF mo Hii art Meter Unit I itt l High Beam Indicator Light zs ze 2 zer 2 Left Turn Signal Indicato
318. ng overheating engine oil level too high Hengine oil viscosity too high 3 30 FUEL SYSTEM DFI DFI System Troubleshooting Guide NOTE OThis is not an exhaustive list giving every possible cause for each problem listed It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties OThe ECU may be involved in the DFI electrical and ignition system troubles If these parts and circuits 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 Doesn t Start Starting Difficulty Symptoms or possible Causes Actions chapter Starter motor not rotating Ignition and engine stop switches not ON Turn both switches ON Starter lockout switch or neutral switch trouble Inspect see chapter 16 Starter motor trouble Inspect see chapter 16 Battery voltage low Inspect and charge see chapter 16 Starter relays not contacting or operating Inspect the starter relay see chapter 16 Starter button not contacting Inspect and replace see chapter 16 Starter system wiring open or shorted Inspect the wiring see chapter 16 Ignition switch trouble Inspect and replace see chapter 16 Engine stop switch trouble Inspect and repair or replace see chapter 16 Main 30A or ignition fuse blown Inspect and replace see chapter
319. ng but engine doesn t turn over starter motor and engine don t turn over fuel flow Ono fuel in tank fuel pump sound engine flooded do not crank engine with throttle opened which promotes engine flooding spark lever is not pulled fully when using the lever pull it fully when using other Engine stops Oright after starting Owhen opening throttle grip Owhen closing throttle grip when moving off when stopping the motorcycle Owhen cruising other Poor running choke lever pulled out fully push it in fully at low speed Overy low choke speed adjust choke cable Overy low idle speed Overy high idle speed Orough idle speed Obattery voltage is low charge the battery spark plug loose tighten it spark plug dirty broken or gap maladjusted remedy it Obackfiring Dafterfiring ojo hesitation when acceleration engine oil viscosity too high FUEL SYSTEM DFI 3 29 Troubleshooting the DFI System brake dragging engine overheating clutch slipping other Poor running choke lever pulled out fully push it in fully or no power at spark plug loose tighten it high speed Ospark plug dirty broken or gap maladjusted remedy it plug incorrect replace it Oknocking fuel poor quality or incorrect use high octane gasoline brake dragging clutch slippi
320. ng the position e Remove the old drive chain from the new drive chain e Apply grease to the new link pins A and new O rings B C e Engage the drive chain on the engine and rear sprockets e Insert the link pins in the drive chain ends e Install the O rings 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 case of the O ring chain be sure to set the O rings correctly e Set the plate holder A A and plate holder B B on the body e Fit the plate holder A to the link plate e Turn the pin holder by hand until the plate holder B touches the other link plate GKO4019BS1 C GK04020BS1 C GK04021BS1 C GK04022BS1 C FINAL DRIVE 11 9 Drive Chain e Turnthe pin holder by wrench clockwise until two pins of the link come into the groove of the plate holder A e Take off the plate holder GK04023BS1 C e Set the plate holder B A and cutting amp riveting pin B as shown e Turn the pin holder until the riveting pin touches the link pin e Turn the wrench clockwise until the tip of the riveting pin hits of the link pin e Rivet it e Some work for the other link pin GK04026BS1 C 11 10 FINAL DRIVE Drive Chain 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 Lin
321. ng to inspection procedure all service codes Remove the auxiliary lead ending the self diagnosis mode Make sure the FI indicator light LED doesn t go ON i OK 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 OK 06171668 FUEL SYSTEM DFI 3 41 Self Diagnosis How to Read Service Codes How to Read Service Codes OService codes are shown by series of long and short blinks of the FI indicator light LED as shown below ORead 10th digit and unit digit as the FI indicator light LED blinks OWhen there are a number of problems all the service codes can be stored and the display will begin starting from the lowest number service code in the numerical order Then after completing all codes the display is repeated until the self diagnosis indicator terminal is open Olf there is no problem no code and unlight OFor example if two problems occurred in the order of 21 12 the service codes are displayed from the lowest number in the order listed 12 21 12 21 2 repeated Self Diagnosis indicator terminal Grounded Open i 1s ioth digit 0 55 0 5s a digit is is 0 5s Fl Indicator Light LED ON Bt a c 1 1 1 2sec 3s 1 8s 0 5s 3s 1 58 1 58 6C17853BW1 C Olf the problem is with the following parts
322. nges the idle speed the throttle cables may be improperly adjusted or incorrectly routed or damaged Be sure to correct any of these conditions before riding see Throttle Control System Inspection or Cable Wire and Hose Routing section in the Appendix chapter A WARNING Operation with improperly adjusted incorrectly routed or damaged cables could result in an unsafe riding condition e Check idle speed x lf the idle speed is out of the specified range adjust it Idle Speed Standard 1 100 50 r min rpm Idle Speed Adjustment e Start the engine and warm it up thoroughly Turn the adjusting screw 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 Choke Operation Inspection e Push the choke lever A fully and ensure by your finger that the choke cam B has the specified play Choke Lever Free Play C Standard 0 0 5 0 0 02 in e Pull the choke lever fully and ensure that the choke cam turns the choke link D x lf the free play is incorrect adjust the choke cable 2 18 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Loosen the locknut A and turn the adjuster B until the cable has the proper amount of free play e Tighten the locknut against the adjuster securely Air Cleaner Element Cleaning NOTE Oln dusty areas the element should be cleaned mor
323. ngth 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 WARNING If the drive chain wear exceeds the service limit re place the chain or an unsafe riding condition may result A chain that breaks or jumps off the sprock ets could snag on the engine sprocket or lock the rear wheel severely damaging the motorcycle and causing it to go out of control For safely use only the standard chain It is an end less type and should not be cut for installation Standard Chain Make ENUMA Type EK520MVXL Link 112 Links 21st 6 04060651 PERIODIC MAINTENANCE 2 35 Periodic Maintenance Procedures Chain Guide Inspection e Visually inspect the chain guide A Replace the chain guide if it shows any signs of abnormal wear or damage 65128071 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 B xIf the brake fluid leaked from any position inspect or re place the problem par
324. ngth 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 6105040481 C 6105040581 C 6105040881 C CRANKSHAFT TRANSMISSION 9 17 Crankshaft and Connecting Rods 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 If connecting rod twist exceeds the service limit the con necting rod must be replaced Connecting Rod Twist Service Limit TIR 0 2 100 mm 0 008 3 94 in 6105040781 Connecting Rod Big End Side Clearance e Measure connecting rod big end side clearance Olnsert a thickness gauge A between the big end and ei ther crank web to determine clearance Connecting Rod Big End Side Clearance Standard 0 13 0 38 mm 0 0051 0 0150 in Service Limit 0 58 mm 0 023 in 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 Connecting Rod Big End Bearing Insert Crankpin Wear e Measure the bearing insert crankpin B
325. nip Retnoval rh e diee al ova eel versa Deed e e le e n RR d 3 87 Fuel Pump Installation 3 87 FUEL SYSTEM DFI 3 3 Operation 3 88 Operating Voltage Inspection bao Ate ee 3 88 Pressure Regulator Removal 3 89 Pump Screen Fuel Filter Cleaning pp 3 89 Fuel Pump Relay cere tenete tn b 3 90 Fuel Pump Relay 3 90 Fuel Pump Relay Inspection pp 3 90 CUO US rms 3 92 Removal 3 92 04161 1 EL aun 3 92 Power Source Voltage Inspection pp 3 92 Output Voltage 1 00 000 0 6 000000000000000000000 3 93 5 c pP 3 94 Injector Resistance Inspection pp 3 95 Injector Unit TSS wr LI rp ER 3 95 Injector Fuel Line Inspection cuire rto re nee 3 95 Throttle Grip and Cables u cte tht e t Ee e eee peto tit et ht edis 3 98 Free Play Inspection 3 98 Sam topo 3 98 eem A 3 98 G ableLubrieatighs 3 98 3 99 Free Pla
326. nserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle tighten the nut clockwise B up to next alignment Olt should be within 30 degree OLoosen once and tighten again when the slot goes past the nearest hole e Bend the cotter pin A over the nut A WARNING If the rear axle nut is not securely tightened or the cotter pin is not installed an unsafe riding condi tion may result 1407000851 6512013851 C 2 34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Wheel Alignment Inspection e Check that the notch A on the left alignment indicator B aligns with the same swingarm mark C or position 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 result in abnormal wear and may result in an unsafe riding condition Drive Chain Wear Inspection e Remove Chain Cover Bolts A Chain Cover B e Rotate the rear wheel to inspect the drive chain for dam aged rollers and loose pins and links x If 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 le
327. nsor trouble Inspect see chapter 3 Main throttle sensor trouble Inspect see chapter 3 Engine stalls easily Fuel pump trouble Inspect see chapter 3 Fuel injector trouble Inspect see chapter 3 Main throttle sensor trouble Inspect see chapter 3 Camshaft position sensor trouble Inspect see chapter 3 Fuel pressure too low or too high Inspect see chapter 3 Inlet air pressure sensor trouble Inspect see chapter 3 inspect see chapter 3 inspect see chapter 3 Inspect and repair see chapter 3 inspect see chapter 3 Inspect fuel pressure and replace fuel pump see chapter 3 inspect ses chapter 16 inspect see chapter 16 Compression Low Spark plug loose Reinstall see chapter 16 Cylinder head not sufficiently tightened down Tighten see chapter 5 No valve clearance Adjust see chapter 2 Cylinder piston worn Inspect and replace see chapter 5 Piston ring bad worn weak broken or sticking Inspect and replace see chapter 5 Piston ring groove clearance excessive Inspect and replace see chapter 5 Cylinder head gasket damaged Replace see chapter 5 Cylinder head warped Inspect and replace see chapter 5 Valve guide worn or stem seal damaged Inspect and replace see chapter 5 Valve spring broken or weak Inspect and replace see chapter 5 Valve not seating properly valve bent worn or carbon accumulating on sea
328. nstallation Front Caliper Disassembly Front Caliper Assembly Rear Caliper Disassembly Rear Caliper Assembly Caliper Fluid Seal Damage Rear Caliper Dust Boot and Friction Boot Damage Caliper Piston and Cylinder 12 2 12 6 12 7 12 8 12 8 12 8 12 8 12 8 12 9 12 10 Rear Brake Pad Removal Rear Brake Pad Installation Brake Pad Wear Inspection Master Cylinder Front Master Cylinder Removal Front Master Cylinder Installation Rear Master Cylinder Removal Rear Master Cylinder Installation Front Master Cylinder Disassembly pp Rear Master Cylinder Disassembly Master Cylinder Assembly Master Cylinder Inspection Brake Brake Disc Removal Brake Disc Installation Brake Disc Brake Disc Warp Brake Fluid pp Brake Fluid Level Inspection Brake Fluid Change Brake Line Bleeding Brake Brake Hose Removal Installation Brake Hose Inspection 12 14 12 15 12 15 12 15 12 16 12 16 12 16 12 17 12 17 12 17 12 17 12 17 PME 12 18 12 18 12 18 12 21 12 21 12 21
329. ntainer 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 the disc pads or disc be careful that no disc brake fluid or any oil gets on them Clean off any fluid or oil that inadvertently gets on the pads or disc with a high flash point solvent Do not use one which will leave an oily residue Replace the pads with new ones if they cannot be cleaned satisfacto rily Brake fluid quickly ruins painted surfaces any spilled fluid should be completely 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
330. o 2 journal B to determine clearance x lf the clearance exceeds the service limit replace the crankcase halves as a set NOTE OThe upper and lower crankcase halves are machined at the factory in the assembled state so the crankcase halves must be replaced as a set 6105019851 C Crankshaft Side Clearance Standard 0 05 0 20 mm 0 0020 0 0079 in Service Limit 0 40 mm 0 0157 in Crankshaft Runout 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 6105042081 Crankshaft 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 not turn the crankshaft during clearance measure ment S OJournal clearance less than 0 025 mm 0 00098 in can PIS RES not be measured by plastigage however using genuine parts maintains the minimum standard clearance Crankshaft Main Bearing Insert Journal Clearance Standard 0 020 0 044 mm 0 0008 0 0017 in Service Limit 0 07 mm 0 0028 in x If the clearance is within the standard no bearing replace ment is required x lf the clearance is between 0 045 mm 0 0018 in and the service limit 0 07 mm 0 0028 in re
331. o the materials of semi conductors Materials of Semi Conductor and Emitting Color Materials of Semi Conductor Emitting Color Red GaAlAs GaP Green GaN Blue Al Aluminum As Arsenic Ga Gallium N Nitrogen P Phosphorus GENERAL INFORMATION 1 17 Technical Information KAWASAKI LOW EXHAUST EMISSION SYSTEM Since the emission regulations become more severe Kawasaki has adopted a type of simplified KAWASAKI LOW EXHAUST EMISSION SYSTEM KLEEN which have no catalyst protection sys tem according to each regulation of different countries The muffler with built in catalyst has the same durability as the conventional muffler however do not use leaded gasoline and do not coast with the ignition system OFF Running the engine without ignition damages catalyst Refer to the ZX900E Service Manual Part No 99924 1255 for more information about the KLEEN theory maintenance and handling precautions including the secondary air injection system Honeycomb Type Catalytic Converter OThe converter is a three way catalytic converter and its surface is covered with alumina upon which platinum and rhodium are applied and has a cylindrical metallic honeycomb structure made by bending a corrugated sheet and a flat sheet of stainless steel into a spiral of increasing diameter The honeycomb structure is convenient for the catalytic converter because it has a large surface area but small size to react effectively and has l
332. oad tested at three times its amp hour rating for 15 seconds Re check voltage and if less than 12 6 volts repeat the charging cycle and load test If still below 12 6 volts the battery is defective Precautions 1 No need of topping up No 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 this chapter When a fast charge is inevitably required do it following precisely the maximum charge current and time conditions indicated on the battery CAUTION This battery is designed to sustain no unusual deterioration if refresh charged according to the method specified above However the battery s performance may be reduced no ticeably if charged under conditions other than given above Never remove the seal cap during refresh charge If by chance an excessive amount of gas is generated due to overcharging the relief valve releases the gas to keep the battery normal 3 When you do not use the motorcycle for months Give a refresh charge before you store the motorcycle and store it with the negative cable re moved Give a refresh charge once a month during storage 4 Battery life If t
333. 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 a cooling system leak It may be caused by exhaust gas leaking into the cooling system Coolant Level Inspection e Refer to the Coolant Change in the Periodic Maintenance 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 the fuel tank see Fuel System DFI chapter e Remove the radiator cap and install a cooling system pressure tester A on the filler neck B NOTE OWet the cap sealing surfaces with water or coolant to prevent pressure leaks e Build up pressure in the system carefully until the pres sure reaches 123 kPa 1 25 kgf cm 17 8 psi CAUTION During pressure testing do not exceed the pres sure for which the system is designed The maxi mum pressure is 123 kPa 1 25 kgf cm 17 8 psi e Watch the gauge for at least 6 seconds the pressure holds steady the system is all right x lf 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 insta
334. ock and disconnect CAUTION Never drop the throttle body assy especially on a hard surface Such a shock to the body assy can damage it e Remove Band A cut Screws B Delivery Pipe C Injectors D Fuel Injectors D x If necessary cut the straps A and take the harness B off the subthrottle valve actuator Throttle Body Assy Assembly OReplace the O rings A and seals B with the new ones e Before assembling blow away dirt or dust from the throttle body and delivery pipe by applying compressed air e Apply engine oil to the new O rings of each injector C insert them into the delivery pipe D and confirm whether the injectors turn smoothly or not e Install the injectors along with the delivery pipe assy into the throttle bodies E Torque Delivery Pipe Screws 3 4 N m 0 35 kgf m 30 in Ib e Insert the each hoses onto the throttle body fittings e Install the throttle body assy see Throttle Body Assy In stallation in the this chapter GC17156BS1 C 6617164851 C FUEL SYSTEM DFI 3 105 Air Cleaner Element Removal installation e Refer to the Air Cleaner Element Replacement in the Pe riodic 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 the element has any tears or breaks rep
335. of the level sensor mounting bolts and tighten it Torque Fuel Level Sensor Bolts 6 9 0 70 kgf m 61 in Ib Fuel Reserve Switch Inspection e Fill the fuel tank with fuel e Close the fuel tank cap surely e Remove Right Frame Cover see Frame chapter e Disconnect the fuel level sensor connector A 16 96 ELECTRICAL SYSTEM Switches and Sensors eConnect the test light 12 V 3 4 W bulb a socket with leads and the 12 V battery B to the fuel level sensor connector C Connections Battery 12 V 3 4 W Bulb one side 12 V 3 4 W Bulb other side Blue Lead Terminal Battery BK Y Lead Terminal x lf the test light turn on the reverse switch is defective Replace the fuel level sensor e Remove Fuel Level Sensor see Fuel Level Sensor Inspection e Connect the test light 12 V 3 4 W bulb in a 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 replace the fuel level sensor NOTE Olt may take a long time to turn on the test light in case that the fuel reserve switch is inspected just after the fuel level sensor is removed Leave the fuel reserve switch with leads for inspection connected for ten 10 minute GP18044BS1 Diode Rectifier Inspection e Remove the meter cover see Meter Removal e Cut the vinyl tape A
336. oint Connector D GP172708W2 C ELECTRICAL SYSTEM 16 73 Immobilizer System Equipped Models This motorcycle is equipped with an immobilizer system to protect the motorcycle from theft This system provides a theft 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 and sub throttle 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 e The FI indicator light illuminates for two seconds and then extinguishes when the ignition is first switched on This shows the system is operating correctly Olf the FI indicator light illuminates when the ignition switch is turned to the ON position and stays illuminated this shows a fault in the DFI system Olf the FI indicator light flashes when the ignition switch is turned to the ON position this shows the immobilizer system has a fault Refer to service code to identify the faulty component e The FI indicator light 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 ke
337. om hitting the crankcase 1 Bolt Length Measurement Method e Be sure to clean the bolts nuts and connecting rods thoroughly with a high flash point solvent because the new connecting rods bolts and nuts are treated with an anti rust solution A WARNING Clean the bolts nuts and connecting rods in a well ventilated area and take care that there is no spark or flame anywhere near the working area This in cludes any appliance with a pilot light Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents to clean them CAUTION Immediately dry the bolts and nuts with com pressed air after cleaning Clean and dry the bolts and nuts completely CRANKSHAFT TRANSMISSION 9 15 Crankshaft and Connecting Rods e Install new bolts in reused connecting rods e Dent both bolt head and bolt tip with a punch as shown e Before tightening use a point micrometer A to measure the length of new connecting rod bolts and record the val ues to find the bolt stretch Connecting Rod B Mark here with a punch C Nuts D Fit micrometer pins into punch marks E e Apply a small amount of molybdenum disulfide oil to the following Threads of Nuts and Bolts Seating Surfaces of Nuts and Con rods e Tighten the big end nuts until the bolt elongation reaches the length specified in the table e Check the length F of the connecting rod bolts x lf the stretch is more than the usab
338. on e Visually inspect the front forks A for oil leakage scoring or scratches on the inner surface of the inner tubes Replace or repair any defective parts if necessary PERIODIC MAINTENANCE 2 39 Periodic Maintenance Procedures e Visually inspect the shock absorber 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 rear portion of the motorcycle down and up 4 or 5 times and inspect the smooth stroke x If the rocker arm A does not smoothly stroke or noise is found inspect the fasteners and bearings see Suspen sion chapter Tie rod Operation Inspection e Pump the seat 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 Suspen sion chapter Steering System Steering Play Inspection e Lift the front wheel off the ground using the jack Special Tool Jack 5700 1238 e With the front wheel pointing straight ahead alternately tap each end of the handlebar The front wheel should swing fully left and right from the force of gravity until the fork hits the stop x If the wheel binds or catches before the stop the steering is too tight e Feel for steering looseness by pushing and pulling the forks x If you feel looseness the steering is too loose NOTE OThe cables and wiring wi
339. or B from the crankshaft Special Tools Flywheel Puller Assembly M38 1 5 M35 x 1 5 57001 1405 NOTE OScrew in the puller while tapping the head C of the puller with a hammer CAUTION Do not attempt to strike the alternator rotor itself Striking the rotor can cause the magnets to lose their magnetism Alternator Rotor Installation e Using a cleaning fluid clean off any oil or dirt on the fol lowing portions and dry them with a clean cloth Crankshaft Tapered Portion A Alternator Rotor Tapered Portion B e Apply a thin coat of molybdenum disulfide grease to the crankshaft C and the face D of the starter clutch gear GPO9045BS1 C GP09132BS1 6209054851 C ELECTRICAL SYSTEM 16 29 Charging System e Install the starter gear e Again clean the crankshaft tapered portion B and dry there e Fit the woodruff key C securely in the slot of the crank shaft before installing the alternator rotor e Install the alternator rotor A while turning B the starter clutch gear C e Install the washer A so that the chamfer side B faces outward NOTE OConfirm the alternator rotor fit or not to the crankshaft before tightening it with specified torque Olnstall the rotor and tighten it with 70 N m 7 0 52 ft lb of torque ORemove the washer and rotor bolt OCheck the tightening torque with rotor puller A xIf the rotor is not pu
340. or Removal CAUTION Do not tap the starter motor shaft or body Tapping the shaft or body could damage the motor e Slide back the rubber cap e Remove the starter motor terminal nut B e Remove the mounting bolts A e Pull out the starter motor B Starter Motor Installation CAUTION Do not tap the starter motor shaft or body Tapping the shaft or body could damage the motor e When installing the starter motor clean the starter mo tor legs A and crankcase B where the starter motor is grounded e Replace the O ring A with a new one e Apply grease to the O ring e Tighten Torque Starter Motor Mounting Bolts 11 1 1 kgf m 95 in Ib Starter Motor Disassembly e Take off the starter motor through bolts A and remove both end covers B and pull the armature out of the yoke C N A GB ELECTRICAL SYSTEM 16 49 Electric Starter System OThe brush plate A and brushes come off with the right hand end cover B e Remove the terminal locknut A and terminal bolt B and then remove the brush with the brush plate C from the right hand end cover Starter Motor Assembly e Install the brush plate and brushes A and then put the armature B among the brushes e Install the O rings A as shown e Align the notch A in the brush plate with the end cover notch B and the mark C on the yoke 16 50 ELECTRICAL SYS
341. ose of the same color 68020238 GENERAL INFORMATION 1 7 Model Identification ZR750 K1 United States and Canada Left Side View ZR750 K1 United States and Canada Right Side View 68038114 1 8 GENERAL INFORMATION Model Identification ZR750 K1 Europe Left Side View 68038169 P ZR750 K1 Europe Right Side View 68038110 P GENERAL INFORMATION 1 9 General Specifications Items ZR750 K1 Dimensions Overall Length Overall Width Overall Height Wheelbase Road Clearance Seat Height Dry Mass Curb Mass Front Rear Fuel Tank Capacity Performance Minimum Turning Radius Engine Type Cooling System Bore and Stroke Displacement Compression Ratio Maximum Horsepower Maximum Torque Carburetion System Starting System Ignition System Timing Advance Ignition Timing Spark Plug Cylinder Numbering Method Firing Order Valve Timing Inlet Open Close Duration Exhaust Open Close 2 080 mm 81 9 in 780 mm 30 7 in 1 180 mm 46 5 in 1 425 mm 56 1 in 165 mm 6 5 in 805 mm 31 7 in 199 kg 438 8 Ib 113 kg 249 2 Ib 109 kg 240 3 Ib 18 L 5 0 US gal 2 9 m 9 5 ft 4 stroke DOHC 4 cylinder Liquid cooled 68 4 x 50 9 mm 2 7 x 2 0 in 748 mL 45 64 cu in 11 3 1 81 kW 110 PS 911 000 r min rpm MY 80 kW 109 PS 11 000 r min rpm HR 78 2 kW 106 PS 11 000 r min rpm US CA
342. ottom Allen bolt e Hold the front fork horizontally in a vise e Hold the cylinder unit B with the special tools and tighten the bottom Allen bolt to secure the cylinder in place Torque Front Fork Bottom Allen Bolt 30 N m 3 1 kgf m 22 ft lb Special Tools Fork Cylinder Holder Handle 57001 183 D Fork Cylinder Holder Adapter 57001 1057 604013881 E e Pour in the specified type of oil see Front Fork Oil Change Inner Tube Outer Tube Inspection e Visually inspect the inner tube A and repair any nicks or rust by using an oil stone xIf the damage is not repairable replace the inner tube Since damage to the inner tube damages the oil seal slip replace the oil seal whenever the inner tube is repaired or replaced CAUTION 8 04172851 C If the inner tube is badly nicked or bent replace it Excessive bending followed by subsequent straightening can weaken the inner tube e Place the inner tube in the outer tube B and pump them back and forth manually to check for smooth operation If the movement is not smooth replace both the inner tube and the outer tube A WARNING Replace the inner and outer tubes with new ones if they are bent because it is dangerous to use them by repairing them Make sure to inspect the inner and outer tubes of the other side Dust Seal Inspection e Inspect the dust seal for any signs of deterioration or A
343. out of the usable range remove the fuel tank and check the wiring If the output voltage is 4 8 V the ECU is normal 9617821851 6017117851 C 6617822851 3 50 FUEL SYSTEM Inlet Air Pressure Sensor Service Code 12 x If the wiring is good check the sensor for various vacuum x If the output voltage for various vacuum is normal check the ECU for its ground and power supply see ECU sec tion e Remove the inlet air pressure sensor A and disconnect the vacuum hose from the sensor ODo not disconnect the sensor connector e Connect an auxiliary hose B to the inlet air pressure sen SOr e Temporarily install the inlet air pressure sensor OConnect a commercially available digital meter C vac uum gauge D the fork oil level gauge E and the har ness adapter to the inlet air pressure sensor Special Tools Fork Oil Level Gauge 57001 1290 Sensor Harness Adapter 57001 1561 Inlet Air Pressure Sensor Output Voltage Connection to Adapter Meter BL sensor Y BL lead Meter Y W sensor BR BK lead 6017119852 C the ignition switch ON OMeasure the inlet air pressure sensor output voltage from various vacuum readings while pulling the handle of the fork oil level gauge OCheck the inlet air pressure sensor output voltage using the following
344. oval e Remove the crankshaft sensor cover see Crankshaft Sensor Removal e Remove the timing rotor A OHolding the timing rotor with the flywheel and pulley holder B and remove the bolt C Special Tool Flywheel and Pulley Holder 57001 1605 Timing Rotor Installation e Fit the rotor to the crankshaft e Tighten the rotor bolt Torque Timing Rotor Bolt 39 N m 4 0 kgf m 29 ft Ib e Install the crankshaft sensor cover see Crankshaft Sen sor Installation Camshaft Position Sensor Removal e Remove Camshaft Position Sensor Lead Connector A Discon nect OPush the tongue B upside and take out the connector from the bracket e Remove Camshaft Position Sensor Bolt A Camshaft Position Sensor B Camshaft Position Sensor Installation e Apply grease or engine oil to the O ring on the camshaft position sensor e Apply a non permanent locking agent to the sensor bolt e Tighten Torque Camshaft Position Sensor Bolt 12 N m 1 2 kgf m 104 in Ib 16 40 ELECTRICAL SYSTEM Ignition System Camshaft Position Sensor Inspection e Remove Camshaft Position Sensor Lead Connector A Discon nect Set the hand tester to the x 10 range and connect it to the yellow and black leads in the connector Special Tool Hand Tester 57001 1394 x If 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 senso
345. ove Fuel Tank see Fuel System DFI chapter Thermostat Bracket Bolt A Clamp Bolt B Ground Lead C Water Temperature Sensor Connector D Water Hoses E e Remove the thermostat housing F e Remove the screws A take off the cap B and take out the thermostat Thermostat Installation e Install the thermostat A in the housing so that the air bleeder hole B is on top e Install a new O ring into the housing e Fill the radiator with coolant see Cooling System in the Periodic Maintenance chapter Thermostat Inspection e Remove the thermostat and inspect the thermostat valve A at room temperature xIf the valve is open replace the thermostat with new one A SS GD09004BS1 C 6009000851 C COOLING SYSTEM 4 15 Thermostat e To check valve opening temperature suspend the ther mostat A in a container of water and raise the tempera ture of the water OThe thermostat must be completely submerged and must not touch the container sides or bottom Suspend an ac curate thermometer B in the water so that the heat sen sitive portions C are located in almost the same depth It must not touch the container either x If the measurement is out of the specified range replace the thermostat with a new one Thermostat Valve Opening Temperature 58 62 C 136 144 F 6009020252 C 4 16 COOLING SYSTEM Hose and Pipes Hose Installation e
346. ow exhaust resistance In addition its inherent strength helps resist vibration and has simple structure welded directly on the silencer OGenerally the temperature of the exhaust gas must be higher than activation temperature so the converters are installed in the exhaust manifold rear end where the temperature of exhaust gas is still high And the converters will be activated even under low load conditions OAfter the exhaust gas is diluted with the secondary air injection the catalytic converter works well because of rich oxygen to reduce CO HC and NOx Accordingly we can keep the exhaust gas emission within regulation OThis type of converter works more efficiently as a three way catalytic converter to reduce CO HC and NOx than the pipe type catalytic converter because of its more and denser catalysts 6806172812 C 1 Manifold 2 Silencer 3 Honeycomb Type Catalyst 4 Mark for Manifold 5 Mark for Silencer 1 18 GENERAL INFORMATION Technical Information Immobilizer System Equipped Models Overview This system provides a theft proof device by means of matching a code between the inbuilt key transponder and the ECU Electronic Control Unit If this code does not match the fuel pump injec tors ignition system sub throttle valve actuator and exhaust butterfly valve actuator will not operate and the engine will not start Related Parts and Function GB06173BW3 C 1 Transponder Inside Keys 8 St
347. per trouble Other noise Bracket nut bolt etc mounted or tightened not properly Oil Pressure Warning Light Goes On Engine oil pump damaged Engine oil screen clogged Engine oil filter clogged Engine oil level too low Engine oil viscosity too low Camshaft bearing worn Crankshaft bearing worn Oil pressure switch damaged Wiring faulty Relief valve stuck open O ring at the oil passage in the crankcase damaged Exhaust Smokes Excessively White smoke Piston oil ring worn Cylinder worn Valve oil seal damaged Valve guide worn Engine oil level too high Black smoke Air cleaner clogged Brown smoke Air cleaner duct loose Air cleaner O ring damaged Air cleaner poorly sealed or missing Handling and or Stability Unsatisfactory Handlebar hard to turn Cable routing incorrect Hose routing incorrect Wiring routing incorrect Steering stem nut too tight Steering stem bearing damaged Steering stem bearing lubrication inade quate Steering stem bent Tire air pressure too low Handlebar shakes or excessively vibrates Tire worn Swingarm pivot bearing worn Rim warped or not balanced Wheel bearing worn Handlebar clamp bolt loose Steering stem nut loose Front rear axle runout excessive Engine mounting bolt loose Handlebar pulls to one side Frame bent Wheel misalignment Swingarm bent or twisted Swingarm pivot shaft runout excessive Steering maladjusted Front fork bent Right and left front fork oil level uneven Shock abso
348. place all seals every other time the pads are changed Rear Caliper Dust Boot and Friction Boot Damage e Remove the calipers see Front Rear Caliper Removal e Check that the dust boot A and friction boot B are not cracked worn swollen or otherwise damaged e If they show any damage replace them 6513047851 6105097851 C 6105098851 C 12 12 BRAKES Calipers Caliper Piston and Cylinder Damage e Visually inspect the piston A and cylinder surfaces B Replace the caliper if the cylinder and piston are badly scores or rusty Caliper Holder Shaft Wear The caliper body must slide smoothly on the caliper holder shaft 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 shaft are not badly worn or stepped and that the dust and friction boots are not damaged x lf the dust and friction boot are damaged replace them To replace the friction boot remove the pads and the caliper bracket x If the caliper holder shaft is damage replace the caliper bracket 9105117851 6105100851 C 6105101851 BRAKES 12 13 Brake Pads Front Brake Pad Removal e Remove the caliper from the disc B e Draw out the clip A and take off the pad pin B e Remove the pad C on the piston side e Pus
349. place 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 of the crankshaft main journal 6105041781 9 20 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods Crankshaft Main Journal Diameter Standard 32 984 33 000 mm 1 2986 1 2992 Service Limit 32 96 1 2976 If any journal has worn past the service limit replace the crankshaft with a new one x lf the measured journal diameters are not less than the service limit but do not coincide with the original diameter markings on the crankshaft make new marks on it Crankshaft Main Journal Diameter Marks None 32 984 32 992 mm 1 2986 1 2989 in 1 32 993 33 000 mm 1 2989 1 2992 in Crankshaft Main Journal Diameter Marks 1 or no mark Measure the main bearing inside diameter and mark the upper crankcase half in accordance with the inside diam eter Crankcase Main Bearing Inside Diameter Marks O or no mark e Tighten the crankcase bolts to the specified torque see Crankcase Assembly NOTE OThe mark already on the upper crankcase half should almost coincide with the measurement Crankcase Main Bearing Inside Diameter Marks O 36 000 36 008 mm 1 4173 1
350. place 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 without any maintenance if it is used under normal conditions COOLING SYSTEM 4 1 Cooling System Table of Contents Exploded View 4 2 Coolant Flow 4 4 SPOCCIICALI ONS 2 4 5 Special Tools and 4 6 4 7 Coolant Deterioration Inspectiom nennen nennen nnns 4 7 Coolant Level 4 7 Mere ABl 4 7 seid 4 7 i i MI iro 4 7 Cooling System itte SG 4 8 Coolant Reserve Tank Removal Installation pp 4 8 Water te ce need 4 9 Water Pump 4 9 Water Pump 4 9 Water Pump Inspection pp 4 9 Water Pump Impeller 4 9 Water Pump Impeller 4 9 Water Pump Housing Disassembly pp 4 9 Water Pump Housing Assembly
351. pter 3 Inlet air pressure sensor trouble Inspect see chapter 3 Atmospheric pressure sensor trouble Inspect see chapter 3 Inlet air temperature sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Conpressom Pull the lever in and shift the gear in neutral Inspect each switch see chapter 16 Inspect and repair or replace see chapter 3 Fuel pressure regulator trouble Piston ring bad worn weak broken or sticking Inspect and replace see chapter 5 Piston ring groove clearance excessive Inspect and replace see chapter 5 Cylinder head gasket damaged Replace see chapter 5 3 32 FUEL SYSTEM DFI System Troubleshooting Guide Symptoms or possible Causes Actions chapter Cylinder head warped Inspect and replace see chapter 5 No valve clearance Adjust see chapter 2 Valve guide worn Inspect and replace see chapter 5 Valve spring broken or weak Inspect and replace see chapter 5 Valve not propery valva Inspect and repair or replace see chapter 5 carbon accumulating on seating surface Poor Running at Low Speed Symptoms or Possible Causes Actions chapter Spark weak Inspect and charge see chapter 16 Replace see chapter 2 Inspect the stick coil see chapter 16 Reinstall or inspect stick coil See chapter 16 Replace it with th
352. r Special Tool Valve Guide Arbor 4 57001 1273 e Wait until the cylinder head cools down and then ream the valve guide with the valve guide reamer A even if the old guide is reused the reamer in a clockwise direction until the reamer turns freely in the guide Never turn the reamer counter clockwise or it will be dulled OOnce the guides are reamed they must be cleaned thor oughly Special Tool Valve Guide Reamer 4 57001 1274 Valve to Guide Clearance Measurement Wobble Method If a small bore gauge is not available inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below e Insert a new valve A into the guide B and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface e Move the stem back and forth C to measure valve valve guide clearance e Repeat the measurement in a direction at a right angle to the first x If the reading exceeds the service limit replace the guide NOTE OThe reading is not actual valve valve guide clearance because the measuring point is above the guide Valve Valve Guide Clearance Wobble Method Standard Exhaust 0 09 0 18 mm 0 0035 0 0071 in Inlet 0 03 0 12 mm 0 0012 0 0047 in Service Limit Exhaust 0 40 mm 0 016 in Inlet 0 33 mm 0 013 in GE15046BS1 C GE15007BS2 C ENGINE TOP END 5 23 Valves
353. r BR BK lead Standard 4 75 5 25 V DC e Turn the ignition switch OFF xIf the input voltage is normal check the sensor output voltage x If the input voltage is less than the standard remove the ECU and check the wiring between these connectors ODisconnect the ECU and sensor connectors Wiring Connection ECU Connector A Throttle Sensor Connector B BL lead ECU terminal 1 BR BK lead ECU terminal 14 ECU Connector A Throttle Sensor Connector B Immobilizer Equipped Models C BL lead ECU terminal 17 BR BK lead ECU terminal 20 the wiring is good check the ECU for its ground and power supply see ECU section 0617815852 C 3 46 FUEL SYSTEM Throttle Sensor Service Code 11 Output Voltage Inspection e Measure the output voltage at the main throttle sensor in the same way as input voltage inspection Note the following e Disconnect the main throttle sensor gray Connector and connect the harness adapter A between these connec tors Special Tool Throttle Sensor Harness Adapter 57001 1538 e Start the engine and warm it up thoroughly e Check idle speed to ensure the throttle opening is correct Idle Speed Standard 1 100 50 r min rpm x lf the idle speed is out of the specified range adjust it see Idle Speed Inspection in the Periodic Maintenance chapter e Turn off the ignition switch e Measure the output
354. r Cap Inspection e Remove Fuel Tank see Fuel System DFI chapter Radiator Cap 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 sealing surfaces with water or coolant to prevent pressure leaks Watching the pressure gauge pump the pressure tester to build up the pressure until the relief valve opens the gauge needle flicks downward Stop pumping and mea sure leak time at once The relief valve must open within the specified range in the table below and the gauge hand must remain within the same range at least 6 seconds Radiator Cap Relief Pressure Standard 93 123 kPa 0 95 1 25 kgf cm 14 17 8 psi If the cap can not hold the specified pressure or if it holds too much pressure replace it with a new one Radiator Filler Neck Inspection e Remove the fuel tank see Fuel System DFI chapter e Remove the radiator cap e Check the radiator filler neck for signs of damage e Check the condition of the top and bottom sealing seats A in the filler neck They must be smooth and clean for the radiator cap to function properly 6007013851 C GD07001BS1 C 4 14 COOLING SYSTEM Thermostat Thermostat Removal e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Rem
355. r Connector C Free OFor California model free the separator e Move A the air cleaner housing backwards e Pull B the throttle body assy out of the holders C 3 102 FUEL SYSTEM Throttle Body Assy e Slide A the throttle body assy leftside and remove it e Loosen the locknut and screw in the throttle cable adjuster fully to give the cables plenty of play e Remove the right handlebar switch housing and take out the accelerator cable upper end A and the decelerator cable upper end B e Remove the throttle cable lower ends A from the throttle pulley e After removing the throttle body assy stuff pieces of lint free clean cloth into the throttle body holders CAUTION If dirt gets into the engine excessive engine wear and possible engine damage will occur Throttle Body Assy Installation e Install the holder clamp bolts A in the direction shown with each bolt heads facing outwards Cylinder Head B e Tighten Torque Throttle Body Assy Holder Clamp Bolts 2 0 N m 0 20 17 in Ib 6617162851 C FUEL SYSTEM DFI 3 103 Throttle Body Assy e Tighten Torque Air Cleaner Duct Clamp Bolts A 2 0 N m 0 20 kgf m 17 in Ib e Run the vacuum hoses see Cable Wire and Hose Rout ing section in the Appendix chapter e Connect the injector and subthrottle valve actuator con nectors e Run the choke cable A into the hole B of the thro
356. r Light Ze 22 52 3 Right Turn Signal Indicator Light 4 T T T 4 Neutral Indicator Light 85 8 5 011 pressure Warning Indicator Light F zo 6 Tachometer Light 7 Tachometer 8 Speedo Tachometer Light 9 Speedometer 16 Speedometer Light Water Temperature Warning Indicator Light LED 12 Indicator Light LED 13 0doneter Trip WeterA B Glack 14 Fuel Level Gauge Right Switch 5 BR Housing i Front Brake TETTE gnition R BL Light Switch egulator Switch R Entia Et Rectifier pirum x Engine Stop 8 6 Switch er Starter Button Front Right Turn Signal Light 12V10y RA Light lt 12 5 ent Headlight ti 12V55y Headlight L0 M 12 56 Front Left Tura Signal E dis Left Switch Housing Light 12V10W 1 Button Joint Connector 2 Hazard Button 3 Turn Signal Switch 4 Dimmer Switch S Starter Lockout Switch LEFT SWITCH HOUSING CONNECTIONS Hazard Button Turn Signal Switch Dimmer Switch Starter Lockout Switch LIU CHUTE LE Main Relay Junction Box ACO Fuse Radiator 1 104 2 Fan Fuse 10A 3 Headlight Fuse 10A 4 Headlight Relay 5 Taillight Fuse 10A 6 lgniton Fuse 10A 7 Horn Fuse 10 B Starter Circuit Relay 9 Turn Signal Relay Fuse 10A W2L0173AW5 C ELECTRICAL SYSTEM 16 13 Wiring Diagram United State
357. r Pipes A e Apply a non permanent locking agent Torque Water Pipe Bolts B 11 N m 1 1 kgf m 95 in Ib Fe 00008101 P ENGINE LUBRICATION SYSTEM 7 13 Oil Pump Oil Pump Drive Gear Removal e Remove Clutch see Clutch chapter Oil Pan see Oil Pan Removal Circlip A Oil Pump Drive Gear B and Washer C Special Tool Outside Circlip Pliers 57001 144 Oil Pump Drive Gear Installation e Apply molybdenum disulfide oil solution to the journal por tions A on the oil pump gear shaft B Install Washers C e Install the new circlip D into the groove of the oil pump drive gear shaft Special Tool Outside Circlip Pliers 57001 144 6009030851 C 7 14 ENGINE LUBRICATION SYSTEM Oil Pressure Measurement Oil Pressure Measurement e Remove the oil passage plug and attach the adapter and gauge B to the plug hole Special Tools Oil Pressure Gauge 10 kgf cm 57001 164 Oil Pressure Gauge Adapter PT3 8 x 19 in 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 immediately x If the reading is much higher than the standard check the oil passages for clogging Oil Pressure Standard 255 314 kPa 2 6 3 2 kgf cm 37 46 psi 4 000 r min rpm oil temperature
358. r 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 57001 241 A Valve Spring Compressor Adapter 6020 57001 1154 B 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 Closed Coil End D Valve Spring White E Retainer F Split Keepers G Valve Guide Removal e Remove Valve see Valve Removal Oil Seal Spring Seat e Heat the area around the valve guide to 120 150 C 248 302 F and hammer lightly on the valve guide arbor A to remove the guide from the top of the head CAUTION Do not heat the cylinder head with a torch This will warp the cylinder head Soak the cylinder head in oil and heat the oil Special Tool Valve Guide Arbor 4 57001 1273 GE15043BS1 C GE15028BS1 C GE15045BS1 C 5 22 ENGINE TOP END Valves Valve Guide Installation e Apply oil to the valve guide outer surface before installa tion e Heat the area around the valve guide hole to about 120 150 C 248 302 F e Drive the valve guide in from the top of the head using the valve guide arbor The flange stops the guide from going in too fa
359. r coil is shorted and must be replaced Camshaft Position Sensor Resistance 400 460 Q 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 lt indicates a short necessitating replacement of the camshaft position sen sor Camshaft Position Sensor Peak Voltage Inspection e Remove Fuel Tank see Fuel System DFI chapter Camshaft Position Sensor Lead Connector A Discon nect e Set the hand tester B to the 10 V DC range e Connect the peak voltage adapter C to the hand tester and camshaft position sensor leads in the connector Special Tools Hand Tester 57001 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Connections Camshaft Position Sensor Lead Adapter Hand Tester Black Red EN Yellow 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 e Repeat the measurement 5 or more times Camshaft Position Sensor Peak Voltage Standard 0 2 V or more x If the peak voltage is lower than the standard inspect the camshaft position sensor ELECTRICAL SYSTEM 16 41 Ignition System Stick Coil Ignition Coil together with Spark Plug Cap Removal e Remove the fuel tank see Fuel System D
360. r runs out any time during the changing operation the brakes will need to be bled since air will have entered the brake line OFront Brake Repeat the above steps for the other caliper ORear Brake Repeat the above steps for the other bleed valve 0513052852 C 2 54 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Follow the procedure below to rear brake fluid reservoir cap correctly OFirst tighten the rear brake fluid reservoir cap B clock wise C by hand until slight resistance is felt indicating that the cap is seated on the reservoir body then tighten the cap an additional 1 6 turn D while holding the brake fluid reservoir body A e Tighten the bleed valve and install the rubber cap Torque Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib e After changing the fluid check the brake for good braking power no brake drag and no fluid leakage x If necessary bleed the air from the lines Master Cylinder Rubber Parts Replacement Front Master Cylinder Disassembly e Remove the front master cylinder see Brakes chapter e Remove the reservoir cap and diaphragm and pour the brake fluid into a container e Unscrew the locknut and pivot bolt and remove the brake lever e Pull the dust cover A out of place and remove the circlip B Special Tool Inside Circlip Pliers 57001 143 e Pull out the piston C secondary cup D primary cup E and return spring F CAUTION Do not remove t
361. r the separate tube 13 Clip 17 26 APPENDIX Troubleshooting Guide NOTE ORefer to the Fuel System chapter for most of DFI trouble shooting guide OThis is not an exhaustive list giving every possible cause for each problem listed It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties Engine Doesn t Start Starting Difficulty Starter motor not rotating Starter lockout switch or neutral switch trou ble Starter motor trouble Battery voltage low Starter relay not contacting or operating Starter button not contacting Wiring open or shorted Ignition switch trouble Engine stop switch trouble Fuse blown Starter motor rotating but engine doesn t turn over Starter clutch trouble Starter idle gear trouble Vehicle down sensor DFI coming off Immobilizer system trouble Engine won t turn over Valve seizure Valve lifter seizure Cylinder piston seizure Crankshaft seizure Connecting rod small end seizure Connecting rod big end seizure Transmission gear or bearing seizure Camshaft seizure Starter idle gear seizure No fuel flow No fuel in tank Fuel pump trouble Fuel tank air vent obstructed Fuel filter clogged Fuel line clogged Engine flooded Clean spark plug and adjust plug gap Starting technique faulty When flooded do not crank the engine with the throttle fully opened This promotes engine flood because more fuel is supplied automatically by DFI No spark
362. r wall of the cylinder e Apply silicone grease ex PBC grease Brake Lever Pivot Bolt Brake Lever Pivot Contact Push Rod Contact Dust Covers e Tighten Torque Brake Lever Pivot Bolt 1 0 N m 0 10 kgf m 9 in Ib Brake Lever Pivot Bolt Locknut 5 9 N m 0 60 kgf m 52 in Ib 2 56 PERIODIC MAINTENANCE Periodic Maintenance Procedures Caliper Rubber Parts Replacement Front Caliper Disassembly e Remove Front Caliper see Brakes chapter Brake Pads e Using compressed air remove the pistons OCover the piston area with a clean thick cloth A OBlow compressed air B into the hole for the banjo bolt to remove the piston A WARNING To avoid serious injury never place your fingers or palm in front of the piston If you apply compressed air into the caliper the piston may crush your hand or fingers OPull out the pistons by hand e Remove the dust seals A and fluid seals B e Remove the bleed valve C and rubber cap D NOTE compressed air is not available with the brake hose still attached apply the brake lever to remove the pis ton The remaining process is as described above Front Caliper Assembly 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 Torque Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib e Replace the fluid seals A
363. ra a a a eA eaa a a e aAa aaae a eA aaa a A OaE Eaa 9 6 Special Tools and 9 8 CGrank ase Splitting misisse a a a aA AE teet 9 9 Splitting mE 9 9 Crankcase Assetfmbly e ped ha x dere ai KE 9 9 Crankshaft and Connecting us 9 12 Crankshatt Removal interrete eer ele eraot 9 12 Crankshaft Installation pe 9 12 Connecting Rod e ER dnl One 9 12 Connecting 1 amp 1 9 12 Crankshaft Connecting Rod 9 16 Connecting Rod tot es esed a 9 16 Connecting Rod TWISL uei eo E Hania reatu o epi ee d d be a ats 9 17 Connecting Rod Big End Side Clearance pp 9 17 Connecting Rod Big End Bearing Insert Crankpin 9 17 Crankshaft Side 9 19 9 19 Crankshaft Main Bearing Insert Journal Wear 9 19 nm LP 9 21 Shift Pedal REMOVAL 9 21 Shift Pedal Installation aa 0 9 21 External Shift Mechanism Removal pp 9 22 External Shift Mechanism Installation pp 9 23 External Shift Mechanism Inspection pp 9 23 Transmission Shaft
364. racks 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 beyond the raised rib of the pipe 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 these hoses with a mini mum of bending so that the emission flow will not be ob structed 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 side stand x 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 ad
365. rake GK05035BS1 C e Tighten Torque Engine Sprocket Nut 125 13 kgf m 92 ft Ib Engine Sprocket Cover Bolts 9 8 N m 1 0 kgf m 87 16 e Adjust the drive chain slack after installing the sprocket see Periodic Maintenance chapter 11 12 FINAL DRIVE Sprocket Coupling Rear Sprocket Removal e Remove the rear wheel see Wheels Tires chapter CAUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground e Remove the rear sprocket nuts e Remove the rear sprocket 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 lb e Install the rear wheel see Wheels Tires chapter Coupling Bearing Removal e Remove Coupling Grease Seal Circlip A Special Tool Inside Circlip Pliers 57001 143 GK05034BS1 C e Remove the bearing A by tapping from the wheel side Special Tool Bearing Driver Set 57001 1129 B Coupling Bearing Installation e Replace the bearing with a new one e Press in the bearing A until it is bottomed Special Tool Bearing Driver Set 57001 1129 B e Replace the circlip with a new one Special Tool Inside Circlip Pliers 57001 143 GK05038BS1 C FINAL DRIVE 11 13 Sprocke
366. ral Pulled in Starts Continue running Released Doesn t start Continue running Up In Gear Pulled in Starts Continue running Down Neutral Released Starts Continue running F Down Neutral Pulled in Starts Continue running Down In Gear Released Down In Gear Pulled in Doesn t start Start Stops Continue running GENERAL INFORMATION 1 15 Technical Information Tail Brake Lights Employing LED Outline This model employs tail brake light containing 9 Light Emitting Diodes LED The LED emits lu minous beams over a longer life span than those emitted from a traditional electric heated bulb more than 5 times longer uses lower voltage expends lower wattage approx 1 5 and is quicker respon sing Due Position of LED Installation The resistors the diodes and the Zener diodes are mounted in the electronic circuits A of the LED which supplies the steady current and voltage to the light Light Emitting Diode LED The Light Emitting Diode LED A is an element of semi conductor diode that converts applied voltage to light The LED emits luminous beams by the collision of nega tive charge electrons A and positive charge holes B when applied the forward voltage and current to the PN junction diode C 6806090851 C 1 16 GENERAL INFORMATION Technical Information Tail Brake Lights Employing LED The emitting color differs according t
367. replace fuel pump see chapter 3 Inspect and repair see chapter 16 Fuel pump trouble Inspect see chapter 3 Fuel injector trouble Inspect see chapter 3 Inlet air temperature sensor trouble Inspect see chapter 3 Atmospheric pressure sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Subthrottle sensor trouble Inspect see chapter 3 Subthrottle valve actuator trouble Inspect see chapter 3 Stick coil trouble Inspect and replace see chapter 16 Engine oil level to high Repair see chapter 7 Spark plug dirty broken or gap maladjusted Replace see chapter 2 Stumble Too low fuel pressure Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Subthrottle valve actuator trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Inlet air pressure sensor trouble Inspect see chapter 3 Fuel pressure regulator trouble Inspect and Unstable fuel pressure replace fuel pump or kinked fuel line Inspect and repair fuel line see chapter 3 Fuel injector trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Backfiring when deceleration Spark plug dirty broken or gap maladjusted Replace see chapter 2 Too low fuel pressure Inspect see chapter 3
368. requiring fuel pressure inspection see Fuel Line section in this chapter OThe click interval becomes shorter as the engine speed rises x If any injector s doesn t click the DFI circuit or the injector is suspect Perform Power Source Voltage Inspection first Power Source Voltage Inspection e Remove the ECU see ECU section ODo not disconnect the ECU connector e Connect a digital meter A to the ECU connector B us ing the needle adapter C Special Tool Needle Adapter Set 57001 1457 OMeasure the power source voltage with the engine stopped and with the connector joined e Turn the ignition switch ON Injector Power Source Voltage at ECU Connections Meter W Y terminal 13 Meter gt Battery Terminal Connections Immobilizer Equipped Models Meter W Y terminal 11 Meter Battery Terminal Service Limit Voltage 12 6 V or more x If the meter doesn t read as specified check the following Main Fuse 30 A see Electrical System chapter Fuel Pump Relay see DFI Power Source section Power Source Wiring see Wiring Diagram below OTo check the W R leads between the injector connector and the fuel pump relay remove the fuel tank see Fuel Tank Removal and the seat cover see Frame chapter xIf the power source voltage is normal check the output voltage of the injectors 6617189851 C 6C17266BS1 6617845851
369. reserve tank As soon as pressure escapes the valve closes and keeps the pressure at 93 123 kPa 0 95 1 25 kgf cm 14 17 8 psi When the engine cools down another small valve vacuum valve in the cap opens As the coolant cools the coolant contracts to form a vacuum in the system The vacuum valve opens and allows the coolant from the reserve tank to enter the radiator COOLING SYSTEM 4 5 Specifications Item Standard Coolant Provided when Shipping Type Recommended Color Mixed Ratio Freezing Point Total Amount Permanent type of antifreeze soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators Green Soft water 50 coolant 50 35 C 31 F 2 9 L 3 1 US qt reserve tank full level including radiator and engine Radiator Cap Relief Pressure 93 123 kPa 0 95 1 25 kgf cm 14 17 8 psi Thermostat Valve Opening Temperature Valve Full Opening Lift 58 62 C 136 144 F 8 mm 0 31 in or more 75 C 167 F 4 6 COOLING SYSTEM Special Tools and Sealant Bearing Driver 32 Kawasaki Bond Silicone Sealant 57001 382 56019 120 875601205 C Bearing Driver Set 57001 1129 7571129ST C COOLING SYSTEM 4 7 Coolant Coolant Deterioration Inspection e Remove the left side cover see Frame chapter e Visually inspect the coolant A in the reserve tank whitish cotton like wafts are
370. ricate with Rust Inhibitor Choke Cable Throttle Cables Clutch Cable e Lubricate the cables by seeping the oil between the cable and housing OThe cable may be lubricated by using a commercially available pressure cable lubricator with an aerosol cable lubricant 6004011481 C e With the cable disconnected at both ends the cable should move freely A within the cable housing x If cable movement is not free after lubricating if the cable gt is frayed B or if the cable housing is kinked C replace 4 the cable A 3 AAA lt 6004020281 PERIODIC MAINTENANCE 2 47 Periodic Maintenance Procedures 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 x lf there are loose fasteners retighten them to the spec ified torque following the specified tightening sequence Refer to the appropriate chapter for torque specifications If torque specifications are not in the appropriate chapter see the Standard Torque Table in this section For each fastener first loosen it by 1 2 turn then tighten it x If cotter pins are damaged replace them with new ones Bolt Nut and Fastener to be checked Wheels Front Axle Front Axle Clamp Bolt Rear Axle Nut Rear Axle Nut Co
371. riterion The light LED should light x lf the light LED does not go on replace the meter unit Fl Indicator light LED Circuit on PARK IGNITION O BR BR BATTERY CO 63 W 80178486842 C ECU Ignition Switch Fl Indicator LED Light Ignition Fuse 10 A Junction Box Starter Relay Main Fuse 30 A Joint Connector C Battery 12 V 8 Ah Terminal 25 Immobilizer Equipped Models ECU Power Source Circuit Ground 3 80 FUEL SYSTEM DFI ECU CAUTION Never drop the ECU especially on a hard surface Such a shock to the ECU can damage it ECU Removal e Remove Seat see Frame chapter Junction Box A e Take the ECU A out along with the harness OFor immobilizer equipped models refer to the ECU Re moval in the Electrical System chapter e Disconnect the ECU lead connectors B ECU Installation e Connect the ECU connectors noting the length of the locks Longer Lock A Shorter Lock B OFor immobilizer equipped models refer to the ECU Instal lation in the Electrical System chapter 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 harness connectors are cracked bent or otherwise dam aged Replace ECU if the terminals of the ECU connectors are cra
372. rm OScrew the needle bearing driver A into the driver holder B 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 s Pressing Depth D NOTE OFor a bearing of inner diameter 18 select the pressing side of the needle bearing driver according to its press ing depth 512 701451 Special Tools Bearing Driver Set 57001 1129 Needle Bearing Driver 417 018 57001 1609 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 rod H Rocker Arm I lt 7 530 4mm LU IE EL H 6 07033 2 C SUSPENSION 13 25 Tie rod 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 locker 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 x If there is any doubt as to the condition of any of the nee dle bearings or sleeve replace the sleeve and needle bearings as a set Rocker Arm Tie rod Bearing Lubr
373. rminals OSet the tester to the x 1 O range and read the tester e Measure the secondary winding resistance B as follows OConnect the tester between the plug terminal and coil terminal OSet the tester to the x 1 kO range and read the tester Ignition Coil Winding Resistance Primary Windings 1 04 1 56 O Secondary Windings 10 8 16 2 xIf 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 ELECTRICAL SYSTEM 16 43 Ignition System eRemove the stick coils see this chapter but do not re move the spark plugs Measure the primary peak voltage as follows OConnect a commercially peak voltage adapter B into the hand tester C which is set to the x 250 V DC range OConnect the adapter to the lead wire peak voltage adapter A which is connected between the stick coil connector and stick coil Olnstall the new spark plug D into each stick coil E and ground them onto the engine ECU F Battery G Special Tools Hand Tester 57001 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Lead Wire Peak Voltage Adapter 57001 1449 Primary Lead Connection Adapter R to lead wire peak voltage adapter W Adapter BK to lead wire peak voltage adapter R A WARNING To avoid extremely high voltage shocks do not touch the spark plugs or tester connections e Turn the ignit
374. rminals in the same man ner as specified in the Liquid Crystal Display LCD Seg ments Check e Set the hand tester to the DC 25 V range and connect it to the terminals 12 and 9 x If the voltage is less than 8 V replace the meter assembly Odometer Check e Check the odometer with the speedometer in the same way x If value indicated in the odometer is not added replace the meter assembly NOTE OThe data is maintained even if the battery is discon nected OWhen the figures come to 999999 they are stopped and locked Trip A B Meter Check e Check the trip A B meters with the speedometer in the same way x If value indicated in the trip B meters not added replace the meter assembly e Check that when the RESET button is pushed for more than two seconds the figure display turns to 0 0 x If the figure display does not indicate 0 0 replace the me ter assembly Water Temperature Warning Indicator Light LED Meter Check e Connect the 12 V battery and terminals in the same man ner as specified in the Liquid Crystal Display LCD Seg ments Check e Connect the variable rheostat A to the terminal 8 as shown e Check that the on or flash of warning indicator light B matches the resistance value of the variable rheostat Resistance Value 0 Warning Indicate 15 2 212 Flash e If any display function does not work replace the meter assembly 00
375. rods e First tighten the nuts to the specified torque See the table below e Next tighten the nuts 120 5 OMark A the connecting rod big end caps and nuts so that nuts can be turned 120 B properly OTighten the hexagon nut by 2 corners Connect ing Rod Assy Torque Angle kgf m ft Ib Use the bolts Attached to attached to new con rod new con rod 20 2 0 14 5 120 Replace the 24 2 4 17 4 120 Used bolts with new ones 18 1 8 13 0 120 New 25 2 6 18 8 120 Crankshaft Connecting Rod Cleaning e After removing the connecting rods from the crankshaft clean them with a high flash point solvent e Blow the crankshaft oil passages with compressed air to remove any foreign particles or residue that may have accumulated in the passages Connecting Rod Bend e Remove the connecting rod big end bearing inserts and reinstall the connecting rod big end cap e Select an arbor A of the same diameter as the connect ing rod big end and insert the arbor through the connect ing rod big end e Select an arbor of the same diameter as the piston pin and at least 100 mm 3 94 in long and insert the arbor B through the connecting rod small end e On a surface plate set the big end arbor on V block C e With the connecting rod held vertically use a height gauge to measure the difference in the height of the arbor above the surface plate over a 100 mm 3 94 in le
376. roducts 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 2004 Kawasaki Heavy Industries Ltd First Edition 1 Nov 8 2004 M LIST OF ABBREVIATIONS A ampere S 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 degree s Celsius r revolution DC direct current rom 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 Q ohm s L liter s Read OWNER S MANUAL before operating EMISSION CONTROL INFORMATION To protect the environment in which we all live Kawasaki has incorporated crankcase emis sion 1 and exhaust emission 2 control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board Addi tionally Kawasaki has incorporated an evaporative em
377. rom the throttle vacuum inlet air pressure sensor output voltage and engine speed crankshaft sensor output voltage This method is called D J method low speed mode As the engine speed increases and the engine load turns middle to heavy the ECU determines the injection quantity by calculating from the throttle opening throttle sensor output voltage and the engine speed This method is called a N method high speed mode This depends on the number of stopped cylinders FUEL SYSTEM DFI 3 45 Main Throttle Sensor Service Code 11 Main Throttle Sensor Removal Adjustment CAUTION Do not remove or adjust the main throttle sensor A since it has been adjusted and set with precision at the factory Never drop the sensor especially on a hard surface Such a shock to the sensor can damage it Main Throttle Sensor Connector Gray B Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Disconnect the main throttle sensor gray Connector and connect the harness adapter A between these connec tors e Connect a digital meter to the harness adapter lead Special Tool Throttle Sensor Harness Adapter 57001 1538 e Measure the sensor input voltage with the engine stopped and with the connector joined e Turn the ignition switch ON Main Throttle Sensor Input Voltage Connections to Adapter Meter R sensor BL lead Meter BK senso
378. rption unsatisfactory Too hard Front fork oil excessive Front fork oil viscosity too high Rear shock absorber adjustment too hard Tire air pressure too high Front fork bent Too soft 17 30 APPENDIX Troubleshooting Guide 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 lead 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 JKAZRDK105A025001 2005 ZR750 K1 ZR750K 000001 JKAZR750JKA025001 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 1344 01 Printed in Japan
379. ry 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 Wattage M ue 15 21 23 140 250 2 42 46 75 95 Cycle s per minute Corrected to one light burned out 8 12040251 ELECTRICAL SYSTEM 16 59 Radiator Fan System Fan System Circuit Inspection e Disconnect the lead connector A from the radiator fan switch e Using an auxiliary wire A connect the radiator fan switch leads x If the fan rotates inspect the fan switch x If the fan does not rotate inspect the following Leads and Connectors Main Fuse and Fan Fuse Fan Motor Fan Motor Inspection e Remove the fuel tank see Fuel System DFI chapter e Disconnect the 2 pin connector A in the fan motor leads OPull the lead until come out the connector e Using two auxiliary wires A supply battery B power to the fan motor x If the fan does not rotate the fan motor is defective and must be replaced Radiator Fan Switch Inspection e Disconnect the connector A 16 60 ELECTRICAL SYSTEM Radiator Fan System e Slide out the dust cover A e Remove the fan switch B e Suspend the switch A in a container of coolant so that the temperature sensing projection and threaded portion are submerged e Suspend an accurate thermometer B in the coolant
380. s 7 9 Oil Pressure Relief 7 10 Oil Pressure Relief Valve Removal eene 7 10 Oil Pressure Relief Valve Installation 4 7 10 Oil Pressure Relief Valve Inspection me 7 10 er giao Ln rM 7 11 Oil Purip RernoVal ee e eh s t e eee id 7 11 Oil Pump Installation cct ertet teaser hr e eg 7 11 Oil Pump Drive Gear Removal 7 13 Oil Pump Drive Gear Installationm 7 13 Oil Pressure Measurement 7 14 Oil Pressure Measurement pp 7 14 Oil Pressure 7 15 Oil Pressure Switch 7 15 Oil Pressure Switch Installation mmn 7 15 7 2 ENGINE LUBRICATION SYSTEM Exploded View ENGINE LUBRICATION SYSTEM 7 3 Exploded View Torque No Fastener kaf 16 1 Filler Plug 1 5 0 15 13 in Ib 2 Engine Oil Drain Bolt 29 3 0 21 3 Oil Filter 31 3 2 23 EO R 4 Holder Mounting Bolt 76 7 8 56 EO 5 Oil Pan Bolts 11 1 1 95 in lb 6 Pipe Holder Bolts 3 113 in Ib Cr Vane sas s t 8 15 18 M ss 9 oi Pressure SwichTemimaBot 15 015 in 10 WaterPumpCowerBols n 14 T WatrPumpimpeler amp o os 10 Coolant Drain Plug Water Pump 11 11 inb EO Apply engine oil G Apply grease L Apply a non permanent locking agent MO Apply molybdenum disulfide o
381. s and Water Temperature Fuel Injectors ub Main Inlet Air Atmospheric Sensorlnlet Air 1 2 3 4 throttle Throttle Speed Camshaft Temperature Pressure Sensor Sensor SensorPostion Sensor ressure 2 Sensor Pressure Crank Side Switch shaft Stand S 9 fal Neutral Seiten BR BK BR BK BR BK Joint Connector D 1 Ground 2 Frame Ground BL R gc Alternator wy Electronic Control Unit R ECU l IL LL dL LI P BL BK BL R BL 6 R Y iUm kis Sn License Plate Light 1258 ai 4 Rear Right BK Y BK Y Turn Signal Light 12V 0W HH Tail Brake LH BK Y BK Y te Light LED Kawasaki 12 0 5 3 8 Self diagnositic System wy BK Y vt Rear Left BK Y SK Y BK Y Turn Signal n VY 5 9 Light 12V10W ecu wt Fuse Joint 15 Connector an diagnosis T HEEL SA Indicator Sa Terminal BY 2 958 starter 5 HM BK Y Joint Connector Turn Vehicle Battery Signal down 12V8Ah Engine Relay Sensor Ground Fuel Pump Relay Starter Motor Wain Fuse trey 304 9 tane Pix Front Brake Light Switch Engine Stop Switch Starter Button Purple Brake Lever OFF
382. s 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 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 OWhenever the DFI electrical connections are to be dis connected first turn off the ignition switch and disconnect the battery terminal Do not pull the lead only the con nector Conversely make sure that all the DFI electrical connections are firmly reconnected before starting the en gine OConnect these connectors until they click A Olf a transceiver is installed 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 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 any fuel hose is disconnected do not turn on the ignition switch Otherwise the fuel pump will operat
383. sconnect the negative cable first e Remove the battery Battery Installation e Apply a light coat of grease on the terminals to prevent corrosion e Install the positive cable A first e Cover the terminal with the cap B e Install the negative cable C 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 ZR750 K1 YTX9 BS CAUTION Be sure to use the electrolyte container with the same model name as the battery since the elec trolyte volume and specific gravity vary with the battery type This is to prevent overfilling of the electrolyte shorting the battery life and deteriora tion of the battery performance 8 08020451 C 16 22 ELECTRICAL SYSTEM Battery CAUTION Do not remove the aluminum sealing sheet A from the filler ports B until just prior to use Be sure to use the dedicated electrolyte container for correct electrolyte volume e Place the battery on a level surface e Check to see that the sealing sheet has no peeling tears or holes in it e Remove the sealing sheet NOTE OThe battery is vacuum sealed If the sealing sheet has leaked air into the battery it may require a longer initial charge 8 08003851 C e Remove the electrolyte container from the vinyl bag
384. scribed in Camshaft Chain Ten sioner Installation Do not turn over the crankshaft while the tensioner is removed This could upset the camshaft chain timing and damage the valves e Remove Cap Bolt A Washer B Spring C Rod D e Remove the mounting bolts E and take off the camshaft chain tensioner Camshaft Chain Tensioner Installation e Release the stopper A and push the push rod B into the tensioner C Olnsert the push rod so that the push rod teeth are leaved five 5 notches e Install the tensioner so that the stopper faces upward e Tighten the tensioner mounting bolts A Torque Camshaft Chain Tensioner Mounting Bolts 11 N m 1 1 kgf m 95 in Ib e Install the rod spring and washer e Tighten the cap bolt B Torque Camshaft Chain Tensioner Cap Bolt 28 N m 2 9 kgf m 21 ft Ib e Turn the crankshaft 2 turns clockwise to allow the ten sioner to expand and recheck the camshaft chain timing ENGINE TOP END 5 15 Camshaft Camshaft Chain Camshaft Removal e Remove Cylinder Head Cover see this chapter Crankshaft Sensor Cover see Electrical System chap ter e Position the crankshaft at 1 4 piston TDC TDC mark A for 1 4 Pistons Timing Mark Crankcase halves mating surface B e Remove Camshaft Chain Tensioner see this chapter Camshaft Cap Bolts A Chain Guide B Camshaft Caps C Camshafts D CAUTION The crankshaft may be turned while the cam
385. see Appendix chapter e Check that the rubber dampers A are on the frame and the fuel tank e Check that the dampers A are in place on the fuel tank as well xIf the dampers are damaged or deteriorated replace them 3 108 FUEL SYSTEM DFI Fuel Tank e Insert the pump outlet hose joint A straight onto the de livery pipe B until the hose joint clicks C Front D e Push and pull A the hose joint B back and forth more than two times and make sure it is locked and doesn t come off When the hose joint is correctly installed it should slide on the delivery pipe about 5 mm 0 20 in WARNING Make sure the hose joint is installed correctly on the delivery pipe by sliding the joint or the fuel could leak x lf it does not slide reinstall the hose joint e Connect the fuel pump and the fuel level sensor connec tors and the battery lead terminal 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 sure to plug the evaporative fuel return hose to prevent fuel spilling before fuel tank removal WARNING For California model be careful not to spill the gasoline through the return hose Spilled fuel is hazardous x If liquid or gasolin
386. serted 0 5second 0 5second gt GP30117BS1 C User Key Collation Error 0 3second gt GO e ULL GP301189BS1 C e The user key 2 is registered in the ECU OThe FI indicator light 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 z e The registration mode automatically ends Ey 8 LET GP30121BS1 C e FI indicator light goes off A gt GP30122BS1 C NOTE the ignition switch ON with the registered user key OCheck that the engine can be started using all regis tered user keys Case 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 ELECTRICAL SYSTEM 16 87 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 GP30028BS1 C Case 5 When replacing the antenna e Prepare a new antenna e Refer to the Immobilizer System Parts R
387. shaft OCheck to see that the shift drum and transmission gears are in the neutral position e Apply liquid gasket A to the mating surface of the lower crankcase half Sealant Kawasaki Bond Liquid Gasket Black 92104 1062 CAUTION Do not apply liquid gasket around the crankshaft main bearing inserts and oil passage holes e Fit the lower crankcase to the upper crankcase 6104057BS1 6104058851 C CRANKSHAFT TRANSMISSION 9 11 Crankcase Splitting e Apply molybdenum disulfide oil solution to the seating sur face A on the lower crankcase for the M9 bolts B Washer C Tighten the lower crankcase bolts using the following steps OFollowing the sequence numbers on the lower crankcase half tighten the M9 bolts 1 6 L 81 mm 3 19 in Torque Crankcase Bolts 9 42 N m 4 3 kgf m 31 ft lb OTighten the M9 bolts 7 10 L 95 mm 3 74 in with washers Torque Crankcase Bolts 9 42 N m 4 3 kgf m 31 ft lb OTighten the M7 bolts A Torque Crankcase Bolts M7 20 N m 2 0 kgf m 14 ft Ib e Tighten the upper crankcase bolts in the order listed Torque Crankcase Bolts M8 A 27 N m 2 8 kgf m 20 ft Ib Crankcase Bolts M7 20 2 0 kgf m 14 ft Ib L 85 mm 3 35 in B L 50 mm 1 97 in C Crankcase Bolts M6 12 N m 1 2 kgf m 104 in Ib L 60 mm 2 36 in D L 40 mm 1 57 in E L 90 mm 3 54 in F Clamp
388. shafts are removed Always pull the chain taut while turn ing the crankshaft This avoids kinking the chain on the lower crankshaft sprocket A kinked chain could damage both the chain and the sprocket Camshaft Installation e Be sure to install the following parts Plug Hole Gaskets A Dowel Pins B e Apply molybdenum disulfide oil solution to all cam parts and journals e If anew camshaft is to be used apply a thin coat of molyb denum disulfide grease to the cam surfaces NOTE OThe exhaust camshaft has a 1 182 EX mark A and the inlet camshaft has a 1 182 IN mark B Be careful not to mix up these shafts 5 16 ENGINE TOP END Camshaft Camshaft Chain e Position the crankshaft at 1 4 piston TDC e Pull the tension side exhaust side A of the chain taut to install the chain e Engage the camshaft chain with the camshaft sprockets so that the timing marks on the sprockets are positioned as shown OThe timing marks of 1 4T must be aligned with the lower surface of crankcase of rear side B OThe timing marks must be aligned with the cylinder head upper surface C EX mark D IN mark E 1 Pin F 2 Pin G 30 Pin H e Install the camshaft cap and chain guide A while push ing the camshaft chain tighten all camshaft bolts and chain guide bolts OFirst tighten the all camshaft cap and all chain guide bolts evenly to seat the camshaft in place then ti
389. sing a syring or some other suitable device lf the oil level is too low add the correct amount of oil through the oil filter 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 ENGINE LUBRICATION SYSTEM 7 9 Oil Pan Oil Pan Removal e Remove Engine Oil drain see Periodic Maintenance chapter Muffler Assy see Engine Top End chapter Oil Pan Bolts A Oil Pan B 5 ORemove the oil pipe oil pressure relief valve and oil screen C as necessary Oil Pan Installation e Clean the oil screen A e Install the oil screen so that the crankcase rib B fits the slot C of the oil screen e Apply engine oil to the O rings on the oil pipe x lf the oil pressure relief valve A was removed install it OApply a non permanent locking agent to the threads of the oil pressure relief valve and tighten it CAUTION Do not apply too much non permanent locking agent to the threads This may block the oil pas sage Torque Oi
390. smission Shift Drum and Fork Removal e Remove Lower Crankcase Half see Crankcase Splitting External Shift Mechanism see External Shift Mecha nism Removal Bolt A and Screw B Shift Drum Bearing Holder C Pull out the shift rods 0 and take off the shift forks Pull out the shift drum Shift Drum and Fork Installation e Install the shift rods A noting the groove position The rods are identical e Position the one with shortest ears B on the drive shaft and place the pin in the center groove in the shift drum C OThe two forks D on the output shaft are identical e Install the forks so that its 266 and 267 side faces clutch side e Apply a non permanent locking agent to the threads of the shift drum bearing holder bolt and screw and tighten them Torque Shift Drum Bearing Holder Bolt 13 N m 1 3 kgf m 113 in Ib Shift Drum Bearing Holder Screw 5 4 N m 0 55 kgf m 48 in lb Shift Drum Disassembly e Remove the shift drum see Shift Drum and Fork Re moval e While holding the shift drum with a vise remove the shift drum cam holder bolt Shift Drum Cam Holder Bolt A Dowel Pin B 6113013481 Shift Drum Assembly e Be sure to install the dowel pin e Apply a non permanent locking agent to the threads of the shift drum cam holder bolt and tighten it Torque Shift Drum Cam Holder Bolt 12 N m 1 2 kgf m 104 in Ib CRANKSHAFT TRANSMISSIO
391. so that the sensitive portions are located in almost the same depth NOTE OThe switch and thermometer must not touch the con tainer sides or bottom e Place the container over a source of heat and gradu ally raise the temperature of the coolant while stirring the coolant gently e Using the hand tester measure the internal resistance of the switch across the terminals at the temperatures shown in the table Special Tool Hand Tester 57001 1394 the hand tester does not show the specified values re place the switch Fan Switch Resistance Rising temperature From OFF to ON at 93 103 C 199 217 F Falling temperature Fan stops with the temperature 3 8 C 38 46 F lower than the operation temperature range ON Less than 0 5 O OFF More than 10 Water Temperature Sensor Inspection e Remove Fuel Tank see Fuel chapter Meter Ground Bolt A e Disconnect the water temperature sensor connector B e Remove the water temperature sensor C see Fuel Sys tem DFI chapter NS GP18003BS2 C ELECTRICAL SYSTEM 16 61 Radiator Fan System e Suspend the sensor A in a container of coolant so that the temperature sensing projection E and threaded por tion E are submerged Suspend an accurate thermometer 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 grad
392. sor B Installation e The UP mark A of the sensor should face upward Torque Vehicle down Sensor Bolts 2 0 N m 0 20 kgf m 17 in Ib Incorrect installation of the vehicle down sensor could cause sudden loss of engine power The rider could lose balance during certain riding situ ations like leaning over in a turn with the potential for an accident resulting in injury or death Ensure that the down sensor is held in place by the sensor brackets Inspection NOTE OBe sure the battery is fully charged e Connect a digital volt meter A to the connector of the vehicle down sensor B with the needle adapter set C Vehicle down Sensor Power Source Voltage Connections to Sensor Meter W Y lead D Meter BK Y lead E e Turn the ignition switch ON and measure the power source voltage with the connector joined Power Source Voltage at Sensor Standard Battery Voltage 12 6 V or more e Turn the ignition switch OFF x lf there is no battery voltage check the following Battery see Electrical System chapter ECU Main Fuse 15 A Wiring for Vehicle down Sensor Power Source see next wiring diagram x If the power source is normal check the output voltage 6617125852 C FUEL SYSTEM DFI 3 67 Vehicle down Sensor Service Code 31 e Turn the ignition switch OFF e Remove the sensor e Connect a digital volt meter to the connector with nee dle adapter set
393. ss OWhen checking a harness A for short circuit open one end B and check the continuity between the other end C and ground D If there is continuity the harness has a short circuit to ground and it must be repaired or re placed e Narrow down suspicious locations by repeating the con tinuity tests from the ECU connectors If no abnormality is found in the wiring or connectors the DFI parts are the next likely suspects Check the part starting with input and output voltages However there is no way to check the ECU itself lf an abnormality is found replace the affected DFI part If no abnormality is found in the wiring connectors and DFI parts replace the ECU OLead Color Codes BK Black G Green P Pink BL Blue GY Gray PU Purple BR Brown LB Light blue R Red CH Chooolate LG Light green W White DG Dark green O Orange Y Yellow 6017029281 3 26 FUEL SYSTEM DFI Troubleshooting the DFI System OThere are two ways to inspect the DFI system One is voltage Check Method and the other is Resistance Check Method Voltage Check Method OThis method is conducted by measuring the input voltage B to a sensor A first and then the output voltage C from the sensor OSometimes this method can detect a fault of the ECU e Refer to each sensor inspection section for detail in this chapter e Use a fully charged battery and a digital meter D which can be read two
394. ss 180 55 ZR17 M C 73W Telescopic fork 120 mm 4 7 in Swingarm uni trak 126 mm 5 0 in Dual discs Single disc GENERAL INFORMATION 1 11 General Specifications ltems ZR750 K1 Electrical Equipment Battery 12 V 8 Ah Headlight Type Semi sealed beam Bulb 12 V 55 W x 2 55 W Hi Lo Tail Brake Light 12 V 0 5 4 1 W LED Alternator Type Three phase AC Rated Output 24 A 14 V 5 000 r min rpm Specifications are subject to change without notice and may not apply to every country CA Canada Model US United States HR With Honeycomb Catalytic Converter Restricted Model MY Malaysia Model 1 12 GENERAL INFORMATION Technical Information Air Inlet System Subthrottle Control System The ZR750 K models employs large bore throttle bodies to increase power output However sud den changes in throttle opening can cause hesitation and jerky throttle response with a single butterfly valve in a large bore Therefore two throttle valves are placed in each inlet tract the main throttle valve located closest to the cylinder and a subthrottle valve placed further up the inlet tract The main throt tle valve is operated by the rider when the throttle grip is turned clockwise or counterclockwise while the subthrottle valve is operated by a stepping motor controlled by the ECU The subthrottle valve automatically adjusts air inlet to more precisely match engine demand so that when the main throttle
395. ss in each bearing A right until they are bottomed Special Tool Bearing Driver Set 57001 1129 B e Replace the grease seals with new ones e Press in the grease seals A so that the seal surface flush B with the end of the hole OApply high temperature grease to the grease seal lips Special Tool Bearing Driver Set 57001 1129 C Hub Bearing Inspection Since the hub bearings are made to extremely close tol erances the clearance can not normally be measured NOTE ODo not remove any bearings for inspection If any bear ings are removed they will need to be replaced with new ones e Turn each bearing in the hub back and forth A while checking for plays roughness or binding 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 6J04090BS1 C 6J06008BS1 C 6J06008BS1 C 6J06002BS1 C FINAL DRIVE 11 1 Final Drive Table of Contents Exploded ad clea aay eed 11 2 DPOCITICATIONS gt 11 4 mereri 11 5 ae 11 6 Drive Chain Slack Inspection pp 11 6 Drive Chain Slack Adjustment 11 6 Wheel Alignment 11 6 Drive Chain Wear Inspection pp 11 6 Drive Chain Lubricatigm
396. stem chapter Turn Signal Relay see Electrical System chapter Harness see light Electrical System chapter e Push the turn signal switch e The turn signal lights and indicator light should go off x If the light does not go off inspect or replace the following item Turn Signal Switch see Electrical System chapter Turn Signal Relay see Electrical 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 x lf the low beam headlight does not go on inspect or re place the following item Headlight Low Beam Bulb see Electrical System chap ter Headlight Fuse 10 A see Electrical System chapter Dimmer Switch see Electrical System chapter Headlight Relay in Junction Box see Electrical System chapter Harness see Electrical System chapter 9517040851 PERIODIC MAINTENANCE 2 43 Periodic Maintenance Procedures e Set the dimmer switch to high beam position e The low beam A and high beam B headlights should go on e The high beam indicator light C should go on x If the high beam headlight and or high beam indicator light does not go on inspect or replace the following item Headlight High Beam Bulb see Electrical System chap ter Dimmer Switch see Electrical System chapter e Turn off the engine stop switch e The low beam and high beam headlights should stay go ing on x If the headlights and high
397. ster the user key correctly see Electrical System chapter x If the service code 36 appears again the transponder in the key is malfunction replace it Ignition Switch Meter Ground Frame Ground Joint Connector B Immobilizer Amplifier Fl Indicator Light LED Meter Unit Immobilizer Antenna Joint Connector A Junction Box 6230125812 C Ignition Fuse 10 ECU Main Relay ECU Main Fuse 15 Main Fuse 30 A Starter Relay Battery 12 V 8 Ah Immobilizer Kawasaki Diagnostic System Connector ECU 3 74 FUEL SYSTEM DFI Stick Coils 1 2 3 4 Service Code 51 52 53 54 Stick Coil 1 Ignition Coil Stick Coil 2 Ignition Coil Stick Coil 3 Ignition Coil Stick Coil 4 Ignition Coil Service Code 51 Service Code 52 Service Code 53 Service Code 54 NNN Removal Installation CAUTION Never drop the stick coils especially on a hard sur face Such a shock to the stick coil can damage it e See the Ignition System section in the Electrical System chapter Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Remove the ECU see this chapter Do not disconnect the ECU connector e Connect a digital voltmeter A as shown with the needle adapter set B OMeasure the input voltage to each primary winding o
398. t 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 banjo bolts Torque Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft Ib e Inspect the brake hose routing x If any brake hose routing is incorrect route the brake hose according to Cable Wire and Hose Routing section in the Appendix chapter GL10020181 C 2 36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Operation Inspection e Inspect the operation of the front and rear brake by run ning the vehicle on the dry road x lf the brake operation is insufficiency inspect the brake system WARNING When inspecting by running the vehicle note a surrounding traffic situation enough in the place of safety 9513107851 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 in
399. t Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 OMeasure the operating voltage with the engine stopped and with the connector joined e Turn the ignition switch ON OThe tester needle should indicate battery voltage for 3 seconds and then 0 V Pump Operating Voltage at Pump Connections to Pump Connectors Tester Y R Lead Tester BK W Lead Operating Voltage at Pump Connector Standard Battery Voltage 12 6 V or more for 3 seconds and then 0 V xIf the reading stays on battery voltage and never shows 0 V Check the ECU and fuel pump relay the voltage is in specification but the pump doesn t work replace the pump x lf there is still no battery voltage check the pump relay see this chapter Pressure Regulator Removal OThe pressure regulator A is built into the fuel pump B and cannot be removed Pump Screen Fuel Filter Cleaning OThe pump screen A and fuel filter B are built into the pump and cannot be cleaned or checked xIf the pump screen or fuel filter is suspected of clogging or being damaged replace it with the fuel pump as a set 3 90 FUEL SYSTEM 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 e Remove the seat cover see Frame chapter e Remove the fuel pump relay A from the tongue of the storage compartment e
400. t lt lt 12 Crankshaft Position Rotor Bolt 40 4 1 30 13 Pressure Switch 15 16 Crankshaft Sensor Cover Bolts 11 17 Do not apply any grease or oil EO Apply engine oil G Apply grease L Apply a non permanent locking agent LG Apply liquid gasket Kawasaki Bond 92104 1062 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 Tightening the fasteners following the specified sequence SS Apply silicone sealant 9 4 CRANKSHAFT TRANSMISSION Exploded View 6102088 5 CRANKSHAFT TRANSMISSION 9 5 Exploded View No Fastener Jorane Remarks N m kgf m ft Ib 1 Shift Pedal Mounting Bolt 34 3 5 25 L 2 Gear Positioning Lever Bolt 12 1 2 104 in Ib 3 Shift Shaft Return Spring Pin 29 3 0 22 L 4 Shift Drum Cam Holder Bolt 12 1 2 104 in Ib L 5 Footpeg Bracket Bolts 34 3 5 25 L 6 j Shift Lever Bolt 6 9 0 70 61 in Ib 7 Tie rod Locknuts 6 9 0 70 61 in Ib 8 Neutral Switch 15 1 5 11 EO Apply engine oil G Apply grease L Apply a non permanent locking agent R Replacement Parts 9 6 CRANKSHAFT TRANSMISSION Specifications Item Standard Service Limit Crankshaft Connecting Rods Connecting Rod Bend TIR 0 2 100 mm 0 008 3 94 in Connecting Rod Twist TIR 0 2 100 mm 0 008 3 94 in Connec
401. t Coupling e Replace the grease seal with a new one e Press in the grease seal so that the seal surface is flush with the end of the hole OApply high temperature grease to the grease seal lips Special Tool Bearing Driver Set 57001 1129 Coupling Installation e Grease the following and install the coupling Coupling Grease Seal A Coupling Internal Surface B e Install the collar GK05040BS1 C Coupling Bearing Inspection Since the coupling bearing is made to extremely close tolerances the clearance can not normally be measured NOTE Olt is not necessary to remove the coupling bearing for inspection If the bearing is removed it will need to be replaced with a new one e Turn the bearing in the coupling back and forth A while checking for plays roughness or binding bearing play roughness or binding is found replace the bearing e Examine the bearing seal B for tears or leakage the seal is torn or is leaking replace the bearing 6J06002BS1 C Coupling Bearing Lubrication OSince the coupling bearing is packed with grease and sealed lubrication is not required Coupling Damper Inspection e Remove the rear wheel coupling and inspect the rubber dampers A e Replace the damper if it appears damaged or deterio rated 11 14 FINAL DRIVE Sprocket Coupling Sprocket Wear Inspection e Visually inspect the engine and rear sprocket teeth for wear and damage
402. t Valve spring broken or weak Camshaft bearing worn Valve lifter worn Other noise Connecting rod small end clearance exces sive Connecting rod big end clearance exces sive Piston ring groove clearance excessive Piston ring worn broken or stuck Piston ring groove worn Piston seizure damage Cylinder head gasket leaking APPENDIX 17 29 Troubleshooting Guide 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 Vacuum switch valve damaged Alternator rotor loose Catalytic converter melt down due to muffler overheating KLEEN Abnormal Drive Train Noise Clutch noise Clutch damper weak or damaged Clutch housing friction plate clearance ex cessive Clutch housing gear worn Wrong installation of outside friction plate Transmission noise Bearings worn Transmission gear worn or chipped Metal chips jammed in gear teeth Engine oil insufficient Drive line noise Drive chain adjusted improperly Drive 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 surface glazed Disc warped Cali
403. t syn chronize the balance of the left 1 2 and right 3 4 assemblies Example 1 165 mmHg 2 190 mmHg 3 170 mmHg 4 200 mmHg e With the engine at the correct idle speed equalize the lower vacuum of 3 and 4 example 170 mmHg to the lower vacuum of 1 and 2 example 165 mmHg by turn ing the center adjusting screw A NOTE OAfter adjustment the final vacuum measurement be tween the lowest throttle valves may not be 165 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 e Open and close the throttle after each measurement and adjust the idle speed as necessary e Once the throttle valves have been synchronized inspect the main throttle sensor s output voltage to ensure proper operation procedure is at the end of this section PERIODIC MAINTENANCE 2 21 Periodic Maintenance Procedures 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 Torque Bypass Screws 0 2 0 02 kgf m 1 7 in Ib 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 throt
404. table Pedal Free Play Non adjustable Pedal Position About 47 mm 1 85 in below footpeg top Brake Fluid Grade DOT4 Brake Pads Lining Thickness Front 4 5 0 18 in 1 0 04 in Rear 5 0 mm 0 20 in 1 mm 0 04 in Brake Discs Thickness Front 4 3 4 5 0 17 0 18 in 4 0 0 16 in Rear 4 8 5 2 0 19 0 20 in 4 5 0 18 in Runout Not more than 0 2 mm 0 008 in 0 3 mm 0 012 in BRAKES 12 7 Special Tools Inside Circlip Pliers Jack 57001 143 57001 1238 7570143ST C i 7571238ST C 12 8 BRAKES Brake Lever Brake Pedal Brake Lever Position Adjustment The brake lever adjuster has 5 positions so that the brake lever position can be adjusted to suit the operator s hand e Push the lever forward and turn the adjuster A to align the number with the arrow mark B on the lever holder OThe distance from the grip to the lever is minimum at num ber 5 and maximum at number 1 Brake Pedal Position Inspection e Check that the brake pedal A is in the correct position Footpeg B Pedal Position Standard About 47 mm 1 85 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 the push rod locknut has been loosened e Remove Reservoir Tank Bolt
405. tainer e Loosen the master cylinder mounting bolts B lightly e Remove Reservoir Tank Bolt C Guard Bracket Bolts D Guard Bracket E e Remove Cotter Pin A Joint Pin B NOTE OPull off the joint pin while pressing down the brake pedal e Unscrew the master cylinder mounting bolts C and re move the master cylinder D with the reservoir tank e Remove Cotter Pin A Reservoir With Hose B Master Cylinder C Rear Master Cylinder Installation e Replace Circlip Cotter Pin Olnsert the cotter pin A and bend the pin end B e Replace the washers on each side of hose fitting with new ones e Tighten the following bolts Torque Rear Master Cylinder Mounting Bolts 25 N m 2 5 kgf m 18 ft lb Brake Hose Banjo Bolt 34 N m 3 5 kgf m 25 ft lb e 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 12 16 BRAKES Master Cylinder Rear Master Cylinder Disassembly e Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter Master Cylinder Assembly e Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter Master Cylinder Inspection e Remove the master cylinders see Front Rear Master Cylinder Removal e Disassemble
406. tand Switch 13 Regulator Rectifier 14 Turn Signal Relay 15 ECU Electronic Control Unit 16 Immobilizer Amplifier Equipped Models 17 Starter Relay and Main Fuse 30A 18 Stick Coils 4 45681 2 P 6704811 P 19 Ignition Switch with Immobilizer Antenna Equipped Models 20 Diode Rectifier 21 Rear Brake Light Switch 22 Crankshaft Sensor 23 Oil Pressure Switch 24 Front Brake Light Switch 16 4 ELECTRICAL SYSTEM Exploded View ELECTRICAL SYSTEM 16 5 Exploded View No Fastener Tordue Remarks N m kgf m ft Ib 1 Turn Signal Light Screws 1 2 0 12 10 in Ib 2 Tail Brake Light Mounting Screws 1 2 0 12 10 in Ib 3 License Plate Light Mounting Screws 1 2 0 12 10 in Ib 4 Front Brake Light Switch Screw 1 0 0 10 9 in Ib 5 Starter Locknut Switch Screws L 6 Left Switch Housing Screws 0 36 31 in Ib Right Switch Housing Screws 31inb 8 Headlight Mounting Bolts 0 60 52 9 Tail Brake Lights LED 10 Install the rear brake spring as shown Longer Side A L Apply a non permanent locking agent EUR Europe MY Malaysia Model 16 6 ELECTRICAL SYSTEM Exploded View 6202195815 C ELECTRICAL SYSTEM 16 7 Exploded View No Fastener Torque Remarks N m kgf m ft Ib 1 Water Temperature Sensor 25 2 5 18 Ss 2 Spark Plugs 13 1
407. tch operation inspect year e e e 2 45 Others Chassis parts lubricate year e 2 45 Botts and nuts ighiness inepect le e Service more frequently when operating in severe conditions dusty wet muddy high speed or frequent starting stopping For higher odometer readings repeat at the frequency interval established here CAL California Model PERIODIC MAINTENANCE 2 5 Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY Whichever ODOMETER READING comes x 1 000 km first x 1 000 mile V CHANGE REPLACE ITEM Every Air cleaner element Engine Oil filter year Fuel hose 4 years Coolant 3 years Radiator hose and O ring 3 years Brake hose and pipe 4 years Brake fluid 2 years Rubber parts of master cylinder and caliper 4 years Spark plug 2 58 Service more frequently when operating in severe conditions dusty wet muddy high speed frequent starting stopping For higher odometer readings repeat at the frequency interval established here 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 liquid gasket Letters used in the Remarks column mean AL Tighten the two clamp bolts alternately two times to ensure even tightening torque EO Apply engine o
408. tem chapter for the ECU fuse inspection ECU Main Relay Removal CAUTION Never drop the relay especially on a hard surface Such a shock to the relay can damage it e Remove the seat cover see Frame chapter e Remove the ECU main relay A and disconnect the con nector ECU Main Relay Inspection e Remove the ECU main relay see above e Connect the hand tester A and one 12 V battery B to the relay connector C as shown Special Tool Hand Tester 57001 1394 Relay Coil Terminals 1 and 2 Relay Switch Terminals 3 and 4 Testing Relay Tester Range 1 O range Criteria When battery is connected 0 When battery is disconnected x If the relay does not work as specified replace the relay 3 84 FUEL SYSTEM Fuel Line Fuel Pressure Inspection NOTE OThis inspection can determine which trouble the system has mechanical or electrical trouble Olt is preferable to measure the fuel pressure while run ning the motorcycle just when trouble occurred in order to know symptom well OBe sure the battery is fully charged e Remove the fuel tank see Fuel Tank Removal a o e Be sure to place a piece of cloth around the pump outlet mmu pipe and the delivery pipe c E e Remove the fuel pump outlet hose H Front B Be prepared for fuel spillage any spilled fuel must ABS be completely wiped up immediately Nd N
409. the Periodic Maintenance chapter Clutch Cover see Clutch Cover Removal Clutch Spring Bolts A Clutch Springs Clutch Spring Plate B with thrust bearing and pusher C spring and washer e Remove Friction Plates Steel Plates Clutch Hub Nut A OHolding the clutch hub B remove the nut and washer Special Tool Clutch Holder C 57001 1243 e Remove Clutch Hub Spacer e Using the two 4 mm 0 16 in screws A pull out the sleeve B needle bearing C and clutch housing D e Remove the spacer Clutch Installation e Install the following parts on the drive shaft Spacer A Needle Bearing B Sleeve C Clutch Housing D Spacer E Clutch Hub F Washer G Nut H GFO6050BS2 C CLUTCH 6 11 Clutch Olnstall the spacer so that the tapered side faces inward Olnstall the washer A so that the OUTSIDE mark faces outward OReplace the clutch hub nut with a new one OHolding the clutch hub tighten the clutch hub nut Special Tool Clutch Holder 57001 1243 Torque Clutch Hub Nut 135 N m 14 kgf m 100 ft Ib e Install the friction plates and steel plates starting with a friction plate and alternating them CAUTION If new dry friction plates and steel plates are in stalled apply engine oil to the surfaces of each plate to avoid clutch plate seizure Olnstall the last friction plate A fitting the tangs in the grooves in the housing as shown e
410. the brake for good braking power no brake drag and no fluid leakage 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 not done BRAKES 12 11 Calipers 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 e Replace the fluid seal if it exhibits any of the conditions listed below OBrake fluid leakage around the pad OBrakes overheat OConsiderable difference in inner and outer pad wear OSeal and piston are stuck together x If the fluid seal is replaced replace the dust seal as well Also re
411. 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 accessories which adversely affect the performance or durability of the motorcycle c Addition of components or accessories that result in the vehicle exceeding the stan dar
412. the ignition switch is turned off The headlight will go out momentarily whenever the starter button is pressed and come back on when the button is released Headlight Beam Horizontal Adjustment e Refer to the Headlight Aiming Inspection in the Periodic Maintenance chapter Headlight Beam Vertical Adjustment e Refer to the Headlight Aiming Inspection in the Periodic Maintenance chapter Headlight Bulb Replacement e Remove Headlight Connector A Headlight Bulb Dust Cover B e Remove Hook A Headlight Bulb B CAUTION When handling the quartz halogen bulb never touch the glass portion with bare hands Always use a clean cloth Oil contamination from hands or dirty rags can reduce bulb life or cause the bulb to explode NOTE OClean off any contamination that inadvertently gets on the bulb with alcohol or soap and water solution e Replace the headlight bulb e Fit the projection of the bulb A in the hollow of the head light e Install the hook B 16 54 ELECTRICAL SYSTEM Lighting System e Fit the dust cover A with the arrow mark upward onto the bulb B firmly as shown Good C Bad D Arrow Mark E e After installation adjust the headlight aim see Periodic Maintenance chapter GP12025BS1 C 62128457 P Headlight Removal Installation e Refer to the Fairing Disassembly and Fairing Assembly in the Frame chapter City Light Bulb Replacement Pull out th
413. the removed parts see appropriate chapters FRAME 15 1 Frame Table of Contents 59400161570 87 M 15 2 Re 15 7 Seat Removal 15 7 SeA 15 7 Side COVers aces 15 6 sde Coya REMOVAL a M 15 8 Side Cover nstallatiOns eoe 15 8 Frame GoveriRermoyvals ie 15 8 ce T 15 9 mner Cover Removal 1 needle ledio sesta La 15 9 Inner Cover Installation E 15 9 Inner Cover Installation pt 15 9 Meter Cover Removal 15 9 Meter Cover Installation pp 15 10 Windshield Removal ERE D ERE een tee 15 10 Windshield Installation pp 15 10 est il Lc 15 10 Fairing Installation c 15 11 Falling Disassembly 15 11 Fairing Assembly 15 12 Fairing Bracket Removals esi Sp 15 12 Se atGover Installatiorix RITE CTI IIT TTE Front Fender Removal
414. the reservoir Check that the brake fluid level in the rear brake reservoir A is above the lower level line B x If the fluid level is lower than the lower level line remove the seats and fill the reservoir to the upper level line C A WARNING Do not mix two brands of fluid 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 reservoir are unidentified After changing the fluid use only the same type and brand of fluid thereafter Recommended Disc Brake Fluid Grade DOT4 PERIODIC MAINTENANCE 2 37 Periodic Maintenance Procedures e Follow procedure below to rear brake fluid reservoir correctly OFirst tighten the rear brake fluid reservoir cap B clock wise C by hand until slight resistance is felt indicating that the cap is seated on the reservoir body then tighten the cap an additional 1 6 turn D while holding the brake fluid reservoir body A Brake Pad Wear Inspection e Check the lining thickness A of the pads in each caliper x If the lining thickness of either pad is less than the service limit B replace both pads in the caliper as a set Pad Lining Thickness Standard Front 4 5 mm 0 18 in Rear 5 0 mm 0 20 in Service Limit 1 mm 0 04 in Brake Light Switch Operation Inspection e Turn on the ignition switch The brake light A should go on
415. ting Collar Locknut 49 5 0 36 S 2 Upper Engine Mounting Bolts 44 4 5 33 S 3 Engine Bracket Bolts 25 2 5 18 S 4 Front Engine Bracket Bolts 44 4 5 33 S 5 Engine Mounting Nut 44 4 5 33 6 Lower Engine Mounting Nut 44 4 5 33 S Engine Ground Cable Terminal Bolt 9 8 1 0 87inb 8 Adjusting Collar 9 Middle Engine Mounting Bolt 10 Lower Engine Mounting Bolt S Follow the specific tightening sequence 8 4 ENGINE REMOVAL INSTALLATION Special Tool Engine Mount Nut Wrench 57001 1450 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 Be sure to hold the front brake when removing the engine or the motorcycle may fall over It could cause an accident and injury GH04011081 C 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 tenance chapter Coolant see Coolant Change in the Periodic Mainte nance chapter e Remove Fairing Bracket with Fairing see Frame chapter Seat see Frame chapter Fuel Tank see Fuel System DFI chapter Right Side Cover A see Frame chapter Clutch Cable Lower End B see Clutch chapter Exhaust Pipe Assy C an
416. ting Rod Big End Side Clearance 0 13 0 38 mm 0 58 mm 0 0051 0 0150 in 0 023 in Connecting Rod Big End Bearing Insert crankpin 0 041 0 071 mm 0 11 mm Clearance 0 0016 0 0028 in 0 0043 in Crankpin Diameter 34 984 35 000 mm 34 97 mm 1 3773 1 3780 in 1 3768 in Marking None 34 984 34 992 mm 1 3773 1 3776 in 34 993 35 000 1 3777 1 3780 in Connecting Rod Big End Inside Diameter 38 000 38 016 mm 1 4961 1 4967 in Marking None 38 000 38 008 mm 1 4961 1 4964 in 38 009 38 016 1 4964 1 4967 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 Big End Bearing Insert Selection Con rod Big End Bore Diameter Marking None Brown 92139 1110 None None Blue 92139 1108 Crankpin Diameter Bearing Insert Marking Size Color Part Number Black 92139 1109 Connecting Rod Bolt Stretch Usable Range New Connecting Rod 0 24 0 36 mm 0 0094 0 0142 in Used Connecting Rod 0 20 0 32 mm eee 0 0079 0 0126 in Crankshaft Side Clearance 0 05 0 20 mm 0 40 mm 0 0020 0 0079 in 0 0157 in CRANKSHAFT TRANSMISSION 9 7 Specifications
417. ting surface Inspect and replace see chapter 5 obstructed inlet Inspect and repair or replace see chapter 3 Fuel pump trouble Inspect see chapter 3 Fuel injector trouble Inspect see chapter 3 Inspect and repair or replace see chapter 5 Inlet air temperature sensor trouble Inspect see chapter 3 Main throttle sensor trouble Inspect see chapter 3 Subthrottle sensor trouble Inspect see chapter 3 Subthrottle valve actuator trouble Inspect see chapter 3 Water temperature 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 Inlet air pressure sensor trouble Inspect see chapter 3 Loose injector connectors Remedy see chapter 3 Crankshaft sensor trouble Inspect and repair or replace see chapter 16 Stick coil trouble Inspect and repair or replace see chapter 16 Loose terminal of battery lead or engine ground lead Dante Inspect crankshaft sensor and IC igniter in ECU Delay of ignition timing see chapter 16 Too low fuel pressure Inspect see chapter 3 Water or foreign matter in fuel Change fuel Inspect and clean fuel system see chapter 3 Clogged fuel filter or pump screen Inspect and
418. tion e Refer to the Electrical System chapter for water temper ature sensor inspection 3 58 FUEL SYSTEM Atmospheric Pressure Sensor Service Code 15 CAUTION Never drop the sensor especially on surface Such a shock to the sensor can damage it NOTE OThe atmospheric pressure sensor is the same part as the inlet air pressure sensor except that the inlet air pressure sensor has the vacuum hose and different wiring Removal e Turn the ignition switch off e Remove the seat cover see Frame chapter e Remove the atmospheric pressure sensor from the rubber damper in the frame e Disconnect the sensor connector Input Voltage Inspection NOTE OBe sure the battery is fully charged OThe inspection is the same as Input Voltage Inspection of the throttle sensor and the inlet air pressure sensor e Turn the ignition switch OFF e Remove the ECU see ECU Removal Do not disconnect the ECU connectors e Connect a digital voltmeter A to the connector B with the needle adapter set Special Tool Needle Adapter Set 57001 1457 e Measure the input voltage with the engine stopped and with the connectors joined e Turn the ignition switch ON Atmospheric Pressure Sensor Input Voltage Connections to ECU Meter BL lead terminal 1 Meter BR BK lead terminal 14 Connections to ECU Immobilizer Equipped Models C Meter B
419. tle closes quickly and completely by the return spring in all steering positions x If the throttle grip doesn t return properly check the throt tle cable routing grip free play and cable damage Then lubricate the throttle cable e Check the throttle grip free play A x lf the free play is incorrect adjust the throttle cable Throttle Grip Free Play Standard 2 3 mm 0 08 0 12 in x If necessary adjust the throttle cable as follows e Loosen the locknut A e Turn the adjuster B until the proper amount of free play can be obtained e Tighten the locknut against the adjuster securely x lf the throttle grip free play can not be adjusted with the adjuster use the adjusters in the middle of the throttle cables e Loosen the locknut and screw the adjuster at the upper end of the accelerator cable all the way in e Tighten the locknut against the adjuster securely e Loosen the locknuts A and turn the lower adjusters B until the proper amount of throttle grip free play is ob tained e Tighten the locknuts against the adjusters securely x lf the throttle grip free play can not be adjusted with the lower adjusters use the adjuster at the upper end of the cable again PERIODIC MAINTENANCE 2 17 Periodic Maintenance Procedures Idle Speed Inspection e Start the engine and warm it up thoroughly e With the engine idling turn the handlebar to both sides A x lf handlebar movement cha
420. tle valves after each measure ment and adjust the idle speed as necessary e Inspect the vacuums as before vacuums are within the specification finish the en gine vacuum synchronization x If any vacuum can not be adjusted within the specification remove the bypass screws 1 4 and clean them e Remove the bypass screw A 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 Torque Bypass Screw 0 2 N m 0 02 kgf m 1 7 in Ib 6505015851 C e Repeat the same procedure for other bypass screws e Repeat the synchronization x lf the vacuums are correct check the output voltage of the main throttle sensor see Output Voltage Inspection of Main Throttle Sensor in the Fuel System DFI chapter Main Throttle Sensor Output Voltage Connections to ECU Meter Y W lead terminal 2 Meter BR BK lead terminal 14 Connections to ECU Immobilizer Equipped Models Meter Y W lead terminal 6 Meter BR BK lead terminal 20 Standard 0 99 1 03 V DC at idle thrott
421. to display the collation error Immobilizer Amplifier Failure 0 2second GP30118BS1 C When Registered User Key is Inserted 0 5second 0 5second gt pe GP30117BS1 C User Key Collation Error 0 3second gt ULL GP30119BS1 e The user key 2 is successfully registered in the ECU OThe FI indicator light 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 The registration mode automatically ends pc Ln GP30121BS1 C e FI indicator light goes off A gt GP30122BS1 C ELECTRICAL SYSTEM 16 83 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 ECU A see Immobilizer System Parts Replacement
422. tor Rectifier Bracket Bolts 6 9 0 70 6tinb 38 Engine Ground Cable Terminal Bolt 9 8 1 0 876 9 Turn Signal Relay 10 Junction Box 11 ECU Electronic Unit Control 12 15 A ECU Fuse 13 Fuel Reserve Switch 14 Diode Rectifier 15 Speed Sensor 16 Regulator Rectifier 17 Battery 12 V 8 Ah L Apply a non permanent locking agent 16 10 ELECTRICAL SYSTEM Specifications Standard Battery Type Sealed Battery Capacity 12 V 8 Ah Voltage 12 6 V or more Charging System Type Three phase AC Alternator Output Voltage 42 V or more Stator Coil Resistance 0 3 0 40 Charging Voltage 14 7 0 5 V regulator rectifier output voltage Ignition System Crankshaft Sensor Resistance 376 564 Crankshaft Sensor Peak Voltage 1 9 V or more Camshaft Position Sensor Resistance 400 460 Camshaft Position Sensor Peak Voltage 0 2 V or more Interlock Operation Voltage 4 V or more Stick Coil Primary Winding Resistance 1 04 1 56 O Secondary Winding Resistance 10 8 16 2 Primary Peak Voltage 88 V or more Spark Plug Spark Plug Gap 0 7 0 8 mm 0 028 0 031 in Electric Starter System Starter Motor Brush Length 12 mm 0 47 in Service limit 8 5 mm 0 33 in Commutator Diameter 28 mm 1 10 in Service limit 27 mm 1 06 in Switch and Sensor Rear Brake Light Switch Timing ON after about 10 mm pedal travel Engine Oil Pressure Switch Connections When engine is stopped ON When engi
423. tor Rectifier Inspection e Remove Bolts A Regulator Rectifier B Connector C disconnect Rectifier Circuit Check BR e Check conductivity of the following pair of terminals W BK Y Rectifier Circuit Inspection W BK1 W BK2 W BK3 Tester connection BK Y BK1 2 BK Y BK3 The resistance should be low in one direction and more than ten times as much in the other direction If any two BK 1 BK2 BK3 leads are low or high in both directions the rectifier is TTE defective and must be replaced NOTE OThe actual meter reading varies with the meter used and the individual rectifier but generally speaking the lower reading should be from zero to one half the scale Regulator Circuit Check To test the regulator out of circuit use three 12 V batteries and a test light 12 V 3 6 W bulb in a socket with leads CAUTION The test light works as an indicator and also a cur rent limiter to protect the regulator rectifier from ex cessive current Do not use an ammeter instead of a test light e Check to be sure the rectifier circuit is normal before con tinuing ELECTRICAL SYSTEM 16 33 Charging System eDothe 1st step regulator circuit test OConnect the test light and the 12 V battery to the regula tor rectifier as shown OCheck BK1 BK2 and BK3 terminal respectively x If the test light turns on the regulator rectifier is defective Replace it x lf the test
424. tor up to the filler neck with coolant e Fill the reserve tank up to the full level line A with coolant and install the cap B e Install the fuel tank see Fuel System DFI chapter e Start the engine warm it up thoroughly until the radiator fan turns on and then stop the engine e Check the coolant level in the reserve tank after the en gine cools down x lf the coolant level is lower than the L level line add coolant to the F level line CAUTION Do not add more coolant above the level line 2 52 PERIODIC MAINTENANCE Periodic Maintenance Procedures Radiator Hose and O ring Replacement e Drain the coolant see Coolant Change e Remove Fuel Tank see Fuel System DFI chapter Thermostat Housing A Hoses B O rings C e Apply grease to the new O rings and install them e Instal the new hoses and tighten the clamps securely e Fill the coolant see Coolant Change e Check the cooling system for leaks Brake Hose and Pipe Replacement CAUTION Brake fluid quickly ruins painted plastic surfaces any spilled fluid should be completely washed away immediately e Remove Banjo Bolt A e When removing the brake hose take care not to spill the brake fluid on the painted or plastic parts e When removing the brake hose 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 fl
425. ts Torque Rear Shock Absorber Nuts 34 N m 3 5 kgf m 25 16 Rear Shock Absorber Inspection e Remove the rear shock absorber e Visually inspect the following items Smooth Stroke Oil Leakage Crack or Dent x If there is any damage to the rear shock absorber replace it e Visually inspect the rubber bushing x lf it show any signs of damage replace it 13 18 SUSPENSION Swingarm Swingarm Removal e Raise the rear wheel off the ground with jack see Rear Shock Absorber Removal Special Tool Jack 57001 1238 Jack Attachment 57001 1608 e Remove Chain Cover see Final Drive chapter Brake Hose Clamp Screw A Brake Hose Clamp B Rear Wheel see Wheels Tires chapter e Remove Lower Shock Absorber Nut and Bolt A Upper Tie rod Nut and Bolt B e Remove the both frame cover see Frame chapter e Unscrew the swingarm pivot locknut A using the nut wrench B Special Tool Swingarm Pivot Nut Wrench 57001 1597 e Unscrew the swingarm pivot nut A and loosen the swingarm pivot shaft B Pull off the pivot shaft and remove the swingarm SUSPENSION 13 19 Swingarm Swingarm Installation OPlace the collar A on the stopper B inside the frame C e Insert the pivot shaft into the frame from the right side e Tighten the pivot shaft so that the clearance D between the collar and the frame comes to 0 mm e Tighten Torque Swingarm Pivot Shaft Nut 108 11 kg
426. ts Exploded AAEN EA EAEE um M RTL Parts E o6allon tr c Ginnie eL Special Tools and DFI Servicing Preca tions E DFI Servicing Precautions 5 Troubleshooting the DFI System lerne TES Inquiries to INQUINFIES DFI System Troubleshooting Guide pp RS TEAS Sas Secret cee aS cand Self di gnosis OUUING Selfdiagnosls Outline SEl CilagGnoOs S Procedures tto Co Self diagnosis Procedures pp Service Code Clearing Procedures tp tinere dein ee que t fetis d iaces Service Code Clearing Procedures pp How to Read Service How to Read Service Codes sse eene nennen eren nnns How to Erase Service How to Erase Service Service Code Table ir ter eu Service Code Table BackUPS en ee BACKUPS
427. tter Pin Brakes Front Master Cylinder Clamp Bolts Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts Brake Lever Pivot Nut Brake Pedal Bolt Brake Rod Joint Cotter Pin Suspension Front Fork Clamp Bolts Front Fender Mounting Bolts Rear Shock Absorber Mounting Nuts Swingarm Pivot Shaft Nut Swingarm Pivot Shaft Lock Nut Uni trak Link Nuts Steering Stem Head Bolt Handlebar Clamp Bolts Engine Throttle Cable Adjuster Locknuts Engine Mounting Bolts and Nuts Muffler Mounting Bolts Exhaust Pipe Holder Nuts Muffler Connecting Clamp Bolt Clutch Lever Pivot Nut Radiator Upper and Lower Bolts Others Side Stand Bolt Footpeg Stay Bolts 2 48 PERIODIC MAINTENANCE Periodic Maintenance Procedures Replacement Parts Air Cleaner Element Replacement e Refer to the Air Cleaner Element Cleaning in this chapter Engine Oil Change e Situate the motorcycle so that it is vertical after warming up the engine e Unscrew the oil filler cap A e Place on oil pan beneath the engine e Remove the engine oil drain bolt A to drain the oil OThe oil in the oil filter can be drained by removing the filter see Oil Filter Replacement Replace the drain bolt gasket B with a new one e Tighten the drain bolt Torque Engine Oil Drain Bolt 29 N m 3 0 kgf m 21 ft Ib e Pour in the specified type and amount of oil Recommended Engine Oil Type API SE SF or SG API SH or SJ with JASO MA Viscosity SAE 10W 40
428. ttle body e Fitthe accelerator cable end A and the decelerator cable end B into the throttle pulley e Tighten the throttle cable plate bolt Torque Throttle Cable Plate Bolt 6 0 N m 0 60 kgf m 52 in Ib e Check fuel leakage from the throttle body assy A WARNING Fuel spilled from the carburetors is hazardous e Apply a thin coating of grease to the throttle cable upper ends e Install the upper ends of the throttle cables in the grip e Fit the projection A of the right switch housing into the hole B of the handlebar e Turn the throttle grip and make sure that the throttle valves move smoothly and return by spring force e Check the throttle grip free play see Periodic Mainte nance chapter WARNING Operation with an incorrectly routed cable could re sult in an unsafe riding condition e Adjust Throttle Grip Free Play Choke Lever Free Play Idle Speed 3 104 FUEL SYSTEM Throttle Body Assy Throttle Body Assy Disassembly CAUTION Do not remove disassemble or adjust the main throttle sensor A subthrottle sensor B sub throttle valve actuator C throttle link mechanism D and throttle body assy E because they are adjusted or set at the manufacturer Adjustment of these parts could result in poor performance requiring replacement of the throttle body assy e Remove the throttle body assy see Throttle Body Assy Removal e Push the l
429. u ally raise the temperature of the coolant while stirring the coolant gently e Using the hand tester measure the internal resistance of the sensor OThe sensor sends electric signals to the ECU Electronic Control Unit and coolant temperature gauge in the meter unit OMeasure the resistance across the terminals and the body for the gauge at the temperatures shown in the table the hand tester does not show the specified values re place the sensor Water Temperature Sensor Resistance for ECU C Resistance Terminal 1 3 0 155 20 C 68 F n 80 176 0 32 0 011 110 C 230 F 0 1426 0 0041 Resistance for Water Temperature 0 Resistance Q Terminal 2 Body 50 C 122 F 210 40 Temperature 120 C 248 F 21 2 1 5 8 18070352 C 16 62 ELECTRICAL SYSTEM Radiator Fan System Radiator Fan Circuit BK Y BK Y RO ERE BK Y BL BL W BL W BL BK GP15029BW2 C Radiator Fan Radiator Fan Switch Joint Connector A Meter Ground Frame Ground Joint Connector B Fan Fuse 10 A Junction Box Main Fuse 30 A Battery 12 V 8 Ah ELECTRICAL SYSTEM 16 63 Meter Gauge Indicator Unit Meter Unit Removal e Remove Windshield see Frame chapter Screws A Quick Rivets B Pull out the rig
430. uel tank cap A to lower the pressure in the tank ODuring tank removal keep the tank cap open to release pressure in the tank This makes fuel spillage less e Draw the fuel out from the fuel tank with a commercially available pump A OUse a soft plastic hose B as a pump inlet hose in order to insert the hose smoothly OPut the hose through the fill opening C into the tank and draw the fuel out Front D A WARNING The fuel could not be removed completely from the fuel tank Be careful for remained fuel spillage e Remove Right Frame Cover see this chapter e Disconnect the fuel pump lead connector A and fuel level sensor lead connector B GCO9033BS1 C FUEL SYSTEM DFI 3 107 Fuel Tank e Be sure to place a piece of cloth A around the fuel hose pump outlet joint B e While pinching the hose joint locks C with fingers pull the joint out along the delivery pipe Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is disconnected fuel spills out from the hose and the pipe because of residual pressure Cover the hose connection with a piece of clean cloth to prevent fuel spillage e Close the fuel tank cap e Remove the fuel tank and place it on a flat surface ODo not remove the pump inlet hose A Fuel Tank Installation e Note the above WARNING see Fuel Tank Removal e Route the hoses correctly
431. uid 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 Ib 6506009853 an lr TEIL PERIODIC MAINTENANCE 2 53 Periodic Maintenance Procedures 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 the reservoir cap e Remove the rubber cap from the bleed valve A on the caliper e Attach a clear plastic hose B to the bleed valve and run the other end of the hose into a container e Fill the reservoir with fresh specified brake fluid e Change the brake fluid ORepeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes 1 Open the bleed valve A 2 Apply the brake and hold it B 3 Close the bleed valve C 4 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 reservoi
432. ures which if not correctly followed could result in per sonal injury or loss of life CAUTION This caution symbol identifies special instructions or procedures which if not strictly observed could result in dam age to or destruction of equipment This manual contains four more symbols in addition to WARNING and CAUTION which will help you distinguish different types of informa tion NOTE OThis note symbol indicates points of par ticular interest for more efficient and con venient operation e Indicates a procedural step or work to be done Olndicates a procedural sub step or how to do the work of the procedural step it follows It also precedes the text of a NOTE Indicates a conditional step or what action to take based on the results of the test or inspec tion in the procedural step or sub step it fol lows In most chapters an exploded view illustration of the system components follows the Table of Contents In these illustrations you will find the instructions indicating which parts require spec ified tightening torque oil grease or a locking agent during assembly GENERAL INFORMATION 1 1 General Information Table of Contents i re 1 2 1 PT 1 7 General Specifications pp 1 9 Technical Information Inlet System 22 2 47 4 11 eene enki 1 12 Technical Information New Ignitio
433. ut the problem still exists replace the ECU see this chapter Main Throttle Sensor Circuit 68617819841 C 6C17820BW1 C ECU Main Throttle Sensor 3 48 FUEL SYSTEM 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 Removal e Remove Fuel Tank see Fuel Tank Removal in the this chapter Water Temperature Sensor Connector A Inlet Air Pressure Sensor Bolt B e Raise the inlet air pressure sensor C and disconnect the inlet air pressure sensor connector D and the vacuum hose Installation NOTE OThe inlet air pressure sensor is the same part as the at mospheric sensor except that the sensor has a vacuum hose and different wiring e Install Vacuum Hose Inlet Air Pressure Sensor Torque Inlet Air Pressure Sensor Bolt 12 N m 1 2 kgf m 104 in Ib Input Voltage Inspection NOTE OBe sure the battery is fully charged OThe inspection is the same as Input Voltage Inspection of the main throttle sensor or the atmospheric pressure sensor FUEL SYSTEM DFI 3 49 Inlet Air Pressure Sensor Service Code 12 e Turn the ignition switch OFF e Remove the ECU see this chapter Do not disconnect the ECU connectors e Connect a digital voltmeter to the connector B with the needle adapter set Special Tool Needle Adapter Set 57001 1457 e Me
434. utator Cleaning and Armature Inspection Brush Lead Inspection Brush Plate and Terminal Bolt 16 51 Starter Relay Inspection 16 51 Lighting System ss 16 53 Headlight Beam Horizontal Adjustment 16 53 Headlight Beam Vertical Adjustment 16 53 Headlight Bulb Replacement 16 53 Headlight Removal Installation 16 54 City Light Bulb Replacement 16 54 Tail Brake Light LED Removal 16 55 Tail Brake Light LED Installation 16 55 Turn Signal Light Bulb Replacement 16 57 Turn Signal Relay Inspection 16 58 16 2 ELECTRICAL SYSTEM Radiator Fan 5 Fan System Circuit Inspection Fan Motor Inspection Radiator Fan Switch Inspection Water Temperature Sensor Meter Gauge Indicator Meter Unit Meter Unit Disassembly Bulb Electronic Combination Meter Unit Inspection Immobilizer System Equipped terree Operational Cautions Key
435. venly 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 IC igniter in ECU trouble Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Overheating Piston slap Cylinder piston clearance excessive Cylinder piston worn Connecting rod bent Piston pin piston pin hole worn Valve noise Valve clearance incorrec
436. vice Code 23 3 63 Camshaft Position Sensor Removal Installation pp 3 63 Camshaft Position Sensor Inspection Nt 3 63 Speed Sensor Service Code 24 25 tace teet Deua dn dec exea eie e ee eade 3 64 Speed Sensor Removal Installation pp 3 64 Speed Sensor Inspectionm pp 3 64 Input Voltage Inspection iit S E ee e rd ERR S 3 64 Output Voltage Inspection pp 3 64 Vehicle down Sensor Service Code 31 nn tnnt 3 66 ET 3 66 ie 3 66 nn 3 66 Subthrottle Sensor Service Code 32 3 69 Subthrottle Sensor 3 69 Input Voltage Irispectior ooo rt eins ee tisk rire rie 3 69 Output Voltage Inspectionm pp 3 70 eet eo ree eade tenue benedi ees ea ed 3 71 Immobilizer Amplifier Immobilizer Equipped Models Service Code 35 3 72 Antenna Resistance 3 72 Amplifier Input Voltage Inspection 3 72 Blank Key Detection Immobilizer Equipped Models Service Code 36 3 73 User ra 3 73 Stick Coils 1 2 3 4 Service Code 51 52 53 54 3 74 Removal Installation seis enti ious ites Aneel peste eae Hein een a 3 74 Input Voltage
437. voltage of the sensor with the engine stopped and with the connector joined e Turn the ignition switch ON Main Throttle Sensor Output Voltage Connections to Adapter Meter R sensor Y W lead Meter W sensor BR BK lead Standard 0 99 1 03 V DC at idle throttle opening 4 19 4 39 V DC at full throttle opening x lf the output voltage is out of the standard inspect the main throttle sensor resistance x If the output voltage is normal check the wiring for conti nuity Wiring Connection ECU Connector Throttle Sensor Connector B Y W lead ECU terminal 2 BR BK lead ECU terminal 14 ECU Connector Throttle Sensor Connector Immobilizer Equipped Models Y W lead ECU terminal 6 BR BK lead ECU terminal 20 x lf the wiring is good check the ECU for its ground and power supply see ECU section GC17816BS2 C FUEL SYSTEM DFI 3 47 Main Throttle Sensor Service Code 11 Resistance Inspection e Turn the ignition switch OFF e Disconnect the main throttle sensor connector e Connect a digital meter A to the main throttle sensor connector B Measure the main throttle sensor resistance Main Throttle Sensor Resistance Connections BL lead BR BK lead D Standard 4 6 80171168851 C x If the reading is out of the range replace the throttle body assy x lf the reading is within the range b
438. vy parts wearing gloves to prevent injury from possible sharp edges on the parts Solvent Use a high flush point solvent when cleaning parts High flush point solvent should be used according to directions of the solvent manufacturer 68020058 Cleaning vehicle before disassembly Clean the vehicle thoroughly before disassembly Dirt or 0 other foreign materials entering into sealed areas during ve hicle disassembly can cause excessive wear and decrease performance of the vehicle 68020068 GENERAL INFORMATION 1 3 Before Servicing Arrangement and Cleaning of Removed Parts Disassembled parts are easy to confuse Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly Storage of Removed Parts After all the parts including subassembly parts have been cleaned store the parts in a clean area Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re assembly Inspection Reuse of worn or damaged parts may lead to serious ac cident Visually inspect removed parts for corrosion discol oration or other damage Refer to the appropriate sections of this manual for service limits on individual parts Replace the parts if any damage has been found or if the part is be yond its service limit Replacement Parts Replacement parts must be KAWASAKI genuine or recommended by KAWASA
439. w driver OThen the tester indicator should flick B the tester indicator does not flick replace the speed sensor DC25V GP18070181 eApply a non permanent locking agent to the sensor bolt and sensor cover bolts Torque Speed Sensor Bolt 6 9 N m 0 70 kgf m 61 in Ib Speed Sensor Cover Bolts 6 9 N m 0 70 kgf m 61 in Ib ELECTRICAL SYSTEM 16 95 Switches and Sensors Fuel Level Sensor Inspection e Remove Fuel Tank see Fuel System DFI chapter e Open the clamps e Remove Bolts B Fuel Level Sensor C e Check that the float moves up and down smoothly without binding It should go down under its own weight x If the float does not move smoothly replace the sensor Float in Full Position A Float in Empty Position B Float Arm Stoppers C 105 2 112 2 mm 4 142 4 417 in from the Sensor Base Line D 33 6 40 6 mm 1 32 1 60 in from the Sensor Base Line E Sensor Base Line F e Using the hand tester A measure the resistance across the terminals in the fuel level sensor lead connector B Black Yellow C White Yellow D Special Tool Hand Tester 57001 1394 the tester readings are not as specified do not change smoothly according as the float moves up and down replace the sensor Fuel Level Sensor Resistance Standard Full position 4 10 Empty position E 90 100 e Apply a non permanent locking agent to the threads
440. w 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 compress it only enough to install it and no more CAUTION Do not reuse snap rings as removal weakens and deforms them They could fall out and score the cylinder wall e Install the cylinder see Cylinder Installation Cylinder Wear e Since there is a difference in cylinder wear in different di rections take a side to side and a front to back measure ment at each of the two locations total of four measure ments shown in the figure any of the cylinder inside diameter measurements ex ceeds the service limit replace the cylinder 10 mm 0 39 in A 60 mm 2 36 in B Cylinder Inside Diameter Standard 68 400 68 412 mm 2 6929 2 6934 in Service Limit 68 50 mm 2 6969 in Piston Wear e Measure the outside diameter A of each piston 5 mm 0 20 in B up from the bottom of the piston at a right angle to the direction of the piston pin x If the measurement is under service limit replace the pis ton Piston Diameter Standard 68 345 68 360 mm 2 6907 2 6913 in Service Limit 68 21 mm 2 6854 in GE16062BS1 C GE16063BS1 C GE16064BS1 C ENG
441. was caused by some other item or items they too must be repaired or replaced or the new replacement part will soon fail again e Measure coil winding resistance when the DFI part is cold at room temperature e Make sure all connectors in the circuit are clean and tight and examine wires for signs of burning fraying short etc Deteriorated wires and bad connections can cause reappearance of problems and unstable operation of the DFI system xIf any wiring is deteriorated replace the wiring 6C17045BS1 C 6617037351 FUEL SYSTEM DFI 3 25 Troubleshooting the DFI System e Pull each connector apart and inspect it for corrosion dirt and damage If the connector is corroded or dirty clean it carefully If it is damaged replace it Connect the connectors securely Check the wiring for continuity 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 Olf both ends of a harness A are far apart ground B the one end C using a jumper lead D and check the con tinuity between the end E and the ground F This en ables to check a long harness for continuity If the harness is open repair or replace the harne
442. 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 A to adjust the switch CAUTION To avoid damaging the electrical connections in side the switch be sure that the switch body does not turn during adjustment 2 38 PERIODIC MAINTENANCE Periodic Maintenance Procedures x If it does not go on inspect or replace the following items Battery see Electrical System chapter Brake Light see Electrical System chapter Main Fuse 30 A and Taillight Fuse 10 A see Electrical System chapter Front Brake Light Switch A see Electrical System chapter Rear Brake Light Switch see 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 Suspension chapter e Pump the rear portion of the motorcycle down and up A 4 or 5 times and inspect the smooth stroke xIf the shock absorber does not smoothly stroke or noise is found inspect the oil leak see Rear Shock Absorber Oil Leak Inspection or shock absorber clamps see Sus pension chapter Front Forks Rear Shock Absorber Oil Leak Inspecti
443. y Mspection 3 99 amp EP 3 99 Choke Cable teer eR eee edad et een Pe cu eae ede 3 99 Cable mc TR 3 99 Throttle Body ASSY 3 100 5 eta D 3 100 Engine Vacuum Synchronization Inspection 3 100 High Altitude Performance Adjustment 442 21 3 100 Throttle Body Assy Removal ertet eerte Roi EXER Rue RR ERREUR RR C ace 3 100 Throttle Body Assy Installations bte eene 3 102 Throttle Body Assy Disassembly pp 3 104 Throttle Body Assy Assembly 3 104 PRET A DT ESET 3 105 Element Removal lnstallation pp 3 105 Air Cleaner Element Inspection pp 3 105 Air Cleaner Oil Draininig 3 105 Air Cleaner Housing Removal 3 105 E Br ml 3 106 Fueli Tank Removal ooa item d du o te oq tes 3 106 Fuel Tank Installall n oct ed eee cor e per bebat 3 107 Fuel Tank Cap Inspection pp 3 109 Fuel Tank od adco ATEA de Rode reed 3 109 Evaporative Emission Control System California 3 110 Parts Removal InstallatiOli tat oe
444. y 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 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 Ga Tos ONo 9 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 Seat see Frame chapter e Disconnect the immobilizer Kawasaki self diagnos
445. y be defective in some manner not readily detectable with the hand tester If all other starter motor and starter motor circuit components check good but the starter motor still does not turn over or only turns over weakly replace the starter motor with a new one Brush Lead Inspection e Using the x 1 hand tester range measure the resis tance as shown Terminal Bolt and Positive Brush A Brush Plate and Negative Brush B Special Tool Hand Tester 57001 1394 x lf there is not close to 0 ohms the brush lead has an open Replace the terminal bolt assembly and or the brush holder assembly Brush Plate and Terminal Bolt Inspection e Using the highest hand tester range measure the resis tance as shown Terminal Bolt and Brush Plate A Terminal Bolt and Right hand End Cover B Special Tool Hand Tester 57001 1394 x lf there is any reading the brush holder assembly and or terminal bolt assembly have a short Replace the brush holder assembly and the terminal bolt assembly Starter Relay Inspection e Remove the battery negative cable from the battery negative terminal see Battery Removal e Remove the right side cover For immobilizer equipped model pull out the immobilizer amplifier A e Pull out the rubber cap A e Disconnect the connector B e Disconnect the starter motor cable C and battery positive cable from the starter relay D CAUTION The battery positive ca

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