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Be sure the battery is fully charged.

1. Saree Sh N ESSE OSS TICA 22 a d 9 KA f p dum t OOH H X LIAT TERA SL ASR ER 08809879045 C APPENDIX 17 39 Cable Wire Hose Routing 1 Run the reserve tank overflow hose between the air suction valve cover and the stick coil 2 Reserve Tank Overflow Hose 3 Run the reserve tank overflow hose under the throttle cables 4 Run the reserve tank overflow hose under the stick coil lead 5 Run the reserve tank overflow hose above the hose on the throttle body assy CAL SEA B1 and TH models 6 Throttle Cables 17 40 APPENDIX Cable Wire and Hose Routing 2 E TEES m cor k EE m ak ING Poh APPENDIX 17 41 Cable Wire and Hose Routing 5 Air Cleaner Housing Air Switching Valve Air Switching Valve Hoses ECU Breather Hose Clamp Drain Hose Throttle Body Assy Vacuum Hose To the Intake Air Pressure Sensor View from A Clamp View from B White Paint Marks 17 42 APPENDIX Cable Wire and Hose Routing CAL SEA B1 and TH Models t 9 C9 gl Al A 1 5 55 SRR Exi qup STH 6 by EN um Qu X Y 3 A WARS 088
2. 12 25 Brake Disc Removal fob nro inet cea tie Lotte deae tue nd dca ie uta 12 25 Brake Disc Installation serie on tratte aa v 12 25 Brake Disc Wear Inspectign 12 25 Brake Disc Warp INSpPe ction e eA ra E AAE aaae A ARE aR 12 25 az caa 12 26 Brake Fluid Level 12 26 Brake Fluid Change sui xp 12 26 Brake Line Bleedirig croi edo o rete ei lac Rien ase Ek bd e Dade 12 26 OSG e ET 12 29 Brake Hose Removallnstallation pp 12 29 Brake Hose Inspectigonm 1 12 29 Anti Lock Brake System Equipped 12 30 o1z a HACET A 12 30 12 2 5 ABS Servicing 12 34 ABS Troubleshooting Outline eoru rim tt e pee e eoe e e eR eee 12 36 Inquiries 12 39 Self diagnosis Outline 12 41 Self diagnosis Procedures WR St Big 12 41 Service Code Clearing 222 1 1 21
3. 13 15 Spring Preload Adjustment pp 13 15 Rear Shock Absorber 13 15 Rear Shock Absorber 13 16 Rear Shock Absorber 13 16 52 MM S 13 17 REMOVAl 13 17 Swingarm Installato ma M ubere seris 13 18 Swingarm Bearing Removal Ne 13 18 Swingarm Bearing Installation pp 13 19 Swingarm Bearing Sleeve Inspection 13 20 Swingarm Bearing Lubrication pp 13 20 Chain Guide Inspection 13 2 SUSPENSION Exploded View SUSPENSION 13 3 Exploded View No Fastener Remarks AL Front Axle Clamp Bolt Front Fork Bottom Allen Bolts 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 6M02357885 C SUSPENSION 13 5 Exploded View 4 Swingarm Pivot Shaft Nut 108 11 0 80 G Apply grease R Replacement Parts 13 6 SUSPENSION Specifications Item Standard Front Fork Per One Unit Fork Inner Tube Outside Diameter Air Pressure Fork Spring Setting Damper Setting Fork Oil Recommended Oil Amount
4. Transmissloft a prete ee re TRANSMISSION Assy s cda Transmission Assy Installation Transmission Assy Disassembly ied Transmission Assy Assembly pp Transmission Shaft Removal esses eene nnne Transmission Shaft Installation pp Transmission Shaft Disassembly 1 etude ete deed cune depen beue c lence Transmission Shaft Assembly pp Shift Drum and Fork Removal pp Shift Drum and Fork Installatiom shift Dr m Disassemibly nido Roa Cr eee de De ee ol ce ce Shift Drum ASSenibly trii eb tne deti endete urit ddl ue t Shift Fork Bending Inspection tte eme Se tp itte eret ipe Ree re ERR Shift Fork Gear Groove Wear 8 Shift Fork Guide Pin Drum Groove Wear Inspection Gear Dog and Gear Dog Hole Damage Inspection Ball Bearing Needle Bearing and Oil Seal Ball and Needle Bearing 22 Ball and Needle Bearing Wear Oil Seal INSPEC CU OM sed toe meer d eee e ve a vd ed 9 2 CRANKSHAFT TRANSMISSION Exploded View imd T inet 6 07
5. FUEL SYSTEM DFI 3 85 Yellow Engine Warning Indicator Light LED Yellow Engine Warning Indicator Light LED Inspection e Refer to the Meter Unit Inspection in the Electrical System chapter Yellow Engine Warning Indicator Light LED Circuit for DFl System j 6C17198FW2 C 1 ECU 2 Meter Unit 3 86 FUEL SYSTEM DFI ECU Identification OMost countries have their own regulations so each ECU has different characteristic So do not confuse ECU with each other and use only the ECU for your model Other wise the motorcycle can not clear the regulation ECU Identification Part Number A Specification AU AU LAMS ID 21175 0705 PH WVTA FULL H GB WVTA FULL H 21175 0706 SEA B2 SEA B1 21175 0707 TH US 21175 0732 CA 21175 0733 CAL 21175 0734 BR 21175 0799 IN ECU Removal NOTICE Never drop the ECU especially on a hard surface Such a shock to the ECU can damage it Remove the fuel tank see Fuel Tank Removal e Disconnect the connectors A and remove the ECU B ECU Installation e Installation is the reverse of removal ECU Power Supply Inspection Remove the fuel tank see Fuel Tank Removal e Visually inspect the ECU connectors If the connector is clogged with mud or dust blow it off with compressed air Remove the ECU see ECU Removal e Visually inspect the terminals A of the ECU conne
6. fa 2d ada ada aga aoa a 5 0 45 0 49 2 8012 8512 90 2 9513 00 3 05 3 1013 15 3 20 3 25 3 30 3 35 3 4013 45 3 B osro ss a odz o oo oo ve eda ri oo afa e 0 60 0 64 2 95 3 0513 10 3 20 3 2513 3013 3513 4013 45 3 m nimimm en 34439 EXE DES ERE ERT DESERT DES DES INSTALL THE SHIM THIS THICKNESS mm GS07119BW3 C 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 42 mm Replace 2 95 mm shim with 3 20 mm shim 5 Remeasure the valve clearance and readjust if necessary 2 24 PERIODIC MAINTENANCE Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE a PRESENT SHIM Example PART No 92180 1018 1020 102211024 1026 1028 010321034 1036 1038 1042 1044 1046 1048 1050 1052 MARK 60 65 70 75 80 85 Q 95 oo 05 19 20 25 30 35 40 45 0 00 0 04 2 502 55 2 60 2 6 2 702 75 2 80 2 85 2 902 95 3 00 3 05 3 10 3 15 3 2013 25 voveo ashe oa eq oe ra sd os a o oo oa 1 nd e 0 e oole s
7. CRANKSHAFT TRANSMISSION 9 3 Exploded View No Fastener Torgus Remarks kgf m ft Ib 1 Connecting Rod Big End Nuts see Text 2 Rotor Bolt 40 4 1 30 3 Oil Plate Bolts 9 8 1 0 87 L 4 Oil Pipe Bolts 9 8 1 0 87 E 5 Breather Plate Bolts 9 8 1 0 87 in lb E 6 Shift Shaft Return Spring Pin 29 3 0 21 L 7 Bolt M6 L 32 19 6 2 0 14 S 8 Bolts M6 L 38 mm 19 6 2 0 14 S 9 Bolts M6 L 45 19 6 2 0 14 S 10 Bolt M8 L 50 27 5 2 8 20 S 11 Bolts M8 L 60 25 5 2 6 19 MO S 12 Crankcase Bolts M8 L 73 mm 25 5 2 6 19 MO S 13 Bolt M8 L 110 27 5 2 8 20 S 14 Crankcase Bolts M9 L 83 mm 44 4 5 32 MO S 15 Crankcase Bolts M9 L 113 mm 44 4 5 32 MO S 16 Bolt M8 L 60 27 5 2 8 20 S 17 Crankcase Bolts M8 L 110 27 5 2 8 20 S Upper Crankcase Bolt M8 L 120 mm S L G Apply grease L Apply a non permanent locking agent LG Apply liquid gasket MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts S Follow the specified tightening sequence 9 4 CRANKSHAFT TRANSMISSION Exploded View ot
8. Fastener Remarks Speed Sensor Bracket Bolts 2 Speed Sensor Bolt 7 8 0 80 69 in Ib L 3 Sprocket Nut 125 12 7 92 MO 4 Engine Sprocket Cover Bolts 9 8 1 0 87 in lb 5 Sprocket Nuts 59 6 0 44 R 6 Rear Axle Nut 108 11 0 80 G Apply grease HG Apply high temperature grease HO Apply heavy oil L Apply a non permanent locking agent MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts 11 4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain Drive Chain Slack Drive Chain Wear 20 link Length Standard Chain Make Type Link Sprockets Rear Sprocket Warp 25 35 mm 1 0 1 4 in 317 5 318 2 mm 12 50 12 53 in DAIDO DID 520VP2 T 114 Links TIR 0 4 mm 0 016 in or less 323 mm 12 7 in TIR 0 5 mm 0 020 in FINAL DRIVE 11 5 Special Tools Inside Circlip Pliers Bearing Driver Set 57001 143 57001 1129 7570143ST C 7571129ST C 11 6 FINAL DRIVE Drive Chain Drive Chain Slack Inspection e Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter Drive Chain Slack Adjustment Refer to the Drive Chain Slack Adjustment in the Periodic Maintenance chapter Wheel Alignment Inspection Adjustment Refer to the Wheel Alignment Inspection in the Periodic Maintenance chapter
9. Oxygen Sensor Incorrect Output Voltage Service Code 94 Equipped Models Oxygen Sensor Removal Installation eise ennemis Oxygen Sensor Inspection Purge Valve Service Code CAL SEA B1 and TH Purge Valve Purge Valve Inspection Yellow Engine Warning Indicator Light LED Yellow Engine Warning Indicator Light LED EOD ree etd ECU Identification ECU ECU Installation ECU Power Supply Inspection DFI Power Source ECU Fuse Remowval ECU Fuse Installation ECU Fuse Inspection ECU Main Relay ECU Main Relay Inspection Fuel 2 2 222 Fuel Pressure Inspection Fuel Flow Rate Inspection Fuel Pump 22 Fuel Pump Removal Fuel Pump Installation Fuel Pump Operation Inspection 0 0000 0 00 0 0000000 Fuel Pump Operating Voltage Inspection pp Pressure Regulator Removal Fuel Fi
10. 12 16 Front Caliper Disassembly 3 6 adeo 12 17 58 4 12 17 Rear Caliper Disassembly pp 12 17 Rear Caliper ASSembly six rrr oan aan 12 17 Caliper Fluid Seal Damage 12 17 Caliper Dust Seal Damage Inspection 12 18 Caliper Dust Boot and Friction Boot Damage 12 18 Caliper Piston and Cylinder Damage Inspection pp 12 19 Caliper Holder Shaft Wear Inspection Ne 12 19 Brake e eue eee e a a net ote nece i P d Front Brake Pad 2 Front Brake Pad Installation Rear Brake Pad Removal Rear Brake Pad Installation Brake Pad Wear Inspection Master Cylinder eot tnit eo Front Master Cylinder FSerowalc uot oec ote Ipae Pes inm 12 21 Front Master Cylinder Installation itn teh 12 21 Rear Master Cylinder Removal bp 12 22 Rear Master Cylinder Installation 12 23 Master Cylinder Disassembly dee helio 12 23 Master Cylinder Assembly Ne 12 23 Master Cylinder Inspection pp 12 24 sj NBI
11. Drive Shaft 1st Gear 2nd Gear 3rd Gear 4th Gear 5th Gear 6th Top Gear Bushing Toothed Washer 34 mm 1 34 in Circlip Bushing Thrust Washer 30 mm 1 18 in Needle Bearing Circlip Output Shaft Spacer 39 mm 1 54 in Washer 40 mm 1 57 Bushing Toothed Washer 38 mm 1 50 in Shim 28 mm 1 10 in Steel Ball Circlip 932 2 mm 1 268 in Thrust Washer 25 mm 0 98 in CRANKSHAFT TRANSMISSION 9 43 Transmission Shift Drum and Fork Removal Refer to the Transmission Assy Disassembly Shift Drum and Fork Installation Refer to the Transmission Assy Assembly Shift Drum Disassembly Refer to the Transmission Assy Disassembly Shift Drum Assembly Refer to the Transmission Assy Assembly Shift Fork Bending Inspection e Visually inspect the shift forks and replace any fork that is bent A bent fork could cause difficulty in shifting or allow the transmission to jump out of gear when under power 90 A A 6113014581 C Shift Fork Gear Groove Wear Inspection e Measure the thickness A of the shift fork ears and mea sure the width B of the gear grooves x If the thickness of a shift fork ear is less than the service limit replace it with a new one Shift Fork Ear Thickness Standard 5 9 6 0 mm 0 232 0 236 in Service Limit 5 8 mm 0 23 in x If the gear groove is worn over the service l
12. DESI 9113321851 9 38 CRANKSHAFT TRANSMISSION Transmission x lf the drive shaft bearing holder A is to be removed fol low the next procedure OApply a non permanent locking agent to the threads of the drive shaft bearing holder screw B and tighten it Torque Drive Shaft Bearing Holder Screw 4 9 0 50 kgf m 43 in Ib CRANKSHAFT TRANSMISSION 9 39 Transmission Apply engine oil to the shift drum groove Install the following on the transmission case A Shift Drum B Pin C Shift Drum Cam D OAlign the pin with the hole on the shift drum cam Apply a non permanent locking agent to the shift drum cam bolt E and tighten it Torque Shift Drum Cam Bolt 12 N m 1 2 kgf m 106 in Ib e Set the shift drum to the neutral position e Install the following as a set Drive Shaft F Output Shaft G e Apply engine oil to the shift fork ears e Install the shift forks as shown in the figure OPosition the one H with shortest ears on the drive shaft and place the pin in the center groove in the shift drum OThe two shift forks J on the output shaft are identical Apply engine oil to the shift rods e Install the shift rods OThe rod K length of the output shaft side is shorter than the rod L length of the drive shaft side e Apply molybdenum disulfide oil solution to the transmis sion gears shown with X marks M e Be sure that the spacer N is on
13. 7 16 Oil Pressure Measurement ctt eel cee 7 16 Oil Press re SWIICINs iss lec e 7 17 Oil Pressure Switch Removal 7 17 Oil Pressure Switch Installation nmn 7 17 7 2 ENGINE LUBRICATION SYSTEM Exploded View ENGINE LUBRICATION SYSTEM 7 3 Exploded View Torque No Fastener 1 Oi Fiter vs ts m 2 HoderMom ngBot 25 25 18 t 3 TOi Passage Pug v6 35 sne 4 oi Passege Pug a 5 Oil Pressure Switch 6 Oil Plate Bolts o8 to 87 in lb L 7 Oil Pressure Relief Valve 15 1 5 11 L 8 Oil Pipe Plate Bolt 9 8 1 0 87 in lb L 9 Filter Plate Bolts 9 8 1 0 87 in Ib L 10 Pan Bolts 12 1 2 106 in Ib S 11 Engine Oil Drain Plug 30 3 1 22 12 Lower Fairing Bracket Bolts 12 1 2 106 in Ib L 13 Oil Pump Chain Guide Bolts 12 1 2 106 in Ib L 14 Oil Pump Cover Bolts 9 8 1 0 87 in Ib L 15 Oil Pump Sprocket Bolt 12 1 2 106 in Ib L Lh EO Apply engine oil G Apply grease L Apply a non permanent locking agent LG Apply liquid gasket Lh Left hand Threads MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts S Follow the specified
14. Electronic Control Unit Rear Wheel Rotation Sen Bk Y 8k Y 8K Y 3K Y BK Y RAY Joint Connector B License Plate 12058 Rear Right ie ita Turn Signal Light 12V10W 157 is Tail Brake Light 1 3 8V 0 3 3 4 Rear Left Turn Signal H H Light 12V108 Fuse P Box 3 fees av pU 5 i 888 AU LAMS am 25 ES To R BK 23 az I TI Kawasaki 1448 55 5 55 Self 5 2 diagnosis 1 5 Frame Frame Systen 1 Ground Ground eX z Connector e 222 1 Relay 2 1 1 a r q 26 ore Fuel Fuel L 5 Reserve Punp 5 5 By ges e Switch Sa Bam i stan Rear hii i m HUS Eu 5 Light 304 3 Switch Battery Self starter diagnosis Abs k Pennie Motor Terminal SS ELATI Ground Ground System Fuse Box 3 ABS Hydraulic Unit Connector 5 Motor Relay Fuse 25 2 5 Solenoid Valve Rekay Fuse 154 LB Light Blue IGNITION SWITCH CONNECTIONS 0 Orange SON i q Ignition Battery Ignition Signal BR GY BL n oo nui ommo Push omm White 98052 0624B 06734 06754 08974 Y Yellow W2RO624BW5 C 16 20 ELECTRICAL SYSTEM Precautions There are a num
15. BRAKES 12 29 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 12 30 5 Anti Lock Brake System Equipped Models Parts Location Front Wheel Rotation Sensor A Front Wheel Rotation Sensor Rotor B Rear Wheel Rotation Sensor A Rear Wheel Rotation Sensor Rotor B Yellow ABS Indicator Light LED A ABS Hydraulic Unit A ABS Solenoid Valve Relay Fuse 15 A A ABS Motor Relay Fuse 25 A B 5 12 31 Anti Lock Brake System Equipped Models ABS Kawasaki Diagnostic System Connector A ABS Self diagnosis Terminal B 12 32 BRAKES Anti Lock Brake System Equipped Models ABS System Wiring Diagram 25 9 9 1 Ignition Switch 10 Fuse Box 2 Front Wheel Rotation Sensor 11 ABS Solenoid Valve Relay Fuse 15 A 3 Front Brake Light Switch 12 ABS Motor Relay Fuse 25 A 4 Rear Wheel Rotation Sensor 13 ABS Kawasaki Diagnostic System Connec 5 Rear Brake Light Switch tor 6 Frame Ground 14 ABS Self diagnosis Terminal 7 Battery 12 V 10 Ah 15 ABS Hydraulic Unit 8 Main Fuse 30 16 Fuse Box 9 Frame Ground 17 Ignition Fuse 10 A 18 Meter Unit OColor Codes BK Black GY Gray R Red BL Blue O Or
16. Spark plug incorrect Replace it with the correct plug see chapter 2 ECU trouble Inspect see chapter 3 Fuel air mixture incorrect Little fuel in tank Supply fuel see Owner s Manual Air cleaner clogged poorly sealed or missing Clean element or inspect sealing see chapter 2 Air duct loose Reinstall see chapter 3 Throttle body assy holder loose Reinstall see chapter 3 Throttle body assy dust seal damage Replace see chapter 3 Fuel injector O ring damage Replace see chapter 3 Fuel filter or pump screen clogged Inspect and replace fuel pump see chapter 3 3 30 FUEL SYSTEM DFI System Troubleshooting Guide Symptoms or Possible Causes Actions Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump see chapter 3 Fuel line clogged Inspect and repair see chapter 3 Intake air pressure sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Intake air temperature sensor trouble Main throttle sensor trouble Subthrottle sensor trouble Subthrottle valve actuator trouble Unstable rough idling Fuel pressure too low or too high Fuel injector trouble Main throttle sensor trouble Subthrottle sensor trouble Subthrottle valve actuator trouble Engine vacuum not synchronizing Intake air pressure sensor trouble Water temperature sensor trouble Inspect see chapter 3 Inspect s
17. plebis de tei eb i eben 2 28 Drive Chain Lubrication Condition Inspection 2 28 Drive Chain Slack 2 29 Drive Chaim Slack Adjustment oie tre n 2 29 Wheel Alignment Inspection nitent trennen tic nnn n 2 30 Drive Chain Wear 2 31 Chain Guide Inspection enhn 2 31 Brake Systemi 2 32 Brake Fluid Leak Brake Hose and Pipe Inspection 2 32 Brake Hose and Pipe Damage and Installation Condition Inspection 2 32 Brake Fluid Level 9 nnnm 2 33 Brake Pad Wear Inspection pp 2 34 Brake Operation Inspection 2 34 Brake Light Switch Operation Inspection 2 34 SIUTer oio 2 35 Front Forks Rear Shock Absorber Operation Inspection 2 35 Front Fork Oil Leak 2 35 Rear Shock Absorber Oil Leak Inspection 2 36 Steering SY SUS 2 36 Steering Play Inspection eb e de 2 36 Steering PlayAdustnmient de ete ral eot
18. 08102370845 C CRANKSHAFT TRANSMISSION 9 5 Exploded View No Fastener Torque Remarks kgf m ft Ib 1 Transmission Case Bolts 20 2 0 15 2 Positioning Lever Bolt 12 1 2 106 in Ib L 3 Trasnmission Case Oil Nozzle 2 9 0 30 26 L 4 Shift Drum Cam Bolt 12 1 2 106 in Ib L 5 Shift Drum Bearing Holder Screws 4 9 0 50 43 L 6 Shift Rod Plate Bolt 9 8 1 0 87 in lb L 7 Neutral Switch Holder Screw 4 9 0 50 43 L 8 Holder Screw 4 9 0 50 43 in lb L 9 Drive Shaft Bearing Holder Screw 4 9 0 50 43 in lb L 10 Shift Shaft Cover Bolts 9 8 1 0 87 in lb L 3 11 Shift Shaft Cover Screw 4 9 0 50 43 L S Neutral Switch 15 Shift Pedal Bolt 12 EO Apply engine oil G Apply grease L Apply a non permanent locking agent MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts S Follow the specified tightening sequence 9 6 CRANKSHAFT TRANSMISSION Specifications Item Standard Service Limit Crankshaft Connecting Rods Connecting Rod Bend SS TIR 0 2 100 mm 0 008 3 94 in Connecting Rod Twist 0 2 100 0 008 3 94 Connecting 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 0 017 0 041 mm 0 08 mm Clearance 0 0007 0 0016
19. GP026148W5 C ELECTRICAL SYSTEM 16 7 Exploded View a Rai Semis ar 2 Front Brake Light Switch Screw 0 12 11 in Ib 3 Engine Ground Lead Terminal Bolt 9 8 1 0 87 in lb 4 Starter Relay Terminal Bolts 3 6 0 36 31 in Ib 5 Starter Motor Cable Terminal Nut 6 0 0 61 53 in Ib 6 Starter Motor Terminal Locknut 11 1 1 97 7 Starter Motor Mounting Bolts 9 8 1 0 87 in lb L 8 Starter Motor Through Bolts 5 0 0 51 44 in Ib 9 EX650F Model G Apply grease L Apply a non permanent locking agent R Replacement Parts 16 8 ELECTRICAL SYSTEM Exploded View GPO2615BWS C ELECTRICAL SYSTEM 16 9 Exploded View Torque No Fastener Lou kgf m ftlb Remarks 2 Fuel Pump Bolts 9 8 1 0 87 in lb L S 3 Sidestand Switch Bolt 8 8 0 90 78 in lb L 4 Spark Plugs 15 1 5 11 5 Water Temperature Sensor 12 1 2 106 in Ib 6 Alternator Cover Bolts 9 8 1 0 87 in Ib 7 Stator Coil Bolts 12 1 2 106 in Ib L 8 Alternator Lead Holding Plate Bolt 9 8 1 0 87 in lb L 9 Starter Motor Clutch Bolts 34 3 5 25 L 10 Alternator Rotor Bolt 155 15 8 114 MO 11 Speed Sensor Bolt 7 8 0 80 69 in Ib L 12 Neutral Switch 15 1 5 11 13 Sensor Equipped Models 44 4 5 32 14 Pressure Switch 15 1 5 11 LG 15 Crankshaft Sensor Bolts 6 0 0 61 53 in Ib 16 Timing Rotor Bolt 40 4 1 30 L Apply a non permanent lock
20. NOTICE 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 Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Air Cleaner Housing see Air Cleaner Housing Removal in the Fuel System DFI chapter Throttle Body Assy see Throttle Body Assy Removal in the Fuel System DFI chapter Radiator and Water Hoses see Radiator and Radiator Fan Removal in the Cooling System chapter Baffle Plate see Cylinder Head Cover Removal in the Engine Top End chapter Frame Covers see Frame Cover Removal in the Frame chapter Lower Fairing Brackets see Lower Fairing Bracket Re moval in the Frame chapter Muffler see Muffler Removal in the Engine Top End chapter Clutch Cable Lower End see Clutch Cover Removal in the Clutch chapter Stick Coils see Stick Coil Removal in the Electrical Sys tem chapter Shift Pedal see Shift Pedal Removal in the Crank shaft Transmission chapter Engine Sprocket see Engine Sprocket Removal in the Final Drive chapter e Disconnect the oil pressure switch lead terminal see Oil Pressure Switch Removal in the Engine Lubrication Sys tem ENGINE REMOVAL INSTALLATION 8 5 Engine Removal Installation e Disconnect Crankshaft Sensor Le
21. 1 22 2 2 444 44441 00001000000000000000000 8 nnne 16 77 Oxygen Sensor Removal Equipped 16 78 Oxygen Sensor Installation Equipped 16 78 Oxygen Sensor Inspection Equipped 16 78 Relay BOX wr PRICE 16 79 Qua ot 16 79 Relay Box 16 79 Relay Circuit MS PSCHON 16 79 Diode Circuit Inspection nct tentent n teet PS E E Rode 16 80 PUSS 16 82 30 A Main Fuse Removal 16 82 PUSS BOX Fuse ia rai a letale des 16 82 FUse iS tell ARON 16 82 EE EM 16 82 ELECTRICAL SYSTEM 16 3 This page intentionally left blank 16 4 ELECTRICAL SYSTEM Exploded View ELECTRICAL SYSTEM 16 5 Exploded View Wem i Front Turn Signal Light Mounting Screws 11 in Ib 2 License Plate Light Mounting Screws 0 12 11 in Ib 16 6 ELECTRICAL SYSTEM Exploded View
22. Cylinder Head ENGINE TOP END 5 29 e Install the front camshaft chain guide A Olnsert the end B of front camshaft chain guide into the hollow on the lower crankcase half e Install the other removed parts see appropriate chap ters Cylinder Head Warp Inspection Remove the cylinder head see Cylinder Head Removal Clean the cylinder head Lay a straightedge across the lower surface of the cylinder head at several positions e Use a thickness gauge A to measure the space between the straightedge B and the head Cylinder Head Warp Standard Service Limit 0 05 mm 0 002 in x If the cylinder head is warped more than the service limit replace it with a new one 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 5 30 ENGINE TOP END Valves Valve Clearance Inspection e Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter Valve Clearance Adjustment e Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter Valve Removal Remove cylinder head see Cylinder Head Removal Remove the valve lifter and shim OMark and record the valve lifter and shim locations so that they can be installed in their original positions e Using the valve spring compressor assembly remove the valve Spe
23. Fuel Injectors FUEL SYSTEM DFI 3 97 Fuel Injector Removal Installation e Refer to the Throttle Body Assy Disassembly Assembly Fuel Injector Audible Inspection e Start the engine and let it to idle e Apply the tip of a screwdriver A to the fuel injector B Put the grip end onto your ear and listen whether the fuel injector is clicking or not OA sound scope C can also be used OThe click interval becomes shorter as the engine speed rises e Do the same for the other fuel injector x If all the injectors click at a regular intervals the injectors are normal e Turn the ignition switch to OFF xIf any fuel injector does not click check the fuel injector resistance see Fuel Injector Resistance Inspection Fuel Injector Resistance Inspection e Remove Fuel Tank see Fuel Tank Removal Air Cleaner Housing see Air Cleaner Housing Removal e Disconnect the injector connector A e Connect a digital meter B to the injector terminal e Measure the fuel injector resistance Fuel Injector Resistance Connections For Fuel Injector 1 WIR BL R Terminal For Fuel Injector 2 WIR BL Y Terminal Standard About 11 7 12 3 at 20 C 68 F x If the reading is out of the standard replace the injector xIf the reading is within the standard check the power source voltage see Fuel Injector Power Source Voltage Inspection 80170120651 80170130651 3 98 F
24. Headlight Circuit Relay 1 3 7 6 ECU Main Relay Fuel Pump Relay Starter Circuit Relay Fan Relay The actual reading varies with the hand tester used 16 80 ELECTRICAL SYSTEM Relay Box Relay Circuit Inspection with the battery connected Tester Tester Connection Reading Q 2 11 1 3 0 Fuel Pump Relay Fan Relay Battery Tester Connection Tester Connection DC 25 V Range Reading V Starter Battery Circuit Relay 1112 Voltage Apply positive lead Apply negative lead If the tester does not read as specified replace the relay box e Install the relay box see Relay Box Installation Diode Circuit Inspection Remove the relay box see Relay Box Removal Check the conductivity of the following pairs of terminals see Relay Box Internal Circuit in this section Diode Circuit Inspection 1 11 2 11 12 13 12 15 12 16 13 14 13 15 Tester Connection The resistance should be low one direction and more than ten times as much in the other direction If any diode shows low or high in both directions the diode is defective and the relay box must be replaced NOTE OThe actual meter reading varies with the meter or tester used and the individual diodes but generally speaking the lower reading should be from zero to one half the scale
25. 61042568W2 C CRANKSHAFT TRANSMISSION 9 17 Crankcase Splitting Fit the lower crankcase half to the upper crankcase half Olnsert A the breather pipe B on the upper crankcase half through the hole C on the lower crankcase half NOTE OMake the application finish within 20 minutes when the liquid gasket to the mating surface of the lower crankcase half is applied fit the case and tighten the case bolts just after finishing the application of the liquid gasket Tighten the lower crankcase bolts following the sequence numbers on the lower crankcase half OThe crankcase bolts 9 1 6 have copper plated washers replace them with new ones OApply molybdenum disulfide oil solution to both sides of the copper plated washers and the threads of the crankcase bolts 9 OTighten Crankcase Bolts M9 1 2 L 113 mm 4 45 in with Copper Plated Washers Crankcase Bolts 9 3 4 L 83 mm 3 27 with Copper Plated Washers Crankcase Bolts 9 5 6 L 113 mm 4 45 in with Copper Plated Washers Torque Crankcase Bolts 9 44 N m 4 5 32 ft lb OApply molybdenum disulfide oil solution to flange and the threads of the crankcase bolts M8 7 10 OTighten Torque Crankcase Bolts M8 25 5 2 6 kgf m 19 ft lb ODo not apply molybdenum disulfide oil solution to the crankcase bolts 8 A OTighten Torque Crankcase Bolts M8 27 5 2 8
26. 879210645 6 ENGINE TOP END 5 11 Clean Air System Air Suction Valve Removal Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Air Cleaner Housing see Air Cleaner Housing Removal in the Fuel System DFI chapter Air Switching Valve see Air Switching Valve Removal Air Suction Valve Cover Bolts A Clamp B Air Suction Valve Cover C e Remove the air suction valve A Air Suction Valve Installation e Install the air suction valve A so that its side where stop per is fixed with the screws B faces the front C GE04048BS1 e Install the air suction valve cover A and clamp B as shown e Tighten Torque Air Suction Valve Cover Bolts C 9 8 1 0 kgf m 87 e Install the other removed parts see appropriate chapter 5 12 ENGINE END Clean Air System Air Suction Valve Inspection e Remove the air suction valve see Air Suction Valve Re moval e Visually inspect the reeds A for cracks folds warps heat damage or other damage x If there is any doubt as to the condition of the reeds re place the air suction valve as an assembly e Check the reed contact areas B of the valve holder for grooves scratches any signs of separation from the holder or heat damage x If there is any doubt as to the condition of the reed contact areas replace the air suction valve as an assembly x If any carbon or other foreign particle
27. A WARNING This battery is sealed type Never remove seal sheet B even at charging Never add water Charge with current and time as stated below Terminal Voltage 11 5 less than 12 8 V Standard Charge 1 2 A x 5 10 h see following chart Quick Charge 5 0Ax1h NOTICE If possible do not quick charge If the quick charge is done unavoidably do the standard charge later on Terminal Voltage less than 11 5 V Charging Method 1 2 20h 8 08010851 0 25 50 75 10000 B GP08071BS1 C 8 09001251 C Charge Time h o2 eo ES 1 1 1 1 L 1 11 6 11 8 12 0 12 2 12 4 12 6 12 8 13 0 Battery Terminal Voltage V GP08021BS1 16 28 ELECTRICAL SYSTEM Battery NOTE v Olncrease the charging voltage to a maximum voltage of 25 V ifthe battery will not accept current initially Charge for than 5 minutes at the increased voltage then check if the battery is drawing current If the battery will accept current decrease the voltage and charge by the standard charging method described on the battery case If the battery will not accept current after 5 min utes replace the battery Battery A Battery Charger B Standard Value C Current starts to flow D GPOS008BS1 C e Determine battery condition after refreshing charge
28. DE eq estin ber Connecting ROG Ipstallstobis cete tnit aeter oa rotto etu uaa Choo dette Crankshaft Connecting Rod Connecting Rod Bend Inspection s eco Connecting Rod Twist InspecHOn eto od ie ene ipta etn bete M E EIE Connecting Rod Big End Side Clearance Connecting Rod Big End Bearing Insert Crankpin Wear Inspection Crankshaft Side Clearance Inspectiom Crankshaft Runout Inspectiom enne nns Crankshaft Main Bearing Insert Journal Wear M G 45 ette nea terrre PT Extr eie tpe E ee rre da Deed Balancer Installation RT ette e Ett can ea e teda a eR tenes Balancer Shaft Bearing Insert Journal Clearance Inspection External Shift Mechanism m ttt tte ae eae rette te eMe Mae e PR LEE Shift Pedal Shift Pedal Installation sis e ete a tree re P Cr este Parere ad External Shift Mechanism External Shift Mechanism Installation pp External Shift Mechanism
29. GE16102BS1 GE16176BS1 GE16144BS1 GE16145BS1 C 5 40 ENGINE END Cylinder Pistons Piston Wear Inspection e Measure the outside diameter A of each piston 18 mm 0 7087 in B up from the bottom of the piston at a right angle to the direction of the piston pin If the measurement is under service limit replace the pis ton Piston Diameter Standard 82 969 82 984 mm 3 2665 3 2671 in Service Limit 82 82 mm 3 261 in Piston Ring Piston Ring Groove Wear Inspection Check for uneven groove wear by inspecting the ring seat ing The rings should fit perfectly parallel to groove surfaces If not replace the piston and all the piston rings e With the piston rings in their grooves make several mea surements with a thickness gauge A to determine piston ring groove clearance Piston Ring Groove Clearance Standard Top 0 03 0 07 mm 0 004 0 003 in Second 0 02 0 06 mm 0 001 0 002 in Service Limit Top 0 17 mm 0 0067 in Second 0 16 mm 0 0063 in Piston Ring Groove Width Inspection e Measure the piston ring groove width 5 a vernier caliper at several points around the piston Piston Ring Groove Width Standard Top A 0 92 0 94 mm 0 0362 0 0370 in Second B 1 01 1 03 mm 0 0398 0 0406 in Service Limit Top 1 02 mm 0 0402 in Second 1 11 mm 0 0437 in xIf the width of an
30. Ocloudy Orain Osnow 5 other Temperature Ohot Ocold Overy cold Dalways other Problem chronic frequency Road Ostreet Ohighway Omountain road Ouphill Odownhill Obumpy Opebble Altitude Dhigh about 1 000 m or more Motorcycle conditions when problem occurred Yellow engine warning indicator light LED 5 on immediately after turning the ignition switch to ON and goes off after about 2 seconds normal L1goes on immediately after turning the ignition switch to ON goes off after about 2 seconds and goes on again after about 10 seconds ECU communication error L1goes on immediately after turning the ignition switch to ON goes off after about 2 seconds and goes on again DFI problem L1goes on immediately after turning the ignition switch to ON and stays on DFI problem 5 not go on after turning the ignition switch to ON light LED ECU or its wiring fault Starting difficulty Ostarter motor not rotating Ostarter motor rotating but engine doesn t turn over Ostarter motor and engine don t turn over Ono fuel flow Ono fuel in tank Ono fuel pump sound flooded do not crank engine with throttle opened which promotes engine flooding spark other Engine stops Dright after starting Owhen opening throttle grip Owhen closing throttle
31. ier 3 103 Throttle Body Assy de 3 104 Throttle Body Assy Disassembly pp 3 105 Throttle Body Assy Assembly btt ertet etapa tn to etn oet ate tanga ien 3 106 Ne rcu 3 107 Air Cleaner Element Removal lnstallation pp 3 107 Air Cleaner Element 3 107 pur Cleaner Oil ie caa Tett teas beso den Oe tet 3 107 Air Cleaner Housing 2 3 107 Air Cleaner Housing Installation cocotte recorte ete neice rro ER Dee 3 108 MI p LTEM 3 109 Fuel Tank REMOVAL ree bo tede cud euet ede lace Due ade ue 3 109 Fuel Tank Installaliofi z adco eh ie dite ts c baie eni uns eds 3 111 Fuel Tank and Cap 3 112 Fuel Tank Dort a an Seda 3 113 Evaporative Emission Control System CAL SEA B1 Models 3 114 Parts tb 3 114 Hose Inspection reir eterne 3 114 Los Latest a Unum e 3 114 C
32. 0 12 kgf m 11 in Ib Intake Air Temperature Sensor Output Voltage Inspection NOTE sure the battery is fully charged e Turn the ignition switch to OFF e Remove the fuel tank see Fuel Tank Removal e Disconnect the intake air temperature sensor connector and connect the harness adapter A between these con nectors as shown in the figure Main Harness B Intake Air Temperature Sensor C g Special Tool Measuring Adapter 57001 1700 Connect a digital meter D to the harness adapter leads ae ac PCT Intake Air Temperature Sensor Output Voltage Connections to Adapter C Digital Meter R sensor R lead 9 D Digital Meter gt BK sensor BR BK lead 2 Measure the output voltage with the engine stopped and the connector joined Turn the ignition switch to ON GC17164FS1 C Output Voltage Standard About DC 2 25 2 50 V at intake air temperature 20 C 68 F NOTE OThe output voltage changes according to the intake air temperature Turn the ignition switch to OFF x If the reading is within the standard check the ECU for its ground and power supply see ECU Power Supply In spection If the ground and power supply are good replace the ECU see Removal lnstallation Intake Air Temperature Sensor Service Code 13 FUEL SYSTEM DFI 3 51 x If the reading is out of the standard remove the ECU and check the wiring for
33. 5 42 Throttle Body Assy Holder Throttle Body Assy Holder Removal e Remove Throttle Body Assy see Throttle Body Assy Removal in the Fuel System DFI chapter Clamps A Bolts B Throttle Body Assy Holders C Throttle Body Assy Holder Installation Replace the O rings A with new ones and apply grease to them Tighten Torque Throttle Body Assy Holder Bolts 12 N m 1 2 kgf m 106 in Ib e Install the clamps B so that their projections C fit on the holes of the holders sure that the clamp bolt heads D face outward View from Top E e Install the throttle body assy see Throttle Body Assy In stallation in the Fuel System DFI chapter 8 17017 52 C Muffler ENGINE TOP END 5 43 Muffler Removal A WARNING The muffler can become extremely hot during nor mal operation and cause severe burns Do not re move the muffler while it is hot Remove Frame Covers see Frame Cover Removal in the Frame chapter Right Footpeg Stay see Footpeg Stay Removal in the Frame chapter Middle Fairings see Middle Fairing Removal in the Frame chapter e For oxygen sensor equipped models remove the engine sprocket cover see Engine Sprocket Removal in the Final Drive chapter to disconnect the connector A and clear the lead from the clamp B Do not pull strongly twist or bend the oxygen sen sor lead T
34. Inspect the primary C and secondary D If a cup is worn damaged softened rotted or swollen the piston assembly should be replaced to renew the cups x If fluid leakage is noted at the brake lever the piston as sembly should be replaced to renew the cups e Check the dust covers E for damage x If they are damaged replace them e Check the piston return springs F for any damage x If the springs are damaged replace them e Check that relief port G and supply port H are not plugged x If the relief port becomes plugged the brake pads will drag on the disc Blow the ports clean with compressed air Front Master Cylinder J Rear Master Cylinder K 0513050852 C Brake Disc BRAKES 12 25 Brake Disc Removal Remove the wheel see Front Rear Wheel Removal in the Wheels Tires chapter Unscrew the mounting bolts A and take off the disc B For front brake disc remove the gaskets Brake Disc Installation e For front brake disc replace the gaskets with new ones e Install the brake disc on the wheel so that the marked A side faces out Apply a non permanent locking agent to the threads of the front and rear brake disc mounting bolts Tighten Torque Brake Disc Mounting Bolts 27 N m 2 8 kgf m 20 ft Ib Brake Disc Wear Inspection Measure the thickness of each disc at the point where it has worn the most x If the disc has worn p
35. Remove the ball bearing and needle bearings with oil seal amp bearing remover A Special Tool Oil Seal amp Bearing Remover 57001 1058 Swingarm Bearing Installation Replace the ball and needle bearings A with new ones Install the ball and needle bearings so that the manufac turer s marks face out Special Tools Bearing Driver Set 57001 1129 Needle Bearing Driver 28 B 57001 1610 Spacer 28 57001 1663 Install the needle bearings A ball bearing B and oil seals C as shown Circlip D 42 5 mm 1 67 in E 24 mm 0 94 in F 41 5 mm 1 63 in G 5 5 mm 0 22 in H Left Side I Right Side J GM06079BS1 GMO6071BS1 C GM062158W2 C 13 20 SUSPENSION Swingarm Swingarm Bearing Sleeve Inspection Do not remove the bearings for inspection Re moval may damage them Inspect the needle bearings A and ball bearing installed in the swingarm OThe rollers and ball in a bearing normally wear very little and wear is difficult to measure Instead of measuring visually inspect the bearing for abrasion discoloration or other damage x If the needle bearings and sleeves B show any sings of abnormal wear discoloration or damage replace them as a set e Turn the bearing in the swingarm back and forth A while checking for plays roughness or binding If bearing play roughness or binding is found repl
36. Any of the following procedures ends self diagnosis OWhen the service code is displayed on the LCD press the upper button for more than 2 seconds OTurn the ignition switch to OFF 3 36 FUEL SYSTEM Self Diagnosis Turn the ignition switch to OFF Turn the ignition switch to ON Display the odometer and press the left button for more than 2 seconds to start the self diagnosis mode Service code s is displayed on the LCD Liquid Crystal Display Turn the ignition switch to OFF Locate the problem with the service code table Inspect and repair the DFI and or ignition system according to the inspection procedure on all the service codes Turn the ignition switch to ON Make sure that the yellow engine warning indicator light LED does not go on Run the engine for several minutes at idling and run the motorcycle at 30 km h 18 mph or more in order to confirm no problem GCI7169F F FUEL SYSTEM DFI 3 37 Self Diagnosis Service Code Reading OThe service code s is displayed on the LCD by the number of two digits OWhen there are a number of problems all the service codes can be stored and the display will begin starting from the lowest number service code in the numerical order OThen after completing all codes the display is repeated until the ignition switch is turned to OFF or the upper button is pressed for more than 2 seconds OFor example if three problems occurr
37. Remove the lower crankcase bolts following the specified sequence OFirstly loosen the M6 bolts A OSecondly loosen the M8 bolts B OLastly loosen the 9 bolts C and copper plated wash ers Tap lightly around the crankcase mating surface with a plastic mallet and split the crankcase Take care not to damage the crankcase Remove the bearing x If the oil pipe is to be removed follow the next procedure OUnscrew the bolts A and remove the oil pipe B 0104352852 9104356851 9 12 CRANKSHAFT TRANSMISSION Splitting 5 mm rod A and insert it to the hole of the upper crankcase half ORemove the oil pipe B tapping C the rod as shown x If the breather plate A is to be removed follow the next procedure ORemove the oil pipe see above OCut the gasket around the plate B ORemove Breather Plate Bolts C Breather Plate with Pipe D x If the oil plate A is to be removed follow the next proce dure ORemove Oil Plate Bolts B Oil Plate Crankcase Assembly 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 If the oil plate A on the upper crankcase half was re moved install it in the following procedure OApply a non permanent locking agent to the oil plate bolts B and tighten the
38. Tap the radiator hoses to force any air bubbles caught inside e Fill the radiator up to the filler neck with coolant and install the radiator cap 2 50 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Fill the reserve tank up to the F full level line A with coolant and install the cap B Start the engine warm it up thoroughly until the radiator fan turns on and then stop the engine Check the coolant level in the reserve tank after the en gine cools down x If the coolant level is lower than the L low level line C add coolant to the F level line Do not add more coolant above the level line e Install the right middle fairing see Middle Fairing Installa tion in the Frame chapter Radiator Hose and O ring Replacement e Drain the coolant see Coolant Change e Remove Thermostat Housing A see Thermostat Removal in the Cooling System chapter Water Pump Cover B see Water Pump Removal in the Cooling System chapter Hoses C O rings D e Apply grease to the new O rings and install them e Install the new hoses and tighten the clamps securely e Tighten Torque Water Hose Clamp Screws 3 0 N m 0 31 kgf m 27 in Ib e Fill the coolant see Coolant Change e Check the cooling system for leaks Engine Oil Change e Remove the left middle fairing see Middle Fairing Re moval in the Frame chapter e Situate the motorcycle so that it is vertical after
39. APPENDIX 17 23 Cable Wire and Hose Routing Guides Run the brake hose front master cylinder front right caliper through the guide Fix the clamp to the bracket Bracket Run the brake hose inside the front fork Brake Hose Front Master Cylinder Front Right Caliper Brake Hose between the Front Calipers Clamp Hold the brake hoses Right Side Clamp Hold the brake hose Left Side 17 24 APPENDIX Cable Wire and Hose Routing ABS Equipped Models The routing on EX650E F is shown using the figure of ER650E F 68098770 6 APPENDIX 17 25 Cable Wire and Hose Routing OOOANOARWN Guides Left Switch Housing Lead Clutch Cable Fix the front wheel rotation sensor lead connector to the bracket Run the front wheel rotation sensor lead as shown Bracket Fix the clamp to the bracket Brake Hose ABS Hydraulic Unit Front Caliper Run the brake hose front master cylinder ABS hydraulic unit through the guide From inside to outside run the right switch housing lead the decelerator throttle cable the accelerator throttle cable and brake hose front master cylinder ABS hydraulic unit Run the brake hose inside the front fork Clamp Hold the brake hoses Run the front wheel rotation sensor lead inside the front fork Brake Hose between the Front Calipers Front Wheel Rotation Sens
40. Apply molybdenum disulfide oil solution to the crankshaft main bearing inserts Align A the timing mark on the balancer gear B with the timing mark on the balancer drive gear C of the crank shaft Install the crankshaft with the camshaft chain A hanging on it e Assemble the crankcase see Crankcase Assembly Connecting Rod Removal Split the crankcase see Crankcase Splitting Remove the connecting rod nuts A Remove the crankshaft see Crankshaft Removal 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 Remove the connecting rods from the crankshaft NOTICE Discard the connecting rod bolts To prevent dam age to the crankpin surfaces do not allow the con necting rod bolts to bump against the crankpins 9 20 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Installation 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 or no mark 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 Apply molybdenum disulfide oil solut
41. If no abnormality is found in the wiring or connectors the DFI parts are the next likely suspects Check the part starting with input and output voltages However there is no way to check the ECU itself If an abnormality is found replace the affected DFI part If no abnormality is found in the wiring connectors and DFI parts replace the ECU DFI Diagnosis Flow Chart Problem occurs Yellow engine warning indicator light Yellow engine warning indicator light LED does not go on LED goes on Y Conduct self diagnosis inspection General fuel system throttle body End assy air cleaner fuel tank etc GCI7160F F FUEL SYSTEM 3 27 Troubleshooting the DFI System Inquiries to Rider OEach rider reacts to problems in different ways so it is important to confirm what kind of symptoms the rider has encountered OTry to find out exactly what problem occurred under exactly what conditions by asking the rider knowing this information may help you reproduce the problem OThe following sample diagnosis sheet will help prevent you from overlooking any areas and will help you decide if it is a DFl system problem or a general engine problem Sample Diagnosis Sheet Rider name Registration No license plate No Year of initial registration Model Engine No Frame No Date problem occurred Mileage Environment when problem occurred Weather
42. Remove Clutch Hub A Spacer B Remove the oil pump sprocket bolt A and washer NOTE OThe oil pump sprocket bolt has a left hand threads e Using the holes B pull out the sleeve C Remove the following as a set Clutch Housing D Oil Pump Chain E Oil Pump Sprocket F e Remove Spacer A Bolts B Oil Pump Chain Guide C 6 12 CLUTCH Clutch Clutch Installation Install the oil pump chain guide A Apply a non permanent locking agent to the upper chain guide bolts B Tighten Torque Oil Pump Chain Guide Bolts 12 N m 1 2 kgf m 106 in Ib Install the spacer C onto the drive shaft e Put the oil pump chain A on the clutch housing gear B and the oil pump sprocket C Install the following on the drive shaft as a set Clutch Housing A Oil Pump Chain B Oil Pump Sprocket C e Apply engine oil to the sleeve D e Install the sleeve so that the holes E face outward If you feel a catch when installing the sleeve replace it with a new one e Align the hole on the oil pump sprocket with the oil pump shaft e Apply a non permanent locking agent to the oil pump sprocket bolt F and install the washer e Tighten Torque Pump Sprocket Bolt 12 N m 1 2 kgf m 106 in Ib NOTE OThe oil pump sprocket bolt has a left hand threads e Install the following parts onto the drive shaft Spacer A Clutch Hub B GF06135
43. e Remove the oil filter A with the oil filter wrench B Special Tool Oil Filter Wrench 57001 1249 SAE 10W 30 I I I 10 1 104CF 6509010BS1 2 52 PERIODIC MAINTENANCE Periodic Maintenance Procedures Replace the filter with a new one e Apply grease to the O ring A before installation Tighten the filter with the oil filter wrench Torque Oil Filter 17 5 N m 1 8 kgf m 13 ft lb NOTE OHand tightening of the oil filter can not be allowed since it does not reach to this tightening torque Pour in the specified type and amount of oil see Engine Oil Change Install the removed parts see appropriate chapters 6005040251 Brake Hose Pipe Replacement NOTICE Brake fluid quickly ruins painted plastic surfaces any spilled fluid should be completely washed away immediately Remove the brake hose banjo bolts A Remove the brake hoses B noting the following OTake care not to spill the brake fluid on the painted or plastic parts OTemporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum PERIODIC MAINTENANCE 2 53 Periodic Maintenance Procedures For models equipped with an ABS note the following NOTE OWhen removing the brake pipes and hoses on the hy draulic unit remove them according to each assembly of the exploded view in the Brakes chapter e Remove
44. 6 7 6 8 Glutch Cover Removal ecce ere e etedeie deferre TREE de Ee iden weed 6 8 Clutch Cover Installation pp 6 8 Release Shaft 6 9 Release Shaft Hee 6 9 Clutch Cover Disassembly eo deep t baee aye omne 6 9 Glutch Gover ASSO tac sh raise 6 10 orte 6 11 Gl tchiFiemoVval 23 A 6 11 Gluten InstallatiOn sore rtr tte e SY Exe OE sero tee ty edv 6 12 Clutch Plate Wear Damage Inspection 6 14 Clutch Plate Warp 6 14 Clutch Spring Free Length Measurement eese eene tenens 6 14 Clutch Housing Finger Inspection area 6 14 Clutch Housing Spline Inspection 6 15 6 2 Exploded View GF022028W5 C Exploded View CLUTCH 6 3 No Fastener Clutch Cable Clamp Bracket Bolt 1 10 87 in lb 2 Clutch Cable Holder Bolts 87 in lb 3 Clutch Cover Bolts T 87 in lb 4 Clutch Hub Nut 130 13 3 96 R 5 Clutch Spring Bolts 9 8 1 0 87 in lb 6 Timing Inspection Cap 3 9 0 40
45. cable terminal e Install the other removed parts see appropriate chap ters Olnstall the fuel tank cover A so that the projections B fit into the grommets C ORun the hose and lead correctly see Cable Wire and Hose Routing section in the Appendix chapter 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 in the tank is 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 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 FUEL SYSTEM DFI 3 113 Fuel Tank Cleaning A WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the tank in a well ventilated area and take care that there are no sparks or flame any where near the working area Do not use gasoline or low flash point solvents to clean the tank e Remove Fuel Tank see Fuel Tank Removal Fuel Pump see Fuel Pump Removal 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 Install Fu
46. me ls s EMIL z 22222 5 5 for ES 25 LH I Electronic Control Unit BK G Ll aK Y BK Y Sr BL G LG BK P BL 8 8K aura BL Y R BL BR Y BK R R G R wex f P BR W 1 4 mv azy ako aK BK Y Joint 3K Y Connector B BK Y li i License Plate LIT ewes Light 12V5W ay A Rear Right BL R BK Turn Signal Tail Brake HA B 13 5V 0 3 3 4W Light 12V10W i Rear Left LL IE Turn Signal Light 12V10W Kawasaki Self diagnosis System Connector envy YR Z ox BK BKZ Y AK AY BL R SUY R BK M BK Howy BKZ Y W R Frame Frame Starter Ground Ground wf Relay 2 1 7 jur Fuel Fuel Reserve Pump Side witch A stan Rear icem ur BET Light 304 E gt Switch N Battery Starter 12V10Ah Wotor LB Light Blue IGNITION SWITCH CONNECTIONS 0 Orange Ignition Battery lgnition Signal Color BR W GY BL OFF LOCK on o Pulled In RUN Push White 98052 0620B 0625B 0626B 06744 W2RO620BWS C 16 18 ELECTRICAL SYSTEM Wiring Diagram EX650F Model Right Switch Housing Front Brake Light Switch 2 Engine Stop Switch 3 Starter Button I Regulator Spaad Rectifi
47. 10 16 Hub Bearing 10 16 H b Bearing EUbri Caton oes e data etn 10 17 10 2 WHEELS TIRES Exploded View WHEELS TIRES 10 3 Exploded View N Fastener Tongue Remarks i Nm kgfm ftib 1 Front Axle 108 11 0 80 Front Axle Clamp Bolt 25 Rear Axle Nut 80 4 EX650F Model G Apply grease HG Apply high temperature grease R Replacement Parts WL Apply soap and water solution or rubber lubricant 10 4 WHEELS TIRES Specifications Item Standard Service Limit Wheels Rims Rim Runout Axial TIR 0 5 mm 0 02 in or less TIR 1 0 mm 0 04 in Radial TIR 0 8 mm 0 03 in or less TIR 1 0 mm 0 04 in Axle Runout 100 mm 3 94 in Wheel Balance TIR 0 03 mm 0 001 in or less 10 g 0 35 oz or less TIR 0 2 mm 0 008 in Balance Weights 10 g 0 35 20 g 0 71 oz 30 4 1 06 Rim Size Front J17M C x MT3 50 SSS Rear J17M C x MT4 50 Tires Air Pressure when Cold Front Up to 200 kg 441 Ib load 225 kPa my 2 25 kgf cm 32 psi Rear Up to 200 kg 441 Ib load 250 kPa Tread Depth Front Rear Standard Tires Front Rear 2 50 kgf cm 36 psi 4 5 mm 0 18 in 6 4 mm 0 25 in Make Type DUNLOP ROADSMART II J DUNLOP ROADSMART II J A WARNING 1 mm 0 04 in AT CH DE 1 6 mm
48. 130 mm 5 12 in 805 mm 31 7 in 209 kg 106 kg 103 kg 211 kg 106 kg 105 kg 461 Ib 234 Ib 227 Ib 465 Ib 234 Ib 232 Ib 211 kg 465 Ib 106 kg 234 Ib 105 kg 232 Ib 16 L 4 2 US gal 2 7 m 8 9 ft 4 stroke DOHC 2 cylinder Liquid cooled 83 0 x 60 0 mm 3 27 x 2 36 in 649 39 6 10 8 1 53 kW 72 1 PS 8 500 r min rpm AU LAMS 35 kW 47 6 PS 8 000 r min rpm US CA CAL SEA B1 B2 TH 52 kW 70 7 PS 8 000 r min rpm 64 Nm 6 5 kgf m 47 ft lb 7 000 r min rpm AU LAMS 55 Nm 5 6 kgfm 41 16 3 800 r min rpm US CA CAL Fl Fuel Injection KEIHIN TTK38 x 2 Electric starter Battery and coil transistorized Electronically advanced IC igniter in ECU From 10 BTDC 1 300 r min rpm 37 5 000 r min rpm CR9EIA 9 Left to right 1 2 1 2 GENERAL INFORMATION 1 11 General Specifications Items EX650EC FC Valve Timing Intake Open 31 BTDC Close 61 ABDC Duration 272 Exhaust Open 50 BBDC Close 30 ATDC Duration 260 Lubrication System Forced lubrication semi dry sump Engine Oil Grade SG SH SJ SL or SM with JASO MA 1 or 2 Viscosity SAE 10W 40 Capacity 2 3 L 2 4 US qt Drive Train Primary Reduction System Type Gear Reduction Ratio 2 095 88 42 Clutch Type Wet multi disc Transmission Type 6 spee
49. 16 74 ELECTRICAL SYSTEM Meter Gauge Indicator Unit Meter Circuit ON PARK TENITION GET spe BATTERY 1921105 GPi7919CW3 C lgnition Switch Speed Sensor Joint Connector C Joint Connector D Water Temperature Sensor Neutral Switch Oil Pressure Switch ECU Fuel Level Gauge 5 Frame Ground Battery 12 V 10 Ah Main Fuse 30 A ABS Hydraulic Unit ABS Equipped Models Fuse Box Ignition Fuse 10 A Meter Fuse 10 A Meter Unit Switches and Sensors ELECTRICAL SYSTEM 16 75 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 the Periodic Maintenance chapter Switch Inspection e Using a hand tester check to see that only the con nections shown in the table have continuity about zero ohms Special Tool Hand Tester 57001 1394 OFor the switch housings and the ignition switch refer to the tables in the Wiring Diagram xIf the switch has an open or short repair it or replace it with a new one Rear Brake Light Switch Connections Rear Brake Light Switch Connections Color BR BL When brake pedal is pushed down O o When brake is released Sidestand Switch Connections Sidestand Switch Con
50. 294 kPa 3 0 kgf cm 43 psi with fuel pump running In tank friction pump 30 mL 1 0 US oz or more for 3 seconds INP 287 Fine Atomizing type with 12 holes About 11 7 12 3 at 20 C 68 F Non adjustable and non removable DC 4 75 5 25 V DC 1 005 1 035 V at Idle Throttle Opening DC 4 2 4 4 V at Full Throttle Opening 4 6 DC 4 75 5 25 V DC 3 80 4 20 V at standard atmospheric pressure see this text for details 5 4 6 6 at 0 C 32 F 0 29 0 39 at 80 C 176 F About 2 25 2 50 V at 20 C 68 F see Electrical System chapter About 2 80 2 97 V at 20 C 68 F About DC 9 11 V at Ignition Switch ON About DC 0 05 0 07 V or DC 4 5 4 9 V at Ignition Switch ON and 0 km h 0 mph Magnetic flux detection method more than 60 70 for each bank DC 4 75 5 25 V 3 18 FUEL SYSTEM Specifications Item Standard Output Voltage Subthrottle Sensor Input Voltage Output Voltage Resistance Subthrottle Valve Actuator Input Voltage Resistance Oxygen Sensor Equipped Models Output Voltage Rich Output Voltage Lean Heater Resistance Purge Valve Resistance Throttle Grip and Cables Throttle Grip Free Play with the sensor tilted 60 70 or more 0 65 1 35 V with the sensor arrow mark pointed up 3 55 4 45 V Non adjustable and non removable DC 4 75 5 25 V DC 0 6 0 8 V at Idle Throttle Opening DC 4 08 4 12 V at Full Thr
51. 4 5 57001 1331 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 OTurn the reamer in a clockwise direction until the reamer turns freely in the guide Never turn the reamer counter clockwise or it will be dulled OOnce the guides are reamed they must be cleaned thor oughly Special Tool Valve Guide Reamer 4 5 57001 1333 Valve to Guide Clearance Measurement Wobble Method If a small bore gauge is not available inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below 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 08 0 16 mm 0 0032 0 0063 in Intake 0 03 0 10 mm 0 0012 0 0039 in Service Limit Exhaust 0 35 mm 0 014 in Intake 0 29 mm 0 011 in GE15046BS1 C GE15007BS2 C 5 32 ENGINE END Valves Valve Seat Inspection Remove
52. Air Cleaner Housing see Air Cleaner Housing Removal the Fuel System DFI chapter Stick Coils see Stick Coil Removal in the Electrical Sys tem chapter Spark Plugs see Spark Plug Replacement in the Peri odic Maintenance chapter 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 1 0 57001 1317 Cylinder Compression Usable Range 1 000 1 520 kPa 10 2 15 5 kgf cm 145 220 psi at 450 r min rpm Repeat the measurement for the other cylinder e Install the spark plugs see Spark Plug Replacement in the Periodic Maintenance chapter OThe following table should be consulted if the obtainable compression reading is not within the us able range Problem Cylinder compression Diagnosis Carbon accumulation on piston and in Remedy Action is higher than usable range Cylinder compression is lower than usable range combustion chamber possibly due to damaged valve stem oil seal and or damaged piston oil rings This may be indicated by white exhaust smoke Incorrect cylinder head gasket thickness Gas leakage around cylinder head Bad condition of valve seating Incorrect valve clearance Incorrect piston
53. Battery Case Battery Case Removal e Remove Battery see Battery Removal in the Electrical System chapter Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Screw A and Connector Holder B ABS Equipped Models Starter Relay C Dust Cover D e Clear the leads from the hook E e Clear the main harness A from the hook B and remove the battery case C Battery Case Installation e Installation is the reverse of removal ORun the leads and harness correctly see Cable Wire and Hose Routing section in the Appendix chapter 15 23 Footpeg Stay Footpeg Stay Removal e Remove Frame Cover see Frame Cover Removal Footpeg Stay Mounting Bolts A Footpeg Stay B Rear Master Cylinder Right Side see Rear Master Cylinder Removal in the Brakes chapter Brake Pedal Right Side see Brake Pedal Removal in the Brakes chapter Rear Brake Light Switch Lead Connector Right Side Footpeg Stay Installation Install Rear Master Cylinder Right Side see Rear Master Cylinder Installation in the Brakes chapter Brake Pedal Right Side see Brake Pedal Installation in the Brakes chapter Rear Brake Light Switch Lead Connector Right Side Install the footpeg stay temporarily OTighten the footpeg stay bolts loosely following the spec ified tightening sequence 1 3 Tighten the footpeg stay bolts following the specified tight ening sequence 1 3 Torque Footpeg Stay
54. Charging System ELECTRICAL SYSTEM 16 31 Using the flywheel puller assembly A remove the alter nator rotor from the crankshaft Special Tool Flywheel Puller Assembly M38 1 5 M35 x 1 5 57001 1405 Do not strike the alternator rotor Striking the rotor can cause the magnets to lose their magnetism Remove the starter clutch gear A and washer B 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 Install the starter clutch gear A and washer B e Again clean the crankshaft tapered portion C and dry there Install the alternator rotor while turning the starter clutch gear clockwise 16 32 ELECTRICAL SYSTEM Charging System Install the washer A NOTE OConfirm that the alternator rotor fits onto the crankshaft before tightening it with specified torque Apply molybdenum disulfide oil solution to the threads and seating surface of the rotor bolt Install the rotor bolt B and tighten it with 68 5 N m 6 99 kgf m 51 16 of torque Remove the rotor bolt and washer Check the tightening torque with flywheel puller x If the rotor is not pulled out with 20 N m 2 0 15 ft lb of drawing torque it is installed corr
55. Left Middle Fairing see Middle Fairing Removal in the 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 blink for one minute Turn Signal Relay A Turn Signal Lights B 12 V Battery C Testing Turn Signal Relay Load The Number of T Blinking Times e Number tum Signal Lights Wantage ne 1 10 140 250 20 75 95 Cycle s per minute Correspond to one light burned out x If the lights do not blink as specified replace the turn sig nal relay 8 12040251 C 16 60 ELECTRICAL SYSTEM Lighting System Turn Signal Light Circuit 9N Park CE BATTERY I I Br NAL 6 GPi2612BW3 C Ignition Switch Meter Unit Joint Connector A Front Right Turn Signal Light 12 V 10 W Front Left Turn Signal Light 12 V 10 W Joint Connector B Rear Right Turn Signal Light 12 V 10 W Rear Left Turn Signal Light 12 V 10 W Frame Ground Battery 12 V 10 Ah Main Fuse 30 A Fuse Box Turn Signal Relay Fuse 10 A Turn Signal Switch Hazard Button Turn Signal Relay ELECTRICAL SYSTEM 16 61 Air Switching Valve Air Switching Valve Operation Test Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Air Cleaner Housing see Ai
56. 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 x If the bearing play roughness or binding is found replace the bearing e Inspect the bearing seal B for tears or leakage x If the seal is torn or is leaking replace the bearing Coupling Bearing Lubrication NOTE OSince the coupling bearing is packed with grease and sealed lubrication is not required Coupling Damper Inspection Remove the rear wheel coupling and inspect the rubber dampers A Replace the dampers if they appear damaged or deterio rated Sprocket Wear Inspection e Visually inspect the engine and rear sprocket teeth for wear and damage x If the teeth are worn as illustrated replace the sprocket and inspect the drive chain wear see Drive Chain Wear Inspection in the Periodic Maintenance chapter Worn Tooth Engine Sprocket A Worn Tooth Rear Sprocket B Direction of Rotation C NOTE Olf a sprocket requires replacement the chain is proba bly worn also When replacing a sprocket inspect the chain 6J06002BS1 C GK05017BS1 C 11 14 FINAL DRIVE Sprocket Coupling Rear Sprocket Warp Inspection e Raise the rear wheel off the ground with a stand so that it will turn freely Set a dial gauge A against the re
57. Ninja 650 Ninja 650 ABS em E R of Kawasaki ER 6f ABS 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 jj O OY I Appendix Ninja 650 Ninja 650 ABS ER 6f ER 6f ABS Kawasaki Motorcycle Service Manual All rights reserved No parts of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Quality Assurance Division Motorcycle amp Engine Company Kawasaki Heavy Industries Ltd Japan No liability can be accepted for any inaccuracies or omissions in this publication although every possible care has been taken to make it as complete and accurate as possible The right is reserved to make change
58. ODetermine the condition of the battery 30 minutes after completion of the charge by measuring the terminal volt age according to the table below Criteria Judgement 12 8 V or higher Good 12 0 lower than 12 8 V Charge insufficient Recharge lower than 12 0 V Unserviceable Replace e Install the battery see Battery Installation Charging System ELECTRICAL SYSTEM 16 29 Alternator Cover Removal e Remove Left Middle Fairing see Middle Fairing Removal in the Frame chapter Left Frame Cover see Frame Cover Removal in the Frame chapter Engine Oil Drain see Engine Oil Change in the Periodic Maintenance chapter Engine Sprocket Cover see Engine Sprocket Removal in the Final Drive chapter e Pull out the alternator lead connector A from the bracket and disconnect it Open the clamps B Remove the alternator cover bolts A and take off the alternator cover B NOTE OPlace a suitable container under the alternator cover Alternator Cover Installation Clean off any oil or dirt and apply liquid gasket to the alter nator lead grommet and crankcase halves mating surface A Sealant Liquid Gasket TB1211F 92104 0004 Be sure that the dowel pins B are in position Replace the alternator cover gasket with a new Install the alternator cover Tighten Torque Alternator Cover Bolts 9 8 1 0 kgf m 87 in Ib 2 8 in Bolt A 1 4 in Bolt
59. OLoosen once and tighten again when the slot goes past the nearest hole GJ04209BS1 WHEELS TIRES 10 9 Wheels Rims e Bend the cotter pin A over the nut B A WARNING A loose axle nut can lead to an accident resulting in serious injury or death Tighten the axle nut to the proper torque and install a new cotter pin GJ04210BS1 e Install the rear caliper see Rear Caliper Installation in the Brakes chapter e For models equipped with an ABS install the rear wheel rotation sensor see Rear Wheel Rotation Sensor Instal lation in the Brakes chapter e Check the rear brake effectiveness see Brake Operation Inspection in the Periodic Maintenance chapter A WARNING After servicing it takes several applications of the brake pedal before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the motorcycle until a firm brake pedal is obtained by pumping the pedal until the pads are against the disc 10 10 WHEELS TIRES Wheels Rims Wheel Inspection e Raise the front rear wheel off the ground Special Tool Jack 57001 1238 Spin the wheel lightly and check for roughness or binding If roughness or binding is found replace the hub bearings see Hub Bearing Removal Installation Inspect the wheel for small cracks dents bending or warp x If there is
60. 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 Inspection Remove the connecting rod big end bearing inserts and reinstall the connecting rod big end cap Select an arbor A of the same diameter as the connect ing rod big end and insert the arbor through the connect ing rod big end Select an arbor of the same diameter as the piston pin and at least 100 mm 3 94 in long and insert the arbor B through the connecting rod small end a surface plate set the big end arbor on V block C With the connecting rod held vertically use a height gauge to measure the difference in the height of the arbor above the surface plate over a 100 mm 3 94 in length to determine the amount of connecting rod bend If 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 6105040881 C 9 24 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Twist Inspection 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 arbo
61. hardened or otherwise damaged WHEELS TIRES 10 1 Wheels Tires Table of Contents Exploded LETT 10 2 oc tnr edere 10 4 eM TP 10 5 Wheels RIIT S eee 10 6 Front Wheel 10 6 Front Wheel 10 6 Rear Wheel Removal ioue QE Mae 10 7 Rear Wheel 10 8 Wheel Inspection ERE RET 10 10 Axle Inspection t Ttc R 10 10 Balance Inspection stent ctio 10 11 Balance 10 11 Balance Weight 10 11 Balance Weight Installation ic 10 11 Mcr 10 13 Air Pressure 5 10 13 Tire Inspection erc EI IM Tire Installation te d e pde aeneus Bearg os tutte Hub Bearing Remowvals ioc ence ore rt cee LU BARS Aot Rute tau Pimp Loa ctas dente ase dd 10 16 Hub Bearing Installation store Rc oet Pte hig Re e A Dai ete keen
62. semble and repair the ABS hydraulic unit 12 58 5 Anti Lock Brake System Equipped Models ABS Hydraulic Unit Installation Install the bracket to the ABS hydraulic unit Brake fluid quickly ruins painted plastic surfaces any spilled fluid should be completely washed away immediately Install the ABS hydraulic unit to the frame e Run the lead correctly see Cable Wire and Hose Rout ing section in the Appendix chapter Connect the connector securely e Run the brake pipes correctly see Cable Wire and Hose Routing section in the Appendix chapter e Install the brake pipes To Rear Master Cylinder A To Rear Caliper B To Front Master Cylinder C To Front Calipers D Tighten the brake pipe joint nuts with the flare nut wrench Torque Brake Pipe Joint Nuts 18 N m 1 8 kgf m 13 16 Install the removed parts see appropriate chapters Fill the brake line see Brake Fluid Change in the Periodic Maintenance chapter ABS Hydraulic Unit Inspection Remove the ABS hydraulic unit see ABS Hydraulic Unit Removal e Visually inspect the ABS hydraulic unit x lf the ABS hydraulic unit is cracked or otherwise dam aged replace it e Visually inspect the connector terminals A Replace the ABS hydraulic unit or main harness if either ofthe terminals are cracked bent or otherwise damaged x If the ABS hydraulic unit connector is clogged with mu
63. tor is aligned with the mating surface B of the crankcase front side e Pull the tension side exhaust side A of the chain taut to install the chain Engage the camshaft chain with the camshaft sprockets so that the timing marks on the sprockets are positioned as shown in the figure OThe timing marks must be aligned with the cylinder head upper surface B EX Mark C Between 1 Pin and 2 Pin IN Mark D Between 31 Pin and 32 Pin 1 Pin E 2 Pin F 31 Pin G 32 Pin H GE112088W2 C Camshaft Camshaft Chain ENGINE TOP END 5 23 e Before installing the camshaft caps install the camshaft chain tensioner body temporarily see Camshaft Chain Tensioner Installation Install the camshaft caps as shown NOTE OThe exhaust cap has an EX mark A and the intake cap has an IN mark B Be careful not to mix up these caps e First tighten the camshaft cap bolts 9 12 evenly to seat the camshaft in place then tighten all bolts following the specified tightening sequence 1 12 Torque Camshaft Cap Bolts 12 1 2 kgf m 106 in Ib 11209 2 C Install the camshaft chain tensioner see Camshaft Chain Tensioner Installation Turn the crankshaft 2 turns clockwise to allow the ten sioner to expand and recheck the camshaft chain timing Replace the O rings on the timing inspection cap and tim ing rotor bolt cap with ne
64. 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 Size 120 70 ZR17 M C 58 W 160 60 ZR17 M C 69 W Some replacement tires may adversely affect handling and cause an accident resulting in serious injury or death To ensure proper handling and stability use only the recommended standard tires for replacement inflated to the standard pressure Special Tools Bearing Driver Set 57001 1129 7571129ST C Jack 57001 1238 7571238ST C WHEELS TIRES 10 5 Bearing Remover Head 20 x 22 57001 1293 7571293ST C Bearing Remover Shaft 13 57001 1377 ST5713778T C 10 6 WHEELS TIRES Wheels Rims Front Wheel Removal e Remove Front Caliper Mounting Bolts A Both Sides Front Calipers B Both Sides Loosen Front Axle Clamp Bolt A Front Axle B Remove Middle Fairings see Middle Fairing Removal in the Frame chapter Lower Fairing Brackets see Lower Fairing Bracket Re moval in the Frame chapter Raise the front wheel off the ground Special Tool Jack 57001 1238 Pull out the front axle to the right side and drop the front wheel out of the front forks 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
65. 12 53 in Service Limit 323 mm 12 7 in A WARNING A chain that breaks or jumps off the sprockets could snag on the engine sprocket or lock the rear wheel severely damaging the motorcycle and causing it to go out of control Inspect the chain for damage and proper adjustment before each ride If chain wear exceeds the service limit replace it with the standard chain It is an endless type and should not be cut for installation Standard Chain Make DAIDO Type DID 520VP2 T Link 114 links Chain Guide Inspection e Visually inspect the chain guide on the swingarm Replace the chain guide if it shows any signs of abnormal wear or damage ORemove Swingarm see Swingarm Removal in the Suspension chapter Chain Guide Bolt A Chain Guide B Olnstallation is the reverse of removal 6 04060651 C 65128230 2 32 Periodic Maintenance Procedures Brake System Brake Fluid Leak Brake Hose and Pipe Inspection e For models equipped with an ABS remove the right swingarm bracket see ABS Hydraulic Unit Removal in the Brakes chapter e Apply the brake lever or pedal and inspect the brake fluid leak from the brake hoses A pipes ABS equipped mod els and fittings x If the brake fluid leaked from any position inspect or re place the problem part Brake Hose and Pipe Damage and Installation Condition Inspection e For models e
66. 17 34 APPENDIX Cable Wire and Hose Routing ABS Equipped Models The routing on EX650E F is shown using the figure of ER650E F 6809906015 C APPENDIX 17 35 Cable Wire and Hose Routing ABS Equipped Models The routing on EX650E F is shown using the figure of ER650E F m pci m C z i 8 wins Se j SF Ea 68809818044 C Guide the front brake hose through the guide Clamps Hold the front brake hose Clamp Hold the front wheel rotation sensor lead Clamps Hold the brake pipe ABS Hydraulic Unit Front Wheel Rotation Sensor Clamps Hold the rear brake hose Clamp Hold the rear brake hose and the rear wheel rotation sensor lead Clamp Hold the rear wheel rotation sensor lead Rear Wheel Rotation Sensor 17 36 APPENDIX Cable Wire and Hose Routing SM 22 9 HI al 2 Lf 3 7 4 No AS ISI 1 Xi am RE S S REA F 777 in 08809878045 C APPENDIX 17 37 Cable Wire and Hose Routing 1 Reserve Tank Overflow Hose 2 Fit the reserve tank hose into the groove on the reserve tank 3 Reserve Tank Hose 4 40 mm 1 6 in 5 Run the reserve tank overflow hose through the clamp 6 View from A 7 Clamp 17 38 APPENDIX Cable Wire and Hose Routing AA SAA
67. A from the bleed valve on the caliper e Attach a clear plastic hose B to the bleed valve C and run the other end of the hose into a container Fill the reservoir with fresh specified brake fluid 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 reservoir runs out any time during the changing operation the brakes will need to be bled since air will have entered the brake line OFront Brake Repeat the above steps for the other caliper e Remove the clear plastic hose Install the diaphragm and reservoir cap Tighten Torque Front Brake Reservoir Cap Screws 1 5 N m 0 15 kgf m 13 in Ib e Follow the procedure below to install the rear brake fluid reservoir cap correctly OFirst tighten the rear brake fluid reservoir cap B clock wise C by hand until slight resistance is felt indicating that the cap is seated on the reservoir body then tighten the cap an additional 1 6 turn D while holding the brake fluid reservoir body A Tighten the bleed valve and install the rubber cap Torque Caliper Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib After cha
68. Apply a non permanent locking agent to the oil passage plug and install it Tighten Torque Oil Passage Plug 20 N m 2 0 kgf m 15 ft Ib e Install Right Lower Fairing Bracket see Lower Fairing Bracket Installation in the Frame chapter Right Middle Fairing see Middle Fairing Installation in the Frame chapter ENGINE LUBRICATION SYSTEM 7 17 Oil Pressure Switch Oil Pressure Switch Removal Drain the engine oil see Engine Oil Change in the Peri odic Maintenance chapter e Remove Right Middle Fairing see Middle Fairing Removal in the Frame chapter Right Lower Fairing Bracket see Lower Fairing Bracket Removal in the Frame chapter Switch Cover A Switch Terminal Bolt B Switch Lead C Oil Pressure Switch D Oil Pressure Switch Installation Clean off any oil or dirt and apply liquid gasket to the threads of the oil pressure switch A and tighten it Sealant Liquid Gasket TB1211 56019 120 Torque Oil Pressure Switch 15 N m 1 5 kgf m 11 ft Ib Install the switch lead B direction downward e Apply grease to the terminal C and tighten the terminal bolt securely Front D GG13006BS2 C NOTE OApply a small amount of grease to the terminal so that grease should not close two breather holes A for switch diaphragm GG13004BS1 Install Switch Cover Right Lower Fairing Bracket see Lower Fairing Bracket Installation in the Frame chapter Right Middle Fair
69. Brown 92139 0116 Black 92139 0115 Blue 92139 0114 6105019851 C 9105140851 CRANKSHAFT TRANSMISSION 9 27 Crankshaft and Connecting Rods Crankshaft Main Bearing Insert Journal Wear Inspection 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 ODo not turn the crankshaft during clearance measure ment OJournal clearance less than 0 025 mm 0 00098 in not be measured by plastigage however using genuine parts maintains the minimum standard clearance Crankshaft Main Bearing Insert Journal Clearance Standard 0 017 0 041 mm 0 0007 0 0016 in Service Limit 0 07 mm 0 003 in x If the clearance is within the standard no bearing replace ment is required xIf the clearance is between 0 042 mm 0 0017 and the service limit 0 07 mm 0 003 in replace the bearing inserts A with inserts painted blue B Check insert jour nal clearance with the plastigage The clearance may ex ceed the standard slightly but it must not be less than the minimum in order to avoid bearing seizure xIf the clearance exceeds the service limit measure the diameter of the crankshaft main journal Crankshaft Main Journal Diameter Standard 37 984 38 000 mm 1 4954 1 4961 in Service Limit 37 96 mm 1 4945 in x If any journal has worn past the service l
70. C G005023BS2 G005025BS1 Fairings FRAME 15 13 Lower Inner Fairing Installation Installation is the reverse of removal OBe sure to install the damper A on the right lower inner fairing ORun the leads correctly see Cable Wire and Hose Rout ing section in the Appendix chapter Middle Fairing Removal Remove Upper Inner Fairing see Upper Inner Fairing Removal Lower Inner Fairing see Lower Inner Fairing Removal e Disconnect the turn signal light lead connector A Remove the quick rivets A from the lower fairings Remove the bolts A and washers Pull the middle fairing outward to clear the stopper Pull the middle fairing rearward to clear the hook portions D and remove it with the lower fairing E G005024BS1 15 14 Fairings Middle Fairing Installation Installation is the reverse of removal OBe sure to install the pads A on the right middle fairing G005018BS2 C OBe sure to install the dampers on the left and right middle fairings Outside A Inside B ORun the cables and leads correctly see Cable Wire and Hose Routing section in the Appendix chapter Olnsert the hook portions A into the slits B on the middle fairing Fairings FRAME 15 15 OTuck the pads A on the left and right middle fairings B under the frame C a non permanent lo
71. Clutch Cable 17 16 APPENDIX Cable Wire and Hose Routing T AS 434 P 68098750 G APPENDIX 17 17 Cable Wire and Hose Routing OOANDABRWDNDN Clamp Hold the headlight lead as shown Clamp Hold the turn signal light lead Clamp Hold the turn signal relay lead Fix the turn signal relay to the frame Main Harness Fix the clamps to the bracket Run the horn leads through the guide and under the main harness Horn Lead Connect the horn lead connectors as shown Meter Unit Lead Fix the clamps to the bracket Left Switch Housing Lead Clutch Cable Run the city light lead and main harness through the clamp Fix the clamps to the bracket Headlight Lead Connector High Beam Left Turn Signal Light Connector Fix the clamps to the lower inner fairing City Light Lead Connectors Right Turn Signal Light Connector Headlight Lead Connector Low Beam Right Switch Housing Lead Decelerator Throttle Cable Accelerator Throttle Cable Brake Hose Front Master Cylinder ABS Hydraulic Unit 17 18 APPENDIX Cable Wire and Hose Routing The routing on EX650E F is shown using the figure of ER650E F 58099070 6 APPENDIX 17 19 Cable Wire and Hose Routing Turn Signal Relay Run the radiator fan lead inside the frame Fix the rear brake light switch lead connector to the clamp on the swingarm brack
72. From rear to front run the following under the hook on the battery case starter relay lead battery positive cable connector lead battery negative cable Locate the ABS Kawasaki diagnostic system connector and ABS self diagnosis terminal inside the dust cover Fix the battery positive cable connector to the clamp Fix the fuse box 3 for ABS to the center clamp on the bracket Damper Clamp Brake Hose Front Master Cylinder ABS Hydraulic Unit Brake Hose ABS Hydraulic Unit Front Calipers Brake Hose Rear Master Cylinder ABS Hydraulic Unit Brake Hose ABS Hydraulic Unit Rear Caliper Front Brake Hose to Front Master Cylinder About 50 Brake Hose to Front Caliper About 65 ABS Hydraulic Unit Brake Pipe to Rear Caliper About 29 9 Brake Pipe to Rear Master Cylinder About 28 3 17 12 APPENDIX Cable Wire and Hose Routing 68008280 6 APPENDIX 17 13 Cable Wire and Hose Routing _ Do not loosen the leads in this area Run the leads above the hook the reinforce Fix the clamp to the reinforce Run the leads under the hook on the reinforce Run the rear right turn signal light lead behind the hook on the reinforce Rear Turn Signal Light Lead Connectors Locate the tail brake light lead connector outside the dust cover Dust Cover License Plate Light Lead Connector Be sure to run the
73. Fuel Hose B Check that the hose joints are securely connected OPush and pull A the hose joint B back and forth more than 2 times and make sure it is locked does not locked reinstall the hose joint A WARNING Leaking fuel can cause a fire or explosion resulting in serious burns Make sure the hose joint is in stalled correctly on the delivery pipe by sliding the joint 2 20 PERIODIC MAINTENANCE Periodic Maintenance Procedures Evaporative Emission Control System Inspection CAL SEA B1 and TH Models e Inspect the canister as follows ORemove Left Frame Cover see Frame Cover Removal in the Frame chapter Canister Bracket Bolts A OUnhook the band B to remove the canister C and dis connect the tubes D from the canister OVisually inspect the canister for cracks or other damage x If the canister has any cracks 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 e Inspect the purge valve see Purge Valve Inspection in the Fuel System DFI chapter OCheck that the hoses are securely connected and clips are in position OReplace any kinked deteriorated or damaged hoses ORun the hoses according to Cable Wire and Hose Rout ing section in the Appendix chapter OWhen installing the hoses avoid sharp bending kinking flattening or twisting and
74. Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Fuel change Use the gasoline recommended in the Owner s Manual Spark plug incorrect Replace it with the correct plug see chapter 2 Stick coil trouble Inspect see chapter 16 ECU trouble Inspect see chapter 3 Engine vacuum not synchronizing Inspect and adjust see chapter 2 Intake air pressure sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Intake air temperature sensor trouble Inspect see chapter 3 Miscellaneous Subthrottle sensor trouble Inspect see chapter 3 Subthrottle valve actuator trouble Inspect see chapter 3 Speed sensor trouble Inspect see chapter 3 Throttle valves will not fully open Inspect throttle cables and lever linkage see chapter 3 FUEL SYSTEM DFI 3 33 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions Engine overheating Water temperature sensor see Overheating of Troubleshooting Guide in crankshaft sensor or speed sensor trouble chapter 17 Air switching valve trouble Inspect and replace see chapter 16 Air suction valve trouble Inspect and replace see chapter 5 Exhaust Smokes Excessively Black smoke Air cleaner element clogged Clean element see chapter 2 Fuel pressure too
75. REE 11 5 Drive Odi LM 11 6 Drive Chain Slack Inspection 4 11 6 Drive Ghainoclack AGIUSUTIBYM e dba edere a tat esas 11 6 Wheel Alignment Inspection Adjustment 11 6 Drive Chain Wear Inspection Drive Chain nenne nnne nennen nenne nnns n Drive Chain Removals eee eed er aee du Le e e eee a etn Drive Chain Sprocket COUPLING et Eee ed eae trei cocks EnginesSprocketRemoyal t Risa d red Engine Sprocket InistallatiOn tee ene Rear Sprocket Fernovali ient tite e np t ap de no Eo ra nt M den Rear Sprocket Gouplinig MS Fall AMON acess END eodd Coupling Bearing Retrnoval rre ee eee ae Coupling Bearing Installation Coupling Bearing nier ien ne ec pne Hee Rd pee kn earn tenis Coupling Bearing Lubrication Coupling Damper Sprocket Wear Rear Sprocket Warp 11 14 11 2 FINAL DRIVE Exploded View FINAL DRIVE 11 3 Exploded View
76. Right Middle Fairing see Middle Side Fairing Removal in the Frame chapter Bracket Bolts A Brackets B Brake Pipe Joint Nuts C Install the brake hose noting the following OReplace the washers A on each side of hose fitting B with new ones OAvoid sharp bending kinking flattening or twisting and route the hoses according to Cable Wire and Hose Rout ing section in the Appendix chapter e Before installing the brake pipe check to see that there is no damage on the threads of the brake pipe joint nut x lf there is any damage replace the damaged parts with new ones NOTE OTighten the brake pipe joint nuts at both ends of the brake pipe temporarily and then tighten them to the specified torque Install the brake pipes at the specified angle see Cable Wire and Hose Routing section in the Appendix chapter Tighten the brake pipe joint nuts with the flare nut wrench Tighten Torque Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft Ib Brake Pipe Joint Nuts EX650F Model 18 N m 1 8 kgf m 13 ft lb e Fill the brake line see Brake Fluid Change GL10000BS1 2 54 PERIODIC MAINTENANCE Periodic Maintenance Procedures 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 Level the brake fluid reservoir Remove the reservoir cap and diaphragm Remove the rubber cap
77. Switch Housing Screws 3 5 0 36 kgf m 31 in Ib e Install the front master cylinder see Front Master Cylinder Installation in the Brakes chapter e Apply a non permanent locking agent to the right handle bar weight bolt and tighten it e Run the leads cables and hoses correctly see Cable Wire and Hose Routing section in the Appendix chapter e Adjust the throttle grip free play see Throttle Control Sys tem Inspection in the Periodic Maintenance chapter 15 1 Table of Contents n ter dad ete eae R aea tete ple E EE ee 15 3 MILII E ETE 15 10 Rear Seat 2 15 10 5 15 10 rete de e er 15 10 Front Seat Installatior inest ett e eet 15 10 lujo 15 11 Upper Inner Fairing Removal 15 11 Upper Inner Fairing 15 11 Lower Inner Fairing Removal cii rep 15 12 Lower Inner Fairing Installation 15 13 Middle Fairing Rerroval o tti o 15 13
78. The fuel ignition and exhaust systems of this motorcycle have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels The exhaust system of this model motorcycle manufactured primarily for sale in California in cludes a catalytic converter system 3 Evaporative Emission Control System Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere In stead fuel vapors are routed into the running engine to be burned or stored in a canister when the engine is stopped 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 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 install
79. This is a normal condition It informs the rider that the ABS is operating normally OService codes detected once by the ABS hydraulic unit will be memorized in the ABS hydraulic unit Therefore after maintenance work is finished be sure to erase the service codes Do not erase the service codes during troubleshooting Wait until all the checks and repair work are finished to prevent duplication of previous service codes and unnecessary maintenance work OBefore delivering the motorcycle to the customer be sure to erase any service codes which might be stored in the ABS hydraulic unit Using the self diagnosis feature make sure that only start code 12 is shown A fully charged battery is a must for conducting reliable self diagnosis Test run the motorcycle at a speed of more than 20 km h 12 mph to see that the yellow ABS indicator light LED does not go on Finally test run the motorcycle at a speed of more than 30 km h 20 mph and brake suddenly to see that the motorcycle stops without loss of steering control and the ABS operates normally The reaction force generated is felt in the brake lever and pedal This completes the final inspection ABS Troubleshooting Outline When an abnormality in the system occurs the yellow ABS indicator light LED goes on to alert the rider In ad dition the nature of the fault is stored in the memory of the ABS hydraulic unit and when in the self diagnosis mode the service code A is indicat
80. Water Pump Drain Bot os 10 srme 78 Water Pump Impeler 98 10 srm G Apply grease R Replacement Parts W Apply water NIO OJAJ 4 4 COOLING SYSTEM Coolant Flow Chart Hot Coolant E Cold Coolant Reserve Tank Overflow Hose Reserve Tank Radiator Cap Radiator Cylinder Cylinder Head Jacket o n I b o o 42 o o lt COOLING SYSTEM 4 5 Coolant Flow Chart Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion When the engine starts the water pump turns and the coolant circulates The thermostat is a wax pellet type which opens or closes with coolant temperature changes The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level When coolant temperature is below 80 5 83 5 C 177 182 F the thermostat closes so that the coolant flow is restricted through the air bleeder hole causing the engine to warm up more quickly When coolant temperature is more than 80 5 83 5 C the thermostat opens and the coolant flows When the coolant temperature goes up beyond 104 C 219 F the radiator fan relay conducts to operate the radiator fan The radiator fan draws air through the radiator core when there is not suffi cient air flow such as at low speeds This increases up the
81. When the repair has been done the yellow engine warn ing indicator light LED goes off But the service codes stored in memory of the ECU are not erased to preserve the problem history The problem history can be referred using the KDS Kawasaki Diagnostic System when solv ing unstable problems When the motorcycle is down the vehicle down sensor operates and the ECU shuts off the fuel pump relay fuel in jectors and ignition system The ignition switch is left ON If the starter button is pushed the electric starter turns but the engine does not start When the starter button is pushed the yellow engine warning indicator light LED blinks but the service code is not displayed To start the engine again raise the motorcycle turn the ignition switch to OFF and then ON Much of the DFI system troubleshooting work consists of confirming continuity of the wiring The DFI parts are assembled and adjusted with precision and it is impossible to disassemble or repair them OThe DFI part connectors A have seals B 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 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
82. chapter Special Tool Throttle Sensor Setting Adapter 57001 1538 Main Throttle Sensor Output Voltage Connections to Adapter Meter R Sensor Y BL lead Meter W Sensor BR BK lead Standard DC 1 005 1 035 V at idle throttle opening x If the output voltage is out of the range check the main throttle sensor input voltage see Main Throttle Sensor In put Voltage Inspection in the Fuel System DFI chapter zy ie 04 Perd ea d E QE TM 9505221851 6505015851 C 2 18 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Disconnect Fuel Pump Lead Connector Extension Tube Remove the air cleaner housing see Air Cleaner Housing Removal the Fuel System DFI chapter take off the vacuum gauge hoses and install the rubber caps onto the fittings on the throttle body assy e For CAL SEA B1 and TH Models install the tubes onto the fittings on the throttle body assy Install Air Cleaner Housing see Air Cleaner Housing Installa tion in the Fuel System DFI chapter Fuel Tank see Fuel Tank Installation in the Fuel System DFI chapter Idle Speed Inspection Start the engine and warm it up thoroughly e With the engine idling turn A the handlebar to both sides handlebar movement changes the idle speed the throttle cables may be improperly adjusted or incorrectly routed or dam
83. erase the service code perform the pre diagnosis inspection 1 and 2 and retrieve the service code x If the yellow ABS indicator light LED A goes on faulty ECU in the ABS hydraulic unit Replace the ABS hy draulic unit If the yellow ABS indicator light LED does not go ABS system is normal service code is not stored tempo rary failure Rear Wheel Rotation Sensor Signal Abnormal Service Code 44 Do the 1st step test as follows OMeasure the air gap between the rear wheel rotation sen sor and sensor rotor Thickness Gauge A Rear Wheel Rotation Sensor Air Gap Standard 0 3 1 7 mm 0 01 0 07 If the measurement is over standard check each part for deformation and looseness and correct accordingly Recheck the air gap x If the measurement is correct go to the 2nd step Do the 2nd step test as follows OCheck that there is iron or other magnetic deposits be tween the sensor A and sensor rotor B and the sensor rotor slots for obstructions OCheck the installation condition of the sensor for loose ness OCheck the sensor and sensor rotor tip for deformation or damage e g chipped sensor rotor teeth If the sensor and sensor rotor in bad condition remove the any deposits Install the properly or replace faulty x If the all items are correct go to the 3rd step Do the 3rd step test as follows ORecheck the service code indication erase the service code pe
84. lI and tighten it Torque Race Holder Screw 4 9 0 50 kgf m 43 in Ib x If the breather plate was removed install it in the following procedure OClean off any oil or dirt and apply liquid gasket to the breather plate mating surface A 1 mm 0 04 in or more thick and then install the breather plate Sealant Liquid Gasket TB1207B 92104 2068 NOTE OMake the application finish within 7 minutes when the liquid gasket to the mating surface of the breather plate is applied OMoreover fit the plate and tighten the bolts just after application of the liquid gasket 9104211851 gt 8104357 52 9104253851 9 14 CRANKSHAFT TRANSMISSION Crankcase Splitting OApply a non permanent locking agent to the threads of the breather plate bolts A and tighten them Torque Breather Plate Bolts 9 8 1 0 kgf m 87 in Ib Olnstall the breather pipe A OAlign the white mark B on the pipe with the white mark C on the breather fitting Olnstall the clamps D so that the pinch heads E face the white marks OApply molybdenum disulfide oil solution to the edge of the oil pipe E Olnstall the oil pipe A so that its flange B touches to the surface C of the upper crankcase half OApply grease to the new O ring D on the oil pipe OReplace the O rings A with new ones OApply grease to the new O rings OApply a non permanent locking agent t
85. see Front Wheel Removal in the Wheels Tires chapter Front Wheel Rotation Sensor Lower End ABS equipped models see Front Wheel Rotation Sensor Removal in the Brakes chapter Loosen the upper front fork clamp bolt A and front fork top plug B beforehand if the fork leg is to be disassem bled NOTE OLoosen the top plug after loosening the upper front fork clamp bolt Loosen the upper front fork clamp bolt and lower front fork clamp bolts C e With a twisting motion work the front fork leg down and out Front Fork Installation Install the front fork so that the top end A of the inner tube is as shown in the figure 3 mm 0 12 in B x If the front fork top plugs were loosened tighten them Torque Front Fork Top Plugs 22 5 2 3 kgf m 17 ft Ib e Tighten Torque Front Fork Clamp Bolts Lower 20 5 2 1 kgf m 15 ft Ib NOTE OTighten the top plug before tightening the upper front fork clamp bolt OTighten the two lower front fork clamp bolts alternately two times to ensure even tightening torque e Tighten Torque Front Fork Clamp Bolts Upper 20 2 0 kgf m 15 ft Ib Install the removed parts see appropriate chapters SUSPENSION 13 9 Front Fork Oil Change e Remove Front Fork see Front Fork Removal Top Plug A with O ring Spacer B Fork Spring Seat C Fork Spring D e Compress A the fork B upside down to draw out the o
86. sensor P lead C Digital Meter BK BL sensor BK lead D e Measure the input voltage with the engine stopped and with the connector joined e Turn the ignition switch to ON Input Voltage Standard About DC 9 11 V at Ignition Switch ON e Turn the ignition switch to OFF xIf the reading is out of the range check the wiring see wiring diagram in this section and meter unit see Meter Unit Inspection in the Electrical System chapter the reading is good check the output voltage GC17158BS1 C 3 58 FUEL SYSTEM Speed Sensor Service Code 24 Speed Sensor Output Voltage Inspection e Before this inspection inspect the input voltage see Speed Sensor Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch to OFF e Remove the left frame cover see Frame Cover Removal in the Frame chapter e Disconnect the speed sensor connector A and connect the harness adapter B between the harness connector and speed sensor connector Special Tool Throttle Sensor Setting Adapter 1 57001 1400 e Connect a digital meter to the harness adapter leads Speed Sensor Output Voltage Connections to Adapter Digital Meter Y W sensor Y lead C Digital Meter BK BL sensor lead D e Measure the output voltage with the engine stopped and with the connector joined Turn the ignition switch to ON Output Voltage Standard Abo
87. 0 1776 in 4 500 4 512 mm 0 1772 0 1776 in 0 08 0 16 mm 0 0032 0 0063 in 0 03 0 10 mm 0 0012 0 0039 in 32 45 55 60 0 8 1 2 mm 0 03 0 05 in 0 5 1 0 mm 0 02 0 04 in 27 6 27 8 mm 1 087 1 094 in 32 6 32 8 mm 1 283 1 291 in 0 5 mm 0 020 in 0 25 mm 0 0098 in TIR 0 05 mm 0 002 in 4 44 mm 0 175 in 4 46 mm 0 176 in 4 58 mm 0 180 in 4 58 mm 0 180 in 0 35 mm 0 014 in 0 29 mm 0 011 in 5 8 ENGINE END Specifications Item Standard Service Limit Valve Spring Free Length Exhaust Intake 41 91 mm 1 650 in 41 91 mm 1 650 in 40 3 mm 1 59 in 40 3 mm 1 59 in Cylinder Pistons Cylinder Inside Diameter Piston Diameter Piston Cylinder Clearance Piston Ring Groove Clearance Top Second Piston Ring Groove Width Top Second Piston Ring Thickness Top Second Piston Ring End Gap Top Second 82 994 83 006 mm 3 2675 3 2679 in 82 969 82 984 mm 3 2665 3 2671 in 0 010 0 037 mm 0 0004 0 0015 in 0 03 0 07 mm 0 001 0 003 in 0 02 0 06 mm 0 001 0 002 in 0 92 0 94 mm 0 0362 0 0370 in 1 01 1 03 mm 0 0398 0 0406 in 0 87 0 89 mm 0 0343 0 0350 in 0 97 0 99 mm 0 0382 0 0390 in 0 25 0 40 mm 0 0098 0 0157 in 0 40 0 55 mm 0 0157 0 0217 in 83 09 mm 3 271 in 82 82 mm 3 261 in 0 17 mm 0 0067 in 0
88. 1129 e Press the new mechanical seal into the housing with the oil seal driver E until its flange F touches the surface G of the housing Special Tool Oil Seal Driver 57001 1660 Impeller Assembly e Clean the sliding surface of the mechanical seal with a high flash point solvent and apply a little coolant to the sliding surface to give the mechanical seal initial lubrica tion e Apply coolant to the surfaces of the rubber seal A and sealing seat B and install the rubber seal and sealing seat into the impeller by pressing them by hand until the seat stops at the bottom of the hole Pump Impeller Inspection e Remove the water pump cover see Water Pump Re moval e Visually inspect the impeller A x If the surface is corroded or if the blades are damaged replace the impeller with a new one see Water Pump Removal Installation GD06087BS1 9006063851 C HE rg Lum TAL 9006116851 C COOLING SYSTEM 4 13 Radiator Radiator and Radiator Fan Removal Drain the coolant see Coolant Change in the Periodic Maintenance chapter Remove the left middle fairing see Middle Fairing Re moval in the Frame chapter Disconnect the radiator fan lead connector A Remove the water hose B from the radiator Clear the rubber cover A from the filler neck Remove Water Hose B Radiator Bolt C and Collar Remove the radiator A by pullin
89. 15 Throttle Control System Inspectigm 2 15 Engine Vacuum Synchronization 2 15 Idle Speed Inspection 2 18 Idle Speed Ad UslITient een etr accen eden tau e es Lee o 2 18 Fuel Hose Inspection fuel leak damage installation condition 2 19 Evaporative Emission Control System Inspection CAL SEA B1 and TH Models 2 20 SY SGT is cactus Ret does stated Gods pei ci a eet e cast Alsons 2 20 Coolant Level Inspections rsr ina a a eaa 2 20 Water Hose Damage and Installation Condition 2 21 Top P CEKAT eter meee wane ees 2 21 Valve Clearance Inspection 2 21 Valve Clearance Adjustment nennen rtr RR EUR ER HER 2 22 Air Suction System Damage Inspection pp 2 25 T 2 25 Clutch Operation Inspectiom 9 2 25 Ac EET 2 26 Air Pressure 2 26 Wheel Tire Damage 000111111 nnne nnne 2 27 Tire Tread Wear Abnormal Wear Inspection pp 2 27 Wheel Bearing Damage Inspection eese nnne 2 28 FInial Drive
90. 3 4 Swi Starter 8 Hazard Button Turn Signal Switch teh Lockout Switch Passing Button Fuse Box 2 i Turn Signal Relay Fuse Headlight 10 i i Left Gity Light 12760 Front Left Turn Signal e SALES Light 12710 eet oe E 5 Tura Signal Relay Fuse 15 2 Weter Fuse Left Switch Housing 3 Fan Fuse 154 4 Brake Horn Fusa 10 Left Switch Housing 5 Ignition Fuse 10A Horn Button 6 Headlight Fuse 15 Relay Box Radiator Fan Relay Headlight cuit Relay ECU Main Relay Fuel Pump Relay Starter Circuit Relay 1 2 3 4 5 Horn Button Hazard Button Turn Signal LEFT SWITCH HOUSING CONNECTIONS Switch Dimmer Switch Starter Lockou t Switch Passing Button W2L0620885 C ELECTRICAL SYSTEM 16 17 Wiring Diagram EX650E Model Intake Intake Sub Air Vehicle Water Air Other than throttle Sub Wain down Fuel Temperature Temperature US and Valve throttle Throttle Sensor Sensor Injectors Sensor Sensor Neutral CAL Models Actuator Sensor Sensor d Switch oil bett r 5 2 Sen Oxygen ae Sensor jani Joint SN cin Connector SM ed T T puree t T T FE E J send E tee ase S53 3 ze F CAL Model ei als n
91. 35 1 Timing Rotor Bolt Cap 4 9 0 50 43 in Ib 8 Filler Plug Hand tighten 9 Pump Chain Guide Bolts 12 1 2 106 in Ib L 10 Oil Pump Sprocket Bolt 12 1 2 106 in Ib L Lh 11 Clutch Lever Clamp Bolts 7 8 0 80 69 in Ib 5 Apply cable lubricant Apply engine oil Apply grease Apply a non permanent locking agent Left hand Threads Apply molybdenum disulfide grease Replacement Parts Follow the specified tightening sequence Apply water 6 4 CLUTCH Specifications Item Standard Service Limit Clutch Lever Clutch Lever Free Play 2 3 mm 0 08 0 12 in Friction Plate Thickness 2 92 3 08 mm 0 115 0 121 in 2 7 mm 0 106 in Friction Plate Warp 0 15 mm 0 059 in or less 0 3 mm 0 012 in Steel Plate Warp 0 2 mm 0 008 in or less 0 3 mm 0 012 in Clutch Spring Free Length 33 60 mm 1 323 in 32 6 mm 1 28 in 6 5 Special Tools and Sealant Clutch Holder Liquid Gasket TB1211F 57001 1243 92104 0004 879200045 6 Filler Cap Driver 57001 1454 7571454ST C 6 6 CLUTCH Clutch Lever and Cable Clutch Lever Free Play Inspection e Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter Clutch Lever Free Play Adjustment e Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter Clutch Cable Removal Remove the right middle
92. 5 42 Camshaft Chain 5 25 Throttle Body Assy Holder Cylinder Head 5 26 Installation 5 42 Cylinder Compression 5 43 5 26 Muffler 5 43 Cylinder Head 5 27 Muffler Installation 5 44 5 2 ENGINE END Exploded View ENGINE END 5 3 Exploded View Fastener Nm kgfm ftib Lrpemmaemm om 2 Air Suction Valve Cover Bolts 87 3 Cylinder Head Cover Bolts T 87 4 Camshaft Cap Bolts 12 1 2 106 in Ib S 5 Throttle Body Assy Holder Clamp Bolts 2 0 0 20 18 in Ib 6 Throttle Body Assy Holder Bolts 12 1 2 106 in Ib 7 Camshaft Sprocket Bolts 15 1 5 11 L 8 Camshaft Chain Tensioner Cap Bolt 20 2 0 15 9 Camshaft Chain Tensioner Mounting Bolts 9 8 1 0 87 in lb L 10 Camshaft Chain Guide Bolt 20 2 0 15 L 11 Cylinder Head Bolts M10 56 5 7 41 5 12 Cylinder Head Bolts M6 12 1 2 106 in Ib L S EO Apply engine oil G Apply grease L Apply a non permanent locking agent LG Apply liquid gasket M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replaceme
93. 544 40 104 F 1 136 0 095 100 212 F 0 1553 0 0070 Reference Information Speed Sensor Removal Never drop the sensor especially hard surface Such a shock to the sensor can damage it Remove the engine sprocket cover see Engine Sprocket Removal in the Final Drive chapter e Disconnect the speed sensor lead connector A Open the clamp B Remove Bolt A Speed Sensor B Speed Sensor Installation Installation is the reverse of removal OApply a non permanent locking agent to the sensor bolt and tighten it Torque Speed Sensor Bolt 6 0 0 61 kgf m 53 in Ib 8 18055 52 Switches and Sensors ELECTRICAL SYSTEM 16 77 Speed Sensor Inspection e Remove the speed sensor see Speed Sensor Removal e Connect the speed sensor connector A with the battery B 10 kO 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 screw driver OThen the tester indicator should flick B x If the tester indicator does not flick replace the speed sensor Fuel Level Sensor Inspection e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Fuel Pump see Fuel Pump Removal in the Fuel System DFI chapter e Check that the float moves up and down smoothly without binding It should
94. A Removal e Inspect the fuse element x If it is blown out replace the fuse Before replacing blown fuse always check the amperage in the affected circuit If the amperage is equal to or greater than the fuse rating check the wiring and related components for a short circuit Housing A Fuse Element B Terminals C Blown Element D NOTICE 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 GP20000181 C SUSPENSION 13 1 Suspension Table of Contents Exploded VieW E Re IR RU 13 2 Specifications oot e eI Wit eh 13 6 Elec 13 7 EONDU FORK dem 13 8 F rort Fork REMOVAl ee rave Ted ee 13 8 Eront Fork Installation saa erret eee tx ht te rt eere nes ae ti e HE ER 13 8 13 9 Eront Fork Disassembly oret ette cete dct i eur Deed a oed bue deat 13 10 PFORUROLKASSOMIDIY 25 RED 13 12 Inner Tube Outer Tube Inspection 000440 1 000000 13 13 DUSUSeal Inspections i Rete didit ete isan pe e WIS 13 13 Spring Tension 8 13 14 Fear Shock Absorber
95. Abnormal Service Code 25 e Do the 1st step test as follows OCheck the following and correct the faulty part Incorrect the tire pressure Tires not recommended for the motorcycle were installed incorrect tire size Deformation of the wheel or tire Sensor rotor for missing teeth and clogging with foreign matter x If the all parts correct go to the 2nd step e Do the 2nd step test as follows ORecheck the service code indication erase the service code perform the pre diagnosis inspection 1 and 2 and retrieve the service code If the yellow ABS indicator light LED A goes on faulty ECU in the ABS hydraulic unit Replace the ABS hy draulic unit xIf the yellow ABS indicator light LED does not go on ABS system is normal service code is not stored tempo rary failure ABS Motor Relay Inspection Service Code 35 e Do the 1st step test as follows OCheck the ABS motor relay fuse A x If the fuse blown go to the 2nd step x If the fuse correct go to the 4th step e Do the 2nd step test as follows ODisconnect the ABS hydraulic unit connector A see ABS Hydraulic Unit Removal OCheck for continuity between the red white and black lead terminals of the ABS hydraulic unit connector x If there is the continuity in the lead replace the ABS hy draulic unit x If there is not the continuity in the lead go to the 3rd step e Do the 3rd step test as follows OCheck for continuity between the red white
96. Bleeding Check the fluid level in the brake reservoirs see Brake Fluid Level Inspection in the Periodic Maintenance chap ter Check the brake for good braking power no brake drag and no fluid leakage A WARNING After servicing it takes several applications of the brake lever or pedal before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the motorcycle until a firm brake lever or pedal is obtained by pumping the lever or pedal until the pads are against the disc 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 Inspection The fluid seal piston seal A is placed around the pis ton to maintain clearance between the pad the disc If O the seal is in a poor condition it could lead the pad to wear excessively or the brake to drag which may cause the tem perature of the discs or the brake fluid to increase Replace the fluid seal s if it shows any of the condit
97. Bolts 25 N m 2 5 18 ft lb Install the frame cover see Frame Cover Installation 15 24 Windshield Windshield Removal Remove Bolts A and Washers Windshield B Windshield Installation Installation is the reverse of removal OTighten Torque Windshield Mounting Bolts 4 2 N m 0 43 kgf m 37 in Ib 15 25 Sidestand Sidestand Removal Raise the rear wheel off the ground using a stand A e Remove Sidestand Switch Bolt A Clamp B Sidestand Switch C e Remove Spring A Sidestand Nut B Sidestand Bolt C Sidestand D Sidestand Installation e Apply grease to the sliding area A of the sidestand B e Replace the sidestand nut C with a new one Tighten the sidestand bolt with the specified torque first and then tighten the sidestand nut securely Torque Sidestand Bolt 44 N m 4 5 kgf m 32 ft lb Hook the spring as shown in the figure e Install the sidestand switch F and clamp G Apply a non permanent locking agent to the threads of the sidestand switch bolt H and tighten it Torque Sidestand Switch Bolt 8 8 N m 0 90 kgf m 78 in Ib e Run the leads and hose correctly see Cable Wire and Hose Routing section in the Appendix chapter G020056BS2 C 15 26 Frame Cover Frame Cover Removal Remove the bolt A and collar Pull the frame cover B outward to cle
98. Bolts 12 1 2 106 in Ib Cylinder Bolt M8 27 5 2 8 20 MO S Cylinder Nut 49 5 0 36 MO S Cylinder Bolts M6 12 1 2 106 in Ib L S Exhaust Pipe Manifold Holder Nuts 17 1 7 13 Muffler Body Mounting Bolts 20 2 0 15 Clutch Clutch Cable Clamp Bracket Bolt 9 8 1 0 87 in Ib Clutch Cable Holder Bolts 9 8 1 0 87 in lb L Clutch Cover Bolts 9 8 1 0 87 in lb Clutch Hub Nut 130 13 3 96 R Clutch Lever Clamp Bolts 7 8 0 80 69 5 Clutch Spring Bolts 9 8 1 0 87 in lb Timing Rotor Bolt Cap 4 9 0 50 43 Oil Filler Plug Hand tighten Oil Pump Chain Guide Bolts 12 1 2 106 L Oil Pump Sprocket Bolt 12 1 2 106 in Ib L Lh Timing Inspection Cap 3 9 0 40 35 Engine Lubrication System Engine Oil Drain Plug 30 3 1 22 Filter Plate Bolts 9 8 1 0 87 in lb L Holder Mounting Bolt 25 2 5 18 L Lower Fairing Bracket Bolts 12 1 2 106 in Ib L Oil Filter 17 5 1 8 13 EO R Oil Pan Bolts 12 1 2 106 in Ib S Oil Passage Plug 20 2 0 15 L Oil Passage Plug M6 3 5 0 36 31 in Ib Oil Pipe Plate Bolt 9 8 1 0 87 in lb L Oil Plate Bolts 9 8 1 0 87 in Ib L Oil Pressure Relief Valve 15 1 5 11 L Oil Pressure Switch 15 1 5 11 LG Oil Pump Chain Guide Bolts 12 1 2 106 in Ib L Oil Pump Cover Bolts 9 8 1 0 87 in Ib L Oil Pump Sprocket Bolt 12 1 2 106 L Lh Engine Removal Installation Front Engine Mounting Bolt Left 44 4 5 32 S Front Engine Mounting Bolt Right 49 5 0 36 S Front Engine Bracket Bolts Left 25 25 18 S Front Engine Bracket Bolts
99. Brake Discs Thickness Front 4 8 5 2 mm 0 19 0 20 in 4 5 mm 0 18 in Rear 4 8 5 2 mm 0 19 0 20 in 4 5 mm 0 18 in Runout TIR 0 15 mm 0 0059 in or less TIR 0 3 mm 0 01 in Brake Fluid Grade ABS Equipped Models Wheel Rotation Sensor Air Gap Front Rear 0 3 1 7 mm 0 01 0 07 in 0 3 1 7 mm 0 01 0 07 in 5 12 13 Special Tools Jack Needle Adapter Set 57001 1238 57001 1457 7571238ST C 5157145751 C Hand Tester 57001 1394 7571394ST C 12 14 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 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 Measure the brake pedal position A Pedal Position Standard About 50 mm 2 0 in below top of footpeg x If 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 Remove Right Footpeg Stay see Footpeg Stay Removal in the Frame chapter Loosen the rear master cylinder push rod locknut A and turn
100. C out of the delivery pipe A WARNING Fuel is flammable and explosive under certain con ditions and can cause severe burns Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is dis connected fuel spills out from the hose and the pipe Cover the hose connection with a clean shop towel to prevent fuel spillage Replace the fuel hose with a new one Insert the fuel hose joint A straight onto the delivery pipe until the hose joint clicks e Push B the joint lock C e Push and pull A the fuel hose joint B back and forth more than two times and make sure it is locked and does not come off A WARNING Leaking fuel can cause a fire or explosion resulting in severe burns Make sure the fuel hose joint is installed correctly on the delivery pipe and that it doesn t leak x If it comes off reinstall the hose joint e Run the fuel hose correctly see Cable Wire and Hose Routing section in the Appendix chapter Install the fuel tank see Fuel Tank Removal in the Fuel System DFI chapter Start the engine and check the fuel hose for leaks Coolant Change A WARNING Coolant can be extremely hot and cause severe burns is toxic and very slippery Do not remove the radiator cap or attempt to change the coolant when the engine is hot allow it cool completely Immediately wipe any spilled coolant from tires frame eng
101. Coolant Change in the Periodic Maintenance chapter Coolant Filling Refer to the Coolant Change in the Periodic Maintenance chapter Pressure Testing Remove the radiator cap see Coolant Change in the Pe riodic Maintenance chapter 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 Build up pressure in the system carefully until the pres sure reaches 141 7 kPa 1 45 kgf cm 20 6 psi NOTICE During pressure testing do not exceed the pres sure for which the system is designed The maxi mum pressure is 141 7 kPa 1 45 kgf cm 20 6 psi e Watch the gauge for at least 6 seconds x If the pressure holds steady the system is all right If the pressure drops and no external source is found check for internal leaks Droplets in the engine oil indicate internal leakage Check the cylinder head gasket and the water pump Remove the pressure tester replenish the coolant and install the radiator cap COOLING SYSTEM 4 9 Coolant Cooling System Flushing Over a period of time the cooling system accumulates rust scale and lime in the water jacket and radiator When this accumulation is suspected or observed flush the cool ing system If this accumulation is not removed it will clog up the water passage and considerable reduce the effi ciency of the cooling system Drain the
102. Cylinder Clamp Bolts 97 in lb Front Brake Light Switch Screw 0 12 11 in Ib Brake Hose Banjo Bolts Caliper Bleed Valve 69inlb Front Caliper Mounting Bolts 25 20 E Brake Disc Mounting Bolts B Apply brake fluid L Apply a non permanent locking agent R Replacement Parts S Follow the specified tightening sequence Si Apply silicone grease ex PBC grease N NIO NIN N N N 12 6 BRAKES Exploded View EX650E Model 6L02490885 C 5 12 7 Exploded View Torque mo Fes Dem Brake Hose Banjo Bolts Rear Master Cylinder Mounting Bolts Rear Master Cylinder Push Rod Locknut 4 Brake PedalBot 090 78b 0 80 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 8 BRAKES Exploded View EX650F Model 08102500845 C 5 12 9 Exploded View Torque kgf m ft Ib Front Brake Reservoir Cap Screws 0 15 13 in Ib Brake Lever Pivot Bolt 9 in Ib Brake Lever Pivot Bolt Locknut 52 in lb Front Master Cylinder Clamp Bolts 97 in Ib Front Brake Light Switch Screw 11 in Ib Brake Hose Banjo Bolts Brake Pipe Joint Nuts Front Caliper Mounting Bolts 34 f 25 Brake Disc Mounting Bolts 27 20 Front Wheel Rotation Sensor Bolt 20 B Apply brake flu
103. D LED Illumination Light E OThe following should appear for 2 seconds Yellow Engine Warning Indicator Light LED F Red Low Battery Voltage Warning Indicator Light LED G Red Water Temperature Warning Indicator Light LED H Blue High Beam Indicator Light LED I x If the multifunction meter does not work as above replace the meter assembly e Disconnect the terminal 8 OThe LED illumination light LCD segments and all the warning indicator lights should disappear x If the multifunction meter does not work as above replace the meter assembly Upper and Lower Button Operation Check Connect the 12 V battery and terminals in the same man ner as specified in the Liquid Crystal Display LCD Seg ments Check Check that the multifunction meter displays shift as shown when the upper button A is pressed x If the multifunction meter display function does not work replace the meter assembly GP17895CS1 GP17896CS1 TPE ngg GP17897092 C 16 68 ELECTRICAL SYSTEM Meter Gauge Indicator Unit Display the odometer Check that when the lower button A is pressed for more than 2 seconds in ODO mode the multifunction meter display turns to the clock set mode OBoth the hour and minute display start blinking In the HOUR MINUTE setting mode press the lower but ton again to effect the HOUR setting mode OThe hour display
104. DC 0 2 V or less Turn the ignition switch to OFF x If the reading is out of the standard with plug DC 0 7 V or more without plug DC 0 2 V or less check the following Fuel Pressure see Fuel Pressure Inspection Fuel Injector see Fuel Injectors section xIf the fuel pressure and fuel injectors are good replace the sensor x If the reading is within the standard with plug DC 0 7 V or more without plug DC 0 2 V or less check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation 3 82 FUEL SYSTEM Oxygen Sensor Incorrect Output Voltage Service Code 94 Equipped Models GCi7iB4FW3 C Oxygen Sensor Circuit renim onjoj BR BATTERY Jojo Ignition Switch Oxygen Sensor ECU Frame Ground 2 Battery 12 V 10 Ah Main Fuse 30 A Relay Box ECU Main Relay Fuse Box 1 FI Fuse 15 A Ignition Fuse 10 A FUEL SYSTEM 3 83 Purge Valve Service Code 3A CAL SEA B1 and Models Purge Valve Removal Installation e Remove Left Frame Cover see Frame Cover Removal in the Frame chapter Purge Valve Connector A Disconnect Tubes B Disconnect Purge Valve Mounting Nut C Purge Valve D Installation is the reverse of removal OTighten Torque Purge Valve Mounting Nut 7 0 N m 0 71
105. FUEL SYSTEM DFI 3 41 Main Throttle Sensor Removal Adjustment NOTICE Do not remove or adjust the main throttle sensor A since it has been adjusted and set with precision at the factory Never drop the throttle body assy especially on a hard surface Such a shock to the sensor can dam age it Main Throttle Sensor Input Voltage Inspection NOTE OBe sure the battery is fully charged Turn the ignition switch to OFF Remove the left middle fairing see Middle Fairing Re moval in the Frame chapter e Disconnect the main throttle sensor connector and con nect the harness adapter A between these connectors Special Tool Throttle Sensor Setting Adapter 57001 1538 Connect a digital meter to the harness adapter leads Main Throttle Sensor Input Voltage Connections to Adapter Digital Meter BK sensor BL lead Digital Meter W sensor BR BK lead e Measure the input voltage with the engine stopped and with the connector joined e Turn the ignition switch to ON Input Voltage Standard DC 4 75 5 25 V e Turn the ignition switch to OFF x If the input voltage is normal check the 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 Continuity Inspection ECU Connector A Main Throttle Sensor Connector B BL lead ECU terminal 8 C BR BK lead EC
106. Fork Oil Level Fork Spring Free Length 41 mm 1 6 in Atmospheric pressure Non adjustable Non adjustable Non adjustable KAYABA KHL34 G10 or equivalent approx 410 mL 13 9 US oz when changing oil 484 4 mL 16 4 0 14 US oz after disassembly and completely dry 98 2 mm 3 86 0 08 in below from inner tube top with fully compressed without fork spring 301 3 mm 11 86 in Service limit 295 mm 11 61 in Rear Shock Absorber Spring Preload Gas Pressure 3rd position Adjustable Range 1st 7th position 980 kPa 10 kgf cm 142 psi Non adjustable Special Tools Inside Circlip Pliers 57001 143 7570143ST C Fork Cylinder Holder Handle 57001 183 7570183ST C Fork Cylinder Holder Adapter 57001 1057 ub 5157105751 6 Oil Seal amp Bearing Remover 57001 1058 5157105851 C Bearing Driver Set 57001 1129 7571129ST C SUSPENSION 13 7 Jack 57001 1238 7571238ST C Front Fork Oil Seal Driver 57001 1219 5157121951 6 Fork Oil Level Gauge 57001 1290 5157129051 C Needle Bearing Driver 28 57001 1610 5157161051 C Spacer 28 57001 1663 5157166351 C 13 8 SUSPENSION Front Fork Removal e Remove Middle Fairings see Middle Fairing Removal in the Frame chapter Front Fender see Front Fender Removal in the Frame chapter Front Wheel
107. Fuel Pump Frame Ground 1 Frame Ground 2 Battery 12 V 10 Ah Main Fuse 30 A Relay Box Fuel Pump Relay ECU Main Relay Radiator Fan Relay Fuse Box 1 Fl Fuse 15A Radiator Fan Fuse 15A Ignition Fuse 10 A Meter Unit Yellow Engine Warning Indicator Light LED Speedometer Tachometer Ignition Switch Engine Stop Switch Starter Button Radiator Fan Motor Stick Coils Air Switching Valve Speed Sensor Subthrottle Valve Actuator Joint Connector C Subthrottle Sensor Main Throttle Sensor Joint Connector D Intake Air Pressure Sensor Vehicle down Sensor Fuel Injectors Water Temperature Sensor Intake Air Temperature Sensor Crankshaft Sensor Oxygen Sensor Equipped Models OLead Color Codes BK Black G Green P Pink BL Blue GY Gray PU Purple BR Brown LB Light Blue R Red CH Chocolate LG Light Green W White DG Dark Green O Orange Y Yellow 3 14 FUEL SYSTEM DFI System Terminal Numbers of ECU Connectors 5 34 33 32 31 30 29 28 27 12112111110 8 817 8 5 41 121 1 44 43 42 41 40 39 38 37 36 26 25 24123 2212112019 11817 16 15 14 Terminal Names External Subthrottle Valve Actuator BK O Subthrottle Valve Actuator G Y Unused Oxygen Sensor Equipped Models BL Y Speed Sensor LG R Main Throttle Sensor Y R Intake Air Pressure Sensor Y BL P
108. Installation GC17288DS1 9017608652 C 3 52 FUEL SYSTEM Intake Air Temperature Sensor Service Code 13 Intake Air Temperature Sensor Circuit 0 BR BK R BR BK R BR BK 3 BR BK 1 ECU 2 Intake Air Temperature Sensor 3 Joint Connector D Water Temperature Sensor Service Code 14 FUEL SYSTEM 3 53 Water Temperature Sensor Removal Installation Never drop the sensor especially hard surface Such a shock to the sensor can damage it e Drain the coolant see Coolant Change in the Periodic Maintenance chapter Remove the left middle fairing see Middle Fairing Re moval in the Frame chapter e Disconnect the sensor connector A and unscrew the water temperature sensor B Installation is the reverse of removal OApply grease to the new O ring on the water temperature sensor OTighten Torque Water Temperature Sensor 12 N m 1 2 kgf m 106 in Ib OFill the engine with coolant and bleed the air from the cool ing system see Coolant Change in the Periodic Mainte nance chapter 3 54 FUEL SYSTEM Water Temperature Sensor Service Code 14 Water Temperature Sensor Output Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch to OFF Remove the left middle fairing see Middle Fairing Re moval in the Frame chapter
109. Motor Assembly totus Sed fe Toledo Rua bed orsa 16 48 Brush Inspection iic eere kenn ek REPE ER RR XR RR RR E TNR Re RR Ee cs 16 50 Commutator Cleaning and 2 2 22 1 2 16 51 Armature Inspection 2 dcr e ex Roo 16 51 Bsh lead Inspection d rise et e ER UE LER LA NE A DREAN 16 51 Right hand End Cover Inspection pp 16 52 Starter Relay Inspectii Maurs nanen o esos de uet 16 52 ra 7 suc atop E e Rossius euni cu AT av atari ts 16 54 Headlight Beam Horizontal Adjustment 16 54 Headlight Beam Vertical 16 54 Headlight Bulb Replacement weet dva ede o etu sur 16 54 City Eight Bulb Replacement esaet ede erret 16 55 Headlight Unit 16 55 Tail Brake Light LED Unit Removal 16 55 Tail Brake Light LED Unit Installation 16 55 License Plate Light Bulb Replacement pp 16 56 Front Turn Signal Light Bulb 16 58 Rear Turn Signal Light Bulb Replacemen
110. R Adapter BK to lead wire peak voltage adapter W 8 10011952 C GP10394BS1 C Ignition System ELECTRICAL SYSTEM 16 43 A WARNING To avoid extremely high voltage shocks do not touch the spark plugs or tester connections Turn the ignition switch to ON and the engine stop switch to run position Pushing the starter button turn the engine 4 5 seconds with the transmission in neutral to measure the primary peak voltage Repeat the measurement 5 times or more for one stick coil Stick Coil Primary Peak Voltage Standard 117 V or more Repeat the test for the other stick coil xIf the reading is less than the specified value check the following Stick Coils see Stick Coil Inspection Crankshaft Sensor see Crankshaft Sensor Inspection ECU see ECU Power Supply Inspection in the Fuel Sys tem DFI chapter e Install the stick coils see Stick Coil Installation 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 Spark Plug Condition Inspection e Remove the spark plugs see Spark Plug Replacement in the Periodic Maintenance chapter e Visually inspect the spark plugs xIf the spark plug center electrode A and or side elec trode B are corroded or damaged or if the insulator C is cracked repl
111. Removal Loosen the banjo bolt A being careful not to spill brake fluid Remove the caliper mounting bolts B Remove the banjo bolt and take off the brake hoses from the caliper NOTICE Immediately wipe up any brake fluid that spilled NOTE Olf the caliper is to be disassembled after removal and compressed air is not available disassemble the caliper before brake hose removal see Caliper Rubber Parts Replacement in the Periodic Maintenance chapter Rear Caliper Removal Loosen the banjo bolt A being careful not to spill brake fluid Remove the caliper mounting bolts B Remove the banjo bolt and take off the brake hose from the caliper NOTICE Immediately wipe up any brake fluid that spilled NOTE Olf the caliper is to be disassembled after removal and compressed air is not available disassemble the caliper before brake hose removal see Caliper Rubber Parts Replacement in the Periodic Maintenance chapter Caliper Installation Install the caliper s Tighten Torque Front Caliper Mounting Bolts 34 N m 3 5 kgf m 25 ft lb Rear Caliper Mounting Bolts 25 N m 2 5 kgf m 18 ft lb Replace the washers A on each side of hose fitting B with new ones Install the brake hose lower end Tighten Torque Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft Ib GL10000BS1 5 12 17 Calipers Bleed the brake line see Brake Line
112. Right 30 3 1 22 S Rear Engine Mounting Bolts 44 4 5 32 S Rear Engine Mounting Nuts 44 4 5 32 R S Rear Engine Bracket Bolts 25 2 5 18 S 2 8 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Torque Remarks kgf m ft Ib Engine Ground Lead Terminal Bolt 9 8 1 0 87 Crankshaft Transmission Breather Plate Bolts 9 8 1 0 87 L Race Holder Screw 4 9 0 50 43 in Ib L Connecting Rod Big End Nuts see Text lt Crankcase Bolt M8 L 110 mm 27 5 2 8 20 5 Crankcase Bolt M6 L 32 mm 19 6 2 0 14 5 Crankcase Bolts M6 L 38 mm 19 6 2 0 14 5 Crankcase Bolts M6 L 45 mm 19 6 2 0 14 5 Crankcase Bolt 8 L 50 mm 27 5 2 8 20 5 Crankcase Bolts M8 L 60 25 5 2 6 19 5 Crankcase Bolt M8 L 60 mm 27 5 2 8 20 5 Crankcase Bolts 8 L 73 mm 25 5 2 6 19 MO S Crankcase Bolts M9 L 113 mm 44 4 5 32 5 Crankcase Bolts 9 L 83 mm 44 4 5 32 5 Upper Crankcase Bolt 8 L 120 27 5 2 8 20 5 Upper Crankcase Bolts 8 L 110 mm 27 5 2 8 20 5 Oil Pipe Bolts 9 8 1 0 87 L Oil Plate Bolts 9 8 1 0 87 L Shift Shaft Return Spring Pin 29 3 0 21 Timing Rotor Bolt 40 4 1 30 Drive Shaft Bearing Holder Screw 4 9 0 50 43 Gear Positioning Lever Bolt 12 1 2 106 in Ib Neutral Switch 15 1 5 11 Neutral Switch Holder Screw 4 9 0 50 43 L Transmission Case Oil Nozzle 2 9 0 30 26 in lb L Shift Drum Bearing Holder Screws 4 9 0 50
113. 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 60 Cutter angle vsus Outer diameter of cutter C Operating Procedures Clean the seat area carefully Coat the seat with machinist s dye e Fit a 45 cutter into the holder and slide it into the valve guide e Press down lightly on the handle and turn it right or left Grind the seating surface only until it is smooth Do not grind the seat too much Overgrinding will redu
114. Torque Oil Pressure Relief Valve 15 1 5 kgf m 11 ft lb Install the oil pan see Oil Pan Installation Oil Pressure Relief Valve Inspection Remove the oil pressure relief valve see Oil Pressure Relief Valve Removal e Check to see if the valve A slides smoothly when push ing it in with a wooden or other soft rod and see if it comes back to its seat by spring B pressure NOTE Olnspect the valve in its assembled state Disassembly and assembly may change the valve performance any rough spots are found during above inspection wash the valve clean with a high flash point solvent and blow out any foreign particles that may be in the valve with compressed air A WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the oil pressure relief valve in a well ventilated area and take care that there are no sparks or flame anywhere near the working area this includes any appliance with a pilot light Do not use gasoline or a low flash point solvent to clean the oil pressure relief valve 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 9008006851 C ENGINE LUBRICATION SYSTEM 7 13 Oil Pump Oil Pump Removal Remove Clutch see Clutch Removal in the
115. Valve Actuator Service Code 62 Subthrottle Valve Actuator Circuit 0 W BL a Y P P amp W BL BK 0 8017187 42 1 2 Subthrottle Valve Actuator 3 76 FUEL SYSTEM Air Switching Valve Service Code 64 Air Switching Valve Removal Installation e Refer to the Air Switching Valve Removal Installation in the Engine Top End chapter Air Switching Valve Inspection e Refer to the Air Switching Valve Operation Test Unit Test in the Electrical System chapter e Remove the fuel tank see Fuel Tank Removal and check the wiring continuity using the following diagram Air Switching Valve Circuit Lon eniti onon BR 1 p BATTERY Jes Li L GCi7iB8FW3 C lgnition Switch Air Switching Valve ECU Frame Ground 2 Battery 12 V 10 Ah Main Fuse 30 Relay Box ECU Main Relay Fuse Box 1 10 Fl Fuse 15 A 11 Ignition Fuse 10 A FUEL SYSTEM DFI 3 77 Oxygen Sensor Heater Service Code 67 Equipped Models Oxygen Sensor Heater Removal Installation The oxygen sensor heater is bult in the oxygen sensor So the heater itself can not be removed Remove the oxy gen sensor see Oxygen Sensor Removal in the Electrical System chapter Oxygen Sensor Heater Inspection e Turn the ignition switch to OFF Remove the engine sprocket cover see Engine Sprocket Remova
116. an arrow B on the wheel spoke Check the wheel rotation mark on the front wheel and install it N 6J04225BS1 WHEELS TIRES 10 7 Wheels Rims e Apply high temperature grease to the grease seal lips e Fit the collars A on the both sides of the hub OThe collars are identical e Insert the front axle Remove the jack Tighten Torque Front Axle 108 N m 11 0 kgf m 80 ft Ib Before tightening the front axle clamp bolt A 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 Torque Front Axle Clamp Bolt 34 3 5 kgf m 25 ft Ib e Install the front calipers see Front Caliper Installation in the Brakes chapter e Check the front brake effectiveness see Brake Operation Inspection in the Periodic Maintenance chapter A WARNING After servicing it takes several applications of the brake lever before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the motorcycle until a firm brake lever is obtained by pumping the lever until the pads are against the disc Rear Wheel Removal e Raise the rear wheel off the ground using the stand A e For models equipped with an ABS remove the rear wheel rot
117. any damage to the wheel replace the wheel e Remove the wheel and support it with the tire by the axle e Measure the rim runout axial A and radial B with a dial gauge x If rim runout exceeds the service limit check the hub bear ings see Hub Bearing Inspection xlIf the problem is not due to the bearings replace the wheel Rim Runout with tire installed Standard Axial TIR 0 5 mm 0 02 in or less Radial TIR 0 8 mm 0 03 in or less Service Limit Axial TIR 1 0 mm 0 04 in Radial TIR 1 0 mm 0 04 in A WARNING Damaged wheel parts may fail and cause an acci dent resulting in serious injury or death Never at tempt to repair a damaged wheel part If the wheel part is damaged it must be replaced with a new one Axle Inspection e Remove the front and rear axles see Front Rear Wheel Removal e Visually inspect the front and rear axles for damages x If the axle is damaged or bent replace it e Measure the axle runout OPlace the axle in V blocks that are 100 mm 3 94 in A apart OSet a dial gauge B on the axle at a point halfway between the blocks OTurn C the axle OThe difference between the highest and lowest dial read ings 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 03 mm 0 001 in or less Service Limit TIR 0 2 mm 0 008 in GJ04130BS1 6J04043BS1 C W
118. blinks on the display e Press the upper button to set the hour In the HOUR setting mode press the lower button to ef fect the MINUTE setting mode OThe minute display blinks on the display e Press the upper button to set the minute In the MINUTE setting mode press the lower button to return the HOUR MINUTE setting mode e Press the upper button to complete the clock setting process OThe clock starts counting the seconds as soon as the up per button is pressed GP17898CS1 GP17899CS1 8 179000651 GP17901CS1 Meter Gauge Indicator Unit ELECTRICAL SYSTEM 16 69 Display the odometer e Check that the multifunction meter displays shift as shown by pressing the lower button while the upper button pressed in NOTE OKm h mph display can alternate between English and metric modes mile and km in the digital meter Make sure that km h or mph according to local regulations is correctly displayed before riding x If the multifunction meter display function does not work replace the meter assembly Speedometer Check Connect the 12 V battery and terminals in the same man ner as specified in the Liquid Crystal Display LCD Seg ments Check 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 14 Olndicates approximately 60 mph in case the input fre quenc
119. cleaner housing clamp bolt A 3 108 FUEL SYSTEM Air Cleaner Pull out the air cleaner housing A from the throttle body assy e Disconnect the air switching valve hose B from the hous ing Air Cleaner Housing Installation Installation is the reverse of removal Olnstall the air cleaner housing onto the throttle body assy securely and tighten the clamp bolt Torque Air Cleaner Housing Clamp Bolt 2 0 N m 0 20 kgf m 18 in Ib ORun the hoses correctly see Cable Wire and Hose Rout ing section in the Appendix chapter FUEL SYSTEM DFI 3 109 Fuel Tank Fuel Tank Removal A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions creating the potential for serious burns 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 to OFF Disconnect the battery terminal To avoid fuel spills draw it from the tank when the engine is cold Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately Turn the ignition switch to OFF and the engine stop switch to stop position e Wait until the engine cools down e Disconnect the battery terminal see Battery Removal in the Electrical System chapter Open the fuel tank cap A to lower the pressure in the tank ODuring tank removal keep
120. cooling action of the radiator When the temperature is below 99 C 210 F the fan relay opens and the radiator fan stops In this way this system controls the engine temperature within narrow limits where the engine op erates most efficiently even if the engine load varies The system is pressurized by the radiator cap to suppress boiling and the resultant air bubbles which can cause engine overheating As the engine warms up the coolant in the radiator and the water jacket expands The excess coolant flows through the radiator cap and hose to the reserve tank to be stored there temporarily Conversely as the engine cools down the coolant in the radiator and the water jacket contracts and the stored coolant flows back to the radiator from the reserve tank The radiator cap has two valves One is a pressure valve which holds the pressure in the system when the engine is running When the pressure exceeds 112 3 141 7 kPa 1 15 1 45 kgf cm 16 3 20 6 psi the pressure valve opens and releases the pressure to the reserve tank As soon as pressure escapes the valve closes and keeps the pressure at 112 3 141 7 kPa 1 15 1 45 kgf cm 16 3 20 6 psi When the engine cools down another small valve vacuum valve in the cap opens As the coolant cools the coolant contracts to form a vacuum in the system The vacuum valve opens and allows the coolant from the reserve tank to enter the radiator 4 6 COOLING SYSTEM Specifications I
121. cooling system see Coolant Change in the Pe riodic Maintenance chapter Fill the cooling system with fresh water mixed with a flush ing compound NOTICE 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 Stop the engine and drain the cooling system Fill the system with fresh water Warm up the engine and drain the system Repeat the previous two steps once more e Fill the system with a permanent type coolant and bleed the air from the system see Coolant Change in the odic Maintenance chapter Coolant Reserve Tank Removal Installation e Remove Right Middle Fairing see Middle Fairing Removal in the Frame chapter Bolts A Cap B e Pour the coolant into a container e Remove Reserve Tank Hose C Reserve Tank Overflow Hose D Coolant Reserve Tank E Installation is the reverse of removal OTighten Torque Coolant Reserve Tank Mounting Bolts 7 9 N m 0 81 kgf m 70 in Ib ORun the hoses correctly see Cable Wire and Hose Rout ing section in the Appendix chapter OFill the coolant reserve tank with coolant see Coolant Change in the Periodic Maintenance chapter 4 10 COOLING SYSTEM Water Pump Water Pump Removal e Drain the coolant see Coolant Change in the P
122. cylinder clearance Piston seizure Remove the carbon deposits and replace damaged parts if necessary Replace the gasket with a standard part Replace damaged gasket and check cylinder head warp Repair if necessary Adjust the valve clearance Replace the piston and or cylinder Inspect the cylinder and replace repair the cylinder and or piston as necessary Bad condition of piston ring and or piston ring grooves Replace the piston and or the piston rings Cylinder Head ENGINE TOP END 5 27 Cylinder Head Removal Drain Engine Oil see Engine Oil Change in the Periodic Main tenance chapter Coolant see Coolant Change in the Periodic Mainte nance chapter Remove Muffler see Muffler Removal Cylinder Head Cover see Cylinder Head Cover Re moval Camshafts see Camshaft Removal Throttle Body Assy see Throttle Body Assy Removal in the Fuel System DFI chapter Throttle Body Assy Holders see Throttle Body Assy Holder Removal Water Hose A Front Camshaft Chain Guide B Water Temperature Sensor Connector C e Firstly remove the M6 cylinder head bolts A e Secondly remove the M6 cylinder bolts B e Thirdly remove the M8 cylinder bolt C e Fourthly remove the M10 cylinder nut D e Lastly remove the M10 cylinder head bolts E e Take off the cylinder head Cylinder Head Installation NOTE OThe camshaft cap is machined with the cylinder head so if a new cylinde
123. diagnosis terminal to the ground terminal ending the self diagnosis mode Activate the ABS by driving the motorcycle at 20 km h 12 mph or NG lit above in order to confirm that the ABS is normal Repeat self diagnosis OK Activate the ABS at a safe place in order to confirm that it operates normally 2 OK 1 The self diagnosis mode continues for a maximum of 5 minutes after which time it terminates Self diagnosis ends when either disconnect the ABS self diagnosis terminal to the ground terminal after about 12 5 seconds in the self diagnosis mode or after executing the service code erase or when the motorcycle is driven while in the self diagnosis mode 2 Apply brake suddenly at 30 km h 19 mph or more to confirm that the motorcycle stops smoothly and steady with pulsation on the brake lever and pedal GLI4593B F 12 44 5 Anti Lock Brake System Equipped Models How to Read Service Codes OService codes are shown by a series of long and short blinks of the yellow ABS indicator light LED as shown below ORead 10th digit and unit digit as the yellow ABS indicator light LED blinks OWhen there are a number of faults a maximum of 6 service codes can be stored and the display will begin starting from the last service code entered OFor the display pattern first start code 12 is shown next up to 6 service codes starting with the last one stored then the display is repeated
124. each primary winding of the stick coils with the engine stopped and with the connec tors joined e Turn the engine stop switch to run position e Turn the ignition switch to ON Input Voltage Standard Battery Voltage e Turn the ignition switch to OFF x If the input voltage is out of the standard check the wiring for continuity see wiring diagram in this section xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see Removal Installation x If the input voltage is within the standard check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see Removal Installation 9617287051 FUEL SYSTEM DFI 3 71 Stick Coils 1 2 Service Code 51 52 Stick Coil Circuit 0 gt on Pari ieni Ti onoo BR 162162 BK O BK Y 8017185 3 C Ipod e m pou c Ignition Switch Engine Stop Switch Stick Coils ECU Frame Ground Battery 12 V 10 Ah Main Fuse 30 A Fuse Box 1 Ignition Fuse 10 A 3 72 FUEL SYSTEM Radiator Fan Relay Service Code 56 Radiator Fan Relay Removal Installation OThe radiator fan relay is built in the relay box A e Refer to the Relay Box Removal in the Electrical System chapter Radiator Fan R
125. fairing see Middle Fairing Re moval in the Frame chapter Open the clamp A Slide the dust cover B out of place Loosen the locknut C and turn the adjusting nut D to give the cable plenty of play Screw in the adjuster A Line up the slots B in the clutch lever C and adjuster and then free the cable from the lever e Remove Bolt A Idle Speed Adjusting Screw Holder B Clutch Cable Holder Bolts C Clutch Cable Lower End D Pull the clutch cable out of the frame Clutch Cable Installation Installation is the reverse of removal ORun the clutch cable correctly see Cable Wire and Hose Routing section in the Appendix chapter Olnstall the clutch cable lower end to the clutch cable holder OApply a non permanent locking agent to the clutch cable holder bolts OTighten Torque Clutch Cable Holder Bolts 9 8 N m 1 0 kgf m 87 in Ib Olnstall the idle speed adjusting screw holder and tighten the bolt Torque Clutch Cover Bolt 9 8 1 0 kgf m 87 in Ib e Adjust the clutch cable see Clutch Operation Inspection in the Periodic Maintenance chapter Clutch Lever and Cable CLUTCH 6 7 Clutch Cable Lubrication Refer to the Chassis Parts Lubrication in the Periodic Maintenance chapter Clutch Lever Installation Install the clutch lever so that the mating surface A of the clutch lever clamp is aligned with the punch mark B Tighten the up
126. from the bracket and disconnect it OOpen the clamp B OConnect the hand tester as shown in the table 1 Special Tool Hand Tester 57001 1394 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 Reading Range Tester to Tester to at 4 000 rpm 250 V AC gowns Another White lead x If the output voltage shows the value in the table the al ternator operates properly x If the output voltage shows a much lower than the value in the table 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 f 0 18 0 26 x10 Another White lead 20 C 68 F 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 white 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 volt
127. ft Ib e Install the rear master cylinder Torque Rear Master Cylinder Mounting Bolts 25 2 5 kgf m 18 ft Ib e Bleed the brake line see Brake Line Bleeding e Check the fluid level in the brake reservoirs see Brake Fluid Level Inspection in the Periodic Maintenance chap ter e Check the brake for good braking power no brake drag and no fluid leakage A WARNING After servicing it takes several applications of the brake lever or pedal before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the motorcycle until a firm brake lever or pedal is obtained by pumping the lever or pedal until the pads are against the disc 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 GL10000BS1 12 24 BRAKES Master Cylinder Master Cylinder Inspection Remove the master cylinders see Front Rear Master Cylinder Removal e Disassemble the front and rear master cylinders see Master Cylinder Disassembly 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 If a master cylinder or piston shows any damage replace them
128. go down under its own weight Float in Full Position A Float in Empty Position B Top C Front D x If the float does not move smoothly replace the fuel pump e Using the hand tester A measure the resistance across the terminals in the fuel level sensor lead connector B Special Tools Hand Tester 57001 1394 Fuel Level Sensor Resistance Standard Full position 9 6 12 4 O Empty position 222 228 O xIf the tester readings are not as specified or do not change smoothly according as the float moves up and down replace the sensor e Install the removed parts see appropriate chapters GP18032BS1 C GP18617BS1 GP18618BS1 C 16 78 ELECTRICAL SYSTEM Switches and Sensors Oxygen Sensor Removal Equipped Models Never drop the sensor especially on a hard surface Such a shock to the sensor can damage it Do not pull strongly twist or bend the oxygen sen sor lead This may cause the wiring open Remove Left Middle Fairing see Middle Fairing Removal in the Frame chapter Engine Sprocket Cover see Engine Sprocket Removal in the Final Drive chapter Connector A Disconnect Oxygen Sensor B Clear the lead from the clamp C Oxygen Sensor Installation Equipped Models Never drop the oxygen sensor A especially on a hard surface Such a shock to the unit can damage it Do not touch the sensing part B and filter holes C of the senso
129. grease Torque Fastener ft lb Remarks Fuel System DFI Fuel Pump Bolts 9 8 1 0 87 in lb L S Air Cleaner Housing Cover Screws 1 2 0 12 11 in Ib Air Cleaner Element Screw 1 2 0 12 11 in Ib Air Cleaner Housing Clamp Bolt 2 0 0 20 18 in Ib Intake Air Temperature Sensor Screw 1 2 0 12 11 in Ib Throttle Body Assy Holder Clamp Bolts 2 0 0 20 18 in Ib Oxygen Sensor Equipped Models 44 4 5 32 Speed Sensor Bolt 7 8 0 80 69 L Speed Sensor Bracket Bolts 9 8 1 0 87 in lb Switch Housing Screws 3 5 0 36 31 in lb Timing Rotor Bolt 40 4 1 30 Water Temperature Sensor 12 1 2 106 in Ib Cooling System Radiator Bolt 70 in Ib Water Hose Clamp Screws 27 in lb Thermostat Housing Bolts 87 in lb Water Pump Cover Bolts 87 Water Pump Drain Bolt 87 Water Pump Impeller Bolt 87 Water Temperature Sensor 106 in Ib Engine Top End Air Suction Valve Cover Bolts 9 8 1 0 87 Baffle Plate Bolts 5 9 0 60 52 in Ib Camshaft Cap Bolts 12 1 2 106 in Ib S Camshaft Chain Tensioner Cap Bolt 20 2 0 15 Camshaft Chain Tensioner Mounting Bolts 9 8 1 0 87 in lb L Camshaft Sprocket Bolts 15 1 5 11 L Cylinder Head Bolts M10 56 5 7 41 MO S Cylinder Head Bolts M6 12 1 2 106 in Ib L S Cylinder Head Cover Bolts 9 8 1 0 87 PERIODIC MAINTENANCE 2 7 Torque and Locking Agent Torque Fastener Nm kgfm ftlb Remarks Rear Camshaft Chain Guide Bolt 20 2 0 15 L Throttle Body Assy Holder
130. grip when moving off Owhen stopping the motorcycle Owhen cruising other 3 28 FUEL SYSTEM Troubleshooting the DFI System Poor running at low speed Poor running or no power at high speed Overy low idle speed Overy high idle speed Orough idle speed voltage is low charge the battery plug loose tighten it plug dirty broken or gap maladjusted remedy it Obackfiring Dafterfiring Dhesitation when acceleration Hengine oil viscosity too high dragging overheating slipping other Spark plug loose tighten it Ospark plug dirty broken or gap maladjusted remedy it plug incorrect replace it Oknocking fuel poor quality or incorrect use high octane gasoline dragging slipping overheating Hengine oil level too high oil viscosity too high other FUEL SYSTEM DFI 3 29 DFI System Troubleshooting Guide NOTE OThis is not an exhaustive list giving every possible cause for each problem listed It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties in DFI system OThe ECU may be involved in the DFI electrical and ignition system troubles If these parts and circuits are checked out good be sure to check the ECU for
131. harness under the frame and outside the rib on the rear fender Hook Hold the rear turn signal light leads the license plate light lead and the tail brake light lead Fix the tail brake light lead connector to the frame gusset Run the tail brake light lead under the frame bracket Run the tail brake light lead on the right side of the gusset 17 14 APPENDIX Cable Wire and Hose Routing The routing on EX650E F is shown using the figure of ER650E F 68092290 6 APPENDIX 17 15 Cable Wire and Hose Routing 1 WD From upper to lower run the following on the left side of the head pipe clutch cable left switch housing lead main harness Guide Run the main harness as follows through the guide on the left side of the head pipe inside the clamp on the bracket Left Switch Housing Lead Run the clutch cable as follows through the guide right side on the right side of the head pipe inside the clamp on the bracket From upper to lower run the following on the right side of the head pipe decelerator throttle cable accelerator throttle cable right switch housing lead Decelerator Throttle Cable Right Switch Housing Lead Accelerator Throttle Cable Guide Run the clutch cable above the frame cross pipe Run the throttle cables under the frame cross pipe Run the right switch housing lead inside the throttle cables Left Side Right Side Main Harness
132. high Inspect see chapter 3 Fuel injector trouble Inspect see chapter 3 3 34 FUEL SYSTEM Self Diagnosis Self diagnosis Outline The self diagnosis system has 2 modes and can be switched to another mode by operating the meter unit User Mode The ECU notifies the rider of troubles in DFI system and ignition system by lighting the yellow engine warning indi cator light LED A when DFI and ignition system parts are faulty and initiates fail safe function In case of serious troubles ECU stops the injection and ignition operations Dealer Mode The LCD Liquid Crystal Display displays the service code s A to show the problem s which the DFI system and ignition system has at the moment of diagnosis Self diagnosis Procedures OWhen a problem occurs with the DFI system and ignition system the yellow engine warning indicator light LED A goes on NOTE OUse a fully charged battery when conducting self diagnosis Otherwise the light LED does not go on 8017202 51 8017203 52 8017202 51 FUEL SYSTEM 3 35 Self Diagnosis Turn the ignition switch to ON e Press the upper button A to display the odometer B 8017206 52 Press the upper button A for more than 2 seconds The service code B is displayed on the LCD by the num ber of two digits 8017207 52
133. in 0 003 in Crankpin Diameter 37 984 38 000 mm 37 97 mm 1 4954 1 4961 in 1 4949 in Marking None Connecting Rod Big End Inside Diameter Marking None Connecting Rod Big End Bearing Insert Thickness Brown Black Blue Connecting Rod Big End Bearing Insert Selection 37 984 37 992 mm 1 4954 1 4957 in 37 993 38 000 mm 1 4958 1 4961 in 41 000 41 016 mm 1 6142 1 6148 in 41 000 41 008 mm 1 6142 1 6145 in 41 009 41 016 mm 1 6145 1 6148 in 1 475 1 480 mm 0 05807 0 05827 in 1 480 1 485 mm 0 05827 0 05846 in 1 485 1 490 mm 0 05846 0 05866 in DERI Diameter Diameter Marking arking None O None None O O Connecting Rod Bolt Stretch New Connecting Rod Used Connecting Rod Crankshaft Side Clearance Bearing Insert Size Color Part Number Brown 92139 0116 Black 92139 0115 Blue 92139 0114 Usable Range 0 24 0 36 mm 0 0094 0 0142 0 20 0 32 mm 0 0079 0 0126 0 05 0 20 0 40 0 0020 0 0079 0 016 CRANKSHAFT TRANSMISSION 9 7 Specifications Item Standard Service Limit Crankshaft Runout 0 02 mm 0 0008 in TIR 0 05 mm or less 0 002 in Crankshaft Main Bearing Insert Journal Clearance 0 017 0 041 mm 0 07 mm 0 0007 0 0016 in 0 003 in Crankshaft Main Journal Diameter 37 984 38 000 mm 37 96
134. in the lead go to the 3rd step GL14610BS1 GL14610BS1 10 15V GL14611BS1 C GL14595BS1 BRAKES 12 47 Anti Lock Brake System Equipped Models Do the 3rd step test as follows ODisconnect the ABS hydraulic unit connector see ABS Hydraulic Unit Removal OCheck for continuity between the black white lead termi nal of the main harness side connector meter unit A and black white lead terminal of the main harness side connector ABS hydraulic unit B x If there is the continuity in the lead replace the ABS hy draulic unit x If there is not the continuity in the lead replace or repair the main harness Yellow ABS Indicator Light LED goes on When the Motorcycle is Running No Service Code e Disconnect ABS Hydraulic Unit Connector see ABS Hydraulic Unit Removal Meter Unit Connector see Meter Unit Removal in the Electrical System chapter e Do the 1st step test as follows OCheck for continuity between the black white lead termi nal of the main harness side connector meter unit A and black white lead terminal of the main harness side connector ABS hydraulic unit B Special Tool Hand Tester 57001 1394 x If there is the continuity in the lead replace the ABS hy draulic unit xIf there is not the continuity in the lead replace or repair the main harness Solenoid Valve Inspection Service Code 13 14 17 18 e Do the 1st step tes
135. kgf m 20 ft lb Crankcase Bolts M6 19 6 N m 2 0 kgf m 14 ft lb 6104257BS2 C 8104355 52 C 9 18 CRANKSHAFT TRANSMISSION Crankcase Splitting The upper crankcase bolts A have copper plated wash ers replace them with new ones Tighten the upper crankcase bolts with copper plated washers Torque Upper Crankcase Bolts 27 5 N m 2 8 kgf m 20 ft lb 0104352852 Wipe up the liquid gasket that seeps out around the crankcase mating surface Check that the crankshaft and balancer shaft turn freely Install the rear camshaft chain guide A e Apply a non permanent locking agent to the rear camshaft chain guide bolt B and tighten it Torque Rear Camshaft Chain Guide Bolt 20 2 0 kgf m 15 ft Ib CRANKSHAFT TRANSMISSION 9 19 Crankshaft and Connecting Rods Crankshaft Removal Split the crankcase see Crankcase Splitting e Remove Camshaft Chain A Crankshaft B Crankshaft Installation NOTE Olf the crankshaft is replaced with a new one refer to the Connecting Rod Big End Bearing Crankshaft Main Bearing Insert Selection in the Specifications NOTICE 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
136. lead F e Hold the sensor vertically e Turn the ignition switch to ON and measure the output voltage 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 D and measure the output voltage Output Voltage Standard with sensor tilted 60 70 or more right or left 0 65 1 35 V with sensor arrow mark pointed up 3 55 4 45 V NOTE Olf you need to test again turn the ignition switch to OFF and then ON e Turn the ignition switch to OFF x If the output voltage is normal check the wiring xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation xIf the output voltage is out of the specified replace the vehicle down sensor 8017166 52 C 3 62 FUEL SYSTEM Vehicle down Sensor Service Code 31 Vehicle down Sensor Circuit 0 BR BK Yz BL BL Y G BR BK 9 de 1 ECU 2 Vehicle down Sensor 3 Joint Connector C GCi7182FW2 C FUEL SYSTEM DFI 3 63 Subthrottle Sensor Service Code 32 Subthrottle Sensor Removal Adjustment NOTICE Do not remove or adjust the subthrottle sensor since it has been adjusted and set with precision at the factory Never drop the throttle body assy especially on a hard surface Such
137. leads Special Tool Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Subthrottle Valve Actuator Input Voltage Connections to Adapter 1 Digital Meter R harness P lead Digital Meter BK harness BK O lead Digital Meter W harness W BL lead Digital Meter Y harness G Y lead Measure the actuator input voltage with the engine stopped and with the connector joined Turn the ignition switch to ON Input Voltage Standard About DC 8 5 10 5 V e Turn the ignition switch to OFF x If the reading is in specification but the actuator does not operate replace the throttle body assy see Throttle Body Assy Removal Installation x If the reading is out of the specification remove the ECU and check the wiring for continuity between main harness connectors Special Tool Hand Tester 57001 1394 ODisconnect the ECU and actuator connectors Wiring Continuity Inspection ECU Connector A Subthrottle Valve Actuator Connector B BK O lead ECU terminal 1 C G Y lead ECU terminal 2 D P lead ECU terminal 14 E WIBL lead ECU terminal 15 F xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see Removal Installation GC17187FS1 9617817051 FUEL SYSTEM DFI 3 75 Subthrottle
138. light sounds for 3 seconds and then stops e Turn the ignition switch to OFF x If the pump does not operate as described above inspect the operating voltage see Fuel Pump Operating Voltage Inspection FUEL SYSTEM DFI 3 95 Fuel Pump Fuel Pump Operating Voltage Inspection OBe sure the battery is fully charged F1 BK Y Turn the ignition switch to OFF Remove the left side cover see Side Cover Removal in the Frame chapter e Disconnect the fuel pump lead connector and connect the harness adapter A between these connectors as shown in the figure 8010080851 Main Harness Fuel Pump C Special Tool Measuring Adapter 57001 1700 Connect digital meter to the harness adapter leads Fuel Pump Operating Voltage Connections to Adapter Digital Meter R pump BK Y lead Digital Meter BK pump BK W lead e Measure the operating voltage with engine stopped and with the connector joined e Turn the engine stop switch to run position Turn the ignition switch to ON Operating Voltage Standard Battery Voltage for 3 seconds and then 0 V e Turn the ignition switch to OFF x If the reading stays on battery voltage and never shows 0 V check the fuel pump relay see Relay Circuit Inspection in the Electrical System chapter x If the pump relay is normal check the ECU for its ground and power supply see ECU P
139. locking agent to the oil pump cover bolts and tighten them Torque Oil Pump Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib e Check that the oil pump turns smoothly e Install the clutch see Clutch Installation in the Clutch chapter 7 16 ENGINE LUBRICATION SYSTEM Oil Pressure Measurement Oil Pressure Measurement e Remove Right Middle Fairing see Middle Fairing Removal in the Frame chapter Right Lower Fairing Bracket see Lower Fairing Bracket Removal in the Frame chapter Oil Passage Plug A NOTE OPlace a suitable container under the oil passage plug e Attach the adapter A and gauge B to the oil passage plug hole Special Tools Oil Pressure Gauge 10 kgf cm 57001 164 Oil Pressure Gauge Adapter PT3 8 57001 1233 e Start the engine and warm up the engine e Run the engine at the specified speed and read the oil pressure gauge x If the oil pressure is much lower than the standard check the oil pump relief valve and or crankshaft bearing insert wear immediately x If the reading is much higher than the standard check the oil passages for clogging Oil Pressure Standard 216 294 kPa 2 2 3 0 kgf cm 31 43 psi at 4 000 r min rpm oil temperature 90 194 Stop the engine Remove the oil pressure gauge and adapter A WARNING Hot oil can cause severe burns Beware of hot en gine oil that will drain through the oil passage when the gauge adapter is removed
140. mm 1 4954 1 4961 in 1 4945 in Marking None 37 984 37 992 mm 1 4954 1 4957 1 37 993 38 000 1 4958 1 4961 Crankcase Main Bearing Inside Diameter 41 000 41 016 mm 1 6142 1 6148 Marking 41 000 41 008 1 6142 1 6145 in 41 009 41 046 1 6145 1 6148 Crankshaft Main Bearing Insert Thickness Brown 1 490 1 494 mm 0 05866 0 05882 in Black 1 494 1 498 mm 0 05882 0 05898 in Blue 1 498 1 502 mm 0 05898 0 05913 in Crankshaft Main Bearing Insert Selection Crankcase Main Crankshaft Main Bearing Insert Bearing Inside Journal Diameter Diameter Marking Marking Size Color Part Number Brown 92028 1905 None Black 92028 1904 Blue 92028 1903 bearing inserts for Nos 1 2 3 journals have oil grooves Balancer Shaft Balancer Shaft Bearing Insert Journal Clearance 0 011 0 033 mm 0 06 mm 0 0004 0 0013 in 0 002 in Balancer Shaft Journal Diameter 27 987 28 000 mm 27 96 mm 1 1019 1 1024 in 1 1008 in Marking None 27 987 27 993 mm a 1 1019 1 1021 in 27 994 28 000 1 1021 1 1024 9 8 CRANKSHAFT TRANSMISSION Specifications Item Standard Service Limit Crankcase Bearing Bore Diameter 31 000 31 016 mm ___ 1 2205 1 2211 Marking 31 000 31 008
141. not badly worn or stepped and that the friction boot B is not damaged x If the friction boot is damaged replace it To replace the friction boot remove the pads and the caliper holder x If the caliper holder shaft is damage replace it GL05247BS1 GL05248BS1 C GL05249BS1 C 9105250851 12 20 5 Brake Pads Front Brake Pad Removal Remove the front caliper with the hose installed see Front Caliper Removal e Draw out the holder shaft pin A and take off the holder shaft B Remove the pad C from the holder shaft D Remove the other side pad Front Brake Pad Installation e Push the caliper pistons in by hand as far as they will go e Install the pad spring in its correct position Install the pad on the piston side first then install the other side pad on the holder Install the front caliper see Front Caliper Installation A WARNING After servicing it takes several applications of the brake lever before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the motorcycle until a firm brake lever is obtained by pumping the lever until the pads are against the disc Rear Brake Pad Removal e Remove the rear caliper with the hose installed see Rear Caliper Removal e Draw out the holder shaft pin A and take off
142. of Contents seio T Model IdentifICatiOn uc ee ep EE rte ren ra ir c Gt ern e agr f ri as General Specifications Unit Conversion Table 1 2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera tion on a motorcycle read the precautions given below To facilitate actual operations notes illustra tions photographs cautions and detailed descriptions have been included in each chapter wherever necessary This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts Especially note the following Battery Ground Before completing any service on the motorcycle discon nect the battery cables from the battery to prevent the en 9 S gine from accidentally turning over Disconnect the ground 2 qe cable first and then the positive When completed Wa with the service first connect the positive cable to the e 4 positive terminal of the battery then the negative A ble to the negative terminal DISASSEMBLY ASSEMBLY 68020248 5 Edges of Parts Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts 6 020048 5 Solvent Use a high flash point solvent when cleaning parts High flash point solvent should be used according t
143. of the specified oil to top offthe 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 Drain the engine oil see Engine Oil Change in the Peri odic Maintenance chapter e Remove Middle Fairings see Middle Fairing Removal in the Frame chapter Lower Fairing Brackets see Lower Fairing Bracket Re moval in the Frame chapter Muffler see Muffler Removal in the Engine Top End chapter Remove Oil Pan Bolts A Oil Pan 80806059852 C Remove the following from the as necessary Filter Plate Bolts A Filter Plate B Filter C Remove the following from the lower crankcase half as necessary Oil Screen A Oil Pipe Plate Bolt B Oil Pipe Plate C Oil Pipes D Dampers E 7 10 ENGINE LUBRICATION SYSTEM Oil Pan Oil Pan Installation x If the following parts were removed install them in the following procedure Oil Pipes Oil Pipe Plate Dampers Oil Screen Filter Filter Plate OReplace the O rings with new ones OApply grease to the O rings on the oil pipes A Olnstall the oil pipe plate B so that its guide portion fits the
144. oil pipe as shown in the figure OApply a non permanent locking agent to the oil pipe plate bolt C OTighten Torque Oil Pipe Plate Bolt 9 8 N m 1 0 kgf m 87 in Ib Olnstall the damper D to the end of the breather pipe OApply grease to the damper OApply grease to the damper A on the oil screen B and install it on the lower crankcase half as shown in the fig ure Olnstall the oil screen so that its guide portion C fits the crankcase rib D Olnstall Filter A Filter Plate B OApply non permanent locking agent to the filter plate bolts C and tighten them Torque Filter Plate Bolts 9 8 N m 1 0 kgf m 87 in Ib e Replace the oil pan gasket with a new one e When installing the oil pan fit the damper A on the breather pipe into the hollow B of the oil pan ENGINE LUBRICATION SYSTEM 7 11 Oil Pan Tighten the oil pan bolts following the specified tightening sequence Torque Oil Pan Bolts 12 N m 1 2 kgf m 106 in Ib GG06060BS2 C 7 12 ENGINE LUBRICATION SYSTEM Oil Pressure Relief Valve Oil Pressure Relief Valve Removal e Remove Oil Pan see Oil Pan Removal Oil Pressure Relief Valve A Oil Pressure Relief Valve Installation Apply a non permanent locking agent to the threads of the oil pressure relief valve and tighten it NOTICE Do not apply too much non permanent locking agent to the threads This may block the oil pas sage
145. opening for reference NOTE OOpen the throttle confirm the output voltage will be raise OThe standard voltage refers to the value when the volt age reading at the Input Voltage Inspection shows 5 V exactly OWhen the input voltage reading shows other than 5 V derive a voltage range as follows Example In the case of a input voltage of 4 75 V 1 005 x 4 75 5 00 0 955 V 1 035 x 4 75 5 00 0 983 V Thus the valid range is 0 955 0 983 V e Turn the ignition switch to OFF xIf the output voltage is out of the standard inspect the main throttle sensor resistance see Main Throttle Sensor Resistance Inspection Main Throttle Sensor Service Code 11 FUEL SYSTEM 3 43 x If the output voltage is normal check the wiring for conti nuity ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Main Throttle Sensor Connector B Y R lead ECU terminal 6 C lead ECU terminal 22 D xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation Main Throttle Sensor Resistance Inspection Turn the ignition switch to OFF e Disconnect the main throttle sensor connector Connect a digital meter A to the main throttle sensor connector B e Measure the main throttle sensor resistance Main Throttle Sen
146. or if they have worn past the service limit replace them with new ones Friction Plate Thickness Standard 2 92 3 08 mm 0 115 0 121 in Service Limit 2 7 mm 0 106 in Clutch Plate Warp Inspection e Place each friction plate or steel plate on a surface plate and measure the gap between the surface plate A and each friction plate or steel plate B with a thickness gauge C The gap is the amount of friction or steel plate warp x If any plate is warped over the service limit replace it with a new one Friction Plate Warp Standard 0 15 mm 0 0059 in or less Service Limit 0 3 mm 0 012 in 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 replace it with a new one Clutch Spring Free Length Standard 33 60 mm 1 323 in Service Limit 32 6 mm 1 28 in Clutch Housing Finger Inspection e Visually inspect the clutch housing fingers A where the friction plate tangs B hit 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 GF06060281 GF13010781 8 06080351 C GF06220BS1 6 15 Clutch Clutch Housing Spline Inspection e Visually inspect where the tee
147. piston come out of the cylinder and then disassemble the caliper Rear Caliper Assembly Clean the caliper parts except for the pads NOTICE For cleaning of the parts use only disc brake fluid isopropyl alcohol or ethyl alcohol e Install the bleed valve and rubber cap Torque Caliper Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib Replace the fluid seal A with a new brake fluid to the fluid seal and install it into the cylinder by hand Replace the dust seal B with a new one if it is damaged brake fluid to the dust seal and install it into the cylinder by hand 6105040251 PERIODIC MAINTENANCE 2 59 Periodic Maintenance Procedures e Apply brake fluid to the outside of the piston and push it into the cylinder by hand Replace the friction boot A and dust cover B with new ones if they are damaged e Apply a thin coat of PBC Poly Butyl Cuprysil grease to the caliper holder shafts C PBC is a special high temperature water resistance grease Install the pad spring A in the caliper as shown Install the pads see Rear Brake Pad Installation in the Brakes chapter e Wipe up any spilled brake fluid on the caliper with wet cloth Spark Plug Replacement Remove Air Cleaner Housing see Air Cleaner Housing Removal in the Fuel System chapter Stick Coils see Stick Coil Removal in the Electrical Sys t
148. relay and pump relay are normal check the power source wiring see wiring diagram in this section xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see Removal Installation x If the reading is in specification check the output voltage see Fuel Injector Output Voltage Inspection PEZ m 80178820651 Fuel Injectors FUEL SYSTEM DFI 3 99 Fuel Injector Output Voltage Inspection NOTE OBe sure the battery is fully charged Turn the ignition switch to OFF Remove the ECU see ECU Removal ODo not disconnect the ECU connector Connect a digital meter A to the connector B with the needle adapter set Special Tool Needle Adapter Set 57001 1457 Fuel Injector Output Voltage Connections to ECU Connector For Fuel Injector 1 Digital Meter BL R lead ECU terminal 34 Digital Meter gt Battery terminal For Fuel Injector 2 Digital Meter BL Y lead ECU terminal 33 Digital Meter gt Battery terminal e Measure the output voltage with the engine stopped and with the connector joined Turn the engine stop switch to run position Turn the ignition switch to ON Output Voltage Standard Battery Voltage for 3 seconds and then 0 V Turn the ignition switch to OFF x lf the reading is in specification check the E
149. see Headlight Unit Removal in the Elec trical System chapter Front Wheel see Front Wheel Removal in the Wheels Tires chapter Front Forks see Front Fork Removal in the Suspension chapter Open the clamps A e Remove Bolts and Nuts B Bracket C Steering Stem Head D see Steering Play Adjustment in the Periodic Maintenance chapter Open the clamp A e Remove Horn Lead Terminals B Disconnect Bolts C Horn Bracket D e Bend the claws A of claw washer straighten e Remove the steering stem locknut B Special Tool Steering Stem Nut Wrench 57001 1100 Remove the claw washer e Pushing up the stem base A remove the steering stem nut B and stem cap C Special Tool Steering Stem Nut Wrench D 57001 1100 Remove the steering stem Steering Stem STEERING 14 7 Remove Upper Ball Bearing Inner Race A Upper Ball Bearing B To remove the ball bearing outer races A pressed into the head pipe B insert a bar C into the recesses of head pipe and applying it to both recess alternately ham mer 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 Remove the lower ball bearing A Remove the lower ball bearing inner race A with its oil seal which is pressed onto the steering stem with a suit ab
150. spring broken or weak Camshaft bearing worn Valve lifter worn Other noise Connecting rod small end clearance exces sive Connecting rod big end clearance exces sive Piston ring groove clearance excessive Piston ring worn broken or stuck Piston ring groove worn Piston seizure damage Cylinder head gasket leaking Exhaust pipe leaking at cylinder head con nection Crankshaft runout excessive Troubleshooting Guide Engine mount loose Crankshaft bearing worn Primary gear worn or chipped Camshaft chain tensioner trouble Camshaft chain sprocket guide worn Air suction valve damaged Air switching valve damaged Alternator rotor loose Catalytic converter melt down due to muffler overheating KLEEN Abnormal Drive Train Noise Clutch noise Clutch 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 Caliper trouble Other noise Bracket nut bolt etc mounted or t
151. the continuity in the lead replace or repair the main harness e Do the 4th step test as follows OCheck the battery terminal voltage between the red black lead terminal of the fuse box A and ground Special Tool Hand Tester 57001 1394 Battery Terminal Voltage Standard Battery Voltage x If the battery terminal voltage is not within the specifica tion go to the 5th step x If the battery terminal voltage is correct go to the 6th step e Do the 5th step test as follows OCheck for continuity between the positive cable A of the battery and red black lead terminal of the main har ness side connector ABS hydraulic unit B x If there is the continuity in the lead go to the 4th step x If there is not the continuity in the lead replace or repair the main harness e Do the 6th step test as follows ORecheck the service code indication erase the service code perform the pre diagnosis inspection 1 and 2 and retrieve the service code x If the yellow ABS indicator light LED A goes on faulty ABS solenoid valve relay in the ABS hydraulic unit Re place the ABS hydraulic unit If the yellow ABS indicator light LED does not go ABS system is normal service code is not stored tempo rary failure GL14600BS1 GL14032BS1 GL14601BS1 C GL14610BS1 Anti Lock Brake System Equipped Models BRAKES 12 49 Front Rear Wheel Rotation Difference
152. the holder shaft B e Remove the pad C from the holder shaft D e Remove the other side pad E Rear Brake Pad Installation e Push the caliper piston in by hand as far as it will go e Install the pad spring in its correct position e Install the pad on the piston side first then install the other side pad on the holder e Install the rear caliper see Rear Caliper Installation A WARNING After servicing it takes several applications of the brake pedal before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the motorcycle until a firm brake pedal is obtained by pumping the pedal until the pads are against the disc Brake Pad Wear Inspection e Refer to the Brake Pad Wear Inspection in the Periodic Maintenance chapter 5 12 21 Master Cylinder Front Master Cylinder Removal e Disconnect the front brake light switch connectors A Loosen the banjo bolt B being careful not to spill brake fluid Remove the banjo bolt and take off the brake hose from the master cylinder C NOTICE Immediately wipe up any brake fluid that spilled e Unscrew the front master cylinder clamp bolts A and take off the master cylinder B as an assembly with the reservoir brake lever and brake switch installed e Remove Brake Lever Pivot Bolt A and Locknut B Brake Le
153. the output shaft e Install the transmission assy see Transmission Assy In stallation Transmission Shaft Removal Refer to the Transmission Assy Disassembly Transmission Shaft Installation Refer to the Transmission Assy Assembly CLER I GI 134578W2 C 9 40 CRANKSHAFT TRANSMISSION Transmission Transmission Shaft Disassembly e Remove the transmission shafts see Transmission Assy Disassembly eRemove the circlips disassemble the transmission shafts S im 53 The 5th gear A the output shaft has three steel balls assembled into it for the positive neutral finder mecha nism Remove the 5th gear OSet the output shaft in a vertical position holding the 3rd gear B OSpin the 5th gear quickly C and pull it off upward Special Tool Outside Circlip Pliers 57001 144 81130828 5 Transmission Shaft Assembly e Apply engine oil to the bushings needle bearings and shafts Install the gear bushings A on the shaft with their holes B aligned 6113040851 Replace any circlips removed with new ones Install the circlips A so that the opening B is aligned with a spline groove C 6113010251 The drive shaft gears 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 a
154. 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 Tighten Torque Rear Master Cylinder Push Rod Locknut 17 1 7 kgf m 13 ft lb Install the right footpeg stay see Footpeg Stay Installation in the Frame chapter Inspect the brake light switch operation see Brake Light Switch Operation Inspection in the Periodic Maintenance chapter 5 12 15 Brake Lever Brake Pedal Brake Pedal Removal e Remove Right Footpeg Stay see Footpeg Stay Removal in the Frame chapter Cotter Pin A Joint Pin B Rear Brake Light Switch Spring C Return Spring D Brake Pedal Bolt E and Washer F Washer G e Take out the brake pedal H Brake Pedal Installation e Apply grease to the pivot shaft A Install Washer B Brake Pedal C Washer D Tighten Torque Brake Pedal Bolt E 8 8 N m 0 90 kgf m 78 in Ib e Install the following parts as shown in the figure Return Spring A Rear Brake Light Switch Spring B e Install the joint pin C e Replace the cotter pin D with a new one e Insert the cotter pin and bend the pin ends as shown e Install the right footpeg stay see Footpeg Stay Installation in the Frame chapter Inspect the brake pedal position see Brake Pedal tion Inspection 12 16 BRAKES Calipers Front Caliper
155. the reservoir runs completely out any time during bleeding the bleeding operation must be done over again from the beginning since air will have entered the line OTap the brake hose lightly from the caliper to the reser voir for more complete bleeding OFront Brake First bleeding the right caliper then repeat the above steps for the left caliper e Remove the clear plastic hose e Install the diaphragm and reservoir cap e Tighten Torque Front Brake Reservoir Cap Screws 1 5 0 15 kgf m 13 in Ib e For rear brake follow the procedure below to install the rear 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 Caliper Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib Check the fluid level in the brake reservoirs see Brake Fluid Level Inspection in the Periodic Maintenance chap ter pus bleeding is done check the brake for good braking power no brake drag and no fluid leakage GL09062BS2 C 12 28 5 Brake Fluid A WARNING When working with the disc brake observe the pre cautions listed below 2 3 Never reuse old brake fluid Do not use fluid from a containe
156. the service limit B replace both pads in the caliper as a set Brake Operation Inspection Inspect the operation of the front and rear brake by ning the vehicle on the dry road x If the brake operation is insufficient inspect the brake sys tem A WARNING When test riding the vehicle be aware of surround ing traffic for your safety Brake Light Switch Operation Inspection Turn the ignition switch to ON e The brake light A should go on when the brake lever is applied or after the brake pedal is depressed about 10 mm 0 39 in x If it does not adjust the brake light switch Remove the right frame cover see Frame Cover Removal in the Frame chapter While holding the switch body A turn the adjusting nut B to adjust the switch Light sooner as the body rises C Light later as the body lowers D NOTICE To avoid damaging the electrical connections in side the switch be sure that the switch body does not turn during adjustment 0513265852 C PERIODIC MAINTENANCE 2 35 Periodic Maintenance Procedures x If it does not go on inspect or replace the following items Battery see Charging Condition Inspection in the Elec trical System chapter Brake Light see Tail Brake Light LED Unit Removal in the Electrical System chapter Main Fuse 30 A and Brake Horn Fuse 10 A see Fuse Inspection in the Electrical System chapter Front Brake Light S
157. the stand raised and the transmission engaged and the rear wheel turns OWhen accelerating so abruptly that the front wheel leaves the ground OWhen the ABS has been subjected to strong electrical interference OWhen tire pressure is abnormal Adjust tire pressure OWhen a tire different in size from the standard size is being used Replace it with standard size OWhen the wheel is deformed Replace the wheel Much of the ABS troubleshooting work consists of con firming continuity of the wiring The ABS parts are assem bled and adjusted by the manufacturer so there is no need to disassemble or repair them Replace the ABS hydraulic unit The basic troubleshooting procedures are listed below e Carry out pre diagnosis inspections as a preliminary in spection Determine the fault using the self diagnosis function Check wiring and connections from the ABS hydraulic unit connector to the suspected faulty ABS part using the hand tester Special Tool Hand Tester 57001 1394 Visually inspect the wiring for signs of burning or fraying If any wiring is poor replace the damaged wiring e Pull each connector A apart and inspect it for corrosion dirt and damage x If the connector is corroded or dirty clean it carefully If it is damaged replace it 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
158. the valve see Valve Removal Check the valve seating surface A between the valve B and valve seat C OMeasure the outside diameter D of the seating pattern on the valve seat x If the outside diameter is too large or too small repair the seat see Valve Seat Repair Valve Seating Surface Outside Diameter Standard Exhaust 27 6 27 8 mm 1 087 1 094 in Intake 32 6 32 8 mm 1 283 1 291 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 Standard Exhaust 0 8 1 2 mm 0 03 0 05 Intake 0 5 1 0 mm 0 02 0 04 in Valve Seat Repair e Repair the valve seat with the valve seat cutters A Special Tools Valve Seat Cutter Holder Bar C 57001 1128 Valve Seat Cutter Holder 44 5 B 57001 1330 For Exhaust Valve Seat Valve Seat Cutter 45 530 57001 1187 Valve Seat Cutter 32 530 57001 1120 Valve Seat Cutter 60 530 57001 1123 For Intake Valve Seat Valve Seat Cutter 45 535 57001 1116 Valve Seat Cutter 32 635 57001 1121 Valve Seat Cutter 55 535 57001 1247 If the manufacturer s instructions are not available use the following procedure 8 15011752 C GE15048BS1 C ENGINE END 5 33 Valves
159. tightening sequence 7 4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart Inlet Camshaft Oil Passage Exhaust Camshaft Oil Passage 011 Jet Oil Jet Crankshaft Oil Passages Oil Filter 011 Pressure Main Oil Passage 011 Screen Feeding 011 Flow Scavenge Pump lt Scavenging 011 Flow ENGINE LUBRICATION SYSTEM 7 5 Engine Oil Flow Chart Balancer Shaft Drive Shaft Oil Pipe 011 Passage Oil Passage Output Shaft 011 Passage Oil Screen Oi Pipe Feed Pump Scavenge Pump Oil in Transmission Room 011 from Crank Room Screen 66042278 6 7 6 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil Type SG SH SJ SL or SM with JASO MA1 2 Viscosity SAE 10W 40 Capacity 1 6 L 1 7 US gt when filter is not removed 1 8 L 1 9 US gt when filter is removed 2 3 L 2 4 US gt when engine is completely dry Level Between upper and lower level lines Oil Pressure Measurement Oil Pressure 216 294 kPa 2 2 3 0 kgf cm 31 43 psi at 4 000 r min rpm Oil Temperature 90 C 194 ENGINE LUBRICATION SYSTEM 7 7 Special Tools and Sealant Oil Pressure Gauge 10 kgf cm Liquid Gasket TB1211 57001 164 56019 120 7570164ST C 875601205 Pressure Gauge Adapter PT3 8 57001 1233 875712335 7 8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter A WARNING Vehicle operation with i
160. wiring open or short 56 Radiator fan relay malfunction wiring open or short 62 Subthrottle valve actuator malfunction wiring open or short 64 Air switching valve malfunction wiring open or short 67 Oxygen sensor heater malfunction wiring open or short Equipped models 94 Oxygen sensor malfunction wiring open or short Equipped models 3A Purge valve malfunction wiring open or short CAL SEA B1 and TH models Notes OThe ECU may be involved in these problems If all the parts and circuits checked out good be sure to check the ECU for ground and power supply If the ground and power supply are checked good replace the ECU OWhen no service code is displayed the electrical parts of the DFI system has no fault and the mechanical parts of the DFI system and the engine are suspect Self Diagnosis FUEL SYSTEM DFI 3 39 Backups OThe ECU takes the following measures to prevent engine damage when the DFI or the ignition system parts have troubles Main Throttle Sensor Intake Air Pressure Sensor Output Signal Usable Range or Criteria Main Throttle Sensor Output Voltage 0 2 4 8V Intake Air Pressure absolute Pv 150 800 mmHg Backups by ECU If the main throttle sensor system fails the output voltage is out of the usable range wiring short or open the ECU locks ignition timing into the ignition timing at closed throttle position and sets the DFI in the D J method 1 Also the main thrott
161. xIf one vacuum is not within the specification turn in the bypass screws until it seats fully but not tightly Special Tool Pilot Screw Adjuster E A 57001 1603 Do not over tighten them They could be damaged requiring replacement e Turn out the bypass screw of the higher vacuum between 1 A and 2 B to the lower vacuum e Open and close the throttle valves after each measure ment and adjust the idle speed as necessary Inspect the vacuums as before x If both vacuums are within the specification finish the en gine vacuum synchronization If any vacuum can not be adjusted within the specification remove the bypass screws 1 2 and clean them e Remove the bypass screw A spring B washer C and O ring D e Check the bypass screw hole in the throttle body for car bon deposits x If any carbons accumulate wipe the carbons off from the hole using a cotton pad penetrated with a high flash point solvent e Replace the bypass screw spring washer and O ring as a set e Turn in the bypass screw until it seats fully but not tightly NOTICE Do not over tighten the bypass screw The tapered portion E of the bypass screw could be damaged e Repeat the same procedure for other bypass screw e Inspect the synchronization again xIf the vacuums are correct check the output voltage of the main throttle sensor see Main Throttle Sensor Output Voltage Inspection in the Fuel System DFI
162. 00 mile 2 28 inspect Drive chain slack inspect Every 1 000 km 600 mile 2 29 Drive chain wear inspect e 2 31 Chain guide wear inspect 9 2 31 5 Brake fluid leak brake hose 2 32 pipe inspect Brake hose and pipe damage inspect pip 9 2 32 Brake hose and pipe installation m 2 32 condition inspect y Brake fluid level inspect 6 months 2 33 year e e Brake pad wear inspect 2 34 Brake operation effectiveness play no drag inspect 2 34 Brake light switch operation 2 34 inspect Suspension Front forks rear shock absorber operation damping and smooth e e 2 35 stroke inspect Front forks rear shock absorber oil leak inspect uoa Steering Steering play inspect year e 2 36 Steering stem bearings 2 years 2 38 lubricate Electrical System Lights and switches operation year 2 2 30 inspect Headlight aiming inspect 2 41 Sidestand switch operation 2 42 inspect Engine stop switch operation 2 43 inspect Others Chassis parts lubricate year e 2 44 Bolts and nuts tightness inspect e e e e 2 45 Service more frequently when operating in severe conditions dusty wet muddy high speed or frequent starting stopping For higher odometer readings repeat at the frequency interval established here Periodic Maintenanc
163. 013BS1 C GD07001BS1 C 4 16 COOLING SYSTEM Radiator Radiator Filler Neck Inspection e Remove the radiator cap see Coolant Change in the Pe riodic Maintenance chapter Inspect the radiator filler neck for signs of damage Inspect 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 COOLING SYSTEM 4 17 Thermostat Thermostat Removal Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Remove Left Middle Fairing see Middle Fairing Removal in the Frame chapter Water Hose A Thermostat Housing Bolts B Thermostat Housing C P Pull the thermostat A out of the cylinder head Thermostat Installation Install the thermostat A in the cylinder head so that the air bleeder hole B is on top Install a new O ring A into the thermostat housing and apply grease to it Tighten Torque Thermostat Housing Bolts 9 8 N m 1 0 kgf m 87 in Ib e When installing the water hose align the white paint mark A with the line B on the thermostat housing e Install the water hose clamp C as shown e Tighten Torque Water Hose Clamp Screws 3 0 0 31 kgf m 27 in Ib e Fill the radiator with coolant see Coolant Change in the Periodic Maintenance chapter 4 18 COOLING SYSTEM Thermostat Thermostat Inspection Remove t
164. 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 Pv 24 55 cmHg cmHg 5 kPa 3 6 170349 3 3 48 FUEL SYSTEM Intake Air Pressure Sensor Service Code 12 Pv 55 86 cmHg gt 26 5 1 1 L 4 1 1 kPa 73 80 90 100 113 ID TO gt Pv abs 115 66170350 3 C ID Idling Ps Standard Atmospheric Pressure Absolute Pv Throttle Vacuum Pressure Absolute ST Standard of Sensor Output Voltage V TO Throttle Full Open UR Usable Range of Sensor Output Voltage V Vv Intake Air Pressure Sensor Output Voltage V Digital Meter Reading FUEL SYSTEM DFI 3 49 Intake Air Pressure Sensor Service Code 12 Intake Air Pressure Sensor Circuit 0 1 2 Intake Air Pressure Sensor 3 Joint Connector C 3 50 FUEL SYSTEM Intake Air Temperature Sensor Service Code 13 Intake Air Temperature Sensor Removal Instal lation 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 e Remove the screw B Pull out the intake air temperature sensor C e Installation is the reverse of removal OTighten Torque Intake Air Temperature Sensor Screw 1 2
165. 09839045 C APPENDIX 17 43 Cable Wire and Hose Routing 1 Blue Label 2 Tube Fuel Tank Canister 3 Purge Valve 4 Canister 5 Green Paint Marks 6 Tube Canister Purge Valve 7 Tube Purge Valve Throttle Body Assy 17 44 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 Vehicle down sensor DFI coming off 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 Whe
166. 0N5S1 C GE16059BS1 GE16060BS1 Cylinder Pistons ENGINE TOP END 5 39 Apply molybdenum disulfide oil solution to the top and second rings e Do not mix up the top and second ring Install the top ring A so that the R mark B faces up e Install the second ring C so that the RN mark D faces up NOTE new piston is used use new piston ring e Install the piston with its dent mark A facing forward e Fit a new piston pin snap ring into the side of the piston so that the ring opening A does not align with the slit B of the piston pin hole OApply molybdenum disulfide oil solution to the piston pins and piston skirt OWhen installing the piston pin snap ring compress it only enough to install it and no more Do not reuse snap rings as removal weakens and deforms them They could fall out and score the cylinder wall e Install the cylinder see Cylinder Installation Cylinder Wear Inspection 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 xIf 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 82 994 83 006 mm 3 2675 3 2679 in Service Limit 83 09 mm 3 271 in
167. 1 1 NEC 1 Ignition Switch 12 Fuse Box 2 Alternator 13 Headlight Fuse 15 A 3 Joint Connector B 14 Passing Button 4 License Plate Light 12 V 5 W 15 Dimmer Switch 5 Tail Brake Light LED 13 5 V 0 3 3 4 W 16 Left City Light 12 V 5 W 6 Frame Ground 17 Headlight Low Beam 12 V 55 W 7 Battery 12 V 10 Ah 18 Headlight High Beam 12 V 55 W 8 Main Fuse 30 19 Right City Light 12 V 5 W 9 Starter Relay 20 Joint Connector A 10 Relay Box 21 Meter Unit 11 Headlight Circuit Relay 16 58 ELECTRICAL SYSTEM Lighting System Front Turn Signal Light Bulb Replacement Turn the socket A counterclockwise and remove it Remove the bulb A from the socket B OPush and turn the bulb counterclockwise Replace the bulb A with a new Insert the bulb by aligning its pins B with the grooves C in the socket and turn the bulb clockwise e Install the socket so that the projections A fit in the hol lows B on the turn signal light Rear Turn Signal Light Bulb Replacement Unscrew the screw A and remove the lens B a Lighting System ELECTRICAL SYSTEM 16 59 Remove the bulb A OPush and turn the bulb counterclockwise Replace the bulb A with a new one Insert the bulb by aligning its pins B with the grooves in the socket and turn the bulb clockwise Install the lens and the screw Turn Signal Relay Inspection e Remove
168. 1 2205 1 2208 31 009 31 016 mm 1 2208 1 2211 Balancer Shaft Bearing Insert Thickness Brown 1 490 1 494 mm NE 0 05866 0 05882 in Black 1 494 1 498 mm ___ 0 05882 0 05898 1 498 1 502 mm 0 05898 0 05913 in Balancer Shaft Bearing Insert Selection Crankcase Bearing Balancer Shaft Bearing Insert Inside Diameter Journal Diameter Marking Marking Size Color Part Number o 9 Bem 521392719 92139 0118 bearing inserts for Nos 1 2 journals oil grooves Transmission Shift Fork Ear Thickness 5 9 6 0 mm 5 8 mm 0 232 0 236 in 0 23 in Gear Groove Width 6 05 6 16 mm 6 3 mm 0 238 0 243 in 0 25 in Shift Fork Guide Pin Diameter 6 9 7 0 mm 6 8 mm 0 272 0 276 in 0 27 in Shift Drum Groove Width 7 05 7 20 mm 7 3 mm 0 278 0 283 in 0 29 in Special Tools and Sealants Outside Circlip Pliers 57001 144 7570144ST C Bearing Driver Set 57001 1129 7571129ST C Liquid Gasket TB1211F 92104 0004 879200045 CRANKSHAFT TRANSMISSION 9 9 Liquid Gasket TB1216B 92104 1064 879210645 6 Liquid Gasket TB1207B 92104 2068 5192206851 C 9 10 CRANKSHAFT TRANSMISSION Crankcase Splitting Crankcase Splitting e Remove the engine see Engine Removal in the Engine Removal Installation chapter Se
169. 10 Crankshaft Sensor Lead Connector 11 Locate the subthrottle valve actuator lead connector under the fuel injector 2 12 Fuel Injector 1 13 Main Throttle Sensor Lead Connector 14 Subthrottle Sensor Lead Connector 15 Clamp 17 8 APPENDIX Cable Wire and Hose Routing 58094260 6 APPENDIX 17 9 Cable Wire and Hose Routing the rear brake light switch lead through the hole frame Hook Hold the main harness Fix the starter relay to the ribs on the battery case Run the tail brake light lead into the groove on the battery case Hook Hold the battery negative cable Hook Hold the battery positive cable Hook Hold the starter relay lead and the battery negative cable Run the starter relay lead and the battery negative cable above the main harness Install the dust cover to the hook as shown Insert the dust cover between the starter relay and the battery case Left Side Battery Positive Cable Starter Relay Lead Section A A Battery Negative Cable Main Harness 17 10 APPENDIX Cable Wire and Hose Routing ABS Equipped Models 58094270 6 APPENDIX 17 11 Cable Wire and Hose Routing CD 10 11 12 14 15 16 17 18 19 20 21 9904 2 C Run the ABS hydraulic unit lead through the hole the frame 2
170. 106030251 9105143851 C CRANKSHAFT TRANSMISSION 9 34 Balancer Put the lower crankcase half on the upper crankcase half without bearing inserts and tighten the case bolts to the specified torque and sequence see Crankcase Assem bly Measure the crankcase bearing bore diameter for the bal ancer shaft and mark the upper crankcase half in accor dance with the bore diameter NOTE OThe mark already on the upper crankcase half should almost coincide with the measurement Crankcase Bearing Bore Diameter Marks 31 000 31 008 mm 1 2205 1 2208 in None 31 009 31 016 mm 1 2208 1 2211 in Crankcase Bearing Bore Diameter Marks O mark or no mark No 1 Journal A No 2 Journal B 9106016852 C Select the proper bearing insert accordance with the combination of the crankcase and the balancer shaft cod ing e Install the new inserts in the crankcase and check in sert journal clearance with a plastigage Crankcase Bearing Balancer Shaft Bearing Insert Inside Diameter Journal Diameter Marking Marking Size Color Part Number o 0o Bem 92590486 o Black 92139 0118 None 32199 0117 bearing insert for Nos 1 2 journals have oil grooves 9 32 CRANKSHAFT TRANSMISSION External Shift Mechanism Shift Pedal Removal Remove Shift Pedal Bolt A Shift Pedal B Shift Pedal Installation Install the shift pe
171. 12 42 Flow to Read Service Codes osu 12 44 How to Erase Service Codes Ne 12 44 Yellow ABS Indicator Light LED Inspection 12 46 Yellow ABS Indicator Light LED does not go on When the Ignition Switch turned to ON eto ponte boo aue ecd dO n LEE 12 46 Yellow ABS Indicator Light LED goes on When the Motorcycle is Running No Service C de mm 12 47 Solenoid Valve Inspection Service Code 13 14 17 18 12 47 ABS Solenoid Valve Relay Inspection Service Code 19 12 47 Front Rear Wheel Rotation Difference Abnormal Service Code 25 12 49 ABS Motor Relay Inspection Service Code 35 12 49 Front Wheel Rotation Sensor Signal Abnormal Service Code 42 12 50 Front Wheel Rotation Sensor Wiring Inspection Service Code 43 12 51 Rear Wheel Rotation Sensor Signal Abnormal Service Code 44 12 52 Rear Wheel Rotation Sensor Wiring Inspection Service Code 45 12 53 Power Supply Voltage Abnormal Under Voltage Service Code 52 12 53 Power Supply Voltage Abnormal Over Voltage Service Code 53 12 54 ECU Inspection Service C
172. 15 23 gejeuier reeirzyMri ais E 15 23 Footpeg Stay e ted 15 23 Windshield ii itr GI deed 15 24 WindshielaREMOVAl udi eot OE HA DE D Deae uie T E 15 24 Windshield InstallatiOn ER E Tee 15 24 odesa 15 25 oidestand Rermioval eet ete oer MI E 15 25 Sidestand Installation recae eee oe debe dee pee Ee eaa 15 25 Errare COVER a rin ed CU Ce lua arse 15 26 Frame Cover Removal eere ete teer oe a e Peto rites E eee e Dag 15 26 Frame Cover Installation 11 eene nennen 15 26 Side Cover Removal redeant dere debe e e ee 15 26 Side Cover 15 26 15 2 Rear View Mirrors Rear View Mirror Removal 60 emn hem ne rne ener ne rne rre Rear View Mirror Installation eee 15 3 Exploded View This page intentionally left blank 15 4 Exploded View 15 5 Exploded View Torque Remarks N m kgf m ft Ib Footpeg Stay Bolts 25 2 5 18 5 2 Sidestand Bolt 44 4 5 32 3 Sidestand Switch Bolt 8 8 0 90 78 L 4 US CA CAL and A
173. 16 mm 0 0063 in 1 02 mm 0 0402 in 1 11 mm 0 0437 in 0 80 mm 0 031 in 0 90 mm 0 035 in 0 7 mm 0 028 in 0 9 mm 0 035 in Special Tools and Sealant Compression Gauge 20 kgf cm 57001 221 7570221ST C Valve Spring Compressor Assembly 57001 241 7570241ST C Valve Seat Cutter 45 535 57001 1116 8 5711165 C Valve Seat Cutter 32 430 57001 1120 5157112051 C Valve Seat Cutter 32 35 57001 1121 T571121ST C ENGINE TOP END 5 9 Valve Seat Cutter 60 530 57001 1123 875711235 C Valve Seat Cutter Holder Bar 57001 1128 7571128ST C Valve Seat Cutter 45 30 57001 1187 8 5711875 C Valve Seat Cutter 55 535 57001 1247 875712475 6 Valve Spring Compressor Adapter 21 57001 1272 75712728T 5 10 ENGINE END Special Tools and Sealant Compression Gauge Adapter M10 1 0 57001 1317 SN 875713175 C Valve Seat Cutter Holder 4 5 57001 1330 5157133051 C Valve Guide Arbor 4 5 57001 1331 N 7571331ST C Valve Guide Reamer 4 5 57001 1333 7571333ST C Filler Cap Driver 57001 1454 7571454ST C Piston Pin Puller 57001 1568 p 7571568ST C Piston Pin Puller Adapter 512 57001 1657 5157165751 6 Liquid Gasket TB1216B 92104 1064
174. 2 36 Steering Stem Bearing Lubrication 2 22 2 4 0 0 2 38 Electrical Syst M ME EE 2 39 Lights and Switches Operation Inspectionm 2 39 2 2 PERIODIC MAINT Headlight Aiming Inspecti ENANCE 2 2 4 4 4 4 2 4 2 4 114 11546 6 6 Sidestand Switch Operation Inspection 999 Engine Stop Switch Operation Inspection pp SS Chassis Parts Lubrication Bolts Nuts and Fasteners Tightness Inspection pp Replacement Parts Air Cleaner Element Repl Fuel Hose Replacement Coolant Change AAI E E E E E e Radiator Hose and O ring Engine Oil Change Oil Filter Replacement Brake Hose and Pipe Brake Fluid Change Master Cylinder Rubber Parts Replacement Caliper Rubber Parts Replacement Spark Plug Replacement 2 41 2 42 2 43 2 44 2 44 2 45 2 46 2 46 2 47 2 48 2 50 2 50 2 51 2 52 2 54 2 55 2 56 2 59 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
175. 250 kPa 2 50 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 Specifications PERIODIC MAINTENANCE 2 13 Item Standard Service Limit Final Drive Drive Chain Slack Chain 20 link Length Standard Chain 25 35 mm 1 0 1 4 in 317 5 318 2 mm 12 50 12 53 in Make DAIDO Type DID 520VP2 T Link 114 links Brakes Brake Fluid Grade DOT4 Brake Pad Lining Thickness Front 4 5 mm 0 18 in 1 mm 0 04 in Rear 5 0 mm 0 20 in 1 mm 0 04 in Brake Light Timing Front Pulled ON ON after about 10 mm 0 39 of ae pedal travel Electrical System Spark Plug Type CR9EIA 9 2 14 PERIODIC MAINTENANCE Special Tools Inside Circlip Pliers 57001 143 7570143ST C Steering Stem Nut Wrench 57001 1100 D 875711005 57001 1238 7571238ST C Oil Filter Wrench 57001 1249 7571249ST C Vacuum Gauge 57001 1369 25 222 875713695 C Throttle Sensor Setting Adapter 57001 1538 7571538ST C Extension Tube 57001 1578 7571578ST C Pilot Screw Adjuster E 57001 1603 5157160351 C PERIODIC MAINTENANCE 2 15 Periodic Maintenance Procedures Fuel System DFI Throttle Control System Inspection Check that the throttle grip A
176. 251 8 04041251 SUSPENSION 13 13 Apply non permanent locking agent to the threads of the bottom Allen bolt A Hold the front fork horizontally in a vise B Hold the cylinder unit with the special tools and tighten the bottom Allen bolt to secure the cylinder in place Special Tools Fork Cylinder Holder Handle D 57001 183 Fork Cylinder Holder Adapter E 57001 1057 Torque Front Fork Bottom Allen Bolt 30 N m 3 1 kgf m 22 ft lb e Pour in the specified type and amount of oil see Front Fork Oil Change Install the front fork see Front Fork Installation Inner Tube Outer Tube Inspection e Visually inspect the inner tube A and repair any dam age Nicks or rust damage can sometimes be repaired by using a wet stone to remove sharp edges or raised areas which cause seal damage xIf the damage is not repairable replace the inner tube Since damage to the inner tube damages the oil seal replace the oil seal whenever the inner tube is repaired or replaced NOTICE If the inner tube is badly bent or creased replace it Excessive bending followed by subsequent straightening can weaken the inner tube Temporarily assemble the inner A and outer B tubes and pump them back and forth manually to check for smooth operation x If you feel binding or catching replace the inner and outer tubes with new ones A WARNING A straightened inn
177. 43 L Shift Drum Cam Bolt 12 1 2 106 in Ib L Shift Pedal Bolt 12 1 2 106 in Ib Shift Rod Plate Bolt 9 8 1 0 87 L Shift Shaft Cover Bolts 9 8 1 0 87 L 3 Shift Shaft Cover Screw 4 9 0 50 43 in Ib L S Transmission Case Bolts 20 2 0 15 Wheels Tires Front Axle 108 11 0 80 Front Axle Clamp Bolt 34 3 5 25 Rear Axle Nut 108 11 0 80 Final Drive Engine Sprocket Nut 125 12 7 92 MO Rear Axle Nut 108 11 0 80 Rear Sprocket Nuts 59 6 0 44 R Speed Sensor Bolt 7 8 0 80 69 in lb L Speed Sensor Bracket Bolts 9 8 1 0 87 in lb PERIODIC MAINTENANCE 2 9 Torque and Locking Agent Torque Fastener Nm kgf m ft Ib Remarks Engine Sprocket Cover Bolts 9 8 1 0 87 in Ib Brakes Caliper Bleed Valves 7 8 0 80 69 in Ib Brake Hose Banjo Bolts 25 2 5 18 Brake Lever Pivot Bolt 1 0 0 10 9 in Ib Si Brake Lever Pivot Bolt Locknut 5 9 0 60 52 R Brake Disc Mounting Bolts 27 2 8 20 L Front Brake Light Switch Screw 1 2 0 12 11 in Ib Front Brake Reservoir Cap Screws 1 5 0 15 13 in Ib Front Caliper Mounting Bolts 34 3 5 25 Front Master Cylinder Clamp Bolts 11 1 1 97 in lb S Brake Pedal Bolt 8 8 0 90 78 Rear Caliper Mounting Bolts 25 2 5 18 Rear Master Cylinder Mounting Bolts 25 2 5 18 Rear Master Cylinder Push Rod Locknut 17 1 7 13 Brake Pipe Joint Nuts EX650F Model 18 1 8 13 Wheel Rotation Sensor Bolts EX650F Model 20 2 0 15 Suspension Front Axle Clamp Bolt 34 3 5 25 Front Fork Bottom Allen Bolts 30 3 1 22 L
178. 44 61 4 5 6 2 33 45 73 98 7 4 10 0 54 72 115 155 11 5 16 0 83 115 165 225 17 0 23 0 125 165 225 325 23 0 33 0 165 240 2 12 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Fuel System DFI Throttle Grip Free Play Idle Speed Bypass Screws Turn out Engine Vacuum Air Cleaner Element 2 3 0 08 0 12 in 1 300 50 r min rpm 0 2 1 2 for reference 35 3 1 3 kPa 265 10 mmHg Polyurethane Foam Cooling System Coolant Type recommended Color Mixed Ratio Freezing Point Total Amount Engine Top End Valve Clearance Exhaust Intake Clutch Clutch Lever Free Play Engine Lubrication System Engine Oil Type Viscosity Capacity Level Wheels Tires Tread Depth Front Rear Air Pressure when Cold Front Rear Permanent type of antifreeze Green Soft water 50 Coolant 50 35 31 F 1 2 L 1 3 US qt 0 22 0 31 mm 0 0087 0 0122 in 0 15 0 21 mm 0 0059 0 0083 in 2 mm 0 08 0 12 in API SG SH SJ SL or SM with JASO MA MA1 or 2 SAE 10W 40 1 6 L 1 7 US qt when filter is not removed 1 8 L 1 9 US qt when filter is removed 2 3 L 2 4 US qt when engine is completely dry Between upper and lower level lines after idling or running 4 5 mm 0 18 in 6 4 mm 0 25 in Up to 200 kg 441 Ib load 225 kPa 2 25 kgf cm 32 psi Up to 200 kg 441 Ib load
179. 8 5 Assembly Order 2 In most cases assembly order is the reverse of disassem TE od bly however if assembly order is provided in this Service cu Om i Manual follow the procedures given x S DE SS WX 2 4 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 agent applied using an impact driver Use a plastic faced mallet whenever tapping is necessary Gasket O ring Hardening shrinkage or damage of both gaskets and O rings af
180. 8 5 Instrument Use a meter that has enough accuracy for an accurate measurement Read the manufacture s instructions thor oughly before using the meter Incorrect values may lead to improper adjustments GB02082BS1 C GENERAL INFORMATION 1 7 Model Identification EX650EC EUR Models Left Side View 62038676 P EX650EC EUR Models Right Side View 1 8 GENERAL INFORMATION Model Identification EX650EC US CA and CAL Models Left Side View 6203865 P EX650EC US CA and CAL Models Right Side View 62028637 GENERAL INFORMATION 1 9 Model Identification EX650FC Left Side View ae Um M 62038625 EX650FC Right Side View 620386729 Frame Number 1 10 GENERAL INFORMATION General Specifications Items EX650EC FC Dimensions Overall Length Overall Width Overall Height Wheelbase Road Clearance Seat Height Curb Mass EX650E Other than IN Model Front Rear EX650E IN Model Front Rear EX650F 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 2 110 mm 83 07 in 770 mm 30 3 in 1 180 mm 46 46 in 1 410 mm 55 51 in
181. 8 5 Oil Seal Grease Seal Do not remove pressed oil or grease seals unless removal is necessary Replace with new ones whenever removed H L Press new oil seals with manufacture and size marks facing out Make sure the seal is aligned properly when installing NS V 2 68020198 5 Apply specified grease to the lip of seal before installing the seal Grease GBO2046BS1 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 AH TN cation points are called out throughout this manual apply A VAT a the specific oil or grease as specified e A 2 x 68020218 5 Direction of Engine Rotation When rotating the crankshaft by hand the free play MN amount of rotating direction will affect the adjustment Ro tate the crankshaft to positive direction clockwise viewed r from output side UM 68020228 5 Electrical Leads A two color lead is identified first by the primary color and then the stripe color Unless instructed otherwise electrical Y R leads must be connected to those of the same color e oar e GB02023
182. A Connecting Rod B Weight Mark Alphabet C Diameter Mark Around Weight Mark D or no mark 6105041781 9105139851 C 6105060151 9 26 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods Select the proper bearing insert A in accordance with the combination of the connecting rod and crankshaft coding Size Color B Connecting Rod Big End Crankpin Diameter Inside Diameter Marking Marking None Install the new inserts the connecting rod and check insert crankpin clearance with the plastigage Crankshaft Side Clearance Inspection Insert a thickness gauge A between the crankcase main bearing and the crank web at the No 2 journal B to determine clearance x If 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 Crankshaft Side Clearance Standard 0 05 0 20 mm 0 0020 0 0079 in Service Limit 0 40 mm 0 016 in Crankshaft Runout Inspection Measure the crankshaft runout If the measurement exceeds the service limit replace the crankshaft Crankshaft Runout Standard TIR 0 02 mm 0 0008 in or less Service Limit TIR 0 05 mm 0 002 in 6105041781 Bearing Insert Size Color Part Number
183. BK BR BK BR W BL Y GCi7iB4FW3 C Oxygen Sensor Circuit on ronim onjoj BR BATTERY Jojo w Ignition Switch Oxygen Sensor ECU Frame Ground 2 Battery 12 V 10 Ah Main Fuse 30 Relay Box ECU Main Relay Fuse Box 1 Fl Fuse 15 Ignition Fuse 10 A 3 70 FUEL SYSTEM Stick Coils 1 2 Service Code 51 52 Stick Coil 1 Service Code 51 Stick Coil 2 Service Code 52 Stick Coil Removal Installation e Refer to the Stick Coil Removal Installation in the Electri cal System chapter Stick Coil Primary Winding Resistance Inspection e Refer to the Stick Coil Inspection in the Electrical System chapter x If the reading is within the standard check the input volt age see Stick Coil Input Voltage Inspection Stick Coil Input Voltage Inspection NOTE sure the battery is fully charged e Turn the ignition switch to OFF e Remove the ECU see ECU Removal ODo not disconnect the ECU connectors e Connect a digital meter A to the connector B with the needle adapter set Special Tool Needle Adapter Set 57001 1457 Stick Coil Input Voltage Connections to ECU Connector For Stick Coil 1 Digital Meter BK lead terminal 35 Digital Meter gt BK Y lead terminal 43 For Stick Coil 42 Digital Meter BK O lead terminal 44 Digital Meter BK Y lead terminal 43 e Measure the input voltage to
184. BS1 C Clutch CLUTCH 6 13 e Install the washer so that the OUT SIDE mark A faces outward Replace the clutch hub nut A with a new one Hold the clutch hub B steady with the clutch holder and tighten the clutch hub nut Special Tool Clutch Holder 57001 1243 Torque Clutch Hub Nut 130 Nm 13 3 kgf m 96 ft lb Install the friction plates and steel plates starting with a friction plate and alternating them NOTICE 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 B in the grooves in the housing as shown in the figure e Apply molybdenum disulfide grease to the pusher end A e Install the pusher B into the drive shaft C e Apply engine oil to the sliding surfaces of the bearing A e Install the spring plate B on the clutch hub C e Install Clutch Springs Clutch Spring Bolts and Washers e Tighten Torque Clutch Spring Bolts 9 8 1 0 kgf m 87 in Ib e Install the clutch cover see Clutch Cover Installation 6 14 Clutch Clutch Plate Wear Damage Inspection e Visually inspect the friction and steel plates for signs of seizure overheating discoloration or uneven wear Measure the thickness of each friction plate A at several points x If any plates show signs of damage
185. CU for its ground and power supply see ECU Power Supply In spection x If the ground and power supply are good replace the ECU see ECU Removal Installation x If the reading is out of the specification remove the ECU and check the wiring for continuity between main harness connectors Special Tool Hand Tster 57001 1394 ODisconnect the ECU and injector connectors Wiring Continuity Inspection ECU Connector A lt gt Fuel Injector Connector B For Fuel Injector 1 C BL R lead ECU terminal 34 D For Fuel Injector 2 BL Y lead ECU terminal 33 xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation 6617298051 6617299051 C 3 100 FUEL SYSTEM Fuel Injectors Fuel Injector Fuel Line Inspection e Remove Fuel Tank see Fuel Tank Removal Fuel Hose see Fuel Hose Replacement in the Periodic Maintenance chapter OBe sure to place a piece of cloth around the fuel supply pipes of the fuel pump and the throttle body assy A WARNING Fuel is flammable and explosive under certain con ditions and can cause severe burns Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is dis connected fuel spills out from the hose and the pipe because of residual pressure Cover the h
186. Clutch chapter Oil Pump Cover Bolts A Temporarily install the oil pump sprocket bolt A NOTE OThe oil pump sprocket bolt has a left hand threads Using the oil pump sprocket bolt pull out the oil pump B as an assembly Remove the oil pump sprocket bolt Remove the outer rotor A for feed pump Remove the oil pump cover A Remove Inner Rotor A for Scavenge Pump Outer Rotor B for Scavenge Pump 7 14 ENGINE LUBRICATION SYSTEM Oil Pump Remove the pin A e Remove Pin A Inner Rotor for Feed Pump B Oil Pump Shaft C Oil Pump Installation Apply molybdenum disulfide oil solution to the portion A of the oil pump shaft as shown in the figure e Assemble the following parts Oil Pump Shaft B Pin C Inner Rotor for Feed Pump D Oil Pump Body E Pin F Inner Rotor G for Scavenge Pump Outer Rotor H for Scavenge Pump NOTE OThe scavenge pump rotors are wider than the feed pump rotors 9009057851 Be sure that the dowel A is in position e Install the outer rotor B for feed pump e Fit the dowel pin into the hole C on the oil pump body OTurn the oil pump shaft so that the inner rotor D fits into the outer rotor for feed pump ENGINE LUBRICATION SYSTEM 7 15 Oil Pump Be sure that the dowel pin A is in position Fit the dowel pin into the hole B on the oil pump cover C e Apply a non permanent
187. Drive Chain Wear Inspection e Refer to the Drive Chain Wear Inspection in the Periodic Maintenance chapter Drive Chain Lubrication Refer to the Drive Chain Lubrication Condition Inspection in the Periodic Maintenance chapter Drive Chain Removal NOTE OSince the drive chain is installed through the swingarm the chain cannot be removed other than by cutting it Prepare the new link pin link plate grease seals and tools for rejoining the chain Remove the muffler see Muffler Removal in the Engine Top End chapter e Using a suitable tool replace the drive chain Recommended Tool DID Chain Joint ZJ Make DAIDO KOGYO Read the Tool Manual before replacing the chain Body A Pin Holder B Positioning Pin C 0 Holder D Plate Holder E Cutting and Riveting Pin F Part for Riveting G Part for Cutting H 048124 Drive Chain FINAL DRIVE 11 7 Grind A the heads of the link pin to make it flat Set the cutting and riveting pin C in the pin holder B as shown in the figure Set the U holder and body align the positioning pin A with the A mark B Tighten the pin holder by hand until the cutting and riveting pin touches the link pin Be sure that the cutting and riveting pin hits center of the link pin Hold the body with a wrench A Turn the pin holder clockwise B with another wrench and remove the link pin Do the sa
188. Fan Fuse 15 A ECU Fuse 15 Ignition Fuse 10 A Intake Air Pressure Sensor G Subthrottle Sensor A Main Throttle Sensor B Subthrottle Valve Actuator C Fuel Injectors 1 2 A Water Temperature Sensor A Fuel Pump A 3 16 FUEL SYSTEM DFI Parts Location Battery 12 V 10 Ah A Kawasaki Diagnostic System Connector B Crankshaft Sensor A Speed Sensor A Neutral Switch B Oxygen Sensor A Equipped Models Purge Valve A CAL SEA B1 and TH Models Specifications FUEL SYSTEM 3 17 Item Standard Digital Fuel Injection System Idle Speed Throttle Body Assy Throttle Valve Bore Bypass Screws Turn out ECU Electronic Control Unit Make Type Usable Engine Speed Fuel Pressure High Pressure Line With Engine Idling Fuel Pump Type Discharge Fuel Injectors Type Nozzle Type Resistance Main Throttle Sensor Input Voltage Output Voltage Resistance Intake Air Pressure Sensor Input Voltage Output Voltage Intake Air Temperature Sensor Resistance Output Voltage Water Temperature Sensor Resistance Output Voltage Speed Sensor Input Voltage Output Voltage Vehicle down Sensor Detection Method Detection Angle Input Voltage 1 300 50 r min rpm Dual throttle valve 38 mm 1 5 in 0 2 1 2 for reference DENSO Digital memory type with built in IC igniter sealed with resin 100 11 350 r min rpm
189. Frame chapter e Disconnect the connector A e Remove Rear Wheel Rotation Sensor Bolt A Rear Wheel Rotation Sensor B Free the sensor lead from the clamps Rear Wheel Rotation Sensor Installation Installation is the reverse of removal ORun the lead correctly see Cable Wire and Hose Rout ing section in the Appendix chapter OTighten Torque Rear Wheel Rotation Sensor Bolt 20 N m 2 0 kgf m 15 16 Wheel Rotation Sensor Inspection Remove the front wheel rotation sensor A from the front fork Remove the rear wheel rotation sensor B from the caliper bracket Visually inspect the wheel rotation sensors Replace the wheel rotation sensor if it is cracked bent or otherwise damaged 5 12 61 Anti Lock Brake System Equipped Models Wheel Rotation Sensor Air Gap Inspection Raise the front rear wheel off the ground see Front Rear Wheel Removal in the Wheels Tires chapter Measure the air gap between the sensor and sensor rotor at several points by turning the wheel slowly Thickness Gauge A Wheel Rotation Sensor Air Gap Standard Front 0 3 1 7 mm 0 01 0 07 in Rear 0 3 1 7 mm 0 01 0 07 in NOTE O The sensor air gap cannot be adjusted x If the air gap is not within the specification inspect the hub bearing see Hub Bearing Inspection in the Wheels Tires chapter sensor installation condition and sensor see Wheel Rotation Sensor Ins
190. Front Fork Clamp Bolts Lower 20 5 2 1 15 AL Front Fork Clamp Bolts Upper 20 2 0 15 Front Fork Top Plugs 22 5 2 3 17 Rear Shock Absorber Mounting Bolts 59 6 0 44 Swingarm Bracket Bolts 44 4 5 32 S Swingarm Bracket Bolt Lower Left 59 6 0 44 S Swingarm Pivot Shaft Nut 108 11 0 80 S Steering Front Fork Clamp Bolts Lower 20 5 2 1 15 AL Front Fork Clamp Bolts Upper 20 2 0 15 Handlebar Holder Bolts 25 2 5 18 S Handlebar Holder Mounting Nuts 34 3 5 25 R Switch Housing Screws 3 5 0 36 31 in Ib Steering Stem Head Bolt 108 11 0 80 Steering Stem Nut 20 2 0 15 Frame Footpeg Stay Bolts 25 2 5 18 S Front Turn Signal Light Mounting Screws 1 2 0 12 11 in Ib Grab Rail Mounting Bolts 25 2 5 18 Lower Fairing Bracket Bolts 12 1 2 106 in Ib L Lower Fairing Mounting Bolts 15 1 5 11 L Seat Lock Mounting Screws 0 4 0 04 4 Sidestand Bolt 44 4 5 32 2 10 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Torgus Remarks kgf m ft Ib Sidestand Switch Bolt 8 8 0 90 78 in Ib L Windshield Mounting Bolts 4 2 0 43 37 in lb Upper Saree Guard Mounting Bolts IN Model 25 2 5 18 Lower Saree Guard Mounting Bolt IN Model 27 2 8 20 L Saree Guard Bracket Bolts IN Model 15 1 5 11 L Electrical System License Plate Light Mounting Screws 1 2 0 12 11 in Ib Alternator Cover Bolts 9 8 1 0 87 Alternator Lead Holding Plate Bolt 9 8 1 0 87 L Alternator Rotor Bolt 155 15 8 114 MO Engine Ground Lead Term
191. Green Neutral Indicator Light LED E Blue High Beam Indicator Light LED F Red Oil Pressure Warning Indicator Light LED G GP17909CS1 C GP17910C81 GP17911CS1 16 72 ELECTRICAL SYSTEM Meter Gauge Indicator Unit e Using the auxiliary leads connect a 12 V battery to the meter unit connector as follows Yellow ABS Indicator Light LED EX650F Model only Battery Negative Terminal to Terminal 9 Yellow Engine Warning Indicator Light LED Battery Negative Terminal to Terminal 16 Red Oil Pressure Warning Indicator Light LED Battery Negative Terminal to Terminal 5 NOTE OThe red oil pressure warning indicator light LED should go on after about 3 seconds from connecting the terminals Green Left and Right Turn Signal Indicator Light LED For Green Left Turn Signal Indicator Light LED Battery Positive Terminal to Terminal 1 For Green Right Turn Signal Indicator Light LED Battery Positive Terminal to Terminal 2 10 15V 8 179140651 ELECTRICAL SYSTEM 16 73 Meter Gauge Indicator Unit Green Neutral Indicator Light LED Battery Negative Terminal to Terminal 3 Blue High Beam Indicator Light LED Battery Positive Terminal to Terminal 4 10 15V GP17916CS1 If each light LED does not go on replace the meter as sembly
192. HEELS TIRES 10 11 Wheels Rims Balance Inspection Remove the front and rear wheels see Front Rear Wheel Removal Support the wheel so that it can be spun freely Spin the wheel lightly and mark A the wheel at the top when the wheel stops ORepeat this procedure several times If the wheel stops of its own accord in various positions it is well balanced x If the wheel always stops in one position adjust the wheel balance see Balance Adjustment Balance Adjustment e f the wheel always stops 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 Rotate the wheel another 1 4 turn and then another 1 4 turn to see if the wheel is correctly balanced Repeat the entire procedure as many times as necessary to achieve correct wheel balance Permanently install the balance weight Balance Weight Removal e Insert a standard tip screwdrivers A B between the rib C and the weight D as shown in the figure Pry the balance weight with two s
193. Ignition System Stick Coil Inspection Remove the stick coils see Stick Coil Removal e Measure the primary winding resistance A as follows OConnect the hand tester between the coil terminals OSet the tester to the x 1 range and read the tester e Measure the secondary winding resistance B as follows OConnect the hand tester between the plug terminal and coil terminal OSet the tester to the x 1 range and read the tester Stick Coil Winding Resistance Primary Windings 1 1 1 5 at 20 C 68 F Secondary Windings 10 8 16 2 at 20 C 68 F x If the tester does not read as specified replace the coil Install the stick coils see Stick Coil Installation Stick Coil Primary Peak Voltage Inspection NOTE OBe sure the battery is fully charged Remove the stick coils see Stick Coil Removal e Measure the primary peak voltage as follows Olnstall the new spark plug A into each stick coil B and ground them onto the engine OConnect the peak voltage adapter C to the hand tester D which is set to the x DC 250 V range OConnect the adapter to the lead wire peak voltage adapter E which is connected between the stick coil connector and stick coil ECU F 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
194. Install the relay box see Relay Box Installation ELECTRICAL SYSTEM 16 81 Relay Box Relay Box Internal Circuit 6 19010 2 C A Headlight Circuit Relay B ECU Main Relay C Fuel Pump Relay D Starter Circuit Relay E Radiator Fan Relay 16 82 ELECTRICAL SYSTEM Fuse 30 A Main Fuse Removal e Remove the starter relay see Starter Relay Inspection Slide out the cap A Open the cover B and pull out the main fuse C straight out of the fuse box with needle nose pliers Fuse Box Fuse Removal Remove the fuel tank see Fuel Tank Removal in the Fuel System DFI chapter Open the lids A e Pull out the fuses A straight out of the fuse box with needle nose pliers Fuse Installation e If a fuse fails during operation inspect the electrical sys tem to determine the cause and then replace it with a new fuse of proper amperage Install the fuse box fuses on the original position as spec ified on the lid Fuse Inspection e Remove the fuse see 30 A Main Fuse Fuse Box Fuse Removal e Inspect the fuse element x If it is blown out replace the fuse Before replacing a blown fuse always check the amperage in the affected circuit If the amperage is equal to or greater than the fuse rating check the wiring and related components for a short circuit Housing A Fuse Element B Terminals C Blown Element D When replacing a fuse be sure the new fuse matches the s
195. K3 GP09258BS1 C Charging System ELECTRICAL SYSTEM 16 35 Do the 1st step regulator circuit test OConnect the test light and the 12 V battery to the regula tor rectifier as shown OCheck the 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 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 W2 terminal OCheck the 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 W2 terminal by adding a 12 V battery OCheck the BK1 BK2 and BK3 terminals respectively Do not apply more than 24 V If more than 24 V is ap plied the regulator rectifier may be damaged Do not apply 24 V more than a few seconds If 24 V is applied for more than a few seconds the regula tor rectifier may be damaged xIf the test light did not light when the 24 V was applied momentarily to the voltage monitoring terminal the regu lator rectifier is de
196. Lever Pivot Bolt Locknut Engine Bracket Bolts Engine Mounting Bolts and Nuts Exhaust Pipe Manifold Holder Nuts Muffler Body Mounting Bolts Wheels Front Axle Front Axle Clamp Bolt Rear Axle Nut Rear Axle Nut Cotter Pin Brakes Brake Lever Pivot Nut Brake Pedal Bolt Caliper Mounting Bolts Front Master Cylinder Clamp Bolts Rear Master Cylinder Mounting Bolts Rear Master Cylinder Push Rod Joint Cotter Pin Suspension Front Fork Clamp Bolts Rear Shock Absorber Bolt and Nut Swingarm Pivot Shaft Nut Swingarm Bracket Bolts Steering Steering Stem Head Bolt Handlebar Holder Bolts Others Footpeg Stay Bolts Sidestand Bolt 2 46 PERIODIC MAINTENANCE Periodic Maintenance Procedures Replacement Parts Air Cleaner Element Replacement NOTE Oln dusty areas the element should be replaced more frequently than the recommended interval AWARNING If dirt or dust is allowed to pass through into the throttle body assy the throttle may become stuck possibly causing accident Replace the air cleaner element according to the maintenance chart If dirt gets through into the engine excessive en gine wear and possibly engine damage will occur Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter ECU A Screw B Clamp C Intake Air Pressure Sensor Connector D Disconnect e Remove Bolts A Fuel Tank Bracket B Rubber Cover C Remove the bolts A and move the brac
197. Method ertet 5 31 Air Switching Valve Unit Test 5 12 Valve Seat Inspection 5 32 Clean Air System Hose Valve Seat Repair 5 32 Irispection e ets 5 13 Cylinder 5 37 Cylinder Head Cover 5 14 Cylinder Removal 5 37 Cylinder Head Cover Removal 5 14 Cylinder Installation 5 37 Cylinder Head Cover Installation 5 15 Piston Remowval 5 38 Camshaft Chain Tensioner 5 17 Piston Installation 5 38 Camshaft Chain Tensioner Cylinder Wear Inspection 5 39 Removal reit ait 5 17 Piston Wear Inspection 5 40 Camshaft Chain Tensioner Piston Ring Piston Ring Groove Installation 5 17 Wear Inspection 5 40 Camshaft Camshaft Chain 5 19 Piston Ring Groove Width Camshaft Removal 5 19 5 40 Camshaft Installation 5 21 Piston Ring Thickness Inspection 5 41 Camshaft Camshaft Cap Wear Piston Ring End Gap Inspection 5 41 Inspection 55 0 eterne 5 24 Throttle Body Assy Holder 5 42 Camshaft Runout Inspection 5 24 Throttle Body Assy Holder Cam Wear Inspection 5 24
198. Middle Fairing Installation 2200 15 14 Middle Fairing Disassembly 15 15 Middle Fainng Assembly zu t oot tectus elo teet etta death 15 15 Lower Fairing Bracket Removal tete ec e the crt e Rp n ERE 15 16 Lower Fairing Bracket Installatiom pp 15 16 Upper Fairing Removal 15 16 Upper Fairing Installatior coit et reete e dte e ente Rr e none RR P 15 16 15 17 Front Seat Cover 15 17 Front Seat Cover 15 17 Rear Seat Cover 15 17 Rear Seat Cover Installation pp 15 18 En cA 15 19 Front Fender 15 19 Front Fender 15 19 Flap Removal ii te i Rt eie te tl a i e Flap mE E Rear Fender Removal Frame EET Battery Case e ticos teens edu EEE e 15 22 Battery Case InstallatlOri mri e 15 22 C mc
199. NG Too much cable play can prevent clutch disengage ment and cause an accident resulting in serious in jury or death When adjusting the clutch or replac ing the cable be sure the upper end of the clutch outer cable is fully seated in its fitting or it could slip into place later creating enough cable play to prevent clutch disengagement e Tighten the locknut and slip the dust cover back onto place e After the adjustment start the engine and check that the clutch does not slip and that it releases properly Wheels Tires Air Pressure Inspection e Remove the air valve cap e Measure the tire air pressure with an air pressure gauge A when the tires are cold that is when the motorcycle has not been ridden more than a mile during the past 3 hours Air Pressure when Cold Front Up to 200 kg 444 Ib 225 kPa 2 25 kgf cm 32 psi 6405007851 Up to 200 441 Ib 250 kPa 2 50 kgf cm 36 psi Adjust the tire air pressure according to the specifications if necessary e Install the air valve cap PERIODIC MAINTENANCE 2 27 Periodic Maintenance Procedures Wheel Tire Damage Inspection Remove any imbedded stones 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 Visually inspect the wheel for cracks cut
200. NSMISSION Crankshaft and Connecting Rods Install new bolts in reused connecting rods e Dent both bolt head and bolt tip with a punch as shown Before tightening use a point micrometer to measure the length of new connecting rod bolts and record the values to find the bolt stretch Connecting Rod A Mark here with a punch B Nuts C Fit micrometer pins into punch marks D Apply a small amount of molybdenum disulfide oil solution to the following Threads A of Nuts and Bolts Seating Surfaces B of Nuts and Connecting Rods Tighten the big end nuts until the bolt elongation reaches the length specified in the table Check the length of the connecting rod bolts x If the stretch is more than the usable range the bolt has stretched too much An overelongated bolt may break in use Bolt Length after tightening Bolt Length before tightening 6105040381 6105040481 Use the bolts attached Connecting Rod Assy Bolt Nut Attached to new connecting rod New Used NOW to new connecting rod Used Replace the bolts with new ones New Usable Range of Connecting Rod Bolt Stretch 0 24 0 36 mm 0 0094 0 0142 in 0 20 0 32 mm 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 Be sure to clean the bolts and nuts thoroughly with a high fla
201. Periodic Inspection FREQUENCY ODOMETER READING Whichever x 1 000 km comes first m 1 000 mile See Page 18 24 11 25 15 Fuel System Throttle control system play smooth return no drag inspect Engine vacuum synchronization inspect Idle speed inspect Fuel leak fuel hose and pipe inspect Fuel hose and pipe damage inspect Fuel hose and pipe installation condition inspect Evaporative emission control system function CAL SEA B1 and TH Models inspect Cooling System Coolant level inspect Coolant leak water hose and pipe inspect Water hose damage inspect Water hose installation condition inspect Engine Top End Valve US CA Model clearance Other than US inspect CA Model Air suction system damage inspect Clutch Clutch operation play disengagement engagement inspect Wheels and Tires Tire air pressure inspect Wheel tire damage inspect Tire tread wear abnormal wear inspect Wheel bearing damage inspect 2 4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY ODOMETER READING Whichever comes first gt 1 000 mile Ss age 4 1 6 12 18 24 45 ITEM Every 0 6 3 75 7 5 11 25 15 18 75 22 5 Final Drive Drive chain lubrication condition Every 600 km 4
202. Periodic Maintenance chapter COOLING SYSTEM 4 1 Cooling System Table of Contents Exploded VIeW s eei eer iet A t eee ne tnis sa Pr PR M Ere READ 4 2 Coolant Flow E 4 4 e eec d aera Greets 4 6 Special 4 7 jura 4 8 Coolant Deterioration Inspectiom enne 4 8 Coolant Level Inspection pp 4 8 Coolant Draining 4 8 Hale ms 4 8 Pressure Testis 4 8 Cooling System lt lt echoes a 4 9 Coolant Reserve Tank Removal Installation pp 4 9 ET 4 10 Water Pump 22 000000002 000000 01000000 000000000000000000 aae 4 4 10 Water Pump Installation pp 4 10 Water Pump Inspection e Tee Ea ep t eaten Tiss 4 11 Mechanical Seal Inspection 89 4 11 Water Pump Housing Disassembly pp 4 12 Water Pump Housing Assembly pp 4 12 Impeller Assembly teo iato dum eti pp o 4 12 Pump Impeller Inspection 9 4 12 PE 4 13 Radiator and Radiator Fan 2 4 13 Radiator
203. Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Crankshaft Sensor Connector B R BK lead ECU terminal 11 C YIBK lead ECU terminal 24 D xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see Removal Installation Crankshaft Sensor Circuit 9617797051 Q Y BK on y BK Y BK g h 5 R BK uo R BK GCci7180FW2 C 1 ECU 2 Crankshaft Sensor FUEL SYSTEM 3 57 Speed Sensor Service Code 24 Speed Sensor Removal Installation e Refer to the Speed Sensor Removal Installation in the Electrical System chapter Speed Sensor Inspection e Refer to the Speed Sensor Inspection in the Electrical System chapter Speed Sensor Input Voltage Inspection NOTE sure the battery is fully charged e Turn the ignition switch to OFF e Remove the left frame cover see Frame Cover Removal in the Frame chapter e Disconnect the speed sensor connector A and connect the harness adapter B between the harness connector and speed sensor connector Special Tool Throttle Sensor Setting Adapter 1 57001 1400 e Connect a digital meter to the harness adapter leads Speed Sensor Input Voltage Connections to Adapter Digital Meter BL
204. U Models 5 AU Model G Apply grease L Apply a non permanent locking agent R Replacement Parts S Follow the specified tightening sequence 15 6 Exploded View 80025558485 C 15 7 Exploded View Torque ON NE Front Turn Signal Light Mounting Screws 11 in Ib Lower Fairing Bracket Bolts 12 11 in Ib L Lower Fairing Mounting Bolts 4 AU Model 5 US CA and CAL Models 6 ID Model L Apply a non permanent locking agent 15 8 Exploded View 15 9 Exploded View Windshield Mounting Bolts 4 2 Seat Lock Mounting Screws 0 4 Grab Rail Mounting Bolts Upper Saree Guard Mounting Bolts Saree Guard Bracket Bolts 15 1 5 11 L Lower Saree Guard Mounting Bolt 27 2 8 20 L 7 US CA and CAL Models 8 Other than US CA CAL and IN Models 9 Other than US CA and CAL Models 10 IN Model O 15 10 Seats Rear Seat Removal Insert the ignition switch key A into the seat lock e Turn the key clockwise and pull up the front part of the seat B Remove the seat forward Rear Seat Installation e Insert the seat hook A into the bracket hole B e Push down the front part of the seat until the lock clicks Front Seat Removal Remove the rear seat see Rear Seat Removal Slide the front seat A rearward B and then pull the front part of the seat upward C to remo
205. U terminal 22 D xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation Install the left middle fairing see Middle Fairing Installa tion in the Frame chapter GC17281DS1 C 3 42 FUEL SYSTEM Main Throttle Sensor Service Code 11 Main Throttle Sensor Output Voltage Inspection e Measure the output voltage at the main throttle sensor in the same way as input voltage inspection noting the following ODisconnect the main throttle sensor connector and con nect the harness adapter A between these connectors Special Tool Throttle Sensor Setting Adapter 57001 1538 Main Throttle Sensor Output Voltage Connections to Adapter Digital Meter R sensor Y R lead Digital Meter W sensor BR BK lead Start the engine and warm it up thoroughly Check the idle speed to ensure the throttle opening is correct Idle Speed Standard 1 300 50 r min rpm xIf the idle speed is out of the specified range adjust it see Idle Speed Inspection in the Periodic Maintenance chapter e Turn the ignition switch to OFF e Measure the output voltage with the engine stopped and with the connector joined e Turn the ignition switch to ON Output Voltage Standard DC 1 005 1 035 V at idle throttle opening DC 4 2 4 4 V at full throttle
206. UEL SYSTEM Fuel Injectors Fuel Injector Power Source Voltage Inspection NOTE OBe sure the battery is fully charged Turn the ignition switch to OFF Remove the air cleaner housing see Air Cleaner Housing Removal e Disconnect the injector connector and connect the har ness adapter A between these connectors as shown in the figure Main Harness B Fuel Injector 1 C Special Tool Measuring Adapter 57001 1700 e Connect a digital meter D to the harness adapter leads Fuel Injector Power Source Voltage Connections to Adapter For Fuel Injector 1 2 Digital Meter R injector W R lead Digital Meter gt Battery terminal e Measure the power source voltage with the engine stopped e Turn the engine stop switch to run position Turn the ignition switch to ON Power Source Voltage Standard Battery Voltage for 3 seconds and then 0 V Turn the ignition switch to OFF x If the reading stays on battery voltage and never shows 0 V check the fuel pump relay see Relay Circuit Inspection in the Electrical System chapter x If the pump relay is normal check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see ECU Removal Installation xIf there is still no battery voltage check the ECU main relay and pump relay see Relay Circuit Inspection in the Electrical System chapter If the main
207. Wrench 57001 1100 Torque Steering Stem Nut 20 N m 2 0 kgf m 15 ft Ib OCheck that there is no play and the steering stem turns smoothly without rattles If not the steering stem bearings may be damaged GNO5060481 C Steering Stem STEERING 14 9 Install the new claw washer A so that its bent claws B face 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 Hand tighten the stem locknut clockwise until the claws are aligned with the grooves ranging from 2nd to 4th of stem nut D and bend the 2 claws downward E e Install the steering stem head e Install the washer and temporarily tighten the steering stem head bolt e Install the front forks see Front Fork Installation in the Suspension chapter NOTE OTighten the upper front fork clamp bolts first next the stem head bolt last the lower front fork clamp bolts OTighten the two lower front fork clamp bolts alternately two times to ensure even tightening torque Torque Front Fork Clamp Bolts Upper 20 2 0 kgf m 15 ft Ib Steering Stem Head Bolt 108 N m 11 0 kgf m 80 ft Ib Front Fork Clamp Bolts Lower 20 5 N m 2 1 kgf m 15 ft lb A WARNING If the handlebar does not turn to the steering stop it may cause an accident resulting in injury or death Be sure the cables harnesses and hoses are routed properly and do not interfer
208. Yellow ABS Indicator Light LED Problems Start code not fault Rear intake solenoid valve trouble open temperature abnormal Rear outlet solenoid valve trouble open temperature abnormal Front intake solenoid valve trouble open temperature abnormal Front outlet solenoid valve trouble open temperature abnormal ABS solenoid valve relay trouble wiring shorted or open stuck relay ON or OFF or dropout Light State After starts turn off ON ON ON Front rear wheel rotation difference abnormal substandard tire sensor rotor teeth number wrong ABS motor relay trouble wiring shorted or open stuck relay ON or OFF Front wheel rotation sensor signal abnormal sensor or rotor missing too large clearance rotor tooth worn or missing Front wheel rotation sensor wiring wiring shorted or open connector bad connection Rear wheel rotation sensor signal abnormal 44 sensor or rotor missing too large ON clearance rotor tooth worn or missing Rear wheel rotation sensor wiring wiring 45 shorted or open connector bad connection 52 Power supply voltage abnormal ON under voltage 53 MAAN Power supply voltage abnormal ON over voltage 55 ECU trouble ECU operation abnormal ON 12 46 5 Anti Lock Brake System Equipped Models Yellow ABS Indicator Light LED Inspection e Turn the ignition switch to ON xIf
209. a shock to the sensor can dam age it Subthrottle Sensor Input Voltage Inspection NOTE OBe sure the battery is fully charged Remove the air cleaner housing see Air Cleaner Housing Removal Turn the ignition switch to OFF e Loosen the throttle body assy holder clamp bolts and pull the throttle body assy out of the holder see Throttle Body Assy Removal e Disconnect the subthrottle sensor connector and connect the throttle sensor setting adapter A between these con nectors Special Tool Throttle Sensor Setting Adapter 1 57001 1400 Install the throttle body assy see Throttle Body Assy In stallation Connect a digital meter to the harness adapter leads Subthrottle Sensor Input Voltage Connections to Adapter Digital Meter BL sensor BL lead Digital Meter BK BL sensor BR BK lead Measure the input voltage with the engine stopped and with the connector joined e Turn the ignition switch to ON Input Voltage Standard DC 4 75 5 25 V e Turn the ignition switch to OFF x If the reading is within the standard check the output volt age see Subthrottle Sensor Output Voltage Inspection 3 64 FUEL SYSTEM Subthrottle Sensor Service Code 32 x lf the reading is out of the standard remove the ECU and check the wiring for continuity between main harness connectors Special Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor connectors Wiring Co
210. ace the bearing e Inspect the bearing seal B for tears or leakage x If the seal is torn or is leaking replace the bearing Swingarm Bearing Lubrication NOTE OSince the bearings are packed with grease and sealed lubrication is not required Chain Guide Inspection e Refer to the Chain Guide Wear Inspection in the Periodic Maintenance chapter STEERING 14 1 Steering Table of Contents M ee ue E ET 14 2 Special Tools eR 14 4 14 5 Steering INSPECUOM 14 5 Steering 5 9 sannta 14 5 Steering eae 14 6 Stem Stem Bearing 14 6 Stem Stem Bearing Installatiom 14 7 Steering Stem Bearing Lubrication 21 4 1 2 2 14 9 Steering Stem Warp Inspection 9 lt 14 9 Stem Cap Deterioration Damage Inspection 14 10 FIANGIGD AR vis 14 11 Handlebar Removal nie eet Went eee 14 11 Handlebar Installation ka aene rk in 14 11 14 2 STEERING Ex
211. ace the plug x If the spark plug is dirtied or the carbon is accumulated replace the spark plug e Measure the gap D with a wire type thickness gauge x If the gap is incorrect replace the spark plug Spark Plug Gap 0 8 0 9 mm 0 03 0 04 in e Use the standard spark plug or its equivalent Spark Plug CR9EIA 9 6517009851 C 16 44 ELECTRICAL SYSTEM Ignition System Interlock Operation Inspection Raise the rear wheel off the ground with a stand 1st Check Start the engine in the following conditions Condition Transmission Gear 1st Position Clutch Lever Release Sidestand Down or Up OTurn the ignition switch to ON and push the starter button OThen the starter motor should not turn when the starter system circuit is normal x If the engine starts inspect the starter lockout switch neu tral switch and relay box 2nd Check Start the engine in the following conditions Condition Transmission Gear 1st Position Clutch Lever Pulled in Sidestand Up OTurn the ignition switch to ON and push the starter button OThen the starter motor should turn when the starter sys tem circuit is normal If the starter motor is not turn inspect the starter lockout switch sidestand switch relay box and starter relay 3rd Check Inspect the engine for its secure stop after the following operations are completed Run the engine in the following conditions Conditi
212. ad Connector A Starter Motor Cable Terminal B Engine Ground Lead Terminal C Water Temperature Sensor Lead Connector D e Disconnect the alternator lead connector A e Disconnect the neutral switch lead terminal A e Support the engine using a suitable stand or jack A OPut planks B to balance the engine e Remove Front Engine Mounting Bolt A and Nut Left Collar B Front Engine Bracket Bolts Left C e Remove the front engine bracket left D 8 6 ENGINE REMOVAL INSTALLATION Engine Removal Installation e Remove Front Engine Mounting Bolt A and Nut Right Front Engine Bracket Bolts Right B Front Engine Bracket Right C e Remove the rear engine mounting bolt and nut upper A e Remove Rear Engine Mounting Bolt and Nut Lower A Rear Engine Bracket Bolts B Rear Engine Bracket C e Take off the engine Engine Installation e Install the following temporarily Rear Engine Bracket A Rear Engine Bracket Bolts B e Support the engine using a suitable stand or jack OPut planks to balance the engine e Install the engine to the frame e Insert the rear engine mounting bolts C e Replace the rear engine mounting nuts with new ones e First tighten the engine mounting nut lower D temporar ily e Then tighten the engine mounting nut upper E tem porarily GH04164BS2 C ENGINE REMOVAL INSTALLATION 8 7 Engine Removal Installation e Instal
213. adiator fan starts e Measure the output voltage with the connector joined Output Voltage with Plug Standard DC 0 7 V or more e Next remove the plug from the fitting A with idling A WARNING The engine gets extremely hot during normal oper ation and can cause serious burns Never touch a hot engine e Measure the output voltage with the connector joined Output Voltage without Plug Standard DC 0 2 V or less e Turn the ignition switch to OFF 3 68 FUEL SYSTEM Oxygen Sensor not activated Service Code 33 Equipped Models x lf the reading is out of the standard with plug DC 0 7 V or more without plug DC 0 2 V or less remove the ECU and check the wiring for continuity between main harness connectors Special Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Oxygen Sensor Connector B BL Y lead ECU terminal 4 C BR BK lead ECU terminal 22 D x If the wiring is good replace the sensor x If the reading is within the standard with plug DC 0 7 V or more without plugs DC 0 2 V or less check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see Removal Installation GC17285DS1 FUEL SYSTEM DFI 3 69 Oxygen Sensor not activated Service Code 33 Equipped Models
214. age A WARNING After servicing it takes several applications of the brake lever or pedal before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the motorcycle until a firm brake lever or pedal is obtained by pumping the lever or pedal until the pads are against the disc Rear Master Cylinder Removal e Loosen the banjo bolt A being careful not to spill brake fluid e Remove the banjo bolt and take off the brake hose from the master cylinder B NOTICE Immediately wipe up any brake fluid that spilled oosen the rear master cylinder mounting bolts A e Remove the right footpeg stay bolts B and move the right footpeg stay C aside GL10000BS1 C 9 078431 Master Cylinder BRAKES 12 23 Remove the cotter pin A Pull off the joint pin B while pressing down the brake pedal e Pull off the reservoir hose lower end and drain the brake fluid into a container Remove the rear master cylinder Rear Master Cylinder Installation Install the joint pin A Replace the cotter pin B with a new Insert the cotter pin and bend the pin ends as shown Replace the washers A on each side of the hose fitting B with new ones Install the brake hose lower end Tighten Torque Brake Hose Banjo Bolt 25 N m 2 5 kgf m 18
215. age any spilled fuel must be completely wiped up immediately Never drop the fuel pump especially on a hard sur face Such a shock to the pump can damage it Draw the fuel out from the fuel tank with a commercially available electric pump Remove the fuel tank see Fuel Tank Removal OBe careful of fuel spillage from the fuel tank since fuel still remains in the fuel tank and fuel pump Plug the fuel supply pipe of the fuel pump e Turn the fuel tank upside down e Remove Fuel Pump Bolts A Fuel Pump B and Gasket e Discard the fuel pump gasket NOTICE Do not pull the leads of the fuel pump If they are pulled the lead terminals may be damaged Fuel Pump Installation Remove dirt or dust from the fuel pump A by lightly ap plying compressed air 3 94 FUEL SYSTEM Fuel Pump Replace the fuel pump gasket A with a new one and apply grease to it Apply a non permanent locking agent to the threads of the fuel pump bolts Tighten the fuel pump bolts to a snug fit and tighten them alternating diagonally Torque Fuel Pump Bolts 9 8 1 0 kgf m 87 in Ib Tighten the pump bolts again alternating diagonally to check the tightness Fuel Pump Operation Inspection NOTE OBe sure the battery is fully charged Turn the engine stop switch to run position Turn the ignition switch to ON and make sure that the fuel pump operates make
216. age check showed the alternator to be defective then the rotor magnets have probably weakened and the rotor must be replaced 16 34 ELECTRICAL SYSTEM Charging System Regulator Rectifier Inspection e Remove Radiator see Radiator and Radiator Fan Removal in the Cooling System chapter Baffle Plate Bolts A Baffle Plate B e Remove Regulator Rectifier Bolts A Regulator Rectifier B Connector C Disconnect Rectifier Circuit Check Check conductivity of the following pair of terminals Rectifier Circuit Inspection W1 BK1 W1 BK2 W1 BK3 BK Y BK1 BK Y BK2 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 leads are low or high in both directions the rectifier is defective and the regulator rectifier 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 Tester connection 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 NOTICE 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 BK1 BK2 B
217. age the bent claws with the grooves of stem locknut C e Hand tighten the stem locknut until it touches the claw washer e Hand tighten the stem locknut clockwise until the claws are aligned with the grooves ranging from 2nd to 4th of stem nut D and bend the 2 claws downward E e Install Steering Stem Head Washer Steering Stem Head Bolt e Tighten Torque Steering Stem Head Bolt 108 N m 11 0 kgf m 80 ft lb Front Fork Clamp Bolts Upper 20 N m 2 0 kgf m 15 ft lb Check the steering again x If the steering is still too tight or too loose repeat the ad justment e Install the other removal parts see appropriate chapters 9515036851 C 2 38 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering Stem Bearing Lubrication e Remove the steering stem see Stem Stem Bearing Re moval in the Steering chapter e Using a high flash point solvent wash the upper and lower ball bearings A in the cages and wipe the upper and lower outer races which are press fitted into the frame head pipe clean off grease and dirt e Visually inspect the outer races and the ball bearings Replace them if they show wear or damage Pack the upper and lower ball bearings in the cages with grease and apply a light coat of grease to the upper and lower outer races Install the steering stem see Stem Stem Bearing Instal lation in the Steering chapter e Adjust the steering see Steering Play Ad
218. aged Be sure to correct any of these conditions before riding see Throttle Control System Inspection and Cable Wire and Hose Routing section in the Appendix chapter A WARNING Operation with improperly adjusted incorrectly routed or damaged cables could result in an unsafe riding condition Follow the service manual to be make sure to correct any of these conditions e Check the idle speed Idle Speed Standard 1 300 50 r min rpm x If the idle speed is out of the specified range adjust it Idle Speed Adjustment e Start the engine and warm it up thoroughly e Turn the adjusting screw A until the idle speed is correct OOpen and close the throttle a few times to make sure that the idle speed is within the specified range Readjust if necessary PERIODIC MAINTENANCE 2 19 Periodic Maintenance Procedures Fuel Hose Inspection fuel leak damage installation condition Olf the motorcycle is not properly handled the high pres sure inside the fuel line can cause fuel to leak A or the hose to burst Remove the fuel tank see Fuel Tank Re moval the Fuel System DFI chapter and check the fuel hose Replace the fuel hose if any fraying cracks B or bulges C are noticed Check that the hoses are routed correctly 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
219. al and its mounting surface of the crankcase Transmission Assy Disassembly e Remove the transmission assy see Transmission Assy Removal e Remove the following from the transmission case A Shift Rods B Shift Forks C Drive Shaft D Output Shaft E e Remove Shift Drum Cam Bolt A Shift Drum B and Pin Shift Drum C 9113517851 61128736 CRANKSHAFT TRANSMISSION 9 37 Transmission Remove the following from the transmission case as nec essary Shift Drum Bearing Holder Screws A Shift Drum Bearing Holder B Remove the following from the transmission case as nec essary Drive Shaft Bearing Holder Screw A Drive Shaft Bearing Holder B Transmission Assy Assembly When the new ball bearing A and new race B are in stalled in the transmission case C press and insert them until they are bottomed Special Tool Bearing Driver Set 57001 1129 NOTE Olnstall the new ball bearing and new race so that the stepped side D faces inside of the transmission case When the ball bearing for shift drum is installed in the transmission case insert the ball bearing until it is bot tomed x If the shift drum bearing holder A is to be removed follow the next procedure OApply a non permanent locking agent to the threads of the shift drum bearing holder screws B and tighten them Torque Shift Drum Bearing Holder Screws 4 9 N m 0 50 kgf m 43 in Ib
220. amshaft chain tensioner body C Camshaft Chain Tensioner Installation Replace the O ring A with a new one and apply grease to it e Release the stopper B and push the push rod C into the tensioner body D 5 18 ENGINE END Camshaft Chain Tensioner Install the tensioner body so that the stopper A faces upward Apply a non permanent locking agent to the camshaft chain tensioner mounting bolts and tighten them Torque Camshaft Chain Tensioner Mounting Bolts 9 8 N m 1 0 kgf m 87 in Ib e Install Spring A Washer B Tighten Torque Camshaft Chain Tensioner Cap Bolt C 20 N m 2 0 kgf m 15 ft Ib Turn the crankshaft 2 turns clockwise to allow the ten sioner to expand and recheck the camshaft chain timing Install the right middle fairing see Middle Fairing Installa tion in the Frame chapter Camshaft Camshaft Chain ENGINE TOP END 5 19 Camshaft Removal e Remove Cylinder Head Cover see Cylinder Head Cover Re moval Timing Inspection Cap A Timing Rotor Bolt Cap B Special Tool Filler Cap Driver C 57001 1454 e Using a wrench on the timing rotor bolt A turn the crank shaft clockwise until the 2 T mark line B on the timing rotor is aligned with the notch C in the edge of the timing inspection hole in the clutch cover xIf the clutch cover is removed perform the next proce dure OUsing a wrench on the timing rotor bolt turn the cra
221. ance again If the clearance still remains out of the limit replace the cylinder head unit Camshaft Runout Inspection Remove the camshaft see Camshaft Removal 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 in the figure 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 Inspection 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 35 843 35 957 mm 1 4111 1 4156 in Intake 36 543 36 657 mm 1 4387 1 4432 in Service Limit Exhaust 35 74 mm 1 407 in Intake 36 44 mm 1 435 in GE11072BS1 C GE11157BS1 GE11012281 ENGINE END 5 25 Camshaft Camshaft Chain Camshaft Chain Removal Split the crankcase see Crankcase Splitting in the Crank shaft Transmission chapter Remove the camshaft chain A from the crankshaft sprocket 5 26 ENGINE END Cylinder Head Cylinder Compression Measurement NOTE OBe sure the battery is fully charged Warm up the engine thoroughly Stop the engine e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter
222. and Radiator Fan 4 14 Radiator 4 15 Radiator Cap Inspection ort e o RE DA Pe nt 4 15 Radiator Filler Neck 4 16 TREEREN 4 17 Thermostat Removal ER Lt der Ro aerate 4 17 Thermostat 4 17 Thermostat IrisDectlOn oett te trt a eo EAT 4 18 Hose and Pipes ier ie rH REM vases dese dade TUER BRE AE SERE RENE 4 19 IA dtr e tela Raed Hema 4 19 HOSE INSPOCUOM pe HL 4 19 Water Temperature Sensor 99999 nnne nennen nnne nnne renes 4 20 Water Temperature Sensor Removal Installation 44 42 4242 4 20 Water Temperature Sensor Inspection 4 20 4 2 COOLING SYSTEM Exploded View COOLING SYSTEM 4 3 Exploded View No Fastener 4 fb 78 089 Om 2 Coolant Reserve Tank Mounting Bois 79 08i 70mb 3 Water Temperature Sensor 12 12 1 4 Water Hose Clamp Screws 30 os Zimb S Thermostat Housing Bots 98 10 srme 6 Water Pump Cover Bos 98 10 srme 7
223. ange W White BR Brown P Pink Y Yellow G Green 5 12 33 Anti Lock Brake System Equipped Models Terminal Names 00990909010 6114589 2 C 1 Ground 2 Unused 3 Front Wheel Rotation Sensor Signal 4 Power Supply 5 ABS Kawasaki Diagnostic System Terminal 6 Front Rear Brake Light Switch 7 ABS Self diagnosis Terminal 8 Unused 9 Power Supply to ABS Solenoid Valve Relay 10 Ground to Motor 11 Unused 12 Power Supply to Front Wheel Rotation Sensor 13 Power Supply to Rear Wheel Rotation Sensor 14 Rear Wheel Rotation Sensor Signal 15 Unused 16 Unused 17 Yellow ABS Indicator Light LED 18 Power Supply to ABS Motor Relay 12 34 BRAKES Anti Lock Brake System Equipped Models ABS Servicing Precautions There are a number of important precautions that should be followed servicing the ABS system OThis ABS 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 ABS hydraulic unit OTo prevent damage to the ABS parts do not disconnect the battery cables or any other electrical connections when the ignition switch is ON or while the engine is running OTake care not to short the leads that are directly con nected to the battery positive terminal to the chassis ground ODo not tur
224. anister Inspection etre ente 3 114 3 4 FUEL SYSTEM Exploded View FUEL SYSTEM 3 5 Exploded View o Teque Remarks Fastener St ie Lr wGemetemerSue 12 om nme 2 Air Cleaner Housing Cover Screws 0 12 11 in Ib 3 Intake Air Temperature Sensor Screw 1 2 0 12 11 in Ib 4 Air Cleaner Housing Clamp Bolt 2 0 0 20 18 in lb 5 Timing Rotor Bolt 40 4 1 30 6 Crankshaft Sensor Bolts 6 0 0 61 53 in Ib 7 Water Temperature Sensor 12 1 2 106 in Ib 8 Oxygen Sensor Equipped Models 44 4 5 32 9 Speed Sensor Bracket Bolts 9 8 1 0 87 10 Speed Sensor Bolt 7 8 0 80 69 in Ib L 11 Vehicle down Sensor 12 Intake Air Pressure Sensor 13 ECU Electronic Control Unit 14 Intake Air Temperature Sensor 15 Air Switching Valve G Apply grease L Apply a non permanent locking agent LG Apply liquid gasket R Replacement Parts S Follow the specified tightening sequence 3 6 FUEL SYSTEM Exploded View 8002543845 C FUEL SYSTEM 3 7 Exploded View renes Sm 2 Fuel Pump Bolts 87 in lb Other than CAL SEA B1 and TH Models CAL SEA B1 and TH Models AU LAMS Model Throttle Cable Accelerator Throttle Cable Decelerator Apply cable lubricant Apply engine oil Apply grease Apply a non permanent locking agent Replacement Parts Follow the spe
225. ap A e Remove the starter motor cable terminal nut B e Remove the mounting bolts C e Pull out the starter motor D Starter Motor Installation NOTICE Do not tap the starter motor shaft or body Tapping the shaft or body could damage the motor Before installing the starter motor clean the starter mo tor legs A and crankcase B where the starter motor is grounded Replace the O ring A with a new one Apply grease to the O ring Install the starter motor to the crankcase Apply a non permanent locking agent to the threads of the bolts and tighten them Torque Starter Motor Mounting Bolts 9 8 N m 1 0 kgf m 87 in Ib e Install the starter motor cable A as shown About 60 B Front C e Tighten Torque Starter Motor Cable Terminal Nut 6 0 0 61 kgf m 53 e Slide back the rubber cap to the original position e Install the other removed parts see appropriate chap ters GP11224BS1 16 48 ELECTRICAL SYSTEM Electric Starter System Starter Motor Disassembly Remove the starter motor see Starter Motor Removal e Take off the starter motor through bolts A and remove the both end covers B Gba Pull out the armature A out of the yoke NOTE ODo not remove the circlip C from the shaft Remove Starter Motor Terminal Locknut A Washer B Collar C 118975 P e Pull out the brus
226. apter Meter Unit for Red Low Battery Voltage Warning Indica tor Light LED see Meter Unit Inspection in the Electri cal System chapter Meter Unit for Green Neutral Indicator Light LED see Meter Unit Inspection in the Electrical System chapter Meter Unit for Red Oil Pressure Warning Indicator Light LED see Meter Unit Inspection in the Electrical System chapter Meter Unit for Red Water Temperature Warning Indicator Light LED see Meter Unit Inspection in the Electrical System chapter Meter Unit for Blue High Beam Indicator Light LED see Meter Unit Inspection in the Electrical System chapter 9517206851 2 40 PERIODIC MAINTENANCE Periodic Maintenance Procedures ECU see ECU Power Supply Inspection in the Fuel Sys tem DFI chapter Ignition Switch see Switch Inspection in the Electrical System chapter Neutral Switch see Switch Inspection in the Electrical System chapter Harness see Wiring Inspection in the Electrical System chapter e Turn the ignition switch to OFF The all lights should go off x If any light does not go off replace the ignition switch Second Step Turn the ignition switch to P Park position 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 Switch Inspection in the Electrical System chapter Third Step Turn the ignition switch to ON Turn on the tur
227. ar sprocket B near the teeth as shown in the figure and rotate C the rear wheel to measure the sprocket runout warp The difference between the highest and lowest dial gauge readings is the amount of runout warp x If the runout exceeds the service limit replace the rear sprocket Rear Sprocket Warp Standard TIR 0 4 mm 0 016 in or less Service Limit TIR 0 5 mm 0 020 in GK05000BS1 C BRAKES 12 1 5 Table of Contents Exploded e eerte eet ene de e rds 12 3 12 12 Special TOS 12 13 Brake Lever Brake Pedal ert tt orbe idoneae din ae 12 14 Brake Lever Position 1 711 1 1 1 nnne nnn tenis 12 14 Brake Pedal Position Inspection 8 12 14 Brake Pedal Position 2 2 1 1 12 14 Brake Pedal Remova se 12 15 Brake Pedal Installation 12 15 2 12 16 Front Caliper 12 16 Rear Caliper Removal iiti ree rh hg Er Dee FEY ELE EC aes 12 16 Caliper Installation
228. ar the stoppers Frame Cover Installation Installation is the reverse of removal OFit the rib A to the inside of the footpeg stay Olnsert the projections B into the grommets C Side Cover Removal Remove Frame Cover see Frame Cover Removal Middle Fairing see Middle Fairing Removal Bolt A and Washer Pull the side cover B outward to clear the stopper Side Cover Installation e Installation is the reverse of removal sure to install the pads A on the left and right side covers Olnstall the side cover so that the projection A fits into the grommet B 15 27 Rear View Mirrors Rear View Mirror Removal e Remove Upper Inner Fairing see Upper Inner Fairing Removal Nuts A Rear View Mirror B Rear View Mirror Installation Installation is the reverse of removal ELECTRICAL SYSTEM 16 1 Electrical System Table of Contents EE T 16 4 SPOCifiGatlOns ETE 16 10 Special Tools and Sealant 16 11 Parts Location sat e E A ON SEE REA HR Re Ea dr E ea e eie n 16 13 Wiring Diagram 650 e ia o educata Paste t ati dtf ea puftdiss 16 16 Wiring Diagram EX650F rete by asse RR e Rr 16 18 Precautoris tte e a e RE 16 20 Electrical VVIFIDg 16 21 Wiring INS pe
229. ast the service limit replace it Measuring Area A Disc Thickness Standard Front 4 8 5 2 mm 0 19 0 20 in Rear 4 8 5 2 mm 0 19 0 20 in Service Limit Front 4 5 mm 0 18 in Rear 4 5 mm 0 18 in Brake Disc Warp Inspection Raise the wheel off the ground see Front Rear Wheel Removal in the Wheels Tires chapter OFor front disc inspection turn the handlebar fully to one side Set up dial gauge against the disc A as shown and measure disc runout while turning B the wheel by hand x If runout exceeds the service limit replace the disc Disc Runout Standard TIR 0 15 mm 0 0059 in or less Service Limit TIR 0 3 mm 0 01 in GL08042BS1 CN GLO8018BS1 o 12 26 5 Brake Fluid Brake Fluid Level Inspection e Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter Brake Fluid Change Refer to the Brake Fluid Change in the Periodic Mainte nance chapter Brake Line Bleeding The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action Air however is easily compressed When air enters the brake lines brake lever or pedal movement will be partially used in compressing the air This will make the lever or pedal feel spongy and there will be a loss in braking power A WARNING Air in the brake lines diminish braking pe
230. at width measurement 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 OPut a little coarse grinding compound on the face of the valve in a number of places around the valve head OSpin the valve against the seat until the grinding com pound produces a smooth matched surface on both the seat and the valve ORepeat the process with a fine grinding compound Lapper A Valve Seat B Valve C e The seating area should be marked about in the middle of the valve face x If the seat area is not in the right place on the valve check to be sure the valve is the correct part If it is it may have been refaced too much replace it e Be sure to remove all grinding compound before assem bly e When the engine is assembled be sure to adjust the valve clearance see Valve Clearance Adjustment in the Peri odic Maintenance chapter GE15012381 GE15012081 5 36 ENGINE TOP END Valves Valve Seat Repair START Machinist s dye on seat 45 Grind Tool 45 Cutter Purpose make seating area smooth and round Measure Seating Area O D Tool Vernier Caliper Purpose check seat O D against spec Too small 45 Grind Tool 45 Cutter Purpose increase O D of seat area to spec Machinist s dye on seat 32 Grind Tool 32 Cutter Purpose reduce O D of seat area to spec M
231. ation sensor from the caliper bracket see Rear Wheel Rotation Sensor Removal in the Brakes chapter e Remove Rear Caliper Mounting Bolts A Rear Caliper B 10 8 WHEELS TIRES Wheels Rims Remove Cotter Pin A Rear Axle Nut B Washer C Rear Axle D from Right Side Remove the drive chain A from the rear sprocket toward the left Move the rear wheel back and remove it NOTICE Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place wooden blocks under the wheel so that the disc does not touch the ground Rear Wheel Installation e Apply high temperature grease to the grease seal lips e Fit the collars on the both sides of the hub Left Side Collar A Right Side Collar B with Flange e Engage the drive chain with the rear sprocket e Install the caliper bracket A onto the stopper B ofthe swingarm Insert the rear axle from the right side of the wheel Install the washer and rear axle nut e Adjust the drive chain slack before tightening the rear axle nut see Drive Chain Slack Inspection in the Periodic Maintenance chapter e Tighten Torque Rear Axle Nut 108 Nm 11 0 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 B up to next alignment Olt should be within 30 degrees
232. ber of important precautions that are musts when servicing electrical systems Learn and ob serve all the rules below ODo not reverse the battery cable connections This will burn out the diodes on the electrical parts OAlways check battery condition before condemning other parts of an electrical system A fully charged battery is a must for conducting accurate electrical system tests OThe electrical parts should never be struck sharply as with a hammer or allowed to fall on a hard surface Such a shock to the parts can damage them OTo prevent damage to electrical parts do not disconnect the battery cables or any other electrical connections when the ignition switch is on or while the engine is running OBecause of the large amount of current never keep the starter button pushed when the starter motor will not turn over or the current may burn out the starter motor wind ings OTake care not to short the cables that are directly con nected to the battery positive terminal to the chassis ground OTroubles may involve one or in some cases all items Never replace a defective part without 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 sy
233. bly required do it following precisely the maximum charge current and time conditions indicated on the battery NOTICE This battery is designed to sustain no unusual deterioration if refresh charged according to the method specified above However the battery s performance may be reduced no ticeably if charged under conditions other than given above Never remove the seal cap during refresh charge If by chance an excessive amount of gas is generated due to overcharging the relief valve releases the gas to keep the battery normal 3 When you do not use the motorcycle for months Give a refresh charge before you store the motorcycle and store it with the negative cable re moved Give a refresh charge once a month during storage 4 Battery life If the battery will not start the engine even after several refresh charges the battery has ex ceeded its useful life Replace it Provided however the vehicle s starting system has no prob lem A DANGER Batteries produce an explosive gas mixture of hydrogen and oxygen that can cause seri ous injury and burns if ignited Keep the battery away from sparks and open flames during charging 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 The electrolyte contains sulfuric acid Be careful not to have it touch your skin or eyes If t
234. brake disc Replace faulty parts OK Front and rear wheels should rotate smoothly without NG brake drag Repair or replace caliper OK There shouldn t be a lot of play in the wheel bearing Replace wheel bedding arse There shouldn t be excessive axle bending or disc runout GLI40012B F 5 12 41 Anti Lock Brake System Equipped Models Pre Diagnosis Inspection 2 Check the yellow ABS indicator light LED Blink Goes on Does the yellow ABS indicator light Does the yellow ABS indicator light LED LED go on with the ignition switch blink with the ignition switch to ON to ON No Yes Drive at 5 km h 3 1 mph or above for Check the power source Check the battery one minute or more wirina and meter unit voltaae ABS is normal Yes When the motorcycle is running does the yellow ABS indicator light LED go off Count the number of times the yellow ABS indicator m light LED blinks in the self diagnosis mode to find the service code appens again GLI4591B F Self diagnosis Outline When the yellow ABS indicator light LED has blinked or goes on the ABS hydraulic unit memorizes and stores the service code 15 codes including Normal Code for the service person to troubleshoot easily The service code memory is powered directly by the battery and cannot be canceled by the ignition switch The ABS hydraulic unit
235. brake line fittings including the ABS hydraulic unit joint nuts or the bleed valve is opened at any time the air must be bled completely from the brake line If the brake lever has a soft or spongy feeling mushy when it is applied there might be air in the brake lines or the brake may be defective Do not operate the vehicle and service the brake system immediately NOTICE Do not ride the motorcycle with air in the brake line or the ABS could malfunction OThe yellow ABS indicator light LED A may go on if the tire pressure is incorrect a non recommended tire is in stalled or the wheel is deformed If the warning indicator light goes on remedy the problem and clear the service code A WARNING Use of non recommended tires may cause malfunc tioning of ABS and can lead to extended braking distance resulting in an accident causing serious e injury or death Always use recommended stan dard tires for this motorcycle 12 36 BRAKES Anti Lock Brake System Equipped Models OThe yellow ABS indicator light LED may go on if the engine is run with the motorcycle on its stand and the transmission in gear If the warning indicator light goes on just turn the ignition switch to OFF then clear service code 42 which indicates a Faulty front wheel rotation sensor OWhen the ABS operates the ABS makes noise and the rider feels the reaction force on the brake lever and brake pedal
236. cable Clutch Cable Run the brake hose ABS hydraulic unit rear caliper between the brake hose rear brake reservoir tank rear master cylinder and the brake hose rear master cylinder ABS hydraulic unit Fix the brake hose to the clamp on the ABS hydraulic unit bracket Brake Hose Rear Brake Reservoir Tank Rear Master Cylinder Brake Hose Rear Master Cylinder ABS Hydraulic Unit Run the brake hose above the clamp on the ABS hydraulic unit bracket Fix the brake hose ABS hydraulic unit rear caliper to the frame with the clamp View from A Fix the rear brake light switch lead connector inside and the rear wheel rotation sensor lead connector outside to the clamp on the swingarm bracket Fix the rear brake light switch lead and the rear wheel rotation sensor lead to the frame with the clamp Hook the ABS hydraulic unit lead and crankshaft sensor lead to the clamp on the frame ABS Hydraulic Unit 17 32 APPENDIX Cable Wire and Hose Routing The routing on EX650E F is shown using the figure of ER650E F 08809815045 C APPENDIX 17 33 Cable Wire and Hose Routing 5 E pd M onus oS A EJ 54 59 C 72 VA 68809816044 C 1 Guide Run the front brake hose through the guide 2 Clamps Hold the front brake hose 3 Clamps Hold the rear brake hose 4 Clamp with Damper Hold the rear brake hose
237. can memorize up to 6 service codes Further service codes are memorized after erasing the preceding 6 service codes If there is no fault only the start code 12 is shown indicating that The ABS is normal Self diagnosis Procedures OWhen a problem occurs with the ABS system the yellow ABS indicator light LED A goes on NOTE OUse a fully charged battery when conducting self diagnosis Otherwise the light blinks very slowly or does not blink OThe motorcycle is stopped OKeep the self diagnosis terminal grounded during self 2114610851 0 diagnosis with an auxiliary lead 12 42 5 Anti Lock Brake System Equipped Models Remove the front seat see Front Seat Removal in the Frame chapter e Ground the self diagnosis terminal A Gray to the bat tery terminal or battery cable connector using a lead Turn the ignition switch to ON OCount the blinks of the yellow ABS indicator light LED to read the service code Keep the auxiliary lead ground until you finish reading the service code Service Code Clearing Procedures e Start the service code erase mode with the following pro cedure OThe erase mode starts when the ABS self diagnosis ter minal is disconnected from the ground terminal after start ing the self diagnosis mode OThe service code can be erased by grounding and un grounding each time for at least 1 second the ABS self diagnosis terminal 3 times or more within abo
238. ce 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 5 34 ENGINE END Valves 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 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 or 55 cutter 60 or 55 F Measure the outside diameter of the seating surface with a vernier caliper x If the outside diameter of the seating surface is too small repeat the 45 grind A until the diameter is within the specified range Original Seating 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 or 55 grinding operation eas ier OWhen the valve guide is replaced be sure to grind with 45 cutter for centering and good contact x If the outside diameter A of the seating surface is too large make the 32 grind described below x If the outside diameter of the seating surface is within the specified range measure the sea
239. charger follow the charger s instructions for newly activated sealed battery Kawasaki recommended chargers Battery Mate 150 9 OptiMate PRO 4 S PRO S PRO2 Yuasa MB 2040 2060 Christie C10122S xIf the above chargers are not available use equivalent one Let battery sit 30 minutes after initial charge then check voltage using a voltmeter Voltage immediately after charging becomes temporarily high For accurate mea suring let the battery sit for given time NOTE OCharging rates will vary depending on how long the battery has been stored temperature and the type of charger used If voltage is not at least 12 8 V repeat charging cycle OTo ensure maximum battery life and customer satisfac tion it is recommended the battery be load tested at three times its amp hour rating for 15 seconds Re check voltage and if less than 12 8 V repeat the charging cycle and load test still below 12 8 V the battery is defective 16 26 ELECTRICAL SYSTEM Battery Precautions 1 No need of topping up No topping up is necessary in this battery until it ends its life under normal use Forcibly prying off the seal cap to add water is very dangerous Never do that 2 Refreshing charge If an engine will not start a horn sounds weak or lamps are dim it indicates the battery has been discharged Give refresh charge for 5 to 10 hours with charge current shown in the specification see Refreshing Charge When a fast charge is inevita
240. cial Tools Valve Spring Compressor Assembly A 57001 241 Valve Spring Compressor Adapter 21 B 57001 1272 Valve Installation e Replace the oil seal with a new one e Apply engine oil to the oil seal lip 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 the side painted in green faces upwards Valve Stem A Oil Seal B Spring Seat C Closed Coil End D Valve Spring E Side Painted in Red F Retainer G Split Keepers H 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 NOTICE Do not heat the cylinder head with a torch This will warp the cylinder head Soak the cylinder head in oil and heat the oil Special Tool Valve Guide Arbor 4 5 57001 1331 GE15043BS1 C GE15115BS1 GE15045BS1 C Valves ENGINE TOP END 5 31 Valve Guide Installation e Apply engine oil to the valve guide outer surface before installation e Heat the area around the valve guide hole to about 120 150 C 248 302 F Drive the valve guide in from the top of the head using the valve guide arbor The flange stops the guide from going in too far Special Tool Valve Guide Arbor
241. cified tightening sequence Im o 3 8 FUEL SYSTEM DFI Exploded View CAL SEA B1 and TH Models 08002544845 C FUEL SYSTEM 3 9 Exploded View nof ee T em RR Ta Purge Valve Mounting Nat 70 on eem 2 Canister 3 Purge Valve 3 10 FUEL SYSTEM DFI System DFI System DFI System FUEL SYSTEM DFI 3 11 ECU Electronic Control Unit Battery Fuel Tank Fuel Pump Pressure Regulator Delivery Pipe Intake Air Temperature Sensor Subthrottle Valve Air Cleaner Housing Subthrottle Sensor Main Throttle Valve Air Switching Valve Fuel Injectors Main Throttle Sensor Water Temperature Sensor Subthrottle Valve Actuator Intake Air Pressure Sensor Speed Sensor Vehicle down Sensor Crankshaft Sensor Oxygen Sensor Equipped Models 3 12 FUEL SYSTEM DFI System DFI System Wiring Diagram 89 Esas HE 9 O CS H HE va zE 4 BK W 5 a aur H i A ae Mon BR BK E s Dm EET Ti DFI System FUEL SYSTEM 3 13 Part Joint Connector Kawasaki Diagnostic System Connector
242. cked more than 2095 by unremovable obstructions or irreparably de formed fins replace the radiator with a new one NOTICE When cleaning the radiator with steam cleaner be careful of the following to prevent radiator damage Keep the steam gun A away more than 0 5 m 1 6 ft B from the radiator core Hold the steam gun perpendicular C not oblique D to the core surface Run the steam gun following the core fin direction Radiator Cap Inspection e Remove the radiator cap see Coolant Change in the Pe riodic Maintenance chapter 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 e Watching the pressure gauge pump the pressure tester to build up the pressure until the relief valve opens the gauge needle flicks downward Stop pumping and mea sure leak time at once The relief valve must open within the specified range in the table below and the gauge hand must remain within the same range at least 6 seconds Radiator Cap Relief Pressure Standard 112 3 141 7 kPa 1 15 1 45 kgf cm 16 3 20 6 psi x If the cap can not hold the specified pressure or if it holds too much pressure replace it with a new one 8007010451 C GDO7
243. cking agent to the threads of the lower fairing mounting bolts OTighten Torque Lower Fairing Mounting Bolts 15 N m 1 5 kgf m 11 16 Middle Fairing Disassembly Remove the middle fairing A with the lower fairing B see Middle Fairing Removal e Remove Screws C Lower Fairing e Remove Screws A Front Turn Signal Light B Middle Fairing Assembly e Assembly is the reverse of disassembly OTighten Torque Front Turn Signal Light Mounting Screws 1 2 N m 0 12 kgf m 11 in Ib G005020BS2 C 9005021851 15 16 Fairings Lower Fairing Bracket Removal e Remove Middle Fairings see Middle Fairing Removal Clamp A Oxygen Sensor Equipped Models Lower Fairing Bracket Bolts B Lower Fairing Bracket Left C e Remove Reserve Tank Overflow Hose A Clamp B Lower Fairing Bracket Bolts C Lower Fairing Bracket Right D Lower Fairing Bracket Installation Installation is the reverse of removal ORun the leads and hose correctly see Cable Wire and Hose Routing section in the Appendix chapter OApply a non permanent locking agent to the threads of the lower fairing bracket bolts and tighten them Torque Lower Fairing Bracket Bolts 12 N m 1 2 kgf m 106 in Ib Upper Fairing Removal e Remove Middle Fairings see Middle Fairing Removal in the Frame chapter City Light Connectors Disconnect Headlight Connectors A Disconnect Bolts B Head
244. clear ance between cam and valve lifter Valve Clearance Standard Exhaust 0 22 0 31 mm 0 0087 0 0122 in Intake 0 15 0 21 mm 0 0059 0 0083 in OEach piston has two intake and two exhaust valves Measure these two intake or exhaust valves at the same crankshaft position NOTE OCheck the valve clearance using this method only Checking the clearance at any other cam position may result in improper valve clearance Valve Clearance Measuring Position 1 Piston TDC at End of Compression Stroke Intake valve clearances of 1 piston and Exhaust valve clearances of 1 piston 2 Piston TDC at End of Compression Stroke Intake valve clearances of 2 piston and Exhaust valve clearances of 2 piston x If the valve clearance is not 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 see the Engine Top End chapter Replace the shim with one of a different thickness NOTE OMark and record the locations of the valve lifters and shims so that they can be reinstalled in their original positions 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 Cam
245. continuity between main harness side connectors Special Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A lt 5 Intake Air Temperature Sensor Connector B R lead ECU terminal 20 C BR BK lead ECU terminal 22 D x If the wiring is good check the intake air temperature sen sor resistance see Intake Air Temperature Sensor Resis tance Inspection Intake Air Temperature Sensor Resistance Inspection e Remove the intake air temperature sensor see Intake Air Temperature Sensor Removal Installation e Suspend the sensor A in a container of machine oil so that the heat sensitive portion is submerged e Suspend a thermometer B with the heat sensitive por 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 following Intake Air Temperature Sensor Resistance Standard 5 4 6 6 at 0 C 32 F 0 29 0 39 at 80 176 F x If the reading is out of the standard replace the sensor xIf the reading is within the standard but the problem still exists replace the ECU see ECU Removal
246. crewdrivers and remove the balance weight e Discard the used balance weight NOTICE Do not tap the screwdrivers The rim could be dam aged Balance Weight Installation Check if the weight portion has any play on the blade A and clip B x lf it does discard it A WARNING Unbalanced wheels can create an unsafe riding condition If the balance weight has any play on the rib of the rim the blade and or clip have been stretched Replace the loose balance weight Do not reuse used balance weight 6J04076BS1 6J04077BS1 6J04088BS1 10 12 WHEELS TIRES Wheels Rims Balance Weight Part Number Weight 41075 0007 10 g 0 35 oz 41075 0008 20 g 0 71 41075 0009 30 1 06 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 not use four or more balance weight more than 90 gram 3 2 oz If the wheel requires an excess balance weight disassemble the wheel to find the cause e Slip the balance weight A onto the rib B by pushing or lightly hammering C the clip D Left Side E Right Side F NOTE e Be sure to install the balance weight OCheck that the blade A and clip B are fully seated on the rim C and that the clip is hooked over the rib D Le
247. ctin e 16 21 i i Pre AT CE T EE NTT 16 22 i i Molino i em 16 22 Battery eerta he Op ttg eerte 16 22 Um 16 23 Precautioris senes meet ee pet ge A 16 26 Interchange 16 26 Charging Condition Inspection band 16 27 Refreshing Charge pete 16 27 anasa 16 29 Alternator Cover Removal 220 16 29 Alternator Cover 16 29 Slator 16 30 Stator 1 5 cete tese ete b Cete Dave e cree eite eun 16 30 Alternator Rotor 16 30 Alternator Rotor 16 31 Alternator Inspection 22 42 4 0 00 000000 16 32 Regulator Rectifier Inspection tanta Medel Danaea ni depen dae dieat 16 34 Charging voltage InspectQDiziu sedet testet nate cdi a hg 16 36 Starter Motor Clutch crrr eare a e Er 16 38 Starter Motor Clutch Removal Installation 9 16 38 Starter Motor Clutch Inspection 9 1 Starter Motor Clutc
248. ction pp 3 51 Water Temperature Sensor Service Code 14 3 53 Water Temperature Sensor Removal Installation 2 1 3 53 Water Temperature Sensor Output Voltage 3 54 Water Temperature Sensor Resistance 3 55 Crankshaft Sensor Service Code 1 222222 1 eternidad ieu aec ee Oven 3 56 Crankshaft Sensor 9 3 56 Crankshaft Sensor Resistance Inspection 01 00000000000000060 00 3 56 Crankshaft Sensor Peak Voltage 3 56 Speed Sensor Service Code 24 3 57 Speed Sensor Removal lnstallation pp 3 57 Speed Sensor Inspection nenne nennen nnne nnne nnne 3 57 Speed Sensor Input Voltage 3 57 Speed Sensor Output Voltage Inspection pp 3 58 Vehicle down Sensor Service Code 31 7 3 60 Vehicle down Sensor Removal Installation sse 3 60 Vehicle down Sensor Inspectigom 3 60 Subthrottle Sensor Service Code 32 3 63 Subthrottle Sensor Removal Adjustment 3 63 3 2 FUEL SYSTEM DFI Subthrottle Sensor Input Voltage Subthrottle Sensor Output Voltage Ins
249. ctor and connect the harness adapter A between these connec tors Special Tool Measuring Adapter 57001 1700 e Connect a digital meter to the harness adapter leads Intake Air Pressure Sensor Input Voltage Connections to Adapter Digital Meter R sensor BL lead Digital Meter gt BK sensor BR BK lead e Measure the input voltage with the engine stopped and with the connector joined e Turn the ignition switch to ON Input Voltage Standard DC 4 75 5 25 V e Turn the ignition switch to OFF x If the reading is within the standard check the output volt age see Intake Air Pressure Sensor Output Voltage In spection FUEL SYSTEM DFI 3 45 Intake Air Pressure Sensor Service Code 12 xIf the reading is out of the standard remove the ECU and check the wiring for continuity between main harness connectors Special Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Intake Air Pressure Sensor Connector B BL lead ECU terminal 8 C BR BK lead ECU terminal 22 D xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation Intake Air Pressure Sensor Output Voltage Inspection Measure the output voltage at the intake air pressure sen sor in the same way as input voltage ins
250. ctors x If the terminals of the main harness connectors are dam aged replace the main harness x If the terminals of the ECU connectors are damaged re place the ECU GC17625ES1 FUEL SYSTEM 3 87 Turn the ignition switch to OFF Disconnect the ECU connectors A Set the hand tester B to the x 1 O range and check the following wiring for continuity Special Tool Hand Tester 57001 1394 ECU Grounding Continuity Inspection Connections BK lead ECU terminal 26 or BK Y leads ECU terminal 42 or 43 Engine Ground Battery Terminal lt gt Battery Terminal Criteria Both 0 Q x If no continuity check the connectors the engine ground lead or main harness and repair or replace them if nec essary xIf the wiring is good check the power source voltage of the ECU NOTE OBe sure the battery is fully charged e Connect the ECU connectors e Connect a digital meter A to the connector B with the needle adapter set Special Tool Needle Adapter Set 57001 1457 ECU Power Supply Inspection Connections 1 Digital Meter Terminal 12 BR W Digital Meter gt Battery terminal Digital Meter Terminal 27 W BK Digital Meter gt Battery terminal Ignition Switch OFF Terminal 12 BR W 0 V Terminal 27 W BK Battery Voltage Ignition Switch ON Both Battery Voltage xIf the reading is out o
251. d and must be replaced e Using the highest resistance range of the tester measure the resistance between the crankshaft sensor leads and chassis ground Any tester reading less than infinity indicates a short 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 A is a more reliable way to determine the condition of the crankshaft sen sor than crankshaft sensor internal resistance measure ments e Disconnect the crankshaft sensor lead connector see Crankshaft Sensor Removal e Set the hand tester B to the x DC 10 V range and con nect it peak voltage adapter e Connect the black lead of the peak voltage adapter to black lead and red lead to yellow lead in the crankshaft sensor connector e Turn the ignition switch to ON and the engine stop switch to run position 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 times or more Crankshaft Sensor Peak Voltage Standard 2 0 V or more Special Tools Hand Tester 57001 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B xIf the tester reading is not the specified one check the crankshaft sensor see Crankshaft Sensor Inspection ELECTRICAL SYSTEM 16 41 Ignition System Timing Rotor Remova
252. d constant mesh return shift Gear Ratios 1st 2 438 39 16 2nd 1 714 36 21 3rd 1 333 32 24 4th 1 111 30 27 5th 0 966 28 29 eth 0 852 23 27 Final Drive System Type Chain drive Reduction Ratio 3 067 46 15 Overall Drive Ratio 5 473 gear Frame Type Tubular diamond Caster Rake Angle 25 Trail 110 mm 4 33 in Front Tire Type Tubeless Size 120 70 ZR17 M C 58W Rim Size J17M C x MT3 50 Rear Tire Type Tubeless Size 160 60 ZR17 M C 69W Rim Size J17M C x MT4 50 1 12 GENERAL INFORMATION General Specifications Rated Output Items EX650EC FC Front Suspension Type Telescopic fork Wheel Travel 125 mm 4 92 in Rear Suspension Type Swingarm Wheel Travel 130 mm 5 12 in Brake Type Front Dual discs Rear Single disc Electrical Equipment Battery 12 V 10 Ah Headlight Type Semi sealed beam Bulb High 12 V 55 W 55 W quartz halogen Low 12 V 55 W quartz halogen Tail Brake Light LED Alternator Type Three phase AC 24 A 14 V 5 000 r min rpm Specifications are subject to change without notice and may not apply to every country Prefixes for Units GENERAL INFORMATION 1 13 Unit Conversion Table Units of Length Tun E km x 0 6214 mile mega x 1 000 000 m EM c PE kilo x 4 000 mm x 0 03937 in centi x 0 01 milli x 0 004 Units of Torque micro x 0 000001 Nim we UAM N m x 07376 ftlb N m x 8 851 in lb Unit
253. d or dust blow it off with compressed air Front Wheel Rotation Sensor Removal The wheel rotation sensor should be handled care fully never struck sharply as with a hammer or al lowed to fall on a hard surface since the wheel rota tion sensor is precision made Be careful not to get water or mud on the wheel rotation sensor Do not try to disassemble or repair the wheel rota tion sensor 5 12 59 Anti Lock Brake System Equipped Models e Disconnect the front wheel rotation sensor connector A e Free the front wheel rotation sensor lead A from the clamps B e Remove Front Wheel Rotation Sensor Bolt A Front Wheel Rotation Sensor B Front Wheel Rotation Sensor Installation Installation is the reverse of removal ORun the lead correctly see Cable Wire and Hose Rout ing section in the Appendix chapter OTighten Torque Front Wheel Rotation Sensor Bolt 20 N m 2 0 kgf m 15 ft lb Rear Wheel Rotation Sensor Removal The wheel rotation sensor should be handled care fully never struck sharply as with a hammer or al lowed to fall on a hard surface since the wheel rota tion sensor is precision made Be careful not to get water or mud on the wheel rotation sensor Do not try to disassemble or repair the wheel rota tion sensor 12 60 BRAKES Anti Lock Brake System Equipped Models Remove Right Frame Cover see Frame Cover Removal in the
254. d replace fuel pump or kinked fuel line Inspect and replace fuel pump see chapter 3 Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Backfiring when deceleration Spark plug dirty broken or gap maladjusted Inspect and replace see chapter 2 Fuel pressure too low Inspect see chapter 3 Fuel pump trouble Inspect see chapter 3 Main throttle sensor trouble Inspect see chapter 3 Subthrottle sensor trouble Inspect see chapter 3 Subthrottle valve actuator trouble Inspect see chapter 3 Intake air pressure sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Intake air temperature sensor trouble Inspect see chapter 3 Air switching valve trouble Air suction valve trouble After fire Spark plug burned or gap maladjusted Fuel injector trouble Intake air pressure sensor trouble Water temperature sensor trouble Intake air temperature sensor trouble Intermittent any DFI fault and its recovery Inspect and replace see chapter 16 Inspect and replace see chapter 5 pee a E __ Check that DFI connectors are clean and tight and examine leads for signs of burning or fraying see chapter 3 3 32 FUEL SYSTEM DFI System Troubleshooting Guide Poor Running or No Power at High Speed Symptoms or Possible Causes Firing incorrect Stick c
255. dal A to the shift shaft OAlign the punch mark on the shift shaft with the punch mark C on the shift pedal Tighten Torque Shift Pedal Bolt 12 N m 1 2 kgf m 106 in Ib e Be sure the shift pedal A position is as shown in the figure External Shift Mechanism Removal Drain the engine oil see Engine Oil Change in the Peri odic Maintenance chapter Remove Engine Sprocket see Engine Sprocket Removal in the Final Drive chapter Shift Pedal see Shift Pedal Removal Neutral Switch Lead Connector A Shift Shaft Cover Bolts B Shift Shaft Cover Screw C Shift Shaft Cover D Remove the shift shaft assembly A CRANKSHAFT TRANSMISSION 9 33 External Shift Mechanism Remove Clutch see Clutch Removal in the Clutch chapter Gear Positioning Lever Bolt A Spacer B Gear Positioning Lever C Washer and Spring External Shift Mechanism Installation Install the gear positioning lever A as shown in the figure Spring B Washer C Spacer D Gear Positioning Lever Bolt E OHook the spring at gear positioning lever pushing up F the hook portion as shown in the figure Apply a non permanent locking agent to the gear posi tioning lever bolt and tighten it 9113241851 Torque Gear Positioning Lever Bolt 12 N m 1 2 kgf m 106 in Ib e Apply molybdenum disulfide oil solution to the rubbing surface A between the lever B and pawl C and move them tw
256. de Diameter Marking Zouma Diameter Size Col Part Numb Marking ize Color art Number O 1 92028 1905 None 1 Black 92028 1904 92028 1903 bearing inserts for Nos 1 2 and 3 journals have oil groove Install the new inserts in the crankcase halves and check insert journal clearance with the plastigage CRANKSHAFT TRANSMISSION 9 29 Balancer Balancer Removal Split the crankcase see Crankcase Splitting Pull the balancer shaft A with the balancer gear out of the crankcase Balancer Installation Apply molybdenum disulfide oil solution to the inside of the balancer shaft bearing insert Align A the timing mark on the balancer gear B with the timing mark on the balancer drive gear C of the crank shaft e Assemble the crankcase see Crankcase Assembly 8104255 52 Balancer Shaft Bearing Insert Journal Clearance Inspection Measure the bearing insert journal clearance using a plastigage OSplit the crankcase and wipe each bearing insert and jour nal surface clean of oil OCut strips of plastigage to bearing insert width and place a strip on each journal parallel to the balancer shaft so that the plastigage will be compressed between the journal and the bearing insert Olnstall the lower crankcase half and tighten the case bolts to the specified torque see Crankcase Assembly 9 30 CRANKSHAFT TRANSMISSION Balancer NOTE ODo
257. diagrniosis PrOCedufes reece sks ee Ae 3 34 Service Code Reading et aere td re dec kp Lv pese RR e nkkita Serat 3 37 Service Code Aen 3 37 Service Code eite erre re ubere Peer E FORTE e ken 3 38 BACKUPS cef a e 3 39 Main Throttle Sensor Service Code 11 3 41 Main Throttle Sensor Removal Adjustment Nt 3 41 Main Throttle Sensor Input Voltage Inspection 3 41 Main Throttle Sensor Output Voltage Inspection 3 42 Main Throttle Sensor Resistance Inspection 3 43 Intake Air Pressure Sensor Service Code 12 3 44 Intake Air Pressure Sensor 3 44 Intake Air Pressure Sensor 3 44 Intake Air Pressure Sensor Input Voltage Inspection pp 3 44 Intake Air Pressure Sensor Output Voltage 3 45 Intake Air Temperature Sensor Service Code 13 3 50 Intake Air Temperature Sensor Removallnstallation pp 3 50 Intake Air Temperature Sensor Output Voltage 3 50 Intake Air Temperature Sensor Resistance Inspe
258. displayed in the trip meter does not indi cate 0 0 replace the meter assembly NOTE OThe integrated value of the odometer cannot be reset Tachometer Check Connect the 12 V battery and terminals in the same man ner as specified 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 12 Olndicates approximately 4 000 rpm in case the input fre quency would be approximately 133 3 Hz the oscillator is not available the tachometer 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 OThen the tachometer needle A sweeps to the maximum reading B then sweeps back to the minimum reading C x If the tachometer needle does not sweep replace the me ter assembly OUsing the insulated auxiliary lead quickly open and con nect the terminal 8 to the terminal 12 repeatedly OThen the tachometer needle sweeps to the maximum reading then sweeps back to the minimum reading If the tachometer needle does not sweep replace the me ter assembly j 235 GP17904CS1 199 g ag GP17905CS1 10 15 GP17906CS1 GP17907C81 Mete
259. djust it to an appropriate position by referring to the table below Spring Preload Adjustment Adjuster Damping Tun Road Driving Position Force Conditions Speed Hardness 1st Weak Soft Light Good Low T T T T T T i l 7th Strong Hard Heavy Bad Highway Rear Shock Absorber Removal Remove Frame Covers see Frame Cover Removal in the Frame chapter Right Footpeg Stay see Footpeg Stay Removal in the Frame chapter Muffler see Muffler Removal the Engine End chapter Lower Fairing Bracket see Lower Fairing Bracket Re moval in the Frame chapter Raise the rear wheel off the ground using the jack Special Tool Jack 57001 1238 Squeeze the brake lever slowly and hold it with a band A A WARNING Be sure to hold the front brake when removing the shock absorber or the motorcycle may fall over It could cause an accident and injury 13 16 SUSPENSION Rear Shock Absorber e Remove Right Stay Cover A e Remove Rear Shock Absorber Mounting Bolt Upper A Washer and O ring Rear Shock Absorber Mounting Bolt Lower B Nut Collar and Washer Remove the rear shock absorber backward Rear Shock Absorber Installation e Installation is the reverse of removal OBe sure to install the oil seals A to the rear shock ab sorber e Apply grease to the lip of oil seals OBe sure to install the collar B and sleeve C to the
260. due to spark plug fouling or poor connection of the stick coil For KLEEN do not coast the motorcycle with the ignition switch off Turn the igni tion switch ON and run the engine 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 Compression high Carbon built up in combustion chamber Engine load faulty Clutch slipping Engine oil level too high 17 46 APPENDIX Troubleshooting Guide Engine oil viscosity too high Drive train trouble Brake dragging Lubrication inadequate Engine oil level too low Engine oil poor quality or incorrect Gauge incorrect Water temperature gauge broken Water temperature sensor broken Coolant incorrect Coolant level too low Coolant deteriorated Wrong coolant mixed ratio Cooling system component incorrect Radiator fin damaged Radiator clogged Thermostat trouble Radiator cap trouble Radiator fan relay trouble Fan motor broken Fan blade damaged Water pump not turning Water pump impeller damaged Over Cooling Gauge incorrect Water temperature gauge broken Water temperature sensor broken Cooling system component incorrect Radiator fan relay 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 uneve
261. e or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below Replacement of the original exhaust system or muffler with a component not in compliance with Federal regulations Removal of the muffler s or any internal portion of the muffler s Removal of the air box or air box cover Modifications to the muffler s or air intake 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 make it useful to the owner who de sires to perform his own basic maintenance and repair work A basic knowledge of mechanics the proper use of tools and workshop proce dures must be understood in order to carry out maintenance and repair satisfactorily When ever the owner has insufficient experience or doubts his ability to do the work all adjust ments maintenance and repair should be car ried out only by qualified mechanics In order to perform the work efficiently and to avoid costly mistakes read the text thor oughly familiarize yourself with the procedures before starting work and then do the work care fully in a clean area Whenever special tools or equipment are specified do no
262. e Chart PERIODIC MAINTENANCE 2 5 Periodic Replacement Parts FREQUENCY Air cleaner element replace Oil filter replace Whichever comes first v Every every 18 Lee km 11 irum mil Engine oil change year e ODOMETER READING x 1 000 km x 1 000 mile 12 24 7 5 15 See Fuel hose replace Coolant change Radiator hose and O ring replace Brake hose replace Brake fluid change Rubber parts of master cylinder and caliper replace Sparcpg reniace 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 2 6 PERIODIC MAINTENANCE Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non permanent locking agent or silicone sealant etc Letters used in the Remarks column mean AL Tighten the two clamp bolts alternately two times to ensure even tightening torque EO Apply engine oil L Apply a non permanent locking agent to the threads LG Apply liquid gasket Lh Left hand Threads MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts S Follow the specified tightening sequence Si Apply silicone grease ex PBC
263. e Disconnect the water temperature sensor connector and connect the harness adapter A between these connec tors as shown in the figure Main Harness B Water Temperature Sensor C Special Tool Measuring Adapter 57001 1700 Connect a digital meter D to the harness adapter leads Water Temperature Sensor Output Voltage Connections to Adapter Digital Meter gt R sensor O lead Digital Meter gt BK sensor BR BK lead e Measure the output voltage with the engine stopped and with the connector joined Turn the ignition switch to ON Output Voltage Standard About DC 2 80 2 97 V at 20 C 68 F NOTE OThe output voltage changes according to the coolant temperature in the engine Turn the ignition switch to OFF xIf the reading is within the standard check the ECU for its ground and power supply see ECU Power Supply In spection If the ground and power supply are good replace the ECU see Removal Installation xIf the reading is out of the standard remove the ECU and check the wiring for continuity between main harness connectors Special Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Water Temperature Sensor Connector B O lead ECU terminal 17 C BR BK lead ECU terminal 22 D x If the wiring is good check the water temperature sensor resistance see Water Temperature Sensor Resistance In
264. e Inspection shows 5 V exactly OWhen the input voltage reading shows other than 5 V derive a voltage range as follows Example In the case of a input voltage of 4 75 V 0 6 x 4 75 5 00 0 57 V 0 8 x 4 75 5 00 0 76 V Thus the valid range is 0 57 0 76 V Turn the ignition switch to OFF xIf the output voltage is out of the standard inspect the subthrottle sensor resistance x If the reading is within the standard remove the ECU and check the wiring for continuity between main harness con nectors Special Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Subthrottle Sensor Connector B BR lead ECU terminal 19 C BR BK lead ECU terminal 22 D x lf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation GC17794DS1 C 3 66 FUEL SYSTEM Subthrottle Sensor Service Code 32 Subthrottle Sensor Resistance Inspection e Turn the ignition switch to OFF e Disconnect the subthrottle sensor connector Connect a digital meter A to the subthrottle sensor con nector B Measure the subthrottle sensor resistance Throttle Sensor Resistance Connections BL lead C lt gt BR BK lead D Standard 4 6 x If the reading is out of the range replace
265. e O rings A with new ones Tighten Torque Starter Motor Through Bolts B 5 0 N m 0 51 kgf m 44 in lb Brush Inspection e Measure the length of each brush A x If any is worn down to the service limit replace the brush assembly Starter Motor Brush Length Standard 12 mm 0 47 in Service Limit 6 5 mm 0 26 in 118976 P Electric Starter System ELECTRICAL SYSTEM 16 51 Commutator Cleaning and Inspection Clean the metallic debris off the between commutator segments A NOTE ODo not use emery or sand paper on the commutator Check the commutator for damage or abnormal wear Replace the starter motor with a new one if there is any damage or wear e Visually inspect the commutator segments for discol oration Replace the starter motor with a new one if discoloration is noticed Armature Inspection Using the x 1 hand tester range measure the resis tance between any two commutator segments A Special Tool Hand Tester 57001 1394 x If there is a high resistance or no reading between 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 x If there is any reading at all the armature has a short and the starter motor must be replaced NOTE OEven if the foregoing checks show the armature to be go
266. e front wheel to stop moving Remove the rear shock absorber see Rear Shock Ab sorber Removal in the Suspension chapter Remove Right Swingarm Bracket Bolts A Swingarm Pivot Shaft Nut Swingarm Pivot Shaft B Right Swingarm Bracket C Clean the ABS hydraulic unit Clean all fittings on the ABS hydraulic unit and the rear master cylinder because dirt around the banjo bolts could contaminate the brake fluid in the line during removal installation Spread out a shop towel around the ABS hydraulic unit before removing the brake line so that brake fluid does not leak on the parts Free the hose A from the clamps 5 12 57 Anti Lock Brake System Equipped Models Remove the brake pipe joint nuts A with the flare nut wrench NOTE ORemove the brake hoses and pipes according to each assembly of the exploded view Tape the brake line opening to prevent brake fluid leakage or contamination by foreign matter NOTICE Brake fluid quickly ruins painted plastic surfaces any spilled fluid should be completely washed away immediately e Disconnect the connector A OPull the lever as shown e Remove ABS Hydraulic Unit Mounting Bolts A Dust Cover B ABS Hydraulic Unit C Remove Bolts A and Washers Bracket B The ABS hydraulic unit has been adjusted and set with precision at the factory Do not try to disas
267. e grease on the terminals to prevent corrosion e Run the cables correctly see Cable Wire and Hose Routing section in the Appendix chapter Install the positive cable first Cover the positive terminal with the cap Install the negative cable e Visually inspect the damper A on the seat bracket B x If the damper is damaged or deteriorated replace it Olnstall the damper so that the thicker side C faces down ward e Install Front Seat Bracket Front Seat see Front Seat Installation in the Frame chapter ELECTRICAL SYSTEM 16 23 Battery Battery Activation Electrolyte Filling 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 EX650E F YT12A BS Each battery comes with its own specific elec trolyte container using the wrong container may overfill the battery with incorrect electrolyte which can shorten battery life and deteriorate battery per formance Be sure to use the electrolyte container with the same model name as the battery since the electrolyte volume and specific gravity vary with the battery type 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 A DANGER Sulfuric acid in battery electrolyte can cause se
268. e lower end to the clutch cable holder Apply a non permanent locking agent to the clutch cable holder bolts Tighten Torque Clutch Cable Holder Bolts 9 8 N m 1 0 kgf m 87 in Ib e Install the idle speed adjusting screw holder e Tighten Torque Clutch Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib e Install the removed parts see appropriate chapters 6 9 Clutch Cover Release Shaft Removal Do not remove the clutch release lever and shaft assembly unless it is absolutely necessary If re moved the oil seal replacement may be required Remove the clutch cover see Clutch Cover Removal Pull the lever and shaft assembly A straight out of the clutch cover Release Shaft Installation e Apply grease to the oil seal lips on the upper ridge of the clutch cover Apply molybdenum disulfide grease to the pusher holding portion A on the release shaft Install the washer B and spring C GF05030BS1 e Insert the release shaft A straight into the upper hole of the clutch cover B When inserting the release shaft be careful not to remove the spring of the oil seal e Fit the spring ends C as shown in the figure Clutch Cover Disassembly e Remove Clutch Cover see Clutch Cover Removal Release Lever and Shaft Assembly see Release Shaft Removal Oil Seal A Needle Bearings B e Remove Oil Level Inspection Window A Timing Ins
269. e rear seat see Rear Seat Removal Slide out the dust cover A e Disconnect License Plate Light Lead Connector B Turn Signal Light Lead Connectors C OClear the leads from the hook D Remove the dust cover A from the leads e Remove Bolts B Screw C Remove the flap together with the reinforce Remove the following to separate the flap A from the reinforce B Bolts C and Collars Bolts D License Plate Bracket E Flap Installation Installation is the reverse of removal ORun the leads correctly see Cable Wire and Hose Rout ing section in the Appendix chapter 15 20 Fenders Rear Fender Removal e Remove Flap with Reinforce installed see Flap Removal Bolts A and Washers Left and Right Rear Brake Fluid Reservoir Mounting Bolt B and Washer e Clear the hook A from the frame to remove the rear fender B Rear Fender Installation Installation is the reverse of removal ORun the leads correctly see Cable Wire and Hose Rout ing section in the Appendix chapter 15 21 Frame Inspection e Visually inspect the frame for cracks dents bending or warp x If there is any damage to the frame replace it A WARNING A repaired frame may fail in use possibly causing an accident resulting in injury or death If the frame is bent dented cracked or warped replace it 15 22
270. e removed cable to chassis ground Connect the hand tester A and 12 V battery B to the starter relay C as shown Special Tool Hand Tester 57001 1394 Testing Relay Tester Range x 1 range Criteria When battery is connected 0 O When battery is disconnected x If the relay does not work as specified the relay is defec tive Replace the relay e Install the removed parts see appropriate chapters OTighten Torque Starter Relay Terminal Bolts 3 6 N m 0 36 kgf m 31 in Ib Pipes GP11229BS1 C Electric Starter System ELECTRICAL SYSTEM 16 53 Electric Starter Circuit Ton Pary Ipattery 0516 GP11230BW3 C Ignition Switch Engine Stop Switch Starter Button Neutral Switch Sidestand Switch Frame Ground Battery 12 V 10 Ah Main Fuse 30 A Starter Relay Starter Motor Relay Box Starter Circuit Relay Fuse Box Ignition Fuse 10 A Starter Lockout Switch 16 54 ELECTRICAL SYSTEM Lighting System This motorcycle adopt the daylight system and have a headlight circuit relay in the relay box The headlight does not go on when the ignition switch and the engine stop switch are first turned on The headlight comes on after the starter button is released and stays on until the ignition switch is turned off The headlight will go out mome
271. e text ELECTRICAL SYSTEM 16 11 Special Tools and Sealants Hand Tester 57001 1394 7571394ST C Flywheel Puller Assembly M38 x 1 5 M35 x 1 5 57001 1405 5 7571405ST C Peak Voltage Adapter 57001 1415 4 875714155 C Lead Wire Peak Voltage Adapter 57001 1449 7571449ST C Needle Adapter Set 57001 1457 5157145751 C Grip 57001 1591 7571591ST C Rotor Holder 57001 1567 7571567ST C Extension Tube 57001 1578 7571578ST C Rotor Holder 57001 1658 5157165851 Stopper 57001 1679 5157167951 6 16 12 ELECTRICAL SYSTEM Special Tools and Sealants Liquid Gasket TB1211 56019 120 875601205 Liquid Gasket TB1211F 92104 0004 879200045 ELECTRICAL SYSTEM 16 13 Parts Location This page intentionally left blank 16 14 ELECTRICAL SYSTEM Parts Location Parts Location Regulator Rectifier Water Temperature Sensor Starter Relay with Main Fuse Battery 12 V 10 Ah Speed Sensor Sidestand Switch Neutral Switch Oxygen Sensor Equipped Models Alternator Turn Signal Relay Radiator Fan Motor ECU Relay Box Starter Lockout Switch Ignition Switch Meter Unit Front Brake Light Switch Air Switching Valve Stick Coils Starter Motor Crankshaft S
272. e the front wheel off the ground with the jack Special Tool Jack 57001 1238 e Turn the handlebar all the way to the right or left Inspect the roughness of the front wheel bearing by push ing and pulling A the wheel Spin B the front wheel lightly and check for smoothly turn roughness binding or noise If roughness binding or noise is found remove the front wheel and inspect the wheel bearing see Front Wheel Removal Hub Bearing Inspection in the Wheels Tires chapter e Raise the rear wheel off the ground with the stand see Rear Wheel Removal in the Wheels Tires chapter Inspect the roughness of the rear wheel bearing by push ing and pulling A the wheel Spin B the rear wheel lightly and check for smoothly turn roughness binding or noise x If roughness binding or noise is found remove the rear wheel and inspect the wheel bearing see Rear Wheel Re moval Hub Bearing Inspection in the Wheels Tires chap ter and coupling see Coupling Bearing Inspection in the Final Drive chapter Final Drive Drive Chain Lubrication Condition Inspection e a special lubricant is not available a heavy oil such as SAE 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication e f the chain appears especially dirty clean it before lubri cation The O rings between the side plates seal in the lu bricant between the pin and the bushing To avoid damag
273. e with handlebar move ment see Cable Wire and Hose Routing section in the Appendix chapter e Install the removed parts see appropriate chapters Steering Stem Bearing Lubrication e Refer to the Steering Stem Bearing Lubrication in the Pe riodic Maintenance chapter Steering Stem Warp Inspection e Whenever the steering stem is removed or if the steering can not be adjusted for smooth action check the steering stem for straightness x If the steering stem A is bent replace it 6515011851 C GNOS112BS1 14 10 STEERING Steering Stem Stem Cap Deterioration Damage Inspection Inspect the stem cap Replace the stem cap if its oil seal A shows damage Handlebar STEERING 14 11 Handlebar Removal Remove Clutch Lever Clamp Bolts A and Washers Clutch Lever Assembly B Left Switch Housing C Handlebar Weight D Left Handlebar Grip E e Remove Front Master Cylinder A see Front Master Cylinder Re moval in the Brakes chapter Right Switch Housing B Handlebar Weight C Throttle Grip D e Remove Handlebar Holder Bolts A Upper Handlebar Holder B Handlebar C Remove the lower handlebar holders A as necessary ORemove Snap Pins B Handlebar Holder Mounting Nuts C Washers D Lower Handlebar Holders Dampers Handlebar Installation If the lower handlebar holders were removed install them OReplace the handlebar holder m
274. easure Seat Width Tool Vernier Caliper Purpose check seat width against spec Too narrow Too wide 45 Grind Tool 45 Cutter Purpose increase width of seat area beyond spec to increase O D Machinist s dye on seat 60 or 55 Grind Tool 60 Cutter Purpose reduce seat width to specification Lap Valve Tools Valve Lapper Grinding Compound Purpose perfectly match valve FINISHED and seat area check valve head for damage Cylinder Pistons ENGINE TOP END 5 37 Cylinder Removal e Remove Cylinder Head see Cylinder Head Removal Front Engine Mounting Bolts A and Nuts Left and Right Collar B Cylinder C Cylinder Installation NOTE Olf a new cylinder is used use new piston ring Be sure that the dowel pins A are in position Install a new cylinder gasket 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 Dent E 30 40 F Apply molybdenum disulfide oil solution to the cylinder bore piston rings and piston skirt Prepare two auxiliary head bolts A with their head cut Olnstall the two bolts diagonally in the crankcase e Position the crankshaft so that the piston heads are al most level Install the cylinder block Olnsert the pi
275. ectly x If the rotor is pulled out with under 20 N m 2 0 kgf m 15 ft lb of drawing torque clean off any oil dirt or flaw of the crankshaft and rotor tapered portion and dry them with a clean cloth Then confirm that it is not pulled out with above torque e Reinstall the rotor bolt and washer e Tighten the alternator rotor bolt while holding the alterna tor rotor steady with the rotor holder Special Tools Grip 57001 1591 Rotor Holder 57001 1658 Stopper 57001 1679 Torque Alternator Rotor Bolt 155 Nm 15 8 kgf m 114 ft Ib Apply a thin coat of molybdenum disulfide grease to the shafts A and install them e Install the torque limiter B and starter idle gear C Install the alternator cover see Alternator Cover Installa tion Alternator Inspection There are three types of alternator failures short open wire burned out or loss in rotor 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 ELECTRICAL SYSTEM 16 33 Charging System To check the alternator output voltage do the following procedures OTurn the ignition switch to OFF ORemove the left frame cover see Frame Cover Removal in the Frame chapter OPull out the alternator lead connector A
276. ed by the number of times the yellow ABS indicator light LED blinks The service codes stored in memory are not erased until the mode has been changed to the fault erase mode after the fault has been corrected Therefore after correcting the problem always erase the service codes and then run the self diagnosis pro gram to confirm normal signal output When due to a mal function the yellow ABS indicator light LED stays on get a thorough understanding of the background before starting the repair work Ask the rider about the conditions B under which the problem occurred and try to determine the cause C Do not rely solely on the ABS self diagnosis function use common sense check the brakes for proper braking power and brake fluid level search for leaks etc If the yellow ABS indicator light LED blinks when the ignition switch is turned to ON or the motorcycle is running ABS system does not function In this case the voltage of the battery is extremely low GC17205FS1 Anti Lock Brake System Equipped Models BRAKES 12 37 Even when the ABS is operating normally the yellow ABS indicator light LED may go on under the conditions listed below Turn the ignition switch to OFF to stop the yel low ABS indicator light LED If the motorcycle runs with out erasing the service code the yellow ABS indicator light LED may go on again OAfter continuous riding on a rough road OWhen the engine is started with
277. ed in the order of 56 14 31 the service codes are displayed each two seconds from the lowest number in the order listed as shown below 14 31 56 14 31 56 repeated 6C17208FW2 Olf there is no problem or when the repair has been done the yellow engine warning indicator light LED goes off and service code is not displayed Service Code Erasing OWhen repair has been done the yellow engine warning indicator light LED goes off and service code is not displayed But the service codes stored in memory of the ECU are not erased to preserve the problem history In this model the problem history can not be erased 3 38 FUEL SYSTEM DFI Self Diagnosis Service Code Table Service Code Problems 11 Main throttle sensor malfunction wiring open or short 12 Intake air pressure sensor malfunction wiring open or short 13 Intake air temperature sensor malfunction wiring open or short 14 Water temperature sensor malfunction wiring open or short 21 Crankshaft sensor malfunction wiring open or short 24 Speed sensor malfunction wiring open or short 31 Vehicle down sensor malfunction wiring open or short 32 Subthrottle sensor malfunction wiring open or short 33 Oxygen sensor inactivation wiring open or short Equipped models 39 ECU communication error 51 Stick Ignition coil 1 malfunction wiring open or short 52 Stick Ignition coil 2 malfunction
278. ed 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 dards d Permanently removing disconnecting or rendering inoperative any component or element of design of the emission control systems WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING 10 000 PER VIOLATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in us
279. ee chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect Inspect see chapter 3 see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect and adjust see chapter 2 Inspect see chapter 3 Inspect see chapter 3 Intake air temperature sensor trouble Inspect see chapter 3 Engine stalls easily Spark plug dirty broken or gap maladjusted Inspect and replace see chapter 2 Stick coil trouble Inspect see chapter 16 Main throttle sensor trouble Inspect see chapter 3 Subthrottle sensor trouble Inspect see chapter 3 Subthrottle valve actuator trouble Inspect see chapter 3 Intake air pressure sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Intake air temperature sensor trouble Inspect see chapter 3 Fuel pump trouble Inspect see chapter 3 Fuel injector trouble Inspect see chapter 3 Fuel pressure too low or too high Inspect see chapter 3 Fuel pressure regulator trouble Fuel line clogged Poor acceleration Fuel pressure too low Water or foreign matter in fuel Fuel filter or pump screen clogged Fuel pump trouble Fuel injector trouble Main throttle sensor trouble Inspect fuel pressure and replace fuel pump see cha
280. el Pump see Fuel Pump Installation Fuel Tank see Fuel Tank Installation 3 114 FUEL SYSTEM Evaporative Emission Control System CAL SEA B1 and TH Models The Evaporative Emission Control System routes fuel va pors from the fuel system into the running engine or stores the vapors 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 to 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 If gasoline solvent water or any other liquid enters the canister the canister s vapor absorbing capac ity is greatly reduced If the canister does become contaminated replace it with a new one Connect the hoses according to the diagram of the sys tem see Cable Wire and Hose Routing section in the Appendix chapter Make sure they do not get pinched or kinked Hose Inspection Refer to the Evaporative Emission Control System In spection in the Periodic Maintenance chapter Purge Valve Inspection e Refer to the Purge Valve Inspection Canister Inspection Refer to the Evaporative Emission Control System In spection in the
281. elay Inspection e Refer to the Relay Circuit Inspection in the Electrical Sys tem chapter xIf the radiator fan relay is normal check the wiring for continuity see wiring diagram in this section xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the see Removal Installation Radiator Fan Relay Circuit ou 62162 GCi7186FW2 1 Ignition Switch 8 Main Fuse 30 A 2 Fan Motor 9 Relay Box 3 Joint Connector D 10 Radiator Fan Relay 4 Water Temperature Sensor 11 Fuse Box 1 5 ECU 12 Radiator Fan Fuse 15A 6 Frame Ground 13 Ignition Fuse 10 A T Battery 12 V 10 Ah FUEL SYSTEM DFI 3 73 Subthrottle Valve Actuator Service Code 62 Subthrottle Valve Actuator Removal NOTICE Do not remove the subthrottle valve actuator A since it has been adjusted and set with precision at the factory Never drop the throttle body assy especially on a hard surface Such a shock to the actuator can damage it Subthrottle Valve Actuator Inspection NOTE OBe sure the battery is fully charged Remove the air cleaner housing see Air Cleaner Housing Removal Turn the ignition switch to ON Check to see that the subthrottle valves A open and close smoothly x If the subthrottle valves do not operate check the
282. em chapter Remove the spark plugs using the 16 mm 0 63 in plug wrench A vertically Replace the spark plugs with new ones Standard Spark Plug Type CR9EIA 9 Insert the spark plug A into the plug wrench Install the spark plug into the plug hole and hand tighten it first The insulator of the spark plug may break if when the wrench is inclined during tightening Tighten Torque Spark Plugs 15 N m 1 5 kgf m 11 ft Ib Install the stick coils securely OPull the stick coils lightly to check the installation condi tion e Run the leads correctly see Cable Wire and Hose Rout ing section in the Appendix chapter e Install the other removed parts see appropriate chap ters FUEL SYSTEM 3 1 Fuel System DFI Table of Contents Exploded VIeW ee eet hee eR epe ted rea HER P Death 3 4 DOE 3 10 DEL Parts Location iie teat en tec b a RESP RERUMS 3 15 Specifications ici er e tek e RR ERR doer een e RR a e 3 17 Special Tools and Sealant eiren pori e ee epe nde o aO e t e e RUE e v en 3 19 DFI Servicing Precautions pp 3 21 DFilServicing Precautions noinine C ES 3 21 Troubleshooting the DFI System pp 3 23 3 23 to LEES 3 27 DFI System Troubleshooting Guide pp 3 29 SNB pM T 3 34 Selfolagnosls ccm 3 34 Self
283. ensor Oil Pressure Switch Rear Brake Light Switch ELECTRICAL SYSTEM 16 15 16 16 ELECTRICAL SYSTEM Wiring Diagram EX650E Model Right Switch Housing Front Brake Light Switch 2 Engine Stop Switch Starter Button Spark Plugs Horn Fan 1 12 3 Motor S uud Hu a E EE 55 5 Regulator Speed Rectifier Sensor Air Switching Valve 3 Blue High Beam Indicator Light LEB Green Neutral Light LED Yellow Engine Warning Indicator Light LED 1011 Pressure Battery Water Temperature Warning Indicator Light LED ll lumimatoe Light LED Speedneter Tachometer 0 0dometer Trip Meter Wileage Cruising Range 1 Clock 2 Fuel Indicator Level Gauge LED Light Emitting Diode js BR Wodel BATIERY 422 d L Ton Ignition a en BR Switch BATIERY x Y wets ay ay 1965 aL Meter Unit iaa 1 Green Left Turn Signal Indicator Light LED 2 Green Right Turn Signal Indicator Light LED Joint Connector Front Right 8 Turn Signal Light 12V10W dl Right City Light 12V5W Bids Headlight HI BK 8K Y BK Y BK Y AT R BK 12 55 BK Y Yy i T 2
284. er Horn Fan 5 12VY3A Motor S uud Air i mm Soils Switching Valve Spark Plugs a BK BK R 19 BR Y BL R BR W 8 BK R R BL BL 16 8 Ignition GRIT IGN oa ISTGNAL Switch Meter Unit 1 Yellow ABS indicator Light LEB 2 reen Left Turn Signal Indicator Light LED 3 Green Right Turn Signal Indicator Light LED 4 High Beam Indicator Light LED Green Neutral Indicator Light LED 6 Yellow Engine Warning Indicator Light LED 1 011 Pressure Battery Water Temperature Warning Indicator Light LED 8 1 lumimatoe Light LED 9 Speedmater i i D Tachometer 1 Odometer Trip Meter Wileage Cruising Range 2 Glock 3 Fuel Level Gauge Front Wheel Rotation Quar H H 3 a H BR Wodel BATTERY 909 ELeNAL ng E LIBERIS za HI 4 mu Lu ies LED Light Emitting Diode Joint Senoeetet AT Front Right Turn Signal e Light 12 10 pi Right City Light 12V5W Headlight HI 12V559 Headlight LO 12 55 90 Left City Light 12V5W Front Left Turn Signal L
285. er or outer fork tube may fall in use possibly causing an accident resulting in seri ous injury or death Replace a badly bent or dam aged inner or outer tube and inspect the other tube carefully before reusing it Dust Seal Inspection Inspect the dust seal A for any signs of deterioration or damage x If necessary replace the dust seal with a new GM04300BS1 GM04301BS1 GM04128BS1 C 13 14 SUSPENSION Spring Tension Inspection Since spring becomes shorter as it weakens check its free length A to determine its condition x If the spring of either fork leg is shorter than the service limit replace it with a new one If the length of a 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 for motorcycle stability Spring Free Length Standard 301 3 mm 11 86 in Service Limit 295 mm 11 61 8 04011851 C Rear Shock Absorber SUSPENSION 13 15 Spring Preload Adjustment e Using the hook wrench A turn the adjusting nut B to adjust the spring preload OThe standard adjuster setting is 3rd position Spring Preload Setting Standard Position 3rd position Adjustable Range 1st to 7th position e f the compression of the spring is not suited to the op erating conditions a
286. er running durability is obtained by perma nent internal repairs than by temporary external ones Also permanent internal repairs have the advantage of permitting a thorough examination for secondary damage not visible from external inspection of the tire For these reasons Kawasaki does not recommend temporary exter nal repair Only appropriate permanent internal repairs are recommended Repair methods may vary slightly from make to make Follow the repair methods indicated by the manufacturer of the repair tools and materials so that safe results can be obtained n 6J05042BS1 C 10 16 WHEELS TIRES Hub Bearing Hub Bearing Removal e Remove the wheels see Front Rear Wheel Removal and take out the following Collars Coupling Out of rear hub Grease Seals e Use the bearing remover to remove the hub bearings A Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place wooden blocks under the wheel so that the disc does not touch the ground Special Tools Bearing Remover Head 20 x 022 57001 1293 Bearing Remover Shaft 13 C 57001 1377 Hub Bearing Installation e Before installing the hub bearings blow any dirt or foreign particles out of the hub with compressed air to prevent contamination of the bearings e Replace the bearings with new ones NOTE Olnstall the bearings so that the marked side faces out e Install the bearings by usin
287. eriodic Maintenance chapter Remove Water Hose A Water Pump Cover Bolts B Water Pump Cover C Shift the transmission into 1st gear While applying the rear brake remove the water pump impeller bolt A and washer Remove Impeller B Water Pump Housing C Water Pump Installation Replace the O rings A on the water pump housing with new ones Replace the water pump housing oil seal B with a new one and install it see Water Pump Housing Assembly e Be sure that the dowel pin A is in position e Install the water pump housing Install the impeller OApply water to the inside of the mechanical seal e Put the washer on the water pump impeller bolt Tighten Torque Water Pump Impeller Bolt 9 8 N m 1 0 kgf m 87 in Ib e Replace the O ring A on the water pump cover with a new one and apply grease to it Water Pump COOLING SYSTEM 4 11 Be sure that the dowel pins A are in position Install the water pump cover and the bolts A L 40 mm 1 6 in B L 30 mm 1 2 in Tighten Torque Water Pump Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib e When installing the water hose align the white paint mark A with the line B on the water pump cover e Install the water hose clamp C so that the screw head faces the front e Tighten Torque Water Hose Clamp Screws 3 0 N m 0 31 kgf m 27 in Ib e Fill the radiator with coolant see C
288. et Hook Hold the rear brake light switch lead and the crankshaft sensor lead Fix the clamp to the frame under the frame cross pipe Run the crankshaft sensor lead along the clutch cover Rear Brake Light Switch NOOR WD 17 20 APPENDIX Cable Wire and Hose Routing Cer er 4 68008320 6 APPENDIX 17 21 Cable Wire and Hose Routing Fix the fuel pump lead connector upper and the alternator lead connector lower to the bracket Canister Purge Valve Run the harness in front of the tube purge valve canister Clamp Hold the following alternator lead speed sensor lead sidestand switch lead oxygen sensor lead 6 Sidestand Switch Lead Connector 7 Speed Sensor Lead Connector 8 Fuel Tank Breather Hose 9 0 QI CN Fuel Drain Hose Run the breathertube outside the sidestand switch lead other than CAL SEA B1 and TH mod els 11 Clamp Hold the breather tube and the fuel drain hose 12 Sidestand Switch Lead 13 Oxygen Sensor Lead Equipped Models 14 Clamp From outside to inside hold the following fuel drain hose oxygen sensor lead side stand switch lead 15 Clamp Hold the following breather tube fuel drain hose alternator lead speed sensor lead oxygen sensor lead CAL SEA B1 and TH Models 17 22 APPENDIX Cable Wire and Hose Routing The routing on EX650E F is shown using the figure of ER650E F 68098760 6
289. ext step Disassemble the starter motor clutch see Starter Motor Clutch Disassembly e Visually inspect the clutch parts x If there is any worn or damaged part replace it NOTE OExamine the starter motor clutch gear as well Replace it if it worn or damaged Starter Motor Clutch Disassembly e Remove Alternator Rotor see Alternator Rotor Removal Starter Motor Clutch Bolts A e Remove the starter motor clutch A Starter Motor Clutch Assembly e Assembly is the reverse of disassembly OApply a non permanent locking agent to the threads of the starter motor clutch bolts and tighten them Torque Starter Motor Clutch Bolts 34 N m 3 5 kgf m 25 ft lb ELECTRICAL SYSTEM 16 39 Ignition System A WARNING The ignition system produces extremely high volt age Do not touch the spark plug ignition coil or ig nition coil lead while the engine is running or you could receive a severe electrical shock NOTICE 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 ECU Crankshaft Sensor Removal Remove Right Frame Cover see Frame Cover Removal in the Frame chapter Crankshaft Sensor Lead Connector A Disconnect Right Middle Fairing see M
290. f the specification check the follow ing Main Fuse 30 A or Fuse Box Fuse see Fuse Inspection in the Electrical System chapter ECU Main Relay see Relay Circuit Inspection in the Electrical System chapter Power Source Wiring see wiring diagram in this sec tion xIf the fuse wiring and relay are good replace the ECU see ECU Removal Installation O OCR 26 GC17295DS1 C GC17296DS1 C 3 88 FUEL SYSTEM DFI ECU Power Source Circuit ECU Frame Ground 1 Frame Ground 2 Battery 12 V 10 Ah Main Fuse 30 A Relay Box ECU Main Relay Fuse Box 1 FI Fuse 15 A Ignition Fuse 10 A Ignition Switch BK Y BK Y BK W 8K GCci7190FW2 C DFI Power Source FUEL SYSTEM DFI 3 89 ECU Fuse Removal e Refer to the 15 ECU Fuse Removal in the Electrical System chapter ECU Fuse Installation x If a fuse fails during operation inspect the DFI system to determine the cause and then replace it with a new fuse of proper amperage e Refer to the Fuse Installation in the Electrical System chapter ECU Fuse Inspection e Refer to the Fuse Inspection in the Electrical System chapter ECU Main Relay Removal Installation OThe ECU main relay is built in the relay box A e Refer to the Relay Box Removal in the Electrical System chapter ECU Main Relay Inspection e Refer to the Relay Ci
291. fairing see Middle Fairing Re moval in the Frame chapter e Disconnect the connector A e Using an auxiliary leads supply the battery power to the fan motor x If the fan does not rotate the fan motor is defective and replace it Radiator Fan Circuit BK Y BR W WABK BK Y 2 SIG EE E GP15123BW3 C 1 Ignition Switch 8 Main Fuse 30 2 Radiator Fan 9 Relay Box 3 Joint Connector D 10 ECU Main Relay 4 Water Temperature Sensor 11 Radiator Fan Relay 5 ECU 12 Fuse Box 6 Frame Ground 13 Ignition Fuse 10 A 7 Battery 12 V 10 Ah 14 Fan Fuse 15 A Meter Gauge Indicator Unit ELECTRICAL SYSTEM 16 65 Meter Unit Removal e Remove Left Upper Inner Fairing see Upper Inner Fairing Re moval in the Frame chapter Remove the screws A and washers B to separate the meter unit from the left upper inner fairing C NOTICE Place the meter unit so that the face is up If ameter unit is left upside down or sideways for any length of time it will malfunction Meter Unit Installation Installation is the reverse of removal Meter Gauge Disassembly Remove Meter Unit see Meter Unit Removal Screws A Upper Meter Case e Remove Screws A and Washers Screws B Separate the meter assembly C and lower meter case 8 179200651 16 66 ELECTRICAL SYSTEM Meter Gauge Ind
292. fective Replace it x If the regulator rectifier passes all of the tests described it may still be defective If the charging system still does not work properly after checking all of the components and the battery test the regulator rectifier by replacing it with a known good unit e Installation is the reverse of removal OTighten Torque Regulator Rectifier Bolts 9 8 N m 1 0 kgf m 87 in Ib Baffle Plate Bolts 5 9 N m 0 60 kgf m 52 in Ib 8 10000451 C 8 10000551 C 8 10000851 C 16 36 ELECTRICAL SYSTEM Charging System Charging Voltage Inspection e Check the battery condition see Charging Condition In spection e Warm up the engine to obtain actual alternator operating conditions Check that the ignition switch is turned to OFF and con nect the hand tester A to the battery terminals B Special Tool Hand Tester 57001 1394 e Start the engine and note the voltage readings at var ious engine speeds with the headlight turned on and then turned off To turn off the headlight disconnect the headlight connector on the headlight unit The readings should show nearly battery voltage when the engine speed is low and as the engine speed rises the readings should also rise But they must be kept under the specified voltage Charging Voltage Tester Range Reading Tester to Tester to 25 V DC Battery Battery 13 9 14 9 V e Turn the igni
293. from the clamps B For models equipped with an ABS remove the rear wheel rotation sensor see Rear Wheel Rotation Sensor Re moval in the Brakes chapter e Remove Rear Wheel see Rear Wheel Removal the Wheels Tires chapter Drive Chain see Drive Chain Removal in the Final Drive chapter 13 18 SUSPENSION Swingarm Support the frame using the jack Special Tool Jack 57001 1238 Remove the following parts and remove the swingarm Rear Shock Absorber Mounting Bolt Lower Nut Collar and Washer Swingarm Pivot Shaft Nut Swingarm Pivot Shaft Swingarm Installation Installation is the reverse of removal OApply grease to the lip of the oil seals A sure to install the oil seals and collar B to the swingarm C Left Side D Right Side Olnstall the swingarm A OBy the following specified sequence tighten the bolts and nuts OTighten Torque Swingarm Pivot Shaft Nut B 108 N m 11 0 kgf m 80 ft lb Swingarm Bracket Bolts C 44 4 5 kgf m 32 ft Ib Swingarm Bracket Bolt D 44 N m 4 5 kgf m 32 ft lb Swingarm Bracket Bolt E 59 N m 6 0 kgf m 44 ft lb Install the removed parts see appropriate chapters Swingarm Bearing Removal Remove Swingarm see Swingarm Removal Collar A Oil Seals B Sleeves C Circlip D Special Tool Inside Circlip Pliers 57001 143 GM06214BS1 GM06216BS2 C Swingarm SUSPENSION 13 19
294. from the start code once again Start Last service Fifth service code 12 code stored code stored L Olf there is no fault only the start code is shown Repeat Indication of Service Gode Exp 1 Start Code 12 5 Start Code 12 Yellow ABS 10th a Exp 2 Service Code 13 and 42 are shown RP Start Sta Indicator digit digit Light LED 0 6 0 35 Code 12 Cod a m r ON 1 Ignition 13 08 11113 38 3 38 Switch to 0 65 0 35 ON 0 9s Yellow ABS Service Indicator Start Gode 13 Light LED Code 12 0 65 0 3s ON rc E 2 Ignition 13 08 11113 38 1 3 38 Switch 0 65 0 35 0 950 35 ON 0 95 Second service First service code stored code stored 05114016841 C 2 222 is normal is shown Start Code 12 rt e 12 Service Code 42 any 4 more service codes 0 65 0 3s Fog om 0 35 0 95 0 65 81145968842 C How to Erase Service Codes OEven if the ignition switch is turned OFF the battery or the ABS hydraulic unit are disconnected all service codes remain in the ABS hydraulic unit ORefer to the Service Code Clearing Procedure for the service code erasure BRAKES 12 45 Anti Lock Brake System Equipped Models Service Code Table Service Code
295. ft Side E Right Side F 6J04074BS1 C 6J04088BS1 C Tires WHEELS TIRES 10 13 Air Pressure Inspection Adjustment Refer to the Air Pressure Inspection in the Periodic Main tenance chapter Tire Inspection Refer to the Wheel Tire Damage Inspection in the Peri odic Maintenance chapter Tire Removal e Remove Wheels see Front Rear Wheel Removal Valve Core Let out the air To maintain wheel balance mark the valve stem position on the tire with chalk so that the tire can be reinstalled in the same position Chalk Mark or Yellow Mark A Air Valve B Align C Lubricate the tire beads and rim flanges on both sides with a soap and water solution or rubber lubricant This helps the tire beads slip off the rim flanges NOTICE Never lubricate with engine oil or petroleum distil lates because they will deteriorate the tire 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 Some replacement tires may adversely affect han dling and cause an accident resulting in serious in jury or death To ensure proper handling and sta bility use only the recommended standard tires for replacement inflated to the standard pressure Inspect the rim and tire and replace them if necessary Clean the sealing surface
296. g it toward the left B noting the baffle plate C on the cylinder head cover Do not touch the radiator core This could damage 24 o the radiator fins resulting loss of cooling effi ciency e Remove Radiator Fan Mounting Bolts A Radiator Fan B 4 14 COOLING SYSTEM Radiator Radiator and Radiator Fan Installation e Install the radiator fan A and tighten the bolts e Install the rubber dampers B and collar C to the radiator and frame Install the radiator so that the projections on the frame fit into the holes E on the dampers ONote the baffle plate on the cylinder head cover when installing the radiator Tighten Torque Radiator Bolt 7 9 N m 0 81 kgf m 70 in Ib e Position the reserve tank hose clamp G so that its pinch heads faces downward Install the water hose clamps H as shown in the figure Tighten Torque Water Hose Clamp Screws 3 0 N m 0 31 kgf m 27 in Ib Fill the radiator with coolant see Coolant Change in the Periodic Maintenance chapter GD07105BW3 C Radiator COOLING SYSTEM 4 15 Radiator Inspection Remove the radiator see Radiator and Radiator Fan Re moval e Inspect the radiator core x If there are obstructions to air flow remove them the corrugated fins A are deformed carefully straighten them x If the air passages of the radiator core are blo
297. g the bearing driver set which does not contact the bearing inner race e Press in each bearing A right until they are bottomed Special Tool Bearing Driver Set B 57001 1129 e Replace the grease seals with new ones e Press in the grease seals A so that the seal surface is flush B with the end of the hole OApply high temperature grease to the grease seal lips Special Tool Bearing Driver Set C 57001 1129 Hub Bearing Inspection Since the hub bearings are made to extremely close tol erances the clearance can not normally be measured NOTE ODo not remove any bearings for inspection If any bear ings are removed they will need to be replaced with new ones e Turn each bearing in the hub back and forth A while checking for plays roughness or binding x If 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 GJ06043BS1 6J06008BS1 C 6J06008BS1 C 6J06002BS1 C WHEELS TIRES 10 17 Hub Bearing Hub Bearing Lubrication NOTE OSince the hub bearings are packed with grease and sealed lubrication is not required FINAL DRIVE 11 1 Final Drive Table of Contents Exploded VIEW ieee oot ee E 11 2 Ex 11 4 Special TOONS
298. g the stan dard level xIf no 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 Fork Spring A Fork Spring Seat B Spacer C e Replace the top plug O ring with a new one Apply grease to the top plug O ring e Install Top Plug Front Fork see Front Fork Installation Front Fork Disassembly e Remove Front Fork see Front Fork Removal Top Plug A with O ring Spacer B Fork Spring Seat C Fork Spring D e Drain the fork oil see Front Fork Oil Change e Remove the fork bottom Allen bolt A and gasket from the bottom of the fork Special Tools Fork Cylinder Holder Handle B 57001 183 Fork Cylinder Holder Adapter C 57001 1057 NOTE OHold the outer tube in a vise D stop the cylinder unit E from turning by using the special tools and unscrew the Allen bolt GM04303BS2 C 8 04040451 C 8 04040251 GM04298BS1 SUSPENSION 13 11 Front Fork Remove the cylinder unit A washer B and the spring C from the inner tube Remove the following from the top of the outer tube Dust Seal A Retaining Ring B Separate the inner tube A from the outer tube B NOTE OFrom the compressed state firmly pull down the outer tube a few times towards the direction of elongation e Remove the following from the
299. gent to the camshaft sprocket bolts and tighten them Torque Camshaft Sprocket Bolts 15 N m 1 5 kgf m 11 ft Ib e Apply molybdenum disulfide oil solution to all cams A journals B and thrust blocks C with x marks 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 2412 EX mark D and the intake camshaft has a 2412 IN mark E Be careful not to mix up these shafts GE11207BS1 U 9 E ye LE 603 55555429 Th 7 7 00009 E 554 ET E L3 GE 11538W2 C 5 22 ENGINE END Camshaft Camshaft Chain Using a wrench on the timing rotor bolt A turn the crank shaft clockwise until the 2 T mark line B on the timing rotor is aligned with the notch C in the edge of the timing inspection hole in the clutch cover The crankshaft may be turned while the camshafts are removed Always pull the chain taut while turn ing the crankshaft This avoids kinking the chain on the lower crankshaft sprocket A kinked chain could damage both the chain and the sprocket If the clutch cover is removed perform the next proce dure OUsing a wrench on the timing rotor bolt turn the crank shaft clockwise until the 1 T mark line A on the timing ro
300. ground and power supply If the ground and power supply are checked good replace the ECU Engine Won t Turn Over Symptoms or Possible Causes Actions Neutral starter lockout or sidestand switch Inspect each switch see chapter 16 trouble Vehicle down sensor operated Turn the ignition switch to OFF see chapter 3 Vehicle down sensor trouble Inspect see chapter 3 Crankshaft sensor trouble Inspect see chapter 16 Stick coil shorted or not in good contact Inspect or Reinstall see chapter 16 Stick coil trouble Inspect see chapter 16 Spark plug dirty broken or gap maladjusted Inspect and replace see chapter 2 Spark plug incorrect Replace it with the correct plug see chapter 2 ECU ground and power supply trouble Inspect see chapter 3 ECU trouble Inspect see chapter 3 Inspect and replace see chapter 3 inspect see chapter 3 Inspect and replace see chapter 3 Fuel filter or pump screen clogged Inspect and replace fuel pump see chapter 3 Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump see chapter 3 Fuel line clogged Inspect and repair see chapter 3 Poor Running at Low Speed Symptoms or Possible Causes Spark weak De el Stick coil shorted or not in good contact Inspect or Reinstall see chapter 16 Stick coil trouble Inspect see chapter 16 Spark plug dirty broken or gap maladjusted Inspect and replace see chapter 2
301. h Disassembly Starter Motor Clutch Assembly pp Ignition ciim E Crankshaft Sensor 9 Crankshaft Sensor Installation pp Crankshaft Sensor 8 Crankshaft Sensor Peak Voltage Inspection 16 40 TMN IP 16 41 Timing Rotor Installations 16 41 Stek Co Re OVA tert usted aaa 16 41 Stick Coil Installation 16 41 SUCK COM Inspection to Rc dedere Re ie Tee REEL RE 16 42 Stick Coil Primary Peak Voltage 16 42 Spark Pl g Removal insta dto Ea 16 43 Spark Plug installat OT E eon ie Pd etai 16 43 Spark Plug Condition Inspection 2 16 43 Interlock Operation 16 44 IC Igriiter Ins pecllOFt is o iare cde ge Ae Deans 16 44 EIGCUIC SlAMMen 16 47 Starter Motor Removal nre Eee cereo so eon eter ead era lere PE EP EE eeu 16 47 16 2 ELECTRICAL SYSTEM Starter Motor Installation tie Fu tetris lel 16 47 Starter Motor Disassermbly a uii cuore ne Decent ceded wine era er ee 16 48 Starter
302. h to run position e Turn the ignition switch to ON The fuel pump will turn 3 seconds and then stop NOTE the ignition switch to ON and inspect the fuel line leakage after installing the special tools Do not drive the fuel pump 3 seconds or more with out the fuel in the fuel tank If the fuel pump is driven without the fuel it may be damaged e Start the engine and let it idle e Measure the fuel pressure with the engine idling Fuel Pressure with Engine Idling Standard 294 kPa 3 0 kgf cm 43 psi Fuel Line FUEL SYSTEM DFI 3 91 NOTE OThe gauge needle will fluctuate Read the pressure at the average of the maximum and minimum indications e Turn the ignition switch to OFF x If the fuel pressure is much higher than specified the fuel pressure regulator in the fuel pump have been clogged or stuck Replace the fuel pump see Fuel Pump Re moval Installation x lf the fuel pressure is much lower than specified check the following Fuel Line Leakage see Fuel Injector Fuel Line Inspec tion Amount of Fuel Flow see Fuel Flow Rate Inspection e After above checks measure the fuel pressure again e Remove the fuel pressure gauge hoses and adapter Install Fuel Hose see Fuel Hose Replacement in the Periodic Maintenance chapter Fuel Tank see Fuel Tank Installation Start the engine and check for fuel leakage Fuel Flow Rate Inspection A WARNING Gasoline is extremely flam
303. he engine ground lead A as shown 45 55 B Front C e Tighten Torque Engine Ground Lead Terminal Bolt 9 8 N m 1 0 kgf m 87 in Ib e Install the removed parts see appropriate chapters e Fill the engine with engine oil see Engine Oil Change in the Periodic Maintenance chapter e Fill the engine with coolant and bleed the air from the cool ing system see Coolant Change in the Periodic Mainte nance chapter e Adjust Throttle Cables see Throttle Control System Inspection in the Periodic Maintenance chapter Clutch Cable see Clutch Operation Inspection in the Pe riodic Maintenance chapter Drive Chain see Drive Chain Slack Adjustment in the Periodic Maintenance chapter Idle Speed see Idle Speed Adjustment in the Periodic Maintenance chapter GH04186BS1 C CRANKSHAFT TRANSMISSION 9 1 Crankshaft Transmission Table of Contents Exploded PLI Specifications LE Special Tools and Each aet abeo dori dita eda etit i add ose E H GCrankcase ASSemibly cesse f bebe e iei honed ated ea AE e Crankshaft and Connecting tries Crankshaft Crankshaft Installation ie ee fee Leo Tere babe tau de DR RR ER Connecting Rod Removal
304. he gear position in the neutral position e Turn the engine stop switch to stop position A e Push the starter button B e The engine should not start x lf the engine starts inspect or replace the following item Engine Stop Switch see Switch Inspection in the Elec trical System chapter Second Step e Turn the ignition switch to ON e Set the gear position in the neutral position e Turn the engine stop switch to run position A e Push the starter button B and run the engine e Turn the engine stop switch to stop position e Immediately the engine should stop x If the engine does not stop inspect or replace the follow ing item Engine Stop Switch see Switch Inspection in the Elec trical System chapter x If the engine stop switch is in good condition replace the ECU see ECU Removal Installation in the Fuel System DFI chapter 2 44 PERIODIC MAINTENANCE Periodic Maintenance Procedures Others Chassis Parts Lubrication Before lubricating each part clean off any rusty spots with rust remover and wipe off any grease oil dirt or grime Lubricate the points listed below with indicated lubricant NOTE OWhenever the vehicle has been operated under wet or rainy conditions or especially after using a high pressure water spray perform the general lubri cation Pivots Lubricate with Grease Brake Lever Brake Pedal Clutch Lever Rear Brake Joint Pin Sidestand Points Lubricate with Grease C
305. he rubber washers A with metal side faces up ward Install the cylinder head cover and tighten the bolts Torque Cylinder Head Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib GE09097BS2 C 8 09051 51 C GE09033BS1 5 16 ENGINE END Cylinder Head Cover e Be sure that the dampers A of the baffle plate are in position Tighten Torque Baffle Plate Bolts 5 9 N m 0 60 kgf m 52 in Ib e Install the other removed parts see appropriate chap ters 8 09086 52 ENGINE END 5 17 Camshaft Chain Tensioner Camshaft Chain Tensioner Removal NOTICE This is a non return type camshaft chain tensioner The push rod does not return to its original position once it moves out to take up camshaft chain slack Observe all the rules listed below When removing the tensioner do not take out the mounting bolts only halfway Retightening the mounting bolts from this position could damage the tensioner and the camshaft chain Once the bolts are loosened the tensioner must be removed and reset as described in Camshaft Chain Ten sioner Installation Do not turn over the crankshaft while the tensioner is removed This could upset the camshaft chain timing and damage the valves Remove Right Middle Fairing see Middle Fairing Removal in the Frame chapter Cap Bolt A and Washer Remove the spring A Remove the mounting bolts B and take off the c
306. he thermostat see Thermostat Removal and inspect the thermostat valve A at room temperature x If the valve is open replace the thermostat with a new one To check valve opening temperature suspend the ther mostat A in a container of water and raise the tempera ture of the water 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 Thermostat Valve Opening Temperature 80 5 83 5 C 177 182 F x If the measurement is out of the specified range replace the thermostat with a new one 6009020252 C COOLING SYSTEM 4 19 Hose and Pipes Hose Installation Install the hoses being careful to follow bending direction Avoid sharp bending kinking flattening or twisting e Run the hoses correctly see Cable Wire and Hose Rout ing section in the Appendix chapter e Install the clamp A as near as possible to the hose end to clear the raised rib of the fitting This will prevent the hoses from working loose OThe clamp screws should be positioned correctly to pre vent the clamps from contacting the other parts Tighten Torque Water Hose Clamp Screws 3 0 0 31 kgf m 27 in Ib MN ZZZNSS Hose Ins
307. her than straight ahead adjust the horizontal beam Headlight Beam Horizontal Adjustment e Turn the horizontal adjuster A on the headlight in or out until the beam points straight ahead x If the headlight beam points too low or high adjust the vertical beam 2 42 PERIODIC MAINTENANCE Periodic Maintenance Procedures Headlight Beam Vertical Adjustment e Turn the vertical adjuster A on the headlight in or out to adjust the headlight vertically NOTE 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 NOTE OFor US and CA model the proper angle is 0 4 degrees below horizontal This is 50 mm 2 0 in 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 0 in A Center of Brightest Spot B 7 6 m 25 ft C Height of Headlight Center D Sidestand Switch Operation Inspection Inspect the sidestand switch A operation according to the table below Sidestand Switch Operation Gear Clutch Engine Engine gidestand Position Lever Start Run Up Neutral Released Starts Continue running Up Neutral Puledin Stats Continue running Up In Gear Released Does net continue start running Up In Gear Pulledin Starts Continue ru
308. hes from the brush holder A e Remove Brush Springs B Starter Motor Terminal C Positive Brush Assembly D Screw E Negative Brush Assembly F Brush Holder Starter Motor Assembly Be sure that the stopper A is in position e Align the hole B on the brush holder C with the boss D on the right hand end cover E ELECTRICAL SYSTEM 16 49 Electric Starter System Align the stoppers A on the negative brush assembly B with the grooves C on the brush holder D Tighten the screw securely e Align the stoppers A on the positive brush assembly B with the grooves C on the brush holder D Install the starter motor terminal Replace the O ring A with a new one Apply grease to the new O ring Install the following parts to the starter motor terminal B O ring Collar C Washer D Starter Motor Terminal Locknut E Olnstall the collar so that the stepped side faces outward Tighten Torque Starter Motor Terminal Locknut 11 N m 1 1 kgf m 97 in Ib GP11104BS1 C e Install the brush springs A and insert the brushes B 16 50 ELECTRICAL SYSTEM Electric Starter System Apply thin coat of grease to the oil seal A Replace the O rings A with new ones e Insert the armature B so that commutator side C faces hollow side D of the yoke E e Align the marks A to assembly the yoke and the end covers B Replace th
309. his may cause the wiring open Remove the exhaust pipe manifold holder nuts A e Remove Muffler Body Mounting Bolts A Muffler Body Mounting Nut B Muffler C P 5 44 ENGINE END Muffler Muffler Installation e Installation is the reverse of removal OReplace the exhaust pipe gaskets A with new ones OTighten Torque Exhaust Pipe Manifold Holder Nuts 17 N m 1 7 kgf m 13 ft lb Muffler Body Mounting Bolts B 20 N m 2 0 kgf m 15 ft lb OFor oxygen sensor equipped models route its lead cor rectly see Cable Wire and Hose Routing section in the Appendix chapter OThoroughly 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 PLI 6 2 E 6 4 Special Tools and Sealant eem 6 5 Clutch Eever and Gables ite Arr rr e ees 6 6 Clutch Lever Free Play InSpectiQFi nocti enr nene erectae 6 6 Clutch Lever Free Play Adjustment nennt 6 6 Clutch Cable Removal diete trit ceterae My colas 6 6 Clutch Cable Installation 9 6 6 teet t die e Ghi te Tee tnb ca ed TR 6 7 Clutch Lever Installationm 9 6 7 Clutch Lever tap tod Ie ara
310. icator Unit Meter Unit Inspection Remove the meter unit see Meter Unit Removal 1 Green Left Turn Signal Indicator Light LED 2 Green Right Turn Signal Indicator Light LED 3 Green Neutral Indicator Light LED 4 Blue High Beam Indicator Light LED 5 Red Oil Pressure Warning Indicator Light LED 6 Battery 7 Unused 8 Ignition 9 Yellow ABS Indicator Light LED EX650F Model 10 Fuel Level Gauge 11 Unused 12 Tachometer Signal 13 Unused 14 Speed Sensor Signal 15 Ground 16 Yellow Engine Warning Indicator Light LED NOTICE 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 Liquid Crystal Display LCD Segment Check e Using the auxiliary leads connect the 12 V battery to the meter unit connector as follows Battery Positive Terminal to Terminal 6 Battery Negative Terminal to Terminal 15 e Connect the terminal 8 to the terminal 6 8 17892052 C 10 15V GP17894CS1 Meter Gauge Indicator Unit ELECTRICAL SYSTEM 16 67 OThen the tachometer needle A sweeps to the maximum reading then sweeps back to the minimum reading OThe following should appear Red Oil Pressure Warning Indicator Light LED B Yellow ABS Indicator Light LED C EX650F Model LCD Segments
311. id L Apply a non permanent locking agent R Replacement Parts S Follow the specified tightening sequence Si Apply silicone grease ex PBC grease 2 9 Fastener 2 3 olo Olo C KR O 1 1 0 12 2 5 1 8 Co 00 O01 ho 9 e N N OWhen disassembling the brake hose pipe disassemble them by the unit as shown in the exploded view 12 10 BRAKES Exploded View EX650F Model 0 S S BRAKES 12 11 Exploded View NI We Fem ug Brake Hose Banjo Bolts Torque R k ftlb emarks 0 80 8 Brake Pedais es ow BIN O oo AJO Apply brake fluid G Apply grease L Apply a non permanent locking agent R Replacement Parts Si Apply silicone grease ex PBC grease NOTE OWhen disassembling the brake hose and pipe disassemble them by the unit as shown in the exploded view 12 12 BRAKES Specifications Item Standard Service Limit Brake Lever Brake Pedal Lever Position Lever Free Play Pedal Position Pedal Free Play 5 way adjustable to suit rider Non adjustable About 50 mm 2 0 in below top of footpeg Non adjustable Brake Pads Lining Thickness Front 4 5 mm 0 18 in 1 mm 0 04 in Rear 5 0 mm 0 20 in 1 mm 0 04 in
312. iddle Fairing Removal in the Frame chapter Oil Pressure Switch Lead see Oil Pressure Switch Re moval in the Engine Lubrication chapter Clutch Cover see Clutch Cover Removal in the Clutch chapter e Remove Bolts A Crankshaft Sensor B Pull out the grommet C Crankshaft Sensor Installation e Run the crankshaft sensor lead correctly see Cable Wire and Hose Routing section in the Appendix chapter Install the crankshaft sensor A Tighten Torque Crankshaft Sensor Bolts B 6 0 N m 0 60 kgf m 53 in Ib e Clean off any oil or dirt and apply liquid gasket to the cir cumference of the crankshaft sensor lead grommet C Sealant Liquid Gasket TB1211F 92104 0004 e Install the grommet to the crankcase and connect the crankshaft sensor lead connector e Install the removed parts see appropriate chapters 16 40 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Inspection Remove the right frame cover see Frame Cover Removal in the Frame chapter Disconnect the crankshaft sensor lead connector A Set the hand tester to the x 10 O range and connect lead to the yellow lead and lead to the black lead in the connector Special Tool Hand Tester 57001 1394 Crankshaft Sensor Resistance Standard 376 564 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 shorte
313. ide oil solution to the threads and seating surface of the engine sprocket nut C Tighten Torque Engine Sprocket Nut 125 12 7 kgf m 92 ft Ib NOTE OTighten the engine sprocket nut while applying the rear brake e Bend one side of the washer over the nut GK05117BS1 C FINAL DRIVE 11 11 Sprocket Coupling Be sure that the dowel pins A are in position Install the speed sensor bracket and tighten the bolts Torque Speed Sensor Bracket Bolts 9 8 N m 1 0 kgf m 87 in Ib e Run the leads and hoses correctly see Cable Wire and Hose Routing section in the Appendix chapter Install the engine sprocket cover and tighten the bolts Torque Engine Sprocket Cover Bolts 9 8 1 0 kgf m 87 in Ib e Install the left frame cover see Frame Cover Installation in the Frame chapter e Adjust the drive chain slack see Drive Chain Slack Ad justment in the Periodic Maintenance chapter Rear Sprocket Removal e Remove the rear wheel see Rear Wheel Removal in the Wheels Tires chapter NOTICE Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks to under the wheel so that the disc does not touch the ground e Remove Rear Sprocket Nuts A Rear Sprocket B Rear Sprocket Installation e Install the sprocket with the tooth number marking A fac ing outward e Replace the rear sprocket nuts with new
314. ight LED A goes on faulty ECU in the ABS hydraulic unit Replace the ABS hy draulic unit xIf the yellow ABS indicator light LED does not go on ABS system is normal service code is not stored tempo rary failure Front Wheel Rotation Sensor Wiring Inspection Service Code 43 e Do the 1st step test as follows ODisconnect ABS Hydraulic Unit Connector see ABS Hydraulic Unit Removal Front Wheel Rotation Sensor Connector see Front Wheel Rotation Sensor Removal OShort the white and yellow lead terminals of the main har ness side connector ABS hydraulic unit A with a jumper lead OCheck for continuity between the white and yellow lead terminals of the main harness side connector front wheel rotation sensor B x If there is the continuity in the lead go to the 2nd step x If there is not the continuity in the lead replace or repair the main harness e Do the 2nd step test as follows OCheck for continuity between the white lead terminal of the sensor connector A and ground and yellow lead ter minal of the sensor connector and ground x If there is the continuity in the lead replace the front wheel rotation sensor x If there is not the continuity in the lead go to the 3rd step GL14610BS1 GL14605BS1 GL14039BS1 C 12 52 5 Anti Lock Brake System Equipped Models e Do the 3rd step test as follows ORecheck the service code indication
315. ight 12V10W BK Y 0 ev R R BK Turn Signal Fuse Box 1 Relay 1 Fuse 15 2 Meter Fuse 10A Left Switch Housing 3 Fan Fuse 15A 4 Brake Horn Fusa Left Switch Housing S Ignition Fuse 10 1 Horn Button 6 Headlight Fuse 15 Relay Box 2 Hazard Button i Radiator Fan Relay 3 Turn Signal Switch 2 Headlight Circuit Relay 4 Dimmer Switch Fuse Box 2 3 ECU Main Relay S Starter Lockout Switch i Turn Signal Relay Fuse 4 Fuel Pump Relay 8 Passing Button 5 S tarter Circuit Relay LEFT SWITCH HOUSING CONNECTIONS Horn Button Hazard Button Turn Signal Switch Dimmer Switch Starter Lockout Switch Passing Button 0 210624885 C ELECTRICAL SYSTEM 16 19 Wiring Diagram EX650F Model Intake Air Temperature Sensor Sub throttle Valve Actuator p Vehicle Main Pressure down Fuel Throttle Sensor Sensor Injectors Neutral Sensor d Switch oin 2 Pressure Purga Switch Valve I ys SEA B1 and TH Models Water Temperature Sensor Sub throttle Sensor Crank shaft Sensor i Oxygen Sensor Joint Connector Joint Connector Y BL BR BK BL WR BL R WR BL Y BR BK 4 BR BK a m P W BL E BL BRZBK BL BR BK Y R di 18 BRZY R Y 3 F BL Y P BK 171 BL R R BK Y BK Lera
316. ightened 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 APPENDIX 17 47 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 holder 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 absorption unsatisfactory Too hard Front fork oi
317. il into the suitable container C Hold the fork tube upright pour in the specified type and amount of fork oil Fork Oil Recommended Oil KAYABA KHL34 G10 or equivalent Amount Per Side When changing oil approx 410 mL 13 9 US oz After disassembly and completely dry 484 4 mL 16 4 0 14 US oz 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 0 gt 0 6M04040281 TS A eu GM04297BS1 ny My GM04525BS1 13 10 SUSPENSION Hold the outer tube vertically 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 from 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 98 2 mm 3 86 0 08 in OPlace the stopper of the level gauge at the top D of the inner tube E and pull the handle slowly to draw out the excess oil from fork into the gauge thus attainin
318. imit replace it with a new one Gear Groove Width Standard 6 05 6 16 mm 0 238 0 243 Service Limit 6 3 mm 0 25 in 9113513851 Shift Fork Guide Pin Drum Groove Wear Inspection a e Measure the diameter A of each shift fork guide pin and measure the width B of each shift drum groove x If the guide pin on any shift fork is less than the service limit replace it with a new one Shift Fork Guide Pin Diameter Standard 6 9 7 0 mm 0 272 0 276 in Service Limit 6 8 mm 0 27 in 8113514851 xIf any shift drum groove is worn over the service limit replace it with a new one Shift Drum Groove Width Standard 7 05 7 20 mm 0 278 0 283 in Service Limit 7 3 mm 0 29 in 9 44 CRANKSHAFT TRANSMISSION Transmission Gear Dog and Gear Dog Hole Damage Inspection e Visually inspect the gear dogs A and gear dog holes B Replace any damaged gears or gears with excessively worn dogs or dog holes 6113135851 C CRANKSHAFT TRANSMISSION 9 45 Ball Bearing Needle Bearing and Oil Seal Ball and Needle Bearing Replacement NOTICE Do not remove the or needle bearings unless it is necessary Removal may damage them e Using a press or puller remove the ball bearing and or needle bearings NOTE Oln the absence of the above mentioned tools satisfac tory results may be obtained by heating the case to ap proximately 93 C 200 F max and tapping
319. imit replace the crankshaft with a new one xIf the measured journal diameters are not less than the service limit but do not coincide with the original diameter markings on the crankshaft make new marks on it Crankshaft Main Journal Diameter Marks None 37 984 37 992 mm 1 4954 1 4957 in 1 37 993 38 000 mm 1 4958 1 4961 in Crankshaft Main Journal Diameter Marks 1 or no mark 51050304 5 6105041751 9105141851 C 9 28 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods 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 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 41 000 41 008 mm 1 6142 1 6145 in None 41 009 41 016 mm 1 6145 1 6148 in 000 Crankcase Main Bearing Inside Diameter Marks mark or no mark No 1 Journal A No 2 Journal B No 3 Journal C Select the proper bearing insert A in accordance with the combination of the crankcase and crankshaft coding Size Color B 0105142852 C 8105041751 Crankshaft Main Bearing Insert Crankcase Main Bearing Insi
320. in Drive Chain FINAL DRIVE 11 9 e After riveting check the ends of the riveted pins for cracks e Measure the outside diameter A and the length B of the link pin Link Pin Outside Diameter Standard 5 5 5 8 mm 0 22 0 23 in Link Pin Length Standard 20 20 mm 0 795 in or less xIf the reading is not within the specified range cut and rejoin the chain again Check that the rollers move smoothly e Adjust the drive chain slack after installing the chain see Drive Chain Slack Adjustment in the Periodic Mainte nance chapter GK04102BS1 11 10 FINAL DRIVE Sprocket Coupling Engine Sprocket Removal e Remove Left Frame Cover see Frame Cover Removal in the Frame chapter Engine Sprocket Cover Bolts A Engine Sprocket Cover B e Remove Speed Sensor Bracket Bolts A Speed Sensor Bracket B e Flatten out the bended washer A Remove the engine sprocket nut B and washer NOTE OLoosen the engine sprocket nut while applying the rear brake Loosen the drive chain see Drive Chain Slack Adjust ment in the Periodic Maintenance chapter Pull the engine sprocket A with drive chain B off the output shaft C e Disengage the drive chain from the engine sprocket Engine Sprocket Installation Replace the sprocket washer A with a new Install the engine sprocket B so that OUT SIDE letters face outward Apply molybdenum disulf
321. inal Bolt 9 8 1 0 87 Front Brake Light Switch Screw 1 2 0 12 11 in Ib Front Turn Signal Light Mounting Screws 1 2 0 12 11 in Ib Fuel Pump Bolts 9 8 1 0 87 L S Regulator Rectifier Bolts 9 8 1 0 87 Switch Housing Screws 3 5 0 36 31 in Ib Sidestand Switch Bolt 8 8 0 90 78 in lb L Starter Motor Cable Terminal Nut 6 0 0 61 53 in Ib Starter Motor Clutch Bolts 34 3 5 25 L Starter Motor Mounting Bolts 9 8 1 0 87 L Starter Motor Terminal Locknut 11 1 1 97 in lb Starter Motor Through Bolts 5 0 0 51 44 in lb Starter Replay Terminal Bolts 3 6 0 36 31 in Ib Stator Coil Bolts 12 1 2 106 in Ib L Crankshaft Sensor Bolts 6 0 0 61 53 in Ib Neutral Switch 15 1 5 11 Oil Pressure Switch 15 1 5 11 LG Oxygen Sensor Equipped Models 44 4 5 32 Spark Plugs 15 1 5 11 Speed Sensor Bolt 7 8 0 80 69 L Timing Rotor Bolt 40 4 1 30 Water Temperature Sensor 12 1 2 106 in Ib PERIODIC MAINTENANCE 2 11 Torque and Locking Agent The table below relating tightening torque to thread diameter lists the basic torque for the bolts and nuts Use this table for only the bolts and nuts which do not require a specific torque value All of the values are for use with dry solvent cleaned threads Basic Torque for General Fasteners Threads Diameter Qmm Nm 3 4 4 9 0 35 0 50 30 43 in lb 5 9 7 8 0 60 0 80 52 69 in lb 14 19 1 4 1 9 10 0 13 5 25 34 2 6 3 5 19 0 25
322. ine Stop Switch Fuel Injectors ECU Frame Ground 1 Frame Ground 2 Battery 12 V 10 Ah Main Fuse 30 Relay Box 10 ECU Main Relay 11 Fuel Pump Relay 12 Fuse Box 1 13 Fl Fuse 15 A 14 Ignition Fuse 10 A 5 3 102 FUEL SYSTEM Throttle Grip and Cables Throttle Grip Free Play Inspection Refer to the Throttle Control System Inspection in the Pe riodic Maintenance chapter Throttle Grip Free Play Adjustment Refer to the Throttle Control System Inspection in the Pe riodic Maintenance chapter Throttle Cable Installation Install the throttle cables in accordance with Cable Wire and Hose Routing section in the Appendix chapter Install the lower ends of the throttle cables in the throttle pulley on the throttle body assy after installing the upper ends of the throttle cables in the grip e After installation adjust each cable properly see Throttle Control System Inspection in the Periodic Maintenance chapter A WARNING Operation with incorrectly routed or improperly ad justed cables could result in an unsafe riding con dition Be sure the cables are routed correctly and properly adjusted Throttle Cable Lubrication e Refer to the Chassis Parts Lubrication in the Periodic Maintenance chapter Throttle Body Assy FUEL SYSTEM 3 103 Idle Speed Inspection Adjustment e Refer to the Idle Speed Inspection Adjustment in the Pe ri
323. ine or other painted parts Do not ingest coolant Remove the right middle fairing see Middle Fairing Re moval in the Frame chapter PERIODIC MAINTENANCE 2 49 Periodic Maintenance Procedures e Place a container under the water pump drain bolt A then remove the drain bolt Remove the radiator cap A in two steps First turn the cap counterclockwise to the first stop Then push and turn it further in the same direction and remove the cap OThe coolant will drain from the radiator and engine Remove the reserve tank hose B Remove the reserve tank cap and pour the coolant into a suitable container Tighten the drain bolt with a new gasket Torque Water Pump Drain Bolt 9 8 1 0 kgf m 87 in Ib e When filling the coolant choose a suitable mixture ratio by referring to the coolant manufacturer s directions 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 1 2 L 1 3 US qt e Fill the radiator up to the filler neck A with coolant NOTE OPour in the coolant slowly as it can expel the air from the engine and radiator Check the cooling system for leaks
324. ing see Middle Fairing Installation in the Frame chapter ENGINE REMOVAL INSTALLATION 8 1 Engine Removal Installation Table of Contents 8 2 Engine Removal InstallatiOri 5 2 meets 8 4 Englne SrmOVa 8 4 Engine Installation 8 6 8 2 ENGINE REMOVAL INSTALLATION Exploded View ENGINE REMOVAL INSTALLATION 8 3 Exploded View Torque No Fastener ftlb Remarks 2 Front Engine Bracket Bolts Rach 22 5 3 Front Engine Mounting Bolt Right gt 36 5 4 Front Engine Mounting Bolt Left 44 4 5 32 5 5 Engine Mounting Bolts 44 4 5 32 5 6 Rear Engine Mounting Nuts 44 4 5 32 5 7 Engine Bracket Bolts 25 2 5 18 5 8 Engine Ground Lead Terminal Bolt 9 8 1 0 87 in lb R Replacement Parts S Follow the specified tightening sequence 8 4 ENGINE REMOVAL INSTALLATION Engine Removal Installation Engine Removal e Support the rear part of the swingarm with a stand e Squeeze the brake lever slowly and hold it with a band A A WARNING Motorcycle may fall over unexpectedly resulting in an accident or injury Be sure to hold the front brake when removing the engine
325. ing agent LG Apply liquid gasket M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil solution Mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts 16 10 ELECTRICAL SYSTEM Specifications Item Standard Battery Type Sealed Battery Model Name YT12A BS Capacity 12 V 10 Ah Voltage 12 8 V or more Charging System Type Three phase AC Alternator Output Voltage Stator Coil Resistance Charging Voltage Regulator Rectifier Output Voltage 42 or more at 4 000 r min rpm 0 18 0 26 at 20 C 68 F 13 9 14 9V Ignition System Crankshaft Sensor Resistance Peak Voltage Stick Coil Primary Winding Resistance Secondary Winding Resistance Primary Peak Voltage Spark Plug Type Gap Electric Starter System Starter Motor Brush Length Air Switching Valve Resistance Switch and Sensor Rear Brake Light Switch Timing Fuel Level Sensor Resistance Engine Oil Pressure Switch Connections Water Temperature Sensor Resistance 376 5640 2 0 V or more 1 1 1 5 O at 20 C 68 F 10 8 16 2 kO at 20 C 68 F 117 V or more CR9EIA 9 0 8 0 9 mm 0 03 0 04 in 12 mm 0 47 in Service limit 6 5 mm 0 26 in 18 22 at 20 C 68 F ON after about 10 mm 0 39 in pedal travel 9 6 12 4 O at Full Position 222 228 at Empty Position When engine is stopped ON When engine is running OFF in th
326. ing the O rings and resultant loss of lubri cant observe the following rules Use only kerosene or diesel oil for cleaning an O ring of the drive chain Any other cleaning solu tion such as gasoline will cause deterioration 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 PERIODIC MAINTENANCE 2 29 Periodic Maintenance Procedures Apply oil to the sides of the rollers so that oil will penetrate to the rollers and bushings Apply the oil to the O rings so that the O rings will be coated with oil 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 it appears dry e Checkthe wheel alignment see Wheel Alignment Inspec tion e Rotate the rear wheel to find the position where the chain is tightest Measure the vertical movement chain slack A midway between the sprockets Drive Chain Slack Standard 25 35 mm 1 0 1 4 in x If the chain slack is not within the standard adjust it Drive Chain Slack Adjustment Raise the rear wheel off the ground with the stand Remove the cotter pin A and loosen the axle nut B Loosen the both chain adjuster locknuts xIf the chain is too loo
327. inner tube Inner Guide Bushing A Outer Guide Bushing B Washer C Oil Seal D Remove the cylinder base A from the bottom of the outer tube GM04735BS1 13 12 SUSPENSION Front Fork Assembly e Replace the following parts with new ones Top Plug O ring Retaining Ring A Dust Seal B Oil Seal C Inner Guide Bushing D Outer Guide Bushing E Fork Bottom Allen Bolt Gasket F Install the following on the end of the inner tube Outer Guide Bushing Inner Guide Bushing Insert the cylinder unit A and the spring into the inner tube e Be sure that the spring B is in position Install the cylinder base onto the end of the cylinder unit as shown in the figure Insert the following as a set into the outer tube Inner Tube Cylinder Unit Washer Spring Cylinder Base Install the new guide bushing A with the used one B Tap the used guide bushing with the front fork oil seal driver C to install the new guide bushing OThe split D of the bushing should face toward the side of the motorcycle Special Tool Front Fork Oil Seal Driver 57001 1219 Remove the used guide bushing e Apply grease to the oil seal lips Install the washer and the oil seal A into the outer tube Special Tool Front Fork Oil Seal Driver B 57001 1219 Install the retaining ring on the outer tube 2 42220 GM04538BS1 8 04031
328. ion A to the inner surfaces of upper and lower bearing inserts ODo not apply any grease or oil B to the cap inside and cap insert outside Olnstall the inserts so that their nails C are on the same side and fit them into the recess of the connecting rod and cap 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 One way to install inserts is as follows Installation D to Cap Installation E to Connecting Rod Push F Spare Dowel Pin G Connecting Rod Bolts H e Remove debris and clean the surface of inserts e Apply molybdenum disulfide oil solution to the threads and seating surfaces of the big end nuts and bolts e Install the crankshaft see Crankshaft Installation e Install each connecting rod on its original crankpin NOTE Olnstall each connecting rod so that its oil jet A faces the exhaust side the front B see Engine Oil Flow Chart in the Engine Lubrication System chapter e Install the cap on the connecting rod aligning the weight and diameter marks 6105060181 9105147851 CRANKSHAFT TRANSMISSION 9 21 Crankshaft and Connecting Rods OThe connecting rod big end is bolted using the plastic region fastening method OThis method precisely achieves the needed clamping force without exceeding it unneces
329. ions 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 s B as well Also replace all seals every other time the pads are changed GL05241BS1 GL05242BS1 12 18 BRAKES Calipers Caliper Dust Seal Damage Inspection e Check that the dust seal s A are not cracked worn swollen or otherwise damaged x If they show any damage replace the dust seals with new ones Piston s B Fluid Seal s C Caliper Dust Boot and Friction Boot Damage Inspection Check that the dust boot A and friction boot B are not cracked worn swollen or otherwise damaged x If they show any damage replace it GL05243BS1 GL05244BS1 GL05245BS1 GL05246BS1 Calipers BRAKES 12 19 Caliper Piston and Cylinder Damage Inspection e Visually inspect the piston s A and cylinder surface s Replace the caliper if the cylinder piston badly scores or rusty Caliper Holder Shaft Wear Inspection 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 Check to see that the caliper holder shaft is
330. it xlIf the yellow ABS indicator light LED does not go ABS system is normal service code is not stored tempo rary failure Front Wheel Rotation Sensor Signal Abnormal Service Code 42 e Do the 1st step test as follows OMeasure the air gap between the front wheel rotation sen sor and sensor rotor Thickness Gauge A Front Wheel Rotation Sensor Air Gap Standard 0 3 1 7 mm 0 01 0 07 in x If the measurement is over standard check each part for deformation and looseness and correct accordingly Recheck the air gap x If the measurement is correct go to the 2nd step GL14032BS1 GL14604BS1 Anti Lock Brake System Equipped Models BRAKES 12 51 Do the 2nd step test as follows OCheck that there is iron or other magnetic deposits be tween the sensor A and sensor rotor B and the sensor rotor slots for obstructions OCheck the installation condition of the sensor for loose ness OCheck the sensor and sensor rotor tip for deformation or damage e g chipped sensor rotor teeth x If the sensor and sensor rotor in bad condition remove the any deposits Install the properly or replace faulty part x lf the all items are correct go to the 3rd step e Do the 3rd step test as follows ORecheck the service code indication erase the service code perform the pre diagnosis inspection 1 and 2 and retrieve the service code If the yellow ABS indicator l
331. itch to OFF x If the reading is within specification but the problem still exists replace the ECU see ECU Removal Installation x If the reading is out of the standard check the following Oxygen Sensor Heater Fuse 10 A see Fuse Inspection in the Electrical System chapter Power Source Wiring see wiring diagram in this section xIf the fuse and wiring are good remove the ECU and check the wiring for continuity between main harness con nectors Special Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Oxygen Sensor Connector B P BK lead ECU terminal 23 C xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation 9617293051 C FUEL SYSTEM 3 79 Oxygen Sensor Heater Service Code 67 Equipped Models GCi7iB4FW3 C Oxygen Sensor Circuit renim onjoj BR BATTERY Jojo w Ignition Switch Oxygen Sensor ECU Frame Ground 2 Battery 12 V 10 Ah Main Fuse 30 Relay Box ECU Main Relay Fuse Box 1 Fl Fuse 15 Ignition Fuse 10 A 3 80 FUEL SYSTEM Oxygen Sensor Incorrect Output Voltage Service Code 94 Equipped Models Oxygen Sensor Removal I
332. ix the ignition switch lead connector upper and the left switch housing lead connector lower to the bracket Bracket Stick Coil Lead Clamps Run the main harness on the right side of the guide Guide Main Harness Run the right switch housing lead as follows on the right side of the head pipe inside the guide between the upper and lower cross pipes Run the ignition switch lead between the relay box and the frame and under the bracket Right Switch Housing Lead Connector 13 Run the ignition switch lead between the upper and lower cross pipes left side and to the lower right of the bracket Run the ignition switch lead above the left switch housing lead Run the left switch housing lead as follows through the clamp on the left side of the bracket on the left side of the head pipe inside the guide in the lower right of the bracket 17 6 APPENDIX Cable Wire and Hose Routing The routing on EX650E F is shown using the figure of ER650E F 68092250 6 APPENDIX 17 7 Cable Wire and Hose Routing Fix the clamp to the frame gusset Run the frame ground lead on the left side of the air cleaner housing Run the frame ground lead terminal to the outside from between the frame gussets and fix the lead terminal on the gusset 4 Frame Ground Lead 5 Fuel Pump Lead 6 Rear Brake Light Switch Lead 7 8 WN Subthrottle Valve Actuator Lead Clamp 9 Fuel Injector 2
333. justment 9515047851 PERIODIC MAINTENANCE 2 39 Periodic Maintenance Procedures Electrical System Lights and Switches Operation Inspection First Step Set the gear position in the neutral position e Turn the ignition switch to ON The following lights should go on according to the table below City Lights A goes on Taillight goes on goes on goes on goes on Yellow Engine Warning Indicator Light goes on LED F about 2 seconds Red Low Battery Voltage Warning goes on Indicator Light LED G about 2 seconds Green Neutral Indicator Light LED H goes on Red Oil Pressure Warning Indicator Light een LED I Red Water Temperature Warning Indicator goes on Light LED J about 2 seconds goes on about 2 seconds Blue High Beam Indicator Light LED K x If the light does not go on inspect or replace the following item Battery see Charging Condition Inspection in the Elec trical System chapter Main Fuse 30 A see Fuse Inspection in the Electrical System chapter Applicable Bulb see Wiring Diagram in the Electrical System chapter Meter Unit for Meter Panel LCD see Meter Unit Inspec tion in the Electrical System chapter Meter Unit for Illumination Light LED see Meter Unit Inspection in the Electrical System chapter Meter Unit for Yellow Engine Warning Indicator Light LED see Meter Unit Inspection in the Electrical Sys tem ch
334. ket B aside PERIODIC MAINTENANCE 2 47 Periodic Maintenance Procedures Remove Screws A Air Cleaner Housing Cover B Loosen the screw A to remove the air cleaner element Remove the screw from the element e Install a new element so that the screen side faces up ward Use only the recommended air cleaner element Kawasaki part number 11013 0713 Using another air cleaner element will wear the engine prema turely or lower the engine performance Tighten Torque Air Cleaner Element Screw 1 2 N m 0 12 kgf m 11 in Ib e Install the air cleaner housing cover and tighten the Screws Torque Air Cleaner Housing Cover Screws 1 2 N m 0 12 kgf m 11 in Ib e Install the other removed parts see appropriate chapter ORun the harness and leads correctly see Cable Wire and Hose Routing section in the Appendix chapter Olnstall the bracket and tighten the bolts following the spec ified tightening sequence shown in the figure Fuel Hose Replacement e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Left Middle Fairing see Middle Fairing Removal in the Frame chapter e Be sure to place a piece of cloth A around the fuel hose joint e Insert a standard tip screwdriver B into the slit on the joint lock C 2 48 PERIODIC MAINTENANCE Periodic Maintenance Procedures Turn A the driver to unlock the joint lock B Pull the fuel hose joint
335. kgf m 43 in Ib External Shift Mechanism Inspection e Inspect the shift shaft A for any damage x If the shaft is bent straighten or replace it x If the serration B are damaged replace the shaft x If the springs C are damaged in any way replace them If the shift mechanism arm D is damaged in any way replace the shaft e Check the return spring pin A is not loose x If it 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 21 ft Ib e Check the gear positioning lever A and its spring for breaks or distortion If the lever or spring are damaged in any way replace them e Visually inspect the shift drum cam B any of them is badly worn or shows any damage re place it CRANKSHAFT TRANSMISSION 9 35 Transmission Transmission Assy Removal Remove Shift Shaft Assembly see External Shift Mechanism Re moval Neutral Switch Holder Screw A Neutral Switch Holder B and Pin Shift Drum Holder C and Pin Remove the collar A and the O ring B from the output shaft C e Remove Clutch see Clutch Removal in the Clutch chapter Transmission Case Bolts A x lf the transmission assy is to be disassembled remove the following Shift Rod Plate Bolt and Plate B Gear Positioning Lever C see External Shift Mecha nism Removal Pull the transmission assy ou
336. kgf m 62 in Ib ORun the tubes correctly see Cable Wire and Hose Rout ing section in the Appendix chapter Purge Valve Inspection e Remove the purge valve see Purge Valve Removal In stallation e Set the hand tester A to the x 1 O range and connect it to the purge valve terminals as shown in the figure Special Tool Hand Tester 57001 1394 Purge Valve Resistance Standard 30 34 at 20 C 68 F x If the resistance reading is out of the specified value re place it with a new one e Connect the 12 V battery A to the purge valve terminals as shown in the figure e Blow the air to the intake air duct A and make sure that the air flows from the outlet air duct B 8017193 51 C GC17194FS1 C 8017195 51 C 3 84 FUEL SYSTEM Purge Valve Service Code CAL SEA B1 Models Disconnect the 12 V battery Blow the air to the intake air duct A again and make sure that the air does not flow from the outlet air duct B x If the purge valve dose not operate as described replace it with a new one 8017196 51 C Purge Valve Circuit Lon eniti onon BR 1 P BATTERY I amp O Li 8017199 3 C 1 Ignition Switch Purge Valve ECU Frame Ground 2 Battery 12 V 10 Ah Main Fuse 30 A Relay Box ECU Main Relay Fuse Box 1 10 Fl Fuse 15A 11 Ignition Fuse 10 A
337. l e Remove Clutch Cover see Clutch Cover Removal in the Clutch chapter Crankshaft Sensor see Crankshaft Sensor Removal Hold the timing rotor A steady with the flywheel amp pulley holder B Special Tool Flywheel amp Pulley Holder 57001 1605 Remove Timing Rotor Bolt C Timing Rotor Timing Rotor Installation e Fit the timing rotor A to the crankshaft Tighten the timing rotor bolt B while holding the timing rotor steady with the flywheel amp pulley holder C Special Tool Flywheel amp Pulley Holder 57001 1605 Torque Timing Rotor Bolt 40 N m 4 1 kgf m 30 ft Ib e Install the removed parts see appropriate chapters Stick Coil Removal e Remove the air cleaner housing see Air Cleaner Housing Removal in the Fuel System DFI chapter e Disconnect Air Switching Valve see Air Switching Valve Removal in the Engine Top End chapter Stick Coil Connectors A Pull out the stick coils B NOTICE Do not pry the connector part of the coil while re moving the coil Stick Coil Installation e Insert the coil as shown being careful of the coil heads A direction Do not tap the coil head while installing the coil e Connect the stick coil connectors e Run the hoses and harness correctly see Cable Wire and Hose Routing section in the Appendix chapter 0P10281B 1 e Install the removed parts see appropriate chapters 16 42 ELECTRICAL SYSTEM
338. l excessive Front fork oil viscosity too high Rear shock absorber adjustment too hard Tire air pressure too high Front fork bent Too soft Tire air pressure too low Front fork oil insufficient and or leaking Front fork oil viscosity too low 17 48 APPENDIX Troubleshooting Guide Rear shock adjustment too soft Battery Trouble Front fork rear shock absorber spring weak Battery discharged Rear shock absorber oil leaking Charge insufficient Battery faulty too low terminal voltage Brake Doesn t Hold Battery cable making poor contact Air in the brake line Load excessive e g bulb of excessive Pad or disc worn wattage Brake fluid leakage Ignition switch trouble Disc warped Alternator trouble Contaminated pad Wiring faulty Brake fluid deteriorated Regulator rectifier trouble Primary or secondary cup damaged in master Battery overcharged cylinder Alternator trouble Master cylinder scratched inside Regulator rectifier trouble Battery faulty MODEL APPLICATION Year Model Beginning Frame No JKAEXEE1DCDA00001 2012 650 JKAEX650EEDA00001 JKAEXEF10CDA00001 2012 650 JKAEX650EFDA00001 This digit in the frame number changes from one machine to another Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Motorcycle amp Engine Company Part No 99924 1454 01 Printed in Japan
339. l in the Final Drive chapter e Disconnect the oxygen sensor lead connector A Connect a digital meter A to the oxygen sensor lead con nector B e Measure the oxygen sensor heater resistance Oxygen Sensor Heater Resistance Connections BK lead BK lead Standard 11 7 14 5 at 20 C 68 F x If the reading is out of the standard replace the sensor x lf the reading is within the standard check the power source voltage see Oxygen Sensor Heater Power Source Voltage Inspection 80178140651 3 78 FUEL SYSTEM DFI Oxygen Sensor Heater Service Code 67 Equipped Models Oxygen Sensor Heater Power Source Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch to OFF Remove the engine sprocket cover see Engine Sprocket Removal in the Final Drive chapter Disconnect the oxygen sensor lead connector and con nect the oxygen sensor measuring adapter A between these connectors Special Tool Oxygen Sensor Measuring Adapter 57001 1682 Connect a digital meter to the harness adapter lead Oxygen Sensor Power Source Voltage Connections to Adapter Digital Meter W sensor BK lead Digital Meter gt Battery terminal Measure the power source voltage with the engine stopped and with the connector joined e Turn the ignition switch to ON Power Source Voltage Standard Battery Voltage e Turn the ignition sw
340. l not to have the battery fall down Keep the container in place Don t remove the container from the battery the battery requires all the electrolyte from the container for proper operation NOTICE Removal of the container before it is completely empty can shorten the service life of the battery Do not remove the container until it is completely empty e After filling let the battery sit for 20 60 minutes with the electrolyte container kept in place which is required for the electrolyte to fully permeate into the plates e Make sure that the container cells have emptied com pletely and remove the container from the battery e Place the strip of caps A loosely over the filler ports press down firmly with both hands to seat the strip of caps into the battery don t pound or hammer When properly installed the strip of caps will be level with the top of the battery Once the strip of caps is installed onto the battery never remove the caps nor add water or electrolyte to the battery NOTE OCharging the battery immediately after filling can shorten service life j Se 7 e gue 8 09000751 C ME02114BS1 Hm LJ LJ ue leis 8 08012851 C 8 08010851 C Battery ELECTRICAL SYSTEM 16 25 Initial Charge Newly activated sealed batteries require an initial charge Standard Charge 1 2 A 5 10 hours x lf using a recommended battery
341. l the following temporarily Front Engine Bracket Right A Front Engine Bracket Bolts Right B e Replace the front engine mounting nut right C with a new one e Install the following temporarily Front Engine Mounting Bolt Right D Front Engine Mounting Nut Right Front Engine Bracket Left E Front Engine Bracket Bolts Left F e Replace the front engine mounting nut left G with a new one e Install the following temporarily Front Engine Mounting Bolt Left H Collar I Front Engine Mounting Nut Left e By the following specified sequence tighten the bolts OTighten Torque Rear Engine Bracket Bolt Upper A 25 2 5 kgf m 18 ft lb Rear Engine Bracket Bolt Lower B 25 N m 2 5 kgf m 18 ft lb Rear Engine Mounting Bolt and Nut Lower C 44 N m 4 5 kgf m 32 ft lb OTighten Torque Rear Engine Mounting Bolt and Nut Upper D 44 Nm 4 5 kgf m 32 ft lb OTighten Torque Front Engine Bracket Bolts Right E 30 N m 3 1 kgf m 22 ft lb Front Engine Mounting Bolt F Right 49 N m 5 0 kgf m 36 ft Ib 8 8 ENGINE REMOVAL INSTALLATION Engine Removal Installation OTighten Torque Front Engine Bracket Bolts Left G 25 N m 2 5 kgf m 18 ft Ib Front Engine Mounting Bolt H Left 44 4 5 kgf m 32 ft Ib e Run the leads cables and hoses correctly see Cable Wire and Hose Routing section in the Appendix chapter e Install t
342. ld cause sudden loss of engine power The rider could lose balance during certain riding situ ations for an accident resulting in injury or death Ensure that the vehicle down sensor is held in place by the sensor bracket Vehicle down Sensor Inspection NOTE sure the battery is fully charged e Connect a digital meter A to the connector B of the vehicle down sensor C with the needle adapter set D Special Tool Needle Adapter Set 57001 1457 Vehicle down Sensor Power Source Voltage Connections to Sensor Connector Meter BL lead E Meter gt BR BK lead e Turn the ignition switch to ON and measure the power source voltage with the connector joined Input Voltage Standard DC 4 75 5 25 V e Turn the ignition switch to OFF x If the reading of input voltage is less than the standard check the ECU for its ground power supply and wiring x If the power source is normal check the output voltage 9505253851 8017165 52 C Vehicle down Sensor Service Code 31 FUEL SYSTEM DFI 3 61 e Remove the vehicle down sensor see Vehicle down Sensor Removal Installation ODo not disconnect the sensor connector e Connect a digital meter A to the connector with needle adapter set B Special Tool Needle Adapter Set 57001 1457 Vehicle down Sensor Output Voltage Connections to Sensor Connector Meter Y G lead E Meter BR BK
343. le Stick coil trouble Fuel air mixture incorrect Bypass screw maladjusted Air passage clogged Air bleed pipe bleed holes clogged Pilot passage clogged Air cleaner clogged poorly sealed or miss ing Fuel tank air vent obstructed Fuel pump trouble Throttle body assy holder loose Air cleaner duct loose Troubleshooting Guide Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head 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 Air switching valve trouble Engine overheating Clutch slipping Poor Running or No Power at High Speed 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 i
344. le commercially available chisel B Stem Stem Bearing Installation Replace the bearing outer races with new ones Drive them into the head pipe at the same time Special Tools Head Pipe Outer Race Press Shaft A 57001 1075 Head Pipe Outer Race Driver 55 B 57001 1446 e Apply grease to the outer races 8 05055 81 C GNOS099BS1 C 14 8 STEERING Steering Stem Replace the lower ball bearing inner race A and oil seal B with new ones e Apply grease to the following Oil Seal Lower Ball Bearing Inner Race Install the oil seal on the steering stem and drive the lower ball bearing inner race onto the stem Special Tools Steering Stem Bearing Driver 42 5 C 57001 1344 Steering Stem Bearing Driver Adapter 41 5 D 57001 1345 e Install the lower ball bearing A onto the stem e Apply grease to the following Inner and Outer Races Lower Ball Bearing e Install the steering stem A through the head pipe and install the upper ball bearing B and upper ball bearing inner race C on it e Apply grease to the stem cap D e Install Stem Cap Steering Stem Nut E e Settle the bearings in place as follows e Tighten the steering stem nut with 55 N m 5 6 kgf m 41 ft Ib of torque first and loosen it a fraction of a turn until it turns lightly Afterward tighten it again with specified torque using a steering stem nut wrench A Special Tool Steering Stem Nut
345. le sensor system and intake air pressure fails the ECU locks ignition timing into the ignition timing at closed throttle position and sets the DFI the a N method 2 If the intake air pressure sensor system fails the signal is out of the usable range wiring short or open the ECU sets the DFI in the a N method Intake Air Temperature Sensor Water Temperature Sensor Crankshaft Sensor Intake Air Temperature Ta 30 120 C Water Temperature Tw 30 C 120 C Crankshaft sensor must send 22 signals to the ECU at the one cranking If the intake 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 If the crankshaft sensor generates other than 22 signals the engine stops by itself Speed Sensor Speed sensor must send 4 signals to the ECU at the one rotation of the engine sprocket The gear position is decided by the signal of the speed sensor If the speed sensor system fails no signal wiring short or open the speedometer shows 0 and the ECU sets the top 6 gear position Vehicle down Sensor Output Voltage signal Vd 0 65 4 45 V 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 pu
346. lead terminal of the main harness side connector ABS hydraulic unit A and red white lead terminal of the fuse box B x If there is the continuity in the lead replace the fuse x If there is not the continuity in the lead replace or repair the main harness GL14610BS1 GL14602BS1 GL14603BS1 C 12 50 5 Anti Lock Brake System Equipped Models e Do the 4th step test as follows OCheck the battery terminal voltage between the red white lead terminal of the fuse box A and ground Special Tool Hand Tester 57001 1394 Battery Terminal Voltage Standard Battery Voltage x If the battery terminal voltage is not within the specifica tion go to the 5th step x If the battery terminal voltage is correct go to the 6th step e Do the 5th step test as follows OCheck for continuity between the positive cable A of the battery and red white lead terminal of the main har ness side connector ABS hydraulic unit B x If there is the continuity in the lead go to the 4th step x If there is not the continuity in the lead replace or repair the main harness e Do the 6th step test as follows ORecheck the service code indication erase the service code perform the pre diagnosis inspection 1 and 2 and retrieve the service code x If the yellow ABS indicator light LED A goes on faulty ABS motor relay in the ABS hydraulic unit Replace the ABS hydraulic un
347. light Unit C e Remove Bolts A Upper Fairing B Upper Fairing Installation Installation is the reverse of removal 15 17 Seat Covers Front Seat Cover Removal Remove Front Seat see Front Seat Removal Screws A Front Seat Covers B Front Seat Cover Installation e Installation is the reverse of removal Rear Seat Cover Removal Remove Front Seat see Front Seat Removal Bolts A and Washers Left and Right Grab Rails B Left and Right Other than US CA and CAL Models Remove Quick Rivets A Center Seat Cover B e Remove Screws A and Washers Rear Seat Covers B 15 18 Seat Covers Rear Seat Cover Installation Installation is the reverse of removal OBe sure to install the pads A on the left and right rear seat covers Olnstall the rear seat cover A so that the ribs B fit inside the rear fender C Olnstall the center seat cover A so that the projections B fit into the slots C OFor other than US CA and CAL models install the grab rails and tighten the bolts Torque Grab Rail Mounting Bolts 25 N m 2 5 kgf m 18 ft Ib 15 19 Fenders Front Fender Removal Remove Bolts A and Washers Left and Right Bolts B Left and Right Front Fender C Front Fender Installation e Install the front fender A together with the brake hose clamps B on both sides Flap Removal Remove th
348. liper Do not loosen the rear wheel rotation sensor lead in this area Run the brake hose between the clamp and swingarm Fix the brake hose to clamp on the swingarm Run the brake hose rear master cylinder ABS hydraulic unit under the brake hose rear brake reservoir tank rear master cylinder Run the rear wheel rotation sensor lead between the brake hose fitting on the rear master cylin der and the brake hose rear brake reservoir tank rear master cylinder Fix the rear wheel rotation sensor lead to the brake hose rear brake reservoir tank rear master cylinder with the band 17 30 APPENDIX Cable Wire and Hose Routing ABS Equipped Models The routing on EX650E F is shown using the figure of ER650E F 68094270 6 APPENDIX 17 31 Cable Wire and Hose Routing ABS Equipped Models 58098380 6 Collar and Damper Hold the brake pipes 2 Run the brake pipe front master cylinder ABS hydraulic unit inside the brake pipe ABS CD 10 11 12 13 14 15 16 17 18 ABS Hydraulic Unit Connector 20 hydraulic unit front caliper Run the brake pipe ABS hydraulic unit front caliper between the right switch housing lead and the frame inside the clutch cable Bracket Hold the brake pipes Throttle Cables Cross the brake pipes in this area Run the brake pipes above the throttle cables and under the clutch
349. lter Cleaning Fuel Injectors Fuel Injector 2 0 2 060 0660000000000000000000000000000000000 4 Fuel Injector Audible Inspection 3 63 3 64 3 66 3 67 3 67 3 67 3 70 3 70 3 70 3 70 3 72 3 72 3 72 3 73 3 73 3 73 3 73 3 74 3 76 3 76 3 76 3 77 3 77 3 77 3 78 3 80 3 80 3 80 3 83 3 83 3 83 3 85 3 85 3 86 3 86 3 86 3 86 3 86 3 89 3 89 3 89 3 89 3 89 3 89 3 90 3 90 3 91 3 93 3 93 3 93 3 94 3 95 3 96 3 96 3 97 3 97 3 97 FUEL SYSTEM DFI 3 3 Fuel Injector Resistance Inspection pp 3 97 Fuel Injector Power Source Voltage Inspection pp 3 98 Fuel Injector Output Voltage Inspectilori 2 5 mt te ebore rettet hee t 3 99 Fuel Injector Fuel Line Inspection 3 100 Throttle Gip and Cables eet mune ee Dus Le pe dive DR 3 102 Throttle Grip Free Play Inspection RN 3 102 Throttle Grip Free Play Adjustiment 2 dise aces tte toin d sa repre undae 3 102 Throttle Cable Installation eerte rrr Re t trt 3 102 Throttle Cable LUbFIGStlOn e 3 102 BODY P cq C 3 103 Idle Speed Inspection Adjustment 3 103 Synchronization Inspection Adjustment 3 103 Throttle Body Assy Removal etr et
350. lutch Inner Cable Upper and Lower Ends A Throttle Inner Cable Upper and Lower Ends Cables Lubricate with Rust Inhibitor Clutch Cable Throttle Cables e Lubricate the cables by seeping the oil between the cable and housing OThe cable may be lubricated by using a commercially available pressure cable lubricator with an aerosol cable lubricant e With the cable disconnected at both ends the inner cable should move freely A within the cable housing If cable movement is not free after lubricating if the cable is frayed B or if the cable housing is kinked C replace the cable 6004040381 C 6604011451 C 6004020281 C PERIODIC MAINTENANCE 2 45 Periodic Maintenance Procedures Bolts Nuts and Fasteners Tightness Inspection Check the tightness of the bolts and nuts listed here Also check to see that each cotter pin is in place and in good condition NOTE 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 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 Engine Clutch
351. m Torque Oil Plate Bolts 9 8 N m 1 0 kfg m 87 in Ib 9104354851 C 9104354851 C CRANKSHAFT TRANSMISSION 9 13 Crankcase Splitting e When the new needle bearing A for the shift drum is installed in the lower crankcase half B press and insert C the new needle bearing until it is bottomed Special Tool Bearing Driver Set 57001 1129 e When the new needle bearing D for the shift shaft is installed in the lower crankcase half press and insert E the new needle bearing so that the bearing surface is flush with the end of hole OThe marked side of the needle bearing faces outside of the crankcase Special Tool Bearing Driver Set 57001 1129 When the new oil plug A and new race B for drive shaft is installed in the upper crankcase half C install them in the following procedure grease to the new O rings D OClean off any oil or dirt and apply liquid gasket to the por tions E on the upper crankcase half and insert F the new oil plug until it is bottomed Sealant Liquid Gasket TB1211F 92104 0004 OPress and insert the new race until it is bottomed Special Tool Bearing Driver Set 57001 1129 NOTE Olnstall the new race so that the stepped side G faces inside of the crankcase ODo not apply liquid gasket to the O ring and the oil line Olnstall the race holder as shown OApply a non permanent locking agent to the threads of the race holder screw
352. mable and can be ex plosive under certain conditions creating the potential for serious burns 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 to OFF Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately NOTE OBe sure the battery is fully charged e Turn the ignition switch to OFF Wait until the engine cools down Prepare a fuel hose Special Tool 57001 1607 and a measuring cylinder Special Tool Fuel Hose 57001 1607 e Remove Side Covers see Side Cover Removal in the Frame chapter Fuel Tank Bolts see Fuel Tank Removal 3 92 FUEL SYSTEM Open the fuel tank A to lower the pressure in the tank Remove the fuel hose from the fuel pump see Fuel Tank Removal OBe sure to place a piece of cloth around the fuel supply pipe of the fuel pump A WARNING Fuel is flammable and explosive under certain con ditions and can cause severe burns Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is dis connected fuel spills out from the hose and the pipe because of residual pressure Cover the hose connection with a piece of clean cloth to prevent fuel spillage Connect the prepared fuel hose A to the fuel supply pipe of the fuel pump Secure the f
353. me procedure for removal of the other link pin Drive Chain Installation Engage the new drive chain to the old drive chain and change the position of the chains by pulling the old chain Remove the old drive chain from the new drive chain Replace the link pin A link plate and grease seals B C with new ones e Apply grease to the link pin and grease seals Install the grease seals on the link pin and insert it in the ends of the drive chain e Install the link plate so that the mark D faces out e Set the cutting and riveting pin B and plate holder C on the pin holder A as shown in the figure GK04090BS1 11 8 FINAL DRIVE Drive Chain Set the U holder and body align the positioning pin with the A mark B Hold the body with a wrench C e Turn the pin holder clockwise D with another wrench press in the link plate on the link pin e Remove the U holder and body e Set the cutting and riveting pin B in the pin holder A as shown in the figure e Set the U holder and body align the positioning pin A with the B mark B e Tighten the pin holder by hand until the cutting and riveting pin touches the link pin e Hold the body with a wrench A e Turn the pin holder clockwise B with another wrench until the cutting and riveting pin touches the link plate e Do the same procedure for installation of the other link p
354. move Extension Tube Fuel Pump Lead Connector Disconnect e Remove the air cleaner housing see Air Cleaner Housing Removal in the Fuel System DFI chapter e Apply a soap and water solution or rubber lubricant to the end of the air switching valve hose A and install the hose on the fitting e Install Air Cleaner Housing see Air Cleaner Housing Installa tion in the Fuel System DFI chapter Fuel Tank see Fuel Tank Installation in the Fuel System DFI chapter Clutch Clutch Operation Inspection e Pull the clutch lever just enough to take up the free play A e Measure the gap between the lever and the lever holder Clutch Lever Free Play Standard 2 3 mm 0 08 0 12 in xIf the gap is too wide the clutch not release fully If the gap is too narrow the clutch may not engage fully In either case adjust it 2 26 PERIODIC MAINTENANCE Periodic Maintenance Procedures A WARNING The engine and exhaust system get extremely hot during normal operation and can cause serious burns Never touch the engine or exhaust pipe during clutch adjustment e Turn the adjuster A so that 5 6 mm 0 20 0 24 in B of threads are visible Remove the right middle fairing see Middle Fairing Re moval in the Frame chapter Open the clamp A Slide the dust cover B out of place Loosen the locknut C e Turn the adjusting nut D until the free play is correct A WARNI
355. moves smoothly from full open to close and the throttle closes quickly and com pletely by the return spring in all steering positions x If the throttle grip does not return properly check the throt tle cable routing grip free play and cable damage Then lubricate the throttle cable Check the throttle grip free play B Throttle Grip Free Play Standard 2 3 mm 0 08 0 12 in x lf the free play is incorrect adjust the throttle cable as follows Loosen the locknut A at the upper end of the accelerator cable e Turn the adjuster B in completely so as to give the throttle grip plenty of play Remove the right middle fairing see Middle Fairing Re moval in the Frame chapter Loosen the locknut A at the middle of the decelerator cable Turn the adjuster B until there is no play when the throttle grip is completely closed Tighten the locknut e Turn the accelerator cable adjuster until the proper amount of throttle grip free play is obtained Tighten the locknut e Install the right middle fairing see Middle Fairing Installa tion in the Frame chapter Engine Vacuum Synchronization Inspection NOTE O These procedures are explained on the assumption that the intake and exhaust systems of the engine are in good condition Situate the motorcycle so that it is vertical Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Air Cleaner Housi
356. mp the fuel injectors and the ignition system 33 Subthrottle Sensor Oxygen Sensor Equipped Models Output Voltage 0 15 4 85 V The oxygen sensor is active and sensor must send signals output voltage continuously to the ECU If the subthrottle sensor system fails the signal is out of the usable range wiring short or open the ECU drive the subthrottle valve to the full closed position and it stops the current to the actuator If the oxygen sensor is not activated the ECU stops oxygen sensor feedback mode 3 40 FUEL SYSTEM Self Diagnosis Service Output Signal Usable Codes Range or Criteria Packups Py eer The ECU sends the 39 ECU data for service code to the meter unit The ECU must send If the stick coil 1 primary winding has failures signals continuously to no signal wiring short or open the ECU the stick coil primary shuts off the injector 1 to stop fuel to the winding cylinder 1 though the engine keeps running The ECU must send If the stick coil 2 primary winding has failures signals continuously to no signal wiring short or open the ECU the stick coil primary shuts off the injector 2 to stop fuel to the winding cylinder 2 though the engine keeps running 51 Stick Coil 1 52 Stick Coil 2 The actuator operates open and close of the If the subthrottle valve actuator fails the Subthrottle signal is out of the usable
357. n 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 spark weak Vehicle down sensor DFI coming off Ignition switch not ON Engine stop switch turned to stop position 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 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 Crankshaft sensor troub
358. n signal switch A left or right position The left or right turn signal lights B front and rear should blink according to the switch position The green turn signal indicator light LED C in the meter unit should blink x If any light does not blink inspect or replace the following item Turn Signal Light Bulb see Turn Signal Light Bulb Re placement in the Electrical System chapter Meter Unit for Green Turn Signal Indicator Light LED see Electronic Combination Meter Unit Inspection in the Electrical System chapter Turn Signal Relay Fuse 10 A see Fuse Inspection in the Electrical System chapter Turn Signal Switch see Switch Inspection in the Electri cal System chapter Turn Signal Relay see Turn Signal Relay Inspection in the Electrical System chapter Harness see Wiring Inspection in the Electrical System chapter Push the turn signal switch The turn signal lights and indicator light LED should go off x If the light does not go off inspect or replace the following item Turn Signal Switch see Switch Inspection in the Electri cal System chapter Turn Signal Relay see Turn Signal Relay Inspection in the Electrical System chapter 9517203851 PERIODIC MAINTENANCE 2 41 Periodic Maintenance Procedures Fourth Step Set the dimmer switch A to low beam position Start the engine The low beam headlight should go on x If the low beam headlight does not go on in
359. n the ignition switch to ON while any of the ABS electrical connectors are disconnected The ABS hydraulic unit memorizes service codes ODo not spray water on the electrical parts ABS parts con nectors leads and wiring Olf a transceiver is installed on the motorcycle make sure that the operation of the ABS system is not influenced by electric wave radiated from the antenna Locate the antenna as far as possible away from the ABS hydraulic unit OWhenever the ABS electrical connections are to be dis connected first turn the ignition switch to OFF OThe ABS 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 OThe ABS parts cannot be disassembled Even if a fault is found do nottry to disassemble and repair the ABS parts replace it OThe ABS has many brake lines pipes and leads And the ABS cannot detect problems with the conventional braking system brake disc wear unevenly worn brake pad and other mechanical faults To prevent trouble check the brake lines and pipes for correct routing and connection the wiring for correct routing and the brakes for proper braking power Be sure to check for fluid leak age and bleed the brake line thoroughly 5 12 35 Anti Lock Brake System Equipped Models A WARNING Air in the brake lines diminish braking performance and can cause an accident resulting in injury or death If any of the
360. nections Color BK G When sidestand is down ae Gee When sidestand is up O Neutral Switch Connections Neutral Switch Connections Color SW Terminal Ground When transmission is in neutral O o When transmission is not in neutral Oil Pressure Switch Connections Oil Pressure Switch Connections Color SW Terminal Ground When engine is running When the engine lubrication system is in good condi tion 16 76 ELECTRICAL SYSTEM Switches and Sensors Water Temperature Sensor Inspection Remove the water temperature sensor see Water Tem perature Sensor Removal Installation in the Fuel System DFI chapter e Suspend the sensor A in a container of coolant so that the temperature sensing projection C is submerged e Suspend an accurate thermometer B with temperature sensing projection 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 gradu ally raise the temperature of the coolant while stirring the coolant gently e Using the hand tester measure the internal resistance of the sensor Special Tool Hand Tester 57001 1394 x If the hand tester does not show the specified values re place the sensor Water Temperature Sensor Resistance Temperature Resistance 20 4 F 18 80 2 37 0 32 F about 6
361. ng see Air Cleaner Housing Removal in the Fuel System DFI chapter Fuel Hose see Fuel Hose Replacement Remove the rubber caps A from the fittings on the throt tle body 2 16 PERIODIC MAINTENANCE Periodic Maintenance Procedures e For CAL SEA B1 and TH models remove the tubes A from the fittings on the throttle body Connect a vacuum gauge special tool and hoses A to the fittings on the throttle body Special Tool Vacuum Gauge 57001 1369 Connect a highly accurate tachometer to one of the stick coil primary leads e Install Air Cleaner Housing see Air Cleaner Housing Installa tion in the Fuel System DFI chapter ECU see ECU Installation in the Fuel System DFI chapter Intake Air Temperature Sensor Connector Connect Connect the following temporarily Fuel Pump Lead Connector A Extension Tube B Special Tool Extension Tube 57001 1578 Start the engine and warm it up thoroughly e Check the idle speed using a highly accurate tachometer Idle Speed Standard 1 300 50 r min rpm x If the idle speed is out of the specified range adjust it see Idle Speed Adjustment NOTICE Do not measure the idle speed by the tachometer of the meter unit While idling the engine inspect the engine vacuum using the vacuum gauge Engine Vacuum Standard 35 3 1 3 kPa 265 10 mmHg at Idle Speed PERIODIC MAINTENANCE 2 17 Periodic Maintenance Procedures
362. nging 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 8813271 52 a PERIODIC MAINTENANCE 2 55 Periodic Maintenance Procedures Master Cylinder Rubber Parts Replacement Front Master Cylinder Disassembly Remove the front master cylinder see Front Master Cylin der Removal in the Brakes chapter Remove the reservoir cap and diaphragm and pour the brake fluid into a container Unscrew the locknut and pivot bolt and remove the brake lever e Pull the dust cover A out of place and remove the circlip Special Tool Inside Circlip Pliers 57001 143 Pull out the piston C secondary D primary E and return spring F NOTICE Do not remove the secondary cup from the piston since removal will damage it Rear Master Cylinder Disassembly NOTE ODo not remove the push rod clevis for master cylinder disassembly since removal requires brake position ad justment Remove the rear master cylinder see Rear Master Cylin der Removal in the Brakes chapter Remove the circlip A Special Tool Inside Circlip Pliers 57001 143 e Pull out the push rod with the piston stop Take off the piston B secondary cup C primary cup D and return spring E Remove the circlip and pull out the brake hose con nector G and O ring H Special Tool I
363. nk shaft clockwise until the 1 T mark line A on the timing ro tor is aligned with the mating surface B of the crankcase front side B P 5 20 ENGINE END Camshaft Camshaft Chain Remove the camshaft chain tensioner see Camshaft Chain Tensioner Removal Loosen the camshaft cap bolts following the sequence 1 12 shown in the figure and remove them Remove Camshaft Caps A Camshafts B The crankshaft may be turned while the camshafts are removed Always pull the chain taut while turn ing the crankshaft This avoids kinking the chain on the lower crankshaft sprocket A kinked chain could damage both the chain and the sprocket Stuff a clean cloth into the chain tunnel to keep any parts from dropping into the crankcase Remove Camshaft Sprocket Bolts A Camshaft Sprockets GE112048W2 C GE11205BS1 Camshaft Camshaft Chain ENGINE TOP END 5 21 Camshaft Installation Replace the plug hole gaskets A with new ones e Be sure to install the following parts Dowel Pins B Plug Hole Gaskets Install the camshaft sprockets so that the marked IN and EX side faces outward OThe intake A and exhaust B camshaft sprockets are identical Intake camshaft sprocket must use IN marked bolt holes C Exhaust camshaft sprocket must use EX marked bolt holes D Apply a non permanent locking a
364. nly 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 incorrect Valve
365. nning Down Neutral Released Starts Conte running Down Neutral Pulled in Starts running Down In Gear Released Stops start Down In Gear Pulled in Poes not stops start PERIODIC MAINTENANCE 2 43 Periodic Maintenance Procedures x If the sidestand switch operation does not work inspect or replace the following item Battery see Charging Condition Inspection in the Elec trical System chapter Main Fuse 30 A see Fuse Inspection in the Electrical System chapter Ignition Fuse 10 A see Fuse Inspection in the Electrical System chapter Ignition Switch see Switch Inspection in the Electrical System chapter Sidestand Switch see Switch Inspection in the Electrical System chapter Engine Stop Switch see Switch Inspection in the Elec trical System chapter Starter Button see Switch Inspection in the Electrical System chapter Neutral Switch see Switch Inspection in the Electrical System chapter Starter Relay see Starter Relay Inspection in the Elec trical System chapter Relay Box see Relay Circuit Inspection in the Electrical System chapter Starter Circuit Relay see Relay Circuit Inspection in the Electrical System chapter Harness see Wiring Inspection in the Electrical System chapter xIf the all parts are in good condition replace the ECU see ECU Removal Installation in the Fuel System DFI chapter Engine Stop Switch Operation Inspection First Step e Turn the ignition switch to ON e Set t
366. not turn the balancer shaft during clearance mea surement ORemove the lower crankcase half and measure the plas tigage width A to determine the bearing insert journal B clearance Balancer Shaft Bearing Insert Journal Clearance Standard 0 011 0 033 mm 0 0004 0 0013 in Service Limit 0 06 mm 0 002 in x If the clearance is within the standard no bearing insert replacement is required x If the clearance is between 0 034 mm 0 00134 in and the service limit 0 08 mm 0 003 in replace the bearing inserts A with inserts painted blue B Check insert jour nal clearance with a plastigage The clearance may ex ceed the standard slightly but it must not be less than the minimum in order to avoid bearing seizure x If the clearance exceeds the service limit measure the diameter of the balancer shaft journal Balancer Shaft Journal Diameter Standard 27 987 28 000 mm 1 1019 1 1024 in Service Limit 27 96 mm 1 1008 in x If either journal has worn past the service limit replace the balancer shaft with a new one xlf the measured journal diameters are not less than the service limit but do not coincide with the original diameter markings on the balancer shaft write new marks on it Balancer Shaft Diameter Marks None 27 987 27 993 mm 1 1019 1 1021 in O 27 994 28 000 mm 1 1021 1 1024 in A Balancer Shaft Journal Diameter Marks O mark or no mark 61060301 S 6
367. nside Circlip Pliers 57001 143 NOTICE Do not remove the secondary cup from the piston since removal will damage it Master Cylinder Assembly e Before assembly clean all parts including the master cylinder with brake fluid or alcohol Except for the disc pads and disc use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning 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 9513267851 9513268852 C 2 56 PERIODIC MAINTENANCE Periodic Maintenance Procedures Apply brake fluid to the new parts and to the inner wall of the cylinder Take care not to scratch the piston or the inner wall of the cylinder e Apply silicone grease to the brake lever pivot bolt and the push rod Replace the brake lever pivot bolt locknut with a new Tighten Torque Brake Lever Pivot Bolt 1 0 N m 0 10 kgf m 9 in Ib Brake Lever Pivot Bolt Locknut 5 9 0 60 kgf m 52 in Ib Caliper Rubber Parts Replacement Front Caliper Disassembly e Remove Front Caliper see Front Caliper Removal in the Brakes chapter Brake Pads see Front Brake Pad Removal in the Brakes chapter Pad Spring e Using compressed air remove
368. nstallation e Refer to the Oxygen Sensor Removal Installation in the Electrical System chapter Oxygen Sensor Inspection e Turn the ignition switch to OFF e Remove the engine sprocket cover see Engine Sprocket Removal in the Final Drive chapter e Disconnect the oxygen sensor connector and connect the oxygen sensor measuring adapter A between these con nectors Special Tool Oxygen Sensor Measuring Adapter 57001 1682 e Connect a digital meter to the harness adapter lead Oxygen Sensor Output Voltage Connections to Adapter Meter BL sensor BL lead Meter BR sensor W lead e Remove the left middle fairing see Middle Fairing Re moval in the Frame chapter e Remove the air switching valve hose A from the fitting e Install the suitable plug on the fitting to shut off the sec ondary air e Turn the ignition switch to ON e Warm up the engine thoroughly until the radiator fan starts e Measure the output voltage with the connector joined Output Voltage with Plug Standard 0 7 V or more FUEL SYSTEM 3 81 Oxygen Sensor Incorrect Output Voltage Service Code 94 Equipped Models Next remove the plug from the fitting A with idling A WARNING The engine gets extremely hot during normal oper ation and can cause serious burns Never touch a hot engine Measure the output voltage with the connector joined Output Voltage without Plug Standard
369. nsufficient DFI Fuel tank air vent obstructed Fuel line clogged Fuel pump trouble Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive APPENDIX 17 45 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 Crankshaft sensor trouble Miscellaneous Throttle valve won t fully open Brake dragging Clutch slipping Engine overheating Engine oil level too high Engine oil viscosity too high Drive train trouble Air suction valve trouble Air switching valve trouble Catalytic converter melt down due to muffler overheating KLEEN Overheating Firing incorrect Spark plug dirty broken or maladjusted Spark plug incorrect 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
370. nsufficient deteriorated or contaminated engine oil will cause accelerated wear and may result in engine seizure accident and injury Check the oil level before each use and change the oil and filter according to the periodic maintenance chart Oil Level Inspection 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 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 red oil pressure warning indicator light LED will light If this light stays on when the en gine is running above idle speed stop the engine immediately and find the cause x If the oil level is too high remove the excess oil using a syringe or some other suitable device xIf 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
371. nt Parts S Follow the specified tightening sequence 5 4 ENGINE END Exploded View ENGINE TOP END 5 5 Exploded View 2 Cylinder M6 2 in Ib 3 Oylinder Nut 49 5 0 36 uo S 4 Exhaust Pipe Manifold Holder Nuts 17 1 7 13 5 Muffler Body Mounting Bolts 20 2 0 15 L Apply a non permanent locking agent MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts S Follow the specified tightening sequence 5 6 ENGINE END Exhaust System Identification Exhaust System MUFFLER Honeycomb Type Catalyst With Oxygen Sensor P No 49070 0723 Mark KHI K 618 EPA Noise Emission Control Information Honeycomb Type Catalyst Without Oxygen Sensor P No 49070 0729 Mark KHI K 618 EPA Noise Emission Control Information Honeycomb Type Catalyst Without Oxygen Sensor P No 49070 0738 Mark KHI K 618 EPA Noise Emission Control Information SPECIFICATION BR WVTA FULL H GB WVTA FULL H ID PH SEA B2 AU AU LAMS SEA B1 TH US CA CAL MODEL EX650EC FC EX650EC FC EX650EC FC EX650EC EX650EC EX650EC EX650FC EX650FC EX650FC EX650FC EX650EC EX650EC EX650EC EX650EC GE24763B F Muffler Mark Position A GE24738BS1 Muffler with Hole A for Oxygen Sensor B GE24780BS1 Honeycomb Type Catalyst Posi
372. ntarily whenever the starter button is pressed and come back on when the button is released Headlight Beam Horizontal Adjustment Refer to the Headlight Aiming Inspection in the Periodic Maintenance chapter Headlight Beam Vertical Adjustment Refer to the Headlight Aiming Inspection in the Periodic Maintenance chapter Headlight Bulb Replacement e Remove Connector A Disconnect Headlight Bulb Dust Cover B Release the hook A and remove the headlight bulb B 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 Replace the headlight bulb with a new e Fit the projections A on the bulb in the hollows on the headlight unit Install the hook B Lighting System ELECTRICAL SYSTEM 16 55 e Fit the dust cover A firmly onto the bulb so that the TOP mark B is aligned with the arrow mark C on the head light unit Connect the connector e After installation adjust the headlight aim see Headlight Aiming Inspection in the Periodic Maintenance chapter City Light Bulb Replacement Pull out the socket A together with the bulb Pull the bulb A out of the socket B Do not turn
373. ntinuity Inspection ECU Connector A Subthrottle Sensor Connector B BL lead ECU terminal 8 C BR BK lead ECU terminal 22 D xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation Subthrottle Sensor Output Voltage Inspection Remove the air cleaner housing see Air Cleaner Housing Removal e Measure the output voltage at the subthrottle sensor in the same way as input voltage inspection Note the fol lowing ODisconnect the subthrottle sensor connector and connect the throttle sensor setting adapter A between these con nectors Special Tool Throttle Sensor Setting Adapter 1 57001 1400 6617793051 FUEL SYSTEM DFI 3 65 Subthrottle Sensor Service Code 32 Subthrottle Sensor Output Voltage Connections to Adapter Digital Meter Y W sensor BR lead Digital Meter BK BL sensor BR BK lead Turn the ignition switch to ON e Measure the output voltage when the subthrottle valve is fully opened or completely closed by hand Output Voltage Standard DC 0 6 0 8 V at idle throttle opening DC 4 08 4 12 V at full throttle opening NOTE OTurn the lever counterclockwise confirm the output volt age will be raise OThe standard voltage refers to the value when the volt age reading at the Input Voltag
374. o directions of the solvent manufacturer 6 020058 5 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 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 68020088 5 Inspection Reuse of worn or damaged parts may lead to serious ac cident Visually inspect removed parts for corrosion discol SN 4 oration or other damage Refer to the appropriate sections of this manual for service limits on individual parts Replace AN the parts if any damage has been found or if the part is be yond its service limit 680200968 5 Replacement Parts Replacement parts must be KAWASAKI genuine or recommended by KAWASAKI Gaskets O rings oil seals grease seals circlips cotter pins or self locking nuts must be replaced with new ones whenever disassembled 6802010
375. o or three times up and down to lubricate them e Be sure that the collar D is on the shaft e Be sure that the spring hook portions E are as shown e Install the shift shaft assembly A e Be sure that the washer B is on the shaft e Be sure that the dowel pins C are in position e When the new needle bearing A is installed in the shift shaft cover B press and insert the new needle bearing until it is bottomed Special Tool Bearing Driver Set 57001 1129 e When the new oil seal C is installed in the shift cover press and insert the new oil seal so that its surface is flush with the end of the hole Special Tool Bearing Driver Set 57001 1129 e Apply engine oil to the needle bearing e Apply grease to the oil seal lips 9113242851 9 34 CRANKSHAFT TRANSMISSION External Shift Mechanism Replace the shift shaft cover gasket with a new one Install the shift shaft cover Apply a non permanent locking agent to the shift shaft cover screw A Apply a non permanent locking agent to the shift shaft cover bolts B C B L 45 mm 1 8 in C L 30 mm 1 2 in ODo not apply a non permanent locking agent to the shift shaft cover bolts D E D L 30 mm 1 2 in E L 40 mm 1 6 in First tighten the shift shaft cover bolts then tighten the shift shaft cover screw Torque Shift Shaft Cover Bolts 9 8 1 0 kgf m 87 in Ib Shift Shaft Cover Screw 4 9 N m 0 50
376. o the threads of the oil pipe bolts and tighten them Torque Oil Pipe Bolts 9 8 N m 1 0 kgf m 87 in Ib Olnstall the clamp with the upper oil pipe bolt 9104254851 CRANKSHAFT TRANSMISSION 9 15 Crankcase Splitting e Install the crankshaft and the balancer shaft on the upper crankcase half OApply molybdenum disulfide oil solution to the following items Crankshaft Main Bearing Insert Balancer Shaft Bearing Insert OAlign A the timing mark on the balancer gear B with the timing mark on the balancer drive gear C of the crank shaft 8104255 52 Be sure to hang the camshaft chain A on the crankshaft e Be sure that the dowel pins A are in position Install the bearing A so that the positioning ring B fits into the bearing groove C 9 16 CRANKSHAFT TRANSMISSION Crankcase Splitting 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 Apply liquid gasket A to the mating surface of the lower crankcase half Sealant Liquid Gasket TB1216B 92104 1064 NOTE OEspecially apply a liquid gasket carefully so that it shall be filled up on the grooves Do not apply liquid gasket around the crankshaft main bearing inserts and oil passage holes ODo not apply liquid gasket to the oil passage B
377. ocate the Electrical System chapter Then use the Table of Contents on the first page of the chap ter to find the Ignition Coil section Whenever you see symbols heed their in structions Always follow safe operating and maintenance practices A DANGER DANGER indicates a hazardous situa tion which if not avoided will result in death or serious injury A WARNING WARNING indicates a hazardous situa tion which if not avoided could result in death or serious injury NOTICE is used to address practices not related to personal injury This manual contains four more symbols which will help you distinguish different types of information NOTE OThis note symbol indicates points of par ticular interest for more efficient and con venient operation e Indicates a procedural step or work 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
378. od it may be defective in some manner not readily detectable with the hand tester If all other starter motor and starter motor circuit components check good but the starter motor still does not turn over or only turns over weakly replace the starter motor with a new one Brush Lead Inspection Using the x 1 hand tester range measure the resis tance as shown Terminal Bolt and Positive Brushes A Right hand End Cover and Negative Brushes B Special Tool Hand Tester 57001 1394 x If there is not close to zero ohms the brush lead has open Replace the brush assembly 16 52 ELECTRICAL SYSTEM Electric Starter System Right hand End Cover Inspection e Using the highest tester range measure the resistance as shown Terminal Bolt and Right hand End Cover A Terminal Bolt and Negative Brushes B Special Tool Hand Tester 57001 1394 x If there is any reading the brush assy and or terminal bolt assy have a short Replace the starter motor Starter Relay Inspection e Remove the front seat see Front Seat Removal in the Frame chapter Pull out the starter relay A from the bracket Slide out the cap A e Disconnect Connector B Starter Motor Cable C Battery Positive Cable D Remove the starter relay The battery positive cable with the rubber cap is connected directly to the battery positive terminal even when the ignition switch to OFF so take care not to short th
379. ode 55 boc Contec yee A eae 12 55 ABS Hydraulic Unit Removal sci een he boli ten pet auri 12 56 ABS Hydraulic Unit IristallatlQni tetuer eee teet Pasar etie o Sind E tee aeo 12 58 ABS Hydraulic 12 58 Front Wheel Rotation Sensor Removal 1 12 58 Front Wheel Rotation Sensor Installation 12 59 Rear Wheel Rotation Sensor Removal 12 59 Rear Wheel Rotation Sensor Installation pp 12 60 Wheel Rotation Sensor Inspectiom 12 60 Wheel Rotation Sensor Air Gap Inspection Ne 12 61 Wheel Rotation Sensor Rotor Inspection pp 12 61 Brake Hose and Pipe 12 61 Brake Hose and Pipe 12 61 ABS Solenoid Valve Relay Fuse 15 A Removal pp 12 61 ABS Motor Relay Fuse 25 A 12 62 Fuse Stell AMON c 12 62 FUSE INS POCON 12 62 5 12 3 Exploded View This page intentionally left blank 12 4 BRAKES Exploded View EX650E Model 08102499845 C BRAKES 12 5 Exploded View N m kgf m ft Ib 5 pr S Front Brake Reservoir Cap Screws 1 0 15 13 in Ib Brake Lever Pivot Bolt 1 0 0 10 9 in Ib Brake Lever Pivot Bolt Locknut 5 9 0 60 52 R 5 A Front Master
380. odic Maintenance chapter Synchronization Inspection Adjustment Refer to the Engine Vacuum Synchronization Inspection in the Periodic Maintenance chapter Throttle Body Assy Removal A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions creating the potential for serious burns 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 to OFF Disconnect the battery terminal To avoid fuel spills draw it from the tank when the engine is cold Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately Never drop the throttle body assy especially on a hard surface Such a shock to the body assy can damage it e Remove Fuel Tank see Fuel Tank Removal Air Cleaner Housing see Air Cleaner Housing Removal Fuel Hose see Fuel Hose Replacement in the Periodic Maintenance chapter Open the clamps e Disconnect the connectors B e Remove Main Throttle Sensor Connector A Disconnect Vacuum Hose B Loosen the throttle body assy holder clamp bolts 3 104 FUEL SYSTEM Throttle Body Assy Pull the throttle body assy A out of the holder e Disconnect the subthrottle sensor connector B Loosen the locknut A and screw the adjuster B to give the throttle grip plenty of play e Rem
381. of the DFI system If any wiring is deteriorated replace the wiring e Pull each connector A apart and inspect it for corrosion dirt and damage x If the connector is corroded or dirty clean it carefully If it is damaged replace it Connect the connectors securely 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 main harness B 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 harness 6617037351 GP07055BS1 C 6017029181 3 26 FUEL SYSTEM Troubleshooting the DFI System 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 6017029281 e Narrow down suspicious locations by repeating the con tinuity tests from the ECU connectors
382. oil shorted or not in good contact Stick coil trouble Spark plug dirty broken or gap maladjusted Spark plug incorrect ECU trouble Fuel air mixture incorrect Air cleaner clogged poorly sealed or missing Air duct loose Throttle body assy holder loose Throttle body assy dust seal damage Water or foreign matter in fuel Actions Inspect or Reinstall see chapter 16 Inspect see chapter 16 Inspect and replace see chapter 2 Replace it with the correct plug see chapter 2 Inspect see chapter 3 Clean element or inspect sealing See chapter 2 Reinstall see chapter 3 Reinstall see chapter 3 Replace see chapter 3 Change fuel Inspect and clean fuel system see chapter 3 Fuel injector O ring damage Replace see chapter 3 Fuel injector clogged Inspect and repair see chapter 3 Fuel line clogged Inspect and repair see chapter 3 Fuel pump operates intermittently and often DFI fuse blows Fuel pump bearings may wear Replace the fuel pump see chapter 3 Fuel pump trouble Intake air pressure sensor trouble Cracked or obstructed intake air pressure sensor vacuum hose Water temperature sensor trouble Intake air temperature sensor trouble Main throttle sensor trouble Subthrottle sensor trouble Subthrottle valve actuator trouble Knocking Fuel poor quality or incorrect Inspect see chapter 3 Inspect see chapter 3 Inspect and repair or replace see chapter 3
383. on Transmission Gear 1st Position Clutch Lever Release Sidestand Up Set the sidestand on the ground then the engine should stop the engine does not stop inspect the neutral switch sidestand switch and relay box x If their parts are normal replace the ECU see ECU Re moval Installation in the Fuel System DFI chapter IC Igniter Inspection OThe IC igniter is built in the ECU A Refer to the Interlock Operation Inspection Ignition Sys tem Troubleshooting chart and Fuel System DFI chapter for ECU Power Supply Inspection ELECTRICAL SYSTEM 16 45 Ignition System Ignition System Troubleshooting Faulty ignition No spark No good Battery Inspection Charge or replace battery Good Ignition system wiring and connector Magoon Repair or replace inspection damaged part Good No good Spark plug inspection Replace spark plug Good No good Stick coil winding resistance inspection Replace stick coil Good 9998 Voltage is less than the specified value Inspect 1 Lower resistance in a hand tester Use KAWASAKI Hand Tester 2 Crankshaft sensor peak voltage Stick coil primary peak voltage inspection Good Stick coil is defective Replace stick coil Voltage is zero No good or almost zero Inspect Replace bad parts or No good 1 Adapter connection is incorrect or inspect them with adapter is defective KAWASAKI Hand 2 Ignition switch and engine
384. ones e Tighten Torque Rear Sprocket Nuts 59 N m 6 0 kgf m 44 ft Ib e Install the rear wheel see Rear Wheel Installation in the Wheels Tires chapter 90058543 Coupling Installation e Apply high temperature grease to the following portions Coupling Grease Seal Lips A Coupling Internal Surface B GK05040BS1 C 11 12 FINAL DRIVE Sprocket Coupling Replace the O ring A with a new one and apply grease to it e Install O ring Collar B Coupling Coupling Bearing Removal e Remove Coupling Grease Seal Circlip A Special Tool Inside Circlip Pliers 57001 143 Remove the bearing A by tapping from the wheel side Special Tool Bearing Driver Set B 57001 1129 Coupling Bearing Installation Replace the bearing with a new e Press in the bearing A until it is bottomed Special Tool Bearing Driver Set B 57001 1129 Replace the circlip with a new one and install it Special Tool Inside Circlip Pliers 57001 143 Replace the grease seal with a new e Apply high temperature grease to the grease seal lips e Press in the grease seal so that the seal surface is flush with the end of the hole Special Tool Bearing Driver Set 57001 1129 GKO5038BS1 Sprocket Coupling FINAL DRIVE 11 13 Coupling Bearing Inspection Since the coupling bearing is made to extremely close tolerances the clearance can not normally be measured
385. ons and push them into each cylinder by hand e Check the 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 PBC is a special high temperature water resistance grease Install the pad spring A Install the pads see Front Brake Pad Installation in the Brakes chapter e Wipe up any spilled brake fluid on the caliper with wet cloth GS138545 P Rear Caliper Disassembly e Remove Rear Caliper see Rear Caliper Removal in the Brakes chapter Brake Pads see Rear Brake Pad Removal in the Brakes chapter Pad Spring 2 58 PERIODIC MAINTENANCE Periodic Maintenance Procedures Using compressed air remove the piston 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 The piston in the brake caliper can crush hands and fingers Never place your hand or fingers in front of the piston Pull out the pistons by hand e Remove Caliper Holder Dust Seal Fluid Seal Bleed Valve Rubber Cap NOTE Olf compressed air is not available do as follows with the brake hose connected to the caliper OPrepare a container for brake fluid and perform the work above it ORemove the brake pads see Rear Brake Pad Removal in the Brakes chapter OPump the brake pedal until the
386. ool Hand Tester 57001 1394 OTurn the ignition switch to ON Battery Terminal Voltage Standard 9 6 V or more x If the battery terminal voltage is not within the specifica tion go to the 3rd step x If the battery terminal voltage is correct go to the 4th step e Do the 3rd step test as follows Olnspect the following parts Battery see Charging Condition Inspection in the Elec trical System chapter Ignition Switch see Switch Inspection in the Electrical System chapter Main Harness see Wiring Inspection in the Electrical System chapter Main Fuse 30 A see Fuse Inspection in the Electrical System chapter e Do the 4th step test as follows ORecheck the service code indication erase the service code perform the pre diagnosis inspection 1 and 2 and retrieve the service code x If the yellow ABS indicator light LED A goes on faulty ECU in the ABS hydraulic unit Replace the ABS hy draulic unit If the yellow ABS indicator light LED does not go ABS system is normal service code is not stored tempo rary failure Power Supply Voltage Abnormal Over Voltage Service Code 53 e Do the 1st step test as follows ODisconnect ABS Kawasaki Diagnostic System Connector ABS Hydraulic Unit Connector see ABS Hydraulic Unit Removal OCheck for continuity between the red white lead terminal of the main harness side connector A and brown white lead terminal of the main harness side connector ABS hydra
387. oolant Change in the Periodic Maintenance chapter Water Pump Inspection e Check the drainage outlet passage A at the bottom of the water pump body for coolant leaks xIf the mechanical seal is damaged the coolant leaks through the seal and drains through the passage Re place the mechanical seal unit with a new one Mechanical Seal Inspection e Remove the impeller see Water Pump Removal e Visually inspect the mechanical seal xIf any of the parts is damaged replace the mechanical seal unit with a new one OThe sealing seat and rubber seal may be removed easily by hand Impeller Sealing Seat Surface A Rubber Seal B Mechanical Seal Diaphragm C 4 12 COOLING SYSTEM Water Pump Water Pump Housing Disassembly Be careful not to damage the sealing surface of the mechanical seal Remove the water pump housing see Water Pump Re moval Take the oil seal A out of the housing B with a hook C Press the mechanical seal A out of the housing with a bearing driver B Special Tool Bearing Driver Set 57001 1129 Water Pump Housing Assembly Using a cleaning fluid clean off any oil or dirt on the outer circumference A of the oil seal and its mounting surface of the housing e Apply grease B to the new oil seal C Press the oil seal into the housing with a bearing driver so that the seal surface is flush D with the end of the hole Special Tool Bearing Driver Set 57001
388. or Position the clamp as shown Clamps Hold the front wheel rotation sensor lead and the brake hose Approx 30 mm 1 2 in 17 26 APPENDIX Cable Wire and Hose Routing 68092350 6 APPENDIX 17 27 Cable Wire Hose Routing NOOR WD Fix the rear brake reservoir tank to the battery case Clamps Run the brake hose rear master cylinder rear caliper through the swingarm Fix the brake hose rear brake reservoir tank rear master cylinder to the frame with the clamps Run the brake hose between the clamp and the swingarm Fix the brake hose to the clamp on the swingarm Run the brake hose rear master cylinder rear caliper under the brake hose rear brake reser voir tank rear master cylinder 17 28 APPENDIX Cable Wire and Hose Routing ABS Equipped Models APPENDIX 17 29 Cable Wire and Hose Routing Fix the rear brake reservoir tank to the battery case Clamps Run the brake hose ABS hydraulic unit rear caliper through the swingarm Fix the brake hose rear brake reservoir tank rear master cylinder to the frame with the clamps Fix the rear wheel rotation sensor lead to the swingarm with the clamps Run the rear wheel rotation sensor lead inside the boss Rear Wheel Rotation Sensor Clamps 55 65 mm 2 2 2 6 in Rear Wheel Rotation Sensor Lead Brake Hose ABS Hydraulic Unit Rear Ca
389. ose connection with a piece of clean cloth to prevent fuel spillage 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 294 kPa 3 0 kgf cm 43 psi NOTICE During pressure testing do not exceed the maxi mum pressure for which the system is designed OWatch the gauge for at least 6 seconds x If the pressure holds steady the fuel line is good x If the pressure drops at once or if bubbles are found in the area the fuel line is leaking Replace the fuel supply pipe assy injectors and related parts ORepeat the leak test and check the fuel line for no leak age Install Fuel Hose see Fuel Hose Replacement in the Periodic Maintenance chapter Fuel Tank see Fuel Tank Installation Start the engine and check for fuel leakage 80170240651 FUEL SYSTEM 3 101 Fuel Injectors Fuel Injector Circuit BK Y BL R BL Y BR Y n GCi7192FW2 C Ignition Switch Eng
390. osis mode the service code A is displayed on the LCD Liquid Crystal Display by the number of two digits If the problem is with the following parts the ECU can not recognize these problem Therefore the yellow engine warning indicator light LED does not go on and service code is not displayed LCD for Meter Unit Fuel Pump Fuel Pump Relay Fuel Injectors Stick Coil Secondary Wiring and Ground Wiring ECU Main Relay ECU Power Source Wiring and Ground Wiring When the service code A is displayed for first ask the rider about the conditions B of trouble and then start to determine the cause C of problem As a pre diagnosis inspection check the ECU for ground and power supply the fuel line for no fuel leaks and for correct pressure The pre diagnosis items are not indicated by the yellow engine warning indicator light LED Don t rely solely on the DFI self diagnosis function use common sense 8017202 51 8017203 52 8017205 51 3 24 FUEL SYSTEM Troubleshooting the DFI System Even when the DFI system is operating normally the yel low engine warning indicator light LED may go on under strong electrical interference Additional measures are not required Turn the ignition switch to OFF to stop the indica tor light If the yellow engine warning indicator light LED of the motorcycle brought in for repair still goes on or blinks check the service code
391. ottle Opening 4 6 About DC 8 5 10 5 V About 5 5 7 50 DC 0 7 V or more DC 0 2 V or less 11 7 14 5 at 20 C 68 F 30 34 O at 20 C 68 F 2 3 mm 0 08 0 12 in Special Tools and Sealant Oil Pressure Gauge 5 kgf cm 57001 125 875701255 C Fork Oil Level Gauge 57001 1290 5157129051 C Vacuum Gauge 57001 1369 225 222 7571369ST C Hand Tester 57001 1394 7571394ST C Throttle Sensor Setting Adapter 1 57001 1400 7571400ST C FUEL SYSTEM DFI 3 19 Peak Voltage Adapter 57001 1415 5157141551 C Needle Adapter Set 57001 1457 5157145751 C Throttle Sensor Setting Adapter 57001 1538 7571538ST C Fuel Pressure Gauge Adapter 57001 1593 875715935 Fuel Hose 57001 1607 5157160751 C 3 20 FUEL SYSTEM Special Tools and Sealant Oxygen Sensor Measuring Adapter Liquid Gasket TB1211 57001 1682 56019 120 5157168251 875601205 Measuring Adapter 57001 1700 875717005 6 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
392. ouched wash it off with liberal amount of water and seek medial at tention for more severe burns 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 Battery ELECTRICAL SYSTEM 16 27 Charging Condition Inspection Battery charging condition can be checked by measuring battery terminal voltage with a digital voltmeter A Remove the battery see Battery Removal Be sure to disconnect the negative lead first Measure the battery terminal voltage NOTE OMeasure with a digital voltmeter which can be read to one decimal place voltage x lf the reading is 12 8 V or more no refresh charge is re quired however if the reading is below the specified re fresh charge is required Battery Terminal Voltage Standard 12 8 V or more Terminal Voltage V A Battery Charge Rate B Refresh charge is required C Good D Install the battery see Battery Installation Refreshing Charge Remove the battery A see Battery Removal Be sure to disconnect the negative lead first e Refresh charge by following method according to the bat tery terminal voltage
393. ounting nuts with new ones Olnstall Dampers Lower Handlebar Holders Washers Handlebar Holder Mounting Nuts OTighten Torque Handlebar Holder Mounting Nuts 34 N m 3 5 kgf m 25 ft lb Olnstall the snap pins 14 12 STEERING Handlebar Set the handlebar onto the lower handlebar holders OAlign the upper punch mark A on the handlebar with the corner edge B of the lower handlebar holder Install the upper handlebar holder A Tighten the front handlebar holder bolts B first and then the rear handlebar holder bolts C There will be a gap D at the rear part of the holder after tightening Torque Handlebar Holder Bolts 25 N m 2 5 kgf m 18 ft Ib Install the clutch lever see Clutch Lever Installation in the Clutch chapter e Clean off any oil or dirt and apply adhesive cement to the handlebar A as shown B 125 mm 4 92 in Apply a non permanent locking agent to the left handlebar weight bolt and tighten it e Install the left switch housing OFit the projection A into a hole B on the handlebar e Tighten Torque Switch Housing Screws 3 5 0 36 kgf m 31 in Ib GN06097BS1 Handlebar STEERING 14 13 e Install Throttle Grip Throttle Cable Tips A Right Switch Housing OFit the projection B into a hole C on the handlebar OThe lower switch housing screw is longer than the upper one Tighten Torque
394. ove the clamp C Pull the throttle cables out of the cable holders D e Free the throttle cable lower ends E from the throttle pulley e After removing the throttle body assy stuff pieces of lint free clean cloths into the throttle body assy holders If dirt gets into the engine excessive engine wear and possible engine damage will occur Throttle Body Assy Installation e Apply a thin coat of grease to the throttle cable lower ends e Fitthe accelerator cable end A and the decelerator cable end B into the throttle pulley e Install the clamp C securely Throttle Body Assy FUEL SYSTEM DFI 3 105 Install the throttle body assy holder clamp bolts A so that their bolt heads B face outward e Install the throttle body assy onto the holder securely Tighten Torque Throttle Body Assy Holder Clamp Bolts 2 0 Nm 0 20 kgf m 18 in Ib e Turn the throttle grip to make sure that the throttle valves move smoothly and return by spring force e Check the throttle body assy for fuel leakage A WARNING Fuel spilled from the throttle body assy is haz ardous e Run the leads and hoses correctly see Cable Wire and Hose Routing section in the Appendix chapter Install the other removed parts see appropriate chap ters Adjust Throttle Grip Free Play see Throttle Control System In spection in the Periodic Maintenance chapter Idle Speed see Idle Speed Adjustmen
395. ower Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation x lf there is still no battery voltage check the ECU main relay and fuel pump relay see Relay Circuit Inspection in the Electrical System chapter xIf the main relay and pump relay are normal check the wiring for continuity see wiring diagram in this section xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation x If the reading is in specification but the pump does not op erate replace the fuel pump see Fuel Pump Removal In stallation 3 96 FUEL SYSTEM Fuel Pump Pressure Regulator Removal OThe pressure regulator A is built into the fuel pump and cannot be removed Fuel Filter Cleaning OThe fuel filter A is built into the pump and cannot be cleaned or checked x If the pump screen or fuel filter is suspected of clogging or being damaged replace it with the fuel pump as a set Fuel Pump Circuit Ignition Switch Engine Stop Switch ECU Fuel Pump Frame Ground 1 Frame Ground 2 Battery 12 V 10 Ah Main Fuse 30 A Relay Box 10 ECU Main Relay 11 Fuel Pump Relay 12 Fuse Box 1 13 Fl Fuse 15 A 14 Ignition Fuse 10 A ar BR 118
396. ower Supply to Sensors BL Vehicle down Sensor Y G Neutral Switch LG Crankshaft Sensor R BK Power Supply to ECU from ECU Main Re lay BR W Communication Line diagnosis System P BL Self Subthrottle Valve Actuator P Subthrottle Valve Actuator W BL Unused Water Temperature Sensor O Unused Subthrottle Sensor BR Intake Air Temperature Sensor R Unused Ground for Sensors BR BK 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 68017248042 C Oxygen Sensor Heater Equipped Models P BK Crankshaft Sensor Y BK Purge Valve CAL SEA B1 and TH Mod els R Y Ground for ECU BK Power Supply to ECU from Battery W BK Engine Stop Switch R Starter Lockout Switch R G Starter Button BK R Fuel Pump Relay BR Y Air Switching Valve R BL Injector 2 BL Y Injector 1 BL R Stick Coil 1 BK Sidestand Switch G BK Radiator Fan Relay P BL External Communication Line LG BK Meter Unit Tachometer LB External Communication Line BL O Meter Ground for Fuel System BK Y Ground for Ignition System BK Y Stick Coil 2 BK O FUEL SYSTEM DFI 3 15 DFI Parts Location Ignition Switch A Relay Box B ECU Main Relay Radiator Fan Relay Fuel Pump Relay ECU C Intake Air Temperature Sensor D Vehicle down Sensor E Fuse Box F Oxygen Sensor Heater Fuse 10 A Radia tor
397. pecified fuse rating for that circuit Installation of a fuse with a higher rating may cause damage to wiring and components 8 20000151 APPENDIX 17 1 Appendix Table of Contents Cable Wire and Hose Routing Ne 17 2 Troubleshooting GUIDE o OR ida putet itio astu Af des 17 44 17 2 APPENDIX Cable Wire and Hose Routing The routing on EX650E F is shown using the figure of ER650E F JF h X rA W Pu SN E 7 Prt 68092220 6 APPENDIX 17 3 Cable Wire Hose Routing 58095230 A LEX Ce S the main harness inside the ribs the air cleaner housing cover Clamp Hold the main harness Fix the clamp to the bracket Run the rear smaller ECU connecter lead above the other one Right Switch Housing Lead Connector Air Switching Valve Lead Connector Stick Coil Lead Connectors Clamps Front Right Switch Housing Lead Ignition Switch Lead Harness Air Switching Valve Lead and Ignition Coil Leads Clamp 17 4 APPENDIX Cable Wire and Hose Routing The routing on EX650E F is shown using the figure of ER650E F 5809240 6 APPENDIX 17 5 Cable Wire Hose Routing WN 11 14 15 Guide Hold the intake air pressure sensor lead Vehicle down Sensor Lead F
398. pection 9 9 Subthrottle Sensor Resistance Inspection Ne Oxygen Sensor not activated Service Code 33 Equipped Oxygen Sensor Removal lnstallation pp Oxygen Sensor Inspection Stick Coils 1 2 Service Code 51 52 Hee Stick Coil Removal Installation Stick Coil Primary Winding Resistance Inspection pp Stick Coil Input Voltage Inspection 70 Radiator Fan Relay Service Code 56 eee cede taie eene diee Radiator Fan Relay Removalllnstallationm Radiator Fan Relay Inspection Subthrottle Valve Actuator Service Code Dy esc rt Subthrottle Valve Actuator Removal Subthrottle Valve Actuator Subthrottle Valve Actuator Resistance Inspection Subthrottle Valve Actuator Input Voltage Inspection Air Switching Valve Service Code 64 Air Switching Valve Removal Installation pp Air Switching Valve Inspection Oxygen Sensor Heater Service Code 67 Equipped Oxygen Sensor Heater Removal lnstallation Oxygen Sensor Heater Inspection pp Oxygen Sensor Heater Power Source Voltage Inspection
399. pection Wheel Rotation Sensor Rotor Inspection Remove the front rear brake discs see Brake Disc Re moval e Visually inspect the wheel rotation sensor rotor x lf the rotor is deformed or damaged chipped teeth A replace the sensor rotor with the brake disc x If there is iron or other magnetic deposits B remove the deposits GL14006BS1 Brake Hose and Pipe Removal Installation e Refer to the Brake Hose and Pipe Replacement in the Periodic Maintenance chapter Brake Hose and Pipe Inspection e Refer to the Brake Hose and Pipe Damage and Instal lation Condition Inspection in the Periodic Maintenance chapter ABS Solenoid Valve Relay Fuse 15 A Removal e Remove the left frame cover see Frame Cover Removal in the Frame chapter e Unlock the hook and open the lid A Pull out the relay fuse B from the fuse box with needle nose pliers 12 62 5 Anti Lock Brake System Equipped Models ABS Motor Relay Fuse 25 A Removal e Remove the left frame cover see Frame Cover Removal in the Frame chapter Unlock the hook and open the lid A e Pull out the relay fuse B from the fuse box with needle nose pliers Fuse Installation e If a fuse fails during operation inspect the electrical sys tem to determine the cause and then replace it with a new fuse of proper amperage Fuse Inspection e Remove the fuse see ABS Solenoid Valve Relay Fuse 15 A ABS Motor Relay Fuse 25
400. pection Refer to the Water Hose Damage and Installation Condi tion Inspection in the Periodic Maintenance chapter 4 20 COOLING SYSTEM Water Temperature Sensor Water Temperature Sensor Removal Installation e Refer to the Water Temperature Sensor Removal Instal lation in the Fuel System DFI chapter Water Temperature Sensor Inspection e Refer to the Water Temperature Sensor Inspection in the Electrical System chapter ENGINE END 5 1 Engine Top Table of Contents Exploded 5 2 Cylinder Head Installation 5 27 Exhaust System Identification 5 6 Cylinder Head Warp Inspection 5 29 Specifications 5 7 ie RO ER RR 5 30 Special Tools and Sealant 5 9 Valve Clearance Inspection 5 30 Clean Air 5 11 Valve Clearance Adjustment 5 30 Air Suction Valve Remowval 5 11 Valve Removal 5 30 Air Suction Valve Installation 5 11 Valve Installation 5 30 Air Suction Valve Inspection 5 12 Valve Guide Removal 5 30 Air Switching Valve Removal 5 12 Valve Guide Installation 5 31 Air Switching Valve Installation 5 12 Valve to Guide Clearance Air Switching Valve Operation Measurement Wobble 5 12
401. pection note the following ODisconnect the intake air pressure sensor connector and connect the harness adapter A between these connec tors Special Tool Measuring Adapter 57001 1700 Intake Air Pressure Sensor Output Voltage Connections to Adapter Digital Meter W sensor Y BL lead Digital Meter BK sensor BR BK lead Measure the output voltage with the engine stopped and with the connector joined Turn the ignition switch to ON Output Voltage Usable Range DC 3 80 4 20 V at standard atmospheric pressure 101 32 kPa 76 cmHg NOTE OThe output voltage changes according to local atmo spheric pressure Turn the ignition switch to OFF x If the reading is out of the usable range replace the sen sor GC17879DS1 C 3 46 FUEL SYSTEM Intake Air Pressure Sensor Service Code 12 x If the reading is within the usable range remove the ECU and check the wiring for continuity between main harness connector Special Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector Intake Air Pressure Sensor Connector B Y BL lead ECU terminal 7 C BR BK lead ECU terminal 22 D x If the wiring is good check the sensor for various vacuum e Remove the intake air pressure sensor A and disconnect the vacuum hose from the sensor e Connect an auxiliary hose B to the intake air pressu
402. pection Cap B Timing Rotor Bolt Cap C Oil Filler Plug D Special Tool Filler Cap Driver 57001 1454 6 10 Clutch Cover Clutch Cover Assembly e Replace the needle bearings A and oil seal B with new ones NOTE Olnstall the needle bearings so that the manufacture s mark face out e Install the needle bearings and oil seal as shown OPress C the bearings so that the bearing surface D are flush with the housing end E of clutch cover e Apply grease to the oil seal lips e Apply water to the rubber of the oil level inspection win dow A and press B it so that the ring C face outside Replace the O rings of the following parts with new ones Timing Inspection Cap Timing Rotor Bolt Cap Oil Filler Plug Apply grease to the new O rings Tighten Torque Timing Inspection Cap 3 9 N m 0 40 35 in Ib Timing Rotor Bolt Cap 4 9 N m 0 50 kgf m 43 in Ib Oil Filler Plug Hand tighten Special Tool Filler Cap Driver 57001 1454 GF05032BS1 GF05031BS1 C 6 11 Clutch Clutch Removal e Remove Clutch Cover see Clutch Cover Removal Clutch Spring Bolts and Washers A Clutch Springs Clutch Spring Plate B with Bearing Pusher C Friction Plates Steel Plates Hold the clutch hub A steady with the clutch holder B and remove the clutch hub nut C and washer D Special Tool Clutch Holder 57001 1243
403. per clamp bolt first and then the lower clamp bolt OThere will be a gap at the lower part of the clamp after tightening Torque Clutch Lever Clamp Bolts 7 8 N m 0 80 kgf m 69 in Ib Clutch Lever Adjustment The adjuster has 5 positions so that the clutch lever posi tion 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 Gen 6 8 CLUTCH Clutch Cover Clutch Cover Removal Drain the engine oil see Engine Oil Change in the Peri odic Maintenance chapter Remove Right Frame Cover see Frame Cover Removal in the Frame chapter Right Middle Fairing see Middle Fairing Removal in the Frame chapter Bolt A Idle Speed Adjusting Screw Holder B Clutch Cable Holder Bolts C Clutch Cable Lower End D Remove the clutch cover bolts A e Turn the release lever A counterclockwise and remove the clutch cover B About 90 C Clutch Cover Installation Clean off any oil or dirt and apply liquid gasket to the fol lowing areas Crankcase Halves Mating Surface A Crankshaft Sensor Lead Grommet B Sealant Liquid Gasket TB1211F 92104 0004 Be sure that the dowel pins C are in position Replace the clutch cover gasket with a new one Install the clutch cover Install the clutch cabl
404. place ment is required x If the clearance is between 0 042 mm 0 00165 in and the service limit 0 08 mm 0 003 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 xIf the clearance exceeds the service limit measure the diameter of the crankpins Crankpin Diameter Standard 37 984 38 000 mm 1 4954 1 4961 in Service Limit 37 97 mm 1 4949 in x If any crankpin has worn past the service limit replace the crankshaft with a new one x If 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 None 37 984 37 992 mm 1 4954 1 4957 in O 37 993 38 000 mm 1 4958 1 4961 in A Crankpin Diameter Marks or no mark e Measure the connecting rod big end inside diameter and mark each connecting rod big end in accordance with the inside diameter e Tighten the connecting rod big end nuts to the specified torque see Connecting Rod Installation NOTE OThe mark already on the big end should almost coincide with the measurement Connecting Rod Big End Inside Diameter Marks None 41 000 41 008 mm 1 6142 1 6145 in O 41 009 41 016 mm 1 6145 1 6148 in Big End Cap
405. ploded View STEERING 14 3 Exploded View No Fastener Torque Remarks kgf m ft Ib 1 Switch Housing Screws 3 5 0 36 31 2 Handlebar Holder Bolts 25 2 5 18 S 3 Steering Stem Head Bolt 108 11 0 80 4 Front Fork Clamp Bolts Upper 20 2 0 15 5 Handlebar Holder Mounting Nuts 34 3 5 25 R 6 Steering Stem Nut 20 2 0 15 7 Front Fork Clamp Bolts Lower 20 5 2 1 15 AL AD Apply adhesive AL Tighten the two clamp bolts alternately two times to ensure even tighten torque G Apply grease L Apply a non permanent locking agent R Replacement Parts S Follow the specified tightening sequence 14 4 STEERING Special Tools Head Pipe Outer Race Press Shaft 57001 1075 ST571075ST C Steering Stem Nut Wrench 57001 1100 5157110051 C Steering Stem Bearing Driver 42 5 57001 1344 Bearing Driver Set 57001 1129 7571129ST C 7571344ST C Steering Stem Bearing Driver Adapter 541 5 57001 1345 875713455 C Head Pipe Outer Race Driver 555 57001 1446 875714465 C Steering STEERING 14 5 Steering Inspection e Refer to the Steering Play Inspection in the Periodic Main tenance chapter Steering Adjustment Refer to the Steering Play Adjustment in the Periodic Maintenance chapter 14 6 STEERING Steering Stem Stem Stem Bearing Removal e Remove Handlebar see Handlebar Removal Headlight Unit
406. position of the lock D and the lead color before measurement Do not reverse connections of the hand tester or a digital meter Be careful not to short circuit the leads of the or elec trical system parts by contact between adapters Turn the ignition switch to ON and measure the voltage with the connector joined Incorrect reverse connection or short circuit by needle adapters could damage the DFI or electrical system parts GC17045BS1 C Troubleshooting the DFI System FUEL SYSTEM 3 25 OAfter measurement remove the needle adapters and ap ply silicone sealant to the seals A of the connector B for waterproofing Sealant Liquid Gasket 1211 56019 120 Always check battery condition before replacing the parts A fully charged battery is a must for conducting accurate tests of the DFI system Trouble may involve one or in some cases items Never replace a defective part without determining what CAUSED the problem If the problem was caused by some other item or items they too must be repaired or replaced or the new replacement part will soon fail again Measure the coil winding resistance when the DFI part is cold at room temperature Make sure all connectors in the circuit are clean and tight and examine leads for signs of burning fraying short etc Deteriorated leads and bad connections can cause reappearance of problems and unstable operation
407. pter 3 Inspect and repair see chapter 3 Inspect see chapter 3 Change fuel Inspect and clean fuel system see chapter 3 Inspect and replace fuel pump see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Subthrottle sensor trouble Subthrottle valve actuator trouble Inspect see chapter 3 Intake air pressure sensor trouble Inspect see chapter 3 Inspect see chapter 3 DFI System Troubleshooting Guide FUEL SYSTEM DFI 3 31 Symptoms or Possible Causes Actions Water temperature sensor trouble Inspect see chapter 3 Intake air temperature sensor trouble Inspect see chapter 3 Spark plug dirty broken or gap maladjusted Inspect and replace see chapter 2 Stick coil trouble Inspect see chapter 16 Stumble Fuel pressure too low Inspect see chapter 3 Fuel injector trouble Inspect see chapter 3 Main throttle sensor trouble Inspect see chapter 3 Subthrottle sensor trouble Inspect see chapter 3 Subthrottle valve actuator trouble Inspect see chapter 3 Intake air pressure sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Intake air temperature sensor trouble Inspect see chapter 3 Unstable fuel pressure Fuel injector trouble Fuel pressure regulator trouble Inspect an
408. q odo esa 19a ale edo on no ofa oo 182 20 al as 8 rade sa ee oe 7 ada esp edo ofa oo ofa o os 29 d 18 asf ee eda ese roa 19 a ef oa d ofa oro 1 ala SPECIFIED CLEARANCE NO CHANGE REQUIRED 2 55 2 60 2 65 2 70 2 75 2 8012 85 2 90 2 9 03 05 3 10 3 15 3 20 3 2513 3013 35 3 4013 45 3 50 2 60 2 65 2 702 75 2 80 2 85 2 90 2 9513 00 3 10 3 15 3 2013 2513 30 3 35 3 40 3 45 3 50 2 65 2 70 2 75 2 80 2 85 2 90 2 9513 00 3 0 013 15 3 20 3 25 3 30 3 3513 4013 4513 50 a whe ofa oso a a afa aoa aol 0 50 0 54 2 7512 80 2 85 2 9012 95 3 00 3 0513 10 3 15 3 20 3 2513 30 3 3513 40 3 45 3 50 ___ oa oa oo ofa 143 142 aa ao aa 0s af 59 0 65 0 69 2 90 2 95 3 00 3 05 3 15 3 20 3 2513 30 3 35 3 40 3 45 3 50 a a afoso fo oda oda fos aoa 50 silo 200 04 odo fa 1a ofa ao oo aa ao a 0 85 0 89 20 3 25 3 30 3 35 3 40 3 45 3 50 25 3 30 3 35 3 40 3 45 3 50 30 3 35 3 40 3 45 3 50 35 3 40 3 45 3 50 40 3 45 3 50 45 3 50 INSTALL THE SHIM THIS THICKNESS mm VALVE CLEARANCE 1 20441 24 3 45 3 50 1 2551 29 3 50 6507120893 C Measu
409. quipped with an ABS remove the right swingarm bracket see ABS Hydraulic Unit Removal in the Brakes chapter Inspect the brake hoses fittings and pipes ABS equipped models for deterioration cracks and signs of leakage OThe high pressure inside the brake line can cause fluid to leak A or the hose pipes ABS equipped models to burst if the line is not properly maintained Bend and twist the rubber hose while examining it Replace the hose and pipe ABS equipped models if any crack B bulge C or leakage is noticed Tighten any brake hose banjo bolts and brake pipe joint nuts Torque Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft lb Brake Pipe Joint Nuts 18 1 8 kgf m 13 16 ABS Equipped Models Inspect the brake hose routing If any brake hose and pipe ABS equipped models rout ing is incorrect correct the routing according to Cable Wire and Hose Routing section in the Appendix chapter GL10020181 C PERIODIC MAINTENANCE 2 33 Periodic Maintenance Procedures Brake Fluid Level Inspection Check that the brake fluid level in the front brake reservoir A is above the lower level line B NOTE OHold the reservoir horizontal by turning the handlebar when checking brake fluid level x If the fluid level is lower than the lower level line remove the reservoir cap and fill the reservoir to the upper level line A Tighten Torque Front Brake Reservoir Cap Scre
410. r Gauge Indicator Unit ELECTRICAL SYSTEM 16 71 Fuel Level Gauge Check Connect the 12 V battery and terminals in the same man ner as specified in the Liquid Crystal Display LCD Seg ments Check Connect the variable rheostat A to the terminal 10 Check that the number of segments A matches the re sistance value of the variable rheostat Variable Rheostat Resistance Q Display Segments 20 6 110 3 190 1 x If the multifunction meter display function does not work replace the meter assembly Fuel Level Warning Check Connect the 12 V battery and terminals in the same man ner as specified in the Liquid Crystal Display LCD Seg ments Check Connect the variable rheostat A to the terminal 10 e Adjust the resistance value to the approximately 220 O Check that one segment A in the fuel gauge starts blink ing Check that the fuel warning symbol B blinks x If the multifunction meter display function does not work replace the meter assembly Indicator Lights Inspection Connect the 12 V battery and terminals in the same man ner as specified in the Liquid Crystal Display LCD Seg ments Check Check that the following lights go on Yellow ABS Indicator Light LED A EX650F Model only Yellow Engine Warning Indicator Light LED B Green Left Turn Signal Indicator Light LED C Green Right Turn Signal Indicator Light LED D
411. r Cleaner Housing Removal in the Fuel System DFI chapter e Take the air switching valve hose end A outside of the frame e Reinstall the air cleaner housing A see Air Cleaner Housing Installation in the Fuel System DFI chapter Connect the fuel pump lead connector B e Using the extension tube C connect the fuel tank D to the throttle body Special Tool Extension Tube 57001 1578 Start the engine and run it at idle speed Plug the air switching valve hose end with your finger and feel vacuum pulsing in the hose x If there is no vacuum pulsation check the hose line for leak If there is no leak check the air switching valve see Air Switching Valve Unit Test Remove Extension Tube Fuel Pump Lead Connector Disconnect Remove the air cleaner housing see Air Cleaner Housing Removal in the Fuel System DFI chapter e Apply a soap and water solution or rubber lubricant to the end of the air switching valve hose A and install the hose on the fitting e Install Air Cleaner Housing see Air Cleaner Housing Installa tion in the Fuel System DFI chapter Fuel Tank see Fuel Tank Installation in the Fuel System DFI chapter 16 62 ELECTRICAL SYSTEM Air Switching Valve Air Switching Valve Unit Test Remove the air switching valve see Air Switching Valve Removal in the Engine Top End chapter Set the hand tester A to the x range and connect it to
412. r head is installed use the cap that is supplied with the new head e Be sure that the dowel pins A are in position e Install a new cylinder head gasket e Install the cylinder head onto the cylinder gs GERE 5 28 ENGINE END Cylinder Head Apply molybdenum disulfide oil solution A to both sides of washers and the threads of bolts and nut M10 Cylinder Head Bolts B M10 Cylinder Nut C M8 Cylinder Bolt D Tighten the all bolts and nut following the tightening se quence 1 8 Torque Cylinder Head Bolts M10 First 25 N m 2 5 kgf m 18 ft lb Final 56 N m 5 7 kgf m 41 ft Ib Cylinder Nut M10 49 N m 5 0 kgf m 36 ft Ib Cylinder Bolt M8 27 5 2 8 kgf m 20 ft Ib NOTE OThe tightening sequence No 1 No 5 are the cylinder head bolts that are tightened between the cylinder head with the crankcase OThe No 6 is the cylinder head bolt that is tightened be tween the cylinder head with the cylinder OThe No 7 and No 8 are the cylinder nut and cylinder bolt that are tightened between the cylinder and the crankcase XXXXXX 3000000000 GE161438W2 C e Apply a non permanent locking agent to the M6 cylinder head bolts and M6 cylinder bolts A and tighten them Torque Cylinder Head Bolts M6 12 1 2 kgf m 106 in Ib Cylinder Bolts M6 12 N m 1 2 kgf m 106 in Ib GE14073BS1
413. r light LED does not go on ABS system is normal Service code is not stored tempo rary failure ECU Inspection Service Code 55 e Do the 1st step test as follows ORecheck the service code indication erase the service code perform the pre diagnosis inspection 1 and 2 and retrieve the service code x lf the yellow ABS indicator light LED A goes on faulty ECU in the ABS hydraulic unit Replace the ABS hy draulic unit x If the yellow ABS indicator light LED does not go on ABS system is normal Service code is not stored tempo rary failure GL14608BS1 GL14610BS1 C GL14610BS1 12 56 5 Anti Lock Brake System Equipped Models ABS Hydraulic Unit Removal The ABS hydraulic unit has been adjusted and set with precision at the factory Therefore it should be handled carefully never struck sharply as with a hammer or allowed to fall on a hard surface Be careful not to get water or mud on the ABS hy draulic unit Drain the brake fluid from the front and rear brake lines ODrain the brake fluid through the bleed valve by pumping the brake lever and pedal e Remove Muffler see Muffler Removal in the Engine Top End chapter Rear Master Cylinder see Rear Master Cylinder Re moval Right Footpeg Stay see Footpeg Stay Removal in the Frame chapter Support the frame using the jack Special Tool Jack 57001 1238 e Put a block in front of th
414. r 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
415. r 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 Connecting Rod Big End Side Clearance Inspection 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 the clearance is too large after connecting rod replace ment the crankshaft also must be replaced Connecting Rod Big End Bearing Insert Crankpin Wear Inspection e Measure the bearing insert crankpin A clearance B with plastigage 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 After measurement replace the connecting rod bolts and nuts Connecting Rod Big End Bearing Insert Crankpin Clearance Standard 0 017 0 041 mm 0 0007 0 0016 in Service Limit 0 08 mm 0 003 in 6105040781 9105236851 CRANKSHAFT TRANSMISSION 9 25 Crankshaft and Connecting Rods x If the clearance is within the standard no bearing re
416. r to prevent oil contact Oil contami nation from hands can reduce sensor performance Tighten Torque Oxygen Sensor 44 N m 4 5 kgf m 32 ft lb Run the oxygen sensor lead correctly see Cable Wire and Hose Routing section in the Appendix chapter Install the left middle fairing see Middle Fairing Installa tion in the Frame chapter Oxygen Sensor Inspection Equipped Models Refer to the Oxygen Sensor Inspection in the Fuel System DFI chapter Gi ELECTRICAL SYSTEM 16 79 NOTE OThe relay box A has relays and diodes The relays and diodes can not be removed Relay Box Removal Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Air Cleaner Element see Air Cleaner Element Replace ment in the Periodic Maintenance chapter Take out the relay box A from the bracket e Disconnect the connectors B Relay Box Installation Installation is the reverse of removal ORun the lead correctly see Cable Wire and Hose Rout ing section in the Appendix chapter Relay Circuit Inspection Remove the relay box see Relay Box Removal Check the conductivity of the following numbered termi nals by connecting the hand tester and one 12 V battery to the relay box as shown see Relay Box Internal Circuit in this section Relay Circuit Inspection with the battery disconnected Tester Reading Q Tester Connection
417. range wiring short 92 Valve Actuator Jove or open the ECU stops the current to the pulse signal from the actuator ECU The oxygen sensor Oxygen Sensor If the oxygen sensor heater fails wiring short temperature of the 67 Equipped 2 open the ECU stops the current to the Models sensor for its earlier heater activation 12V 6 6W i 0 55A The oxygen sensor MOET SONSON MUST send signgis If the oxygen sensor output voltage is incorrect 94 Equipped output voltage yg P 9 Models continuously to the the ECU stops oxygen sensor feed back mode ECU The purge valve Purge Valve controls the flow of 3A CAL SEA B1 the secondary air by and TH Models and shutting the solenoid valve Note 1 D J Method When the engine load is light like at idling or low speed the ECU determines the injection quantity by calculating from the throttle vacuum intake air pressure sensor output voltage and engine speed crankshaft sensor output voltage This method is called D J method low speed mode 2 a N Method As the engine speed increases and the engine load turns middle to heavy the ECU determines the injection quantity by calculating from the throttle opening throttle sensor output voltage and the engine speed This method is called a N method high speed mode This depends on the number of stopped cylinders Main Throttle Sensor Service Code 11
418. rcuit Inspection in the Electrical Sys tem chapter 3 90 FUEL SYSTEM Fuel Line Fuel Pressure Inspection NOTE OBe sure the battery is fully charged Remove Fuel Tank see Fuel Tank Removal Fuel Hose see Fuel Hose Replacement in the Periodic Maintenance chapter OBe sure to place a piece of cloth around the fuel supply pipes of the fuel pump and the throttle body assy A WARNING Fuel is flammable and explosive under certain con ditions and can cause severe burns Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is dis connected fuel spills out from the hose and the pipe because of residual pressure Cover the hose connection with a piece of clean cloth to prevent fuel spillage Install the fuel pressure gauge adapter A and fuel hoses Special Tool 57001 1607 B between the fuel supply pipes of the fuel pump and throttle body assy Secure the fuel hoses with the clamps Connect the pressure gauge C to the fuel pressure gauge adapter Special Tools Oil Pressure Gauge 5 kgf cm 57001 125 Fuel Pressure Gauge Adapter 57001 1593 Fuel Hose 57001 1607 A WARNING Fuel is extremely flammable and can be explosive under certain conditions resulting in serious injury or death Do not try to start the engine with the fuel hoses disconnected e Connect the fuel pump lead connector e Turn the engine stop switc
419. re sensor e Temporarily install the intake air pressure sensor OConnect a digital meter C vacuum gauge D the fork oil level gauge E and the harness adapter to the intake air pressure sensor Special Tools Fork Oil Level Gauge 57001 1290 Vacuum Gauge 57001 1369 Measuring Adapter 57001 1700 Intake Air Pressure Sensor Output Voltage Connections to Adapter Digital Meter W sensor Y BL lead Digital Meter BK sensor BR BK lead OTurn the ignition switch to ON OMeasure the intake air pressure sensor output voltage from various vacuum readings while pulling the handle of the fork oil level gauge OCheck the intake air pressure sensor output voltage us ing the following formula and chart 6617880051 0017119852 C FUEL SYSTEM DFI 3 47 Intake Air Pressure Sensor Service Code 12 Suppose Pg Vacuum Pressure Gauge to Sensor Local Atmospheric Pressure Absolute measured by a barometer Pv Vacuum Pressure Absolute to Sensor Vv Sensor Output Voltage V then PI Pg For example suppose the following data is obtained Pg 8 cmHg Vacuum Gauge Reading PI 70 cmHg Varometer Reading Vv 3 2 V Digital Meter Reading then Pv 70 8 62 cmHg Absolute Plot this Pv 62 cmHg at a point 1 on the chart and draw a vertical line through the point Then you can get the usable range 2 of the sensor output voltage Usable range 3
420. re properly in place Install the 3rd 4th gear onto the drive shaft with their oil holes aligned Install the 6th gear bushing onto the drive shaft with their oil holes aligned The output shaft gears can be recognized by size the gear with the largest diameter is 1st gear and the small est one is 6th gear Be sure that all parts are put back in the correct sequence and all circlips and washers are properly in place Install the 5th and 6th gears onto the output shaft with their oil holes aligned Install the 3rd 4th gear bushings onto the output shaft with their oil holes aligned CRANKSHAFT TRANSMISSION 9 41 Transmission e Fit the steel balls into the 5th gear holes in the output shaft aligning oil hole as shown in the figure 5th Gear A Output Shaft B Steel Balls C Oil Holes D NOTICE Do not apply 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 9 42 CRANKSHAFT TRANSMISSION Transmission 1942 844 0 9 00 5 00 9 6 2 Q 04 eC GI13323BW3 C
421. re the clearance when engine is cold Check present shim size Match clearance in vertical column with present shim size in horizontal column Install the shim specified where the lines intersect This shim will give the proper clearance Example Present shim is 2 95 mm 5 Measured clearance is 0 47 mm Replace 2 95 mm shim with 3 15 mm shim Remeasure the valve clearance and readjust if necessary PERIODIC MAINTENANCE 2 25 Periodic Maintenance Procedures Air Suction System Damage Inspection Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Air Cleaner Housing see Air Cleaner Housing Removal in the Fuel System chapter e Take the air switching valve hose end A outside of the frame B e Reinstall the air cleaner housing A see Air Cleaner Housing Installation in the Fuel System DFI chapter e Connect the fuel pump lead connector B e Using the extension tube C connect the fuel tank D to the throttle body Special Tool Extension Tube 57001 1578 e Start the engine and run it at idle speed e Plug the air switching valve hose end with your finger and feel vacuum pulsing in the hose x If there is no vacuum pulsation check the hose line for leak If there is no leak check the air switching valve see Air Switching Valve Unit Test in the Electrical Sys tem chapter or air suction valve see Air Suction Valve Inspection in the Engine Top End chapter e Re
422. rear shock absorber Install the rear shock absorber so that the label D side faces inside Replace the O ring with a new one Replace the rear shock absorber mounting nut F with a new one Install the washers and collar H Tighten the rear shock absorber mounting bolts I and nut Torque Rear Shock Absorber Mounting Bolts 59 N m 6 0 kgf m 44 ft lb e Install the removed parts see appropriate chapters Rear Shock Absorber Inspection e Remove the rear shock absorber see Rear Shock Ab sorber Removal e Visually inspect the following items Smooth Stroke Oil Leakage Crack or Dent x lf there is any damage to the rear shock absorber replace it e Visually inspect the rubber bushing x If it shows any signs of damage replace it GM05463BS2 C SUSPENSION 13 17 Swingarm Swingarm Removal e Remove Chain Cover Bolts A Chain Cover B e Remove Frame Covers see Frame Cover Removal in the Frame chapter Engine Sprocket Cover see Engine Sprocket Cover Re moval in the Final Drive chapter Footpeg Stays see Footpeg Stay Removal in the Frame chapter Muffler see Muffler Removal in the Engine Top End chapter Rear Caliper see Rear Caliper Removal in the Brakes chapter Loosen the lower rear shock absorber mounting bolt A and nut B Loosen Swingarm Pivot Shaft Nut A Swingarm Bracket Bolts B Left and Right Free the brake hose A
423. ressed air until the tire beads seat in the sealing surfaces A WARNING Overinflating a tire can cause it to explode causing serious injury or death 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 GJ05041BS1 6J05030781 6J05044BS1 C Tires WHEELS TIRES 10 15 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 Install the valve core and inflate the tire again e After the tire beads seat in the rim flanges check for air leakage Olnflate the tire slightly above standard inflation OUse a soap and water solution or submerge the tire and check for bubbles that would indicate leakage e Adjust the air pressure to the specified pressure see Air Pressure Inspection in the Periodic Maintenance chap ter e Install the air valve cap e Adjust the wheel balance see Balance Adjustment 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 high
424. reverse the battery cable connections This will damage the ECU OTo prevent damage to the DFI parts do not disconnect the battery cables or any other electrical connections when the ignition switch is on or while the engine is running OTake care not to short the cables that are directly con nected to the battery positive terminal to the chassis ground OWhen charging remove the battery from the motorcycle This is to prevent ECU damage by excessive voltage OWhenever the DFI electrical connections are to be 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 ODo not turn the ignition switch ON while any of the DFI electrical connectors are disconnected The ECU memo rizes service codes ODo not spray water on the electrical parts DFI parts con nectors leads and wiring a transceiver is installed on the motorcycle make sure that the operation of the DFI system is not influenced by electric wave radiated from the antenna Check operation of the system with the engine at idle Locate the antenna as far as possible away from the ECU OWhen any fuel hose is disconnected fuel may spout out by residual pressure in the fuel line Cover the hose joint with a piece of clean cloth
425. rform the pre diagnosis inspection 1 and 2 and retrieve the service code x If the yellow ABS indicator light LED A goes on faulty ECU in the ABS hydraulic unit Replace the ABS hy draulic unit If the yellow ABS indicator light LED does not go ABS system is normal service code is not stored tempo rary failure GL14610BS1 5 12 53 Anti Lock Brake System Equipped Models Rear Wheel Rotation Sensor Wiring Inspection Service Code 45 e Do the 1st step test as follows ODisconnect ABS Hydraulic Unit Connector see ABS Hydraulic Unit Removal Rear Wheel Rotation Sensor Connector see Rear Wheel Rotation Sensor Removal OShort the red and green lead terminals of the main har ness side connector ABS hydraulic unit A with a jumper lead OCheck for continuity between the red and green lead ter minals of the main harness side connector rear wheel rotation sensor B x lf there is the continuity in the lead go to the 2nd step x lf there is not the continuity in the lead replace or repair the main harness e Do the 2nd step test as follows OCheck for continuity between the red lead terminal of the sensor connector A and ground and green lead terminal of the sensor connector and ground x If there is the continuity in the lead replace the rear wheel rotation sensor x If there is not the continuity in the lead go to the 3rd step e Do the 3rd step te
426. rformance and can cause an accident resulting in injury or death If the brake lever or pedal has a soft or spongy feeling mushy when it is applied there might be air in the brake lines or the brake may be defective Do not operate the vehicle and service the brake system immediately 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 Remove the reservoir cap and diaphragm e Fill the reservoir with fresh brake fluid to the upper level line A Slowly pump the brake lever several times until no air bubbles can be seen rising up through the fluid from the holes at the bottom of the reservoir OBleed the air completely from the master cylinder by this operation Remove the rubber cap A on the caliper e Attach a clear plastic hose B to the bleed valve C and run the other end of the hose into a container 65190257 Brake Fluid BRAKES 12 27 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 holding the brake applied 3 Release the brake C NOTE OThe fluid level must be checked often during the bleed ing operation and replenished with fresh brake fluid as necessary If the fluid in
427. run the hoses with a minimum of bending so that the emission flow will not be obstructed 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 sidestand x If the coolant level is lower than the L level line B re move the right center fairing see Center Fairing Removal in the Frame chapter unscrew the reserve tank cap and add coolant to the F level line C L Low F Full For refilling add the specified mixture of coolant and soft water Adding water alone dilutes the coolant and degrades its anticorrosion properties The diluted coolant can attack the aluminum en gine parts In an emergency soft water alone can be added But the diluted coolant must be returned to the correct mixture ratio within a few days If coolant must be added often or the reservoir tank has run completely dry there is probably leakage in the cooling system Check the system for leaks Coolant ruins painted surfaces Immediately wash away any coolant that spills on the frame engine wheels or other painted parts 9505252851 PERIODIC MAINTENANCE 2 21 Periodic Maintenance Procedures Water Hose Damage and Installation Condition Inspection OThe high pressure inside the water hose can cause coolant to leak A or the ho
428. s COUNTRY AND AREA CODES AT Austria ID Indonesia AU Australia IN India AU LAMS Australia Leaner Approved M Motorcycle Brazil SEA B1 Southeast Asia 1 with Evaporative Emission Control System CA Canada SEA B2 Southeast Asia B2 CAL California TH Thailand CH Switzerland US United States DE Germany WVTA Whole Vehicle Type Approval EUR Europe WVTA FULL H 2 Catalytic Unten kingdom 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 emission control system 3 in compliance with applicable regulations of the California Air Resources Board on vehicles sold in California only 1 Crankcase Emission Control System This system eliminates the release of crankcase vapors into the atmosphere Instead the vapors are routed through an oil separator to the 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
429. s B 1 0 in Bolts C 1 0 in Bolt D Tighten with Clamp 70 mm 35 mm 25 mm 25 mm 16 30 ELECTRICAL SYSTEM Charging System Stator Coil Removal e Remove Alternator Cover see Alternator Cover Removal Alternator Lead Holding Plate Bolt A and Holding Plate B Alternator Lead Grommet C Stator Coil Bolts D e Take off the stator coil E from the alternator cover Stator Coil Installation Apply a non permanent locking agent to the threads of the stator coil bolts A and the alternator lead holding plate bolt B e Clamp the alternator lead C with the alternator lead hold ing plate D e Install the stator coil E e Tighten Torque Stator Coil Bolts 12 N m 1 2 kgf m 106 in Ib Alternator Lead Holding Plate Bolt 9 8 1 0 kgf m 87 in Ib e Clean off any oil or dirt and apply liquid gasket to the cir cumference of the alternator lead grommet F and fit the grommet into the notch of the cover Sealant Liquid Gasket TB1211F 92104 0004 Alternator Rotor Removal e Remove Alternator Cover see Alternator Cover Removal Starter Idle Gear A and Shaft B Torque Limiter C and Shaft D e Wipe oil off the circumference of the rotor e Hold the alternator rotor steady with the rotor holder A Special Tools Grip B 57001 1591 Rotor Holder 57001 1658 Stopper C 57001 1679 e Remove the rotor bolt D and the washer
430. s so always use it Sample Diagnosis Sheet vibration or noise ABS indicator light LED stays on mal pedal move ment Rider name Registration No license plate No Year of initial registration Model Engine No Frame No Date problem occurred Frequency Weather Mileage O Brake Yellow O Braking L1 ABS not ABS L1 ABS op lever ABS distance working works erating vibration indicator too long but too fre or noise light yellow quently LED ABS Phenome blinks indicator non OPedal Yellow light LED doesn t go on Engine conditions at problem Road conditions At start up O Slippery road Rough surface Other L1 After starting snow At 5 000 r min rpm or more L1 other Driving conditions Brake application Other conditions 1 When stopping O When turning Gradual Abrupt O High speed cornering L1 Driving 10 km h 6 mph or above Driving below 10 km h 6 mph L1 Large brake lever stroke Large pedal stroke 12 40 5 Anti Lock Brake System Equipped Models Pre Diagnosis Inspection 1 NG Check brake fluid level in brake reservoir Replenish brake fluid OK NG Check for brake fluid leakage Repair brake line OK NG Check brake lever and brake pedal function Repair or replace master cylinder OK NG Check brake pad and
431. s and dents dam age If any damage is found replace the wheel 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 Tread Depth Standard Front 4 5 mm 0 18 in Rear 6 4 mm 0 25 in Service Limit Front 1 mm 0 04 in AT CH DE 1 6 mm 0 06 in Rear 2 mm 0 08 in Up to 130 km h 80 mph 3 mm 0 12 in Over 130 km h 80 mph xIf any measurement is less than the service limit replace the tire see Tire Removal Installation in the Wheels Tires chapter A WARNING Some replacement tires may adversely affect han dling and cause an accident resulting in serious in jury or death To ensure proper handling and sta bility use only the recommended standard tires for replacement inflated to the standard pressure NOTE 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 2 28 PERIODIC MAINTENANCE Periodic Maintenance Procedures Wheel Bearing Damage Inspection Rais
432. s at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously See your Motorcycle dealer for the latest information on product improvements incorporated after this publication All information contained in this publication is based on the latest product information available at the time of publication Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts 2011 Kawasaki Heavy Industries Ltd 1st Edition 2 Sep 22 2011 LIST OF ABBREVIATIONS A ampere s KDS Kawasaki Diagnostic System ABDC after bottom dead center km h kilometers per hour AC alternating current L liter s Ah ampere hour Ib pound s ATDC after top dead center LCD Liquid Crystal Display BBDC before bottom dead center LED Light Emitting Diode BDC bottom dead center m meter s BTDC before top dead center min minute s C degree s Celsius mph miles per hour cmHg centimeters of mercury N newton s cu in Cubic inch s OZ ounce s DC direct current Pa pascal s DFI Digital Fuel Injection PS horsepower ECU Electronic Control Unit psi pound s per square inch F degree s Fahrenheit qt quart s ft foot feet r revolution g gram s revolution s perminute gal gallon s TDC top dead center h hour s TIR total indicator reading HP horsepower s V volt s IC Integrated Circuit W watt s in inch s Q ohm
433. s have accumulated between the reed and the reed contact area wash the valve assembly clean with a high flash point solvent NOTICE Do not scrape off the deposits with a scraper as this could damage the rubber requiring replacement of the suction valve assembly Air Switching Valve Removal Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Air Cleaner Housing see Air Cleaner Housing Removal in the Fuel System DFI chapter e Disconnect the connector A and hoses B to remove the air switching valve C NOTICE Never drop the air switching valve especially on a hard surface Such a shock to the valve can dam age it Air Switching Valve Installation Installation is the reverse of removal Olnstall the air switching valve hoses so that the white paint marks A are located as shown in the figure B View from Top ORun the hoses and lead correctly see Cable Wire and Hose Routing section in the Appendix chapter Air Switching Valve Operation Test e Refer to the Air Suction System Damage Inspection in the Periodic Maintenance chapter Air Switching Valve Unit Test e Refer to the Air Switching Valve Unit Test in the Electrical System chapter Clean Air System ENGINE TOP END 5 13 Clean Air System Hose Inspection Be certain that all the hoses are routed without being flat tened or kinked and are connected correctly to the air cleaner ho
434. s of Mass 9 807 N m kg x 2 205 Ib kgfm x 7233 9 0 03527 OZ kgf m x 86 80 in Ib Units of Volume Units of Pressure L x 0 2642 05 0 01020 kgf cm L x 0 2200 x 0 1450 psi L x 1 057 qt US kPa x 0 7501 cmHg L x 0 8799 qt IMP kgf cm x 98 07 kPa L x 2 113 pint US kgf cm x 14 22 psi L x 1 816 pint IMP cmHg x 1 333 kPa mL x 0 03381 oz US mL x 0 02816 02 IMP Units of Speed mL x 0 06102 cu in km h x 0 0244 mph Units of Force Units of Power N 0 1020 kg kW x 1 360 PS N x 0248 kW x 1341 HP kg N 5 x 07355 kW kg 7209 de dB PS 0 9863 HP Units of Temperature 9 C 40 40 F 5 F 40 ee oF oF 32 68 104 248 284 4 20 10 20 i40 320 40 60 20 i 26 7 48 9 176 212 80 100 120 140 160 180 200 1220 240 260 280 300 i i 100 714 93 3 116 1120 1140 138 160 PERIODIC MAINTENANCE 2 1 Periodic Maintenance Table of Contents Periodic Maintenance 2 2 3 Torque and Locking dette 2 6 Specifications fr tent n Ra RE RU EX YR OM 2 12 opecial Tools meets te ehe eot tbe p ERN 2 14 Periodic Maintenance 2 15 System DEL 2
435. s of the rim and tire and smooth the sealing surfaces of the rim with a fine emery cloth if necessary Remove the air valve and discard it NOTICE Replace the air valve whenever the tire is replaced Do not reuse the air valve 6J05040BS1 10 14 WHEELS TIRES Tires Install a new valve in the rim ORemove the valve cap lubricate the stem seal A with a soap and water solution or rubber lubricant and pull B the valve stem through the rim from the inside out until it snaps into place NOTICE Do not use engine oil or petroleum distillates to lu bricate the stem because they will deteriorate the rubber OThe air valve is shown in the figure Valve Cap A Valve Core B Stem Seal C Valve Stem D Valve Seat E Valve Opened F Check the tire rotation mark on the front and rear tires and install them on the rim accordingly Tire Rotation Mark A Rotating Direction B e Position the tire on the rim so that the air valve A align with the tire balance mark B the chalk mark made during removal or the yellow paint mark on a new tire e Install the tire bead over the rim flange using a suitable commercially available tire changer e Lubricate the tire beads and rim flanges with a soap and water solution or rubber lubricant to help seat the tire beads in the sealing surfaces of the rim while inflating the tire e Center the rim in the tire beads and inflate the tire with comp
436. sarily 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 NOTICE 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 Be careful not to overtighten the nuts The bolts must be positioned on the seating surface correctly to prevent the bolt heads from hitting the crankcase 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 Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the bolts nuts and connecting rods in a well ventilated area and take care that there are no sparks or flame anywhere near the working area this includes any appliance with a pilot light Do not use gasoline or a low flash point solvent to clean them Immediately dry the bolts and nuts with com pressed air after cleaning Clean and dry the bolts and nuts completely 9 22 CRANKSHAFT TRA
437. se turn out the right and left chain adjusters D evenly x lf the chain is too tight turn in the right and left chain adjusters evenly and kick the wheel forward e Turn the 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 or position G that the right indicator notch aligns with A WARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition Be sure the wheel is properly aligned e Tighten the both chain adjuster locknuts securely e Tighten Torque Rear Axle Nut 108 11 0 kgf m 80 ft Ib e Turn the wheel measure the chain slack again at the tight est position and readjust if necessary 2 30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Insert a new cotter pin A NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle tighten the nut clockwise B up to next alignment Olt should be within 30 degrees OLoosen once and tighten again when the slot goes past the nearest hole Bend the cotter pin A over the nut A WARNING A loose axle nut can lead to an accident resulting in serious injury or death Tighten the axle nut to the proper torque and install a new cotter pin Wheel Alignment Inspec
438. se to burst if the line is not properly maintained Visually inspect the hoses for signs of deterioration Squeeze the hoses A hose should not be hard and brittle nor should it be soft or swollen Replace the hose if any fraying cracks B or bulges are noticed Check that the hoses are securely connected and clamps are tightened correctly Torque Water Hose Clamp Screws 3 0 N m 0 31 kgf m 27 in lb Engine Top End Valve Clearance Inspection NOTE OValve clearance must be checked and adjusted when the engine is cold room temperature Remove Cylinder Head Cover see Cylinder Head Cover Re moval in the Engine Top End chapter Timing Inspection Cap A Timing Rotor Bolt Cap B Special Tool Filler Cap Driver C 57001 1454 Check the valve clearance when the pistons are at TDC OThe pistons are numbered beginning with the engine left side e Using a wrench on the timing rotor bolt turn the crank shaft clockwise until the 1 T mark line A on the timing rotor is aligned with the notch B in the edge of the timing inspection hole C in the clutch cover for 1 piston and 2 T mark line D for 2 piston OMeasure the valve clearance of the valves for which the cams A are turned away from each other 6506005851 C 15517 P 9507118851 9507072851 2 22 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Using the thickness gauge A measure the valve
439. sh point solvent because the new bolts and nuts are treated with an anti rust solution A WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the bolts and nuts in a well ventilated area and take care that there are no sparks or flame anywhere near the working area this includes any appliance with a pilot light Do not use gasoline or a low flash point solvent to clean the bolts and nuts Immediately dry the bolts and nuts with com pressed air after cleaning Clean and dry the bolts and nuts completely CRANKSHAFT TRANSMISSION 9 23 Crankshaft and Connecting Rods Install new bolts in reused connecting rods Apply a small amount of molybdenum disulfide oil solution to the following Threads A of Nuts and Bolts Seating Surfaces B of Nuts and Connecting Rods e First tighten the nuts to the specified torque See the table below 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 6105040451 6105040551 Torque Angle Nm kgf m ft lb Attached to new Use the bolts attached 18 1 8 13 0 120 New to new connecting rod SOnnecung Tod Sus New 20 2 0 15 120 Used Replace the bolts with Used 24 2 4 17 4 120 new ones New 25 2 6 18 8 120 Crankshaft Connecting Rod Cleaning
440. shaft Installation in the Engine Top End chapter e Remeasure any valve clearance that was adjusted Readjust if necessary 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 9507073851 PERIODIC MAINTENANCE 2 23 Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART INTAKE VALVE PRESENT SHIM Example PART No 92180 1018 1020 1022 1024 1026 1028 01103211034 1036 1038 1042 1044 1046 1048 1050 1052 MARK 60 65 70 75 80 85 95 00 05 19 20 25 30 35 40 45 0 00 0 01 5 2 50 2 5512 60 2 652 742 752 80 2 85 2 90 2 95 3 003 05 3 10 3 15 3 203 25 3 30 esol se oa sa re ae eo o n o end v9 20 a 10 59 facade sa oe oa ed es ofa oo ofa a 2 s 9 foot asf ee ofa es roa vfs a ef oo ons oso t es n ad to fo aaso 24 256 ode efe naj re ea ez DIE DIS ERE ENE eo as oo 443254 2 60 2 65 2 702 75 2 80 2 85 2 90 2 9513 00 3 10 3 15 3 2013 25 3 30 3 35 3 40 3 45 3 50 2 65 2 70 2 75 2 80 2 85 2 90 2 9513 00 3 0 013 15 3 20 3 25 3 30 3 35 3 4013 4513 50 2 70 2 75 2 80 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 aec ns
441. sor Resistance Connections lead C lt gt BR BK lead D Standard 4 6 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 ECU Removal Installation Main Throttle Sensor Circuit 9617262051 GC17283DS1 C GCi7176FW2 C 1 ECU 2 Joint Connector D 3 Main Throttle Sensor 4 Joint Connector C 3 44 FUEL SYSTEM Intake Air Pressure Sensor Service Code 12 Intake Air Pressure Sensor Removal Never drop the sensor especially on a hard surface Such a shock to the part can damage it Remove the fuel tank see Fuel Tank Removal e Pull the intake air pressure sensor A rearward to remove it from the bracket Disconnect the connector B and the vacuum hose Intake Air Pressure Sensor Installation Installation is the reverse of removal OBefore installing the vacuum hose A apply soap and water solution to the nozzle B of the intake air pressure sensor C ORun the lead and hose correctly see Cable Wire and Hose Routing section in the Appendix chapter GC17188FS1 Intake Air Pressure Sensor Input Voltage Inspection NOTE sure the battery is fully charged e Turn the ignition switch to OFF e Remove the fuel tank see Fuel Tank Removal e Disconnect the intake air pressure sensor conne
442. spect or re place the following item Headlight Low Beam Bulb see Headlight Bulb Replace ment in the Electrical System chapter Headlight Fuse 15 A see Fuse Inspection in the Electri cal System chapter Dimmer Switch see Switch Inspection in the Electrical System chapter Headlight Circuit Relay in Relay Box see Relay Circuit Inspection in the Electrical System chapter Harness see Wiring Inspection in the Electrical System chapter e Set the dimmer switch to high beam position e The low beam A and high beam B headlights should go on e The blue high beam indicator light LED C should go on xIf the high beam headlight and or indicator light LED does not go on inspect or replace the following item Headlight High Beam Bulb see Headlight Bulb Replace ment in the Electrical System chapter Dimmer Switch see Switch Inspection in the Electrical System chapter e Turn the engine stop switch to stop position e The low beam and high beam headlights should stay go ing on x If the headlights and or the blue high beam indicator light LED goes off inspect or replace the following item Headlight Circuit Relay in Relay Box see Relay Circuit Inspection in the Electrical System chapter e Turn the ignition switch to OFF e The headlights and the indicator light LED should go off 9517204851 Headlight Aiming Inspection Inspect the headlight beam for aiming xIf the headlight beam points to one side rat
443. spection e Install the left middle fairing see Middle Fairing Installa tion in the Frame chapter 6617798051 GC17881DS1 FUEL SYSTEM DFI 3 55 Water Temperature Sensor Service Code 14 Water Temperature Sensor Resistance Inspection e Refer to the Water Temperature Sensor Inspection in the Electrical System chapter x If the reading is within the standard but the problem still exists replace the ECU see ECU Removal Installation Water Temperature Sensor Circuit 0 9 BR BK 1 2 Water Temperature Sensor 3 Joint Connector D 3 56 FUEL SYSTEM Crankshaft Sensor Service Code 21 The crankshaft sensor has no power source and when the engine stops the crankshaft sensor generates no sig nals Crankshaft Sensor Removal Installation e Refer to the Crankshaft Sensor Removal Installation in the Electrical System chapter Crankshaft Sensor Resistance Inspection e Refer to the Crankshaft Sensor Inspection in the Electrical System chapter x If the reading is within the standard check the peak volt age see Crankshaft Sensor Peak Voltage Inspection Crankshaft Sensor Peak Voltage Inspection e Refer to the Crankshaft Sensor Peak Voltage Inspection in the Electrical System chapter x If the reading is within the standard remove the ECU check the wiring for continuity between main harness con nectors Special
444. st as follows ORecheck the service code indication erase the service code perform the pre diagnosis inspection 1 and 2 and retrieve the service code x If the yellow ABS indicator light LED A goes on faulty ECU in the ABS hydraulic unit Replace the ABS hy draulic unit xIf the yellow ABS indicator light LED does not go on ABS system is normal service code is not stored tempo rary failure Power Supply Voltage Abnormal Under Voltage Service Code 52 e Do the 1st step test as follows ODisconnect ABS Kawasaki Diagnostic System Connector ABS Hydraulic Unit Connector see ABS Hydraulic Unit Removal OCheck for continuity between the red white lead terminal of the main harness side connector A and brown white lead terminal of the main harness side connector ABS hydraulic unit B x If there is the continuity in the lead go to the 2nd step xIf there is not the continuity in the lead replace or repair the main harness GL14606BS1 C GL14039BS1 C GL14610BS1 9114607851 12 54 BRAKES Anti Lock Brake System Equipped Models Do the 2nd step test as follows OConnect the ABS Kawasaki diagnostic system connector and ABS hydraulic unit connector OCheck the battery terminal voltage connect the hand tester to the brown white terminal of ABS Kawasaki diagnostic system connector A and ground Special T
445. stem op eration OMeasure coil and winding resistance when the part is cold at room temperature Electrical Wiring ELECTRICAL SYSTEM 16 21 Wiring Inspection Visually inspect the wiring for signs of burning fraying etc xIf any wiring is poor replace the damaged wiring e Pull each connector A apart and inspect it for corrosion dirt and damage x If the connector is corroded or dirty clean it carefully If it is damaged replace it 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 O range and read the tester x If the tester does not read 0 the lead is defective Re place the lead or the wiring harness B if necessary GP07055BS1 C 16 22 ELECTRICAL SYSTEM Battery Battery Removal e Turn the ignition switch to OFF e Remove the front seat see Front Seat Removal in the Frame chapter e Remove Front Seat Bracket Bolts A Front Seat Bracket B e Disconnect the negative cable A Be sure to disconnect the negative cable first Slide out the positive terminal cap B and then discon nect the positive cable C e Remove the battery D Battery Installation Turn the ignition switch to OFF Put the battery into the battery case e Apply a littl
446. ston rings with your thumbs Install the cylinder head see Cylinder Head Installation Install the front engine mounting bolts and nuts left and right and tighten them see Engine Installation in the En gine Removal Installation chapter 5 38 ENGINE TOP END Cylinder Pistons Piston Removal Remove the cylinder see Cylinder Removal e Place a clean cloth under the pistons Remove the piston pin snap ring A by using the pliers B from the outside of each piston e Remove the piston pins Special Tools Piston Pin Puller A 57001 1568 Piston Pin Puller Adapter 12 D 57001 1657 Center Bolt B Shell of Piston C Remove the pistons Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring A to remove it Remove the 3 piece oil ring with your thumbs in the same manner Piston Installation Apply molybdenum disulfide oil solution to the oil ring ex pander install the oil ring expander A in the bottom pis ton ring groove so the ends B butt together Apply molybdenum disulfide oil solution to the oil ring steel rails and install the oil ring steel rails one above the ex pander and one below it OSpread the rail with your thumbs but only enough to fit the rail over the piston ORelease the rail into the bottom piston ring groove NOTE OThe oil ring rails have no top or bottom SIK25
447. 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 A the forks x If you feel looseness the steering is too loose NOTE OThe cables and wiring will have some effect on the mo tion of the fork which must be taken into account OBe sure the leads and cables are properly routed OThe bearings must be in good condition and properly lubricated in order for any test to be valid Steering Play Adjustment e Remove Handlebar see Handlebar Removal in the Steering chapter Upper Inner Fairings see Upper Inner Fairing Removal in the Frame chapter e Clear the cables from the guides A e Loosen the upper front fork clamp bolts B e Remove Steering Stem Head Bolt Plug C Steering Stem Head Bolt D and Washer Steering Stem Head E PERIODIC MAINTENANCE 2 37 Periodic Maintenance Procedures e Bend the claws A of the claw washer straighten Remove the steering stem locknut B and claw washer Special Tool Steering Stem Nut Wrench 57001 1100 Adjust the steering Special Tool Steering Stem Nut Wrench A 57001 1100 x If the steering is too tight loosen the stem nut B a fraction of a turn x If the steering is too loose tighten the stem nut a fraction of a turn NOTE OTurn the stem nut 1 8 turn at time maximum e Install the new claw washer A so that its bent claws B face upward and eng
448. stop switch Tester 3 Crankshaft sensor peak voltage Replace bad parts ECU is defective Replace ECU GPI0280B F 16 46 ELECTRICAL SYSTEM Ignition System Ignition System Circuit ooh BK Y W BK S Y BK P BK BR BK BR o BR R BK 16 Y G BL Y R LG R BL Y jpa 4o 8 ah 8 ye 1 Ignition Switch 10 Vehicle down Sensor 18 Battery 12 V 10 Ah 2 Engine Stop Switch 11 Water Temperature Sensor 19 Main Fuse 30 A 3 Spark Plugs 12 Neutral Switch 20 Relay Box 4 Stick Coils 13 Crankshaft Sensor 21 ECU Main Relay 5 Speed Sensor 14 Oxygen Sensor Equipped 22 Fuse Box 6 Joint Connector C Models 23 Ignition Fuse 10 A 7 Subthrottle Sensor 15 ECU 24 Starter Lockout 8 Main Throttle Sensor 16 Sidestand Switch Switch 9 Joint Connector D 17 Frame Ground ELECTRICAL SYSTEM 16 47 Electric Starter System Starter Motor Removal NOTICE Do not tap the starter motor shaft or body Tapping the shaft or body could damage the motor e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Air Cleaner Housing see Air Cleaner Housing Removal in the Fuel System DFI chapter Throttle Body Assy see Throttle Body Assy Removal in the Fuel System DFI chapter Throttle Body Assy Holder see Throttle Body Assy Holder Removal in the Engine Top End chapter e Slide out the rubber c
449. sub throttle valve actuator resistance see Subthrottle Valve Actuator Resistance Inspection Subthrottle Valve Actuator Resistance Inspection Turn the ignition switch to OFF Remove the air cleaner housing see Air Cleaner Housing Removal Disconnect the subthrottle valve actuator connector A Connect a digital meter to the subthrottle valve actuator connector A Measure the subthrottle valve actuator resistance Subthrottle Valve Actuator Resistance Connections BK lead 1 P lead 2 G lead 3 W BL lead 4 Standard About 5 5 7 5 xIf the reading is out of the standard replace the throttle body assy see Throttle Body Assy Removal Installation x If the reading is within the range check the input voltage see Subthrottle Valve Actuator Input Voltage Inspection GC17159BS1 C 3 74 FUEL SYSTEM Subthrottle Valve Actuator Service Code 62 Subthrottle Valve Actuator Input Voltage Inspection NOTE OBe sure the battery is fully charged Remove the air cleaner housing see Air Cleaner Housing Removal e Turn the ignition switch to OFF e Disconnect the subthrottle valve actuator connector and connect the harness adapter A between these connec tors as shown in the figure Main Harness B Subthrottle Valve Actuator C Special Tool Measuring Adapter 57001 1700 Connect the peak voltage adapter D and a digital meter E to the harness adapter
450. t eene 16 58 Turn Signal Relay teet 16 59 M EE 16 61 Air Switching Valve Operation TeSst nennen nennen 16 61 Air switching Valve Unit Test Tete D roe ER e eade Posh Du deu ea v 16 62 Radiator Fan System cue dioi aided dau dece 16 64 Fan Motor INSP ECON oe RE 16 64 Meter Gauge Indicator 16 65 Meter Unit Removal 16 65 Meter Unit 16 65 Meter Gauge Disassembly 16 65 Meter Unit et Re te ber 16 66 Swilches and Sensors e elder ta duc dub 16 75 Brake Light Timing InsSpectiort oo e tee tne dti ere eee 16 75 Brake Light Timing Adjustment 222 2 2 2 1244 4 444 44111 11 16 75 SWItCh aio eleg 16 75 Water Temperature Sensor Inspection 16 76 Speed Sensor 16 76 Speed Sensor 16 76 Speed Sensor 2 12 0 0 000000008 0 000000060000000006 0004 9 22 00 16 77 Fuel Level Sensor
451. t as follows ORecheck the service code indication erase the service code perform the pre diagnosis inspection 1 and 2 and retrieve the service code xIf the yellow ABS indicator light LED A goes on faulty solenoid valve in the ABS hydraulic unit Replace the ABS hydraulic unit xIf the yellow ABS indicator light LED does not go on ABS system is normal service code is not stored tempo rary failure ABS Solenoid Valve Relay Inspection Service Code 19 e Do the 1st step test as follows OCheck the ABS solenoid valve relay fuse A x If the fuse blown go to the 2nd step x If the fuse correct go to the 4th step GL14598BS1 GL14598BS1 GL14610BS1 12 48 BRAKES Anti Lock Brake System Equipped Models e Do the 2nd step test as follows ODisconnect the ABS hydraulic unit connector A see ABS Hydraulic Unit Removal OCheck for continuity between the red black and black lead terminals of the ABS hydraulic unit connector x If there is the continuity in the lead replace the ABS hy draulic unit x If there is not the continuity in the lead go to the 3rd step e Do the 3rd step test as follows OCheck for continuity between the red black lead terminal of the main harness side connector ABS hydraulic unit A and red black lead terminal of the fuse box B x If there is the continuity in the lead replace the fuse x If there is not
452. t in the Periodic Maintenance chapter A WARNING Operation with incorrectly routed or improperly ad justed cables could result in an unsafe riding con dition Be sure the cables are routed correctly and properly adjusted Throttle Body Assy Disassembly NOTICE 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 Never drop the throttle body assy especially on a hard surface Such a shock to the body assy can damage it esos P 3 106 FUEL SYSTEM Throttle Body Assy e Remove Throttle Body Assy see Throttle Body Assy Removal Screws A Pull out the fuel injectors B from the throttle body assy together with the delivery pipe C Pull out the fuel injectors from the delivery pipe Throttle Body Assy Assembly Replace the O rings A and seals B with new ones 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 and confirm whether the injectors turn smoothly or not Install the injectors along with the delivery pipe assy in
453. t of the crankcase Transmission Assy Installation e Be sure that the dowel pins A are in position e Apply grease to the new O ring B on the oil pipe C Install the transmission assy on the crankcase Tighten Torque Transmission Case Bolts 20 2 0 kgf m 15 ft Ib x If the gear positioning lever A was removed install it see External Shift Mechanism Installation lf the shift rod plate B was removed install it in the fol lowing procedure OApply a non permanent locking agent to the shift rod plate bolt C and tighten it Torque Shift Rod Plate Bolt 9 8 N m 1 0 kgf m 87 in Ib Set the gear positioning lever to the neutral position D Check that the drive and output shaft turn freely 9 36 CRANKSHAFT TRANSMISSION Transmission Install Pin A Shift Drum Holder B Pin C Neutral Switch Holder D Apply anon permanent locking agent to the neutral switch holder screw E and tighten it Torque Neutral Switch Holder Screw 4 9 N m 0 50 kgf m 43 in lb e Apply grease to the new O ring A and install it on the output shaft e Apply grease to the oil seal lips Install the collar B to the output shaft e When the new oil seal C is installed press in it onto the collar so that the surface of the oil seal is flush with the surface D of the crankcase OUsing a cleaning fluid clean off any oil or dirt on the outer circumference E of the oil se
454. t the engine on a clean surface and hold the engine steady while parts are being removed Remove Cylinder Head Cover see Cylinder Head Cover Re moval in the Engine Top End chapter Cylinder Head see Cylinder Head Removal in the En gine Top End chapter Cylinder see Cylinder Removal in the Engine Top End chapter Pistons see Piston Removal in the Engine Top End chapter Alternator Rotor see Alternator Rotor Removal in the Electrical System chapter Starter Motor see Starter Motor Removal in the Electri cal System chapter Crankshaft Sensor see Crankshaft Sensor Removal in the Electrical System chapter Timing Rotor see Timing Rotor Removal in the Electrical System chapter Clutch see Clutch Removal in the Clutch chapter Oil Pump see Oil Pump Removal in the Engine Lubri cation System chapter Water Pump see Water Pump Removal in the Cooling System chapter Transmission Assy see Transmission Assy Removal Oil Filter see Oil Filter Replacement in the Periodic Maintenance chapter e Remove Rear Camshaft Chain Guide Bolt A Rear Camshaft Chain Guide B CRANKSHAFT TRANSMISSION 9 11 Crankcase Splitting Remove the upper crankcase bolts A and the copper plated washers Remove Oil Pan see Oil Pan Removal in the Engine Lubrication System chapter Oil Screen see Oil Pan Removal in the Engine Lubrica tion System chapter Oil Pipes see Oil Pan Removal in the Engine Lubrication System chapter
455. t 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 motorcycles are introduced by the Service Manual Genuine parts provided as spare parts are listed in the Parts Catalog e Follow the procedures in this manual care fully Don t take shortcuts Remember to keep complete records of main tenance and repair with dates and any new parts installed How to Use This Manual In this manual the product is divided into its major systems and these systems make up the manual s chapters The Quick Reference Guide shows you all of the product s system and assists in locating their chapters Each chapter in turn has its own comprehensive Ta ble of Contents For example if you want ignition coil informa tion use the Quick Reference Guide to l
456. t width as described be low e Grind the seat at a 32 angle B until the seat outside diameter is within the specified range OTo make the 32 grind fit a 32 cutter into the holder and slide it into the valve guide OTurn the holder one turn at a time while pressing down very lightly Check the seat after each turn 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 x If the seat width is too narrow repeat the 45 grind until the seat is slightly too wide and then return to the seat outside diameter measurement step above 8 15011951 C GE15012181 GE15012281 Valves ENGINE TOP END 5 35 x If the seat width is too wide make the 60 or 55 A grind described 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 or 55 angle until the seat width is within the specified range OTo make the 60 or 55 grind fit 60 or 55 cutter into the holder and slide it into the valve guide OTurn the holder while pressing down lightly OAfter making the 60 or 55 grind return to the se
457. tem Standard Coolant Provided when Shipping Type Recommended Color Mixed Ratio Freezing Point Total Amount Radiator Cap Relief Pressure Thermostat Valve Opening Temperature Valve Full Opening Lift 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 1 2 L 1 3 US qt reserve tank full level including radiator and engine 112 3 141 7 kPa 1 15 1 45 kgf cm 16 3 20 6 psi 80 5 83 5 C 177 182 F 8 mm 0 31 in or more at 95 C 203 F COOLING SYSTEM 4 7 Special Tools Bearing Driver Set Oil Seal Driver 57001 1129 57001 1660 7571129ST C 5157166051 4 8 COOLING SYSTEM Coolant Coolant Deterioration Inspection Remove the right middle fairing see Middle Fairing Re moval in the Frame chapter e Visually inspect the coolant A in the reserve tank If whitish cotton like wafts are observed aluminum parts in the cooling system are corroded If the coolant is brown iron or steel parts are rusting In either case flush the cooling system x lf the coolant gives off an abnormal smell check for cooling system leak It may be caused by exhaust gas leaking into the cooling system Coolant Level Inspection Refer to the Coolant Level Inspection in the Periodic Main tenance chapter Coolant Draining Refer to the
458. ter 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 68020128 5 GB020138 5 68020148 5 J 2 68020158 5 68020188 5 GENERAL INFORMATION 1 5 Before Servicing Press For items such as bearings or oil seals that must be r pressed into place apply small amount of oil to the con D uua tact area Be sure to maintain proper alignment and use dai d smooth movements when installing gt GB020178 Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary Replace with new ones whenever m removed Press bearings with the manufacturer and size MI marks facing out Press the bearing into place by putting RQ RSs pressure on the correct bearing race as shown 2 B Bh B Pressing the incorrect race can cause pressure between 5 A the inner and outer race and result in bearing damage 77 orem 6802018
459. th A on the steel plates wear against the clutch hub splines B x If there are notches worn into the splines replace the clutch hub Also replace the steel plates if their teeth are damaged GF06104BS1 ENGINE LUBRICATION SYSTEM 7 1 Engine Lubrication System Table of Contents e delroro Tela EEEE DET 7 2 Engine Onslow Chart rroo ET 7 4 ee 7 6 Special Tools Sealant 7 7 7 8 Oil Level INSpectiON aani 7 8 rene aa e ere eee eee 7 8 Oil Filter Replacement pp 7 8 OUP aereas i n n Ma ai ae 7 9 Oil Par Removals 22 72 7 9 Oil Pan Installation iss et ee eee eee 7 10 Oil Pressure Relief Valve 7 12 Oil Pressure Relief Valve Removal 4 7 12 Oil Pressure Relief Valve Installation 7 12 Oil Pressure Relief Valve Inspection pp 7 12 OM teda D t vetet diee eet um pde ee HE Ret Erg 7 13 Removal nire E e etre REO FU ses 7 13 Oil Pump Installatiori ooi 7 14 Oil Pressure Measurement eee a Dota
460. the air switching valve terminals as shown Special Tool Hand Tester 57001 1394 Air Switching Valve Resistance Standard 18 22 at 20 C 68 F x If the resistance reading is not within the specified range replace the air switching valve with a new one Connect the 12 V battery A to the air switching valve terminals as shown Blow the air to the intake air duct A and make sure that the air does not flow through the outlet air duct B e Disconnect the 12 V battery Blow the air to the intake air duct A again and make sure that the air flows through the outlet air duct B x If the air switching valve does not operate as described replace it with a new one NOTE OTo check air flow through the air switching valve just blow through the air switching valve hose intake side GE04089BS1 GE04090BS1 GP18142BS1 C GP18144BS1 C ELECTRICAL SYSTEM 16 63 BK Air Switching Valve Air Switching Valve Circuit Lon eniti onon BR 1 F BATTERY Li BR W GCi7iB8FW3 C Ignition Switch Air Switching Valve ECU Frame Ground 2 Battery 12 V 10 Ah Main Fuse 30 Relay Box ECU Main Relay Fuse Box 1 Fl Fuse 15 Ignition Fuse 10 A 16 64 ELECTRICAL SYSTEM Radiator Fan System Fan Motor Inspection Remove the left middle
461. the bearing in or out NOTICE Do not heat the case with a torch This will warp the case Soak the case in oil and heat the oil e Using a press and the bearing driver set A install the new ball bearing until it stops at the bottom of its housing OThe new needle bearings must be pressed into the crankcase so that the end is flush with the end of the hole Special Tool Bearing Driver Set 57001 1129 6114060581 Ball and Needle Bearing Wear Inspection Do not remove the bearings for inspection Re moval may damage them Check the ball bearings OSince the ball bearings are made to extremely close toler ances the wear must be judged by feel rather than mea surement Clean each bearing in a high flash point sol vent dry it do not spin the bearing while it is dry and oil it with engine oil OSpin A the bearing by hand to check its condition x If the bearing is noisy does not spin smoothly or has any rough spots replace it e Check the needle bearings OThe rollers in a needle bearing normally wear very little and wear is difficult to measure Instead of measuring inspect the bearing for abrasion color change or other damage x If there is any doubt as to the condition of a needle bear ing replace it 9114000851 Oil Seal Inspection Inspect the oil seals Replace it if the lips are misshapen discolored indicating that the rubber has deteriorated
462. the bulb Pull the bulb out to prevent damage to the bulb Do not use bulb rated for greater wattage then the specified valve Replace the bulb with a new one Insert the socket into the headlight unit Headlight Unit Removal Installation e Refer to the Upper Fairing Removal Installation in the Frame chapter Tail Brake Light LED Unit Removal e Remove Front Seat see Front Seat Removal in the Frame chap ter Rear Seat Covers see Rear Seat Cover Removal in the Frame chapter e Remove the tool bag e Disconnect the tail brake light lead connector A e Free the tail brake light lead from the hook B e Remove the tail brake light mounting bolts C and take off the tail brake light unit D Tail Brake Light LED Unit Installation e Installation is the reverse of removal 16 56 ELECTRICAL SYSTEM Lighting System License Plate Light Bulb Replacement e Remove Screws A License Plate Light Cover B Pull the bulb A out of the socket B 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 Replace the bulb with a new one Insert the bulb into the socket Install the license plate light cover ELECTRICAL SYSTEM 16 57 Lighting System Headlight Tail Light Circuit Ti Her er BATTERY 62109 AF f 4 JRO r 1 1
463. the ends of the leads Special Tool Hand Tester 57001 1394 OSet the tester to the x 1 O range and read the tester x If the tester does not read 0 the lead is defective Re place the main harness B if necessary e Narrow down suspicious parts and close in on the faulty ABS part by repeating the continuity tests If no abnormality is found in the wiring or connectors the ABS parts are the next likely suspects Check each part one by one x If an abnormality is found replace the affected ABS part GP07055BS1 C 12 38 5 Anti Lock Brake System Equipped Models ABS Diagnosis Flow Chart Problem occurs Confirm problems Gather information from rider Conduct pre diagnosis inspection 1 2 Conduct self diagnosis Check by other than self diagnosis Check by self diagnosis If harness or connector is faulty If ABS part is faulty Repair or replace Check ABS parts NG Final inspection OK End GLI4011B F Anti Lock Brake System Equipped Models BRAKES 12 39 Inquiries to Rider OEach rider reacts to problems in different ways so it is important to confirm what kind of condition the rider is dissatisfied with OTry to find out exactly what problem occurs under exactly what conditions by asking the rider know ing this information may help you reproduce the problem in the shop OThe diagnosis sheet will help prevent you from overlooking any key
464. 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 The piston in the brake caliper can crush hands and fingers Never place your hand or fingers in front of the piston e Pull out the pistons by hand e Remove Caliper Holder Dust Seals Fluid Seals Bleed Valve Rubber Cap NOTE Olf compressed air is not available do as follows with the brake hose connected to the caliper OPrepare a container for brake fluid and perform the work above it ORemove the brake pads see Front Brake Pad Removal in the Brakes chapter OPump the brake lever until the pistons come out of the cylinders and then disassemble the caliper 6513804 PERIODIC MAINTENANCE 2 57 Periodic Maintenance Procedures Front Caliper Assembly Clean the caliper parts except for the pads For cleaning the parts use only disc brake fluid isopropyl alcohol or ethyl alcohol e Install the bleed valve and rubber cap Torque Caliper Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib e Replace the fluid seals A with new ones brake fluid to the fluid seals and install them into the cylinders by hand e Replace the dust seals B with new ones if they are dam aged OApply brake fluid to the dust seals and install them into the cylinders by hand e Apply brake fluid to the outside of the pist
465. the tank cap open to release pressure in the tank This makes fuel spillage less e Remove Front Seat see Front Seat Removal in the Frame chap ter Fuel Drain Hose A Fuel Tank Breather Hose B Fuel Tank Bolt C and Washer e Remove Ignition Switch Cover A Bolts B and Collars Left and Right Fuel Tank Cover C 3 110 FUEL SYSTEM Fuel Tank Remove the fuel tank bolts A and washers e Draw the fuel out from the fuel tank with a commercially available pump A OUse a soft plastic hose B as a pump intake hose in order to insert the hose smoothly OPut the hose through the fill opening C into the tank and draw the fuel out Front D A WARNING Spilled fuel is flammable and can be explosive un der certain conditions The fuel can not be removed completely from the fuel tank Be careful for re mained fuel spillage e Remove the left frame cover see Frame Cover Removal in the Frame chapter e Pull out the fuel pump lead connector A from the bracket and disconnect it e Be sure to place a piece of cloth A around the fuel hose joint e Insert a standard tip screwdriver B into the slit on the joint lock C GCO9033BS1 C Fuel Tank FUEL SYSTEM 3 111 Turn the driver A to disconnect the joint lock B Pull the fuel hose joint C out of the outlet pipe D A WARNING Fuel is flammable and explosive under certain con di
466. the throttle body assy see Throttle Body Assy Removal Installation the reading is within the range but the problem still exists replace the ECU see ECU Removal Installation Subthrottle Sensor Circuit 0 BR BK i BR BK 1 ECU 2 Joint Connector D 3 Subthrottle Sensor 4 Joint Connector C GC17293BS1 C GCi7183FW2 FUEL SYSTEM DFI 3 67 Oxygen Sensor not activated Service Code 33 Equipped Models Oxygen Sensor Removal Installation e Refer to the Oxygen Sensor Removal Installation in the Electrical System chapter Oxygen Sensor Inspection e Turn the ignition switch to OFF e Remove the engine sprocket cover see Engine Sprocket Removal in the Final Drive chapter e Disconnect the oxygen sensor connector and connect the oxygen sensor measuring adapter A between these con nectors Special Tool Oxygen Sensor Measuring Adapter 57001 1682 e Connect a digital meter to the harness adapter leads Oxygen Sensor Output Voltage Connections to Adapter Digital Meter BL sensor BL lead Digital Meter gt BR sensor W lead e Remove the left middle fairing see Middle Fairing Re moval in the Frame chapter e Remove the air switching valve hose A from the fitting e Install the suitable plug on the fitting to shut off the sec ondary air e Turn the ignition switch to ON e Warm up the engine thoroughly until the r
467. the yellow ABS indicator light LED A goes on it is normal x If the yellow ABS indicator light LED does not go on go to step Yellow ABS Indicator Light LED does not go on When the Ignition Switch turned to ON Turn the ignition switch to OFF x If the yellow ABS indicator light LED A does not go on it is normal x If the yellow ABS indicator light LED goes on go to step Yellow ABS Indicator Light LED goes on When the Mo torcycle is Running No Service Code Yellow ABS Indicator Light LED does not go on When the Ignition Switch turned to ON e Disconnect the meter unit connector see Meter Unit Re moval in the Electrical System chapter e Do the 1st step test as follows OCheck the terminal voltage between the black white lead terminal of the meter unit connector A and ground 9 Yellow ABS Indicator Light LED 15 Ground Special Tool Hand Tester 57001 1394 Needle Adapter 57001 1457 OTurn the ignition switch to ON Terminal Voltage Standard About 8 V x If the terminal voltage is not within the specification go to the 2nd step xIf the terminal voltage is correct replace the meter as sembly e Do the 2nd step test as follows OCheck for continuity between the black white lead termi nal of the main harness side connector meter unit A and ground B x If there is the continuity in the lead replace or repair the main harness x If there is not the continuity
468. tion Check that the notch A on the left wheel alignment indi cator B aligns with the same swingarm mark or position C that the right wheel 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 Be sure the wheel is properly aligned GJ04082BS1 PERIODIC MAINTENANCE 2 31 Periodic Maintenance Procedures Drive Chain Wear Inspection Remove the chain cover see Swingarm Removal in the Suspension chapter 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 Stretch the chain taut by hanging 98 N 10 kg 20 Ib weight A on the chain Measure the length of 20 links B on the straight part C of the chain from the pin center of the 1st pin to the pin center of the 21st pin Since the chain may wear unevenly take measurements at several places If any measurements exceed the service limit replace the chain Also replace the front and rear sprockets when the drive chain is replaced Drive Chain 20 link Length Standard 317 5 318 2 mm 12 50
469. tion A GE24739BS1 Specifications ENGINE TOP END 5 7 Item Standard Service Limit Camshafts Cam Height Exhaust Intake Camshaft Journal Camshaft Cap Clearance Camshaft Journal Diameter Camshaft Bearing Inside Diameter Camshaft Runout Cylinder Head Cylinder Compression Cylinder Head Warp 35 843 35 957 mm 1 4111 1 4156 in 36 543 36 657 mm 1 4387 1 4432 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 1 000 1 520 kPa 10 2 15 5 kgf cm 145 220 psi at 450 r min rpm 35 74 mm 1 407 in 36 44 mm 1 435 in 0 16 mm 0 0063 in 23 92 mm 0 9417 in 24 08 mm 0 9480 in TIR 0 1 mm 0 004 in Valves Valve Clearance Exhaust Intake Valve Head Thickness Exhaust Intake Valve Stem Bend Valve Stem Diameter Exhaust Intake Valve Guide Inside Diameter Exhaust Intake Valve Valve Guide Clearance Wobble Method Exhaust Intake Valve Seat Cutting Angle Valve Seating Surface Width Exhaust Intake Outside Diameter Exhaust Intake 0 22 0 31 mm 0 0087 0 0122 in 0 15 0 21 mm 0 0059 0 0083 in 0 8 mm 0 031 0 5 mm 0 020 in TIR 0 01 mm 0 0004 in or less 4 455 4 470 mm 0 1754 0 1760 in 4 475 4 490 mm 0 1762 0 1768 in 4 500 4 512 mm 0 1772
470. tion switch to OFF to stop the engine and disconnect the hand tester x If the charging voltage is kept between the values given in the table the charging system is considered to be working normally xIf the charging voltage is much higher than the values specified in the table the regulator rectifier is defective or the regulator rectifier leads are loose or open xIf the charging voltage does not rise as the engine speed increases then the regulator rectifier is defective or the alternator output is insufficient for the loads Check the alternator and regulator rectifier to determine which part is defective ELECTRICAL SYSTEM 16 37 Charging System Charging System Circuit GP093428W2 1 Ignition Switch 2 Load 3 Alternator 4 Regulator Rectifier 5 Frame Ground 6 Battery 12 V 10 Ah 7 Main Fuse 30 16 38 ELECTRICAL SYSTEM Starter Motor Clutch Starter Motor Clutch Removal Installation e Refer to the Alternator Rotor Removal Installation Starter Motor Clutch Inspection e Remove Alternator Cover see Alternator Cover Removal Starter Idle Gear and Shaft see Alternator Rotor Re moval Torque Limiter and Shaft see Alternator Rotor Removal 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 If the starter motor clutch does not operate as it should or if it makes noise go to the n
471. tions and can cause severe burns Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is dis connected fuel spills out from the hose and the pipe because of residual pressure Cover the hose connection with a piece of clean cloth to prevent fuel spillage Close the fuel tank cap Remove the fuel tank A and place it on plank B ODo not apply the load to the fuel outlet pipe C of the fuel pump Fuel Tank Installation e Note the above WARNING see Fuel Tank Removal e Check that the rubber dampers A are on the frame and the fuel tank x If the dampers are damaged or deteriorated replace them with new ones e Insert the fuel hose joint A straight onto the outlet pipe until the hose joint clicks When installing the fuel hose joint do not apply strong force to the outlet pipe on the fuel pump The pipe made from resin could be damaged e Push the joint lock B until it clicks 3 112 FUEL SYSTEM Fuel Tank Push and pull A the hose joint B back and forth more than 2 times and make sure it is locked and does not come off A WARNING Leaking fuel can cause a fire or explosion resulting in serious burns Make sure the hose joint is in stalled correctly on the delivery pipe by sliding the joint x If it comes off reinstall the hose joint Connect the fuel pump lead connector and the battery
472. to the throttle body e Install the throttle body assy see Throttle Body Assy In stallation GCITESOS FUEL SYSTEM DFI 3 107 Air Cleaner Air Cleaner Element Removal Installation Refer to the Air Cleaner Element Replacement in the Pe riodic Maintenance chapter Air Cleaner Element Inspection Remove the air cleaner element see Air Cleaner Element Replacement in the Periodic Maintenance chapter e Visually inspect the element A for tears or breaks xIf the element has any tears or breaks replace it with a nee Air Cleaner Oil Draining A drain hose A is connected to the bottom of the air cleaner to drain water or oil accumulated in the cleaner part e Visually inspect the drain hose for accumulation of water or oil If any water or oil accumulates the hose remove the plug B from the drain hose and drain it A WARNING Oil on tires will make them slippery and can cause an accident and injury Be sure to reinstall the plug in the drain hose after draining Air Cleaner Housing Removal Remove Fuel Tank see Fuel Tank Removal Air Cleaner Housing Cover see Air Cleaner Element Re placement in the Periodic Maintenance chapter Left Middle Fairing see Middle Fairing Removal in the Frame chapter Left Side Cover see Side Cover Removal in the Frame chapter Disconnect the breather hose A on the upper crankcase Loosen the air
473. to prevent fuel spillage OWhen any fuel hose is disconnected do not turn on the ignition switch Otherwise the fuel pump will operate and fuel will spout from the fuel hose ODo not operate the fuel pump if the pump is completely dry This is to prevent pump seizure OBefore removing the fuel system parts blow the outer sur faces of these parts clean with compressed air OTo prevent corrosion and deposits in the fuel system do not add to fuel any fuel antifreeze chemicals 6017036881 3 22 FUEL SYSTEM DFI Servicing Precautions Olf the motorcycle is not properly handled the high pres sure inside the fuel line can cause fuel to leak or the hose to burst Remove the fuel tank see Fuel Tank Removal and check the fuel hose A Replace the fuel hose if any fraying cracks or bulges are noticed see Fuel Hose Replacement in the Periodic Maintenance chapter OTo maintain the correct fuel air mixture F A there must be no intake air leaks in the DFI system Be sure to install the oil filler plug A after filling the engine oil Torque Oil Filler Plug Hand tighten Troubleshooting the DFI System FUEL SYSTEM DFI 3 23 Outline When a problem occurs with DFI system the yellow en gine warning indicator light LED A goes on or blinks to alert the rider In addition the condition of the problem is stored in the memory of the ECU With the engine stopped and turned in the self diagn
474. uel hose with a clamp Insert the fuel hose into the measuring cylinder B A WARNING Wipe off spilled out fuel immediately Be sure to hold the measuring cylinder vertical Close the fuel tank cap Turn the engine stop switch to run position Turn the ignition switch to ON OThe fuel pump should operate for 3 seconds and then should stop Do not drive the fuel pump 3 seconds or more with out the fuel in the fuel tank If the fuel pump is driven without the fuel it may be damaged e Measure the discharge for 3 seconds ORepeat this operation several times Amount of Fuel Flow Standard 30 mL 1 0 US oz or more for 3 seconds Turn the ignition switch to OFF If the fuel flow is much less than the specified replace the fuel pump see Fuel Pump Removal Installation Install the fuel tank see Fuel Tank Installation Start the engine and check for fuel leakage GEO P FUEL SYSTEM DFI 3 93 Fuel Pump Fuel Pump Removal A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions creating the potential for serious burns 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 to OFF Disconnect the battery terminal To avoid fuel spills draw it from the tank when the engine is cold Be prepared for fuel spill
475. ulic unit B xIf there is the continuity in the lead go to the 2nd step x If there is not the continuity in the lead replace or repair the main harness GL14608BS1 GL14610BS1 E 10700000000 9114607851 Anti Lock Brake System Equipped Models BRAKES 12 55 Do the 2nd step test as follows OConnect the ABS Kawasaki diagnostic system connector and ABS hydraulic unit connector OCheck the battery terminal voltage connect the hand tester to the brown white terminal of ABS Kawasaki diagnostic system connector A and ground Special Tool Hand Tester 57001 1394 OTurn the ignition switch to ON Battery Terminal Voltage Standard 16 6 V or less x If the battery terminal voltage is not within the specifica tion go to the 3rd step x If the battery terminal voltage correct go to the 4th step Do the 3rd step test as follows OCheck the battery condition and regulator rectifier see Charging Condition Inspection Regulator Rectifier In spection in the Electrical System chapter Do the 4th step test as follows ORecheck the service code indication erase the service code perform the pre diagnosis inspection 1 and 2 and retrieve the service code x If the yellow ABS indicator light LED A goes on faulty ECU in the ABS hydraulic unit Replace the ABS hy draulic unit x lf the yellow ABS indicato
476. using air switching valve and air suction valve cover x lf they are not correct them Replace them if they are damaged 5 14 Cylinder Head Cover Cylinder Head Cover Removal Remove the right middle fairing see Middle Fairing Re moval in the Frame chapter Clear the rubber cover A from the filler neck Remove the radiator bolt B and lower the radiator C for extra clearance e For models equipped with an ABS remove the bolt A and damper B Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Air Cleaner Housing see Air Cleaner Housing Removal in the Fuel System DFI chapter Throttle Body Assy see Throttle Body Assy Removal in the Fuel System DFI chapter Air Suction Valve see Air Suction Valve Removal Stick Coils see Stick Coil Removal in the Electrical Sys tem chapter Regulator Rectifier Bracket A Baffle Plate Bolts B Baffle Plate C Clamp D Cylinder Head Cover Bolts E and Rubber Washers Cylinder Head Cover F Cylinder Head Cover ENGINE TOP END 5 15 Cylinder Head Cover Installation Replace the head cover gasket A with a new one Clean off any oil or dirt and apply liquid gasket to the areas B on the cylinder Sealant Liquid Gasket TB1216B 92104 1064 Replace the plug hole gaskets A with new ones Be sure to install the following parts Dowel Pins B Plug Hole Gaskets e Install t
477. ut 12 5 sec onds after starting the erase mode OThe yellow ABS indicator light LED stays on during the erase mode and after erasing OOnce erasing is finished enter the self diagnosis mode again to confirm that the service codes have been erased If the ABS has been reset and all codes have been erased only start code 12 will be shown Erasing of Service Code Yellow ABS Indicator Light LED 1 2 OFF ABS Self diagnosis Terminal ee is Ground l 2 5 i 1 18 rf Within 12 55 Service code End of Service erase starts Code Erase 6114609 2 C 5 12 43 Anti Lock Brake System Equipped Models Self diagnosis Flow Chart Turn the ignition switch to OFF Connect the ABS self diagnosis terminal to the ground terminal Turn the ignition switch to ON Self diagnosis mode starts The yellow ABS warning indicator light LED blinks to display the service code s in about 3 seconds after entering the self diagnosis mode 1 If the service code s is not displayed drive at 20 km h 12 mph or more for 1 minute stop and try self diagnosis again Check the faulty point with the service code table and repair according to fault inspection 1 to 14 Erase the service code memorized in the ABS hydraulic unit Start the self diagnosis mode to confirm that erasing has been completed Disconnect the ABS self
478. ut DC 0 05 0 07 V or DC 4 5 4 9 V NOTE ORotate the rear wheel by hand confirm the output volt age will be raise or lower e Turn the ignition switch to OFF x If the reading is out of the range check the speed sensor see Speed Sensor Inspection in the Electrical System chapter and the wiring to ECU see wiring diagram in this section x If the reading speed sensor and wiring are good check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see ECU Removal Installation GC17144BS1 C FUEL SYSTEM DFI 3 59 Speed Sensor Service Code 24 Speed Sensor Circuit GCi7181FW2 1 2 Joint Connector D 3 Joint Connector C 4 Speed Sensor 5 Meter Unit 3 60 FUEL SYSTEM Vehicle down Sensor Service Code 31 Vehicle down Sensor Removal Installation Never drop the vehicle down sensor especially on a hard surface Such a shock to the sensor can damage it e Remove Fuel Tank see Fuel Tank Removal Fuel Tank Bracket see Air Cleaner Element Replace ment in the Periodic Maintenance chapter Clamp A Connector B Disconnect Vehicle down Sensor C and Damper e Installation is the reverse of removal OApply grease to the vehicle down sensor terminals OThe UP mark A of the sensor should face upward A WARNING Incorrect installation of the vehicle down sensor cou
479. ve it Front Seat Installation Slide the front seat A rearward B to position it on the frame Slide the front seat forward C to engage the front seat hook D with the bracket E Fairings FRAME 15 11 Upper Inner Fairing Removal e Remove Windshield see Windshield Removal Bolts A and Washers Quick Rivet B Clear the hook portions C Remove the left upper inner fairing D e Remove Quick Rivets A Bolts B and Washers Clear the hook portions C Remove the meter cover D Slide out the dust cover A and disconnect the connector Remove the bolts Remove the bolts A and washers Clear the hook portions B e Remove Wellnuts C Right Upper Inner Fairing D with Meter Unit Upper Inner Fairing Installation Installation is the reverse of removal OBe sure to install the damper A on the right upper inner fairing 9005022851 15 12 Fairings Olnsert the hook portion A into the hole B on the upper fairing Olnsert the hook portions C into the slits D on the upper fairing on both sides Olnsert the hook portions A into the slits B on the middle fairing OWhile holding the portion A install the bolt B and washer Lower Inner Fairing Removal Clear the front turn signal light leads from the clamps A e Remove Quick Rivets B Lower Inner Fairings
480. ver C Front Brake Light Switch Screw Front Brake Light Switch D GLO7138BS1 o Front Master Cylinder Installation e Apply silicone grease to the brake lever pivot bolt e Replace the brake lever pivot bolt locknut with a new one e Install Front Brake Light Switch Front Brake Light Switch Screw Brake Lever Brake Lever Pivot Bolt and Locknut e Tighten Torque Front Brake Light Switch Screw 1 2 0 12 kgf m 11 in Ib Brake Lever Pivot Bolt 1 0 0 10 kgf m 9 in Ib Brake Lever Pivot Bolt Locknut 5 9 0 60 kgf m 52 in Ib 12 22 BRAKES Master Cylinder Install the front master cylinder OAlign the punch mark A on the handlebar with the mating surface B of the master cylinder clamp e Tighten the upper clamp bolt C first and then the lower clamp bolt D There will be a gap at the lower part of the clamp after tightening Torque Front Master Cylinder Clamp Bolts 11 N m 1 1 kgf m 97 in Ib e Connect the front brake light switch connectors e Replace the washers A on each side of the hose fitting B with new ones e Install the brake hose upper end e Tighten Torque Brake Hose Banjo Bolt 25 N m 2 5 kgf m 18 ft Ib e Bleed the brake line see Brake Line Bleeding e Check the fluid level in the brake reservoirs see Brake Fluid Level Inspection in the Periodic Maintenance chap ter e Check the brake for good braking power no brake drag and no fluid leak
481. vere burns To prevent burns wear protective clothing and safety glasses when handling electrolyte If the electrolyte comes in contact with your skin or eyes wash the area with liberal amounts of water and seek medical attention for more severe burns e Place the battery on a level surface Check to see that the sealing sheet has no peeling tears or holes in it Remove the sealing sheet NOTE OThe battery is vacuum sealed If the sealing sheet has leaked air into the battery it may require a longer initial charge Remove the electrolyte container from the vinyl bag 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 GP08135BS1 C ME02112BS1 GP08139BS1 C 16 24 ELECTRICAL SYSTEM Battery 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 Check the electrolyte flow If no air bubbles A are coming up from the filler ports or if the container cells have not emptied completely tap the container B a few times NOTE OBe carefu
482. w ones Apply grease to the new O rings Install the timing inspection cap and timing rotor bolt cap and tighten them Special Tool Filler Cap Driver 57001 1454 Torque Timing Inspection Cap 3 9 N m 0 40 kgf m 35 in Ib Timing Rotor Bolt Cap 4 9 N m 0 50 kgf m 43 in Ib e Install the cylinder head cover see Cylinder Head Cover Installation 5 24 ENGINE TOP END Camshaft Camshaft Chain Camshaft Camshaft Cap Wear Inspection Remove the camshaft caps see Camshaft Removal e Cut strips of plastigage press gauge to journal width Place a strip on each journal parallel to the camshaft in stalled in the correct position Tighten the camshaft cap bolts to the specified torque see Camshaft Installation NOTE not turn the camshaft when the plastigage is be tween the journal and camshaft cap e Remove the camshaft cap again measure each clear ance between the camshaft journal and the camshaft cap using plastigage A Camshaft Journal Camshaft Cap Clearance Standard 0 028 0 071 mm 0 0011 0 0028 in Service Limit 0 16 mm 0 0063 in If any clearance exceeds the service limit measure the diameter of each camshaft journal with a micrometer Camshaft Journal Diameter Standard 23 950 23 972 mm 0 9429 0 9438 in Service Limit 23 92 mm 0 9417 in x If the camshaft journal diameter is less than the service limit replace the camshaft with a new one and measure the clear
483. warming up the engine e Unscrew the oil filler plug A PERIODIC MAINTENANCE 2 51 Periodic Maintenance Procedures e Place the oil pan beneath the engine Remove the engine oil drain plug 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 plug gasket with a new one Tighten Torque Engine Oil Drain Plug 30 N m 3 4 kgf m 22 ft lb e Pour in the specified type and amount of oil Recommended Engine Oil Type API SG SH SJ SL or SM with JASO MA MA1 or MA2 Viscosity SAE 10W 40 Capacity 1 61 1 7 US qt when filter is not removed 1 8 L 1 9 US qt when filter is removed 2 3 L 2 4 US qt when engine is completely dry NOTE ODo not add any chemical additive to the oil Oils fulfilling the above requirements are fully formulated and provide adequate lubrication for both the engine and the clutch 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 Oil Level Inspection in the Engine Lubrication System chapter e Install the left middle fairing see Middle Fairing Installa tion in the Frame chapter Oil Filter Replacement e Drain the engine oil see Engine Oil Change e Remove the right middle fairing see Middle Fairing Re moval in the Frame chapter
484. witch A see Switch Inspection in the Electrical System chapter Rear Brake Light Switch see Switch Inspection in the Electrical System chapter Harness see Wiring Inspection in the Electrical System chapter Suspensions Front Forks Rear Shock Absorber Operation Inspection Pump the forks down and up A 4 or 5 times to inspect the smooth stroke x If the forks do not smoothly stroke or noise is found in spect the fork oil level or fork clamps see Front Fork Oil Change in the Suspension chapter e Pump the seat down and up A 4 or 5 times to 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 Front Fork Oil Leak Inspection e Visually inspect the front forks A for oil leakage Replace or repair any defective parts if necessary 2 36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Rear Shock Absorber Oil Leak Inspection e Visually inspect the shock absorber A for oil leakage x If the oil leakage is found on it replace the shock absorber with a new one Steering System Steering Play Inspection Raise the front wheel off the ground using the jack Special Tool Jack 57001 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
485. ws 1 5 N m 0 15 kgf m 13 in Ib e 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 front seat see Front Seat Removal in the Frame chap ter and fill the reservoir to the upper level line C A WARNING Mixing brands and types of brake fluid can reduce the brake system s effectiveness and cause an ac cident resulting in injury or death Do not mix two brands of brake fluid Change the brake fluid in the brake line completely if the brake fluid must be re filled but the type and brand of the brake fluid that is already in the reservoir are unidentified Recommended Disc Brake Fluid Grade DOT4 e Follow the procedure below to install the rear brake fluid reservoir cap correctly OFirst tighten the rear brake fluid reservoir cap B clock wise C by hand until slight resistance is felt indicating that the cap is seated on the reservoir body then tighten the cap an additional 1 6 turn D while holding the brake fluid reservoir body A 65130357 2 34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Pad Wear Inspection Check the lining thickness A of the pads in each caliper Pad Lining Thickness Standard Front C 4 5 mm 0 18 in Rear D 5 0 mm 0 20 in Service Limit 1 mm 0 04 in x If the lining thickness of either pad is less than
486. y of the two grooves is wider than the service limit at any point replace the piston GE16146BS1 GE16147BS1 GE16070781 Cylinder Pistons ENGINE TOP END 5 41 Piston Ring Thickness Inspection Measure the piston ring thickness OUse the micrometer to measure at several points around the ring Piston Ring Thickness Standard Top A 0 87 0 89 mm 0 0343 0 0350 in Second B 0 97 0 99 mm 0 0382 0 0390 in Service Limit Top 0 80 mm 0 031 in Second 0 90 mm 0 035 in xIf any of the measurements is less than the service limit on either of the rings replace all the rings NOTE OWhen using new rings in a used piston check for un even groove wear The rings should fit perfectly parallel to the groove sides If not replace the piston Piston Ring End Gap Inspection e Place the piston ring A inside the cylinder using the pis ton to locate the ring squarely in place Set it close to the bottom of the cylinder where cylinder wear is low e Measure the gap B between the ends of the ring with a thickness gauge Piston Ring End Gap Standard Top 0 25 0 40 mm 0 0098 0 0157 in Second 0 40 0 55 mm 0 0157 0 0217 in Service Limit Top 0 7 mm 0 028 in Second 0 9 mm 0 035 in xIf the end gap of either ring is greater than the service limit replace all the rings GE16103BS1 C GE16148BS1
487. y would be approximately 169 6 Hz Olndicates approximately 60 km h in case the input fre quency would be approximately 106 Hz x If the oscillator is not available the speedometer can be checked as follows Olnstall the meter unit see Meter Unit Installation ORaise the rear wheel off the ground using the stand see Rear Wheel Removal in the Wheels Tires chapter the ignition switch to ON ORotate the rear wheel by hand OCheck that the speedometer shows the speed x If the speedometer does not work replace the meter as sembly NOTE OThe input frequency of the oscillator adds the integrated value of the odometer OThe integrated value of the odometer cannot be reset 8 17902 652 C DUTY 50 T 10 15V GP17903CS1 16 70 ELECTRICAL SYSTEM Meter Gauge Indicator Unit Odometer Check e Check the odometer with the speedometer in the same way If the value indicated in the odometer is not added re place the meter assembly NOTE OThe integrated value of the odometer cannot be reset OWhen the figures come to 999999 they are stopped and locked Trip Meter A B Check Check the trip meter with the speedometer in the same way x If the value indicated the trip meter A B is not added replace the meter assembly Check that the figure display turns to 0 0 when the lower button is pressed for more than 2 seconds x If the figure

Be sure the battery is fully charged.

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