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Ninja 650R Service Manual

1. 0 00 mm mene mnn nnne nene mener a rne Audible Inspection 3 57 3 57 3 57 3 57 3 57 3 59 3 59 3 59 3 59 3 62 3 62 3 62 3 63 3 64 3 66 3 66 3 66 3 68 3 68 3 68 3 70 3 70 3 70 3 71 3 71 3 71 3 71 3 71 3 72 3 73 3 73 3 73 3 74 3 74 3 74 3 76 3 76 3 76 3 78 3 79 3 80 3 80 3 80 3 81 3 83 3 83 3 85 3 87 3 87 3 87 3 88 3 88 3 89 3 89 3 91 3 91 3 91 FUEL SYSTEM DFI 3 3 Fuel Injector Power Source Voltage Inspection pp 3 91 Fuel Injector Output Voltage Inspection 3 92 Injector Signal Test tte eto cod 3 92 Injector Resistance Inspection pe 3 93 Injector Unit TeSt 2 3 94 Injector Fuel Line Inspection etna ides ata ag 3 94 Throttle Grip and Cables 3 96 Throttle Grip Free Play Inspection pp 3 96 Throttle Grip Free Play Adjustment esee nennen nennen nnne 3 96 Throttle Cable Installation 2 dne rer iare ee 3 96 Throttle Cable Lubrication 3 96 Fhrottle Body ASSY bue etus dee nc ea tex dude 3 97 Idle Speed 3 97 Engine Vacuum Synchronization Inspection Adjustment pp 3 97 High Altitude Performance
2. 2 33 Brake Fluid Level Inspection pp 2 33 Brake Pad Wear 2 34 Brake Light Switch Operation Inspection pp 2 34 SUSPENSIONS zo idee ver esie hes bb ea vede vea ee eoe aee Avent dava etg el dU 2 35 Front Forks Rear Shock Absorber Operation 2 35 Front Fork Oil Leak Inspection pp 2 35 Rear Shock Absorber Oil Leak Inspection pp 2 35 Steering System sis cidit tiii dese Cn iod o LIS cruenta 2 36 Steering Play IMSPSCUOM ined I det iei Lote es 2 36 Steering Play Adjustment idee Pneterea tae Eae 2 36 2 2 PERIODIC MAINT ENANCE Steering Stem Bearing Lubrication 222222 22 2 1 1 14411 1 enne annees Electrical System Spark Plug Condition Inspection Lights and Switches Operation Headlight Aiming Inspecti ER E FEN REED E Er VM qu Ne da rx C V Pad dE URN E dE d Sidestand Switch Operation Inspection pp Bolts Nuts and Fasteners Tightness Replacement Parts Air Cleaner Element Repl Fuel Hose Replacement Coolant Change desee dus vt EE veg oe eer eee
3. t en aan So dU 3 20 Troubleshooting the DFI System pp 3 22 p 3 22 UN 3 22 IMNQUIFIES TO Rider m EE 3 26 10 3 26 DFI System Troubleshooting Guide ppp 3 29 SIBI E 3 37 Self diagnosis Outline pp 3 37 Selrdiagnosis utlli6 sas ass cine decido a a a 3 37 Selfdiagnosis Procedures 3 37 Self diagriosis PIOCedUles sure tutte Lord asp Cab te po heu i testor teo pags 3 37 Service Code Clearing Procedures pp 3 38 Service Code Clearing 01 0 3 38 How to Read Service 3 40 How to Read Service 3 40 How to Erase Service 3 40 How to Erase Service 3 40 Service Gode Table I a e eM nih d ER E MIA Ue ENG da SERRA 3 41 Service Code Table ote Re Le eb re tedadbadebebdeaysh gente 3 41 sry 3 42 3 42 Main Throttle Sensor Service Code 11 1 1 4 3 44 Main Throttle Sensor Removal Adjustment 3 44
4. ennemis 3 56 3 2 FUEL SYSTEM Speed Sensor Service Code 24 25 Speed Sensor Removal Installation pp Speed Sensor INSPECTION pp Speed Sensor Input Voltage Inspection 8 Speed Sensor Output Voltage Inspection pp Vehicle down Sensor Service Code 31 eee sesenta nennen nete Vehicle down Sensor Removal pp Vehicle down Sensor Installation pp Vehicle down Sensor Inspectigom Subthrottle Sensor Service Code 32 n teet ER RUE eese et Subthrottle Sensor Removal Adjustment Subthrottle Sensor Input Voltage Inspection pp Subthrottle Sensor Output Voltage Inspection pp Subthrottle Sensor Resistance Inspection pp Oxygen Sensor not activated Service Code 33 Europe Oxygen Sensor Removal lnstallation pp rit edt te optet Stick Coils 1 2 Service Code 51 52 eee Stick Coil Removallnstallationm 98929999 Stick Coil Input Voltage Inspectiom nnne Radiator Fan Relay Service Code 506 erue dodo ees eene o gen epa de E edid Radiator Fan Relay Removal lnstallatiom Radiator Fan Relay INSpection pe Subthrottle Valve Actuator Service Code 62 Subthrottle Valve Actuator Removal 8 Subthrottle Valve Actuator Audible Inspection pp
5. PERIODIC MAINTENANCE 2 21 Periodic Maintenance Procedures Radiator Hose Damage and Installation Condition Inspection OThe high pressure inside the radiator hose and pipe can cause coolant to leak A or the hose to burst if the line is not properly maintained e Visually inspect the hoses for signs of deterioration Squeeze the hoses A hose should not be hard and brittle nor should it be soft or swollen Replace the hose if any fraying cracks B or bulges C are noticed e Check that the hoses are securely connected and clamps are tightened correctly Torque Radiator Hose Clamp Screws 2 0 N m 0 20 kgf m 17 in Ib Air Suction System Air Suction System Damage Inspection e Remove the fuel tank see Fuel Tank Removal in the Fuel System DFI chapter e Remove the fuel hose see Fuel Hose Replacement e Connect Fuel Pump Lead Connector A Extension Tube B Special Tool Extension Tube 57001 1578 e Pull the air switching valve hose C out of the air cleaner housing e Start the engine and run it at idle speed e Plug A the air switching valve hose end with your finger and feel vacuum pulsing in the hose x lf 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 Engin
6. 10814 ENGINE END 5 37 Cylinder Pistons eRemove the piston pins Special Tools Piston Pin Puller A 57001 1568 Piston Pin Puller Adapter C D 57001 1657 Center Shall of Piston eRemove the pistons SIK250N581 C e Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring A to remove it e Remove the 3 piece oil ring with your thumbs in the same manner GE16059BS1 C Piston Installation e Install the oil ring expander A in the bottom piston ring groove so the ends B butt together e Install the oil ring steel rails one above the expander and one below it B OSpread the rail with your thumbs but only enough to fit the rail over the piston ORelease the rail into the bottom piston ring groove NOTE GET16060BS1 C OThe oil ring rails have no top or bottom e Do not mix up the top and second ring A e Install the top ring A so that the mark B faces up e Install the second ring C so that the RN mark D faces B up D GE16102BS1 5 38 ENGINE END Cylinder Pistons NOTE Olf a new piston is used use new piston ring e Install the piston with its marking hollow facing forward e Fit a new piston pin snap ring into the side of the piston so that the ring opening A does not coincide with the slit B of the piston pin hole OAp
7. Rear Caliper Remowval Caliper Installation Front Caliper Disassembly Front Caliper Assembly Rear Caliper Disassembly Rear Caliper Assembly Caliper Fluid Seal Damage Rear Caliper Dust Boot and Friction Boot Damage Caliper Piston and Cylinder Rear Caliper Holder Shaft Wear Brake Pads 2 Front Brake Pad Remowval Front Brake Pad Installation Rear Brake Pad Removal Rear Brake Pad Installation Brake Pad Wear Inspection Master Cylinder Front Master Cylinder Removal Front Master Cylinder Installation Rear Master Cylinder Removal Rear Master Cylinder Installation Front Master Cylinder Disassembly Rear Master Cylinder Disassembly Master Cylinder Assembly Master Cylinder Inspection Brake Brake Disc Removal Brake Disc Installation Brake Disc Brake Disc Warp Brake Fluid pp Brake Fluid Level Inspection Brake Fluid Change Brake Line Bleeding Brake Brakes Table of C
8. BL 16 we T EIS 3 di E Frama Ground a th Side stand Switch Battery 12V10Ah Starter Relay Relay Box 1 Fan Relay 2 Headlight Relay 3 ECU Main Relay 4 Pump Relay 5 Starter Circuit Relay Main Fuse 30A BA LG BK s qam sees 5 SK Y SK Y Self 25 diagnosis Fuel Kawasaki Termin Reserve Self diagnosis Switch System Rear Brake Pump Light Switch COE Electronic Gontrol Unit EGU 8K BL ey R we BL Joint Connector License Plate Light 12 5 Rear Right Turn Signal Light 12 21 Tail Brake Light 12y21 5W Left Turn al Light 1 33 LB Light Blue IGNITION SWITCH CONNECTIONS 0 Orange W2RO226BW5 C 16 22 ELECTRICAL SYSTEM Precautions There a number of important precautions that musts when servicing electrical systems Learn and ob serve all the rules below ODo not reverse the battery cable 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 stru
9. bearing inserts for Nos 1 2 journals have oil grooves Transmission Shift Fork Ear Thickness Gear Groove Width Shift Fork Guide Pin Diameter Shift Drum Groove Width 5 9 6 0 mm 0 232 0 236 in 6 05 6 15 mm 0 238 0 242 in 6 9 7 0 mm 0 272 0 276 in 7 05 7 20 mm 0 278 0 283 in 5 8 mm 0 228 in 6 25 mm 0 246 in 6 8 mm 0 268 in 7 3 mm 0 287 in CRANKSHAFT TRANSMISSION 9 9 Special Tools and Sealant Outside Circlip Pliers Kawasaki Bond 57001 144 92104 1064 7570144ST C 7921064ST C Bearing Driver Set 57001 1129 7571129ST C 9 10 CRANKSHAFT TRANSMISSION Crankcase Splitting Crankcase Splitting e Remove Engine see Engine Removal in the Engine Removal In stallation chapter Cylinder see Cylinder Removal in the Engine Top End chapter Pistons see Piston Removal in the Engine Top End chapter Stater Motor see Starter Motor Removal in the Electrical System chapter Clutch see Clutch Removal in the Clutch chapter Transmission Assy see Transmission Assy Removal Alternator Rotor see Alternator Rotor Removal in the Electrical System chapter e Remove the upper crankcase bolts A and the washers 6104207BS1 e Remove the oil pan relief valve oil screen and oil pipes see Oil Pan Removal in the Engine Lubrication System chapter e Remove the lower crankcase bolts OFirstly loosen the M6 bol
10. 13 18 SUSPENSION Swingarm Swingarm Bearing Removal e Remove Swingarm see Swingarm Removal Collar A Oil Seals B Sleeve C Circlip D Special Tool Inside Circlip Pliers 57001 143 Remove the ball bearing and needle bearings Special Tool Oil Seal amp Bearing Remover A 57001 1058 Swingarm Bearing Installation Replace the ball and needle bearings A with new ones e Install the ball and needle bearings so that the manufac turer s marks face out Special Tools Bearing Driver Set 57001 1129 Stem Bearing Driver 528 B 57001 1610 Spacer 528 57001 1663 GMO6084BS2 C GM06079BS1 GMO6071BS1 C SUSPENSION 13 19 Swingarm e Install the needle bearings A ball bearing and oil seals C position as shown Circlip D 25 mm 0 98 in E 17 mm 0 67 in F 1 mm 0 04 0 5 mm 0 02 in H 1 mm 0 04 in I 23 5 mm 0 93 in J 6 mm 0 24 in K fp id SA AUNT ir f 4 O O 6 06085 2 C Swingarm Bearing Sleeve Inspection CAUTION Do not remove the bearings for inspection Re moval may damage them e Inspect the needle bearings A and ball bearing installed in the swingarm OThe rollers and ball in a bearing normally wear very little and wear is difficult to measure Instead of measuring visually inspect the bearing fo
11. Rotor Bolt 40 4 1 30 3 Oil Plate Bolts 9 8 1 0 87 L 4 Plate Bolts 9 8 1 0 87 in lb L 5 Shift Shaft Return Spring Pin 29 2 9 22 L 6 Oil Pipe Bolts 9 8 1 0 87 L 7 Crankcase Bolts M9 L 113 mm 44 4 5 32 MO S 8 Crankcase Bolts M9 L 83 mm 44 4 5 32 MO S 9 Crankcase Bolts M8 L 73 mm 35 3 6 26 MO S 10 Crankcase Bolts 8 L 60 mm 35 3 6 26 MO S 11 Crankcase Bolts M8 L 110 mm 27 5 2 8 20 S 12 Crankcase Bolts M8 L 50 mm 27 5 2 8 20 S 13 Crankcase Bolts M6 19 6 2 0 15 S 14 Upper Crankcase Bolts 27 5 2 8 20 S 15 Do not apply any grease or oil G Apply grease L Apply a non permanent locking agent LG Apply liquid gasket M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts S Follow the specified tightening sequence SS Apply silicone sealant 9 4 CRANKSHAFT TRANSMISSION Exploded View 6102141BW5 C CRANKSHAFT TRANSMISSION 9 5 Exploded View No Fastener Torque Remarks N m kgf m ft Ib 1 Gear Positioning Lever Bolt 12 1 2 106 in Ib L 2 Transmission Case Bolts 20 2 0 15 3 Shift Drum Cam Bolt 12 1 2 106 in Ib L 4 Shift Drum Bearing Holder Screw 4 9 0 50 43 in lb L 5 Shift Rod Plate Bolt 9 8 1 0 87 in lb 6 Neutral Switch Holder Screw 4 9 0 50
12. BK Y x SR ABS Stick i Coils Hydraulic C O H 1 TE H HI ay LI Water proof Joint 5 ze DM ABS Self 2 924 aq diagnosis i nuri d ABS ae ae gee of te 2 BR 55 n cas a LAR LAR Meter Unit Kawasaki 1 ABS Indicator Light LED Salf Turn Signal Indicator Light LED diagnosis i Indicator Light LED 2 3 High Beam System 4 Neutral Indicator Light LEB Connector Front Rear 5 011 Pressure Warning Indicator Light LED Wheel Wheel 6 FI Indicator Light LED Rotation Rotation 7 0dometer Trip Meter Clock Sensor Sensor S Water Temperature Gauge ABS Solenoid we I o 1 2 Fuel Warning Valve Relay WR ito H 10 Tachometer 11 Speedmeter Unit 12 Illumination Light LED ABS Motor R Y Relay LED Light Emitting Diode Z Frame kj 6I Bo Fr Meter Unit 1 y 1 i E BK Y BK Y SK Y Water proof BK Y Joint 1 BK Y BKZ Y 1 1 a rues akK Y BK Y Water proof Siy Joint 1 M BK Y BK Y BK Y BK Front Right Turn Signal Light 12V2iW Right City Light 12V5W i xt R BK zzeobt i ER Headlight HI ii
13. END 5 21 Camshaft Camshaft Chain OThe timing marks must be aligned with the cylinder head upper surface C EX Mark D Between 1 Pin and 2 Pin IN Mark E Between 31 Pin and 32 Pin 1 Pin F 2 Pin G 31 Pin H 32 Pin J GE 11548W2 C e Install the camshaft cap while pushing the camshaft chain tighten all camshaft bolts and chain guide bolts NOTE OThe exhaust cap has a EX mark A and the inlet cap has a IN mark B Be careful not to mix up these caps OFirst tighten all the camshaft cap bolts evenly to seat the camshaft in place then tighten all bolts following the spec ified tightening sequence Aa T 2 x 4 k 7 m 4 p Q yA e Torque Camshaft Cap Bolts 1 12 12 N m 1 2 kgf m 106 in Ib e Install Camshaft Chain Tensioner see Camshaft Chain Ten sioner Installation Cylinder Head Cover see Cylinder Head Cover Instal lation Right Lower Fairing see Lower Fairing Removal in the Frame chapter 5 22 ENGINE END Camshaft Camshaft Chain Camshaft and Sprocket Assembly OThe inlet and exhaust sprockets are identical e Install the sprockets so that the marked IN and side faces to the right side CAUTION Inlet sprocket must use IN marked bolts holes A Exhaust sprocket must use EX marked bolts h
14. Remove the brush plate A from the plate cover NOTE ODo not remove the negative carbon brushes form the brush plate Starter Motor Assembly e Install the brush plate A to the plate cover B as shown e Install the brush plate assy to the yoke Clamp the springs A with the clips e Fit the armature C to the brush plate assy D Remove the clips ELECTRICAL SYSTEM 16 51 Electric Starter System e Install the new O ring A as shown e Install Washers B and Terminal Locknut C Tighten Torque Starter Motor Terminal Locknut 11 N m 1 1 kgf m 97 in lb GP11072BS1 e Align the lines A on the yoke with the end cover lines B e Tighten the through bolts Torque Starter Motor Through Bolts 4 9 N m 0 50 kgf m 43 in Ib Brush Inspection e Measure the length of each brush A xIf any is worn down to the service limit replace the brush plate assy B and the terminal bolt assy C Starter Motor Brush Length Standard 12 mm 0 47 in Service Limit 6 0 mm 0 24 in Commutator Cleaning and Inspection e Smooth the commutator surface A if necessary with fine emery cloth B and clean out the grooves 8 11061051 C Measure the diameter A of the commutator B x If the commutator diameter is less than the service limit replace the starter motor with a new Commutator Diameter Standard 28 mm 1 10 in Servic
15. e Remove Bolt A Rear Wheel Rotation Sensor B Rear Wheel Rotation Sensor Installation e Installation is the reverse of removal ORoute the lead correctly see Cable Wire and Hose Routing section in the Appendix chapter BRAKES 12 57 Anti Lock Brake System Wheel Rotation Sensor Inspection Remove the front wheel rotation sensor A from the front fork Remove the rear wheel rotation sensor from the caliper bracket e Visually inspect the wheel rotation sensors Replace the wheel rotation sensor if it is cracked bent or otherwise damaged Wheel Rotation Sensor Air Gap Inspection e Raise the front rear wheel off the ground see Front Rear Wheel Removal in the Wheels Tires chapter e Measure the air gap between the sensor and sensor rotor at several points by turning the wheel slowly Thickness Gauge A Air Gap Standard Front 1 mm 0 04 in Rear 1 mm 0 04 in NOTE O The sensor air gap cannot be adjusted x lf 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 Inspection Wheel Rotation Sensor Rotor Inspection e Remove the front rear brake discs see Brake Disc Re moval e Visually inspect the wheel rotation sensor rotor xIf the rotor is deformed or damaged chipped teeth A replace the sensor rotor with the brake
16. Balancer Shaft Bearing Insert Journal Clearance e 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 NOTE not turn the balancer shaft during clearance 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 08 mm 0 0031 in xIf the clearance is within the standard no bearing insert replacement is required 61060301 S xIf the clearance is between 0 050 mm and the service limit 0 09 mm replace the bearing inserts A with in serts painted blue B Check insert journal clearance with a plastigage The clearance 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 balancer shaft journal Balancer Shaft Journal Diameter 8106030281 Standard 27 987
17. CAUTION Do not put shim stock under the shim This may cause the shim to pop out at high rpm causing ex tensive engine damage Do not grind the shim This may cause itto fracture causing extensive engine damage 2 24 PERIODIC MAINTENANCE Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART INLET VALVE Part 92180 1014 1016 1022 so INLET PRESENT SHIM 1024 1026 1028 4 Exanple 1032 1034 1036 1038 1040 1042 1044 1046 1048 1050 1082 1054 os s 10 15 25 4 sol om 2 sol 2 55 VALVE CLEARANCE MEASUREMENT mm Example 1 4 COE EIS 2 50 0 00 0 02 0 03 0 07 2 55 2 55 2 60 2 65 2 70 2 60 2 70 2 75 2 60 2 65 2 70 2 rs 2 80 2 851 2 90 2 96 2 75 2 80 2 5 2 90 2 95 3 00 3 05 3 10 3 15 2 20 3 25 3 20 2 85 2 9 2 95 3 00 2 05 3 10 3 15 3 20 3 25 3 20 3 26 3 00 3 05 3 10 2 15 2 20 3 25 3 30 3 36 3 40 0 08 0 12 0 13 0 14 2 50 2 55 2 60 2 65 2 70 2 75 2 80 2 85 2 95 3 00 3 05 3 10 3 15 3 20 3 25 3 30 2 35 3 40 3 45 0 15 0 24 SPECIFIED CLEARANCE NO CHANGE REQUIRED jo 25 0 27 2 58 2 60 2 65 2 70 2 75 2 80 2 85 2 90 2 95 3 00 3 05 3 10 3 15 3 20 3 25 2 30 3 35 3 40 3 45 3 50 lt 0 28 0 32 2 60 2 1
18. GK04018BS1 C GKO4019BS1 C GK04020BS1 C GK04021BS1 C 11 8 FINAL DRIVE Drive Chain e Fit the plate holder a to link plate e Turn the pin holder by hand until plate holder b touches the other link plate e Turn the pin holder by wrench clockwise until two pins of link come into groove of plate holder a Take off the plate holder a Set the plate holder b A and cutting and riveting pin as shown Turn the pin holder until riveting pin touches link pin Turn the wrench clockwise until tip of riveting pin hits of link pin Rivet it e Same work for the other link pin GK04026BS1 C FINAL DRIVE 11 9 Drive Chain e After staking check the staked area of the link pin for cracks Measure the outside diameter A of the link pin and link plates width B Link Pin Outside Diameter Standard 5 7 6 0 mm 0 22 0 24 in Link Plates Outside Width Standard 17 25 17 45 mm 0 679 0 687 in x If the reading exceeds the specified length cut and rejoin the chain again e Check Movement of the Rollers e Adjust the drive chain slack after installing the chain see Drive Chain Slack Adjustment in the Periodic Mainte nance chapter GK04028BS1 11 10 FINAL DRIVE Sprocket Coupling Engine Sprocket Removal e Remove Engine Sprocket Cover Bolts A Engine Sprocket Cover B e Remove
19. Sealant Oil Pressure Gauge 5 kgf cm 57001 125 7570125ST C Fork Oil Level Gauge 57001 1290 875712905 C Hand Tester 57001 1394 7571394ST C Throttle Sensor Setting Adapter 1 57001 1400 7571400ST C Peak Voltage Adapter 57001 1415 875714155 C Needle Adapter Set Throttle Sensor Setting Adapter 57001 1538 57001 1457 8 5714578 C Sensor Harness Adapter 57001 1561 Fuel Pressure Gauge Adapter 57001 1593 Fuel Hose 57001 1607 8 5715615 C 7571593ST C 875716075 C FUEL SYSTEM DFI 3 19 Special Tools and Sealant Kawasaki Bond Silicone Sealant 56019 120 875601205 C 3 20 FUEL SYSTEM DFI 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 12 V sealed battery as its power source Do not use any other battery except for a 12 V sealed battery as a power source ODo not reverse the battery cable connections This will damage the ECU OTo prevent damage to the DFI parts do not disconnect the battery cables or any other electrical connections when the ignition switch is on or while the engine is running OTake care not to short the leads that are directly con nected to the battery positive terminal to the chassis ground OWhen charging remove the
20. Terminal Reserve Self diagnosis aoe Switch System witch Rear Brake Ping Battery Light Switch 12 10 Starter Starter Relay Relay Box Notor Main Fuse Fan Relay Headlight Relay SUR ECU Main Relay Fuel Pump Relay Starter Circuit Relay LB Light Blue RIGHT SWITCH HOUSING CONNECTIONS 0 Orange Front Brake Light Switch Engine Stop Switch Starter Button Pink Color BK BK Color Y R R BK RIBK R Brake Lever OFF Purple Red Pulled to RUN ommo Push ommo w White 98052 02248 W2RO224BW5 C IGNITION SWITCH CONNECTIONS Ignition Battery 11 Tail2 Battery Tail3 Ignition lgnition Color BR BL R W BK W G GAY OFF LOCK ON ommo 16 18 ELECTRICAL SYSTEM Wiring Diagram Australia and South Africa Right Switch Housing Regulator Rectifier 1 Brake Light Switch 2 Engine Stop Switch 3 Starter Button Fan P Motor Ignition Switch 855 5 25 rari BATTERY ODI X FALL3 IGNITION 19 ignition jGo J Meter Unit 1 Torn Signal Indicator Light LED 2 High Beam Indicator Light LED 3 Neutral Indicator Light LED 4 011 Pressure Warning Indicator Light LEB 5 Indicator Light LED 8 0doneter Trip Meter Clock 7 Water Temperature Gauge B Fuel Warning 9 Tachometer 10 Speedmeter
21. lf there is the continuity in the lead replace the ABS hy draulic unit x If there is not the continuity in the lead 3rd step e Do the 3rd step test OCheck for continuity between the white red lead terminal of the main harness side connector A and white red lead terminal of the fuse box B lf 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 e Do the 4th step test OCheck the battery terminal voltage between the white red lead terminal of the fuse box A and ground Special Tool Hand Tester 57001 1394 Battery Terminal Voltage Standard Battery Voltage xIf the battery terminal voltage is not within the specifica tion 5th step x If the battery terminal voltage correct 6th step e Do the 5th step test OCheck for continuity between the positive cable A of the battery and white red lead terminal of the main harness side connector B x If there is the continuity in the lead 4th step x If there is not the continuity in the lead replace or repair the main harness e Do the 6th step test 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 ABS indicator light LED A lit faulty ABS solenoid valve relay in the ABS hydraulic unit Replace the ABS hydraulic unit xIf the ABS indicator light LED A unlit ABS syst
22. lt 650R ER 6f ABS Kawasaki ER 6f Motorcycle Service Manual This quick 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 O0 o DO OP gt Appendix NINJA 650R Kawasaki ER 6f ER 6f ABS Motorcycle Service Manual All rights reserved No parts of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Quality Division Consumer Products amp Machinery Company Kawasaki Heavy Industries Ltd Japan No liability can be accepted for any inaccuracies or omissions in this publication although every possible care has been taken to make it as complete and accurate as possible The right is reserved to make changes at any
23. 35 31 1 2L 1 3 US dt 0 22 0 31 mm 0 0087 0 0122 in 0 15 0 21 mm 0 0059 0 0083 in 2 3 mm 0 08 0 12 in em Engine Lubrication System Engine Oil Type Viscosity Capacity Level API SE SF or SG API SH SJ or SL with JASO MA SAE 10W 40 ae 1 7 L 1 8 US qt when filter is not SiS removed 1 9 L 2 0 US qt when filter is removed 2 4 L 2 5 US qt when engine is completely dry Between upper and lower level lines after idling or running Wheels Tires Tread Depth Front Rear Air Pressure when Cold Front Rear 4 3 mm 0 17 in 1 mm 0 04 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 7 0 mm 0 28 in Up to 180 kg 397 Ib load 225 kPa 2 25 kgf cm 32 psi Up to 180 kg 397 Ib load 25 250 kPa 2 50 kgf cm 36 psi 2 12 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Final Drive Drive Chain Slack Drive Chain Wear 20 link 30 40 mm 1 2 1 6 in 317 5 318 2 mm 12 50 12 53 in 323 mm 12 7 in Length Standard Chain Make ENUMA Type EK520MVXL1 Link 114 links Brakes Brake Fluid Grade DOT4 Brake Pad Lining Thickness Front 4 5 mm 0 18 in 1 mm 0 04 Rear 5 0 mm
24. 8 Engine Ground Cable Terminal Bolt 9 8 9 Main Harness EX650B Models G Apply grease L Apply a non permanent locking agent R Replacement Parts 16 8 ELECTRICAL SYSTEM Exploded View GP022348W5 C ELECTRICAL SYSTEM 16 9 Exploded View No Fastener Torque Remarks N m kgf m ft Ib 1 Alternator Cover Bolts 9 8 1 0 87 in Ib 2 Alternator Lead Holding Plate Bolt 9 8 1 0 87 L 3 Alternator Rotor Bolt 155 15 8 114 MO 4 Crankshaft Sensor Bolts 6 0 0 60 53 in Ib 5 Neutral Switch 15 1 5 11 6 Pressure Switch 15 1 5 11 SS 7 Oxygen Sensor 44 1 4 50 32 5 8 Regulator Rectifier Bolts 8 8 0 90 78 9 Sidestand Switch Bolt 8 8 0 90 78 in Ib L 12 Starter Motor Clutch Bolts 34 3 5 25 L 13 Stator Coil Bolts 12 1 2 106 in Ib L 16 EX650B Models 17 EX650A Models L Apply a non permanent locking agent M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil solution Mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts SS Apply silicone sealant 16 10 ELECTRICAL SYSTEM Specifications Item Standard Battery Type Sealed Battery Model Name YTX12 BS Capacity 12 V 10 Ah Voltage 12 8 V or more Charging System Type Three phase AC Alternator Output Voltage 42 V or more at 4 000 r min rpm Stator Coil Resistance 0 18 0 27 Q Charging Voltage
25. 15 ft lb of drawing torque clean off any oil dirt or flaw of the crankshaft and rotor tapered portion and dry them with a clean cloth Then confirm that it is not pulled out with above torque e Tighten the alternator rotor bolt while holding the alterna tor rotor steady with the rotor holder Special Tools Grip 57001 1591 Rotor Holder 57001 1658 Torque Alternator Rotor Bolt 155 15 8 kgf m 114 ft Ib 16 34 ELECTRICAL SYSTEM Charging System e Apply a thin coat of molybdenum disulfide grease to the shafts A and install them Install the torque limiter and starter idle gear e Install the alternator cover see Alternator Cover Installa tion Alternator Inspection There are three types of alternator failures short open wire burned out or loss in rotor magnetism A short or open in one of the coil wires will result in either a low output or no output at all A loss in rotor magnetism which may be caused by dropping or hitting the alternator by leaving it near an electromagnetic field or just by aging will result in low output e To check the alternator output voltage do the following procedures OTurn off the ignition switch ODisconnect the alternator lead connector A OConnect the hand tester as shown in the table 1 OStart the engine ORun it at the rpm given in the table 1 ONote the voltage readings total 3 measurements Table 1 Alternator Output Voltage
26. 65020198 5 Apply specified grease to the lip of seal before installing the seal Grease GB02046BS1 C Circlips Cotter Pins Replace circlips or cotter pins that were removed with new ones Take care not to open the clip excessively when in stalling to prevent deformation 68020268 5 1 6 GENERAL INFORMATION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation Lubri cation points are called out throughout this manual apply the specific oil or grease as specified Direction of Engine Rotation When rotating the crankshaft by hand the free play amount of rotating direction will affect the adjustment Ro tate the crankshaft to positive direction clockwise viewed from output side Electrical Wires A two color wire is identified first by the primary color and then the stripe color Unless instructed otherwise electrical wires must be connected to those of the same color Instrument Use a meter that has enough accuracy for an accurate measurement Read the manufacture s instructions thor oughly before using the meter Incorrect values may lead to improper adjustments 68020228 5 GB02082BS1 C GENERAL INFORMATION 1 7 Model Identification EX650A6F United States and Canada Left Side View 00038211 EX650A6F United States
27. Lap Valve Tools Valve Lapper Grinding Compound Purpose perfectly match valve FINISHED and seat area check valve head for damage 5 36 ENGINE END Cylinder Pistons Cylinder Removal e Remove Cylinder Head see Cylinder Head Removal Front Engine Mounting Bolts Both Side A see Engine Removal in the Engine Removal Installation chapter Front Engine Brackets Both Side B see Engine Re moval the Engine Removal Installation chapter Cylinder C Cylinder Installation NOTE Olf a new cylinder is used use new piston ring e Install the dowel pins A and new cylinder gasket B e The piston ring openings must be positioned as shown in the figure The openings of the oil ring steel rails must be about 30 40 of angle from the opening of the top ring Top Ring A Second Ring B Oil Ring Steel Rails C Oil Ring Expander D Hollow E 30 40 F e Apply molybdenum disulfide oil solution to the cylinder bore piston rings and piston e Prepare two auxiliary head bolts with their head cut Olnstall the two bolts A diagonally in the crankcase e Position the crankshaft so that all the piston heads are almost level e Install the cylinder block Olnsert the piston rings with your thumbs Piston Removal e Remove the cylinder see Cylinder Removal e Place a clean cloth under the pistons and remove the pis ton pin snap ring A from the outside of each piston
28. Power Source Ignition Power Source Battery Power Source Indicator Light Output ABS Indicator Light LED ECU ABS Solenoid Valve Relay Output Monitor Input 10 Valve Output 11 Outlet Solenoid Valve 5 12 13 14 15 16 17 18 19 20 68114020844 C Inlet Solenoid Valve ABS Motor Relay Pump Motor Hydraulic Unit ABS Controller ABS Hydraulic Unit ABS Kawasaki Self diagnosis System Con nector Wheel Rotation Input Wheel Rotation Sensor GENERAL INFORMATION 1 17 Technical Information ABS Anti Lock Brake System Related Parts and Function 8 140018 6 1 Front Wheel Rotation Sensor 2 Front Wheel Rotation Sensor Rotor 3 Rear Wheel Rotation Sensor 4 Rear Wheel Rotation Sensor Rotor 5 ABS Indicator Light LED 6 ABS Hydraulic Unit 7 ABS Fuse Box 8 ABS Kawasaki Self diagnosis System Connector Wheel Rotation Sensor The wheel rotation sensors output the rotation speed of each wheel to the ECU in the ABS hydraulic unit The wheel rotation sensor is installed to the front fork and rear caliper bracket and the sensor rotor is pressed into the brake disc The number of teeth on the front and rear sensor rotor is 50 ABS Indicator Light LED The condition or the failure of the ABS system is indicated by various patterns of the ABS indicator light LED blinking 1 18 GENERAL INFORMATION Technical Information ABS Anti L
29. Right Side View 00038212 1 8 GENERAL INFORMATION Model Identification EX650A6F Europe Left Side View EX650A6F Europe Right Side View GENERAL INFORMATION 1 9 Model Identification EX650B6F Left Side View EX650B6F Right Side View 1 10 GENERAL INFORMATION General Specifications Items EX650A6F EX650B6F Dimensions Overall Length 2 105 mm 82 9 in Overall Width 760 mm 29 9 in Overall Height 1 210 mm 47 6 in Wheelbase 1 410 mm 55 5 in Road Clearance 145 mm 5 7 in Seat Height 790 mm 31 1 in Dry Mass EX650A6F 178 kg 392 5 Ib CAL 178 5 kg 393 6 Ib EX650B6F 182 kg 401 3 Ib Curb Mass Front EX650A6F 101 kg 222 7 Ib EX650B6F 103 kg 227 1 Ib Rear EX650A6F 99 kg 216 1 Ib CAL 99 5 kg 219 4 Ib EX650B6F 101 kg 222 7 Ib Fuel Tank Capacity 15 5 L 4 1 US gal Performance Minimum Turning Radius 2 7 m 8 9 ft Engine Type 4 stroke DOHC 2 cylinder Cooling System Bore and Stroke Displacement Compression Ratio Maximum Horsepower Maximum Torque Carburetion System Starting System Ignition System Timing Advance Ignition Timing Spark Plug Cylinder Numbering Method Firing Order Valve Timing Inlet Open Close Duration Liquid cooled 83 x 60 mm 3 3 x 2 4 in 649 cm 39 60 cu in 11 3 1 53 kW 72 PS 8 500 r min rpm 66 N m 6 7 kgf m 49 ft lb 7 000 r min rpm FI Fuel
30. Throttle Body Assy e Remove Screws A Delivery Pipe B Fuel Injectors C Throttle Body Assy Assembly OReplace the O rings A and seals B with the 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 into the throttle bodies e Install the throttle body assy see Throttle Body Assy In stallation 86617019651 FUEL SYSTEM DFI 3 101 Air Cleaner Air Cleaner Element Removal Installation e Refer to the Air Cleaner Element Replacement in the Pe riodic Maintenance chapter Air Cleaner Element Inspection e Remove the air cleaner element see Air Cleaner Element Replacement in the Periodic Maintenance chapter e Visually check the element A for tears or breaks x lf the element has any tears or breaks replace the ele ment Air Cleaner Oil Draining A drain hose is connected to the bottom of the air cleaner to drain water or oil accumulated in the cleaner part e Remove the left center fairing see Center Fairing Re moval in the Frame chapter e Visually check the drain hose A if the water or oil accu mulates xIf any water or oil accumulates the hose remove the plug B from the drain hose an
31. e After inspection install the fuel tank see Fuel Tank Instal lation e Start the engine and check for fuel leakage FUEL SYSTEM 3 87 Fuel Pump Fuel Pump Removal CAUTION Never drop the fuel pump especially on a hard sur face Such a shock to the pump can damage it A WARNING Gasoline is extremely flammable and can be explo sive under certain conditions Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Turn the ignition switch OFF Disconnect the battery terminal To make fuel spillage minimum draw the fuel out from the fuel tank when the engine is cold Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately e Draw the fuel out from the fuel tank with a commercially available electric pump Remove the fuel tank see Fuel Tank Removal careful of fuel spillage from the fuel tank since fuel still remains in the fuel tank and fuel pump Plug the fuel pipe of the fuel tank e Turn the fuel tank upside down e Remove Fuel Pump Bolts A Fuel Pump B and gasket e Discard the fuel pump gasket CAUTION Do not pull the lead of the fuel pump If they are pulled the lead terminals may be damaged Fuel Pump Installation e Remove dirt or dust from the fuel pump A by lightly ap plying compressed air
32. ret to FEE 5 29 Valve Clearance 5 29 Valve Clearance Adjustment 5 29 t d Ad e Ar Le A 5 29 Valve Installation teet tte ei tn S EE ER TRUE 5 29 Valve Guide Removal eoo eo eo d Lo e Ere P er ees 5 29 Valve Guide Installation sse nemen enemies 5 30 Valve to Guide Clearance Measurement Wobble Method 5 30 Valve Seat 5 31 Valve Seat Repair 5 oerte tete Bee irit anaes eee Tein Aes 5 31 GYlINGEF IPISIOMS 5 36 ee tendo de Gv aE 5 36 CV MOT Installato EM cC 5 36 Piston Removal iere eere RR ERR RE LR TR WE Re eR RN EET RR 5 36 Piston Installation s eene 5 37 Cylinder Wean a 5 38 Piston WO 5 38 Piston Ring Piston Ring Groove Wear pp 5 39 5 2 ENGINE END Muffler Body Exhaust Pipe Muffler Body and Exhaust Pipe Installation 5 39 5 39 5 40 5 4
33. 17 36 APPENDIX Cable Wire and Hose Routing California Model APPENDIX 17 37 Cable Wire Hose Routing 1 Through the hose between main harness and air cleaner housing 2 To Fuel Tank Red 3 To Fuel Tank Blue 4 Left Side View 5 Through the hose between main harness and air cleaner housing 6 Front 7 Lower Side View 17 38 APPENDIX Cable Wire and Hose Routing 6809916 5 C APPENDIX 17 39 Cable Wire Hose Routing 1 Clamp Insert the clamp in the front fender 2 Brake Hose 3 Clamp 4 Clamp 17 40 APPENDIX Cable Wire and Hose Routing EX650B Models ali 68099208W5 C APPENDIX 17 41 Cable Wire Hose Routing 1 Clamp Insert the clamp in the front fender 2 Brake Hose 17 42 APPENDIX Cable Wire and Hose Routing p MS S 08809862845 APPENDIX 17 43 Cable Wire Hose Routing 1 Brake Hose 2 Clamp 3 Clamp 17 44 APPENDIX Cable Wire and Hose Routing EX650B Models MOUN 88099068845 C APPENDIX 17 45 Cable Wire Hose Routing 1 Brake Hose 2 Clamp 3 Clamp 4 Clamp 17 46 APPENDIX Troubleshooting Guide NOTE Spark plug dirty broken or gap malad ORefer to the Fuel System chapter for most justed of DFI trouble shooting guide Stick coil shorted or not in good cont
34. 3 16 FUEL SYSTEM DFI Specifications Item Standard Digital Fuel Injection System Idle Speed Throttle Assy Type Bore ECU Electronic Control Unit Make Type Usable Engine Speed Fuel Pressure High Pressure Line Right after Ignition Switch ON After 3 Seconds from Ignition Switch ON With Engine Idling Fuel Pump Type Discharge Fuel Injectors Type Nozzle Type Resistance Main Throttle Sensor Input Voltage Output Voltage at Idle Throttle Opening Output Voltage at Full Throttle Opening Resistance Inlet Air Pressure Sensor Input Voltage Output Voltage Inlet Air Temperature Sensor Resistance Output Voltage at ECU Water Temperature Sensor Resistance Output Voltage at ECU Speed Sensor Input Voltage at Sensor Output Voltage at Sensor Vehicle down Sensor Detection Method Detection Angle 1 300 50 r min rpm Two barrel type 38 mm 1 50 in Denso Digital memory type with built in IC igniter sealed with resin 100 11 000 r min rpm Europe Models 100 11 160 r min rpm Other than Europe Models 323 kPa 3 3 kgf cm 47 psi with fuel pump running 265 kPa 2 7 kgf cm 38 psi with fuel pump stopped 333 kPa 3 4 kgf cm 48 psi with fuel pump running In tank friction pump 60 mL or more for 3 seconds INP 287 One spray type with 12 holes About 11 7 12 3 at 20 C 68 F Non adjustable and non removable 4 75 5 25 V DC between BL and BR BK leads 1
35. 3 88 FUEL SYSTEM DFI Fuel Pump e Replace the fuel pump gasket A with a new one e Apply a non permanent locking agent to the threads of the fuel pump bolts e Tighten the fuel pump bolts to a snug fit tighten them alternating diagonally Torque Fuel Pump Bolts 9 8 1 0 kgf m 87 in Ib e Tighten the pump bolts again alternating diagonally to check the tightness Fuel Pump Operation Inspection NOTE OBe sure the battery is fully charged OJust listen to the pump sound in the fuel tank to confirm pump operation e Turn the ignition switch ON and make sure that the fuel pump operates make light sounds for 3 seconds and then stops e Turn the ignition switch OFF x If the pump does not work as described above inspect the operating voltage Fuel Pump Operating Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Remove the left side cover see Side Cover Removal in the Frame chapter GC10045BS1 C FUEL SYSTEM DFI 3 89 Fuel Pump e Connect the hand tester 25 V DC to the fuel pump con nector A with needle adapter set Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 OMeasure the operating voltage with the engine stopped and with the connector joined e Turn the ignition switch ON OThe tester needle should indicate battery voltage for 3 seconds and then 0 V Pump Operating Voltage at Pump Connections
36. 6J05040BS1 C 10 14 WHEELS TIRES Tires e Install a new valve in the rim ORemove the valve cap lubricate the stem seal A with a soap and water solution or rubber lubricant and pull B the valve stem through the rim from the inside out until it snaps into place CAUTION Do not use engine oil or petroleum distillates to lu bricate the stem because they will deteriorate the rubber GJ05041BS1 OThe air valve is shown in the figure Valve Cap A Valve Core B Stem Seal C Valve Stem D Valve Seat E Valve Opened F 6J05030781 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 GJOS085BS1 C e Position the tire on the rim so that the valve A align with the tire balance mark B the chalk mark made during removal or the yellow paint mark on a new tire e Install the tire bead over the rim flange using a suitable commercially available tire changer e Lubricate the tire beads and rim flanges with a soap and water solution or rubber lubricant to help seat the tire beads in the sealing surfaces of the rim while inflating the tire e Center the rim in the tire beads and inflate the tire with compressed air until the tire beads seat in the sealing surfaces 6J05044BS1 C A WARNING Be sure to install the valve core whenever inflating the tire and do
37. Brake Hose Clamp Ignition Switch Lead Main Harness Left Switch Housing Lead Clutch Cable Clamp Insert the clamp to the inner fairing Clamp Clamp Clamp Clamp the left switch housing lead and ignition switch lead 20 mm 0 79 in 50 mm 1 97 17 22 APPENDIX Cable Wire Hose Routing EX650B Models 5 taf eje APPENDIX 17 23 Cable Wire Hose Routing Right Switch Housing Lead Throttle Cables Headlight LO Connector Green Tape Headlight Connector Brake Hose Through the brake hose at the right side of the throttle cables Clamp Ignition Switch Lead Main Harness Left Switch Housing Lead Clutch Cable Clamp Insert the clamp to the inner fairing Clamp Clamp Front Wheel Rotation Sensor Lead Front Baffle Plate Clamp Insert the clamp to the baffle plate Front Wheel Rotation Sensor Lead Connector Clamp Clamp the left switch housing lead and ignition switch lead 20 mm 0 79 in 50 mm 1 97 in 17 24 APPENDIX Cable Wire Hose Routing 63 APPENDIX 17 25 Cable Wire Hose Routing AON Clamp Clamp Clamp Clamp Clamp the subthrottle sensor lead and subthrottle valve actuator lead to the delivery pipe Ground Lead Clamp Subthrottle Sensor Lead Connector Subthro
38. Hand tighten 3 Oil Filler Plug Hand tighten 4 Clutch Cover Mounting Bolts 9 8 1 0 87 in lb 5 Spring Bolts 9 8 1 0 87 a 6 Clutch Hub Nut 132 13 5 on Pump Spede j 12 ein 78 Clutch Lever Clamp Bos 78 oso S 79 OI Pump Chain Guide Bots 12 12 oem 710 __ 98 10 L 74 Clutch Cable Clamp Bot 10 ain L Apply cable lubricant EG Apply engine oil G Apply grease HG Apply high temperature grease L Apply a non permanent locking agent Lh Left hand threads M Apply molybdenum disulfide grease R Replacement Parts S Follow the specified tightening sequence W Apply water 6 4 CLUTCH Specifications Item Standard Service Limit Clutch Lever Free Play 2 mm 0 08 0 12 in Clutch Friction Plate Thickness Friction Plate Warp Steel Plate Warp Clutch Spring Free Length 2 92 3 08 mm 0 115 0 121 in 0 15 mm 0 16 in or less 0 2 mm 0 008 in or less 33 6 mm 1 32 in 2 8 mm 0 110 in 0 3 mm 0 012 in 0 3 mm 0 012 in 32 6 mm 1 28 in CLUTCH 6 5 Special Sealant Clutch Kawasaki Bond Silicone Sealant 57001 1243 92104 0004 gt 7571243ST C 879200045 6 6 CLUTCH Clutch Lever Cable Clutch Lever Free Play Inspection e Refer to the Clutch Operation Inspection in the Periodic Maintenance cha
39. e Apply silicone sealant to the seals of the ECU connector for waterproofing Sealant Kawasaki Bond Silicone Sealant 56019 120 Injector Signal Test e Prepare two test light sets with male terminals as shown Rating of Bulb A 12 V x 3 3 4 W Terminal Width B 1 8 mm 0 071 in Terminal Thickness C 0 8 mm 0 031 in CAUTION Do not use larger terminals than specified above A larger terminal could damage the injector main har ness connector female leading to harness repair or replacement Be sure to connect bulbs in series The bulb works as a current limiter to protect the solenoid in the injector from excessive current 80170150651 6017024281 FUEL SYSTEM DFI 3 93 Fuel Injectors Remove the fuel tank see Fuel Tank Removal Remove the air cleaner housing see Air Cleaner Housing Removal e Remove connectors for injector A e Connect each test light set B to the injector sub harness connector C e Turn the ignition switch ON e While cranking the engine with the starter motor watch the test lights xIf the test lights flicker at regular intervals the injector circuit in the ECU and the wiring are good Perform the Injector Resistance Inspection Olnjector signals can be also confirmed by connecting the hand tester x 10 V AC instead of the test light set to the injector main harness female connector Crank the engine with the starter
40. e Fill the radiator up to the filler neck A with coolant NOTE OPour in the coolant slowly so that it can expel the air from the engine and radiator e Check the cooling system for leaks e Tap the radiator hoses to force any air bubbles caught inside e Fill the radiator up to the filler neck with coolant 2 48 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Temporarily install the reserve tank to the frame with two bolts e Fill the reserve tank up to the F full level line A with coolant and install the cap B e Start the engine warm it up thoroughly until the radiator fan turns on and then stop the engine e Check the coolant level in the reserve tank after the en gine cools down xIf the coolant level is lower than the L level line add coolant to the F level line CAUTION Do not add more coolant above the level line Radiator Hose and O ring Replacement e Drain the coolant see Coolant Change e Remove Thermostat Housing A see Water Pump 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 Fill the coolant see Coolant Change e Check the cooling system for leaks 85808028883 C PERIODIC MAINTENANCE 2 49 Periodic Maintenance Procedures E
41. inspect Air Suction System Air suction system damage inspect Engine Top End Valve clearance 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 DieTman l1 1 1 L1 Drive chain lubrication condition inspect Every 600 km 400 mile 2 28 Drive chain slack inspect Every 1 000 km 600 mile 2 29 Drive chain wear inspect e 2 31 2 4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY Whichever ODOMETER READING comes x 1 000 km first x 1 000 mile See 1 6 12 15 24 s0 36 Page INSPECTION Every 0 6 4 7 5 12 15 20 24 Drive chain guide wear inspect e e e 2 31 Brake System Brake fluid leak brake hose and pipe inspect Steering System E Brake hose and pipe damage inspect year e 2 32 pide and pipe installation condition year n 2 32 2 effectiveness play year 224142227 2 33 Brake fluid level inspect 6 months 2 33 Brake pad wear inspect Sener 2 34 Brake light switch operation inspect 2 34 Suspensions Front forks rear shock absorber operation Pye jel fel 2 35 damping and smooth stroke inspect Fro
42. 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 27 mm 0 0106 in 0 22 mm 0 0087 in ENGINE 5 11 Specifications ltem Standard Service Limit Valve Spring Free Length Exhaust 41 91 mm 1 650 in 40 3 mm 1 587 in Inlet 41 91 mm 1 650 in 40 3 mm 1 587 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 83 10 mm 3 2716 in 82 82 mm 3 2606 in 0 010 0 037 mm 0 0004 0 0015 in ar 0 03 0 07 mm 0 0012 0 0028 in 0 02 0 06 mm 0 0008 0 0024 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 0342 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 0 17 mm 0 0067 in 0 16 mm 0 0063 in 1 02 mm 0 040 in 1 11 mm 0 044 in 0 80 mm 0 031 0 90 mm 0 035 in 0 7 mm 0 028 in 0 8 mm 0 031 in 5 12 ENGINE END Special Tools Sealant Compression Gauge 20 kgf cm Valve Seat Cutter 60 530 57
43. 1 Piston TDC at End of Compression Stroke Inlet valve clearances of 1 piston and Exhaust valve clearances of 1 piston NOTE OCheck the valve clearance using this method only Checking the clearance at any other cam position may result in improper valve clearance PERIODIC MAINTENANCE 2 23 Periodic Maintenance Procedures Valve Clearance Measuring Position 2 Piston TDC at End of Compression Stroke Inlet valve clearances of 2 piston and Exhaust valve clearances of 2 piston x lf the valve clearance is not with in the specified range first record the clearance and adjust it Valve Clearance Adjustment e To change the valve clearance remove the camshaft chain tensioner camshafts and valve lifters Replace the shim with one of a different thickness NOTE OMark and record the valve lifter and shim locations so they can be reinstalled in their original positions Olf there is no clearance select a shim which is several sizes smaller and then measure the clearance Ul 9507073851 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 Camshaft Installation in the Engine Top End chapter e Remeasure any valve clearance that was adjusted Readjust if necessary
44. 11 Battery 12 V 10 Ah 12 Sidestand Switch 13 Frame Ground 14 Joint Connector 15 Neutral Switch 16 Water proof Joint C 17 Starter Button 18 Engine Stop Switch 5 ELECTRICAL SYSTEM 16 55 Lighting System This motorcycle adopt the daylight system and have a headlight relay in the relay box The headlight does not go on when the ignition switch and the engine stop switch are first turned on The headlight comes on after the starter button is released and stays on until the ignition switch is turned off The headlight will go out momentarily whenever the starter button is pressed and come back on when the button is released Headlight Beam Horizontal Adjustment e 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 Upper Inner Fairing see Upper Inner Fairing Removal in the Frame chapter Headlight Connector A Headlight Bulb Dust Cover B Remove Hook A Headlight Bulb B CAUTION When handling the quartz halogen bulb never touch the glass portion with bare hands Always use a clean cloth Oil contamination from hands or dirty rags can reduce bulb life or cause the bulb to explode NOTE OClean off any contamination that inadvertently gets on the bulb with alcohol or soap and wate
45. 11 6 Wheel Alignment Inspection Adjustment nennen 11 6 Drive Chain Wear Inspection Drive Chaim LUBrICAUON ARE Drive Chain Removal pp 1 5 EEE SPFOCkeSt EE Engirie Sprocket Removal Engine Rear Sprocket Removal Rear Sprocket Installation iint en ee i etii ao t EO ERR EAE Coupling Installation reete rettet tant Coupling Bearing REMOWAl s ei io utente os af as Pon a Pei ibus Coupling Bearing Installation Coupling Bearing Inspection pp Coupling Bearing Lubrication Coupling Damper 9 a Sprocket Wear INSPECTION pp Rear Sprocket Warp 11 14 11 2 FINAL DRIVE Exploded View FINAL DRIVE 11 3 Exploded View Torque No Fastener Navi kaf ilb Remarks 1 Sprocket Nut 125 12 7 92 MO 2 Rear Axle Nut 108 11 0 80 3 Sprocket Nuts 59 6 0 44 4 Speed Sensor Bolt 7 8 0 80 69 L 5 Speed Sensor Bracket Bolts 9 8 1 0 87 in Ib G Apply grease HG Apply high temperature grease HO Apply heavy oil L Apply a non permanent locking agent MO Apply molybdenum disulfide oil solu
46. 9505087851 PERIODIC MAINTENANCE 2 15 Periodic Maintenance Procedures A WARNING Clean the element in a well ventilated area and make sure that there are no sparks or flame any where near the working area Because of the danger of highly flammable liquids do not use gasoline or a low flash point solvent to clean the element Clean the element A in a bath of high flash point solvent and then dry it with compressed air or by shaking it e After cleaning saturate a clean lint free towel with SE SF or SG class SAE 30 oil and apply the oil to the element by tapping the element outside with the towel e Visually check the element for tears or breaks e f the element has any tears or breaks replace the ele ment e Install the element unit A with the foam element side gray B facing down Throttle Control System Inspection e Check that the throttle grip moves smoothly from full open to close A and the throttle closes quickly and completely by the return spring in all steering positions x lf the throttle grip doesn t return properly check the throt tle cable routing grip free play and cable damage Then lubricate the throttle cable e Check the throttle grip free play A x lf the free play is incorrect adjust the throttle cable Throttle Grip Free Play Standard 2 3 mm 0 08 0 12 in 2 16 PERIODIC MAINTENANCE Periodic Maintenance Procedures x If nec
47. ABS Hydraulic Unit Removal ABS Hydraulic Unit Installation ABS Hydraulic Unit Inspection 12 28 12 28 12 29 12 32 12 34 12 37 12 39 12 39 12 40 12 42 12 42 12 44 12 44 12 45 12 45 cca 12 47 12 48 12 49 12 50 12 51 12 51 12 52 12 53 12 53 12 54 12 55 12 2 BRAKES Front Wheel Rotation Sensor FRE MOVAl ote e tec Front Wheel Rotation Sensor Installation Rear Wheel Rotation Sensor Rear Wheel Rotation Installation Wheel Rotation Sensor Wheel Rotation Air Inspection pp Wheel Rotation Sensor Rotor Inspection pp Brake Hose and Pipe Removal Installation Brake Hose and Pipe Inspection ABS Solenoid Valve Relay Fuse ABS Motor Relay Fuse Removal Fuse Installation Fuse BRAKES 12 3 Exploded View Dummy Page 12 4 BRAKES Exploded View BRAKES 12 5 Exploded View No Fastener Remarks N m kgf m ft Ib 1 Bleed Valve 7 8 0 80 69 in lb 2 Brake Hose Banjo Bolts 25 2 5 18 3 Brake Lever Pivot Bolt 0 10 9 in Ib 5 5 Front Brake Disc Mounting Bolts 20 Front Brake Light Swi
48. CAUTION 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 Right Center Fairing see Center Fairing Removal in the Frame chapter e Slide back the rubber A e Remove the starter motor cable terminal nut B e Remove the mounting bolts A e Pull out the starter motor B Starter Motor Installation CAUTION Do not tap the starter motor shaft or body Tapping the shaft or body could damage the motor e When installing the starter motor clean the starter mo tor legs A and crankcase B where the starter motor is grounded e Replace the O ring A with a new one e Apply grease to the O ring e Apply a non permanent locking agent to the threads of the bolts and tighten the bolts Torque Starter Motor Mounting Bolts 9 8 N m 1 0 kgf m 87 in Ib e Install the starter motor cable e Tighten Torque Starter Motor Cable Terminal Nut 6 0 N m 0 60 kgf m 53 in lb PHBM P 16 50 ELECTRICAL SYSTEM Electric Starter System Starter Motor Disassembly e Remove the starter motor see Starter Motor Removal e Take off the starter motor through bolts A and remove the both end covers B and pull the armature out of the yoke C P e Remove Terminal Locknut and Washers O ring Remove the brush plate assy A from the yoke
49. Connecting Rod Removal ep oett dedu eode Connecting Rod Installation Crankshaft Connecting Rod Gleanlrigus Connecting Bend osse o ense to okt Connecting Rod necks Lane eerte d egeret tubes ia Connecting Rod Big End Side Connecting Rod Big End Bearing Insert Crankpin Crankshaft Side Clearance pp Gra kshaft or epe Tak ttem E rH a i Crankshaft Main Bearing Insert Journal SELETO S IUIUS r pee a t D RE e EUG M o ar ARAE Balancer Installation 4 Balancer Shaft Bearing Insert Journal Clearance ppp TRANSMISSION si E tebea on dacaneys Shift Pedal Removal cay eere waded feeds ete e Pede Shift Pedal Installation pp External Shift Mechanism Rerrioval 1 2 External Shift Mechanism External Shift Mechanism Inspection pp Transmission Assy RemoVval Transmission Assy Disassembly Ne Transmission
50. Housing A Fuse Element B Terminals C Blown Element D CAUTION When replacing a fuse be sure the new fuse matches the specified fuse rating for that circuit Installation of a fuse with a higher rating may cause damage to wiring and components GP20000181 C APPENDIX 17 1 Appendix Table of Contents Cable Wire Hose Routing Ne 17 2 Troubleshooting recien 17 46 17 2 APPENDIX Cable Wire Hose Routing APPENDIX 17 3 Cable Wire Hose Routing Clamp From the on sequentially through the ignition switch lead left switch housing lead and main harness Left Switch Housing Lead Connector Clamp Insert the clamp from air cleaner side Air Switching Valve Lead Connector Main Harness Clamp Clamp Insert the clamp in the frame Clamp Insert the clamp in the frame Clamp Inlet Temperature Sensor Lead Connector Clamp Insert the clamp from air cleaner side Ignition Switch Lead Connector Clamp Clamp the left switch housing lead main harness side ignition switch lead main har ness side and air switching valve lead Through the air switching valve lead on the left switch housing lead Cable Wire Hose Routing 17 4 APPENDIX 0 o0 N amp 6 APPENDIX 17 5 Cable Wire Hose Routing Rel
51. Separator Operation Test A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Connect the hoses to the separator and install the sepa rator on the motorcycle e Disconnect the breather hose from the separator and in ject about 20 mL 0 68 US oz of gasoline A into the separator B through the hose fitting e Disconnect the fuel return hose C from the fuel tank D e Run the open end of the return hose into the container and hold it level with the tank top E Start the engine and let it idle x If the gasoline in the separator comes out of the hose the separator works well If it does not replace the separator with a new one Canister Inspection Refer to the Evaporative Emission Control System In spection in the Periodic Maintenance chapter NOTE OThe canister A is designed to work well through the motorcycle s life without any maintenance if it is used under normal conditions COOLING SYSTEM 4 1 Cooling System Table of Contents 401061570 Ei 4 2 Coolant Flow CAM eee eae b PUEDE IR Lan 4 4 Specifications san EE 4 6 Special Tool Sarta E e tete e v e La du ERR RE ed Eg
52. Specifications Item Standard Front Fork Per One Unit Fork Inner Tube Outside Diameter Air Pressure Fork Spring Setting Damper Setting Fork Oil Viscosity Amount EX650A Models EX650B Models Fork Oil Level EX650A Models EX650B Models Fork Spring Free Length Rear Shock Absorber Spring Preload Gas Pressure 41 mm 1 6 in Atmospheric pressure Non adjustable Non adjustable Non adjustable KAYABA KHL34 G10 or equivalent approx 415 mL 14 0 US oz when changing oil 489 4 mL 16 5 0 14 US oz after disassembly and completely dry approx 420 mL 14 2 US oz when changing oil 498 3 mL 16 8 0 10 US oz after disassembly and completely dry 98 2 mm 3 9 0 08 in below from inner tube top with fully compressed without fork spring 89 2 mm 3 5 0 08 in below from inner tube top with fully compressed without fork spring 277 2 mm 10 91 in Service limit 272 mm 10 7 in 2nd position Adjustable Range 1st 7th position 980 kPa 10 kgf cm 142 psi Non adjustable SUSPENSION 13 7 Special Tools Inside Circlip Pliers Jack 57001 143 57001 1238 7570143ST C 7571238ST C Fork Cylinder Holder Handle Fork Oil Seal Driver 41 57001 183 57001 1288 875701835 C T5712888T C Fork Cylinder Holder Adapter Fork Oil Level Gauge 57001 1057 57001 1290 ST571057ST C ST571290ST C Oil Seal amp Bearing Remover Jac
53. Torque Radiator Hose Clamp Screws 2 0 N m 0 20 kgf m 17 in Ib ZL SSS 6010020151 C Hose Inspection e Refer to the Radiator Hose Damage and Installation Con dition Inspection in the Periodic Maintenance chapter COOLING SYSTEM 4 19 Water Temperature Sensor CAUTION The water temperature sensor should never be al lowed to fall on a hard surface Such a shock to the water temperature sensor can damage it Water Temperature Sensor Removal Installation e Refer to the Water Temperature Sensor Removal Instal lation in the Fuel System DFI chapter Water Temperature Sensor A Water Temperature Sensor Inspection e Refer to the Water Temperature Sensor Inspection in the Electrical System chapter 5 1 Engine Top End Table of Contents deeem A Exhaust System DPOSCITICATIONS et tet iiv OE REN Special Tools and Clean Ait SV SUS Ease Air Suction Valve 2 Air Suction Valve enn Air Suction Valve Air Switching Valve Removal pp Air owitenimg valve InstallatlQpi da ba 5 14 Air Switching Valve Operation Test 5
54. Turn the ignition switch ON and self diagnosis mode starts using an auxiliary lead Dealer Dealer Dealer Mode 1 Dealer Mode 2 Ground the self diagnosis terminal Ground and open the self diagnosis for more than 2 seconds and then terminal more than five times within 2 keep it grounded seconds and then keep it grounded indicator light LED blinks to display the service code for more than 2 seconds Locate the problem with the service code table and check and repair DFI or ignition system according to inspection procedure on all service codes Remove the auxiliary lead ending the self diagnosis mode NG Make sure the FI indicator light LED doesn t go ON i OK Run the engine for several minutes at idling and run the motorcycle at 30 km h 18 mph or above in order to confirm no problem NG OK 06171668 F 3 40 FUEL SYSTEM Self Diagnosis How to Read Service Codes How to Read Service Codes OService codes are shown by a series of long and short blinks of the Fl indicator light LED as shown below ORead 10th digit and unit digit as the FI indicator light LED blinks OWhen there are a number of problems all the service codes can be stored and the display will begin starting from the lowest number service code in the numerical order Then after completing all codes the disp
55. cutter removes material very quickly Check the seat outside diameter frequently to pre vent overgrinding OAfter making the 32 grind return to the seat outside di ameter measurement step above e To measure the seat width use a vernier caliper to mea sure the width of the 45 angle portion of the seat at sev eral places around the seat xIf the seat width is too narrow repeat the 45 grind until the seat is slightly too wide and then return to the seat outside diameter measurement step above 8 15011951 C GE15012181 GE15012281 5 34 ENGINE END Valves x lf 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 seat 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 g
56. or warped replace it 15 18 FRAME Sidestand Sidestand Removal Raise the rear wheel off the ground with stand e Remove Frame Cover see Frame Cover Removal Bolts A Footpeg Stay B e Remove Sidestand Switch Bolt A with Clamp Sidestand Switch B 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 Tighten the bolt and lock them with the nut Torque Sidestand Bolt 44 N m 4 5 kgf m 33 ft lb e Hook the spring Install the sidestand switch OApply a non permanent locking agent to the thread of the switch bolt Torque Sidestand Switch Bolt 8 8 0 90 kgf m 78 in Ib e Install the footpeg stay e Tighten Torque Footpeg Stay Bolts 34 N m 3 5 kgf m 25 ft lb 9020013851 15 19 Frame Cover Frame Cover Removal e Remove the bolt A e Pull the frame cover B outward to clear the stoppers Frame Cover Installation e Insert the projections A into the holes B e Tighten the bolt 60218010 P ELECTRICAL SYSTEM 16 1 Electrical System Table of Contents molem m Specifications ed p rt eO d na e Redde ea Special Tools and Sealant pe Parts Locations icto te mettent ce n dte e es Electrical VVITIBO aet edo eee as
57. x lf the display function does not work replace the meter assembly e Indicate the clock mode e Check that when the RESET button in CLOCK mode is pushed for more than two seconds the meter display turns to the clock set mode OBoth the hour and minute display start flashing GP17381BS1 4 140 Q O GP17382BS1 GP17383BS1 ELECTRICAL SYSTEM 16 67 Meter Gauge Indicator Unit the HOUR MINUTE setting mode press the RESET button again to effect the HOUR setting mode CLOCK OThe hour display flashes the display 2 3 the button to set the 4 CLOCK e In the HOUR setting mode press the RESET button to ete effect the MINUTE setting mode EORR 424 7 OThe minute display flashes on the display e Press the MODE button to set the minute i CLOCK 1 e In the MINUTE setting mode press the RESET button to CLOCK ole return to the HOUR MINUTE setting mode 42 e Press the MODE button to complete the time setting A process OThe clock starts counting the seconds as soon as the 2 MODE button is pressed LOOK GP17064BS1 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 e The speed equivalent to the input frequency is indicated in the oscillator A if th
58. 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 stop switch Tester 3 Crankshaft sensor peak voltage Replace bad parts ECU is defective Replace ECU GPI0280B F 16 48 ELECTRICAL SYSTEM Ignition System Ignition System Circuit Ignition Switch Engine Stop Switch Spark Plugs Stick Coils Water proof Joint C Speed Sensor Subthrottle Sensor Main Throttle Sensor Water proof Joint D Vehicle down Sensor Water proof Joint E A Water Temperature Sensor Neutral Switch Crankshaft Sensor Oxygen Sensor Meter Unit Water proof Joint A Water proof Joint B Starter Lockout Switch Oxygen Sensor Heater Fuse 10A ECU Fuse 15A GP102828W4 C Ignition Fuse 10 A Fuse Box ECU Main Relay Relay Box Main Fuse 30 A Starter Relay Battery 12 V 10 Ah Frame Ground Sidestand Switch Joint Connector ECU ELECTRICAL SYSTEM 16 49 Electric Starter System Starter Motor Removal
59. 141 7 kPa 1 15 1 45 kgf cm 16 3 20 5 psi Thermostat Valve Opening Temperature Valve Full Opening Lift 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 875711295 C ST571660ST 6 4 8 COOLING SYSTEM Coolant Coolant Deterioration Inspection Remove the right center fairing see Center Fairing Re moval in the Frame chapter e Visually inspect the coolant A in the reserve tank x If whitish cotton like wafts are observed aluminum parts in the cooling system are corroded If the coolant is brown iron or steel parts are rusting In either case flush the cooling system 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 in the Periodic Maintenance chapter Coolant Draining e Refer to the Coolant Change in the Periodic Maintenance chapter Coolant Filling e Refer to the Coolant Change in the Periodic Maintenance chapter Pressure Testing e Remove the reserve tank see Coolant Change in the Pe riodic Maintenance chapter e Remove the radiator cap and install a cooling system pressure tester A on the filler neck B NOTE OWet the cap sealing surfaces with water or coolant to prevent pressure leaks e Build
60. 244140 3 97 Throttle Body Assy Removal pp 3 97 Throttle Body Assy IMS Calls iu erdt o eea 3 98 Throttle Body Assy Disassembly pp 3 99 Throttle Body Assy Assembly ista iet Seca diete ure p 3 100 LYCEE 3 101 Air Cleaner Element Removal Installation pp 3 101 Air Cleaner Element Inspection pp 3 101 Ait Cleaner Oil Drainipig occi rire r tae s 3 101 Air Cleaner Housing Removal pp 3 101 Air Cleaner Housing Installation iren eedem de dee eurer 3 102 PU Peal mte E 3 103 Fuel Tank REMOVE ssc 3 103 Fuel Tank Installaatio Mennea Mtoe iti tos Recte Tes bre 3 105 Fuel Tank and Cap 3 106 Fuel Tank Cleaning beds a EN 3 107 Evaporative Emission Control System California 3 108 Parts Removal Installatiori 4 5 Ode SAO Maka Mets 3 108 lale i dejo elo 3 108 Separator encre ntt ee eee prre e e e ker 3 108 Separator Operation TeSt emen 3 109 Canister Inspection iritare metere irre creme oreet ae tee e treten is 3 109 3 4 FUEL SYSTEM Exploded View FUEL SYSTEM DFI 3 5 Exploded View N Fastener 301906 Remarks R N m k
61. 4 5 LEFT SWITCH HOUSING CONNECTIONS Horn Button Hazard Button Switch Dimmer Switch Starter Lockout Switch Turn Signal Headlight Fuse 10 Taillight Fuse 10 Ignition Fuse 10 Horn Fuse 104 W2L0224885 C ELECTRICAL SYSTEM 16 17 Wiring Diagram United States Canada New Zealand and Malaysia Sub S throttle throttle Sensor Valve Actuator cis Speed Sensor Hain Throttle Inlet Air Sensor Pressure Sensor oil Neutral Pressure Smile Switch Crankshaft Sensor 949 ey eg Inlet N Temperature Sensor Sensor Water Air Vehicle down Sensor i JH Fuel Injectors Laer ek Y BR BK eL e L BR BK Yo BR BK Y BL Water procf Joint E Water proof EGS Air Switching Valve T R BL His Electronic Gontrol Unit EGU oun BL Y va Joint Connector R License Plate BK Y Light 12V5W Rear Right Turn Signal Light 12V21W ey RAY a 90 89 BK Y BK Y zt ze 52 5 s BLR L 2 Tail Brake Light BK Y BK Y ES m ess R R 12V21 5W Ground M Rear Left Turn Signal Light 12 21 BK Y H Self diagnosis L8 BK BR W torn O o Horn n 12V2 Edel
62. B Torque Water Temperature Sensor 12 N m 1 2 kgf m 106 in Ib e Apply grease to new O ring on the water temperature sen SOr e Fill the engine with coolant and bleed the air from the cool ing system see Coolant Change in the Periodic Mainte nance chapter Water Temperature Sensor Output Voltage Inspection NOTE OBe sure the battery is fully charged e Remove the ECU see ECU Removal Do not disconnect the connectors e Connect a digital voltmeter A to the ECU connector B with the needle adapter set Special Tool Needle Adapter Set 57001 1457 e Measure the sensor output voltage with the engine stopped and the connector joined e Turn the ignition switch ON Water Temperature Sensor Output Voltage Connections to ECU Meter O lead terminal 20 Meter BR BK lead terminal 28 Standard About 2 80 2 97 V at 20 C 68 F NOTE OThe output voltage changes according to the coolant temperature in the engine e Turn the ignition switch OFF x If the output voltage is within the standard check the ECU for its ground and power supply see ECU Power Supply Inspection x If the output voltage is out of the standard check the wiring And if the output voltage is 4 8 V the ECU is nor mal x If the wiring is good check the water temperature sensor resistance e Remove the needle adapter set and apply silicone sealant to the seals of the connector for waterproofing Sealant Kaw
63. Damping Shock Road Driving i Absorber Load He Position Force Conditions Speed Hardness 1st Weak Low T 7th Strong Highway Rear Shock Absorber Removal e Remove Frame Covers see Frame Cover Removal in the Frame chapter Muffler Body see Muffler Body Removal in the Engine Top End chapter Raise the rear wheel off the ground with jack Special Tools Jack 57001 1238 Jack Attachment 57001 1608 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 tall over It could cause an accident and injury e Remove Right Stay Cover A GH04011081 C 13 16 SUSPENSION Rear Shock Absorber e Remove Upper Shock Absorber Bolt A Lower Shock Absorber Nut and Washer Lower Shock Absorber Bolt B Remove the shock absorber from backward Rear Shock Absorber Installation e Installation is the reverse of removal e Apply grease to the lip of oil seals OBe sure to install the oil seals to the shock absorber e Tighten Torque Rear Shock Absorber Bolt 59 N m 6 0 kgf m 44 ft lb Rear Shock Absorber Nut 59 N m 6 0 kgfm 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
64. Fuel spilled from the carburetors is hazardous e Apply a thin coating of grease to the throttle cable upper ends e Install the upper ends of the throttle cables in the grip e Fit the projection A of the right switch housing into the hole B of the handlebar e Turn the throttle grip and make sure thatthe throttle valves move smoothly and return by spring force e Check the throttle grip free play see Throttle Control Sys tem Inspection in the Periodic Maintenance chapter A WARNING Operation with an incorrectly routed cable could re sult in an unsafe riding condition e Adjust Throttle Grip Free Play see Throttle Control System In spection in the Periodic Maintenance chapter Idle Speed see Idle Speed Adjustment in the Periodic Maintenance chapter Throttle Body Assy Disassembly CAUTION Do not remove disassemble or adjust the main throttle sensor A subthrottle sensor B sub throttle valve actuator C throttle link mechanism D and throttle body assy E because they are adjusted or set at the manufacturer Adjustment of these parts could result in poor performance requiring replacement of the throttle body assy e Remove the throttle body assy see Throttle Body Assy Removal CAUTION Never drop the throttle body assy especially on a hard surface Such a shock to the body assy can damage it 86617018651 3 100 FUEL SYSTEM DFI
65. OCount the blinks of the light LED to read the service code Keep the auxiliary lead ground until you finish read ing the service code Ga s 57 200 GC17071BS1 3 38 FUEL SYSTEM DFI Self Diagnosis e To enter the self diagnosis dealer mode 2 open B and ground A the lead more than five times F within 2 sec onds C after the lead is first grounded and then keep it grounded continuously D for more than 2 seconds OCount the blinks of the light LED to read the service code Keep the auxiliary lead ground until you finish read ing the service code Auxiliary Lead E Self diagnosis Terminal G NOTE OTo enter the dealer mode 2 from the dealer mode 1 turn off the ignition switch once Service Code Clearing Procedures Service Code Clearing Procedures eEnter the self diagnosis dealer mode 2 see Self diagnosis Procedures NOTE OMake sure to keep the grounding until the following opening and grounding starts Pull the clutch lever in more than 5 seconds and then release it Repeat opening B and grounding A the lead self diagnosis terminal more than five times F within 2 seconds C after the lead is grounded and then keep it grounded continuously D for more than 2 seconds Auxiliary Lead E Self diagnosis Terminal G 6C17072BS1 6C17072BS1 FUEL SYSTEM DFI 3 39 Self Diagnosis Turn the ignition switch OFF
66. Radiator Hose and O ring Replacement pp Engine Oil Change Oil Filter Replacement Brake Hose and Pipe Brake Fluid Change Master Cylinder Rubber Parts Replacement pp Caliper Rubber Parts Replacement Ne Spark Plug Replacement 2 37 2 37 2 37 2 38 2 40 2 41 2 42 2 43 2 43 2 44 2 45 2 45 2 45 2 46 2 48 2 49 2 49 2 50 2 51 2 52 2 54 2 56 PERIODIC MAINTENANCE 2 3 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition The initial maintenance is vitally important and must not be neglected Periodic Inspection FREQUENCY Whichever ODOMETER READING comes x 1 000 km first 1 000 mile V 30 36 INSPECTION Every 20 24 Fuel System Air cleaner element clean 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 CAL Evaporative emission control system function inspect Cooling System Coolant level inspect Coolant leak radiator hose and pipe inspect Radiator hose damage inspect Radiator hose installation condition
67. Tester Reading Range Tester to Tester to at4 000 rpm 250 V AC One Black lead Another Black 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 higher than the value in the table the regulator rectifier is damaged A much lower reading than that given in the table indicates that the alternator is defective e Check the stator coil resistance as follows OStop the engine OConnect the hand tester as shown in the table 2 ONote the readings total 3 measurement Table 2 Stator Coil Resistance Reading Range Tester to Tester to One Black lead Another Black lead 0 18 0 27 ELECTRICAL SYSTEM 16 35 Charging System x If there is more resistance than shown in the table or no hand tester reading infinity for any two leads the stator has an open lead and must be replaced Much less than this resistance means the stator is shorted and must be replaced e Using the highest resistance range of the hand tester measure the resistance between each of the black leads and chassis ground Any hand tester reading less than infinity indicates a short necessitating stator replacement x If the stator coils have normal resistance but the voltage check showed the alternator to be defective then the rotor magnets have probably weakened and the rotor must be replaced Special Tool Hand Tester
68. e Inspect the headlight beam for aiming the headlight beam points to one side rather than straight ahead adjust the horizontal beam Headlight Beam Horizontal Adjustment e Turn the horizontal adjuster A on the headlight with the screwdriver in or out until the beam points straight ahead xIf the headlight beam points too low or high adjust the vertical beam 65178164 PERIODIC MAINTENANCE 2 41 Periodic Maintenance Procedures Headlight Beam Vertical Adjustment e Turn the vertical adjuster A on the headlight with the screwdriver in or out to adjust the headlight vertically NOTE OON high beam the brightest points should be slightly below horizontal with the motorcycle on its wheels and the rider seated Adjust the headlight to the proper an gle according to local regulations OFor US model the proper angle is 0 4 degrees below horizontal This is 50 mm 2 in drop at 7 6 25 ft measured from the center of the headlight with the motorcycle on its wheels and the rider seated 9517057851 50 mm 2 in A Center of Brightest Spot B 7 6 m 25 ft C Low Beam D Height of Headlight Center E High Beam F 9517058851 Sidestand Switch Operation Inspection e Inspect the sidestand switch A operation accordance to below table Sidestand Switch Operation Gear Clutch Engine Engine sidestand Lever Start Run running running
69. see Center Fairing Removal in the Frame chapter Reserve Tank Bolts A Reserve Tank B e Put A the projection B on the reserve tank into the hole C on the frame bracket and place the reserve tank on the right side of frame e Place a container under the water pump drain bolt A then remove the drain bolt PERIODIC MAINTENANCE 2 47 Periodic Maintenance Procedures eRemove the radiator 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 Turn over A the reserve tank remove the cap and pour the coolant into a suitable container e Place the reserve tank on the right side of frame Tighten the drain bolt with the gasket OReplace the drain bolt gasket with a new one Torque Water Pump Drain Bolt 7 0 N m 0 70 kgf m 62 in Ib e When filling the coolant choose a suitable mixture ratio by referring to the coolant manufacturer s directions CAUTION Soft or distilled water must be used with the an tifreeze in the cooling system If hard water is used in the system it causes scales accumulation in the water passages and consider ably reduces the efficiency of the cooling system Water and Coolant Mixture Ratio Recommended Soft Water 50 50 Freezing Point 35 31 F Total Amount 1 2 L 1 3 US qt
70. see Seat Removal in the Frame chapter Side Covers see Side Cover Removal in the Frame chapter Fuel Tank Bolts A e Draw the fuel out from the fuel tank with a commercially available pump A OUse a soft plastic hose B as a pump inlet hose in order to insert the hose smoothly OPut the hose through the fill opening C into the tank and draw the fuel out Front D A WARNING The fuel could not be removed completely from the fuel tank Be careful for remained fuel spillage 62178129 P GCO9033BS1 C 3 104 FUEL SYSTEM Fuel Tank e Disconnect the fuel pump lead connector A and the tube e Remove Fuel Return Hose C Red California Model Fuel Tank Breather Hose D Blue California Model e Be sure to place a piece of cloth A around the fuel hose joint e Insert a minus screw driver B into the slit C on the joint lock e Turn A the driver to disconnect the joint lock B e Pull C the fuel hose joint out D of the outlet pipe CAUTION When removing 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 A WARNING Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is disconnected fuel spills out from the hose and the pipe because of residual pressure Cover the hose connection with a piece of clean cloth to p
71. 0 20 in 1 mm 0 04 in Brake Light Timing Front Pulled ON ON after about 10 mm 0 39 in of pedal travel Electrical System Spark Plug Gap 0 8 0 9 mm 0 03 0 04 in PERIODIC MAINTENANCE 2 13 Special Tools Inside Circlip Pliers Extension Tube 57001 143 57001 1578 7570143ST C 7571578ST C Steering Stem Nut Wrench Pilot Screw Adjuster E 57001 1100 57001 1603 875711005 C 875716035 C Oil Filter Wrench 57001 1249 7571249ST C 2 14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System DFI Air Cleaner Element Cleaning NOTE Oln dusty areas the element should be cleaned more frequently than the recommended interval OAfter riding through rain or on muddily roads the ele ment should be cleaned immediately A WARNING If dirt or dust is allowed to pass through into the throttle assy the throttle may become stuck possi bly causing accident CAUTION If dirt gets through into the engine excessive en gine wear and possibly engine damage will occur e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Air Switching Valve Hose A Disconnect Air Cleaner Element Screw B Air Cleaner Element C Remove Upper Plastic Holder A Element B NOTE OThe wire screen A is fastened with an adhesive for the shaded portion B Do not remove the wire screen
72. 12 ELECTRICAL SYSTEM Parts Location c 9048172 P gt AE 1 Air Switching Valve 13 Rear Brake Light Switch 2 Alternator 14 Regulator Rectifier 3 Battery 12 V 10 Ah 15 Relay Box 4 Crankshaft Sensor 16 Sidestand Switch 5 ECU 17 Speed Sensor 6 Fan Motor 18 Starter Lockout Switch 7 Front Brake Light Switch 19 Starter Motor 8 Fuse Box with ECU Main Fuse 20 Starter Relay with Main Fuse 9 Ignition Switch 21 Stick Coils 10 Meter Unit 22 Turn Signal Relay 11 Neutral Switch 23 Water Temperature Sensor 12 Oil Pressure Switch 24 Oxygen Sensor Europe Models ELECTRICAL SYSTEM 16 13 Parts Location Dummy Page 16 14 ELECTRICAL SYSTEM Wiring Diagram Europe Korea Hong Kong and Kuwait Regulator Right Switch Housing Rectifier 1 Front Brake Light Switch 2 Engine Stop Switch Alternator 3 Starter Button Cit ped be Lt Spark otor Plugs R BK R BK R BL 39 a M BK Y R Ignition Switch FAILS 1851651 ay Water proof Joint Meter Unit i Turn Signal Indicator Light LED 2 High Beam Indicator Light LED 3 Neutral Indicator Light LED 4 011 Pressure Warning Indicator Light LED 5 FL Indicator Light LED 6 Odometer Trip Weter Clock 7 Water Temperature Gauge B Fuel Warning 9 Tachometer H 10 Speedmeter
73. 14 2 15 2 V Regulator Rectifier Output Voltage Ignition System Crankshaft Sensor Resistance 376 564 Crankshaft Sensor Peak Voltage 1 9 V or more Stick Coil Primary Winding Resistance 1 1 1 5 0 Secondary Winding Resistance 10 8 16 2 kO Primary Peak Voltage 88 V or more Spark Plug Spark Plug Gap 0 8 0 9 mm 0 03 0 04 in Electric Starter System Starter Motor Brush Length 12 mm 0 47 in Service limit 6 0 mm 0 24 in Commutator Diameter 28 mm 1 10 in Service limit 27 mm 1 06 in Air Switching Valve Resistance 18 22 at 20 C 68 F Switch and Sensor Rear Brake Light Switch Timing ON after about 10 mm 0 39 in pedal travel Engine Oil Pressure Switch Connections When engine is stopped ON When engine is running OFF Water Temperature Sensor Resistance in the text ELECTRICAL SYSTEM 16 11 Special Tools and Sealants Hand Tester Grip 57001 1394 57001 1591 4 7571394ST C 7571591ST C Flywheel Puller Assembly M38 x 1 5 M35 x 1 5 Flywheel amp Pulley Holder 57001 1405 57001 1605 875714055 C 875716055 C Peak Voltage Adapter Rotor Holder 57001 1415 57001 1658 875714155 C ST571658ST Lead Wire Peak Voltage Adapter Kawasaki Bond Silicone Sealant 57001 1449 56019 120 7571449ST C 875601205 C Needle Adapter Set Kawasaki Bond Silicone Sealant 57001 1457 92104 0004 T571457ST C 879200045 6 16
74. 16 Thermostat Inspection t 4 16 Hose and Pipes oce tote e ee Fh ERE Ee eet te eed n dede ga 4 18 Hose nstallatiori 2 deett ak Yee te eee OE 4 18 HOSE INSPSCUOM ceres eee beet cre AA eere eat tea tr Ern e ee ex ER ee 4 18 Water Temperature Sensor pp 4 19 Water Temperature Sensor Removal Installation pp 4 19 Water Temperature Sensor Inspection pp 4 19 4 2 COOLING SYSTEM Exploded View COOLING SYSTEM 4 3 Exploded View No Fastener Torque Remarks N m kgf m ft Ib 1 Radiator Hose Clamp Screws 2 0 0 20 17 in lb 2 Pump Impeller Bolt 9 8 1 0 87 3 Water Pump Cover Bolts 9 8 1 0 87 in lb 4 Water Pump Drain Bolt 7 0 0 70 62 in Ib 5 Thermostat Housing Bolts 9 8 1 0 87 6 Water Temperature Sensor 12 1 2 106 in Ib 7 Baffle Plate Bolts 5 9 0 60 52 in Ib 8 Reserve Tank 9 Baffle Plate 10 Cylinder Head Cover 11 Thermostat 12 Water Pump Impeller 13 Apply grease Apply high temperature grease Replacement Parts HG Mechanical Seal 4 4 COOLING SYSTEM Coolant Flow Chart Cylinder Head Jacket Thermostat Housing Cylinder Jacket Reserve Tank F adn Hose erve Tank Water Pump Radiator Radiator Fan Radiator Cap Reserve Tank Hose gt Hot Coolant gt Cold Coolant 60040328 5
75. 28 000 mm 1 1019 1 1024 in Service Limit 27 96 mm 1 10068 in 9 28 CRANKSHAFT TRANSMISSION Balancer x lf either journal has worn past the service limit replace the balancer shaft with a new one xIf the measured journal diameters 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 27 994 28 000 1 1021 1 1024 in A Balancer Shaft Journal Diameter Marks mark no mark e 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 e 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 mark or no mark No 1 Journal A No 2 Journal B Select the proper bearing insert in 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 wit
76. 4 Exhaust Pipe Manifold Holder Nuts 17 1 7 12 5 Muffler Body Mounting Bolt Front 20 2 0 15 6 Muffler Body Mounting Bolt Rear 20 2 0 15 7 R marked side faces up 8 RN marked side faces up 9 Hollow mark faces forward O 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 M 5 8 ENGINE END Exhaust System Exhaust System EX650A6F EX650B6F MANIFOLD SILENCER ITEM NAME ORG PRODUCT Honeycomb Type Catalyst with Oxygen Sensor WVTA FULL H EX650A6F EX650B6F P No 18091 0284 GB WVTA FULL H EX650AGF EX650B6F Mark KHI K 492 Non Catalyst P No 39178 0059 Mark KHI M101 Honeycomb Type Catalyst without Oxygen US EX650A6F US CALIF EX650A6F P No 18091 0296 Canada EX650A6F Mark KHI K 498 Australia EX650A6F EPA Noise Emission Control Information GE24004B F Full Full Power H Honeycomb Type Catalyst Silencer A with Hole B for Oxygen Sensor C GE02208BS1 ENGINE END 5 9 Exhaust System Manifold Mark Position Silencer Mark Position A Catalyst mm Exhaust Gas 5 10 ENGINE END Specifications Item Standard Service Limit Camshafts Cam Height Exhaust 35 843 35 957 mm 1 4111 1 4156 in 35 74 mm 1 4071 Inlet 36 543 36 657 mm 1 4387 1 4432 36
77. 43 in lb L 7 Neutral Switch 15 1 5 11 8 Shift Shaft Cover Bolts 9 8 1 0 87 in lb L 2 9 Shift Shaft Cover Screw 4 9 0 50 43 in lb L 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 9 6 CRANKSHAFT TRANSMISSION Specifications Item Standard Service Limit Crankshaft Connecting Rods Connecting Rod Bend TIR 0 2 100 mm 0 008 3 94 in Connecting Rod Twist TIR 0 2 100 mm 0 008 3 94 in 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 in 0 0031 in Crankpin Diameter 37 984 38 000 mm 37 97 mm 1 4954 1 4961 in 1 4949 in Marking None 37 984 37 992 mm 1 4954 1 4957 in 37 993 38 000 1 4958 1 4961 in Connecting Rod Big End Inside Diameter 41 000 41 016 mm 1 6142 1 6148 in Marking None 41 000 41 008 mm 1 6142 1 6145 in 41 009 41 016 mm 1 6145 1 6148 in Connecting Rod Big End Bearing Insert Thickness Brown 1 475 1 480 mm 0 05807 0 05827 in Black 1 480 1 485 mm 0 05827 0 05846 in Blue 1 485 1 490
78. 44 mm 1 4346 in Camshaft Journal Camshaft Cap Clearance Camshaft Journal Diameter Camshaft Bearing Inside Diameter Camshaft Runout Cylinder Head Cylinder Compression Cylinder Head Warp 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 961 1 471 kPa 9 8 15 0 kgf cm 139 213 psi at 400 r min rpm 0 16 mm 0 0063 in 23 92 mm 0 942 in 24 08 mm 0 948 in TIR 0 1 mm 0 004 Valve Clearance Exhaust Inlet Valve Head Thickness Exhaust Inlet Valve Stem Bend Valve Stem Diameter Exhaust Inlet Valve Guide Inside Diameter Exhaust Inlet Valve Valve Guide Clearance Wobble Method Exhaust Inlet Valve Seat Cutting Angle Valve Seating Surface Width Exhaust Inlet Outside Diameter Exhaust Inlet 0 22 0 31 mm 0 0087 0 0122 in 0 15 0 21 mm 0 0059 0 0083 in 0 8 mm 0 0371 in 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 0 1776 in 4 500 4 512 mm 0 1772 0 1776 in 0 07 0 14 mm 0 0028 0 0055 in 0 02 0 08 mm 0 0008 0 0032 in 32 45 55 60 0 5 1 0 mm 0 020 0 039 in 0 5 1 0 mm 0 020 0 039 in 27 6 27 8 mm 1 087 1 094 in 32 6 32 8 mm 1 283
79. 49 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 tightened not properly Oil Pressure Warning Light Goes On Engine oil pump damaged Engine oil screen clogged Engine oil filter clogged Engine oil level too low Engine oil viscosity too low Camshaft bearing worn Crankshaft bearing worn Oil pressure switch damaged Wiring faulty Relief valve stuck open O ring at the oil passage in the crankcase damaged Exhaust Smokes Excessively Wh
80. A WARNING Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is disconnected fuel spills out from the hose and the pipe Cover the hose connec tion with a clean shop towel to prevent fuel spillage e Install the new fuel hose e Insert A the fuel hose joint B straight onto the delivery pipe until the hose joint clicks e Push C the joint lock D e Push and pull A the fuel hose joint B back and forth more than two times and make sure it is locked and doesn t come off A WARNING Make sure the fuel hose joint is installed correctly on the delivery pipe or the fuel could leak x lf it comes off reinstall the hose joint e Run the fuel hose correctly see Cable Wire and Hose Routing section in the Appendix chapter e Install the removed parts see appropriate chapters e Start the engine and check the fuel hose for leaks 2 46 PERIODIC MAINTENANCE Periodic Maintenance Procedures Coolant Change WARNING To avoid burns do not remove the radiator cap or try to change the coolant when the engine is still hot Wait until it cools down Coolant on tires will make them slippery and can cause an accident and injury Immediately wipe up or wash away any coolant that spills on the frame engine or other painted parts Since coolant is harmful to the human body do not use for drinking e Remove Right Center Fairing
81. Alternator hor LI Hi Fan 2 Motor spark Plugs y y TUR ERR 842822 Ba Stick Rem IGNITION BR BR Coils P y BL Bt Ignition Switch R R 8 55 vee ins 2 5 IGNITION 99 GY ey Te C d Meter Unit i Turn Signal Indicator Light LEB 2 High Beam Indicator Light LED 3 Neutral Indicator Light LED 4 011 Pressure Warning Indicator Light LED Indicator Light 8 0dometer Trip Meter Clack 7 Water Temperature Gauge 8 Fuel Warning 9 Tachometer 10 Speedmeter Unit 11 Illumination Light LED IB LED Light Emitting Diode Water procf Joint Is x Z Frame Ground BK Y Meter Unit of 5 J all Water proof Joint A WE Water proof Joint B Front Right Turn Signal Light 12V2iW Right City Light 12V5W Headlight HI 12V55W R BK a Headlight Lo 8 RAY 12 55 Signal at 1 5 Relay qe Oh ILS 1L 7 Ce Front Left Turn Signal 5 Light 12V21W a Left Switch Housing re Horn Button js Hazard Button Relay Box Turn Signal Switch Dimmer Switch Starter Lockout Switch Fuse Box 1 Oxygen Sensor Heater Fuse 10 2 Fan Fuse 15 3 ECU Fuse 15 4 Turn Signal Relay Fuse 10A 1 2 3
82. Assy Assembly ete dee D ee tate uae tage ab d adero ee bU coe meas Transmission Assy Installation ete th de tre tei Rebus Transmission Shaft Removal aee ease sudo ay see net tacta eaa Molde be Pe Transmission Shaft Installation Transmission Shaft Disassembly Transmission Shaft Assembly pp Shift Drum and Fork Shift Drum and Fork Installatigom Shirt Dr m DisasssrTibly soo oerte Shit DPI s aei Coe Shift BOFK Bending en Ph uiuis Shift Fork Gear Groove Wear Nan Shift Fork Guide Pin Drum Groove Wear Gear Dog and Gear Dog Hole Damage Ball Bearing Needle Bearing and Oil Ball and Needle Bearing Replacement pp Ball and Needle Bearing Wear Oil Seals Inspection rrr eret ee rtv lees 9 2 CRANKSHAFT TRANSMISSION Exploded View onl LOTT WF gt MEE GS er Vi A AE D p 6 T extis ty CRANKSHAFT TRANSMISSION 9 3 Exploded View No Fastener Remarks Nm kgf m ft Ib 1 Connecting Rod Big End Nuts see Text lt lt 2
83. Bearing Insert Selection Crankshaft Main Journal Diameter Crankcase Main Bearing Inside Bearing Insert Diameter Marking Marking Size Color Part Number 92028 1905 92028 1904 Blue 92028 1903 bearing inserts for Nos 1 2 3 journals have oil grooves Balancer Shaft Balancer Shaft Bearing Insert Journal Clearance Balancer Shaft Journal Diameter Marking None 0 011 0 033 mm 0 0004 0 0013 in 27 987 28 000 mm 1 1019 1 1024 in 27 987 27 993 mm 1 1019 1 1021 in 27 994 28 000 mm 1 1021 1 1024 in 0 08 mm 0 0031 in 27 96 mm 1 1108 in 9 8 CRANKSHAFT TRANSMISSION Specifications Item Standard Service Limit Crankcase Bearing Bore Diameter Marking Balancer Shaft Bearing Insert Thickness Brown Black Blue Balancer Shaft Bearing Insert Selection 31 000 31 016 mm 1 2205 1 2228 in 31 000 31 008 mm 1 2205 1 2208 31 009 31 016 mm 1 2208 1 2211 in 1 490 1 494 mm 0 0587 0 0588 in 1 494 1 498 mm 0 0588 0 0590 in 1 498 1 502 mm 0 0590 0 0591 Crankcase Bearing Balancer Shaft Bearing Insert Bore Diameter Journal Diameter Marking Marking Size Color Part Number O O Brown 92139 0119 92139 0118 None Blue 92139 0117
84. Brake Fluid Level Inspection in the Periodic Maintenance chapter Brake Fluid Change Refer to the Brake Fluid Change in the Periodic Mainte nance chapter Brake Line Bleeding The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action Air however is easily compressed When air enters the brake lines brake lever or pedal movement will be partially used in compressing the air This will make the lever or pedal feel spongy and there will be a loss in braking power sure to bleed the air from the brake line ever brake lever or pedal action feels soft or spongy after the brake fluid is changed or when ever a brake line fitting has been loosened for any reason NOTE OThe procedure to bleed the front brake line is as follows Bleeding the rear brake line is the same as for the front brake e Remove the reservoir cap A and diaphragm e Fill the reservoir with fresh brake fluid to the upper level line in the reservoir e Slowly pump the brake lever several times until no air bubbles can be seen rising up through the fluid from the holes at the bottom of the reservoir OBleed the air completely from the master cylinder by this operation e Remove the rubber cap from the bleed valve A on the caliper e Attach a clear plastic hose B to the bleed valve and run the other
85. C is cracked replace 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 6515011851 C al GY PS 55 SOS IBSEN SS WN My Ves SN fa GN050602S1 C 6517009851 C 2 38 PERIODIC MAINTENANCE Periodic Maintenance Procedures Lights and Switches Operation Inspection First Step e Turn on the ignition switch The following lights should go on according to below table City Light A goes on Taillight B goes on License Plate Light C goes on Meter Panel LCD D goes on Neutral Indicator Light LED E goes on Oil Pressure Warning Indicator Light LED IF goes on Water Temperature Warning Indicator goes on Light LED G FI Indicator Light LED H goes on about 2 seconds EX650B Models ABS Indicator Light LED I goes on x If the light does not go on inspect or replace the following item Battery see Charging Condition Inspection in the Elec trical System chapter Applicable Bulb see Wiring Diagram in the Electrical System chapter Meter Unit for Meter Panel LCD see Electronic Com bination Meter Unit Inspec
86. CAUTION Do not remove the secondary cup from the piston since removal will damage it 9813130852 C a 9513111851 C PERIODIC MAINTENANCE 2 53 Periodic Maintenance Procedures Rear Master Cylinder Disassembly NOTE 8 not remove the push rod clevis for master cylinder disassembly since removal reguires brake position ad justment Remove the rear master cylinder see Rear Master Cylin der Removal in the Brakes chapter e Slide the dust cover on the push rod out of place and remove the circlip Special Tool Inside Circlip Pliers 57001 143 e Pull out the push rod with the piston stop e Take off the piston A secondary cup B primary cup C and return spring D CAUTION Do not remove the secondary cup from the piston since removal will damage it GL07048BS2 C Master Cylinder Assembly e Before assembly clean all parts including the master cylinder with brake fluid or alcohol CAUTION Except for the disc pads and disc use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning brake parts Do not use any other fluid for cleaning these parts Gasoline engine oil or any other petroleum distillate will cause deterioration of the rubber parts Oil spilled on any part will be diffi cult to wash off completely and will eventually de teriorate the rubber used in the disc brake e App
87. 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 93 103 C 199 217 F the radiator fan relay conducts to operate the radiator fan The radiator fan draws air through the radiator core when there is not sufficient air flow such as at low speeds This increases up the cooling action of the radiator When the temperature is below 91 C 196 F temperature less than ON temperature 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 t
88. Control System This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this motorcycle The fuel ignition and exhaust systems of this motorcycle have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels The exhaust system of this model motorcycle manufactured primarily for sale in California in cludes a catalytic converter system 3 Evaporative Emission Control System Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere In stead fuel vapors are routed into the running engine to be burned or stored in a canister when the engine is stopped Liquid fuel is caught by a vapor separator and returned to the fuel tank The Clean Air Act which is the 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
89. Cylinder Head Warp e Clean the cylinder head Lay a straightedge across the lower surface of the cylinder head at several positions e Use a thickness gauge A to measure the space between the straightedge B and the head Cylinder Head Warp Standard Service Limit 0 05 mm 0 002 in x If the cylinder head is warped more than the service limit replace it x If the cylinder head is warped less than the service limit repair the head by rubbing the lower surface on emery paper secured to a surface plate first No 200 then No 400 ENGINE END 5 29 Valves Valve Clearance Inspection e Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter Valve Clearance Adjustment e Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter Valve Removal e Remove cylinder head see Cylinder Head Removal Remove the valve lifter and shim OMark and record the valve lifter and shim locations so they can be installed in their original positions e Using the valve spring compressor assembly remove the valve Special Tools Valve Spring Compressor Assembly A 57001 241 Valve Spring Compressor Adapter 21 B 57001 1272 Valve Installation e Replace the oil seal with a new one OApply 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 co
90. E OHook the spring at gear positioning lever pushing up F the hook portion as shown e Apply a non permanent locking agent to the gear posi tioning lever bolt and tighten it Torque Gear Positioning Lever Bolt 12 N m 1 2 kgf m 106 in Ib e Install the shift shaft assembly OApply A molybdenum disulfide oil solution to the rub bing surface between the lever B and pawl C and move them two or three times up and down to lubricate them OBe sure that the washer A is on the shaft OBe sure that the spring hook portions B are as shown 9113241851 Viewed from 9113252851 CRANKSHAFT TRANSMISSION 9 31 Transmission 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 9113242851 Install the shift shaft cover OBe sure that the dowel pins A are in position Olnstall the new gasket B 9113243851 e Apply a non permanent locking agent to the shift shaft cover screw A and bolts B C and tighten them ODo not apply a non permanent locking agent to the shift shaft cover bolts D E OTighten the cover sc
91. FUEL SYSTEM Inlet Air Pressure Sensor Service Code 12 Inlet Air Pressure Sensor Output Voltage Inspection NOTE OThe output voltage changes according to the local at mospheric pressure e Measure the output voltage at the ECU in the same way as input voltage inspection Note the following Inlet Air Pressure Sensor Output Voltage Connections to ECU Meter Y BL lead terminal 8 Meter BR BK lead terminal 28 Usable Range 3 74 4 26 V DC at the standard atmospheric pressure 101 32 kPa 76 cmHg abs e Turn the ignition switch OFF x If the output voltage is within the usable range check the ECU for its ground and power supply see ECU Power Supply Inspection x lf the output voltage is out of the usable range remove the fuel tank and check the wiring If the output voltage is 4 8 V the ECU is normal x If the wiring is good check the sensor for various vacuum x If the output voltage for various vacuum is normal check the ECU for its ground and power supply see ECU Power Supply Inspection e Remove the inlet air pressure sensor A and disconnect the vacuum hose from the sensor ODo not disconnect the sensor connector e Connect an auxiliary hose B to the inlet air pressure sen sor Temporarily install the inlet air pressure sensor OConnect a commercially available digital meter C vac uum gauge D the fork oil level gauge E and the har ness adapter to the in
92. FUEL SYSTEM DFI 3 95 Fuel Injectors e Watch the gauge for at least 6 seconds x If the pressure holds steady the system is good x If the pressure drops at once or if bubbles are found in the area the line is leaking Replace the delivery pipe injectors and related parts ORepeat the leak test and check the fuel line for no leak age e Install the pump outlet hose see Fuel Tank Installation e Run the hoses correctly see Cable Wire and Hose Rout ing section in the Appendix chapter Fuel Injector Circuit 4 Y R BR W E JON PARK IGNITION ar BR BATTERY F 6C17989BW2 ECU Fuel Injectors Water proof Joint C Engine Stop Switch Ignition Switch Ignition Fuse 10 A Fuel Pump Relay for fuel pump and injectors Relay Box Main Fuse 30 A Battery Frame Ground Joint Connector 3 96 FUEL SYSTEM DFI Throttle Grip and Cables Throttle Grip Free Play Inspection e Refer to the Throttle Control System Inspection in the Pe riodic Maintenance chapter Throttle Grip Free Play Adjustment e Refer to the Throttle Control System Inspection in the Pe riodic Maintenance chapter Throttle Cable Installation e Install the throttle cables in accordance with Cable Wire and Hose Routing section in the Appendix chapter e Install the lower ends of the thrott
93. Housing Screws 3 5 0 36 31 in lb Steering Stem Head Bolt 108 11 0 80 Steering Stem Nut 20 2 0 15 Frame Footpeg Stay Bolts 25 Front Fender Bolts 35 in Ib Front Fender Bracket Bolts 78 in lb Front Turn Signal Light Mounting Screws 11 in Ib Grab Rail Mounting Bolts 18 Seat Lock Mounting Screws 11 in Ib Sidestand Bolt 32 Sidestand Switch Bolt f 78 in lb Electrical System Alternator Cover Bolts 9 8 1 0 87 Alternator Lead Holding Plate Bolt 9 8 1 0 87 in lb L Alternator Rotor Bolt 155 15 8 114 MO Crankshaft Sensor Bolts 6 0 0 60 53 in lb Engine Ground Cable Terminal Bolt 9 8 1 0 87 in lb Front Brake Light Switch Screw 1 2 0 12 11 in lb Front Turn Signal Light Mounting Screws 1 2 0 12 11 in lb Left Switch Housing Screws 3 5 0 36 31 in Ib License Plate Light Cover Screws 0 90 0 090 8 in Ib License Plate Light Mounting Screws 1 2 0 12 11 in Ib Meter Screws 1 2 0 12 11 in Ib Neutral Switch 15 1 5 11 Oil Pressure Switch 15 1 5 11 SS Oxygen Sensor 44 1 4 50 32 5 Regulator Rectifier Bolts 8 8 0 90 78 Right Switch Housing Screws 3 5 0 36 31 in lb Sidestand Switch Bolt 8 8 0 90 78 in lb L Spark Plugs 15 1 5 11 Speed Sensor Bolt 7 8 0 80 69 in Ib L 2 10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Kam kgfm ftlb Remarks Starter Motor Cable Terminal Nut 6 0 0 60 53 in Ib Starter Motor Clutch Bolts 34 3 5 25 L Starter Motor Mounting Bolts 9 8 1 0 87 L Starter Mo
94. In Gear Released Doesnt Stops start In Gear Pulled in Starts Continue running Neutral Released Starts running Neutral Pulled in Starts Continue running Doesn t In Gear Released Stops start In Gear Pulledin Doesn t Stops start 2 42 PERIODIC MAINTENANCE Periodic Maintenance Procedures x lf 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 x lf the all parts are good condition replace the ECU see ECU Removal Installation in the Fuel System DFI chap ter Engine Stop Switch Operation I
95. Leakage Crack or Dent x If there is any damage to the rear shock absorber replace it e Visually inspect the rubber bushing x If it show any signs of damage replace it SUSPENSION 13 17 Swingarm Swingarm Removal e Remove Chain Cover Bolts A and Cover B e Remove Right Side Cover see Side Cover Removal in the Frame chapter Frame Covers see Frame Cover Removal in the Frame chapter Remove the brake hose banjo bolt from the rear caliper free the brake hose A from the clamps B and remove the footpeg stay with the rear master cylinder see Rear Caliper Removal in the Brakes chapter e Remove Muffler Body see Muffler Body Removal in the Engine Top End chapter Rear Wheel see Rear Wheel Removal in the Wheels Tires chapter e Raise the rear wheel off the ground with jack Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Remove the lower shock absorber nut and bolt A e Remove the drive chain see Drive Chain Removal in the Final Drive chapter e Unscrew the swingarm pivot shaft nut A e Pull off the pivot shaft B and remove the swingarm Swingarm Installation e Installation is the reverse of removal OApply grease to the lip of the oil seals OBe sure to install the oil seal and collar to the swingarm e Tighten the pivot shaft nut Torque Swingarm Pivot Shaft Nut 108 N m 11 0 kgf m 80 ft Ib e Install the removed parts see appropriate chapters
96. Lubricate with Grease Clutch Inner Cable Upper and Lower Ends A Throttle Inner Cable Upper and Lower Ends 6004040381 C Cables Lubricate with Rust Inhibitor Clutch Cable Throttle Cables e Lubricate the cables by seeping the oil between the cable and housing OThe cable may be lubricated by using a commercially available pressure cable lubricator with an aerosol cable lubricant 6604011451 C e With the cable disconnected at both ends the inner cable should move freely A within the cable housing x If cable movement is not free after lubricating if the cable is frayed B or if the cable housing is kinked C replace the cable eP 6004020281 2 44 PERIODIC Periodic Maintenance Procedures Bolts Nuts and Fasteners Tightness Inspection e Check the tightness of the bolts and nuts listed here Also check to see that each cotter pin is in place and in good condition NOTE OFor the engine fasteners check the tightness of them when the engine is cold at room temperature x lf there are loose fasteners retighten them to the spec ified torque following the specified tightening sequence Refer to the appropriate chapter for torque specifications If torque specifications are not in the appropriate chapter see the Standard Torque Table 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
97. Nut and Fastener to be checked Engine Clutch Lever Pivot Nut 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 Brake Rod Joint Cotter Pin Caliper Mounting Bolts Front Master Cylinder Clamp Bolts Rear Master Cylinder Mounting Bolts Suspension Front Fork Clamp Bolts Rear Shock Absorber Bolt and Nut Swingarm Pivot Shaft Nut Steering Steering Stem Head Bolt Handlebar Holder Bolts Others Footpeg Stay Bolts Front Fender Bolts Sidestand Bolt PERIODIC MAINTENANCE 2 45 Periodic Maintenance Procedures Replacement Parts Air Cleaner Element Replacement Refer to the Air Cleaner Element Cleaning Fuel Hose Replacement CAUTION When removing and installing the fuel hose joint do not apply strong force to the outlet pipe on the fuel pump and delivery pipe on the throttle body assy The pipes made from resin could be damaged e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Left Center Fairing see Center Fairing Removal in the Frame chapter e Be sure to place a piece of cloth A around the fuel hose joint e Insert a minus screw driver B into the slit C on the joint lock e Turn A the driver to disconnect the joint lock B e Pull C the fuel hose joint D out of the delivery pipe
98. 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 on the piston side e Push the holder D towards the piston and remove the pad of the other side E from the holder shaft F Front Brake Pad Installation e Push the caliper pistons in by hand as far as they will go e Install the anti rattle spring in its correct position e Install the pad on the piston side first then install the other pad on the holder e Install the front caliper see Caliper Installation WARNING not attempt to drive the motorcycle until full brake lever is obtained by pumping the brake lever until the pads are against the disc The brake will not function on the first application of the lever if this is not done Rear Brake Pad Removal Remove the rear caliper with the hose installed see Rear Caliper Removal e Draw out the holder shaft pin A and take off the holder shaft B Remove the pad on the piston side e Push the holder D towards the piston and remove the pad of the other side E from the holder shaft F Rear Brake Pad Installation e Push the caliper piston in by hand as far as it will go e Install the anti rattle spring in its correct position e Install the pad on the piston side first then install the other pad on the holder e Install the rear caliper se
99. Remove the oil passage plug and attach the adapter A and gauge B to the plug hole Special Tools Oil Pressure Gauge 10 kgf cm 57001 164 Oil Pressure Gauge Adapter PT3 8 57001 1233 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 Cil Pressure Standard 216 294 kPa 2 2 3 0 kgf cm 31 43 psi at 4 000 r min rpm oil temperature 90 194 F e Stop the engine e Remove the oil pressure gauge and adapter A WARNING Take care against burns form hot engine oil that will drain through the oil passage when the gauge adapter is removed e Apply a non permanent locking agent to the oil passage plug and install it Torque Oil Passage Plug 20 N m 2 0 kgf m 15 ft Ib ENGINE LUBRICATION SYSTEM 7 15 Oil Pressure Switch Oil Pressure Switch Removal e Remove Engine Oil Drain see Engine Oil Change in the Periodic Maintenance chapter Right Lower Fairing see Lower Fairing Removal in the Frame chapter Switch Cover A Switch Terminal Bolt B Oil Pressure Switch C Oil Pressure Switch Installation e Apply silicone sealant to the threads of the oil pressure switch and tighten it Seal
100. 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 after disassembly can reduce sealing per formance Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains Install new gaskets and replace used O rings when re assembling Liquid Gasket Non perm
101. Speed Sensor Bracket Bolts A Speed Sensor Bracket B e Flatten out the bended washer A Remove the engine sprocket nut and washer NOTE OWhen loosening the engine sprocket nut hold the rear brake on Raise the rear wheel off the ground with stand Remove the axle cotter pin and loosen the rear axle nut Loosen the drive chain see Drive Chain Slack Adjust ment in the Periodic Maintenance chapter Remove the drive chain from the rear sprocket toward the right e Pull the engine sprocket A with drive chain B off the output shaft C Disengage the drive chain from the engine sprocket FINAL DRIVE 11 11 Sprocket Coupling Engine Sprocket Installation Replace the sprocket washer and axle cotter pin e Install the engine sprocket A so that OUTSIDE letters face outward e Apply molybdenum disulfide oil solution to the threads of the output shaft and seating surface of the engine sprocket nut e After torquing the engine sprocket nut bend the one side of the washer B over the nut NOTE OTighten the engine sprocket nut while applying the rear brake e Tighten Torque Engine Sprocket Nut 125 N m 12 7 kgf m 92 ft Ib Speed Sensor Bracket Bolts 9 8 1 0 kgf m 87 in Ib e Install the engine sprocket cover and tighten the bolts e Adjust the drive chain slack after installing the sprocket see Drive Chain Slack Adjustment in the Periodic Main tenance chapte
102. Switching Valve Water proof Joint C Ignition Switch Water proof Joint A ECU Fuse 15 A ECU Main Relay Relay Box Main Fuse 30 A 10 Battery 11 Frame Ground 12 Joint Connector 3 74 FUEL SYSTEM Oxygen Sensor Heater Service Code 67 Europe Models Oxygen Sensor Heater Removal Installation The oxygen sensor heater is built in the oxygen sensor So the heater itself can not be removed Remove the oxy gen sensor see Oxygen Sensor Removal in the Electrical System chapter Oxygen Sensor Heater Inspection e Remove the engine sprocket cover see Engine Sprocket Removal in the Final Drive chapter e Disconnect the oxygen sensor lead connector A e Set the hand tester A to the x 1 O range and connect it to the terminals in the oxygen sensor lead connector B Black C Black D Special Tool Hand Tester 57001 1394 Oxygen Sensor Resistance Standard 11 7 14 5 at 20 68 x lf the tester reading is not as specified replace the oxygen sensor with a new one GP18070BS1 x lf the tester reading is specified check the power source voltage Inspection NOTE OBe sure the battery is fully charged Connect a digital voltmeter A to the oxygen sensor nector B using the needle adapter C Special Tool Needle Adapter Set 57001 1457 Measure the power source voltage with the engine stopped and with the oxy
103. Upper Fairing Removal in the Frame chapter Under Bracket A see Upper Fairing Bracket Removal in the Frame chapter e Remove Upper Fairing Bracket A see Upper Fairing Bracket Removal in the Frame chapter e Remove Front Wheel see Front Wheel Removal in the Wheels Tires chapter Front Forks see Front Fork Removal in the Suspension chapter Handlebar see Handlebar Removal Steering Stem Head Bolt Plug A Steering Stem Head Bolt B and Washer Front Fork Clamp Bolts Upper C Loosen Steering Stem Head D e Bend the claws A of the claw washer straighten e Remove the steering stem locknut B and claw washer C e Pushing up the stem base and remove the steering stem nut A with stem cap B Special Tool Steering Stem Nut Wrench C 57001 1100 e Remove the steering stem D under side e Remove the upper stem bearing inner race and bearing STEERING 14 7 Steering Stem To remove the 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 hammer it to drive the race out NOTE Olf either steering stem bearing is damaged it is recom mended that both the upper and lower bearings includ ing outer races should be replaced with new ones e Remove the lower bearing inner race A which is pressed onto the steering stem with a suitable commercially avail able chisel B Stem Stem B
104. W White DG Dark Green O Orange Y Yellow OElectrical Connectors Female Connectors A 8 06010151 C ELECTRICAL SYSTEM 16 23 Precautions Male Connectors B 8 06010251 16 24 ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection e Visually inspect the wiring for signs of burning fraying etc If any wiring is poor replace the damaged wiring e Pull each connector A apart and inspect it for corrosion dirt and damage x If the connector is corroded or dirty clean it carefully If it is damaged replace it e Check the wiring for continuity OUse the wiring diagram to find the ends of the lead which is suspected of being a problem OConnect the hand tester between the ends of the leads Special Tool Hand Tester 57001 1394 OSet the tester to the x 1 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 GPO7002BS1 C GP07008BS1 C ELECTRICAL SYSTEM 16 25 Battery Battery Removal e Remove Seat see Seat Removal in the Frame chapter Disconnect the negative cable A e Slide out the positive terminal cap and then discon nect the positive cable CAUTION sure to disconnect the negative cable first Remove the battery Battery Installation e Put the battery into the rear fender front e Apply a
105. absorber oil leaking Charge insufficient Battery faulty too low terminal voltage Brake Doesn t Hold Battery lead 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 JKAEXEA106A000001 ane EXGSOAGF JKAEX650AAA000001 2006 EX650B6F JKAEX650ABA000001 O This digit in the frame number changes from one machine to another Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Consumer Products amp Machinery Company Part No 99924 1361 01 Printed in Japan
106. activated Service Code 33 Europe Models Oxygen Sensor Removal Installation e Refer to the Oxygen Sensor Removal Installation in the Electrical System chapter Oxygen Sensor Inspection e Warm up the engine thoroughly until the radiator fan starts e Turn the ignition switch OFF e Remove Left Lower Fairing see Lower Fairing Removal in the Frame chapter Engine Sprocket Cover see Engine Sprocket Removal in the Final Drive chapter e Connect a digital voltmeter A to the oxygen sensor con nector B main harness side using the needle adapter set C Special Tool Needle Adapter Set 57001 1457 Oxygen Sensor Output Voltage Connections to Oxygen Sensor Connector Meter BL Y lead Meter BR BK lead e Remove the air switching valve hose from the fitting e Install the suitable plugs A on the fitting B and shut off the secondary air e Turn the ignition switch ON e Start the engine and let it idle e Measure the output voltage of the sensor with the con nector joined Oxygen Sensor Output Voltage with Plugs Standard 0 7 V or more e Next remove the plugs from the fitting A with idling FUEL SYSTEM 3 67 Oxygen Sensor not activated Service Code 33 Europe Models e Measure the output voltage of the sensor with the con nector joined Oxygen Sensor Output Voltage without Plugs Standard 0 2 V or less xIf the reading is within range with plugs 0 7 V
107. and all codes have been erased only start code 12 will be shown Erasing of Service Code ABS Indicator Light LED 0FF ABS Self diagnosis Terminal Open Ground 2 3 IO e 18 more 2S ee Within 12 88 ervice code n erase starts Code Erase 8114009882 C BRAKES 12 41 Anti Lock System Self diagnosis Flow Chart Turn the ignition switch OFF Connect the ABS self diagnosis terminal to the ground terminal Turn the ignition switch ON Self diagnosis mode starts The ABS indicator light LED blinks to display the service code in about 3 seconds after entering the self diagnosis mode 1 If no service code is shown drive at 20 km h 12 mph or more for one 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 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 Unlit Activate the ABS at a safe place in order to confirm that it operates normally 2 OK End The se
108. and replace any fork that is bent A bent fork could cause difficulty in shifting or allow the transmission to jump out of gear when under power 90 A A 6113014581 Shift Fork Gear Groove Wear e Measure the thickness of the shift fork ears A and mea sure the width B of the gear grooves x If the thickness of a shift fork ear is less than the service limit the shift fork must be replaced Shift Fork Ear Thickness Standard 5 9 6 0 mm 0 232 0 236 in Service Limit 5 8 mm 0 228 in x If the gear groove is worn over the service limit the gear must be replaced Gear Groove Width Standard 6 05 6 15 mm 0 238 0 242 in Service Limit 6 25 mm 0 246 in 6113133851 C 9 40 CRANKSHAFT TRANSMISSION Transmission Shift Fork Guide Pin Drum Groove Wear e Measure the diameter of each shift fork guide pin A and measure the width B of each shift drum groove x If the guide pin any shift fork is less than the service limit the fork must be replaced Shift Fork Guide Pin Diameter Standard 6 9 7 0 mm 0 272 0 276 in Service Limit 6 8 mm 0 268 in x If any shift drum groove is worn over the service limit the drum must be replaced Shift Drum Groove Width Standard 7 05 7 20 mm 0 278 0 283 in Service Limit 7 3 mm 0 287 in Gear Dog and Gear Dog Hole Damage e Visually inspect the gear dogs A and gear dog holes B Replace any damaged gears or gears with
109. any kinked deteriorated or damaged hoses ORoute the hoses according to Cable Wire and Hose Routing section in the Appendix chapter OWhen installing the hoses avoid sharp bending kinking flattening or twisting and route the hoses with a minimum of bending so that the emission flow will not be obstructed 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 xIf 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 and unscrew the reserve tank cap and add coolant to the level line C L low full CAUTION For refilling add the specified mixture of coolant and soft water Adding water alone dilutes the coolant and degrades its anticorrosion properties The diluted coolant can attack the aluminum en gine parts In an emergency soft water alone can be added But the diluted coolant must be returned to the correct mixture ratio within a few days If coolant must be added often or the reservoir tank has run completely dry there is probably leakage in the cooling system Check the system for leaks Coolant ruins painted surfaces Immediately wash away any coolant that spills on the frame engine wheels or other painted parts
110. attempt to drive the motorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against the disc The brake will not function on the first application of the lever if this is not done 10 8 WHEELS TIRES Wheels Rims Rear Wheel Removal e Raise the rear wheel off the ground with stand A e Remove Brake Caliper Mounting Bolts A Rear Brake Caliper B Remove the rear wheel rotation sensor from the caliper bracket see Rear Wheel Rotation Sensor Removal in the Brakes chapter EX650B Models e Remove Cotter Pin A Axle Nut B Washer C Axle D with Washer Remove the drive chain A from the rear sprocket toward the left Move the rear wheel back and remove it CAUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place 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 A on the both sides of the hub WHEELS TIRES 10 9 Wheels Rims e Engage the drive chain with the rear sprocket e Install the caliper bracket A onto the swingarm stop B Insert the axle from the right side of the wheel and tighten the axle nut Torque Rear Axle Nut 108 N m 11 0 80 ft Ib e Insert a new cotter pin A NOTE OWhen inserting the cotter pin if the s
111. balance weight CAUTION Do not tap the screwdrivers The rim could be dam aged Balance Weight Installation e Check if the weight portion has any play on the blade A and clip B does discard it A WARNING If the balance weight has any play on the rib of the rim the blade and or clip have been stretched Re place the loose balance weight Do not reuse used balance weight Unbalanced wheels can create an unsafe riding condition 6J04076BS1 6J04077BS1 6J04088BS1 C 10 12 WHEELS TIRES Wheels Rims Balance Weight Part Number Weight 41075 0007 10 g 0 35 oz 41075 0008 20 g 0 71 oz 41075 0009 30 g 1 06 oz NOTE OBalance weights are available from Kawasaki dealers in 10 20 and 30 grams 0 35 0 71 and 1 06 oz sizes An imbalance of less than 10 grams 0 35 oz will not usually affect running stability ODo not use four or more balance weight more than 90 gram 3 17 oz If the wheel requires an excess bal ance 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 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 Left Side E Right Side F 6J04074BS1 C 6J0
112. 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 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 07 0 14 mm 0 0028 0 0055 in Inlet 0 02 0 08 mm 0 0008 0 0032 in Service Limit Exhaust 0 27 mm 0 0106 in Inlet 0 22 mm 0 0087 in GE15046BS1 GE15007BS2 C ENGINE END 5 31 Valves Valve Seat Inspection Remove the valve see Valve Removal Check the valve seating surface A between the valve 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 Exhaus
113. 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 Clean the bolts nuts and connecting rods in a well ventilated area and take care that there is no spark or flame anywhere near the working area This in cludes any appliance with a pilot light Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents to clean them CAUTION Immediately dry the bolts and nuts with com pressed air after cleaning Clean and dry the bolts and nuts completely 9 20 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods e Install new bolts in reused connecting rods e Dent both bolt head and bolt tip with a punch as shown e Before tightening use a point micrometer A to measure the length of new connecting rod bolts and record the val ues to find the bolt stretch Connecting Rod B Mark here with a punch C Nuts D Fit micrometer pins into punch marks E e Apply a small amount of molybdenum disulfide oil solution to the following Threads of Nuts and Bolts Seating Surfaces of Nuts and Con rods e Tighten the big end nuts until the
114. column 4 Install the shim specified where the lines intersect This shim will give the proper clearance Example Present shim is 2 95 mm Measured clearance is 0 47 mm Replace 2 95 mm shim with 3 15 mm shim 5 Remeasure the valve clearance and readjust if necessary 2 26 PERIODIC MAINTENANCE Periodic Maintenance Procedures Clutch Clutch Operation Inspection e Pull the clutch lever just enough to take up the free play A e Measure the gap between the lever and the lever holder xIf the gap is too wide the clutch may not release fully If the gap is too narrow the clutch may not engage fully In either case adjust it Clutch Lever Free Play Standard 2 3 mm 0 08 0 12 in A WARNING To avoid a serious burn never touch the engine or exhaust pipe during clutch adjustment Turn the adjuster A so that 5 6 mm 0 20 0 24 in of threads are visible Remove the right center fairing see Center Fairing Re moval in the Frame chapter e Slide the dust cover A at the middle of the clutch cable out of place e Loosen the locknut B at the middle of clutch cable e Turn the adjusting nut C until the free play is correct WARNING sure that the outer cable end at the clutch lever is fully seated in the adjuster at the clutch lever or it could slip into place later creating enough cable play to prevent clutch disengagement After the adjustment tighten the
115. continuity in the lead 2nd step x If there is not the continuity in the lead replace or repair the main harness GL14040BS1 GL14039BS1 C GL14042BS1 12 52 BRAKES Anti Lock System e Do the 2nd step test OConnect the ABS Kawasaki self diagnosis system con nector and ABS hydraulic unit connector OCheck the battery terminal voltage connect the hand tester to the brown terminal of ABS Kawasaki self diagnosis system connector A and ground Special Tool Hand Tester 57001 1394 Battery Terminal Voltage Standard Battery Voltage x lf the battery terminal voltage is not within the specifica tion 3rd step x If the battery terminal voltage correct 4th step e Do the 3rd step test OCharge or replace the battery e Do the 4th step test ORecheck the service code indication erase the service code perform the pre diagnosis inspection 1 and 2 and retrieve the service code xIf the ABS indicator light LED A lit faulty ECU in the ABS hydraulic unit Replace the ABS hydraulic unit x If the ABS indicator light LED A unlit ABS system is normal service code is not stored temporary failure Power Supply Voltage Abnormal Over Voltage Service Code 53 e Do the 1st step test OCheck the battery terminal voltage connect the hand tester to the brown terminal of ABS Kawasaki self diagnosis system connector A and gr
116. cylinder head gasket Replace the gasket with a standard thickness part Cylinder compression Sas leakage around cylinder head Replace damaged gasket and is lower than usable check cylinder head warp range Bad condition of valve seating Repair if necessary Incorrect valve clearance Adjust the valve clearance Incorrect piston cylinder clearance Replace the piston and or cylinder Inspect the cylinder and Piston seizure replace repair the cylinder and or piston as necessary Bad condition of piston ring and or Replace the piston and or the piston ring grooves piston rings Cylinder Head Removal e Remove Exhaust Pipes see Exhaust Pipe 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 Holder Water Hose Water Temperature Sensor Connector Front Camshaft Chain Guide 5 26 ENGINE END Cylinder Head e Firstly remove the M6 cylinder head bolts and M6 cylinder bolts A Secondly remove the 8 bolts e Thirdly remove the M10 nut C e Fourthly remove the M10 bolts D GE14073BS1 Cylinder Head Installation NOTE OThe camshaft cap is machined with the cylinder head so if a new cylinder head is installed use the cap that is supplied with the new head e Install a new cylinder head gasket A and dowel pins B E
117. diagnosis System Connector Front Wheel Rotation Sensor Rear Wheel Rotation Sensor ABS Solenoid Valve Relay ABS Motor Relay Frame Ground 10 Meter Unit 11 Front Brake Switch 12 Water proof Joint C 13 Ignition Fuse 10 A 14 Main Fuse 30 A 15 Battery 12 V 10 Ah 16 Frame Ground 17 Rear Brake Switch 18 Joint Connector 00 10o00 amp oN2o BRAKES 12 31 Anti Lock System Terminal Names Bea 1 RE bx EXP DE 3 3 De Bs DL DOR 9 A h m 5 Ida 1617118192021 22 23 24125 26 21617189 10111 12 113114115 6114007 2 C Ground to Motor Power Supply to ABS Motor Relay Power Supply to ABS Solenoid Valve Relay Ground Front Wheel Rotation Sensor Signal Unused Power Supply to Rear Wheel Rotation Sensor Unused Unused 10 Unused 11 ABS Kawasaki Self diagnosis System Terminal 12 ABS Indicator Light LED 13 Unused 14 Unused 15 Unused 16 Power Supply to Front Wheel Rotation Sensor 17 Unused 18 Power Supply 19 Rear Wheel Rotation Sensor Signal 20 Front Brake Light Switch 21 Rear Brake Light Switch 22 Unused 23 Unused 24 Unused 25 ABS Self diagnosis Terminal 26 Unused 12 32 BRAKES Anti Lock Brake System ABS Servicing Precautions There are a number of important precautions that should be followed servicing the ABS system OThis AB
118. disc x If there is iron or other magnetic deposits B remove the deposits GL14006BS1 C Brake Hose and Pipe Removal Installation e Refer to the Brake Hose and Pipe Replacement in the Periodic Maintenance chapter 12 58 BRAKES Anti Lock Brake System 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 Removal e Remove the seat see Seat Removal in the Frame chap ter e Unlock the hook A to lift up the lid B e Pull out the relay fuse A from the fuse box with needle nose pliers ABS Motor Relay Fuse Removal e Remove the seat see Seat Removal in the Frame chap ter e Unlock the hook A to lift up the lid B e Pull out the relay fuse A from the fuse box with needle nose pliers Fuse Installation e f 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 BRAKES 12 59 Anti Lock System Fuse Inspection e Remove the fuse see ABS Solenoid Valve Relay ABS Motor Relay Fuse Removal e Inspect the fuse element x lf it is blown out replace the fuse Before replacing a blown fuse always check the amperage in the affected circuit If the amperage is equal to or greater than the fuse rating check the wiring and related components for a sho
119. disulfide oil solution to the following Threads A of Nuts and Bolts Seating Surfaces B of Nuts and Con rods 6105040451 First tighten the nuts to the specified torque See the table below e Next tighten the nuts 120 5 OMark A the connecting rod big end caps and nuts so that nuts can be turned 120 B properly Torque Angle Connect 5 5 Bolt ut Assy N m kgf m 16 Use the bolts Attached to 18 1 8 13 0 120 6105040581 New attached to new con rod W N new con rod 20 2 0 14 5 120 Replace the 24 2 4 17 4 120 Ne Used bolts with new ones w 25 2 6 18 8 120 Crankshaft Connecting Rod Cleaning e After removing the connecting rods from the crankshaft clean them with a high flash point solvent Blow the crankshaft oil passages with compressed air to remove any foreign particles or residue that may have accumulated in the passages Connecting Rod Bend Remove the connecting rod big end bearing inserts and reinstall the connecting rod big end cap Select an arbor A of the same diameter as the connect ing rod big end and insert the arbor through the connect ing rod big end Select an arbor of the same diameter as the piston pin and at least 100 mm 3 94 in long and insert the arbor B through the connecting rod small end a surface plate set the big end arbor on V block C e With the con
120. e n eie bae uie ot See aa bugs Inner Fairing Installation eee or battens to aw do oe deco Ave sle Xen rp DEP Side Cover Removal nie cette oer ree ER ere dtt Side Cover Installation pp DEAL COVENS pe TEE e ben e en e re Ed Dee kasd Seat Cover Removal 9 Seat Cover Installation pp F enders Fe e Front Fender Front Fender Installation s eonia 1 erret ie ee tao LA Laeti dn Flap and Rear Fender Rear Removal pp Flap and Rear Fender Rear Installation pp Rear Fender Front Erame INSPeCliONn mvs Ae aes Cen tate on coe Pat at Sidestand Removal e e eee tee eere es Sidestand Installator 5 er tito ee home t os tenetis Frame COVE REC RIETI Frame Gover eee iu ces Frame Cover Installation reae eiit 15 2 FRAME Exploded View x 6002158BW5 C 15 3 Exploded View Torque No Fastener kgf m Remarks 1 Footpeg Stay Bolts 34 3 5 25 2 Sidestand Bolt 44 4 5 33 3 Sidestand Switch Bolt 8 8 0 90 78 in Ib L 4 EX650B Models 5 EX650A Models G Apply grease L Apply a non p
121. end of the hose into a container 12 26 BRAKES Brake Fluid e Bleed the brake line and the caliper ORepeat this operation until no more air can be seen com ing out into the plastic hose 1 Pump the brake lever until it becomes hard and apply the brake and hold it A 2 Quickly open and close B the bleed valve while hold ing the brake applied 3 Release the brake C NOTE OThe fluid level must be checked often during the bleed ing operation and replenished with fresh brake fluid as necessary If the fluid in the reservoir runs completely out any time during bleeding the bleeding operation must be done over again from the beginning since air will have entered the line OTap the brake hose lightly from the caliper to the reser voir for more complete bleeding OFront Brake First bleeding the right caliper then repeat the above steps for the left caliper e Remove the clear plastic hose e Install the diaphragm and reservoir cap e Tighten Torque Front Brake Reservoir Cap Screws 1 0 N m 0 10 kgf m 9 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 t
122. fingers A where the friction plate tangs B hit them x If they are badly worn or if there are groove cuts where the tangs hit replace the housing Also replace the friction plates if their tangs are damaged Clutch Housing Spline Inspection e Visually inspect where the teeth 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 GF06060381 C GF06105BS1 C GF06104BS1 C ENGINE LUBRICATION SYSTEM 7 1 Engine Lubrication System Exploded Engine Oil Flow Chart Specifications Special Tools and Sealant Engine Oil and Oil Filter Oil Level Engine Oil Change Table of Contents Oil Pressure Relief Valve Installation Oil Pressure Relief Valve Inspection pp Oil PUMP Oil Pump Oil Pump Installation Oil Pressure Measurement Oil Pressure Measurement Oil Pressure Switch Oil Pressure Switch Removal Oil Pressure Switch Installation 7 2 7 4 7 6 7 7 7 8 7 8 7 8 7 9 7 9 7 10 7 11 7 11 7 11 7 11 7 12
123. for steering looseness by pushing and pulling the forks x If you feel looseness the steering is too loose NOTE OThe cables and wiring will have some effect on the mo tion of the fork which must be taken into account OBe sure the wires and cables are properly routed OThe bearings must be in good condition and properly lubricated in order for any test to be valid Steering Play Adjustment e Remove Upper Inner Fairings see Upper Inner Fairing Removal in the Frame chapter Handlebar see Handlebar Removal in the Steering chapter Upper Fork Clamp Bolts A Steering Stem Head Bolt Plug B Stem Head Bolt C e Remove the steering stem head D e Bend the claws A of the claw washer straighten e Remove the steering stem locknut B and claw washer C e Adjust the steering Special Tool Steering Stem Nut Wrench A 57001 1100 x If the steering is too tight loosen the stem nut B a fraction of a turn x lf 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 65158131 P PERIODIC MAINTENANCE 2 37 Periodic Maintenance Procedures e Install the claw washer A so that its bent side faces upward and engage the bent claws with the grooves of stem locknut C e Hand tighten the stem locknut until it touches the claw washer Tighten the stem locknut clockwise until the claws are aligned with the grooves rangin
124. from overlooking any keys so always use it Sample Diagnosis Sheet Rider name Registration No license plate No Year of initial registration Model Engine No Frame No Date problem occurred Frequency Weather Mileage L1 Brake lever vibration or noise Phenome L1 Abnor mal brake lever move ment O Indicator O Braking light distance blinks too long non L1 Pedal vibration or noise Engine conditions at problem Road conditions Driving conditions Brake application Other conditions Abnor mal pedal move ment O Indicator light remains lit up At start up O Slippery road Rough surface O Other High speed cornering Driving 10 km h 6 mph or above O Driving below 10 km h 6 mph O When stopping O When turning L1 Gradual Abrupt L1 Large brake lever stroke O Large pedal stroke snow O ABS not O0 ABS working L1 After starting 1 gravel CABS op erating too fre quently works but indicator light doesn t light up 5 000 r min rpm or more O other 12 38 BRAKES Anti Lock Brake System Pre Diagnosis Inspection 1 Check brake fluid level in brake reservoir Replenish brake fluid Check for brake fluid leakage Repair brake line Check brake lever and brake pedal function Repair or replace master cylinder Check brake pad and brake disc Repla
125. fuel is supplied automatically by DFI No spark spark weak Vehicle down sensor DFI coming off Ignition switch not ON Engine stop switch turned OFF Clutch lever not pulled in or gear not in neu tral Battery voltage low 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 trouble 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 APPENDIX 17 47 Troubleshooting Guide Compression low Spark plug loose Cylinder head not sufficient
126. iat e Fuse BK Y PI gt r 2R gt B xx Box EEEE 255555 Relay t 9 Left Switch Housing Horn Button Hazard Button Relay Box Turn Signal Switch Fuse Bax 1 2 E 4 Dimmer Switch 2 1 0xygen Sensor Heater Fuse 10 Lockout Switch 2 Fan Fuse 15 Passing Button 3 Fuse 15 4 Turn Signal Relay Fuse 10 Front Left Turn Signal Light 12V2iW Headlight LO 12 55 Signal Headlight Fuse 10 Taillight Fuse 10 lgnition Fuse 10 Horn Fuse 104 e mo LEFT SWITCH HOUSING CONNECTIONS Horn Button Hazard Button Turn Signal Switch Dimmer Switch Starter Lockout Switch Passing Button Color BK W BK Y Color 0 GY celer R BKBL Y R Y Color Push Push PFF Um Released F Push m Pulled in W2L0226885 C ELECTRICAL SYSTEM 16 21 Wiring Diagram EX650B Models Sub Sub throttle Speed 41760 Sensor Sensor Actuator Nain ghrottle Inlet Air ensor Pressure Sansor z 2 5 5 85 aii act g zs zz 24 sx Water proof Joint D 9 Air Switching Valve T R BL oil Neutral Pressure See Switch Ww fra Sen Inlet Vehicl Water Air ewe Fuel Temperature Temperature 7 e 1 Sensor Injectors Sensor ensor Water procf 3 nkshaft sor Oxygen Sensor eur gen Ei are Zac
127. is drawing current If the battery will accept current decrease the voltage and charge by the standard charging method described on the battery case If the battery will not accept current after 5 min utes replace the battery Battery A Battery Charger B Standard Value C Current starts to flow D e Determine the battery condition after refresh charge ODetermine the condition of the battery left for 30 minutes after completion of the charge by measuring the terminal voltage according to the table below Criteria Judgement 12 0 lower than 12 8 V Charge insufficient Recharge lower than 12 0 V Unserviceable Replace Charge Time h 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 GPO8021BS1 C v B aa ig GPO8022BS1 C ELECTRICAL SYSTEM 16 31 Charging System Alternator Cover Removal e Remove Left Center Fairing see Center Fairing Removal in the Frame chapter Alternator Lead Connector A e Place a suitable container under the alternator cover A and remove the cover bolts B e Pull the alternator cover outside Alternator Cover Installation e Apply silicone sealant to the alternator lead grommet and crankcase halves mating surface A on the front and rear sides of the cover mount Sealant Kawasaki Bond Silicone Sealant 92104 0004 e Check that dowel pins B are in place on the cra
128. kgf m 18 ft lb Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft lb e Check the fluid level in the brake reservoirs Bleed the brake line see Brake Line Bleeding Check the brake for good braking power no brake drag and no fluid leakage A WARNING Do not attempt to drive the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against the disc The brakes will not function on the first appli cation of the lever or pedal if this is not done 12 18 BRAKES Calipers Front Caliper Disassembly e Refer to the Caliper Rubber Parts Replacement in the Pe riodic Maintenance chapter Front Caliper Assembly e Refer to the Caliper Rubber Parts Replacement in the Pe riodic Maintenance chapter Rear Caliper Disassembly e Refer to the Caliper Rubber Parts Replacement in the Pe riodic Maintenance chapter Rear Caliper Assembly e Refer to the Caliper Rubber Parts Replacement in the Pe riodic Maintenance chapter Caliper Fluid Seal Damage The fluid seal piston seal A is placed around the pis ton to maintain clearance between the pad and the disc If the seal is in a poor condition it could lead the pad to wear excessively or the brake to drag which may cause the tem perature of the discs or the brake fluid to increase Replace the fluid seal if it exhibits any of the conditions listed below OBrake fluid leakage around the pad OBrakes
129. lead terminal 43 Meter BK Y lead terminal 51 Connections for Stick Coil 2 Meter BK G lead terminal 52 Meter BK Y lead terminal 51 Input Voltage at ECU Standard Battery Voltage 12 8 V or more x If the reading is out of the standard check the wiring see next wiring diagram x If the reading is good the input voltage is normal Crank the engine and check the peak voltage of the stick coils see Stick Coil Primary Peak Voltage in the Electrical Sys tem chapter in order to check the primary coils 80170070651 FUEL SYSTEM DFI 3 69 Stick Coils 1 2 Service Code 51 52 Stick Coil Circuit GC17980BW2 ECU Water proof Joint C Stick Coils Engine Stop Switch Ignition Switch Ignition Fuse 10 A Main Fuse 30 A Battery Frame Ground 10 Joint Connector gt 3 70 FUEL SYSTEM DFI Radiator Fan Relay Service Code 56 Radiator Fan Relay Removal Installation e Radiator fan relay is built in the relay box e Remove the relay box see Relay Box Removal in the Electrical System chapter Radiator Fan Relay Inspection e Refer to the Relay Circuit Inspection in the Electrical Sys tem chapter e Remove the relay box and ECU see ECU Removal Do not disconnect the relay box and ECU connectors Check the wiring for continuity using the following diagram x lf wiring and radiator f
130. light coat of grease on the terminals to prevent corrosion Install the positive cable A first Cover the positive terminal with the cap e Install the negative cable 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 for EX650A B YTX12 BS CAUTION Be sure to use the electrolyte container with the 8 020481 0 same model name as the battery since the elec trolyte volume and specific gravity vary with the battery type This is to prevent overfilling of the electrolyte shorting the battery life and deteriora tion of the battery performance CAUTION Do not remove the aluminum sealing sheet A from the filler ports B until just prior to use Be sure to use the dedicated electrolyte container for correct electrolyte volume e Place the battery on a level surface e Check to see that the sealing sheet has no peeling tears or holes in it e Remove the sealing sheet NOTE OThe battery is vacuum sealed If the sealing sheet has leaked air into the battery it may require a longer initial charge 8 08003851 C 16 26 ELECTRICAL SYSTEM Battery eRemove the electrolyte container from the vinyl bag Detach the strip of caps A from the container and set aside these will be used later
131. locknut and start the en gine and check that the clutch does not slip and that it releases properly Wheels Tires Air Pressure Inspection 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 e Install the air valve cap x Adjust the tire air pressure according to the specifications if necessary 6J05007BS1 Air Pressure when Cold Front Up to 180 kg 397 Ib 225 kPa 2 25 kgf cm 32 psi Rear Up to 180 kg 397 Ib 250 kPa 2 50 kgf cm 36 psi PERIODIC MAINTENANCE 2 27 Periodic Maintenance Procedures Wheel Tire Damage Inspection e Remove any imbedded stones A or other foreign parti cles B from tread e Visually inspect the tire for cracks and cuts and replace the tire if necessary Swelling or high spots indicate inter nal damage requiring tire replacement e Visually inspect the wheel for cracks cuts and dents dam age xf any damage is found replace the wheel if necessary Tire Tread Wear Abnormal Wear Inspection As the tire tread wears down the tire becomes more sus ceptible to puncture and failure An accepted estimate is that 90 of all tire failures occur during the last 1096 of tread life 9096 worn So it is false economy and unsafe to use the tires until they are bald e Measure the tread depth at the cen
132. motor and check to see if the hand oscillates at regular intervals Special Tool Hand Tester 57001 1394 x If the test light doesn t flicker or the tester needle doesn t oscillates check the wiring and connectors again If the wiring is good check the injector voltage If the wiring is good inspect the ECU for its ground and power supply see ECU Power Supply Inspection Injector Resistance Inspection e Remove the fuel tank see Fuel Tank Removal e Remove the air cleaner housing see Air Cleaner Housing Removal e Disconnect the connector from the injector A e Measure the injector resistance with the hand tester B Special Tool Hand Tester 57001 1394 Injector Resistance Connections to Injector Meter Meter 1 WIR BLIR Terminal 2 WIR BL G Terminal Standard About 11 7 12 3 at 20 C 68 F x If the reading is out of the range perform the Injector Unit Test x lf the reading is normal perform the Injector Unit Test for confirmation 6017024381 3 94 FUEL SYSTEM DFI Fuel Injectors Injector Unit Test e Use two leads A and the same test light set B as in Injector Signal Test Rating of Bulb C 12 V x 3 3 4 W 12 V Battery D CAUTION Be sure to connect the bulb in series The bulb works as a Current limiter to protect the solenoid in the injector from excessive current e Connect the test light set to the in
133. out of the range check the wiring see wiring diagram in this section and meter see Electronic Combination Meter Unit Inspection in the Electrical Sys tem chapter x lf the reading is good check the output voltage e Turn the ignition switch OFF 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 OFF GC17158BS1 C 3 58 FUEL SYSTEM Speed Sensor Service Code 24 25 Disconnect the speed sensor connector connect the harness adapter between the harness connector speed sensor connector Connect a digital meter to the harness adapter leads Special Tool Throttle Sensor Setting Adapter 1 57001 1400 Measure the sensor output voltage with the engine stopped and with the connector joined e Turn the ignition switch ON Speed Sensor Output Voltage at Sensor Connections to Adapter Meter Y W sensor LG R lead C Meter gt BK sensor BK Y lead D Standard About 0 05 0 07 V DC NOTE Olf you rotate the engine sprocket the output voltage will be increased GC17144BS1 C x If the reading is out of the range check the speed sensor operation see Speed Sensor Inspection in the Electrical System chapter and the wiring to ECU see wiring dia gram in this section x lf the readin
134. rhe ep aed oie tede deci oce Meade Laune Brie colo psu FE ETT Batten f nate sins Battery REMOVAL Battery Installation 2 e Het RR ete Bot uet eo de lebe Battery etae thes p cents interchange niii ianen Charging Condition Inspection earth teer tte hane Race b in t t enean rites Felreshing bett pe Charging esa cite os Alternator teri gerere hee edv inue ibas eade Alternator Cover Stator Coil Removals Stalor Coll Installations esset desis adam AlternatorRotorRermeva ie aoc Alternator Rotor Installation eoe ape de Alternator Inspection sorser aa Re gs Regulator Rectifier Inspection Charging Voltage Inspection pp
135. see Center Fairing Removal in the Frame chapter e Disconnect Main Throttle Sensor Connector A Fuel Hose Lower End B Vacuum Hose C e Disconnect 1 2 Injector Connector A Subthrottle Sensor Connector B Subthrottle Sensor Actuator Connector C e Loosen Holder and Duct Clamp Bolts 3 98 FUEL SYSTEM DFI Throttle Body Assy e Loosen the locknut and screw in the throttle cable adjuster fully to give the cables plenty of play Remove the right switch housing and take out the acceler ator cable upper end A and the decelerator cable upper end B e Remove the throttle cable lower ends A from the throttle pulley e After removing the throttle body assy stuff pieces of lint free clean cloth into the throttle body holders CAUTION If dirt gets into the engine excessive engine wear and possible engine damage will occur Throttle Body Assy Installation e Install the holder clamp bolts A in the direction shown with each bolt heads B facing outwards e Install the air cleaner duct clamp screws A so that their screw heads B face the right e Run the vacuum hose see Cable Wire and Hose Rout ing section in the Appendix chapter 80170170651 FUEL SYSTEM DFI 3 99 Throttle Body Assy e Fitthe accelerator cable end A and the decelerator cable end B into the throttle pulley e Check fuel leakage from the throttle body assy A WARNING
136. shock to the part can damage it Inlet Air Pressure Sensor Removal e Remove Left Upper Inner Fairing see Upper Inner Fairing Re moval in the Frame chapter e Disconnect the inlet air pressure sensor connector A and the vacuum hose e Pull up the inlet air pressure sensor B Inlet Air Pressure Sensor Installation Install Vacuum Hose Inlet Air Pressure Sensor Inlet Air Pressure Sensor Input Voltage Inspection NOTE OBe sure the battery is fully charged OThe inspection is the same as Input Voltage Inspection of the main throttle sensor 5 e Turn the ignition switch OFF e Remove the ECU see ECU Removal Do not disconnect the ECU connectors e Connect a digital voltmeter A to the connector B with the needle adapter set Special Tool Needle Adapter Set 57001 1457 e Measure the input voltage with the engine stopped and with the connectors joined e Turn the ignition switch ON Inlet Air Pressure Sensor Input Voltage Connections to ECU Meter BL lead terminal 10 Meter BR BK lead terminal 28 Standard 4 75 5 25 V DC x If the reading is within the standard range check the sen sor output voltage x If the reading is less than the standard range remove the ECU and check the wiring between these connectors xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection 80170010651 3 48
137. standard remove the ECU and check the wiring between these connectors ODisconnect the ECU and sensor connectors Wiring Connection ECU Connector A Throttle Sensor Connector B BL lead ECU terminal 10 BR BK lead ECU terminal 28 8017998852 x lf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection FUEL SYSTEM DFI 3 45 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 Note the following e Disconnect the main throttle sensor connector and con nect the harness adapter A between these connectors Special Tool Throttle Sensor Harness Adapter 57001 1538 e Start the engine and warm it up thoroughly e Check idle speed to ensure the throttle opening is correct Idle Speed Standard 1 300 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 off the ignition switch e Measure the output voltage of the sensor with the engine stopped and with the connector joined e Turn the ignition switch ON Main Throttle Sensor Output Voltage Connections to Adapter Meter R sensor Y W lead Meter W sensor BR BK lead Standard 1 073 1 077 V DC at idle throttle opening 4 29 4 49 V DC at full th
138. tensioner so that the stopper faces upward e Tighten the tensioner mounting bolts A Torque Camshaft Chain Tensioner Mounting Bolts 9 8 N m 1 0 kgf m 87 in Ib e Install the spring and washer e Tighten the cap bolt B Torque Camshaft Chain Tensioner Cap Bolt 20 N m 2 0 kgf m 15 ft lb Turn the crankshaft 2 turns clockwise to allow the ten sioner to expand and recheck the camshaft chain timing nips ar e ENGINE END 5 19 Camshaft Camshaft Chain Camshaft Removal e Remove Cylinder Head Cover see Cylinder Head Cover Re moval Right Lower Fairing see Lower Fairing Removal in the Frame chapter e Position the crankshaft as follows ORemove the upper A and lower B caps on the clutch cover OUsing a wrench on the crankshaft rotation bolt turn the crankshaft clockwise until the 2 T mark line A on the tim ing rotor is aligned with the notch B in the edge of the upper hole C in the clutch cover GE11186BS1 C e Remove Camshaft Chain Tensioner see Camshaft Chain Ten sioner Removal Camshaft Cap Bolts A Camshaft Caps B Camshafts C CAUTION The crankshaft may be turned while the camshafts are removed Always pull the chain taut while turn ing the crankshaft This avoids kinking the chain on the lower crankshaft sprocket A kinked chain could damage both the chain and the sprocket Camshaft Installation e Be sure to install the fol
139. the cylinder unit A washer and the spring B from the inner tube Remove the following from the top of the outer tube Dust Seal A Retaining Ring B e 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 13 12 SUSPENSION Front Fork eRemove the following from the inner tube Inner Guide Bushing Outer Guide Bushing B Washer Oil Seal 8 04117851 C Remove the cylinder base A from the bottom of the outer tube Front Fork Assembly Check the top plug O ring and replace it with a new one Replace the following parts with new ones Retaining Ring A Dust Seal B Oil Seal C Inner Guide Bushing D Outer Guide Bushing E Fork Bottom Allen Bolt Gasket F e Install the guide bushing on the end of the inner tube e Insert the cylinder unit and the spring into the inner tube and install the cylinder base A onto the cylinder end B that protrudes from the bottom Olnstall the cylinder base starting with its stepped end e Insert the inner tube cylinder unit washer spring and cylinder base as a set into the outer tube e Install the guide bushing into the outer tube e After installing the washer install the oil seal A by using the fork oil seal driver B Special Tool Fork Oil Seal Driver 541 57001 1288 e Install the
140. the ignition switch OFF to stop the indicator light When the FI indicator light LED goes on and the motor cycle is brought in for repair check the service codes When the repair has been done the light LED doesn t go on But the service codes stored in memory are not erased to preserve the problem history and the light LED can display the codes in the self diagnosis mode The problem history is referred when solving unstable problems When the motorcycle is down the vehicle down sensor is turned OFF and the ECU shuts off the fuel injectors and ignition system The FI indicator light LED blinks but the service code cannot be displayed The ignition switch is left ON If the starter button is pushed the electric starter turns but the engine doesn t start To start the engine again raise the motorcycle turn the ignition switch OFF and then ON The vehicle down sensor is turned ON and the light LED goes OFF 80171220651 FUEL SYSTEM DFI 3 23 Troubleshooting the DFI System 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 CAUTION Insert the needle adapter straight along the terminal in the connector to prevent short circuit between terminals Make sure that measuring p
141. 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 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 If an abnormality is found replace the affected ABS part GL14010BS2 C 12 36 BRAKES Anti Lock Brake System 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 Final inspection OK GLI4011B F BRAKES 12 37 Anti Lock Brake System 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
142. the one rotation of the engine sprocket The gear position is decided by the signal of the speed sensor Vehicle down Sensor Output Voltage signal Vd 0 65 V 4 45 V If the speed sensor system fails no signal wiring short or open the speedometer shows 0 and the ECU sets the top 6 gear position If the vehicle down sensor system has failures the output voltage Vd is more than usable range wiring open the ECU shuts off the fuel pump the fuel injectors and the ignition system 33 Subthrottle Sensor Oxygen Sensor Europe Models Subthrottle Sensor 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 actuator locks sub throttle valve at full open position If the oxygen sensor is not activated the ECU stops oxygen sensor feedback mode FUEL SYSTEM 3 43 Self Diagnosis Service Codes Parts Stick Coil 1 Ignition Coil Output Signal Usable Range or Criteria The stick coil primary winding must send signals output voltage continuously to the ECU Backups by ECU If the ignition primary winding 1 has failures no signal wiring short or open the ECU shuts off the injector 1 to stop fuel to the cylinder 1 though the engine keeps running Stick Coil 2 Ignit
143. the steering cannot be adjusted for smooth action check the steering stem for straightness x If the steering stem A is bent replace the steering stem GNO5054BS1 C Stem Cap Deterioration Damage Replace the stem cap if its oil seal A shows damage 14 10 STEERING Handlebar Handlebar Removal e Remove Clutch Lever Assembly A Left Switch Housing B Left Handlebar Weight C e Remove Front Brake Master Cylinder A see Front Master Cylin der Removal in the Brakes chapter Right Switch Housing B Right Handlebar Weight C Throttle Grip D e Remove the handlebar holder bolts A e Remove the handlebar holder B and then pull out the handlebar Handlebar Installation e Align the punch mark A on the handlebar and the corner edge B on the stem head e Tighten the front holder bolts first and then the rear holder bolts There will be a gap A at the rear part of the han dlebar holder after tightening Torque Handlebar Holder Bolts 25 N m 2 5 kgf m 18 ft Ib STEERING 14 11 Handlebar Install the clutch lever see Clutch Lever Installation in the Clutch chapter e Apply adhesive cement to the inside of the left handlebar grip e Apply a non permanent locking agent to the left handlebar weight bolt e Install the left switch housing OFit the projection A into a small hole B in the handlebar Torque Left Switch Housing Screws 3 5 N m 0 36 kgf m 31
144. to Pump Connectors Tester W R Lead Tester BK Y Lead Operating Voltage at Pump Connector Standard Battery Voltage 12 8 V or more for 3 seconds and then 0 V xIf the reading stays on battery voltage and never shows 0 V Check the ECU and fuel pump relay the voltage is in specification but the pump doesn t work replace the pump see Fuel Pump Removal Instal lation x lf there is still no battery voltage check the pump relay see Relay Box section in the Electrical System chapter Pressure Regulator Removal OThe pressure regulator A is built into the fuel pump B and cannot be removed Pump Screen Fuel Filter Cleaning OThe fuel filter A is built into the pump and cannot be cleaned or checked x If the fuel filter is suspected of clogging or being damaged replace it with the fuel pump as a set 3 90 FUEL SYSTEM DFI Fuel Pump Fuel Pump Circuit 7 L can MM o8 PARK LENITION IOO j BATTERY OSGIOS BR W GC17984BW2 ECU Water proof Joint C Engine Stop Switch Ignition Switch Ignition Fuse 10 A Fuel Pump Relay Relay Box Main Fuse 30 A Battery Frame Ground Fuel Pump FUEL SYSTEM DFI 3 91 Fuel Injectors Removal Installation e Refer to the Throttle Body Assy Disassembly Assembly Audible Inspection e Start the engine e Apply the tip of a
145. up pressure in the system carefully until the pres sure reaches 141 7 kPa 1 45 kgf cm 20 5 psi CAUTION 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 5 psi e Watch the gauge for at least 6 seconds x If the pressure holds steady the system is all right x lf the pressure drops and no external source is found check for internal leaks Droplets in the engine oil indicate internal leakage Check the cylinder head gasket and the water pump e Remove the pressure tester replenish the coolant and install the radiator cap 9005018851 C COOLING SYSTEM 4 9 Coolant Cooling System Flushing Over a period of time the cooling system accumulates rust scale and lime in the water jacket and radiator When this accumulation is suspected or observed flush the cool ing system If this accumulation is not removed it will clog up the water passage and considerable reduce the effi ciency of the cooling system e Drain the cooling system see Coolant Change in the Pe riodic Maintenance chapter e Fill the cooling system with fresh water mixed with a flush ing compound CAUTION Do notuse a flushing compound which is harmful to the aluminum engine and radiator Carefully follow the instructions supplied by the manufacturer of the cleaning product e Warm up the engine and run it at normal oper
146. wiring is deteriorated replace the wiring 6C17045BS1 C 617037381 3 24 FUEL SYSTEM DFI Troubleshooting the DFI System e Pull each connector A apart and inspect it for corrosion dirt and damage x If the connector is corroded or dirty clean it carefully If it is damaged replace it Connect the connectors securely e Check the wiring for continuity OUse the wiring diagram to find the ends of the lead which is suspected of being a problem OConnect the hand tester between the ends of the leads OSet the tester to the x 1 range and read the tester x lf the tester does not read 0 Q the lead is defective Re place the lead or the main harness or the sub harness Olf both ends of a harness A are far apart ground B the one end C using a jumper lead D and check the con tinuity between the end E and the ground F This en ables to check a long harness for continuity Ifthe harness is open repair or replace the harness OWhen checking a harness A for short circuit one end B and check the continuity between the other end C and ground D If there is continuity the harness has a short circuit to ground and it must be repaired or re placed e Narrow down suspicious locations by repeating the con tinuity tests from the ECU connectors If no abnormality is found the wiring or connectors the DFI parts are the next likely suspects Check the part star
147. 0 2 75 2 90 2 95 3 00 3 05 3 10 3 15 3 20 3 25 3 30 3 35 3 40 2 45 3 50 0 33 0 37 2 65 2 10 2 75 2 80 2 90 2 95 3 00 3 05 ER 3 20 3 25 3 30 2 50 0 38 0 42 2 10 2 75 2 80 2 85 3 00 3 05 3 10 3 25 3 30 3 35 ERE 0 48 0 52 HL zs Las a 3 25 3 3 50 5 0 57 2 85 2 90 2 951 3 00 3 05 3 10 3 15 3 20 3 25 3 30 3 35 3 40 3 45 0 58 0 62 2 90 2 95 3 00 2 95 3 00 3 05 0 63 0 67 0 68 0 72 0 73 0 77 3 5 3 10 3 15 3 20 3 25 0 83 0 87 3 15 3 20 3 25 0 88 0 92 0 93 0 97 3 25 3 30 3 35 3 46 3 45 0 98 1 02 3 30 3 35 3 40 3 45 3 50 1 08 1 12 3 40 3 45 3 50 1 13 1 17 3 45 3 50 1 18 1 22 3 50 das oe 3 50 b INSTALL THE SHIM OF THIS THICKNESS 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 Install the shim specified where the lines intersect This shim will give the proper clearance Example Present shim is 2 95 mm Measured clearance is 0 45 mm Replace 2 95 mm shim with 3 20 mm shim 5 Remeasure the valve clearance and readjust if necessary PERIODIC MAINTENANCE 2 25 Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE EXHAUST Pert No 92180 nois
148. 001 221 57001 1123 875702215 8 75711235 C Valve Spring Compressor Assembly Valve Seat Cutter Holder Bar 57001 241 57001 1128 7T5702418T C ST571128ST C Valve Seat Cutter 45 535 Valve Seat Cutter 45 530 57001 1116 57001 1187 T5711168T C ST571187ST C Valve Seat Cutter 32 030 Valve Seat Cutter 55 535 57001 1120 57001 1247 7571120ST C 875712475 6 Valve Seat Cutter 32 535 Valve Spring Compressor Adapter 21 57001 1121 57001 1272 ST5711218T C 75712728T C ENGINE END 5 13 Special Tools Sealant Compression Gauge Adapter M10 x 1 0 Piston Pin Puller 57001 1317 57001 1568 ST5713178T C Valve Seat Cutter Holder 4 5 Piston Pin Puller Adapter C 57001 1330 57001 1657 1571330 C Valve Guide Arbor 4 5 Kawasaki Bond Silicone Sealant 57001 1331 92104 0004 875716575 875713315 C 879200045 Valve Guide 4 5 57001 1333 7571333ST C 5 14 ENGINE END Clean Air System Air Suction Valve Removal e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Air Cleaner Housing see Air Cleaner Housing Removal the Fuel System DFI chapter Air Switching Valve with Hoses see Air Switching Valve Removal Air Suction Valve Cover Bolts A and Clamp Air Suction Valve Cover B Air Suction Valve C Air Suction Valve Installa
149. 073 1 077 V DC between Y W and BR BK leads 4 29 4 49 V DC between Y W and BR BK leads 4 6 4 75 5 25 V DC between BL BR BK leads 3 80 4 20 V DC at standard atmospheric pressure see this text for details 5 4 6 6 KQ at 0 C 32 F 0 29 0 39 kQ 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 9 11 V DC at Ignition Switch ON About 0 05 0 07 V DC at Ignition Switch ON and 0 km h Magnetic flux detection method more than 60 70 for each bank FUEL SYSTEM 3 17 Specifications Item Standard Output Voltage Subthrottle Sensor Input Voltage Output Voltage at Idle Throttle Opening Output Voltage at Full Throttle Opening Resistance Subthrottle Valve Actuator Resistance Input Voltage Oxygen Sensor Europe Models Output Voltage Rich Output Voltage Lean Heater Resistance Throttle Grip and Cables with the sensor tilted 60 70 or more 0 65 1 35 V with sensor arrow mark pointed up 3 55 4 45 V Non adjustable and non removal 4 75 5 25 V DC between BL and BR BK leads 0 4 0 6 V DC between BL W and BR BK leads 3 625 3 775 V DC between BL W and BR BK leads 4 6 About 5 5 7 50 About 8 5 10 5 V DC 0 7 V or more 0 2 V or less 11 7 14 5 O at 20 C 68 F Throttle Grip Free Play 2 3 mm 0 08 0 12 in 3 18 FUEL SYSTEM Special Tools
150. 0851 ENGINE LUBRICATION SYSTEM 7 9 Oil Pan Oil Pan Removal e Remove Engine Oil Drain see Engine Oil Change in the Periodic Maintenance chapter Exhaust Pipe see Exhaust Pipe Removal in the Engine Top End chapter Muffler Body see Muffler Body Removal in the Engine Top End chapter Oil Pan Bolts A Oil Pan B Gasket C Damper D Remove the following from the oil pan 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 Oil Pressure Relief Valve E 7 10 ENGINE LUBRICATION SYSTEM Oil Pan Oil Pan Installation e Apply grease to the O rings on the oil pipes A e Install the oil pipe plate B so that its guide portion C fits the breather pipe D as shown e Apply a non permanent locking agent to the oil pipe plate bolt Torque Oil Pipe Plate Bolt E 9 8 N m 1 0 kgf m 87 in Ib x If the oil pressure relief valve F was removed install it OApply a non permanent locking agent to the threads G of the oil pressure relief valve and tighten it CAUTION Do not apply too much non permanent locking agent to the threads This may block the oil pas sage Torque Oil Pressure Relief Valve 15 1 5 kgf m 11 ft lb e Apply grease to the O ring A on the oil screen B and install it on the lower cr
151. 1 PERIODIC MAINTENANCE 2 31 Periodic Maintenance Procedures Drive Chain Wear Inspection e Remove Chain Cover see Swingarm Removal in the Suspension chapter Rotate the rear wheel to inspect the drive chain for dam aged rollers and loose pins and links x lf there is any irregularity replace the drive chain x Lubricate the drive chain if it appears dry e Stretch the chain taut by hanging 98 10 kg 20 Ib weight A on the chain peace Measure the length of 20 links on the straight part of the chain from the pin center of the 1st pin to the pin center of the 21st pin Since the chain may wear unevenly take measurements at several places x If any measurements exceed the service limit replace the chain Also replace the front and rear sprockets when the drive chain is replaced Drive Chain 20 link Length Standard 317 5 318 2 mm 12 50 12 53 in Service Limit 323 mm 12 7 in A WARNING If the drive chain wear exceeds the service limit re place the chain or an unsafe riding condition may result A chain that breaks or jumps off the sprock ets could snag on the engine sprocket or lock the rear wheel severely damaging the motorcycle and causing it to go out of control For safely use only the standard chain It is an end less type and should not be cut for installation Standard Chain Make ENUMA Type EK520MVXL1 Link 114 links Chain Guide I
152. 1 Camshaft cam worn Inspect and replace see chapter 5 Air switching valve trouble Inspect and replace see chapter 5 Air suction valve trouble Inspect and replace see chapter 5 Catalytic converters melt down due to muffler Replace muffler see chapter 5 overheating Inspect and replace see chapter 5 Inspect and replace see chapter 5 Replace see chapter 5 Valve guide worn Replace the guide see chapter 5 Engine oil level too high Repair see chapter 7 Black smoke Air cleaner clogged Clean see chapter 3 Too high fuel pressure Inspect see chapter 3 Injector stuck open Inspect see chapter 3 Water temperature sensor trouble Inspect and replace see chapter 3 Inlet air temperature sensor trouble Inspect and replace see chapter 3 Brown smoke Air cleaner duct loose Reinstall see chapter 3 Air cleaner O ring damaged Replace see chapter 3 Too low fuel pressure Inspect fuel line and fuel pump see chapter 3 Water temperature sensor trouble Inspect and replace see chapter 3 Inlet air temperature sensor trouble Inspect and replace see chapter 3 FUEL SYSTEM DFI 3 37 Self Diagnosis Self diagnosis Outline Self diagnosis Outline The self diagnosis system has three modes and can be switched to another mode by grounding the self diagnosis terminal User Mode The ECU notifies the rider of troubles in DFI system and ign
153. 1 5 41 5 42 5 42 5 42 5 43 ENGINE END 5 3 Exploded View Dummy Page 5 4 ENGINE END Exploded View ENGINE END 5 5 Exploded View No Fastener Remarks Nm kgf m ft Ib 1 Air Suction Valve Cover Bolts 9 8 1 0 87 2 Cylinder Head Cover Bolts 9 8 1 0 87 3 Camshaft Cap Bolts 12 1 2 106 in Ib S 4 Cylinder Head Bolts M10 New Bolts 54 5 5 40 MO S Cylinder Head Bolts M10 Used Bolts 49 5 0 36 MO S 5 Oylinder Head Bolts M6 12 1 2 106 in Ib S 6 Throttle Body Holder Bolts 12 1 2 106 in Ib 7 Rear Camshaft Chain Guide Bolts 20 2 0 15 L 8 Camshaft Chain Tensioner Mounting Bolts 9 8 1 0 87 in lb 9 Camshaft Chain Tensioner Cap Bolt 20 2 0 15 10 Spark Plugs E E 11 11 Camshaft Sprocket Bolts Baffle Plate Bolts 0 x 52 in lb L Apply a non permanent locking agent M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts S Follow the specified tightening sequence SS Apply silicone sealant 5 6 ENGINE END Exploded View ENGINE END 5 7 Exploded View No Fastener Remarks N m kgf m ft Ib 1 Cylinder Bolt M8 27 5 2 8 20 MO S 2 Cylinder Nut M10 49 5 0 36 MO S 3 Cylinder Bolts M6 12 1 2 106 in Ib S
154. 1016 1018 1020 1022 1024 1076 1028 1032 1034 1036 1038 1040 1042 1044 1046 1048 1050 1052 los sol ss eol es 70 75 so ss sof 95 00 20 25 sol MARK 75 80 85 90 THICKNESS wm 2 50 2 55 2 60 2 65 2 701 2 75 2 80 2 85 2 90 2 95 3 00 3 05 3 10 3 15 2 50 2 55 2 60 2 65 2 70 2 8 2 80 2 86 2 90 2 95 2 00 3 15 2 60 2 65 2 70 2 75 2 80 3 00 2 95 3 00 3 o5 3 10 15 3 20 3 25 3 30 3 35 3 40 45 3 50 EE oa 4 05 3 35 3 40 3 45 3 50 FE 0 50 0 54 2 75 2 80 2 85 2 90 2 95 3 00 2 05 2 10 3 15 3 20 25 3 30 3 35 3 40 3 45 3 50 50 55 0 59 2 80 2 85 2 90 2 95 3 00 2 05 3 10 EET 2 0 64 2 85 2 90 2 95 3 00 3 05 3 10 3 15 3 20 3 25 3 30 3 35 3 40 3 45 3 50 4 3 45 a 3 50 25 3 30 3 35 3 40 3 45 50 ose 3 05 3 10 3 15 3 20 3 25 3 30 3 35 3 40 3 46 2 50 loss 0 89 3 10 3 15 3 20 3 25 3 20 3 35 2 40 3 45 3 50 9 0 90 0 94 3 15 3 20 3 25 3 30 3 35 3 40 45 3 50 INSTALL THE SHIM OF THIS THICKNESS ma 0 95 0 90 3 20 3 25 3 30 3 35 3 40 3 45 2 50 3 25 45 3 50 1 00 1 04 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
155. 15 Air Switching Valve Unit Test 2 5 oa Pe Pet sd 5 15 Clean Air System Hose Inspection 1 1 2 4 1 0 46 5 15 Cylinder Head Cover is doe eroe eene 5 16 Cylinder Head Cover Removal esee nennt teen hh nnn nan nenne nins 5 16 Cylinder Head Cover Installation oie retire eter tenete fas reat ete Pere nd lore 5 16 Camshaft Chain 5 18 Camshaft Chain Tensioner Removal pp 5 18 Camshaft Chain Tensioner Installation pp 5 18 Camshaft Camshaft Chain Nt 5 19 Camshaft 5 19 Camshaft Installation 5 19 Camshaft and Sprocket Assembly pp 5 22 Camshaft Camshaft Cap Wear 4 5 22 Camshaft ter Re e eerte tdem a de eet ds 5 23 Gam Wear ek lem RE cut peg dan FED Mete rk de banned dE D e ten bra a dta 5 23 Camshaft Chain Rermoval iiir extre evt reta Pe br t rrr pp ad 5 23 Oylinder Ra eee ee e eer es LC eee 5 24 Cylinder Compression 001 0 10 5 24 Cylinder Mead Removal 5 25 Cylinder Head Installation 5 26 Cylinder Head aa ea taata AAA Soat eH tag 5 28 Vales eere tio n Ho a A
156. 17386BS1 locked Trip A B Meter Check e Check the trip A or B meters with the speedometer in the same way x If value indicated in the trip A B meters is not added re place the meter assembly e Check that when the RESET button is pushed for more than two seconds the figure display turns to 0 0 x If the figure display does not indicate 0 0 replace the me ter assembly GP17387BS1 o Tachometer Check e Connect the 12 V battery and terminals in the same man ner as specified in the Liquid Crystal Display LCD Seg ments Check e The revolutions per minute rpm equivalent to the input frequency is indicated in the oscillator A if the square wave illustrated as shown would be input into the termi nal 7 Olndicates approximately 6 000 rpm in case the input fre quency would be approximately 200 Hz BEN RE s DUTY 50 OV GP17388BS1 o e If the oscillator is not available the tachometer can be checked as follows OConnect the 12 V battery and terminals in the same man ner as specified in the Liquid Crystal Display LCD Seg ments Check OUsing an auxiliary wire quick open and connect the ter minal 1 to the terminal 7 repeatedly OThen the tachometer needle A should flick B x If the needle does not flick replace the meter assembly GP17389BS1 C ELECTRICAL SYSTEM 16 69 Meter Gauge Indicator Unit Indicator Lights Inspection eC
157. 2 24 Tester Connection Tester Reading E 7 6 Main Relay 15 Note 7 8 eo Fuel Pump Relay 9 10 Nora Starter Circuit Relay EO 11 12 a _ 18 19 Not The actual reading varies with the hand tester used 16 78 ELECTRICAL SYSTEM Relay Box Relay Circuit Inspection with the battery connected Battery Tester Tester Connection Reading O 2 11 1 3 0 ECU Main Relay 0 Fuel Pump Relay 0 Fan Relay 18 19 17 20 0 Battery Tester Connection Tester Connection DC 25 V Range Reading V 9 Doe Starter Battery Circuit Relay ele Me Voltage Apply positive lead Apply negative lead Diode Circuit Inspection e Remove the relay box see Relay Box Removal e Check conductivity of the following pairs of terminals see Relay Box Internal Circuit in this section Diode Circuit Inspection 1 11 2 11 12 13 12 15 12 16 13 14 Tester Connection 13 15 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 ELECTRICAL SYSTEM 16 79 Relay Box Relay Box I
158. 4088BS1 C WHEELS TIRES 10 13 Tires Air Pressure Inspection Adjustment e 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 Wheel see Front Rear Wheel Removal Valve Core Let out the air To maintain wheel balance mark the valve stem position on the tire with chalk so that the tire can be reinstalled in the same position Chalk Mark or Yellow Mark A Air Valve B Align C Lubricate the tire beads and rim flanges on both sides with a soap and water solution or rubber lubricant This helps the tire beads slip off the rim flanges CAUTION Never lubricate with engine oil or petroleum distil lates because they will deteriorate the tire e Remove the tire from the rim using a suitable commer cially available tire changer NOTE OThe tires cannot be removed with hand tools because they fit the rims too tightly Tire Installation A WARNING Use the same manufacturer s tires on both front and rear wheels e Inspect the rim and tire and replace them if necessary e Clean the sealing surfaces of the rim and tire and smooth the sealing surfaces of the rim with a fine emery cloth if necessary e Remove the air valve and discard it CAUTION Replace the air valve whenever the tire is replaced Do not reuse the air valve
159. 57001 1394 Regulator Rectifier Inspection EX650A Models e Remove Bolts A e Disconnect the connector A Remove the regulator rectifier EX650B Models e Remove the bolts A e Disconnect the connector B e Remove the regulator rectifier C 16 36 ELECTRICAL SYSTEM Charging System Rectifier Circuit Check Check conductivity of the following pair of terminals W BL BK Y Rectifier Circuit Inspection W BL BK1 WIBL BK2 W BL BK3 Tester connection BK Y BK1 BK Y BK2 BK Y BK3 The resistance should be low 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 BK1 BK2 BK3 GP09143BS1 C NOTE OThe actual meter reading varies with the meter used and the individual rectifier but generally speaking the lower reading should be from zero to one half the scale Regulator Circuit Check To test the regulator out of circuit use three 12 V batteries and a test light 12 V 3 6 W bulb in a socket with leads CAUTION The test light works as an indicator and also a cur rent limiter to protect the regulator rectifier from ex cessive current Do not use an ammeter instead of a test light e Check to be sure the rectifier circuit is normal before con tinuing e Do the 1st step regulator circuit test OConnect the t
160. 658 e Using the flywheel puller A remove the alternator rotor from the crankshaft Special Tool Flywheel Puller Assembly M38 x 1 5 M35 x 1 5 57001 1405 CAUTION Do not attempt to strike the alternator rotor itself Striking the rotor can cause the magnets to lose their magnetism Alternator Rotor Installation e Using a cleaning fluid clean off any oil or dirt on the fol lowing portions and dry them with a clean cloth Crankshaft Tapered Portion A Alternator Rotor Tapered Portion B e Apply a thin coat of molybdenum disulfide grease to the crankshaft C GP09142BS1 C ELECTRICAL SYSTEM 16 33 Charging System e Install the starter gear and washer e Again clean the crankshaft tapered portion C and dry there e Install the alternator rotor A while turning B it counter clockwise e Install the washer A NOTE OConfirm the alternator rotor fit or not to the crankshaft before tightening it with specified torque e Apply molybdenum disulfide oil solution to the threads and seating surface of the rotor bolt e Install the rotor bolt B and tighten it with 70 N m 7 0 kgf m 52 ft lb of torque Remove the rotor bolt and washer Check the tightening torque with flywheel puller x lf the rotor is not pulled out with 20 N m 2 0 15 ft lb of drawing torque it is installed correctly x If the rotor is pulled out with under 20 N m 2 0
161. 6F Type Swingarm Wheel Travel 125 mm 4 9 in Brake Type Front Dual discs Rear Single disc Electrical Equipment Battery 12 V 10 Ah Headlight Type Semi sealed beam Bulb 12 V 55 W x 2 55 W Hi Lo Tail Brake Light 12 V 5 21 W Alternator Type Three phase AC Rated Output 24 A 14 V 5 000 r min rpm Specifications are subject to change without notice and may not apply to every country GENERAL INFORMATION 1 13 Technical Information Cassette Type Transmission Cassette Type Transmission The transmission of the current model is unable to be removed without disassembling upper and lower crankcase halves The EX650A B enables transmission to be removed from the right side of engine as an assy without disassembling crankcase halves see Transmission Assy Removal in the Crankshaft Transmission chapter Transmission Assy Drive Shaft A Output Shaft B Shift Rods C Shift Dram D Shift Forks E Transmission Case F 62061778 5 1 14 GENERAL INFORMATION Technical Information Inlet Air Pressure Sensor Atmospheric pressure sensor and camshaft position sensor are not equipped with the EX650A B As a substitute of these sensors above the EX650A B recognizes atmospheric pressure and intake stroke of 1 by the signal of inlet air pressure sensor The ECU detects atmospheric pressure when the ignition is switched ON While the engine is run ning the ECU also presumes atmospheric pressure by anal
162. 7 in Ib e Fill the radiator with coolant see Coolant Change in the Periodic Maintenance chapter Thermostat Inspection e Remove the thermostat and inspect the thermostat valve A at room temperature xIf the valve is open replace the thermostat with new one COOLING SYSTEM 4 17 Thermostat To check valve opening temperature suspend the ther mostat A in a container of water and raise the tempera ture of the water OThe thermostat must be completely submerged and must not touch the container sides or bottom Suspend an ac curate thermometer B in the water so that the heat sen sitive portions C are located in almost the same depth It must not touch the container either x If the measurement is out of the specified range replace the thermostat with a new one Thermostat Valve Opening Temperature 80 5 83 5 C 177 182 F 6009020252 C 4 18 COOLING SYSTEM Hose and Pipes Hose Installation e Install the hoses and pipes being careful to follow bend ing direction Avoid sharp bending kinking flattening or twisting Run the hoses see Cable Wire and Hose Routing sec tion in the Appendix chapter e Install the clamp A as near as possible to the hose end to clear the raised rib of the fitting This will prevent the hoses from working loose OThe clamp screws should be positioned correctly to pre vent the clamps from contacting the other parts
163. 7 12 7 13 7 14 7 14 7 15 7 15 7 15 7 2 ENGINE LUBRICATION SYSTEM Exploded View PS i ay 4 6002073885 C LUBRICATION SYSTEM 7 3 Exploded View Torque No Fastener Nem kaf ft lb Remarks 1 Engine Oil Drain Bolt 30 3 0 22 2 Filter Plate Bolts 9 8 1 0 87 in lb L 3 Oil Filter 17 2 1 75 13 EO R 4 Holder Mounting Bolt 25 2 5 18 L 5 Oil Pan Bolts 12 1 2 106 in Ib 6 Oil Pipe Plate Bolt 9 8 1 0 87 in lb L 7 Oil Pressure Relief Valve 15 1 5 11 L 8 Oil Pressure Switch 15 1 5 11 SS 9 Oil Pump Cover Bolts 9 8 1 0 87 in Ib L 10 Oil Pump Sprocket Bolt 12 1 2 106 in Ib L Lh 11 Passage Plug 20 2 0 15 L 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 Plate Bolts 9 8 1 0 87 in lb L EO Apply engine oil G Apply grease L Apply a non permanent locking agent Lh Left hand threads MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts SS Apply silicone sealant 7 4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart Inlet Camshaft Oil Passage Exhaust Camshaft 2 0il Passage Oil Jet Crankshaft Oil Passagey 011 Filter 011 Pressure Switch Main Oil Passage 011 Screen Feeding 011 Flow Scavenge Pump lt Scavenging 011 Flow 650406078 5
164. 8 in lb e Replace the washers on each side of the hose fitting with new ones e Tighten the brake hose banjo bolt Torque Brake Hose Banjo Bolt 25 N m 2 5 kgf m 18 ft Ib e Bleed the brake line see Brake Line Bleeding e Check the brake for good braking power no brake drag and no fluid leakage 12 22 BRAKES Master Cylinder Rear Master Cylinder Removal e Unscrew the brake hose banjo bolt A on the master cylin der see Brake Hose Removal Installation e Unscrew the master cylinder mounting bolts A e Remove the cotter pin B NOTE OPull off the joint pin while pressing down the brake pedal e Pull off the reservoir hose lower end C and drain the brake fluid into a container e Remove the master cylinder Rear Master Cylinder Installation e Replace the cotter pin A with a new one e Replace the washers on each side of hose fitting with new ones e Tighten the following bolts Torque Rear Master Cylinder Mounting Bolts 25 N m 2 5 kgf m 18 ft Ib Brake Hose Banjo Bolt 25 Nm 2 5 kgf m 18 ft lb Bleed the brake line see Brake Line Bleeding Check the brake for good braking power no brake drag and no fluid leakage Front Master Cylinder Disassembly e Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter Rear Master Cylinder Disassembly e Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance
165. 8851 C e Replace the O ring A on the water pump cover with a new one and grease it COOLING SYSTEM 4 11 Water Pump e Install the water pump cover being careful of the two dowel pins A Torque Water Pump Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib Mechanical Seal Inspection e Visually inspect the mechanical seal x If any one of the parts is damaged replace the mechani cal seal as a unit OThe sealing seat and rubber seal may be removed easily by hand Impeller Sealing Seat Surface A Rubber Seal B Mechanical Seal Diaphragm C Water Pump Housing Disassembly CAUTION Be careful not to damage the sealing surface of the mechanical seal e Take the oil seal A out of the housing B with a hook C GD06087BS1 e Press the mechanical seal A out of the housing with a bearing driver B Special Tool Bearing Driver Set 57001 1129 9006063851 C Water Pump Housing Assembly e Apply high temperature grease A to the new oil seal B e Press the oil seal into the housing with a bearing driver so that the seal surface is flush C with the end of the hole e Press the new mechanical seal into the housing with the oil seal driver D until its flange E touches the surface F of the housing Special Tool Oil Seal Driver 57001 1660 9006066851 C 4 12 COOLING SYSTEM Water Pump Impeller Assembly e Clean the sliding surface of the mechan
166. A on the frame the fuel tank Check that the dampers A are in place on the fuel tank as well xlf the dampers are damaged or deteriorated replace them 3 106 FUEL SYSTEM DFI Fuel Tank e Be sure that the trim seal A is on the fuel tank Reverse Side of Fuel Tank B Side Cover C Approx 17 mm 0 67 in D Front E For California model note the following OTo prevent the gasoline from flowing into or out of the canister hold the separator perpendicular to the ground OConnect the hoses according to the diagram of the sys tem see Cable Wire and Hose Routing section in the Appendix chapter Make sure they do not get pinched or kinked ORoute hoses with a minimum of bending so that the air or vapor will not be obstructed e Insert A the fuel hose joint B straight onto the delivery pipe until the hose joint clicks CAUTION 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 C the joint lock D e Push and pull A the hose joint B back and forth more than two times and make sure it is locked and doesn t come off A WARNING Make sure the hose joint is installed correctly on the delivery pipe by sliding the joint or the fuel could leak x lf it comes off reinstall the hose joint e Connect the fuel pump and the fuel level sensor connec tors and th
167. A into the hole for the banjo bolt to remove the piston A WARNING To avoid serious injury never place your fingers or palm inside the caliper opening If you apply com pressed air into the caliper the piston may crush your hand or fingers Remove the dust seal and fluid seal Remove the bleed valve and rubber NOTE Olf compressed air is not available with the brake hose still attached apply the brake pedal to remove the pis ton The remaining process is as described above Rear Caliper Assembly Clean the caliper parts except for the pads CAUTION For cleaning of the parts use only disc brake fluid isopropyl alcohol or ethyl alcohol e Install the bleed valve and rubber cap Torque Bleed Valve 7 8 0 80 kgf m 69 in Ib 2 56 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Replace the fluid seal A with a new one OApply brake fluid to the fluid seal and install it into the cylinder by hand e Replace the dust seal B with a new one if it is damaged OApply brake fluid to the dust seal and install it into the cylinder by hand e Apply brake fluid to the outside of the piston and push it into the cylinder by hand e Replace the shaft rubber friction boot A and dust cover B if they are damaged e Apply a thin coat of PBC Poly Butyl Cuprysil grease to the caliper holder shafts C and holder holes D PBC is a special high temperature water resist
168. BS1 C 12 34 BRAKES Anti Lock Brake System ABS Troubleshooting Outline When an abnormality in the system occurs the ABS in dicator light LED lights up to alert the rider In addition the nature of the fault is stored in the memory of the ABS hydraulic unit and when in the self diagnosis mode the ser vice code A is indicated by the number of times the 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 program to confirm normal signal output When due to a malfunction the ABS indicator light LED remains lit 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 Even when the ABS is operating normally the ABS indi cator light LED may light up under the conditions listed be low Turn the ignition switch OFF to stop blinking or lighting of the indicator light If the motorcycle runs without erasing the service code the light may light up again OAfter continuous riding on a rough road OWhen the engi
169. Balance Inspection Remove the front and rear wheels see Front Rear Wheel Removal e Support the wheel so that it can be spun freely e Spin the wheel lightly and mark A the wheel at the top when the wheel stops ORepeat this procedure several times If the wheel stops of its own accord in various positions it is well balanced x If the wheel always stops in one position adjust the wheel balance see Balance Adjustment Balance Adjustment e f the wheel always stops in one position provisionally attach a balance weight A on the rim at the marking using adhesive tape e Rotate the wheel 1 4 turn B and see whether or not the wheel stops in this position If it does the correct balance weight is being used x If the wheel rotates and the weight goes up replace the weight with the next heavier size If the wheel rotates and the weight goes down replace the weight with the next lighter size Repeat these steps until the wheel remains at rest after being rotated 1 4 turn e Rotate the wheel another 1 4 turn and then another 1 4 turn to see if the wheel is correctly balanced e Repeat the entire procedure as many times as necessary to achieve correct wheel balance e Permanently install the balance weight Balance Weight Removal e Insert a regular tip screwdrivers A B between the rib C and the weight D as shown e Pry the balance weight with two screwdrivers and remove the balance weight e Discard the used
170. Battery BK Lead Terminal xIf the test light turn on the reserve switch is defective Replace the fuel level sensor e Remove the fuel pump see Fuel Pump Removal in the Fuel System DFI chapter e Connect the test light 12 V 3 4 W bulb in a socket with leads and the 12 V battery to the fuel pump connector as shown 12 V Battery A Test Light B Fuel Pump Connector C Fuel Reserve Switch D x lf the test light doesn t light replace the fuel pump NOTE Olt may take a long time to turn on the test light in case that the fuel reserve switch is inspected just after the fuel pump is removed Leave the fuel reserve switch with leads for inspection connected for few minutes 188215 GP18195BS1 C ELECTRICAL SYSTEM 16 77 Relay Box The relay box A has relays and diodes The relays and diodes can not be removed Relay Box Removal e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Take out the relay box A and disconnect the connectors Relay Circuit Inspection Remove the relay box see Relay Box Removal e Check conductivity of the following numbered terminals by connecting the hand tester and one 12 V battery to the relay box as shown see Relay Box Internal Circuit in this section x If the tester does not read as specified replace the relay box Relay Circuit Inspection with the battery disconnected 22
171. Check the terminal voltage between the orange black and black yellow lead terminals of the meter connector A Special Tool Hand Tester 57001 1394 Terminal Voltage Standard About 9 V x If the terminal voltage is not within the specification 2nd step x If the terminal voltage correct replace the meter assem bly e Do the 2nd step test ODisconnect the ABS hydraulic unit connector and meter connector OCheck for continuity between the orange black lead terminal of the main harness side connector A and orange black lead terminal of the main harness side connector B If there is the continuity in the lead 3rd step x If there is not the continuity in the lead replace or repair the main harness e Do the 3rd step test OCheck the battery terminal voltage see 2nd Step in the Power Supply Voltage Abnormal Under Voltage Ser vice Code 52 xIf the battery terminal voltage correct replace the ABS hydraulic unit GL14004BS1 C GL14004BS1 C GL14043BS1 GL14045BS1 C BRAKES 12 45 Anti Lock Brake System ABS Indicator Light LED Lights When the Motorcycle is Running No Service Code Do the 1st step test OCheck the terminal voltage between the orange black and black yellow lead terminals of the meter connector A Special Tool Hand Tester 57001 1394 Terminal Voltage Standard About 9 12 V xIf the terminal voltage is not within the sp
172. E Remove the engine F ENGINE REMOVAL INSTALLATION 8 7 Engine Removal Installation Engine Installation e Firstly insert the rear engine mounting bolts A from the left side of the engine e Secondly temporally tighten the right engine mounting bracket bolts B and then the right front engine mounting bolt C OPosition the collar D as shown e Thirdly temporally tighten the left engine mounting bracket bolts E and then the left front engine mounting bolt F e Fourthly temporally tighten the rear engine mounting nuts G e Fifthly tighten the rear engine mounting nuts Torque Rear Engine Mounting Nuts 44 N m 4 5 kgf m 32 ft Ib e Sixthly tighten the right engine mounting bracket bolts Torque Engine Mounting Bracket Bolts 25 2 5 18 ft lb e Seventhly tighten the right front engine mounting bolt Torque Front Engine Mounting Bolt 44 N m 4 5 kgf m 32 ft Ib e Eighthly tighten the left engine mounting bracket bolts Torque Engine Mounting Bracket Bolts 25 N m 2 5 kgf m 18 ft lb e astly tighten the left front engine mounting bolt Torque Front Engine Mounting Bolt 44 N m 4 5 kgf m 32 ft lb e Install the engine sprocket see Engine Sprocket Installa tion in the Final Drive chapter e Run the leads cables and hoses correctly see Cable Wire and Hose Routing section in the Appendix chapter e Insta
173. ENGINE LUBRICATION SYSTEM 7 5 Engine Oil Flow Chart Balancer Shaft Drive Shaft Oil Pipe 011 Passage 011 Passage 011 Pipe Output Shaft Oil P 011 Screen Oil Pipe 11 Passage Feed Pump Scavenge Pump h AA X 556590 0il in Transmission Room 7 6 ENGINE LUBRICATION SYSTEM Specifications Standard Engine Oil Type API SE SF or SG API SH SJ or SL with JASO MA Viscosity SAE 10W 40 Capacity 1 7 L 1 8 US gt when filter is not removed 1 9 L 2 0 US gt when filter is removed 2 4 L 2 5 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 F ENGINE LUBRICATION SYSTEM 7 7 Special Tools and Sealant Oil Pressure Gauge 10 kgf cm 57001 164 Oil Filter Wrench 57001 1249 7570164ST C 7571249ST C Oil Pressure Gauge Adapter PT3 8 57001 1233 Kawasaki Bond Silicone Sealant 56019 120 875712335 6 875601205 C 7 8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter A WARNING Motorcycle operation with insufficient deteri orated or contaminated engine oil will cause accelerated wear and may result in engine or trans mission seizure accident and injury Oil Level Inspection e Check that the engine oil level is between the upper A and lower B levels in t
174. FUEL SYSTEM Inlet Air Pressure Sensor Service Code 12 Pv 55 86 cmHg a abs 115 68017035043 ID Idling Ps Standard Atmospheric Pressure Absolute Pv Throttle Vacuum Pressure Absolute ST Standard of Sensor Output Voltage V TO Throttle Full Open UR Usable Range of Sensor Output Voltage V Vv Inlet Air Pressure Sensor Output Voltage V Digital Meter Reading FUEL SYSTEM DFI 3 51 Inlet Air Pressure Sensor Service Code 12 Inlet Air Pressure Sensor Circuit TU 28 d a x a FTTTI n gt 1 Su 3 pe 6C179738W2 C 1 ECU 2 Water proof Joint E 3 Water proof Joint D 4 Inlet Air Pressure Sensor 3 52 FUEL SYSTEM DFI Inlet Air Temperature Sensor Service Code 13 Inlet Air Temperature Sensor Removal Installation CAUTION Never drop the sensor especially on a hard surface Such a shock to the sensor can damage it e Remove the fuel tank see Fuel Tank Removal e Disconnect the connector A from the inlet air tempera ture sensor e Remove the screw B e Pull out the inlet air temperature sensor C e Put the inlet air temperature sensor into the air cleaner housing e Tighten the screw securely Inlet Air Temperature Sensor Output Voltage Inspection NOTE OBe sure the battery is fu
175. Front Rear Tires Air Pressure when Cold Front Rear Tread Depth Front Rear TIR 0 03 mm 0 0012 in or less 10 g 0 35 oz or less 10 g 0 35 oz 20 g 0 71 oz 30g 1 06 oz 17 x 3 50 17 x 4 50 Up to 180 kg 397 Ib load 225 kPa 2 25 kgf cm 32 psi Up to 180 kg 397 Ib load 250 kPa 2 50 kgf cm 36 psi 4 3 mm 0 17 in 7 0 mm 0 28 in TIR 0 2 mm 0 008 in 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 Standard Tires Front Rear Make Type Size BRIDGESTONE BATTLAX BTO20F RADIAL GG BRIDGESTONE BATTLAX BTO20R RADIAL 120 70 ZR17 58 W 160 60 ZR17 M C 69 W A WARNING Use the same manufacturer s tires on both front and rear wheels WHEELS TIRES 10 5 Special Tools Bearing Driver Set Bearing Remover Shaft 13 57001 1129 57001 1377 7571129ST C ST5713778T C Jack Jack Attachment 57001 1238 57001 1608 7571238ST C ST571608ST C Bearing Remover Head 20 x 22 57001 1293 7571293ST C 10 6 WHEELS TIRES Wheels Rims Front Wheel Removal e Remove Brake Caliper Mounting Bolts A Front Brake Calipers B e Loosen Axle Clamp Bolt A Remove the front axle Remove the lower fairings see Lower Fairing Removal the Frame chapter Raise the front wheel off the gro
176. Front Axle Clamp Bolt Rear Axle Nut Final Drive Engine Sprocket Nut 92 MO Rear Axle Nut 80 Rear Sprocket Nuts 44 Speed Sensor Bolt 69 in Ib L Speed Sensor Bracket Bolts 87 in lb Brakes Bleed Valve 7 8 0 80 69 in Ib Brake Hose Banjo Bolts 25 2 5 18 Brake Lever Pivot Bolt 1 0 0 10 9 Lever Pivot Bolt Locknut 5 9 0 60 52 in lb Brake Pedal Bolt 8 8 0 90 78 in Ib Brake Pipe Joint Nuts EX650B Models 18 1 8 13 Front Brake Disc Mounting Bolts 27 2 8 20 L Front Brake Light Switch Screw 1 0 0 10 9 in Ib Front Brake Reservoir Cap Screws 1 0 0 10 9 in Ib Front Caliper Mounting Bolts 34 3 5 25 Front Master Cylinder Clamp Bolts 8 8 0 90 78 in Ib S Rear Brake Disc Mounting Bolts 27 2 8 20 L Rear Caliper Mounting Bolts 25 2 5 18 Rear Master Cylinder Mounting Bolts 25 2 5 18 Rear Master Cylinder Push Rod Locknut 18 1 8 13 Suspension Front Axle Clamp Bolt 34 3 5 25 Front Fork Bottom Allen Bolts 30 3 1 22 L PERIODIC MAINTENANCE 2 9 Torque and Locking Agent Torque Fastener es kgf m ftlb Remarks Front Fork Clamp Bolts Lower 20 2 0 15 AL Front Fork Clamp Bolts Upper 20 2 0 15 Front Fork Top Plugs 25 2 5 18 Rear Shock Absorber Bolt 59 6 0 44 Rear Shock Absorber Nut 59 6 0 44 Swingarm Pivot Shaft Nut 108 11 0 80 Steering Front Fork Clamp Bolts Lower 20 2 0 15 AL Front Fork Clamp Bolts Upper 20 2 0 15 Handlebar Holder Bolts 25 2 5 18 S Left Switch Housing Screws 3 5 0 36 31 in Ib Right Switch
177. Injection KEIHIN TTK38 x 2 Electric starter Battery and coil transistorized Electronically advanced digital igniter From 10 BTDC 91 300 r min rpm to 35 BTDC 4 800 r min rpm CR9EIA 9 Left to right 1 2 1 2 31 BTDC 61 ABDC 272 GENERAL INFORMATION 1 11 General Specifications ltems EX650A6F EX650B6F Exhaust Open 50 Close 30 ATDC Duration 260 Lubrication System Forced lubrication semi dry sump Engine Oil Type API SE SF or SG API SH SJ or SL with JASO MA Viscosity SAE 10W 40 Capacity 2 4 L 2 5 US qt Drive Train Primary Reduction System Type Reduction Ratio Clutch Type Transmission Type Gear Ratios 1st 2nd 3rd 4th 5th 6th Final Drive System Type Reduction Ratio Overall Drive Ratio Gear 2 095 88 42 Wet multi disc 6 speed constant mesh return shift 2 438 1 714 1 333 1 111 0 966 0 852 39 16 36 21 32 24 30 27 28 29 23 27 pe ERU e ta Chain drive 3 067 46 15 5 473 gear Frame Type Caster Rake Angle Trail Front Tire Type Size Rim Size Rear Tire Type Size Rim Size Front Suspension Type Wheel Travel Rear Suspension Tubular diamond 25 106 mm 4 2 in Tubeless 120 70 ZR17 M C 58W 17 x 3 50 Tubeless 160 60 ZR17 M C 69W 17 x 4 50 Telescopic fork 120 mm 4 7 in 1 12 GENERAL INFORMATION General Specifications Items EX650A6F EX650B
178. L SYSTEM 16 61 Air Switching Valve Air Switching Valve Operation Test Remove the fuel tank see Fuel Tank Removal in the Fuel System DFI chapter e Pull the air switching valve hose A out of the air cleaner base e Take the air switching valve hose end outside of the frame e Reinstall the fuel tank see Fuel Tank Installation in the Fuel System DFI chapter e Start the engine and run it at idle speed e Plug A the air switching valve hose B 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 e Apply a soap and water solution or rubber lubricant to the end of the air switching hose and install the hose on the fitting Air Switching Valve Unit Test e Remove the air switching valve see Air Switching Valve Removal in the Engine Top End chapter e Set the hand tester A to the x O range and connect it to the air switching valve terminals as shown Special Tool Hand Tester 57001 1394 Air Switching Valve Resistance Standard 18 22 O at 20 C 68 F x lf the resistance reading is except the specified value re place it with a new one e Connect the 12 V battery A to the air switching valve terminals as shown GE04030BS1 C GE04033BS1 C 16 62 ELECTRICAL SYSTEM Air Switching Valve e Blow the air to the i
179. Leda RR 2 20 Radiator Hose Damage and Installation Condition 2 21 PAU SUCTION do toon sse os 2 21 Air Suction System Damage Inspection pp 2 21 Engine Top End ascend EE 2 21 Valve Clearance Inspection pp 2 21 Valve Clearance Adjustment e m 2 23 iji a TATE AEE E 2 26 Clutch Operation Inspectionm 2 26 MIEMBRO UIS UCM 2 26 Air Pressure 2 26 Wheel Tire Damage Inspection smit 2 27 Tire Tread Wear Abnormal Wear Inspection pt 2 27 Wheel Bearing Damage Inspection 2 28 Drive TAU 2 28 Drive Chain Lubrication Condition 1 2 28 Drive Chain Slack Inspection pp 2 29 Drive Chain Slack Adjustment 2 2 29 Wheel Alignment Inspection pp 2 30 Drive Chain Wear Inspection pp 2 31 Chain Guide Inspectionm nnne nnne ener nn nennen nnns 2 31 Brake Rum 2 32 Brake Fluid Leak Brake Hose and Pipe Inspection 2 32 Brake Hose and Pipe Damage and Installation Condition Inspection 2 32 Brake Operation
180. Lower Fairings see Lower Fairing Removal Center Fairings see Center Fairing Removal Headlight Lead Connectors Rear View Mirror Nuts Both Side A e Remove the upper fairing forward 15 11 Fairings Upper Fairing Disassembly e Remove Headlight A see Headlight Removal Installation in the Electrical System chapter Upper Fairing Assembly e Install the headlight see Headlight Removal Installation in the Electrical System chapter Upper Fairing Installation e Installation is the reverse of removal Upper Inner Fairing Removal e Remove the bolts A e Pull the upper inner fairing B backward and clear the hooks Upper Inner Fairing Installation e Insert the hook A into the slot B e Tighten the bolts Upper Fairing Bracket Removal e Remove Upper Fairing see Upper Fairing Removal Meter Unit see Meter Unit Removal Installation in the Electrical System chapter Clamp A Bolts B Horn Leads C Under Bracket D 15 12 FRAME Fairings e Remove Bolts A Clamps B Upper Fairing Bracket C Inner Fairing Removal e Remove Center Fairings see Center Fairing Removal Mounting Screws A Inner Fairing B Inner Fairing Installation e Tighten the mounting screws Torque Front Turn Signal Light Mounting Screws 1 2 N m 0 12 kgf m 11 in Ib e Install the center fairings see Center Fairing Installation 15 13 Side Covers Side Cov
181. Main Throttle Sensor Input Voltage 1 lt 3 44 Main Throttle Sensor Output Voltage Inspection 3 45 Main Throttle Sensor Resistance Inspection 2 3 46 Inlet Air Pressure Sensor Service Code 12 7 3 47 Inlet Air Pressure Sensor Removal pp 3 47 Inlet Air Pressure Sensor Installation seem 3 47 Inlet Air Pressure Sensor Input Voltage 3 47 Inlet Air Pressure Sensor Output Voltage 3 48 Inlet Air Temperature Sensor Service Code 13 3 52 Inlet Air Temperature Sensor Removal Installation esses 3 52 Inlet Air Temperature Sensor Output Voltage 3 52 Inlet Air Temperature Sensor Resistance Inspection pp 3 53 Water Temperature Sensor Service Code 14 3 54 Water Temperature Sensor Removal Installation pp 3 54 Water Temperature Sensor Output Voltage 3 54 Water Temperature Sensor Resistance 3 55 Crankshaft Sensor Service Code 1 eee trennen nennt 3 56 Crankshaft Sensor Removallnstallationm 3 56 Crankshaft Sensor Inmspectigm
182. N m 2 0 kgf m 15 ft Ib e Install the removed parts see appropriate chapters Front Fork Oil Change O D Remove the front fork see Front Fork Removal c e Remove B i Top Plug A with O ring Collar B AD Fork Spring Seat C Fork Spring D 6M04040281 13 10 SUSPENSION Front Fork e Compress A the fork upside down to draw out the oil into the suitable container C e Pour in the specified amount of oil Fork Oil Viscosity KAYABA KHL34 G10 or equivalent Amount Per Side When changing oil EX650A Models approx 415 mL 14 0 US oz EX650B Models approx 420 mL 14 2 US oz After disassembly and completely dry EX650A Models 489 4 mL 16 5 0 14 US oz EX650B Models 498 3 mL 16 8 0 10 US oz NOTE OMove the outer tube and down a few times to remove the air that is trapped in the fork oil in order to stabilize the oil level Hold the outer tube vertically in a vise and compress the fork completely e Wait until the oil level stabilizes e Use the fork oil level gauge A to measure the distance between the top of the inner tube to the oil level Special Tool Fork Oil Level Gauge 57001 1290 OSet the oil level gauge stopper B so that the distance 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 th
183. ND 5 15 Clean Air System Air Switching Valve Operation Test e Refer to the Air Switching Valve Operation Test in the Electrical System chapter Air Switching Valve Unit Test e Refer to the Air Switching Valve Unit Test in the Electrical System chapter Clean Air System Hose Inspection e Be certain that all the hoses are routed without being flat tened or kinked and are connected correctly to the air cleaner housing air switching valve 1 and 2 throttle body holders and air suction valve covers xIf they are not correct them Replace them if they damaged 5 16 ENGINE END Cylinder Head Cover Cylinder Head Cover Removal e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Air Cleaner Housing see Air Cleaner Housing Removal the Fuel System DFI chapter Air Suction Valve Cover A with Hose B Stick Coils C Baffle Plate D Throttle Cables E Clutch Cable Holder F with Bolt G Cylinder Head Cover Bolts H Cylinder Head Cover I EX650B Models e Remove the radiator with radiator hoses and move it forward see Radiator and Radiator Fan Removal in the Cooling System chapter Cylinder Head Cover Installation e Replace the head cover gasket A with a new one e Apply silicone sealant B to the cylinder head as shown Sealant Kawasaki Bond Silicone Sealant 92104 0004 e Install Dowel Pins C Plug Hole Gaskets D e Install Washers A Cylind
184. NGINE END 5 27 Cylinder Head eApply molybdenum disulfide oil solution 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 the bolts and nut following the tightening sequence 1 8 Torque Cylinder Head Bolts M10 First 25 N m 2 5 kgf m 18 16 Final Used Bolts 49 N m 5 0 kgf m 36 ft Ib New Bolts 54 5 5 kgf m 40 ft lb Cylinder Nut M10 49 N m 5 0 kgf m 36 ft Ib Cylinder Bolt M8 27 5 N m 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 GE 61438W2 C 5 28 ENGINE END Cylinder Head Tighten the M6 cylinder head bolts and M6 cylinder bolts A Torque Cylinder Head Bolts M6 12 N m 1 2 kgf m 106 in Ib Cylinder Bolts M6 12 N m 1 2 kgf m 106 in Ib as ae Wi TO S 7 GE14073BS1 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 removed parts see appropriate chapters
185. NSMISSION Crankcase Splitting e Press and insert A the new needle bearing B for the shift drum until it is bottomed Special Tool Bearing Driver Set 57001 1129 e Press and insert C the new needle bearing D for the shift shaft so that the bearing surface is flush with the end of the hole Special Tool Bearing Driver Set 57001 1129 Lower Crankcase Half E e Apply silicone sealant to the breather plate mating surface A 1 mm 0 04 in or more thick and then install the breather plate Sealant Three Bond TB1207B 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 e Apply a non permanent locking agent to the threads and tighten the bolts A Torque Breather Plate Bolts 9 8 N m 1 0 kgf m 87 in Ib e Install the breather pipe A OAlign the white mark B on the pipe with the white mark C on the breather fittling Olnstall the clamp D so that the pinch portions E face the white marks e Install the oil pipe A so that its flange B touches to the surface C of the upper crankcase half e Apply grease to the O ring D on the oil pipe 9104212851 9104214851 CRANKSHAFT TRANSMISSION 9 13 Crankcase Splitting e Install the crankshaft assembly and the balancer shaft as se
186. OWhen a problem occurs with the ABS system the ABS indicator light LED A is blinks and lights NOTE OUse a fully charged battery when conducting self diagnosis Otherwise the light blinks very slowly or doesn t blink OThe motorcycle is stopped OKeep the self diagnosis terminal grounded during self diagnosis with an auxiliary lead GL14004BS1 12 40 BRAKES Anti Lock Brake System the seat see Seat Removal the Frame chap ter e Ground the self diagnosis terminal A Gray to the bat tery terminal or battery lead connector using lead e Turn on the ignition switch OCount the blinks of the light 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 one second the ABS self diagnosis terminal three times or more within about 12 5 seconds after starting the erase mode OThe ABS indicator light LED remains lit 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
187. Runout 0 15 mm 0 006 in or less 0 3 mm 0 01 in Brake Fluid Grade DOT4 BRAKES 12 13 Special Tools Inside Circlip Pliers 57001 143 Jack 57001 1238 Hand Tester 57001 1394 7570143ST C 7571394ST C Jack Attachment 57001 1608 7571238ST C 7571608ST C 12 14 BRAKES Brake Lever Pedal Brake Lever Position Adjustment The brake lever adjuster has 5 positions so that the brake lever position can be adjusted to suit the operator s hand e Push the lever forward and turn the adjuster A to align the number with the arrow mark B on the lever holder OThe distance from the grip to the lever is minimum at num ber 5 and maximum at number 1 Brake Pedal Position Inspection e Check that the brake pedal A is in the correct position Footpeg B Pedal Position Standard About 40 mm 1 6 in C below top of footpeg x lf it is incorrect adjust the brake pedal position Brake Pedal Position Adjustment NOTE OUsually it is not necessary to adjust the pedal position but always adjust it when the push rod locknut has been loosened e Remove Frame Cover see Frame Cover Removal in the Frame chapter Bolts A Right Footpeg Stay B e Loosen the locknut A and turn the push rod with the hex head B to achieve the correct pedal position x If the length C shown is 70 1 mm 2 76 0 04 in the pedal position will be within the standard range e T
188. S 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 turn the ignition switch ON while any of the ABS electrical connectors are disconnected The ABS hy draulic 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 off the ignition switch 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 not try to disassemble and repair the ABS parts replace it OThe ABS has many brake lines pipes and leads And the ABS cannot
189. Sensor Signal Unused Ground to Sensors Oxygen Sensor Heater Signal Europe Models Crankshaft Sensor Signal Unused External Diagnosis System Signal Unused Ground to ECU Engine Stop Switch Signal Starter Lockout Switch Signal Starter Button Signal Unused Fuel Pump Relay Signal Air Switching Valve Signal Fuel Injector 2 Signal Fuel Injector 1 Signal Stick Coil 1 Signal Sidestand Switch Signal Radiator Fan Relay Signal External Communication Line Mode Switch Tachometer Signal FI Indicator Light LED Ground for Fuel System Ground for Ignition System Stick Coil 2 Signal FUEL SYSTEM 3 15 DFI Parts Location 9 eni 5 DFI NOOR WD 8 9 10 11 Digital Fuel Injection Parts Fl Indicator Light LED Ignition Switch Throttle Body Assy Inlet Air Temperature Sensor Injectors Fuel Pump Relay Box ECU Main Relay Fuel Pump Relay Radiator Fan Relay Fuse Box ECU Fuse 15 A Oxygen Sen sor Heater Fuse 10 A ECU Battery Oxygen Sensor Europe Models 6171190 5 Speed Sensor Neutral Switch Water Temperature Sensor Subthrottle Sensor Main Throttle Sensor Subthrottle Valve Actuator Stick Coils Inlet Air Pressure Sensor Diagnosis Connector Self diagnosis Terminal Air Switching Valve Crankshaft Sensor Vehicle down Sensor
190. Spark Plugs see Spark Plug Replacement in the Peri odic Maintenance chapter Owner s Tool Spark Plug Wrench 16 mm 92110 1132 NOTE OReconnect the connectors of the air switching valve lead and the inlet air temperature sensor lead When the ignition switch is turned ON with the above connec tors disconnected the service codes 13 64 are stores in the ECU e Attach the compression gauge A and adapter B firmly into the spark plug hole OUsing the starter motor turn the engine over with the throt tle fully open until the compression gauge stops rising the compression is the highest reading obtainable Special Tools Compression Gauge 20 kgf cm 57001 221 Compression Gauge Adapter M10 x 1 0 57001 1317 Cylinder Compression Usable Range 961 1 471 kPa 9 8 15 0 kgf cm 139 213 psi at 400 r min rpm e Repeat the measurement for the other cylinders e Install the spark plugs Torque Spark Plugs 15 N m 1 5 kgf m 11 ft Ib ENGINE END 5 25 Cylinder Head OThe following table should be consulted if the obtainable compression reading is not within the us able range Remedy Action Cylinder compression Carbon accumulation on piston and in is higher than usable combustion chamber possibly due to Remove the carbon deposits damaged valve stem oil seal and or and replace damaged parts if damaged piston oil rings This may necessary indicated by white exhaust smoke Incorrect
191. Subthrottle Valve Actuator Inspection Nt Subthrottle Valve Actuator Resistance Inspection Ne Subthrottle Valve Actuator Input Voltage Inspection pp Air Switching Valve Service Code 64 Air Switching Valve Removal Installation pp Air Switching Valve Inspection pp Oxygen Sensor Heater Service Code 67 Europe Oxygen Sensor Heater Removal Installation pp Oxygen Sensor Heater Inspection Oxygen Sensor Incorrect Output Voltage Service Code 94 Europe Models Oxygen Sensor Removal Installation Oxygen Sensor Inspection EUER de e ades o gi Rib Fl Indicator Light LED Inspection 1 4711 1 2 1 41 12 1 44 4 tnnt EGU orsus eset ECU Removal ECU Installation ECU Power Supply Fuel Line Fuel Pressure Inspection pp Fuel Flow Rate Inspection pp Fuel Pump Fuel Pump Removal viet eee Qu tede vere tec rri ieee Fuel Pump Installatlon uite HE d ede UO en TEE Ue TERR D RR Fuel Pump Operation Inspection pp Fuel Pump Operating Voltage Inspection pp Pressure Regulator Removal Pump Screen Fuel Filter Cleaning pp Fuel Injectors
192. UTION VS Be sure to disconnect the negative cable first as e Measure the battery terminal voltage NOTE OMeasure with a digital voltmeter which be read one decimal place voltage x lf the reading is 12 8 V or more no refresh charge is re quired however if the read is below the specified refresh charge is required Battery Terminal Voltage Standard 12 8 V or more Terminal Voltage V A Battery Charge Rate B Good C Refresh charge is required D Refreshing Charge Remove the battery A see Battery Removal Do refresh charge by following method according to the battery terminal voltage A WARNING This battery is sealed type Never remove sealing cap B even at charging Never add water Charge with current and time as stated below 8 09001251 16 30 ELECTRICAL SYSTEM Battery Terminal Voltage 11 5 less than 12 8 V Standard Charge 1 2 A x 5 10 h see following chart Quick Charge 1 CAUTION If possible do not quick charge If quick charge is done unavoidably do standard charge later on Terminal Voltage less than 11 5 V Charging Method 1 2Ax20h NOTE Olncrease the charging voltage to a maximum voltage of 25 V if the battery will not accept current initially Charge forno more than 5 minutes at the increased voltage then check if the battery
193. Unit 11 LEB Light Emitting Diode Alternator Spark TI Plugs TT 111 DO R Y a o BK BK Water proof Joint C ml Frame trouna 9 lluminstion Light LEB Water proof Joint ge Water proof Joint B Front Right ey Turn Signal BK Y Light 12V2iW Right City BR Light 12V5W BK Y BK Y R BK Headlight HI BK Y 12V55W Headlight 10 BK Y 12V55N Relay io tte ont L Front Left Turn Signal e Light 12V21W as Left Switch Housing Horn Button Hazard Button 1 2 3 Turn Signal Switch 4 Dimmer Switch 5 Starter Lockout Switch 6 Passing Button Fuse Box 1 0xygen Sensor Heater Fuse 10 2 Fan Fuse 15 3 ECU Fuse 15 4 Signal Relay Fuse 10 S Headlight Fuse 10 6 Taillight Fuse 10 1gnitien Fuse 10 8 Horn Fuse 10 LEFT SWITCH HOUSING CONNECTIONS Horn Button Hazard Button Turn Signal Switch W2L0270AW5 C ELECTRICAL SYSTEM 16 19 Wiring Diagram Australia and South Africa Sub Sub ro PEU throttle Speed A TUNE Sensor Sensor Actuator Wain Jerottle Inlet Air ensor Pressure Sensor 82450 zag 255 FEES ag 875 zz gt gt Water proof Joint D aw Air Switc
194. Unit 1 R BL BL R 12 R R BK R BL Y R R BK 6 11 Clumination Light LED LED Light Emitting Diode Frame Ground yy ar Meter Unit Water proof Joint A yi BK Y 11 BK Y E Nater proof Joint B Front Right ey Turn Signal kjY Light 12V21W Right City BR W Light 12V5W BK Y R BK Headlight HI BK Y 12 55 Headlight 10 8 BK Y 12 55 On Front Left Turn Signal D Light 12V21W 3k Y Left Switch Housing PS o Horn Button Fuse Relay 8 Hazard Button P BL Relay Box Turn Signal Switch Fuse Box 1 2 3 4 Bimmer Switch n l Oxygen Sensor Heater Fuse 10 HOM Lockout Switch 2 Fan Fuse 15 Passing Button 3 Fuse 15 4 Turn Signal Relay Fuse 10 Headlight Fuse 10 Taillight Fuse 10 Ignition Fuse 10A Horn Fuse 10 LEFT SWITCH HOUSING CONNECTIONS Horn Button Hazard Button Turn Signal Switch Dimmer Switch Starter Lockout Switch Passing Button 210232 5 C ELECTRICAL SYSTEM 16 15 Wiring Diagram Europe Korea Hong Kong and Kuwait Sub Sub throttle Speed 41760 Sensor Sensor Actuator diis i DM pressure Neutral Pressure Senter viteh Switch Sansor 5 ranks
195. ace them with new ones when installing e Tighten Torque Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft Ib Brake Pipe Joint Nuts 18 1 8 kgf m 13 16 EX650B Models e When installing the hoses avoid sharp bending kink ing flatting or twisting and route the hoses according to Cable Wire and Hose Routing section in the Appendix chapter e Fill the brake line after installing the brake hose see Brake Fluid Change Brake Fluid Change NOTE OThe procedure to change the front brake fluid is as fol lows Changing the rear brake fluid is the same as for the front brake Level the brake fluid reservoir e Remove the reservoir cap and diaphragm Remove the rubber cap from the bleed valve A on the caliper e Attach a clear plastic hose B to the bleed valve and run the other end of the hose into a container e Fill the reservoir with fresh specified brake fluid 2 52 PERIODIC Periodic Maintenance Procedures e Change the brake fluid ORepeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes Open the bleed valve Apply the brake and hold it B Close the bleed valve C Release the brake D NOTE OThe fluid level must be checked often during the chang ing operation and replenished with fresh brake fluid If the fluid in the reservoir runs out any time during the changing operation t
196. act OThis is not an exhaustive list giving every Stick coil trouble 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 Spark plug incorrect IC igniter in ECU trouble Neutral starter lockout or side stand switch trouble Crankshaft sensor trouble Engine Doesn t Start Starting Difficulty Ignition switch or engine stop switch Starter motor not rotating IDE E Starter lockout switch or neutral switch trou Imng shorted or open Fuse blown 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 When flooded do not crank the engine with the throttle fully opened This promotes engine flood because more
197. ain Camshaft Runout Remove the camshaft see Camshaft Removal Set the camshaft in a camshaft alignment jig or on V blocks Measure runout with a dial gauge at the specified place as shown x If the runout exceeds the service limit replace the shaft Camshaft Runout Standard TIR 0 02 mm 0 0008 in or less Service Limit TIR 0 1 mm 0 004 in GE11157BS1 C Cam Wear e Remove the camshaft see Camshaft Removal e Measure the height A of each cam with a micrometer x If the cams are worn down past the service limit replace the camshaft Height Standard Exhaust 35 843 35 957 mm 1 4111 1 4156 in Inlet 36 543 36 657 mm 1 4387 1 4432 in Service Limit Exhaust 35 74 mm 1 4071 in Inlet 36 44 mm 1 4346 in Camshaft Chain Removal Split the crankcase see Crankcase Splitting in the Crank shaft Transmission chapter e Remove the camshaft chain A from the crankshaft sprocket 5 24 ENGINE END Cylinder Head Cylinder Compression Measurement NOTE OUse the battery which is fully charged e Warm up the engine thoroughly e Stop the engine e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Air Cleaner Housing see Air Cleaner Housing Removal in the Fuel System DFI chapter Stick Coils see Stick Coil Ignition Coil together with Spark Plug Cap Removal in the Electrical System chap ter
198. al pp 6 6 Clutch Gable Installation ioi Pa eroe 6 6 Clutch Cable Lubricatigm eren ener nnne nnne 6 6 Clutch bever Installation iiie e Rte e rd bad eb 6 7 Clutch Lever Adjustment iilii e c eee ette edi e ert ite P em 6 7 GULCH m 6 8 Clutch Cover 9 6 8 Clutch Cover Installation cete edere 6 8 Release Shaft Removal 6 9 Release Shaft Installation pp 6 9 Clutch Cover Disassembly uei endet eene adore ioo ui nas esed ete tti etate ae Mb haee tp due 6 9 Clutch Cover ASSeImbly soto io decere ce dte cane cee 6 10 6 11 Glutch Rermoval 2 eir Re err e EXER REPE FT rea EURO EG pat e bete Pa ERR iS 6 11 Clutch Installation rd cete 6 11 Clutch Plate Wear Damage Inspection 9 6 13 Clutch Plate Warp INSpection 6 14 Clutch Spring Free Length Measurement pp 6 14 Clutch Housing Finger InspeGCtlOl oot ned dla eec tede ined 6 14 Clutch Housing Spline Ree 6 14 6 2 CLUTCH Exploded View GF020788W5 C CLUTCH 6 3 Exploded View No Fastener Remarks 1 Upper Cap on Clutch Cover 3 9 0 40 35 in Ib 2 Lower Cap on Clutch Cover
199. alfunction wiring open or short Crankshaft sensor malfunction wiring open or short Speed sensor malfunction wiring open or short First 24 is displayed and then 25 repeatedly Vehicle down sensor malfunction wiring open or short Subthrottle sensor malfunction wiring open or short Oxygen sensor inactivation wiring open or short Europe Models Stick Ignition coil 1 malfunction wiring open or short Stick Ignition coil 2 malfunction wiring open or short Radiator fan relay malfunction wiring open or short Subthrottle valve actuator malfunction wiring open or short Air switching valve malfunction wiring open or short Notes Oxygen sensor heater malfunction wiring open or short Europe Models Oxygen sensor malfunction wiring open or short Europe Models OThe ECU may be involved in these problems If all the parts and circuits checked out good be sure to check the ECU for ground and power supply If the ground and power supply are checked good replace the ECU OWhen no service code is displayed the electrical parts of the DFI system has no fault and the mechanical parts of the DFI system and the engine are suspect 3 42 FUEL SYSTEM Self Diagnosis Backups Backups OThe ECU takes the following measures to prevent engine damage when the DFI or the ignition system parts have troubles Output Signal Usable Range or Criteria Backups by ECU Ma
200. all the removed parts see appropriate chapters Stick Coil Ignition Coil together with Spark Plug Cap Removal e Remove the air cleaner housing see Air Cleaner Housing Removal in the Fuel System DFI chapter e Disconnect the stick coil connectors A e Pull the stick coils B off the spark plugs CAUTION Do not pry the connector part of the coil while re moving the coil Stick Coil Ignition Coil together with Spark Plug Cap Installation e Insert the coil as shown being careful of the coil heads A direction e Connect the connectors CAUTION Do not tap the coil head while installing the coil e Run the hoses and harness correctly see Cable Wire and Hose Routing section in the Appendix chapter e Install the removed parts see appropriate chapters 16 44 ELECTRICAL SYSTEM Ignition System Stick Coil Ignition Coil together with Spark Plug Cap Inspection e Remove the stick coils see Stick Coil Ignition Coil to gether with Spark Plug Cap 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 O range and read the tester e Measure the secondary winding resistance B as follows OConnect the tester between the plug terminal and coil terminal OSet the tester to the x 1 kO range and read the tester Ignition Coil Winding Resistance Primary Win
201. amp M cT 16 46 16 2 ELECTRICAL SYSTEM Electric Starter Syste Miya 16 49 Starter Motor Removal oae ue E si 16 49 Starter Motor InstallatiOfi iet bx de ie dei 16 49 Starter Motor Disassembly nsina etes it tud 16 50 Starter Motor Assembly cerei te ete pent 16 50 better irt io tdi 16 51 Commutator Cleaning and Inspectigon enne 16 51 Armature Inspectlon 2 1 error veg re nd d e yere ug e e eee e ete o a ree reed 16 52 Brush Lead Inspection pp 16 52 Brush Plate and Terminal Bolt Inspection pp 16 52 Starter Relay Ins Pe COs et TL 16 53 Lighting Syste M errre 16 55 Headlight Beam Horizontal Adjustment 16 55 Headlight Beam Vertical Adjustment enn 16 55 Headlight Bulb Replacement pp 16 55 City Light Bulb Replacement Europe Models pp 16 56 Headlight Removal lnstallation tato be peto eeu a tad trina eet ata 16 56 Tail Brake Light Removal 2 e teer cnt irte pee Rr RD ERR RR REP REUS 16 56 Tail Brake Light Installation cub ast S inp 16 56 License Plate Light Bulb Replacement pp 16 57 Turn Signal Light Bulb Replacem
202. an relay 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 Radiator Fan Relay Circuit CD a a BK Y 68017987842 Water proof Joint Water proof Joint B Radiator Fan Fuse 15 Relay Box Radiator Fan Relay Main Fuse 30 A Battery Frame Ground Joint Connector FUEL SYSTEM DFI 3 71 Subthrottle Valve Actuator Service Code 62 Subthrottle Valve Actuator Removal CAUTION Do not remove the subthrottle valve actuator A since it has been adjusted and set with precision at the factory Never drop the throttle body assy especially on a hard surface Such a shock to the actuator can damage it Subthrottle Valve Actuator Audible Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch ON and ensure that the actuator valves open and close make light sounds several times within seconds and then close at the idle throttle opening position e Turn the ignition switch OFF x lf the actuator does not work as described above do the visual inspection Subthrottle Valve Actuator Inspection e Remove the air cleaner housing see Air Cleaner Housing Removal e Turn the ignition switch ON e Check to see that all the subthrottle
203. ance grease e Install the anti rattle spring A in the caliper as shown e Install the pads see Rear Brake Pad Installation in the Brakes chapter e Wipe up any spilled brake fluid on the caliper with wet cloth Spark Plug Replacement e Remove Stick Coils see Stick Coil Ignition Coil together with Spark Plug Cap Removal in the Electrical System chap ter e Remove the spark plugs using the 16 mm plug wrench A Owner s Tool Spark Plug Wrench 16 mm 92110 1132 e Insert the spark plug vertically into the plug hole with the spark plug installed in the plug wrench A Owner s Tool Spark Plug Wrench 16 mm 92110 1132 e Tighten Torque Spark Plugs 15 N m 1 5 kgf m 11 ft Ib e Install Stick Coils see Stick Coil Ignition Coil together with Spark Plug Cap Installation in the Electrical System chapter 6105040251 C FUEL SYSTEM DFI 3 1 Fuel System DFI Table of Contents Exploded VIGW e be ut Y 3 4 BEC Mer 3 10 DF e 3 12 DEI Parts Location oie ed eee een CEN EE RR TER ath ards 3 15 Specifications ie eek hea ka ere EO ie repe reet eee i aep pee ee erg 3 16 Special Tools and Sealant rrt t RE RE EU Eu d ER de Rr da 3 18 DFI Servicing Precautions Ne 3 20 DFI Servicing
204. and turn the bulb counterclockwise and remove it e Insert the new bulb A by aligning its upper and lower pins B with the upper and lower grooves C in the socket and turn the bulb clockwise OTurn the bulb about 15 e Install the license plate light cover e Tighten Torque License Plate Light Cover Screws 0 90 Nm 0 090 kgf m 8 in Ib 16 58 ELECTRICAL SYSTEM Lighting System Headlight Tail Light Circuit Ignition Switch Water proof Joint A Water proof Joint B Position Light Headlight High Beam Headlight Low Beam Dimmer Switch Passing Switch Headlight Relay 10 Relay Box 11 Starter Relay Turn Signal Light Bulb Replacement e Unscrew the screw A and remove the lens B OTurn the lens counterclockwise GP12205BW3 C Main Fuse 30 A Battery 12 V 10 Ah Frame Ground Tail Brake Light License Plate Light 12 V 5 W Joint Connector Water proof Joint C Regulator Rectifier Fuse Box Headlight Fuse 10 A Tail Light Fuse 10 A ELECTRICAL SYSTEM 16 59 Lighting System e Push and turn the bulb A counterclockwise and remove it e Insert the new bulb A by aligning its upper and lower pins B with the upper and lower grooves C in the socket and turn the bulb clockwise OTurn the bulb about 15 e Install the projections of the lens to the dints of the turn sig
205. anent Locking Agent For applications that require Liquid Gasket or a Non permanent Locking Agent clean the surfaces so that no oil residue remains before applying liquid gasket or non permanent locking agent Do not apply them exces sively Excessive application can clog oil passages and cause serious damage 68020148 5 08020158 5 08020168 5 GENERAL INFORMATION 1 5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place apply small amount of oil to the lt NE tact area Be sure to maintain proper alignment and use d fr n smooth movements when installing CA gt gt Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is E absolutely necessary Replace with new ones whenever removed Press bearings with the manufacturer and size N A pa marks facing out Press the bearing into place by putting NN S A pressure on the correct bearing race as shown Gh J Pressing the incorrect race can cause pressure between fe 5 At the inner and outer race and result in bearing damage L 08020188 5 Oil Seal Grease Seal Do not remove pressed oil or grease seals unless removal is necessary Replace with new ones whenever removed H Lt GS Press new oil seals with manufacture and size marks facing out Make sure the seal is aligned properly when installing Rss v
206. ankcase half as shown e Be sure the damper C is on the end of the breather pipe D e Replace the oil pan gasket with a new one e When installing the oil pan align A the damper B on the breather pipe with the hollow C on the oil pan e Tighten Torque Oil Pan Bolts 12 1 2 106 in Ib GG06018BS2 C ENGINE LUBRICATION SYSTEM 7 11 Oil Pressure Relief Valve Oil Pressure Relief Valve Removal e Refer to the Oil Pan Removal Oil Pressure Relief Valve Installation Refer to the Oil Pan Installation Oil Pressure Relief Valve Inspection e Check to see if the valve A slides smoothly when push ing it in with a wooden or other soft rod and see if it comes back to its seat by spring B pressure NOTE Olnspect the valve in its assembled state Disassembly and assembly may change the valve performance x If any rough spots are found during above inspection wash the valve clean with a high flash point solvent and blow out any foreign particles that may be in the valve with compressed air A WARNING Clean the oil pressure relief valve in well ventilated area and take care that there is no spark or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline or low flash point solvent x lf cleaning does not solve the problem replace the oil pressure relief valve as an assembly The oil pressure relief
207. ant Kawasaki Bond Silicone Sealant 56019 120 Torque Oil Pressure Switch 15 N m 1 5 kgf m 11 ft Ib e Tighten the terminal bolt securely e Apply a small amount grease to the terminal so that grease should not close two breather holes A for switch diaphragm GG13004BS1 ENGINE REMOVAL INSTALLATION 8 1 Engine Removal Installation Table of Contents Exploded VI8W dg te e e A be Re e EY PER ea 8 2 Engine Removallnistallatior usciti eu tlg eate orae aude 8 4 Engine REMOVE sce rre eco recep teal ae ast aie buts ene oV vena intu Ua ARE TRA HM 8 4 Engine Installation TL TT 8 7 8 2 ENGINE REMOVAL INSTALLATION Exploded View S P d S A VII N NS 52 Q DA 6 02069 5 C ENGINE REMOVAL INSTALLATION 8 3 Exploded View Torque No Fastener Nm kgfm ilb Remarks 1 Rear Engine Mounting Nuts 44 4 5 32 S 2 Front Engine Mounting Bolts 44 4 5 32 5 3 Mounting Bracket Bolts 25 2 5 18 S 4 Engine Mounting Brackets 5 Collar 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 Be sure to hold the front brake when r
208. apter GS13024B 5 PERIODIC MAINTENANCE 2 35 Periodic Maintenance Procedures Suspensions Front Forks Rear Shock Absorber Operation Inspection Pump the forks down and up A 4 or 5 times and inspect the smooth stroke x If the forks do not smoothly or noise is found inspect the fork oil level or fork clamps see Front Fork Oil Change in the Suspension chapter e Pump the seat down and up A 4 or 5 times and inspect the smooth stroke 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 65148251 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 2 36 PERIODIC Periodic Maintenance Procedures Steering System Steering Play Inspection Raise the front wheel off the ground with jack see Front Wheel Removal in the Wheels Tires chapter With the front wheel pointing straight ahead alternately tap each end of the handlebar The front wheel should swing fully left and right from the force of gravity until the fork hits the stop x If the wheel binds or catches before the stop the steering is too tight e Feel
209. asaki Bond Silicone Sealant 56019 120 6617003651 FUEL SYSTEM DFI 3 55 Water Sensor Service Code 14 Water Temperature Sensor Circuit 20 FTTTTTTTTTTTTTTTTTTTTTTI o pes BL W BR BK aj 6C179758W2 1 ECU 2 Water Temperature Sensor 3 Water proof Joint E 4 Meter Unit Water Temperature Sensor Resistance Inspection e Remove the water temperature sensor see Water Tem perature Sensor Removal Installation e Refer to the Water Temperature Sensor Inspection in the Electrical System chapter 3 56 FUEL SYSTEM DFI Crankshaft Sensor Service Code 21 Start the engine and switch the diagnosis mode to Dealer 1 mode to know all the problem that the DFI system has at the time of self diagnosis If the engine cannot be started the self diagnosis system does not detect dynamic condi tion of the crankshaft sensor In this case turn off the igni tion switch and turn it on again to enter the Dealer 2 mode In this mode the system tells all the troubles which the DFI system had in both static and dynamic conditions Crankshaft Sensor Removal Installation e Refer to the Crankshaft Sensor Removal Installation in the Electrical System chapter Crankshaft Sensor Inspection OThe crankshaft sensor has no power source and when the engine stops the crankshaft sensor generates no sig nals e Crank the engi
210. ate C Gear Positioning Lever Bolt D Gear Positioning Lever E with Spring Washer and Spacer Pull the transmission assy A out of the crankcase CRANKSHAFT TRANSMISSION 9 33 Transmission Transmission Assy Disassembly e Remove the transmission assy see Transmission Assy Removal Remove the following from the transmission case A Shift Rods B Shift Forks C Drive Shaft D Output Shaft E e Remove Shift Drum Cam Bolt A Shift Drum B and Pin Shift Drum C Transmission Assy Assembly e When the new ball bearings A are installed in the trans mission case B press and insert them until they are bot tomed Special Tool Bearing Driver Set 57001 1129 9113245851 9 34 CRANKSHAFT TRANSMISSION Transmission e 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 e 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 Install the following as a set Drive Shaft F Output Shaft G e Install the forks as shown 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 forks J on the output shaft are identical e Install the shift rods noting the groove position OThe rod K length of the output shaft side is
211. ates the ABS makes noise and the rider feels the reaction force on the brake lever and brake pedal 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 ABS indicator light LED does not come on Finally test run the mo torcycle 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 OColor Codes BK Black G Green P Pink BL Blue GY Gray PU Purple BR Brown LB Light Blue R Red CH Chocolate LG Light Green W White DG Dark Green O Orange Y Yellow GL14004
212. ating tem perature for about ten minutes e Stop the engine and drain the cooling system e Fill the system with fresh water e Warm up the engine and drain the system e Repeat the previous two steps once more e Fill the system with a permanent type coolant and bleed the air from the system see Coolant Change in the Peri odic Maintenance chapter Coolant Reserve Tank Removal Installation e The coolant reserve tank is removed and installed dur ing coolant change see Coolant Change in the Periodic Maintenance chapter 4 10 COOLING SYSTEM Water Pump Water Pump Removal b d e Drain the coolant see Coolant Change in the Periodic Maintenance chapter Loosen the clamp and remove the radiator hose A from the water pump cover B e Remove the water pump cover bolts C e Shift the transmission into 1st gear e While applying the rear brake remove the water pump impeller bolt A e Remove Impeller B Water Pump Housing C Water Pump Installation When installing the water pump impeller bolt shift the transmission into 1st gear and apply the rear brake e Replace the O rings A on the water pump housing with new ones and apply grease them e Apply high temperature grease to the lips of the water pump housing oil seal B e Be sure that the dowel pin A is in position e Install the water pump housing e Tighten Torque Water Pump Impeller Bolt 9 8 N m 1 0 87 in Ib 900606
213. ay Box Main Harness Clamp Insert the clamp in the bracket Battery Negative Cable Battery Positive Cable ECU Connectors Clamp Clamp Tail Light Connector 10 License Plate Light Connector 11 Rear Left Turn Signal Light Connector 12 Rear Right Turn Signal Light Connector 13 Clamp Insert the clamp in the rear fender rear 14 Frame Ground 15 Clamp 16 Water proof Joint 17 Clamp 18 Fuse Box 19 Clamp 20 Clamp 21 Band 22 Band 23 Clamp 24 To the Vehicle down Sensor Crankshaft Sensor and Rear Brake Switch 25 Clamp Clamp the regulator rectifier lead and insert the clamp in the rear fender front 26 Battery Negative Lead Connector 27 Fuel Pump Lead 28 Starter Motor Cable 29 To Starter Relay 30 Regulator Rectifier Lead 31 View A 17 6 APPENDIX Cable Wire Hose Routing EX650B Models APPENDIX 17 7 Cable Wire Hose Routing 1 To Main Harness 2 Battery Positive Cable 3 ABS Kawasaki Self diagnosis System Connector Insert the connector to the bracket 4 ABS Motor Relay Fuse 5 ABS Solenoid Valve Relay Fuse 17 8 APPENDIX Cable Wire and Hose Routing APPENDIX 17 9 Cable Wire Hose Routing 1 Inlet Pressure Sensor 2 Turn Signal Relay 3 4 From this side through the fuel tank drain tube corrugated tube and air cleaner drain tube Air Cleaner Drain Tube between chain guide and e
214. battery from the motorcycle This is to prevent ECU damage by excessive voltage ODo not turn the ignition switch ON while any of the electrical connectors are disconnected The ECU memo rizes service codes not spray water on the electrical parts DFI parts con nectors leads and wiring OWhenever the DFI electrical connections are to be dis connected first turn off the ignition switch and disconnect the battery terminal Do not pull the lead only the con nector Conversely make sure that all the DFI electrical connections are firmly reconnected before starting the en gine OConnect these connectors until they click A Olf a transceiver is installed 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 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 pr
215. bolt elongation reaches the length specified in the table e Check the length F 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 Bolt Length after tightening before tightening 7 Stretch Connect Usable Range of ing Rod Bolt Nut Connecting Rod Assy Bolt Stretch Use the bolts Attached to 0 24 0 36 mm new con rod ME ae 0 0094 0 0142 in new con rod Used 1 1566 0 20 0 32 ae 0 0079 0 0126 in 2 Rotation Angle Method x If you don t have a point micrometer you may tighten the nuts using the Rotation Angle Method e Be sure to clean the bolts and nuts thoroughly with a high flash point solvent because the new bolts and nuts are treated with an anti rust solution A WARNING Clean the bolts and nuts in a well ventilated area and take care that there is no spark or flame any where near the working area This includes any ap pliance with a pilot light Because of the danger or highly flammable liquids do not use gasoline or low flash point solvents to clean them CAUTION Immediately dry the bolts and nuts with com pressed air after cleaning Clean and dry the bolts and nuts completely CRANKSHAFT TRANSMISSION 9 21 Crankshaft Connecting Rods e Install new bolts in reused connecting rods e Apply a small amount of molybdenum
216. button not contacting Inspect and replace see chapter 16 Starter motor rotating but engine doesn t turn over Camshaft seizure Inspect and replace see chapter 5 Connecting rod small end seizure Inspect and replace see chapter 9 Connecting rod big end seizure Inspect and replace see chapter 9 Crankshaft seizure Inspect and replace see chapter 9 Transmission gear or bearing seizure Inspect and replace see chapter 9 Balancer bearing seizure Inspect and replace see chapter 9 No fuel flow No or little fuel in tank Supply fuel see Owner s Manual Fuel pump not rotating Inspect see chapter 3 Fuel injector trouble Inspect and replace see chapter 3 Fuel tank air vent obstructed Inspect and repair see chapter 3 Fuel filter or pump screen clogged Inspect and replace fuel pump see chapter 3 Fuel pressure regulator clogged Inspect and replace fuel pump see chapter 3 Fuel line clogged Inspect and repair see chapter 3 Engine flooded prm nd Spark plug dirty broken or gap maladjusted Replace see chapter 2 Starting technique faulty When flooded don t crank engine with throttle fully opened No spark or spark weak Lu 7 Ignition and engine stop switches not ON Turn both switches ON 3 30 FUEL SYSTEM DFI DFI System Troubleshooting Guide Symptoms or possible Causes Actions chapter Clutch lever not pulled in and gear not in neu
217. c current in the solenoids of the outlet solenoid valve 2 way 2 position electromagnetic valve to move the armature and change the fluid pressure to Increase Mode Hold Mode or Decrease Mode 08114027841 C 1 Decrease Mode 2 Increase and Hold Mode 3 Armature 4 Valve 5 To Reservoir 1 20 GENERAL INFORMATION Technical Information ABS Anti Lock Brake System Reservoir When the passage opens between the caliper and the reservoir with the outlet solenoid valve in Decrease the brake fluid flows into the reservoir by pushing the piston stays there temporar ily and then returns to the master cylinder With the outlet solenoid valve Increase or Hold Mode the pump returns the remaining brake fluid in the reservoir to the master cylinder GL14021BS1 1 From Outlet Solenoid Valve 2 To Pump Pump Motor The pump motor operates the pump supply or return the brake fluid from the pump Pump The pump operates continuously when the ABS is activated The pump is driven by the motor and supply the brake fluid to the caliper or return the brake fluid in the reservoir to the master cylinder The piston is reciprocated by the eccentric cam A on the end of the motor shaft and the pump sucks in or discharge the brake fluid When the pump pulls fluid in the piston B is moved right by the force of the spring C At this time the spring D is compressed by the pressure of th
218. cator dud sree Start Start Start Light 0 65 0 35 Code 12 Code 12 Code 12 LED m r ON 1 ill 13 0s 3 3s 3 35 3 36 3 3s an ots Ignition d 1411 Switch 0 65 0 35 ON 0 9s Exp 2 Service Code 13 and 42 are shown ABS Service Service loa teats Start Gode 13 Code 42 any a Code 12 0 6s 0 3s 0 6s 0 3s four more service code LED i i 1 1 1 ON LL 1 o rH Ignition 13 08 11113 38 1 3 38 Switch 0 6s 0 35 0 9s0 3s 0 6s 0 3s ON 0 9s 0 9s 68114008842 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 43 Anti Lock Brake System Service Code Table ABS Indicator Light LED Problems Start code not fault Light State After starts turn off Rear inlet solenoid valve trouble open temperature abnormal ON Rear outlet solenoid valve trouble open temperature abnormal ON Front inlet solenoid valve trouble open temperature abnormal ON Front outlet solenoid valve trouble open temperature abnormal ON ABS solenoid valve relay trouble wiring shorted or open stuck rela
219. ce faulty parts Front and rear wheels should rotate smoothly without NG brake drag Repair or replace caliper There shouldn t be a lot of play in the wheel bearing There shouldn t be excessive axle bending or disc runout Replace wheel bearing or axle GL14012B F BRAKES 12 39 Anti Lock Brake System Pre Diagnosis Inspection 2 Unlit Check the ABS indicator light LED Does the indicator light light up with the ignition switch ON Check the power source wiring and meter unit Yes lit Drive at 5 km h 3 1 mph or above for one minute or more When the motorcycle is running does the indicator light go off ABS is not abnormal Count the number of times the indicator light blinks in Ask the rider if the problem the self diagnosis mode to find the service code happens again 806 F Self diagnosis Outline When the indicator light has blinked or come 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 can memorize up to six service codes Further service codes are memorized after erasing the preceding six service codes If there is no fault only the start code 12 is shown indicating that The ABS is normal Self diagnosis Procedures
220. ch and 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 Starter Motor Clutch A Starter Motor Clutch Assembly e Apply 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 Ib ELECTRICAL SYSTEM 16 41 Ignition System A WARNING The ignition system produces extremely high volt age Do not touch the spark plugs or stick coils while the engine is running or you could receive a severe electrical shock CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition switch is on or while the engine is running This is to prevent ECU Electric 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 e Remove Lower Fairing see Lower Fairing Removal in the Frame chapter Right Frame Cover see Frame Cover Removal in the Frame chapter Crankshaft Sensor Lead Connector A e Remove Rubber Boot Slide Out A Oil Pressure Switch Lead Terminal B Clutch Cover see Clutch Cover Removal in the Cl
221. ch Cover Mounting Bolts 9 8 N m 1 0 kgf m 87 in lb GF050298W2 C CLUTCH 6 9 Clutch Cover Release Shaft Removal CAUTION Do not remove the clutch release lever and shaft assembly unless it is absolutely necessary If re moved the oil seal replacement may be required Remove the clutch cover see Clutch Cover Removal Pull the lever and shaft assembly straight out of the clutch cover Release Shaft Installation Apply high temperature grease to the oil seal lips on the upper ridge of the clutch cover Apply engine oil to the needle bearings the hole of the clutch cover e Apply molybdenum disulfide grease to the pusher holding portion A on the release shaft e Install the washer and spring e Insert the release shaft straight into the upper hole of the clutch cover CAUTION When inserting the release shaft be careful not to remove the spring of the oil seal e Fit the spring A as shown Release Shaft B Clutch Cover C Clutch Cover Disassembly e Remove Oil Seal A Needle Bearings B GF05030BS1 6 10 CLUTCH Clutch Cover eRemove the oil level gauge WA PPS NS S Clutch Cover Assembly e Replace the needle bearings and oil seal with new ones NOTE Olnstall the needle bearings so that the manufacture s mark face out e Install the needle bearings A and oil seal B positio
222. chapter Master Cylinder Assembly e Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter BRAKES 12 23 Master Cylinder Master Cylinder Inspection e Remove the master cylinders see Front Rear Master Cylinder Removal Disassemble the front and rear master cylinders Check that there no scratches rust or pitting on the WD inner wall A of each master cylinder and on the outside RSS aS of each piston B x If a master cylinder or piston shows any damage replace them e Inspect the primary cup C and secondary cup D a cup is worn damaged softened rotted or swollen the piston assembly should be replaced to renew the cups x If fluid leakage is noted at the brake lever the piston as sembly should be replaced to renew the cups Front Master Cylinder J GS13049BS1 C 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 xIf the relief port becomes plugged the brake pads will drag on the disc Blow the ports clean with compressed air Rear Master Cylinder K 0513050852 C 12 24 BRAKES Brake Disc Brake Disc Removal Remove the wheel see Front Rear Wheel Removal in the Wheels Tires chapter U
223. chapter 16 Spark plug dirty broken or gap maladjusted Replace see chapter 2 Stick coil trouble Inspect the stick coil see chapter 16 Reinstall or inspect stick coil see chapter 16 Replace it with the correct plug see chapter 16 see chapter 16 see chapter 16 see chapter 16 Fuelairmituemeoret SSS Little fuel in tank Air cleaner clogged poorly sealed or missing Clean element or inspect sealing see chapter 2 3 Air cleaner duct loose Reinstall see chapter 3 Air cleaner O ring damaged Replace see chapter 3 Fuel tank air vent obstructed Inspect and repair see chapter 3 Throttle body assy loose Reinstall see chapter 3 Throttle body assy O ring damage Replace see chapter 3 Fuel filter or pump screen clogged Inspect and replace fuel pump see chapter 3 Inspect fuel pressure and replace fuel pump see chapter 3 Fuel line clogged Inspect and repair see chapter 3 Inlet air pressure sensor trouble Inspect see chapter 3 Inlet air temperature sensor trouble Inspect see chapter 3 Thermostat trouble Inspect and replace see chapter 4 n Fuel pressure regulator clogged Crankshaft sensor rouble inspect see chapter 3 nspect see chapter 3 Fuel pressure too low or too high Inspect see chapter 3 Battery voltage low Inspect and charge see chapter 16 Incorrect idle speed Water temperature sensor trouble Inspect see c
224. ck 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 ODo not use a meter illumination bulb rated for other than voltage or wattage specified in the wiring diagram as the meter or gauge panel could be warped by excessive heat radiated from the bulb 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 system op eration OMeasure coil and winding resistance when the part is cold at room temperature OColor Codes BK Black G Green P Pink BL Blue GY Gray PU Purple BR Brown LB Light Blue R Red CH Chocolate LG Light Green
225. cket Throttle Cables Through the brake hose at the right side of the throttle cables 17 14 APPENDIX Cable Wire Hose Routing EX650B Models APPENDIX 17 15 Cable Wire Hose Routing 1 Right Switch Housing Lead 2 Throttle Cable Decelerator 3 Throttle Cable Accelerator 4 Through the brake hose at the right side of the throttle cables 17 16 APPENDIX Cable Wire Hose Routing APPENDIX 17 17 Cable Wire Hose Routing 1 Crankshaft Sensor Lead Connector 2 Clamp Insert the clamp in the bracket 17 18 APPENDIX Cable Wire Hose Routing APPENDIX 17 19 Cable Wire Hose Routing Tail Light Connector License Plate Light Connector Rear Right Turn Signal Light Connector Rear Left Turn Signal Light Connector Clamp Insert the clamp in the rear fender rear Clamp Insert the clamp in the rear fender rear Diagnosis Connector Clamp Insert the clamp in the rear fender front Rear Brake Light Switch Lead Band Clamp the main harness with the frame Band ABS Kawasaki Self diagnosis System Connector EX650B Models 17 20 APPENDIX Cable Wire Hose Routing APPENDIX 17 21 Cable Wire Hose Routing Right Switch Housing Lead Throttle Cables Headlight LO Connector Green Tape Headlight Connector
226. 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 A Crankpin Diameter Marks O or no mark 8105139851 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 A Connecting Rod B Weight Mark Alphabet C Diameter Mark Around Weight Mark D O or no mark 6105060181 Select the proper bearing insert A in accordance with the combination of the connecting rod and crankshaft coding Size Color B Con rod Big End Crankpin Bearing Insert Inside Diameter Diameter Marking Marking Size Color Part Number None None m Black 92139 0115 Blue 92139 0114 Install the new inserts in the connecting rod and check insert crankpin clearance with the plastigage 9 24 CRANKSHAFT TRANSMISSION Crankshaft Connecting Rods Crankshaft Side Clearance e Insert a thickness
227. collar and washers e Clear the hook portions from the slots e Separate the left lower fairing from the right lower fairing Lower Fairing Installation e Insert the hook portions A into the slots B e Set the quick rivet and push the core Center Fairing Removal e Remove Lower Fairings see Lower Fairing Removal Upper Inner Fairing see Upper Inner Fairing Removal Screw A Bolt B with Washers e Remove the meter cover see Meter Unit Removal Instal lation in the Electrical System chapter e Disconnect the turn signal lead connector A e Remove the screw B e Pull the center fairing C evenly outward to clear the stop pers e Remove the inner fairing see Inner Fairing Removal e Remove the screw A and turn signal light B Center Fairing Installation e Install the turn signal light to the center fairing e Install the inner fairing see Inner Fairing Installation 15 10 FRAME Fairings e Insert the hook A into the slot e Insert the projection A into the hole e Connect the turn signal lead connector e Install the bolt and screws Windshield Removal e Remove Bolts A with Washers Windshield B Dampers Windshield Installation e Install the dampers e Insert the hook A into the slot B e Tighten the bolts with washers Upper Fairing Removal e Remove Windshield see Windshield Removal Upper Inner Fairings see Upper Inner Fairing Removal
228. cycle NOTE OWhen the ABS is functioning you may feel a pulsing in the brake lever or pedal This is normal You need not suspend applying brakes Olmmediately after turning the ignition switch on you may hear a click of the relay operating This is the sound of self checking and is quite normal OABS does not function at the speed of approx 6 km h or below OABS does not function if the battery is discharged GENERAL INFORMATION 1 27 Unit Conversion Table Prefixes for Units Units of Length Prefix Symbol Power Sm milg mega M x 1 000 000 B v kilo k x 1 000 mm x 0 03937 in centi C x 0 01 milli 0 001 Units of Torque micro 0 000001 Om N m x 0 7376 ft lb N m x 8 851 in Ib Units of Mass kgf m x 9 807 N m kg x 2 205 Ib 7 233 ft lb g x 0 03527 OZ kgf m x 86 80 in lb Units of Volume Units of Pressure L x 0 2642 gal US kPa x 0 01020 kgf cm L x 0 2200 gal imp kPa x 0 1450 L x 1 057 qt US kPa x 0 7501 cmHg L x 0 8799 qt imp kgf cm 98 07 kPa L x 2 113 pint US kgf cm x 14 22 psi L x 1 816 pint imp cmHg x 1 333 kPa mL x 0 03381 oz US mL x 0 02816 oz imp Units of Speed mL x 0 06102 cu in km h x 0 6214 mph Units of Force Units of Power N x 0 1020 kg kW x 1 360 PS N x 0248 Ib kW 1341 HP kg IN PS x 07355 kW kg x 2 205 Ib PS x 0 9863 HP Units of Tempera
229. d 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 Raise the rear wheel off the ground with stand so that it will turn freely e Set a dial gauge A against the rear sprocket B near the teeth as shown and rotate C the rear wheel to measure the sprocket runout warp The difference between the highest and lowest dial gauge readings is the amount of runout warp x If the runout exceeds the service limit replace the rear sprocket Rear Sprocket Warp Standard 0 4 mm 0 016 in or less Service Limit 0 5 mm 0 020 in GK05000BS1 C BRAKES 12 1 Exploded Specifications Special Brake Lever Brake Pedal Brake Lever Position Adjustment Brake Pedal Position Inspection Brake Pedal Position Adjustment Brake Pedal Removal Brake Pedal Installation Calipers 244 4 2 Front Caliper Removal
230. d drain it A WARNING Be sure to reinstall the plug in the drain hose after draining Oil on tires will make them slippery and can cause an accident and injury Air Cleaner Housing Removal e Remove Fuel Tank see Fuel Tank Removal Hose Disconnect A Inlet Air Temperature Sensor Connector B Screws C Cover D e Disconnect the breather hose A on the upper crankcase 3 102 FUEL SYSTEM Air Cleaner e Unscrew the bolts Al and remove the air cleaner housing Air Cleaner Housing Installation e Install the clamp on the hose A so that its pinch heads B face the right e Install the clamp on the breather hose C so that its pinch heads D face the front GCO7037BS2 C FUEL SYSTEM DFI 3 103 Fuel Tank Fuel Tank Removal A WARNING Gasoline is extremely flammable and can be explo sive under certain conditions Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Turn the ignition switch OFF Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately e Turn the ignition switch and engine stop switch OFF e Wait until the engine cools down e Open the fuel tank cap A to lower the pressure in the tank ODuring tank removal keep the tank cap open to release pressure in the tank This makes fuel spillage less e Remove Seat
231. 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 A WARNING If any of the 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 CAUTION Do not ride the motorcycle with air in the brake line or the ABS could malfunction BRAKES 12 33 Anti Lock System OThe ABS indicator light LED A may light if the tire pres sure is incorrect a non recommended tire is installed or the wheel is deformed If the indicator light lights 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 The rider could have an accident as a re sult Always use recommended standard tires for this motorcycle OThe ABS indicator light LED may come on if the engine is run with the motorcycle on its stand and the transmis sion in gear If the indicator light comes on just turn the ignition switch OFF then clear service code 42 which in dicates a Faulty front wheel speed sensor OWhen the ABS oper
232. dings 1 1 1 5 0 Secondary Windings 10 8 16 2 xIf the tester does not read as specified replace the coil Stick Coil Primary Peak Voltage NOTE OBe sure the battery is fully charged e Remove the stick coils see Stick Coil Ignition Coil to gether with Spark Plug Cap Removal but do not remove the spark plugs 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 into 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 Special Tools Hand Tester 57001 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Lead Wire Peak Voltage Adapter 57001 1449 Primary Lead Connection Adapter R to lead wire peak voltage adapter W Adapter BK to lead wire peak voltage adapter R 8 10011952 C GP10283BS1 C ELECTRICAL SYSTEM 16 45 Ignition System A WARNING To avoid extremely high voltage shocks do not touch the spark plugs or tester connections e Turn the ignition switch and the engine stop switch ON e Pushing the starter button turn the engine 4 5 seconds with the transmission in neutral to measure the primary peak voltage Repeat the measurements 5 times for on
233. dle will fluctuate Read the pressure at the average of the maximum and minimum indications x If the fuel pressure is normal the fuel circulation system fuel pump pressure regulator and fuel passage is no faults Check the DFI electronic control system injectors sensors crankshaft sensor and ECU xIf the fuel pressure is much lower than specified check the following Fuel Line Leakage Fuel Pump Operation check the sound of the pump Amount of Fuel Flow see Fuel Flow Rate Inspection xIf the fuel pressure is much higher than specified check the following Delivery Pipe Clogging Injector Clogging e Remove the fuel pressure gauge and adapter e Install the removed parts see appropriate chapters FUEL SYSTEM DFI 3 85 Fuel Line Fuel Flow Rate Inspection NOTE OBe sure the battery is fully charged A WARNING Gasoline is extremely flammable and can be explo sive under certain conditions Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Turn the ignition switch OFF Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately e Turn the ignition switch and engine stop switch OFF Wait until the engine cools down e Prepare a plastic hose of the inside diameter 7 5 mm 0 30 in and a measuring cylinder Remove the fuel tank bolt see Fuel Tank Removal Open t
234. e 4 7 iorum 4 8 Coolant Deterioration Inspectionm nnne 4 8 Coolant Level Inspectiom 9 4 8 Coolant Dea UNG E 4 8 Coolant FING 4 8 Press re Testing M RE 4 8 Cooling System Flushing Ne 4 9 Coolant Reserve Tank Removal Installation pp 4 9 Water PUP isc bic cand 4 10 Water Pump Removal 4 10 Water Pump 0000000 aa a tAr rennen 4 10 Mechanical Seal Inspection pp 4 11 Water Pump Housing Disassembly pp 4 11 Water Pump Housing Assembly pp 4 11 Impeller Assembly 4 12 Pump Impeller 4 12 N 4 13 Radiator and Radiator Fan Removal pp 4 13 Radiator and Radiator Fan Installation pp 4 14 Radiator 4 14 Radiator Cap 4 14 Radiator Filler Neck 4 15 4 16 Thermostat Removal peperit eed ae AE 4 16 Thermostat Installation esses eee 4
235. e Caliper Installation WARNING Do not attempt to drive the motorcycle until a full brake pedal is obtained by pumping the brake pedal until the pads are against the disc The brake will not function on the first application of the pedal if this is not done Brake Pad Wear Inspection e Refer to the Brake Pad Wear Inspection in the Periodic Maintenance chapter BRAKES 12 21 Master Cylinder Front Master Cylinder Removal e Remove the banjo bolt A to disconnect the brake hose from the master cylinder B see Brake Hose Removal In stallation e Disconnect the front brake light switch connectors A e Unscrew the clamp bolts B and take off the master cylin der as an assembly with the reservoir brake lever and brake switch installed CAUTION Immediately wash away any brake fluid that spills e Remove Brake Lever Pivot Bolt A and Locknut Brake Lever B Front Brake Light Switch C Front Master Cylinder Installation e Install the front master cylinder so that the punch mark A of the handlebar is aligned with the mating surface B of the master cylinder clamp to level the reservoir e The master cylinder clamp must be installed with the ar row mark A upward e Tighten the upper clamp bolt B first and then the lower clamp bolt C There will be a gap at the lower part of the clamp after tightening Torque Front Master Cylinder Clamp Bolts 8 8 N m 0 90 kgf m 7
236. e DFI System other Poor running or no power at high speed spark plug loose tighten it plug dirty broken or gap maladjusted remedy it plug incorrect replace it Oknocking fuel poor quality or incorrect use high octane gasoline brake dragging clutch slipping engine overheating engine oil level too high engine 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 OThe ECU may be involved in the electrical and ignition system troubles If these parts and circuits are checked out good be sure to check the ECU for ground and power supply If the ground and power supply are checked good replace the ECU Engine Doesn t Start Starting Difficulty Symptoms or possible Causes Actions chapter Starter motor not rotating Ignition and engine stop switches not ON Turn both switches ON Starter lockout switch or neutral switch trouble Inspect see chapter 16 Starter motor trouble Inspect see chapter 16 Battery voltage low Inspect and charge see chapter 16 Starter relays not contacting or operating Inspect the starter relay see chapter 16 Starter
237. e Inspect the operation of the front and rear brake by run ning the vehicle on the dry road x lf the brake operation is insufficiency inspect the brake system A WARNING When inspecting by running the vehicle note a surrounding traffic situation enough in the place of safety 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 fill the reservoir to the upper level line C in the reservoir e Remove the seat see Seat Removal in the Frame chap ter Check that the brake fluid level in the rear brake reservoir A is above the lower level line B x lf the fluid level is lower than the lower level line fill the reservoir to the upper level line C WARNING the brake fluid brake line completely if the brake fluid must be refilled but the type and brand of the brake fluid that is already in the reser voir are unidentified After changing the fluid use only the same type and brand of fluid thereafter Recommended Disc Brake Fluid Grade DOT4 2 34 PERIODIC Periodic Maintenance Procedures e Follow the procedure below to install the rear brake fluid reservoir cap correctly OFirst tighten the rear brake fluid res
238. e Limit 27 mm 1 06 in GP11060781 C 16 52 ELECTRICAL SYSTEM Electric Starter System Armature Inspection e Using the x 1 hand tester range measure the resis tance between any two commutator segments A Special Tool Hand Tester 57001 1394 x If there is a high resistance or no reading between any two segments a winding is open and the starter motor must be replaced e Using the highest hand tester range measure the resis tance between the segments and the shaft B lf there is any reading at all the armature has a short and the starter motor must be replaced NOTE OEven if the foregoing checks show the armature to be good it may be defective in some manner not readily detectable with the hand tester If all other starter motor and starter motor circuit components check good but the starter motor still does not turn over or only turns over weakly replace the starter motor with a new one Brush Lead Inspection Using the x 1 hand tester range measure the resis tance as shown Terminal Bolt and Positive Brushes A Brush Plate 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 terminal bolt assy and or the brush plate assy Brush Plate and Terminal Bolt Inspection e Using the highest hand tester range measure the resis tance as shown Terminal Bolt and Brush Plate A Terminal Bolt and N
239. e Replace the filter with a new one e Apply engine oil to the gasket A before installation e Tighten the filter with the oil filter wrench Torque Oil Filter 17 2 N m 1 75 kgf m 13 ft Ib NOTE OHand tightening of the oil filter can not be allowed since it does not reach to this tightening torque e Pour in the specified type and amount of oil see Engine Oil Change Brake Hose and Pipe Replacement CAUTION Brake fluid quickly ruins painted plastic surfaces any spilled fluid should be completely washed away immediately e Remove the banjo bolts A e When removing the brake hose take care not to spill the brake fluid on the painted or plastic parts e When removing the brake hoses B temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum e Immediately wash away any brake fluid that spills 6005040251 PERIODIC MAINTENANCE 2 51 Periodic Maintenance Procedures e Remove Rear Fender Front see Rear Fender Front Removal in the Frame chapter EX650B Models Right Center Fairing see Center Fairing Removal in the Frame EX650B Models Air Cleaner Housing see Air Cleaner Housing Removal in the Fuel System DFI chapter EX650B Models Remove the brake pipe joint nuts EX650B Models e Remove the bracket bolt D and bracket E EX650B Models e There are washers on each side of the brake hose fitting Repl
240. e Top End Valve Clearance Inspection NOTE OValve clearance must be checked and adjusted when the engine is cold room temperature e Remove Cylinder Head Cover see Cylinder Head Cover Re moval in the Engine Top End chapter Right Lower Fairing see Lower Fairing Removal in the Frame chapter e Unscrew the upper A and lower B caps on the clutch cover 85806005851 C 2 22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Check the valve clearance when the pistons are at TDC OThe pistons are numbered beginning with the engine left side Using a wrench A on the crankshaft rotation bolt turn the crankshaft clockwise until the 1 T mark on the timing rotor is aligned with the notch B in the edge of the upper hole in the clutch cover for 1 piston and 2 T mark for 2 piston 65078106 P 1 T Mark A 2 T Mark B Hole C of Upper Cap Notch D in Edge of Upper Hole 6807071BS1 OMeasure the valve clearance of the valves for which the cam A are turned away from each other e Using the thickness gauge A measure the valve clear ance between cam and valve lifter Valve Clearance Standard Exhaust 0 22 0 31 mm 0 0087 0 0122 in Inlet 0 15 0 21 mm 0 0059 0 0083 in OEach piston has two inlet and two exhaust valves Mea sure these two inlet or exhaust valves at the same crank shaft position Valve Clearance Measuring Position
241. e and warm it up thoroughly Check the idle speed Tachometer A Open and close the throttle x lf the idle speed is out of the specified range adjust it CAUTION Do not measure the idle speed by the tachometer of the meter unit While idling the engine inspect the engine vacuum using the vacuum gauge B Engine Vacuum Standard 35 3 1 3 kPa 265 10 mmHg at Idle Speed 1 300 50 r min rpm x If any 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 CAUTION 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 Open and close the throttle valves after each measure ment and adjust the idle speed as necessary e Inspect the vacuums as before x If both vacuums are within the specification finish the en gine vacuum synchronization x If any vacuum can not be adjusted within the specification remove the bypass screws 1 2 and clean them 9505086851 C e Remove the bypass screw A spring B washer C and O ring D OCheck the bypass screw and its hole for carbon deposits x If any carbon accumulates wipe the carbon off the bypass screw and the hole using a cotton pad penetrated with a high flash point solvent OReplace the O r
242. e battery cable terminal Fuel Tank and Cap Inspection e Visually inspect the gasket A on the tank cap for any damage Replace the gasket if it is damaged Check to see if the water drain pipe and fuel breather pipe C 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 CAUTION Do not apply compressed air to the air vent holes D in the tank cap This could cause damage and clogging of the labyrinth in the cap GCO9086BS1 C FUEL SYSTEM DFI 3 107 Fuel Tank Fuel Tank Cleaning A WARNING Clean the tank in a well ventilated area and take care that there are no sparks or flame anywhere near the working area Because of the danger or highly flammable liquids do not use gasoline or low flash point solvents to clean the tank Remove the fuel tank see Fuel Tank Removal Remove the fuel pump inlet hose and the 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 e Install the fuel pump see Fuel Pump Installation e Install the fuel tank see Fuel Tank Installation 3 108 FUEL SYSTEM Evaporative Emission Control System California The Evaporative Emissi
243. e brake fluid in the reservoir to open the inlet valve E and the brake fluid flows into the cylinder F The outlet valve G is held closed by the force of the spring H Suction N m 08114022841 C When the pump discharges the brake fluid the inlet valve E is closed by the spring D and the piston B is moved left by the cam A producing pressure in the cylinder F The pressure pushes the spring H opens the outlet valve G and the brake fluid returns to the master cylinder Spring C Discharge Le pa c NN lt SG Z 08114023841 C GENERAL INFORMATION 1 21 Technical Information ABS Anti Lock Brake System ABS Solenoid Valve Relay ABS solenoid valve relay supply or intercept the power to the inlet or outlet solenoid valves ABS Motor Relay ABS motor relay supply or intercept the power to the pump motor ECU ECU inputs the sensor signal ECU calculates the wheel condition for the slip ECU controls the hydraulic unit ECU sends the actuating signals to the ABS indicator light LED 1 22 GENERAL INFORMATION Technical Information ABS Anti Lock Brake System ABS Operation The ABS has two independent hydraulic lines one for the front wheel and the other for the rear wheel The front wheel system is explained here and is identical to the rear wheel system ABS in Action Increase Mode When the caliper fluid pressure is to be i
244. e brake fluid in the reservoir to the master cylinder The brake fluid pressure is decreased and the wheel is prevented from locking Decrease Mode GLi4019BW3 C Brake Lever Front Inlet Solenoid Valve Pump Motor Pump Front Reservoir Front Outlet Solenoid Valve Front Caliper NOORWN GENERAL INFORMATION 1 25 Technical Information ABS Anti Lock Brake System ABS Disabled Conventional Mode During cruising without braking or in case of a malfunction with the ABS the ECU stops operating This is Conventional Mode When the caliper fluid pressure is to be increased first the tappet of inlet solenoid valve opens normally open The brake fluid flows through the valve body as shown in the diagram below to increase the brake fluid pressure in the caliper The master cylinder pressurizes to the brake caliper directly increasing the braking force Conventional Mode GL14047BW3 C Brake Lever Front Inlet Solenoid Valve Pump Motor Pump Front Reservoir Front Outlet Solenoid Valve Front Caliper NOORWN 1 26 GENERAL INFORMATION Technical Information ABS Anti Lock Brake System Riding Characteristics of ABS ABS is designed to help prevent the wheels from locking up when hard brakes are applied while running straight The ABS automatically regulates brake force Intermittently gaining gripping force and braking force helps prev
245. e inner tube Cil Level fully compressed without spring Standard EX650A Models 98 2 mm 3 9 0 08 in EX650B Models 89 2 mm 3 5 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 attaining the stan dard level Olf not oil is drawn out there is not enough oil in the fork Pour in some more oil and measure again e Repeat the same procedure for adjusting the other fork e Install the fork spring A fork spring seat B and collar C e Inspect the top plug O ring and replace it with a new one e Install the front fork see Front Fork Installation B a GM04297BS1 GM04303BS2 6 04040451 SUSPENSION 13 11 Front Fork Front Fork Disassembly e Remove the front fork see Front Fork Removal e Remove the top plug A with O ring take out the collar B fork spring seat C and fork spring D e Drain the fork oil see Front Fork Oil Change 6M04040281 e Remove the Allen bolt A 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 stop the cylinder unit lef e E from turning by using the special tools and unscrew the Allen bolt GM04298BS1 Remove
246. e it x lf the regulator rectifier passes all of the tests described it may still be defective If the charging system still does not work properly after checking all of the components and the battery test the regulator rectifier by replacing it with a known good unit 8 10000851 C 16 38 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 e Remove the seat see Seat Removal in the Frame chap ter e Check that the ignition switch is turned off and connect the hand tester A to the battery terminals B Special Tool Hand Tester 57001 1394 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 read ings should also rise But they must be kept under the specified voltage Charging Voltage Connections Tester Range Reading Tester to Tester to 25 V DC Battery Battery 14 2 15 2 V e Turn off the ignition switch to stop the engine and discon nect the hand tester x If the charging voltage is kept between the values given in the table the charging syste
247. e regulator trouble Inspect fuel pressure and replace fuel pump see chapter 3 Main throttle sensor trouble Inspect see chapter 3 Fuel pressure may be low Inspect see chapter 3 Fuel pump trouble Inspect see chapter 3 Fuel injector trouble Inspect see chapter 3 Inlet air temperature sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Inlet air pressure sensor trouble Inspect see chapter 3 Crankshaft sensor trouble Inspect see chapter 3 Compression low Spark plug loose Reinstall see chapter 16 Cylinder head not sufficiently tightened down Tighten see chapter 5 Inspect and replace see chapter 5 Inspect and replace see chapter 5 Inspect and replace see chapter 5 Replace see chapter 5 Inspect and replace see chapter 5 FUEL SYSTEM DFI 3 31 DFI System Troubleshooting Guide Symptoms or possible Causes Actions chapter No valve clearance Adjust see chapter 2 Valve guide worn Inspect and replace see chapter 5 Valve spring broken or weak Inspect and replace see chapter 5 Valve not seating properly valve bent worn or carbon accumulating on seating surface Inspect and repair or replace see chapter 5 Poor Running at Low Speed Symptoms or Possible Causes Actions chapter Spark weak Battery voltage low Inspect and charge see
248. e square wave illustrated as shown would be input into the terminal 16 Olndicates approximately 60 mph in case the input fre Er quency would be approximately 169 0 Hz PS Olndicates approximately 60 km h in case the input fre quency would be approximately 105 6 Hz e f the oscillator is not available the soeedometer can be checked as follows Olnstall the meter unit ORaise the rear wheel off the ground with stand OTurn on the ignition switch ORotate the rear wheel by hand OCheck that the speedometer shows the speed x If the speedometer does not work check the speed sen sor electric source voltage and speed sensor The electric source voltage and speed sensor are normal replace the meter assembly 16 68 ELECTRICAL SYSTEM Meter Gauge Indicator Unit Speed Sensor Electric Source Check eConnectthe 12 V battery and terminals in the same man ner as specified in the Liquid Crystal Display LCD Seg ments Check Set the hand tester to the DC 25 V range and connect it to the terminals 12 and 9 x If the voltage is less than 8 V replace the meter assembly Odometer Check e Check the odometer with the speedometer in the same way x If value indicated in the odometer is not added replace the meter assembly NOTE OThe data is maintained even if the battery is discon nected 8 5 1 OWhen the figures come to 999999 they are stopped and ep
249. e stick coil Stick Coil Primary Peak Voltage Standard 88 V or more Repeat the test for the other stick coil x lf the reading is less than the specified value check the following Stick Coils see Stick Coil Ignition Coil together with Spark Plug Cap Inspection Crankshaft Sensor see Crankshaft Sensor Inspection ECU see ECU Power Supply Inspection in the Fuel Sys tem DFI chapter Spark Plug Removal e Refer to the Spark Plug Replacement in the Periodic Maintenance chapter Spark Plug Installation e Refer to the Spark Plug Replacement in the Periodic Maintenance chapter Spark Plug Condition Inspection Refer to the Spark Plug Condition Inspection in the Peri odic Maintenance chapter Interlock Operation Inspection Raise the rear wheel off the ground with stand 1st Check e Start the engine to the following conditions Condition Transmission Gear 1st Position Clutch Lever Release Sidestand Down or Up OTurn the ignition switch ON and push the starter button OThen the starter motor should not turn when the starter system circuit is normality x lf the engine is start inspect the starter lockout switch neutral switch and relay box x lf their parts are normality replace the ECU 16 46 ELECTRICAL SYSTEM Ignition System 2nd Check e Start the engine to the following conditions Condition Transmission Gear 1st Position Clutch Lever Pulled in Sidestand Up OTur
250. earing Installation e Replace the bearing outer races with new ones Apply grease to the outer races and drive them into the head pipe at the same time Special Tool Bearing Driver Set A 57001 1129 e Replace the bearing inner races and oil seal with new ones e Apply grease to the oil seal e Drive the lower ball bearing inner race applied the grease onto the stem Special Tools Steering Stem Bearing Driver 42 5 A 57001 1344 Steering Stem Bearing Driver Adapter 41 5 B 57001 1345 e Apply grease to the lower ball bearing A and install it onto the stem Apply grease to the upper ball bearing B and inner race C GNOSO055BS1 C 14 8 STEERING Steering Stem e Install the stem A through the head pipe and install the ball bearing B and inner race C on it e Install the stem cap D and steering stem nut E Settle the inner races in place as follows OTighten the steering stem nut with 39 N m 4 0 kgfm 29 ft lb of torque first and loosen it a fraction of a turn until it turns lightly Afterward tighten it again with specified torque using a stem nut wrench A in the direction shown OCheck that there is no play and the steering stem turns smoothly without rattles If not the steering stem bearings may be damaged Special Tool Steering Stem Nut Wrench 57001 1100 Torque Steering Stem Nut 20 N m 2 0 kgf m 15 16 e Install the claw washer A so that
251. ecification re place the meter assembly x lf the terminal voltage correct 2nd step e Do the 2nd step test ODisconnect the ABS hydraulic unit connector OCheck the terminal voltage between the orange black and black yellow lead terminals of the main harness side con nector A Special Tool Hand Tester 57001 1394 x If the terminal voltage is about 9 12 V replace the main harness xIf the terminal voltage is 0 V replace the ABS hydraulic unit Solenoid Valve Inspection Service Code 13 14 17 18 e Do the 1st step test 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 ABS indicator light LED A lit faulty solenoid valve in the ABS hydraulic unit Replace the ABS hydraulic unit xIf the ABS indicator light LED A unlit ABS system is normal service code is not stored temporary failure ABS Solenoid Valve Relay Inspection Service Code 19 e Do the 1st step test OCheck the ABS solenoid valve relay fuse A x If the fuse blown 2nd step x If the fuse correct 4th step GL14043BS1 2 GL14046BS1 GL14004BS1 C 12 46 BRAKES Anti Lock Brake System e Do the 2nd step test ODisconnect the ABS hydraulic unit connector A OCheck for continuity between the white red and black yel low lead terminals of the ABS hydraulic unit connector
252. ed Special Tool Bearing Driver Set B 57001 1129 e Replace the circlip with a new one Special Tool Inside Circlip Pliers 57001 143 GK05038BS1 C FINAL DRIVE 11 13 Sprocket Coupling e Replace the grease seal with a new one e Press in the grease seal so that the seal surface is flush with the end of the hole OApply high temperature grease to the grease seal lips Special Tool Bearing Driver Set 57001 1129 Coupling Bearing Inspection Since the coupling bearing is made to extremely close tolerances the clearance can not normally be measured NOTE Olt is not necessary to remove the coupling bearing for inspection If the bearing is removed it will need to be replaced with a new one 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 Examine 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 damper if it appears damaged or deterio rated Sprocket Wear Inspection e Visually inspect the engine and rear sprocket teeth for wear and damage x If the teeth are worn as illustrate
253. ee chapter 3 FUEL SYSTEM DFI 3 35 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions chapter Throttle body assy O ring damaged Replace see chapter 3 Fuel tank air vent obstructed Inspect and repair see chapter 3 Fuel line clogged Inspect and repair see chapter 3 Fuel pump operates intermittently and often fuse blows Cracked or obstructed inlet air pressure sensor hose Pump bearings may wear Replace the pump see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect and repair or replace see chapter 3 Injector clogged Visually inspect and replace see chapter 3 Compression low Spark plug loose Reinstall see chapter 16 Cylinder head not sufficiently tightened down Tighten see chapter 5 No valve clearance Adjust see chapter 2 Cylinder piston worn Inspect and replace see chapter 5 Piston ring bad worn weak broken or sticking Inspect and replace see chapter 5 Piston ring groove clearance excessive Inspect and replace see chapter 5 Cylinder head gasket damaged Replace see chapter 5 Cylinder head warped Inspect and replace see chapter 5 Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulating on the seating surface Carbon built up in co
254. egative Brush Holders B Terminal Bolt and Yoke C Special Tool Hand Tester 57001 1394 lf there is any reading the brush plate assy and or termi nal bolt assy have a short Replace the brush plate assy and the terminal bolt assy 8 11080851 C ELECTRICAL SYSTEM 16 53 Electric Starter System Starter Relay Inspection e Remove Bolt A and Cover B e Disconnect the connector A e Disconnect the starter motor cable B and battery positive cable C from the starter relay D CAUTION The battery positive cable with the rubber cap is connected directly to the battery positive termi nal even when the ignition switch off so take care not to short the removed cable to chassis ground e Connect the hand tester A and 12 V battery to the starter relay C as shown Special Tool Hand Tester 57001 1394 x If the relay does not work as specified the relay is defec tive Replace the relay Testing Relay Tester Range x 1 range Criteria When battery is connected 0 Q When battery is disconnected Q GP110189BS1 C 16 54 ELECTRICAL SYSTEM Electric Starter System Electric Starter Circuit GP11073BW3 C Ignition Switch Water proof Joint B Starter Lockout Switch Ignition Fuse 10 A Fuse Box Starter Circuit Relay Relay Box Starter Motor Starter Relay 10 Main Fuse 30 A
255. eld see Windshield Removal in the Frame chapter Upper Inner Fairings see Upper Inner Fairing Removal in the Frame chapter Screws A Both Side and Meter Cover B e Slide the dust cover A and remove the connector B e Remove the meter unit by taking off the mounting nuts C CAUTION Place the meter unit so that the face is up If a meter unit is left upside down or sideways for any length of time it will malfunction e Installation is the reverse of removal e Insert the hooks A into the slots B Meter Gauge Disassembly e Remove Meter Unit see Meter Unit Removal Installation Screws A Lower Meter Cover B e Separate the meter assembly A and upper meter cover B ELECTRICAL SYSTEM 16 65 Meter Gauge Indicator Unit Electronic Combination Meter Unit Inspection e Remove the meter unit A see Meter Unit Removal In stallation 1 Ignition 2 Fuel Level Warning Indicator Light LED 3 Unused EX650A Models ABS Indicator Light LED EX650B Models 4 Unused 5 Neutral Indicator Light LED 6 FI Indicator Light LED 7 Tachometer Signal 8 Water Temperature Sensor 9 Ground 10 Battery 11 Pressure Warning Indicator Light LED 12 Speed Sensor Supply Voltage 13 Right Turn Signal Indicator Light LED 14 Left Turn Signal Indicator Light LED 15 High Beam Indicator Light LED 16 Speed Sensor Si
256. em is normal service code is not stored temporary failure GL14031BS1 GL14032BS1 GL14004BS1 C BRAKES 12 47 Anti Lock System Front Rear Wheel Rotation Difference Abnormal Service Code 25 e Do the 1st step test 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 lf the all parts correct 2nd step e Do the 2nd step test O Recheck the service code indication erase the service code perform the pre diagnosis inspection 1 and 2 and retrieve the service code xIf the ABS indicator light LED A lit faulty ECU in the ABS hydraulic unit Replace the ABS hydraulic unit If the ABS indicator light LED A unlit ABS system is normal service code is not stored temporary failure ABS Pump Motor Relay Inspection Service Code 35 e Do the 1st step test OCheck the ABS pump motor relay fuse A x If the fuse blown 2nd step xIf the fuse correct 4th step e Do the 2nd step test ODisconnect the ABS hydraulic unit connector OCheck for continuity between the red white and black yel low lead terminals of the ABS hydraulic unit connector A x lf there is the continuity in the lead replace the ABS hy draulic unit x lf there is n
257. emoving the engine or the motorcycle may fall over It could cause an accident and injury CAUTION Be sure to hold the front brake when removing the engine or the motorcycle may fall over The engine or the motorcycle could be damaged e Drain Engine Oil see Engine Oil Change in the Periodic Main tenance chapter Coolant see Coolant Change in the Periodic Mainte nance chapter e Remove Seat see Seat Removal in the Frame chapter Lower Fairings see Lower Fairing Removal in the Frame chapter Upper Inner Fairings see Upper Inner Fairing Removal in the Frame chapter Windshield see Windshield Removal in the Frame chapter Meter Cover see Meter Unit Removal Installation in the Electrical System chapter Center Fairings see Center Fairing Removal in the Frame chapter Side Covers see Side Cover Removal in the Frame chapter Frame Covers see Frame Cover Removal in the Frame chapter Radiator and Hoses see Radiator and Radiator Fan Re moval in the Cooling System chapter e Pull the clamp A on the lower fairing bracket e Unscrew the lower fairing bracket bolts both sides B and remove the brackets both sides C e Disconnect the oil pressure switch terminal D GH04011081 ENGINE REMOVAL INSTALLATION 8 5 Engine Removal Installation e Disconnect the crankshaft sensor lead connector A e Remove Exhaust Pipe see Exhaust Pipe Removal in the Engine Top E
258. en the tester indicator should flick B x lf the tester indicator does not flick replace the speed sensor DC25V GP18030BS1 C Oxygen Sensor Removal Europe Models e Remove Left Lower Fairing see Lower Fairing Removal in the Frame chapter e Disconnect the oxygen sensor lead connector A e Remove the oxygen sensor A Oxygen Sensor Installation Europe Models CAUTION Never drop the oxygen sensor A especially on a hard surface Such a shock to the unit can damage it Do not touch the sensing part B and filter holes C of the sensor to prevent oil contact Oil contami nation from hands can reduce sensor performance e Tighten 74 Torque Oxygen Sensor 44 1 N m 4 50 kgf m 32 5 ft Ib e Run the oxygen sensor lead correctly see Cable Wire and Hose Routing section in the Appendix chapter 16 76 ELECTRICAL SYSTEM Switches and Sensors Oxygen Sensor Inspection Europe Models e Refer to the Oxygen Sensor Inspection in the Fuel System DFI chapter Fuel Reserve Switch Inspection e Fill the fuel tank with fuel e Close the fuel tank cap surely Remove the fuel tank see Fuel Tank Removal in the Fuel System DFI chapter e Connect the test light A 12 V 3 4 W bulb a socket with leads and the 12 V battery B to the fuel pump connector C Connections Battery 12 V 3 4 W Bulb One Side 12 V 3 4 W Bulb Other Side BL Lead Terminal
259. ent 1 0 1111 1 0 ener enn 16 58 Turn Signal Relay Inspection 16 59 Air Switching etm 16 61 Air Switching Valve Operation Test 16 61 Air Switching Valve Unit Test eren D te ete Ce pe ad hades 16 61 Radiator Fan System darte thts deste ecce etta ret doct 16 63 Fan Motor 2 16 63 Meter Gauge Indicator Unit 22 16 64 Meter Unit Removal lnstallation 16 64 Mater Gauge Disassembly uite iconic tht tht poat idet od eio titre tur dre en ed oris i det 16 64 Electronic Combination Meter Unit Inspection pp 16 65 Switches ANG SSNS OMS wat c t 16 73 Brake Light Timing Inspection Ne 16 73 Brake Light Timing Adjustment ep agere 16 73 SWITCH PECUOM I E c TREES 16 73 Water Temperature Sensor Inspection pp 16 74 Speed Sensor Removal pp 16 74 Speed Sensor Installation pp 16 74 Speed Sensor Inspectlori oor cm ete pss phe beat Eo DER p 16 75 Oxygen Sensor Removal Europe 16 75 Oxygen Sensor Installation Europe Models pp 16 75 Oxygen Sensor Inspection Europe 5 16 76 Fuel Reserve Switch Inspection pp 16 76 Relay BOX oc eet ies e m eR LM LEE diee 16 77 i is Gri 16 77 Rela
260. ent wheel lock up and allows stable steering control while stopping Brake control function is identical to that of a conventional motorcycle The brake lever is used for the front brake and the brake pedal for the rear brake Although the ABS provides stability while stopping by preventing wheel lock up remember the fol lowing characteristics OABS cannot compensate for adverse road conditions misjudgement or improper application of brakes You must take the same care as with motorcycles not equipped with ABS OABS is not designed to shorten the braking distance On loose uneven or downhill surfaces the stopping distance of a motorcycle with ABS may be longer than that of an equivalent motorcycle without ABS Use special caution in such areas OABS will help prevent wheel lock up during straight up braking but it cannot control wheel slip which may be caused by braking during cornering When turning a corner it is better to limit braking to the light application of both brakes or not to brake at all Reduce your speed before you get into the corner OThe ECU integrated in the ABS compare vehicle speed with wheel speed Since non recommended tires can affect wheel speed they may confuse the ECU which can extend braking distance WARNING Use of non recommended tires may cause malfunctioning of ABS and can lead to extended braking distance The rider could have an accident as a result Always use recommended standard tires for this motor
261. er Head Cover Bolts B Olnstall the washers with metal side C faces upward e Tighten Torque Cylinder Head Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib ENGINE END 5 17 Cylinder Head Cover e Install the baffle plate Tighten Torque Baffle Plate Bolts B 5 9 N m 0 60 kgf m 52 in Ib GE09045BS1 5 18 ENGINE END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION This is a non return type camshaft chain tensioner The push rod does not return to its original position once it moves out to take up camshaft chain slack Observe all the rules listed below When removing the tensioner do not take out the mounting bolts only halfway Retightening the mounting bolts from this position could damage the tensioner and the camshaft chain Once the bolts are loosened the tensioner must be removed and reset as described in Camshaft Chain Ten sioner Installation Do not turn over the crankshaft while the tensioner is removed This could upset the camshaft chain timing and damage the valves e Remove Right Center Fairing see Center Fairing Removal in the Frame chapter Cap Bolt A Washer B Spring C e Remove the mounting bolts D and take off the camshaft chain tensioner Camshaft Chain Tensioner Installation e Release the stopper A and push the push rod B into the tensioner C e Install the
262. er Removal e Remove the seat see Seat Removal Remove the bolt A e Pull the side cover B evenly outward to clear the stop pers Side Cover Installation e Insert the tabs A into the holes B Tighten the bolt e Install the seat see Seat Installation 15 14 FRAME Seat Covers Seat Cover Removal e Remove Seat see Seat Removal Bolts A Grab Rails B Other than United States and Canada Models Screw Rivets C e Push the central pin and then remove the quick rivets A e Pull the front and rear portions of the seat cover outside and then remove the seat covers Seat Cover Installation e Installation is the reverse of removal e Put the projection A into the grommet B on the rear fender rear e Put the projection A into the hole B of the seat cover e Install Grab Rails Other than United States and Canada Mod els and Bolts Torque Grab Rail Mounting Bolts 25 2 5 kgf m 18 ft Ib e Insert the projections A of the center seat cover into the holes B of the side seat cover e Install Screw Rivets Seat see Seat Installation 15 15 Fenders Front Fender Removal e Remove Brake Hose Clamps A Bolts B with Collar Both Side Remove the front fender Front Fender Installation Tighten Torque Front Fender Bolts 3 9 N m 0 40 kgf m 35 in Ib e Install the brake hose clamps to the front fender holes Flap a
263. ermanent locking agent R Replacement Parts 15 4 Exploded View 6002159BW5 C 15 5 Exploded View Torque No Fast R k astener Nm ftlb emarks 1 Front Fender Bolts 3 9 0 40 35 2 Front Fender Bracket Bolts 8 8 0 90 78 in lb L 3 Front Turn Signal Light Mounting Screws 1 2 0 12 11 in Ib L Apply a non permanent locking agent 15 6 FRAME Exploded View 15 7 Exploded View Torque No Fast Remarks meas Nm kgf m ft lb 1 Grab Rail Mounting Bolts 25 2 5 18 2 Seat Lock Mounting Screws 1 2 0 12 11 in lb 3 Seat United States and Canada Models 4 Seat Lock Bracket EX650B Models 5 EX650B Models 6 Grab Rails Other than United States and Canada Models 7 Washers United States and Canada Models 15 8 FRAME Seat Seat Removal e Insert the ignition switch key A into the seat lock turning the key clockwise pulling up on the rear of the seat B and pulling the seat backward Seat Installation e Slip the seat hook A under the brace B on the fuel tank bracket e Insert the seat latch A into the latch hole B e Push down the rear part of the seat until the lock clicks 15 9 Fairings Lower Fairing Removal e Pull up the core by the thin blade driver Remove the quick rivets A Remove the bolts with
264. erminal 10 of the Meter Battery Terminal BR R Lead Terminal 6 of the Meter Battery Terminal Criterion The light LED should light x If the light LED does not go on replace the meter unit see Meter Unit Removal Installation in the Electrical Sys tem chapter Fl Indicator Light LED Circuit 86617123651 ECU Water proof Joint Ignition Switch Meter Unit Ignition Fuse 10 A Main Fuse 30 A Battery Frame Ground Joint Connector 6C179828W2 3 80 FUEL SYSTEM DFI ECU CAUTION Never drop the ECU especially on a hard surface Such a shock to the ECU can damage it ECU Removal e Remove Seat see Seat Removal in the Frame chapter Grab Rails A see Seat Cover Removal in the Frame chapter Center Seat Cover B see Seat Cover Removal in the Frame chapter Seat Covers C see Seat Cover Removal in the Frame chapter Rear Fender Rear Bolts D e Pull down the rear fender rear A e Remove the ECU bracket bolts A e Take the ECU B out along with the harness e Disconnect the ECU lead connectors ECU Installation e Fit A the bracket on the ECU as shown FUEL SYSTEM DFI 3 81 ECU ECU Power Supply Inspection e Visually inspect the terminals A of the ECU connectors xIf the connector is clogged with mud or dust blow it off with compressed air Replace t
265. ervoir cap B clock wise C by hand until slight resistance is felt indicating that the cap is seated on the reservoir body then tighten the cap an additional 1 6 turn D while holding the brake fluid reservoir body A Brake Pad Wear Inspection e Check the lining thickness A of the pads in each caliper x If the lining thickness of either pad is less than the service limit B replace both pads in the caliper as a set Pad Lining Thickness Standard Front 4 5 mm 0 18 in Rear 5 0 mm 0 20 in Service Limit 1 mm 0 04 in Brake Light Switch Operation Inspection e Turn on the ignition switch 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 e Disconnect the connector A e Turn the brake light switch to adjust the switch e Connect the connector 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 Removal in the Electri cal System chapter Main Fuse 30 A and Taillight Fuse 10 A see Fuse In spection in the Electrical System chapter Front Brake Light Switch A see Switch Inspection in the Electrical System chapter Rear Brake Light Switch see Switch Inspection in the Electrical System chapter Harness see Wiring Inspection in the Electrical System ch
266. ery has ex ceeded its useful life Replace it Provided however the vehicle s starting system has no prob lem A WARNING Keep the battery away from sparks and open flames during charging since the battery gives off an explosive gas mixture of hydrogen and oxygen When using a battery charger connect the battery to the charger before turning on the charger This procedure prevents sparks at the battery terminals which could ignite any battery gases No fire should be drawn near the battery or no terminals should have the tightening loos ened The electrolyte contains sulfuric acid Be careful not to have it touch your skin or eyes If touched wash it off with liberal amount of water Get medial attention if severe Interchange A sealed battery can fully display its performance only when combined with a proper vehicle electric system Therefore replace a sealed battery only on a motorcycle which was originally equipped with a sealed battery Be careful if a sealed battery is installed on a motorcycle which had an ordinary battery as original equipment the sealed battery s life will be shortened ELECTRICAL SYSTEM 16 29 Battery Charging Condition Inspection OBattery charging condition can be checked by measuring battery terminal voltage with a digital voltmeter A e Remove Seat see Seat Removal in the Frame chapter Battery Cable Cap see Battery Removal e Disconnect the battery terminals CA
267. essary adjust the throttle cable as follows e 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 e Remove the right center fairing see Center Fairing Re moval in the Frame chapter e Loosen the locknut A at the middle of the decelerator cable e Turn the adjuster B until there is no play when the throttle grip is completely closed e Tighten the locknut e Turn the accelerator cable adjuster until the proper amount of throttle grip free play is obtained e Tighten the locknut Engine Vacuum Synchronization Inspection NOTE O These procedures are explained on the assumption that the inlet and exhaust systems of the engine are in good condition e Situate the motorcycle so that it is vertical e Remove the center fairings see Center Fairing Removal in the Frame chapter e Pull off the rubber caps A from the fitting of each throttle body In the photo the throttle body has been removed for clarity CAUTION Do not remove the inlet air pressure sensor hose B on the left fitting of the throttle body e Connect a commercially available vacuum gauge and hoses A to the fittings of the throttle body as shown e Connect a highly accurate tachometer to one of the stick coil primary leads GS05085BS1 PERIODIC MAINTENANCE 2 17 Periodic Maintenance Procedures e Start the engin
268. essive 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 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 APPENDIX 17
269. est 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 8 10000451 C e Do the 2nd step regulator circuit test OConnect the test light and the 12 V battery in the same manner as specified in the Regulator Circuit Test 1st Step OApply 12 V to the voltage BR terminal OCheck the BK1 BK2 and BK3 terminal respectively x If the test light turns on the regulator rectifier is defective Replace it x lf the test light does not turn on continue the test 8 10000551 C ELECTRICAL SYSTEM 16 37 Charging System e Do the 3rd step regulator circuit test OConnect the test light and the 12 V battery in the same manner as specified in the Regulator Circuit Test 1st Step OMomentarily apply 24 V to the voltage BR terminal by adding a 12 V battery OCheck the BK1 BK2 and BK3 terminals respectively CAUTION Do not apply more than 24 V If more than 24 V is ap plied the regulator rectifier may be damaged Do not apply 24 V more than a few seconds If 24 V is applied for more than a few seconds the regula tor rectifier may be damaged xIf the test light did not light when the 24 V was applied momentarily to the voltage monitoring terminal the regu lator rectifier is defective Replac
270. ets 14 10 Handlebar Removal 14 10 Handlebar Install amp tiOri i eo re eoe eb p ee pra Eben 14 10 14 2 STEERING Exploded View STEERING 14 3 Exploded View Torque No Fastener kaf ftlb Remarks 1 Front Fork Clamp Bolts Lower 20 2 0 15 AL 2 Front Fork Clamp Bolts Upper 20 2 0 15 Handlebar Holder Bolts 25 2 5 18 5 4 Left Switch Housing Screws 3 5 0 36 31 in Ib 5 Right Switch Housing Screws 3 5 0 36 31 in Ib 6 Steering Stem Head Bolt 108 11 0 80 7 Steering Stem Nut 20 2 0 15 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 Steering Stem Nut Wrench Steering Stem Bearing Driver 42 5 57001 1100 57001 1344 875711005 C 7571344ST C Bearing Driver Set Steering Stem Bearing Driver Adapter 41 5 57001 1129 57001 1345 7571129ST C 875713455 C STEERING 14 5 Steering Steering Inspection e Refer to the Steering Play Inspection in the Periodic Main tenance chapter Steering Adjustment Refer to the Steering Play Adjustment the Periodic Maintenance chapter 14 6 STEERING Steering Stem Stem Stem Bearing Removal e Remove Upper Fairing see
271. event corrosion and deposits in the fuel system do not add to fuel any fuel antifreeze chemicals 6017036881 FUEL SYSTEM DFI 3 21 DFI Servicing Precautions OTo maintain the correct fuel air mixture F A there must be no inlet air leaks in the DFI system Be sure to install the oil filler plug A after filling the engine oil Clutch Cover B Torque Oil Filler Plug Hand tighten 3 22 FUEL SYSTEM Troubleshooting the DFI System Outline Outline When an abnormality in the system occurs the FI indi cator light LED goes on to alert the rider on the meter panel In addition the condition of the problem is stored in the memory of the ECU electronic control unit With the engine stopped and turned in the self diagnosis mode the service code A is indicated by the number of times the FI indicator light LED blinks When due to a malfunction the FI indicator light LED re mains lit ask the rider about the conditions B under which the problem occurred and try to determine the cause C First conduct a self diagnosis inspection and then a non self diagnosis inspection The non self diagnosis items are not indicated by the FI indicator light LED Don t rely solely on the DFI self diagnosis function use common sense Even when the DFI system is operating normally the FI indicator light LED A may light up under strong electrical interference No repair needed Turn
272. excessively worn dogs or dog holes 6113134851 C 6113135851 C CRANKSHAFT TRANSMISSION 9 41 Ball Bearing Needle Bearing Oil Seal Ball and Needle Bearing Replacement CAUTION Do not remove the ball or needle bearings unless it is necessary Removal may damage them e Using a press or puller remove the ball bearing and or needle bearings NOTE Oln the absence of the above mentioned tools satisfac tory results may be obtained by heating the case to ap proximately 93 C 200 F max and tapping the bearing in or out CAUTION 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 6114060551 Special Tool Bearing Driver Set 57001 1129 Ball and Needle Bearing Wear CAUTION Do not remove the bearings for inspection Re moval may damage them e 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 c
273. f the ground with stand see Rear Wheel Removal in the Wheels Tires chapter e Inspect the roughness of the rear wheel bearing by push ing and pulling A the wheel e Spin B the rear wheel lightly and check for smoothly turn roughness binding or noise 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 Drive Train Drive Chain Lubrication Condition Inspection e f a special lubricant is not available a heavy oil such as SAE 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication e f the chain appears especially dirty clean it before lubri cation CAUTION The O rings between the side plates seal in the lu bricant between the pin and the bushing To avoid damaging the O rings and resultant loss of lubri cant observe the following rules Use only kerosene or diesel oil for cleaning an O ring drive chain Any other cleaning solution such as gasoline or trichloroethylene will cause deterio ration and swelling of the O ring Immediately blow the chain dry with compressed air after cleaning Complete cleaning and drying the chain within 10 minutes PERIODIC MAINTENANCE 2 29 Periodic Maintenance Procedures e Apply oil to the sides of the rollers so tha
274. 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 Lh Left hand threads MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts S Follow the specified tightening sequence Si Apply silicone grease ex PBC grease SS Apply silicone sealant Torque Fastener mm ftlb Remarks Fuel System DFI Water Temperature Sensor 12 1 2 106 in Ib Speed Sensor Bolt 7 8 0 80 69 in lb L Fuel Pump Bolts 9 8 1 0 87 in lb L S Oxygen Sensor Europe Models 44 1 4 50 32 5 Cooling System Radiator Hose Clamp Screws 17 in lb Water Pump Impeller Bolt 87 Water Pump Cover Bolts 87 Water Pump Drain Bolt 62 in Ib Thermostat Housing Bolts 87 Water Temperature Sensor 106 in Ib Baffle Plate Bolts 52 in Ib Engine Top End Air Suction Valve Cover Bolts 9 8 1 0 87 Cylinder Head Cover Bolts 9 8 1 0 87 Camshaft Cap Bolts 12 1 2 106 in Ib S Cylinder Head Bolts M10 New Bolts 54 5 5 40 MO S Cylinder Head Bolts M10 Used Bolts 49 5 0 36 MO S Cylinder Bolt M8 27 5 2 8 20 MO S Cylinder Nut M10 49 5 0 36 MO S Cyli
275. g 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 6 8 CLUTCH Clutch Cover Clutch Cover Removal e Remove Engine Oil Drain see Engine Oil Change in the Periodic Maintenance chapter Right Frame Cover see Frame Cover Removal in the Frame chapter Right Center Fairing see Center Fairing Removal in the Frame chapter Clutch Cable Lower End A Clutch Cover Mounting Bolts B e Turn the release lever A toward the rear as shown and remove the clutch cover B About 90 C e Push the release lever toward the front of the motorcycle and tape the release lever to the clutch cover to prevent the release shaft from falling out GF05010381 C Clutch Cover Installation e Apply silicone sealant to the area A where the mating surface of the crankcase touches the clutch cover gasket and to the crankshaft sensor lead grommet B Sealant Kawasaki Bond Silicone Sealant 92104 0004 e Be sure that the dowel pins C are in position e Replace the clutch cover gasket D with a new one e Tighten the clutch cover mounting bolts Torque Clut
276. g x The rings should fit perfectly parallel to groove surfaces If not replace the piston and all the piston rings e With the piston rings in their grooves make several mea surements with a thickness gauge A to determine piston ring groove clearance Piston Ring Groove Clearance Top Standard 0 03 0 07 mm 0 0012 0 0028 in Service Limit 0 17 mm 0 0067 in Second Standard 0 02 0 06 mm 0 0008 0 0024 in Service Limit 0 16 mm 0 0063 in Piston Ring Groove Width Measure the piston ring groove width OUse a vernier caliper at several points around the piston Piston Ring Groove Width Top A Standard 0 92 0 94 mm 0 0362 0 0370 in Service Limit 1 02 mm 0 040 in Second B Standard 1 01 1 03 mm 0 0398 0 0406 in Service Limit 1 11 mm 0 044 in x lf the width of any of the two grooves is wider than the service limit at any point replace the piston Piston Ring Thickness e Measure the piston ring thickness OUse the micrometer to measure at several points around the ring Piston Ring Thickness Top A Standard 0 87 0 89 mm 0 0342 0 0350 in Service Limit 0 80 mm 0 031 in Second B Standard 0 97 0 99 mm 0 0382 0 0390 in Service Limit 0 90 mm 0 035 in x If any of the measurements is less than the service limit on either of the rings replace all the rings NOTE OWhen using new rings in a used piston check for un even groove wear The ri
277. g speed sensor operation and wiring are good check the ECU for its ground and power supply see ECU Power Supply Inspection Speed Sensor Circuit 6C179778W2 1 ECU 2 Speed Sensor 3 Meter Unit 4 Water proof Joint B 5 Frame Ground 6 Joint Connector FUEL SYSTEM DFI 3 59 Vehicle down Sensor Service Code 31 Vehicle down Sensor Removal CAUTION Never drop the down sensor especially on a hard surface Such a shock to the sensor can damage it e Remove Bolts A Connector and Vehicle down Sensor B Vehicle down Sensor Installation e The UP mark A of the sensor should face upward A WARNING Incorrect installation of the vehicle down sensor could cause sudden loss of engine power The rider could lose balance during certain riding situ ations like leaning over in a turn with the potential for an accident resulting in injury or death Ensure that the down sensor is held in place by the sensor brackets 80170040651 Vehicle down Sensor Inspection NOTE OBe sure the battery is fully charged Connect a digital volt meter A to the connector of the vehicle down sensor C with the needle adapter set D Vehicle down Sensor Power Source Voltage Connections to Sensor Meter BL lead E Meter BR BK lead e Turn the ignition switch ON and measure the power source voltage with the connect
278. g 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 tighten the stem head bolt e Tighten Torque Steering Stem Head Bolt 108 N m 11 0 kgf m 80 ft Ib Front Fork Clamp Bolts Upper 20 N m 2 0 kgf m 15 ft lb e Check the steering again x lf the steering is still too tight or too loose repeat the ad justment e Install the removed parts see appropriate chapters 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 in the cages and wipe the upper and lower outer races which are press fitted into the frame head pipe clean off grease and dirt e Visually check the outer races and the ball bearings Replace the bearing assemblies if they show wear or damage e Pack the upper and lower ball bearings A in the cages with grease and apply a light coat of grease to the upper and lower outer races e Install the steering stem see Stem Stem Bearing Instal lation in the Steering chapter e Adjust the steering see Steering Play Adjustment Electrical System Spark Plug Condition Inspection e Remove the spark plugs see Spark Plug Replacement e Visually inspect the spark plugs x lf the spark plug center electrode A and or side elec trode B are corroded or damaged or if the insulator
279. gauge A between the crankcase main bearing and the crank web at the No 2 journal B to determine clearance x lf the clearance exceeds the service limit replace the crankcase halves as a set NOTE OThe upper and lower crankcase halves are machined at the factory in the assembled state so the crankcase halves must be replaced as a set Crankshaft Side Clearance Standard 0 05 0 20 mm 0 0020 0 0079 in Service Limit 0 40 mm 0 0157 in Crankshaft Runout Measure the crankshaft runout x If the measurement exceeds the service limit replace the crankshaft Crankshaft Runout Standard TIR 0 02 mm 0 0008 in or less Service Limit TIR 0 05 mm 0 0020 in Crankshaft Main Bearing Insert Journal Wear e Using a plastigage press gauge A measure the bear ing insert journal B clearance NOTE OTighten the crankcase bolts to the specified torque see Crankcase Assembly ODo not turn the crankshaft during clearance measure ment OJournal clearance less than 0 025 mm 0 00098 in can not be measured by plastigage however using genuine parts maintains the minimum standard clearance Crankshaft Main Bearing Insert Journal Clearance Standard 0 012 0 036 mm 0 0005 0 0014 in Service Limit 0 07 mm 0 0028 in x If the clearance is within the standard no bearing replace ment is required x If the clearance is between 0 037 mm 0 0015 in and the service limit 0 07 mm 0 0028 in replace
280. gen sensor connector joined 6617008651 C Oxygen Sensor Power Source Voltage Connections to Oxygen Sensor Connector Tester W Y lead D Tester Battery Terminal E Standard Battery Voltage 12 8 V or more Oxygen Sensor F x lf the reading is incorrect check the following Battery Main Fuse 30 A Oxygen Sensor Heater Fuse 10 A x If the reading is good the power source voltage is normal Inspect the Red Black lead between the oxygen sensor connector and the ECU for continuity using the following diagram x If the wiring is good inspect the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see ECU Removal Installation FUEL SYSTEM 3 75 Oxygen Sensor Heater Service Code 67 Europe Models Oxygen Sensor Circuit x c 6GC179868W2 ECU Oxygen Sensor Water proof Joint E Water proof Joint D Oxygen Sensor Heater Fuse 10 A Main Fuse 30 A Battery Frame Ground Joint Connector 3 76 FUEL SYSTEM Oxygen Sensor Incorrect Output Voltage Service Code 94 Europe Models Oxygen Sensor Removal Installation e Refer to the Oxygen Sensor Removal Installation in the Electrical System chapter Oxygen Sensor Inspection e Warm up the engine thoroughly until the radiator fan starts e Turn the ignition switch OFF e Rem
281. gf m ft lb Fuel Pump Bolts 9 8 1 0 87 in lb L S Fl Indicator Light LED Throttle Cable Accelerator Throttle Cable Decelerator Throttle Body Assy Injectors Meter Unit EX650B Models Apply cable lubricant Apply engine oil Apply grease Apply a non permanent locking agent Replacement Parts Follow the specified tightening sequence Im o 3 6 FUEL SYSTEM DFI Exploded View FUEL SYSTEM DFI 3 7 Exploded View Torque No Fastener Nm kgf m Remarks 1 Water Temperature Sensor 12 1 2 106 in Ib 2 Speed Sensor Bolt 7 8 0 80 69 in Ib L 3 Oxygen Sensor Europe Models 44 1 4 50 32 5 4 Inlet Air Pressure Sensor 5 Air Switching Valve 6 Inlet Air Temperature Sensor 7 Crankshaft Sensor 8 Battery 9 Relay Box 10 Stick Coil 11 Vehicle down Sensor 12 ECU Electronic Control Unit 13 California Model G Apply grease L Apply a non permanent locking agent R Replacement Parts SS Apply silicone sealant 3 8 FUEL SYSTEM DFI Exploded View California Model 6002204BW5 C FUEL SYSTEM DFI 3 9 Exploded View 1 Tube Green 2 Tube Blue 3 Tube White 4 Tube Blue 5 Tube Red 3 10 FUEL SYSTEM DFI System DFI System zg LN 4 FUEL SYSTEM DFI 3 11 DFI System Ignition Swi
282. gnal CAUTION Do not drop the meter unit Place the meter unit so that it faces upward If the meter unit is left upside down or sideways for a long time or dropped it will malfunction Do not short each terminals 8 17377 52 C Liquid Crystal Display LCD Segment Check e Using the auxiliary wires connect the 12 V battery to the meter unit connector as follows OConnect the battery positive terminal to the terminal 10 OConnect the battery negative terminal to the terminal 9 OThe needles of the meter move e Connect the terminal 1 to the terminal 10 go0000000 GP17379BS1 C GP17380BS1 16 66 ELECTRICAL SYSTEM Meter Gauge Indicator Unit OWhen the terminals are connected the LCD segment A and LED warning lights B appear x lf the LCD segment and LED warning lights will not ap pear replace the meter assembly e Disconnect the terminal 1 OThe LCD segment and LED warning lights disappear x lf the segment do not disappear replace the meter as sembly MODE AND RESET 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 display change to the CLOCK ODO TRIP A TRIP displays each time the MODE button A is pressed Olf the fuel level gauge flashed display change to CLOCK FUEL ODO TRIP A and TRIP B
283. h a plastigage Balancer Shaft Bearing Insert Selection Crankcase Main Bearing Bore Diameter Crankshaft Main 9106016852 C Bearing Insert Journal Diameter Mark Size Color Part Number Brown 92139 0119 Black 92139 0118 Blue 92139 0117 CRANKSHAFT TRANSMISSION 9 29 Transmission Shift Pedal Removal e Remove Shift Lever Bolt A Shift Lever B Shift Pedal Installation e Align the mark A on the shift shaft with the slit B on the shift lever e Tighten the shift lever bolt securely e Be sure the shift pedal position is as shown Shift Pedal Damper A Bottom B of Left Footpeg Stay Shift Lever C Bolt D of Left Footpeg Stay External Shift Mechanism Removal e Remove Engine Oil Drain see Engine Oil Change in the Periodic Maintenance chapter Shift Pedal see Shift Pedal Removal Engine Sprocket see Engine Sprocket Removal in the Final Drive chapter Neutral Switch Lead Connector Disconnect Shift Shaft Cover Bolts A Shift Shaft Cover Screw B Shift Shaft Cover C e Remove the shift shaft assembly A 9113249851 9 30 CRANKSHAFT TRANSMISSION Transmission e Remove Clutch see Clutch Removal in the Clutch chapter Gear Positioning Lever Bolt A Gear Positioning Lever B Spacer Washer and Spring External Shift Mechanism Installation e Install the gear positioning lever A as shown Spring B Washer C Spacer D Bolt
284. haft x 12 Sensor p Inlet Sensor Vehicl Water Air down Fuel Temperature Temperature zz 2a M e 1 3 3 50045 4 EHE sensar Injectors Sensor Sensor i 11 Lin Water proof 5 Joint D TIIT T7771 Air m Switching i m i3 Valve 22 5 55 BE T R BL H H H 1 Exc mu Gontrol Unit EGU BK BL H ey v W Y BL BK Y Joint Connector License Plate Light 12 5 Rear Right Turn Signal Light 12 21 BK Y BK Y Tail Brake Light 12y21 5W Tz 88 Ground x ie Boze 8 ae For Saas 25455 Rear Left Turn Signal Light Self 120219 diagnosis Fuel Kawasaki Termin Side Reserve Self diagnosis stand Switch System Switch Rear Fuel Connector Brake Pump Battery Light Switch 12 10 Starter Relay od oar Main Fuse Fan Relay tk 2 Headlight Relay 3 ECU Main Relay 4 5 Fuel Pump Relay LB Light Blue Starter Circuit Relay IGNITION SWITCH CONNECTIONS 0 Orange W2RO232AW5 C 16 16 ELECTRICAL SYSTEM Wiring Diagram United States Canada New Zealand and Malaysia Right Switch Housing 1 Front Brake Light Swite 2 Engine Stop Switch S Starter Button Regulator Rectifier h
285. hapter 3 Main throttle sensor trouble Inspect see chapter 3 3 32 FUEL SYSTEM DFI DFI System Troubleshooting Guide Symptoms or Possible Causes Actions chapter Engine stalls easily Fuel pump trouble Inspect see chapter 3 Fuel injector trouble Inspect see chapter 3 Main throttle sensor trouble Inspect see chapter 3 Le Fuel pressure too low or too high Inspect see chapter 3 Inlet air pressure sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Inlet air temperature sensor trouble Inspect see chapter 3 Fuel line clogged Inspect and repair see chapter 3 Fuel pressure too low or too high Inspect see chapter 3 Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump see chapter 3 Inspect see chapter 16 inspect see chapter 16 Spark plug loose Reinstall see chapter 16 Tighten see chapter 5 Adjust see chapter 2 Cylinder piston worn Inspect and replace see chapter 5 Piston ring bad worn weak broken or sticking Inspect and replace see chapter 5 Piston ring groove clearance excessive Inspect and replace see chapter 5 Cylinder head gasket damaged Replace see chapter 5 Cylinder head warped Inspect and replace see chapter 5 Valve guide worn or stem seal damaged Inspect and replace see chapter 5 Valve spring br
286. hat 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 12 28 BRAKES Hose Brake Hose Removal Installation e Refer to the Brake Hose and Pipe Replacement in the Periodic Maintenance chapter Brake Hose Inspection e Refer to the Brake Hose Damage and Installation Condi tion Inspection in the Periodic Maintenance chapter BRAKES 12 29 Anti Lock Brake System Parts Location 8140018 1 Front Wheel Rotation Sensor 2 Front Wheel Rotation Sensor Rotor 3 Rear Wheel Rotation Sensor 4 Rear Wheel Rotation Sensor Rotor 5 ABS Indicator Light LED 6 ABS Hydraulic Unit 7 ABS Fuse Box 8 ABS Kawasaki Self diagnosis System Connector 12 30 BRAKES Anti Lock Brake System ABS System Wiring Diagram uem 8 karren ies GL14002BW3 C lgnition Switch ABS Hydraulic Unit ABS Self diagnosis Terminal ABS Kawasaki Self
287. he brakes will need to be bled since air will have entered the brake line OFront Brake Repeat the above steps for the other caliper AON Remove the clear plastic hose e Install the diaphragm and reservoir cap e Tighten Torque Front Brake Reservoir Cap Screws 1 0 N m 0 10 kgf m 9 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 Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib e After changing the fluid check the brake for good braking power no brake drag and no fluid leakage x If necessary bleed the air from the lines Master Cylinder Rubber Parts Replacement Front Master Cylinder Disassembly Remove the front master cylinder see Front Master Cylin der Removal in the Brakes chapter e 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 Pull the dust cover A out of place and remove the circlip Special Tool Inside Circlip Pliers 57001 143 e Pull out the piston C secondary cup D primary cup E and return spring F
288. he fuel tank cap A to lower the pressure in the tank A WARNING Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is disconnected fuel spills out from the hose and the pipe because of residual pressure Cover the hose connection with a piece of clean cloth to prevent fuel spillage Connect the plastic hose A to the fuel pump outlet pipe e Secure the plastic hose with a clamp B e Run the other side of the plastic hose into the measuring cylinder C A WARNING Wipe off spilled out fuel immediately Be sure to hold the measuring cylinder vertical Temporarily install the fuel tank and close the fuel tank With the engine stopped turn the ignition switch ON The fuel pump should operate for 3 seconds and then should stop Repeat this several times until the plastic hose is filled with fuel 3 86 FUEL SYSTEM DFI Fuel Line CAUTION Do not drive the fuel pump without the fuel in the fuel tank Measure the discharge for 3 seconds with the plastic hose filled with fuel ORepeat this operation several times Amount of Fuel Flow Standard 60 mL or more for 3 seconds xIf the fuel flow is much less than the specified check the battery condition see Charging Condition Inspection in the Electrical System chapter If the battery is good re place the fuel pump see Fuel Pump Removal Installa tion
289. he gauge NOTE OSituate the motorcycle so that it is perpendicular to the ground Olf the motorcycle has just been used wait several min utes for all the oil to drain down Olf the oil has just been changed start the engine and run it for several minutes at idle speed This fills the oil filter with oil Stop the engine then wait several minutes until the oil settles CAUTION Racing the engine before the oil reaches every part can cause engine seizure If the engine oil gets extremely low or if the oil pump or oil passages clog up or otherwise do not function properly the oil pressure warning light will light If this light stays on when the engine is running above idle speed stop the engine immediately and find the cause x lf the oil level is too high remove the excess oil using a syring or some other suitable device lf the oil level is too low add the correct amount of oil through the oil filter opening Use the same type and make of oil that is already in the engine NOTE Olf the engine oil type and make are unknown use any brand ofthe specified oil to top off the level in preference to running the engine with the oil level low Then at your earliest convenience change the oil completely Engine Oil Change e Refer to the Engine Oil Change in the Periodic Mainte nance chapter Oil Filter Replacement e Refer to the Oil Filter Replacement in the Periodic Main tenance chapter 600501
290. he main harness if the terminals of the main harness connectors are cracked bent or otherwise dam aged Replace the ECU if the terminals of the ECU connectors are cracked bent or otherwise damaged e With the ECU connectors A connected check the fol lowing ground lead for continuity with the ignition switch OFF using a tester and needle adapter set Battery B Tester C Special Tool Needle Adapter Set 57001 1457 ECU Grounding Inspection 34 50 or 51 BK Y Terminal Engine Ground Battery Terminal 0 Battery Terminal 0 x If no continuity check the connector the engine ground lead or main harness and repair or replace them if nec essary e Check the ECU power source voltage with a digital meter A OPosition the terminal in accordance with terminal numbers of ECU connectors B in this chapter figure Battery C ECU Power Source Inspection Meter Connections Between Terminal 16 BR W and Battery Terminal Between Terminal 17 W BK and Battery Terminal Ignition Switch OFF Terminal 16 BR W 0 V Terminal 17 W BK Battery Voltage 12 8 V or more Ignition Switch ON Both Battery Voltage 12 8 V or more x If the meter does not read as specified check the follow ing Main Fuse 30 A see Fuse Inspection in the Electrical System chapter ECU Fuse 15 A see Fuse Inspection in the Electrical System chapter ECU Main Relay see Relay Circuit Inspection
291. he 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 5 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 5 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 Item Standard Coolant Provided when Shipping Type Recommended Color Mixed Ratio Freezing Point Total Amount Permanent type of antifreeze soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators Green Soft water 50 coolant 50 35 C 31 F 1 2 L 1 3 US qt reserve tank full level including radiator and engine Radiator Cap Relief Pressure 112 3
292. he rubber cap Torque Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib Check the fluid level see Brake Fluid Level Inspection in the Periodic Maintenance chapter e After bleeding is done check the brake for good braking power no brake drag and no fluid leakage GL09036BS2 C M OT eer BRAKES 12 27 Brake Fluid A WARNING When working with the disc brake observe the pre cautions listed below 1 2 3 Never reuse old brake fluid Do not use fluid from a container that has been left unsealed or that has been open for a long time Do not mix two types and brands of fluid for use in the brake This lowers the brake fluid boiling point and could cause the brake to be ineffective It may also cause the rubber brake parts to deteriorate Don t leave the reservoir cap off for any length of time to avoid moisture contamination of the fluid Don t change the fluid in the rain or when a strong wind is blowing Except for the disc pads and disc use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning of the brake parts Do not use any other fluid for cleaning these parts Gasoline engine oil or any other petroleum distillate will cause deterio ration of the rubber parts Oil spilled on any part will be difficult to wash off completely and will eventually deteriorate the rubber used in the disc brake When handling the disc pads or disc be careful t
293. heck its condition x If the bearing is noisy does not spin smoothly or has rough spots replace it 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 e Inspect the oil seals Replace it if the lips are misshapen discolored indicating that the rubber has deteriorated hardened or otherwise damaged WHEELS TIRES 10 1 Wheels Tires Table of Contents Exploded VIEW 10 2 SDpOeCcITICatlOriS 10 4 Special DoS 10 5 E 10 6 Eront Wheel Removals dee teca toe id duet rive tee wine nea Ma 10 6 Front Wheel Installation pp 10 6 Rear Wheel 10 8 Rear Wheel InistallatiQr 1 2 iiit ti et ee e le Lag ae e do p e A PER Lege dadas 10 8 Wheel Inspection nhanh rra nnne nnne rennen 10 10 AXle Irispectioni s dote e eee inea ta e n 10 10 Balance Inspection ie eer eR etn 10 11 Balarice Adjustment teet Mende poer da
294. heck the brake pedal position see Brake Pedal Position Inspection BRAKES 12 17 Calipers Front Caliper Removal e Loosen the banjo bolt A at the brake hose lower end and tighten it loosely e Unscrew the caliper mounting bolts B and detach the caliper C from the disc e Unscrew the banjo bolt and remove the brake hoses D from the caliper see Brake Hose Removal Installation CAUTION Immediately wash away any brake fluid that spills NOTE Olf the caliper is to be disassembled after removal and if compressed air is not available disassemble the caliper before the brake hose is removed see Front Caliper Disassembly Rear Caliper Removal e Loosen the banjo bolt A at the brake hose lower end and tighten it loosely e Unscrew the caliper mounting bolts B and detach the caliper C from the disc e Unscrew the banjo bolt and remove the brake hose D from the caliper see Brake Hose Removal Installation CAUTION Immediately wash away any brake fluid that spills NOTE Olf the caliper is to be disassembled after removal and if compressed air is not available disassemble the caliper before the brake hose is removed see Rear Caliper Disassembly Caliper Installation e Install the caliper and brake hose lower end OReplace the washers on each side of hose fitting with new ones e Tighten Torque Caliper Mounting Bolts Front 34 N m 3 5 kgf m 25 ft Ib Rear 25 N m 2 5
295. hing Valve T R BL Vehicle Kater down Fuel Sensor Injectors 1 42 Water proof Joint E SS Air Temperature Temperature Sensor Sensor oil Neutral Pressure Se Switch Crankshaft Sensor Inlet Electronic Control Unit EGU BK BL BL Y LG R Ui Y BL Joint Connector R 12 2 5 Battery 12 10 Starter Relay elay Box Fan Relay Headlight Relay ECU Main Relay Fuel Pump Relay Starter Circuit Relay Main Fuse 30A ES S589 Fuel Kawasaki Reserve Self diagnosis Switch System Rear Fuel Connector Brake Pump Light Switch Self diagnosis Terminal License Plate Light 12V5W Rear Right Turn Signal Light 12V218 Tail Brake Light 12 21 5 Left Turn al Light 1 r n 2 LB Light Blue IGNITION SWITCH CONNECTIONS 0 Orange W2RO270AW5 C 16 20 ELECTRICAL SYSTEM Wiring Diagram EX650B Models Regulator BR Right Switch Housing Rectifier ae 1 Feont Brake Light Switch Ignition Switch R 2 Engine Stop Switch Alternator 3 Button BR WABL BK Y BK BK e BK Y R R BK R BK R E wu teg et pan Spark wR Motor
296. ical seal with a high flash point solvent and apply a little coolant to the sliding surface to give the mechanical seal initial lubrica tion 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 Visually check the impeller A If the surface is corroded or if the blades are damaged replace the impeller see Water Pump Removal COOLING SYSTEM 4 13 Radiator Radiator and Radiator Fan Removal e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Remove Center Fairings see Center Fairing in the Frame chap ter Reserve Tank see Coolant Change in the Periodic Main tenance chapter Radiator Fan Motor Connector A Disconnect Radiator Hose Clamp Screw B Loosen e Loosen Radiator Hose Clamp Screw A e Remove Radiator Bolt B Pull A the radiator toward the left noting the baffle plate C on the cylinder head cover CAUTION Do not touch the radiator core This could damage the radiator fins resulting in loss of cooling effi ciency e If necessary remove Radiator Fan Mounting Bolts A Radiator Fan B 4 14 COOLING SYSTEM Radiator Radiator and Radiator Fan Installation e Install the radiator A to the frame OAlign B the projection on the fra
297. ighten Torque Rear Master Cylinder Push Rod Locknut 18 N m 1 8 kgf m 13 ft Ib e Install the footpeg stay and tighten the bolts Torque Footpeg Stay Bolts 34 N m 3 5 kgf m 25 ft lb e Check the brake light switch operation see Brake Light Switch Operation Inspection in the Periodic Maintenance chapter BRAKES 12 15 Brake Lever Brake Pedal Brake Pedal Removal e Remove Frame Cover see Frame Cover Removal in the Frame chapter Bolts A Right Footpeg Stay B e Remove Cotter Pin A Joint Pin B Rear Brake Light Switch Spring C Return Spring D e Remove the mounting bolt E and take out the brake pedal Brake Pedal Installation e Apply grease to the pivot shaft A and install the washer e Install Brake Pedal C Washer D Brake Pedal Bolt E Torque Brake Pedal Bolt 8 8 N m 0 90 kgf m 78 in Ib e Hook the lower end of the rear brake light switch spring A on the pedal hook e Hook the upper end of the return spring B on the pedal hook e Replace the cotter pin with a new one e Insert the cotter pin A and bend the pin ends B 12 16 BRAKES Brake Lever Brake Pedal e Install the right footpeg stay and tighten the bolts Torque Footpeg Stay Bolts 34 N m 3 5 kgf m 25 ft lb ODepress the brake pedal A and then align the bolts holes of the master cylinder B Torque Rear Master Cylinder Mounting Bolts 25 N m 2 5 kgf m 18 ft Ib e C
298. il 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 Green 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 CAUTION Do not heat the cylinder head with a torch This will warp the cylinder head Soak the cylinder head in oil and heat the oil Special Tool Valve Guide Arbor 4 5 57001 1331 GE15043BS1 C GE15115BS1 C GE15045BS1 C 5 30 ENGINE END Valves 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 e Drive the valve guide in from the top of the head using the valve guide arbor The flange stops the guide from going in too far Special Tool Valve Guide Arbor 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
299. ils Fan Motor Engine Stop Switch Ignition Switch Fl Indicator Light LED Water Temperature Gauge Tachometer Speedometer Water proof Joint A Water proof Joint B Oxygen Sensor Heater Fuse 10 A Radiator Fan Fuse 15 A ECU Fuse 15 A Ignition Fuse 10 A Radiator Fan Relay ECU Main Relay Fuel Pump Relay Relay Box Main Fuse 30 A Battery Frame Ground Fuel Pump Diagnosis Connector Self diagnosis Terminal Joint Connector ECU 3 14 FUEL SYSTEM DFI DFI System 43 42 40 3 9 3 8 3 7 3 6 35 17 1 6 15 1 4 1 3412 10 9 615 312 52 5 1 494847464544 3 4 3 3 3 2 3 113 0 2 9 27 26 24 23 22 20 19 GC17969BW2 Terminal Names Subthrottle Valve Actuator Drive Signal 2 Subthrottle Valve Actuator Drive Signal 1 Water Temperature Warning Light Signal Unused Oxygen Sensor Signal Europe Models Speed Sensor Signal Main Throttle Sensor Signal Inlet Air Pressure Sensor Signal Unused Power Supply to Sensors Vehicle down Sensor Signal Neutral Switch Signal Crankshaft Sensor Signal Unused Unused Power Supply to ECU from ECU Main Re lay Power Supply to ECU from Battery Subthrottle Valve Actuator Drive Signal 4 Subthrottle Valve Actuator Drive Signal 3 Water Temperature Sensor Signal Unused Self diagnosis Terminal Unused Subthrottle Sensor Signal Unused Inlet Air Temperature
300. in use possibly causing an accident Replace a badly bent or damaged inner or outer tube and inspect the other tube carefully before reusing it Dust Seal Inspection e Inspect the dust seal A for any signs of deterioration or damage Replace it if necessary GM04300BS1 GM04301BS1 C GM04128BS1 C 13 14 SUSPENSION Front Fork Fork Spring Inspection e Measure the free length A of the fork spring B x If the measured length is shorter than the service limit the spring must be replaced If the free length of the replace ment spring and that of the remaining spring vary greatly the remaining spring should also be replaced in order to keep the fork legs balanced to ensure stability Fork Spring Free Length Standard 277 2 mm 10 91 in Service Limit 272 mm 10 7 in GM04302BS1 SUSPENSION 13 15 Rear Shock Absorber Spring Preload Adjustment e Using the hook wrench A turn the adjusting nut B to adjust the spring preload OThe standard adjuster setting for average build rider of 68 kg 150 Ib with no passenger and no accessories is 2nd position Spring Preload Setting Standard Position 2nd position Adjustable Range 1st to 7th position e f the compression of the spring is not suited to the op erating conditions adjust it to an appropriate position by referring to the table below Spring Preload Adjustment Adjuster
301. in Ib e Install Throttle Grip Throttle Cable Tips A Right Switch Housing OFit the projection B into a small hole C in the handlebar Torque Right Switch Housing Screws 3 5 Nm 0 36 31 in Ib e Apply a non permanent locking agent to the right handle bar weight bolt e Install the front brake master cylinder see Front Master Cylinder Installation in the Brakes chapter 15 1 Frame Table of Contents Exploded au Nin Seatisemoval ud teet Feeders uet te ette te A bue dae ats Seat Installation nore EE P alg TT IET Lower Fairing Removal oA E Lower Center Fairing Removal Center Fairing Windshield Windshield Installation s r insni a r a a e a a aeia Upper Fairing Removal pp Upper Fairing Disassembly ete uae tes toda A donus Upper Falring Assembly nsus eiie ad Upper Fairing Upper Inner Fairing Upper Inner Fairing Installation pp Upper Fairing Bracket Removal pp Inner Fairing Rernoval ie eco Ehe Re
302. in Throttle Sensor Inlet Air Pressure Sensor Main Throttle Sensor Output Voltage 0 20 4 8 V Inlet Air Pressure absolute Pv 150 mmHg 800 mmHg If the main throttle sensor system fails the signal is out of the usable range wiring short or open the ECU locks ignition timing into the ignition timing at closed throttle position and sets the DFI in the D J method Also the main throttle sensor system and inlet air pressure fails the ECU locks ignition timing into the ignition timing at closed throttle position and sets the DFI in the a N method If the inlet air pressure sensor system fails the signal Pv is out of the usable range wiring short or open the ECU sets the DFI in the a N method Inlet Air Temperature Sensor Inlet Air Temperature Ta 30 C 120 C If the inlet air temperature sensor fails the signal is out of the usable range wiring short or open the ECU sets Ta at 40 C Water Temperature Sensor Crankshaft Sensor Water Temperature Tw 30 C 120 Crankshaft sensor must send 22 signals output signal to the ECU at the one cranking If the water temperature sensor system fails the signal is out of the usable range wiring short or open the ECU sets Tw at 80 C If crankshaft sensor generates other than 22 signals the engine stops by itself Speed Sensor Vehicle down Sensor Speed sensor must send 4 signals output signal to the ECU at
303. in locating their chapters Each chapter in turn has its own comprehensive Ta ble of Contents For example if you want ignition coil informa tion use the Quick Reference Guide to locate the Electrical System chapter Then use the Table of Contents on the first page of the chap ter to find the Ignition Coil section Whenever you see these WARNING and CAUTION symbols heed their instructions Always follow safe operating and maintenance practices A WARNING This warning symbol identifies special instructions or procedures which if not correctly followed could result in per sonal injury or loss of life CAUTION This caution symbol identifies special instructions or procedures which if not strictly observed could result in dam age to or destruction of equipment This manual contains four more symbols in addition to WARNING and CAUTION which will help you distinguish different types of informa tion NOTE OThis note symbol indicates points of par ticular interest for more efficient and con venient operation e Indicates a procedural step or work to be done Olndicates a procedural sub step or how to do the work of the procedural step it follows It also precedes the text of a NOTE Indicates a conditional step or what action to take based on the results of the test or inspec tion in the procedural step or sub step it fol lows In most chapters an exploded view illustration of the system co
304. in the Electrical System chapter Power Source Wiring see wiring diagram below x If the inspection checks good the ECU is damaged Re place the ECU see ECU Removal Installation The ECU itself cannot be checked or serviced 80170100651 86617011651 3 82 FUEL SYSTEM ECU ECU Power Source Circuit 6C179838W2 ECU Water proof Joint C Ignition Switch Water proof Joint A ECU Main Fuse 15 A ECU Main Relay Relay Box Main Fuse 30 A Battery Frame Ground Joint Connector gt FUEL SYSTEM DFI 3 83 Fuel Line Fuel Pressure Inspection NOTE OThis inspection can determine which trouble the system has mechanical or electrical trouble Olt is preferable to measure the fuel pressure while run ning the motorcycle just when trouble occurred in order to know symptom well OBe sure the battery is fully charged Remove the fuel tank see Fuel Tank Removal e Remove the left center fairing see Center Fairing Re moval in the Frame chapter e Be sure to place a piece of cloth around the fuel hose joint and the delivery pipe e Insert a minus screw driver A into the slit on the joint lock B e Turn the driver to disconnect the joint lock e Remove the fuel hose C A WARNING Be prepared for fuel spillage any spilled fuel must be completely w
305. ing Brake dragging of 22 relief and supply ports see chapter 12 Clutch slipping Inspect friction plates for wear see chapter 6 See Overheating of Troubleshooting Guide see Engine overheating chapter 17 Air switching valve trouble Inspect and replace see chapter 5 Air suction valve trouble Inspect and replace see chapter 5 Intermittent any DFI fault and its recovery Check that DFI connectors are clean and tight and examine wires for signs of burning or fraying see chapter 3 Poor Running or No Power at High Speed Symptoms or Possible Causes Actions chapter Firing incorrect Spark plug dirty broken or maladjusted Replace see chapter 2 Stick coil trouble Inspect stick coil see chapter 16 Stick coil shorted or not in good contact Reinstall or inspect stick coil see chapter 16 Spark plug incorrect Replace it with the correct plug see chapter 16 IC igniter in ECU trouble Inspect see chapter 16 Crankshaft sensor trouble Inspect see chapter 16 Stick coil trouble Inspect see chapter 16 Fuel air mixture incorrect Air cleaner clogged poorly sealed or missing Clean element or inspect sealing see chapter 3 Air cleaner duct loose Reinstall see chapter 3 Air cleaner O ring damaged Replace see chapter 3 Water or foreign matter in fuel Change fuel Inspect and clean fuel system see chapter 3 Throttle body assy loose Reinstall s
306. ing with a new one OCheck the tapered portion E of the bypass screw for wear or damage x If the bypass screw is worn or damaged replace it e Turn in the bypass screw until it seats fully but not tightly GSO5015BS1 C 2 18 PERIODIC Periodic Maintenance Procedures e Repeat the same procedure for other bypass screws Repeat the synchronization x lf the vacuums are correct check the output voltage of the main throttle sensor see Main Throttle Sensor Output Voltage Inspection in the Fuel System DFI chapter Main Throttle Sensor Output Voltage Connections to ECU Meter Y W lead terminal 7 Meter BR BK lead terminal 28 Standard 1 055 1 095 V DC at idle throttle opening x If the output voltage is out of the range check the throt tle input voltage see Main Throttle Sensor Input Voltage Inspection in the Fuel System DFI chapter e Remove the vacuum gauge hoses and install the vacuum hoses and rubber caps Idle Speed Inspection e Start the engine and warm it up thoroughly e With the engine idling turn the handlebar to both sides A handlebar movement changes the idle speed the throttle cables may be improperly adjusted or incorrectly routed or damaged Be sure to correct any of these conditions before riding see Throttle Control System Inspection or Cable Wire and Hose Routing section in the Appendix chapter Operation with impr
307. ion Coil Subthrottle Valve Actuator The stick coil primary winding must send signals output voltage continuously to the ECU The actuator operates open and close of the subthrottle valve by the pulse signal from the ECU If the ignition primary winding 2 has failures no signal wiring short or open the ECU shuts off the injector 2 to stop fuel to the cylinder 2 though the engine keeps running If the subthrottle valve actuator fails the signal is out of the usable range wiring short or open the ECU stops the current to the actuator Oxygen Sensor Europe Models The oxygen sensor heater raise temperature of the sensor for its earlier activation 12V 6 6W 0 55A If the oxygen sensor heater fails wiring short or open the ECU stops the current to the heater Note Oxygen Sensor Europe Models The oxygen sensor must send signals output voltage continuously to the ECU If the oxygen sensor output voltage is incorrect the ECU stops oxygen sensor feed back mode 1 D J Method and a 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 inlet air pressure sensor output voltage and engine speed crankshaft sensor output voltage This method is called D J method low speed mode As the engine speed increases and the engine load turns middle to heavy the ECU determines the i
308. iped up immediately When the fuel hose is disconnected fuel spills out from the hose and the pipe because of residual pressure Cover the hose connection with a piece of clean cloth to prevent fuel spillage e Install the fuel pressure gauge adapter A and fuel hoses between the fuel pump outlet pipe B and the delivery pipe e Connect the pressure gauge D 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 6617023651 A WARNING Do not try to start the engine with the fuel hoses disconnected Temporarily install the fuel tank E Clamps F 3 84 FUEL SYSTEM Fuel Line e Turn the ignition switch ON The fuel pump will turn for 3 seconds and then stop CAUTION Do not drive the fuel pump without the fuel in the fuel tank e Measure the fuel pressure with the engine stopped Fuel Pressure Right after Ignition Switch ON with pump running Standard 323 kPa 3 3 kgf cm 47 psi After 3 seconds from Ignition Switch ON with pump stopped Standard 265 kPa 2 7 kgf cm 38 psi residual fuel pressure The system should hold the residual pressure about 30 seconds e Start the engine and let it idle Measure the fuel pressure with the engine idling Fuel Pressure Idling Standard 333 kPa 3 4 kgf icm 48 psi NOTE OThe gauge nee
309. is locked If it does not locked reinstall the hose joint A WARNING Make sure the hose joint is installed correctly on the delivery pipe by sliding the joint or the fuel could leak 9505084851 Evaporative Emission Control System Inspection e Inspect the canister as follows ORemove Left Center Fairing see Center Fairing Removal in the Frame chapter ORemove the canister A and disconnect the hoses from the canister OVisually inspect the canister for cracks or other damage x lf 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 2 20 PERIODIC Periodic Maintenance Procedures e Check the liquid vapor separator as follows ORemove Left Center Fairing see Center Fairing Removal in the Frame chapter ODisconnect the hoses from the separator and remove the separator A from the motorcycle left side OVisually inspect the separator for cracks and other dam age x If the separator has any cracks or damage replace it with a new one OTo prevent the gasoline from flowing into or out of the canister hold the separator perpendicular to the ground e Check the hoses of the evaporative emission control sys tem as follows OCheck that the hoses are securely connected and clips are in position OReplace
310. it ABS system is normal service code is not stored temporary failure Front Wheel Rotation Sensor Signal Abnormal Service Code 42 e Do the 1st step test OMeasure the air gap between the front wheel rotation sen sor and sensor rotor Thickness Gauge A Air Gap Standard 1 mm 0 04 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 2nd step GL14032BS1 a BRAKES 12 49 Anti Lock System Do the 2nd step test 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 correct 3rd step e Do the 3rd step test ORecheck the service code indication erase the service code perform the pre diagnosis inspection 1 and 2 and retrieve the service code lf the ABS indicator light LED A lit faulty ECU in the ABS hydraulic unit Replace the ABS hydraulic unit If the ABS indicator light LED A unlit ABS system is normal service code is not st
311. ite 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 oil excessive Front fork oil viscosity too high Rear shock absorber adjustment too hard Tire air pressure too high Front fork bent Too soft Tire air pressure too low Front fork oil insufficient and or leaking Front fork oil viscosity too low 17 50 APPENDIX Troubleshooting Guide Rear shock adjustment too soft Battery Trouble Front fork rear shock absorber spring weak Battery discharged Rear shock
312. ition system by lighting the FI indicator when DFI system and ignition system parts are faulty and initiates fail safe function In case of serious troubles the ECU stops the injection ignition starter motor operation Dealer Mode 1 The Fl indicator light LED emits service code s to show the problem s which the DFI system and ignition system has at the moment of diagnosis Dealer Mode 2 The Fl indicator light LED emits service code s to show the problem s which the DFI system and ignition system had in the past Self diagnosis Procedures Self diagnosis Procedures OWhen a problem occurs with the DFI system and ignition system the FI indicator light LED A goes on NOTE OUse a ful charged battery when conducting self diagnosis Otherwise the light LED blinks very slowly or doesn t blink OKeep the self diagnosis terminal grounded during self diagnosis with an auxiliary lead Remove the seat see Seat Removal in the Frame chap ter Ground A the self diagnosis terminal Orange Black lead to the battery terminal C or battery lead con nector using a wire Turn on the ignition switch Connect an auxiliary lead E to the self diagnosis terminal G for grounding e To enter the self diagnosis dealer mode 1 ground A the self diagnosis indicator terminal to the battery terminal for more than 2 seconds C and then keep it grounded continuously D B
313. its bent side B faces upward and engage the bent claws with the grooves of stem locknut C e Hand tighten the stem locknut until it touches the claw washer Tighten the stem locknut clockwise until the claws are aligned with the grooves ranging from 2nd to 4th of stem nut D and bend the 2 claws downward E e Install the stem head e Install the washer and tighten the stem head bolt with specified torque e Install the front forks see Front Fork Installation in the Suspension chapter NOTE OTighten the upper fork clamp bolts first next the stem head bolt last the lower fork clamp bolts OTighten the two clamp bolts alternately two times to en sure even tightening torque Torque Front Fork Clamp Bolts Upper 20 N m 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 N m 2 0 kgf m 15 ft lb A WARNING Do not impede the handlebar turning by routing the cables harnesses and hoses improperly see Ca ble Wire and Hose Routing section in the Appen dix chapter e Install the steering stem head bolt plug e Install the removed parts see appropriate chapters GNO5015BS1 C GNO5060481 C 6515011851 C STEERING 14 9 Steering Stem Stem Bearing Lubrication Refer to the Steering Stem Bearing Lubrication in the Pe riodic Maintenance chapter Steering Stem Warp e Whenever the steering stem is removed or if
314. jector E as shown e Open and connect F the end of the lead to the battery terminal repeatedly The injector should click x If the injector does not click replace the injector x lf the injector clicks check the wiring again If the wiring is good replace the injector may be clogged or ECU Injector Fuel Line Inspection e Remove Fuel Tank see Fuel Tank Removal Left Center Fairing see Center Fairing Removal in the Frame chapter e Be sure to place a piece of cloth around the fuel hose joint and the delivery pipe e Insert a minus screw driver A into the slit on the joint lock e Turn the driver to disconnect the joint lock e Pull the fuel hose joint C out of the delivery pipe e Check the injector fuel line for leakage as follows OConnect a commercially available vacuum pressure pump A to the nipple of the delivery pipe B with a high pressure fuel hose C both ends connected with the clamps D as shown Torque Fuel Hose Clamp Screws 1 5 N m 0 15 kgf m 13 in Ib OApply soap and water solution to the areas E as shown OWatching the pressure gauge squeeze the pump lever F and build up the pressure until the pressure reaches the maximum pressure Injector Fuel Line Maximum Pressure Standard 333 kPa 3 4 kgf cm 48 psi CAUTION During pressure testing do not exceed the maxi mum pressure for which the system is designed 6617024451 6617024651
315. k Attachment 57001 1058 57001 1608 ST571058ST C ST571608ST C Bearing Driver Set Stem Bearing Driver 528 57001 1129 57001 1610 7571129ST C 8 5716105 C 13 8 SUSPENSION Special Tools Spacer 28 57001 1663 ST571663ST SUSPENSION 13 9 Front Fork Front Fork Removal e Remove Upper Inner Fairing see Upper Inner Fairing Removal in the Frame chapter Front Wheel see Front Wheel Removal in the Wheels Tires chapter Front Fender see Front Fender Removal in the Frame chapter Front Wheel Rotation Sensor see Front Wheel Rotation Sensor Removal in the Brakes chapter EX650B Mod els x Loosen the upper fork clamp bolt A and fork top plug B beforehand if the fork leg is to be disassembled NOTE OLoosen the top plug after loosening the upper fork clamp bolt e Loosen the upper fork clamp bolt and lower fork clamp bolts C e With a twisting motion work the fork leg down and out Front Fork Installation e Install the fork so that the top end A of the inner tube as shown 10 mm 0 40 in B e Tighten Torque Front Fork Clamp Bolts Lower 20 N m 2 0 kgf m 15 ft Ib Front Fork Top Plug 25 N m 2 5 kgf m 18 16 NOTE GM04299BS1 C OTighten the top plug before tightening the upper fork clamp bolt OTighten the two clamp bolts alternately two times to en sure even tightening torque e Tighten Torque Front Fork Clamp Bolt Upper 20
316. k 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 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 Left Upper Inner Fairing see Upper Inner Fairing Re moval in the Frame chapter Bolt A Clamp B e Disconnect the connector A 9 149014 12 56 BRAKES Anti Lock Brake System e Remove Clamp A Bolt B Front Wheel Rotation Sensor C Front Wheel Rotation Sensor Installation e Installation is the reverse of removal ORoute the lead correctly see Cable Wire and Hose Routing section in the Appendix chapter Rear Wheel Rotation Sensor Removal CAUTION 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 e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Air Cleaner Housing see Air Cleaner Housing Removal in the Fuel System DFI chapter e Disconnect the connector A
317. kshaft and Connecting Rods Connecting Rod Installation CAUTION To minimize vibration the connecting rods should have the same weight mark Big End Cap A Connecting Rod B Weight Mark Alphabet C Diameter Mark D O or no mark CAUTION If the connecting rods big end bearing inserts or crankshaft are replaced with new ones select the bearing insert and check clearance with a plasti gage press gauge before assembling engine to be sure the correct bearing inserts are installed e Apply molybdenum disulfide grease A to the outer sur face of the upper insert and the inner surface of the con necting rod big end e Apply molybdenum disulfide oil solution B to the inner surfaces of upper and lower bearing inserts OThe molybdenum disulfide oil solution is a mixture of en gine oil and molybdenum disulfide grease with a weight ratio 10 1 ODo not apply any grease or oil C to the cap inside and cap insert outside Olnstall the inserts so that their nails D are on the same side and fit them into the recess of the connecting rod and cap CAUTION Wrong application of oil and grease could cause bearing damage OWhen installing the inserts A be careful not to damage the insert surface with the edge of the connecting rod B or the cap C One way to install inserts is as follows Installation D to Cap Installation E to Connecting Rod Push F Spare Do
318. lay is repeated until the self diagnosis indicator terminal is open Olf there is no problem no code and unlight OFor example if two problems occurred in the order of 21 12 the service codes are displayed from the lowest number in the order listed 12 21 12 21 repeated Self Diagnosis indicator terminal Grounded Open _ 1s ioth digit 0 55 0 5s a digit is is 0 55 Fl Indicator Light LED ON mt M 1 1 1 otros 2sec 3s 1 8s 0 5s 3s 1 58 1 58 80617853841 C Olf the problem is with the following parts the ECU cannot memorize these problems the Fl indicator light LED doesn t go on and no service codes can be displayed FI Indicator Light LED Fuel Pump Fuel Pump Relay DFI Main Relay ECU Power Source Wiring and Ground Wiring see ECU Inspection Fuel Injectors How to Erase Service Codes How to Erase Service Codes OEven if the ignition switch is turned OFF the battery or the ECU are disconnected or the problem is solved all service codes remain in the ECU ORefer to the Service Code Clearing Procedure for the service code erasure FUEL SYSTEM DFI 3 41 Self Diagnosis Service Code Table Service Code Table Main throttle sensor malfunction wiring open or short Inlet air pressure sensor malfunction wiring open or short Inlet air temperature sensor malfunction wiring open or short Water temperature sensor m
319. le cables in the cable bracket on the throttle body assy after installing the upper ends of the throttle cables in the grip e After installation adjust each cable properly A WARNING Operation with incorrectly routed or improperly ad justed cables could result in an unsafe riding con dition Throttle Cable Lubrication e Refer to the Chassis Parts Lubrication in the Periodic Maintenance chapter FUEL SYSTEM DFI 3 97 Throttle Body Assy Idle Speed Inspection e Refer to the Idle Speed Inspection in the Periodic Main tenance chapter Engine Vacuum Synchronization Inspection Ad justment Refer to the Engine Vacuum Synchronization Inspection in the Periodic Maintenance chapter High Altitude Performance Adjustment e Any modification is not necessary in this model since the inlet air pressure sensor senses inlet air pressure change due to high altitude and the ECU compensates the change Throttle Body Assy Removal A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Disconnect the battery cable ter minal Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately e Remove Air Cleaner Housing see Air Cleaner Housing Removal Center Fairings
320. lead Meter BK sensor BR BK lead Standard 4 75 5 25 V DC FUEL SYSTEM DFI 3 63 Subthrottle Sensor Service Code 32 e Turnthe ignition switch OFF xIf the input voltage is normal check the sensor output voltage x If the input voltage is less than the standard remove the ECU and check the wiring between these connectors ODisconnect the ECU and sensor connectors Wiring Connection ECU Connector A Subthrottle Sensor Connector B BL lead terminal 10 BR BK lead terminal 28 xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection Subthrottle Sensor Output Voltage Inspection e 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 e Disconnect the subthrottle sensor connector and black connect the harness adapter A between these connec tors Special Tool Throttle Sensor Harness Adapter 57001 1400 e Measure the output voltage of the sensor with the engine stopped and with the connector joined e Turn the ignition switch ON e Measure the output voltage when the subthrottle valve is fully opened or completely closed by hand Subthrottle Sensor Output Voltage Connections to Adapter Meter Y sensor BL W lead Meter BK sensor BR BK lead Standard 0 4 0 6 V DC at idle throttle openi
321. led 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 Inspection Reuse of worn or damaged parts may lead to serious ac cident Visually inspect removed parts for corrosion discol oration or other damage Refer to the appropriate sections of this manual for service limits on individual parts Replace the parts if any damage has been found or if the part is be yond its service limit Replacement Parts Replacement parts must be KAWASAKI genuine or recommended by KAWASAKI Gaskets O rings oil seals grease seals circlips or cotter pins must be replaced with new ones whenever disassembled Assembly Order In most cases assembly order is the reverse of disassem bly however if assembly order is provided in this Service Manual follow the procedures given 8020088 5 802998 5 08020108 5 gt X es ER Se gt 68020118
322. let air pressure sensor Special Tools Fork Oil Level Gauge 57001 1290 Sensor Harness Adapter 57001 1561 Inlet Air Pressure Sensor Output Voltage Connection to Adapter Meter G sensor Y BL lead Meter gt BK sensor BR BK lead OTurn the ignition switch ON 80170700651 0017119852 C OMeasure the inlet air pressure sensor output voltage from various vacuum readings while pulling the handle of the fork oil level gauge OCheck the inlet air pressure sensor output voltage using the following formula and chart Suppose Pg Vacuum Pressure gauge to Sensor Local Atmospheric Pressure absolute measured by a barometer Pv Vacuum Pressure absolute to Sensor Vv Sensor Output Voltage V FUEL SYSTEM DFI 3 49 Inlet Air Pressure Sensor Service Code 12 then Pv 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 volt meter reading then Pv 70 8 62 cmHg Abs Plot this Pv 62 cmHg at a point 1 on the chart and draw a vertical line through the point Then you can get the usable range 2 of the sensor output voltage Usable range 3 04 3 49 V Plot Vv 3 2 V on the vertical line Point 3 Results In the chart Vv is within the usable range and the sensor is normal Pv 24 55 cmHg cmHg kPa 6Ci70349N3 3 50
323. lf 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 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 S 1 140158 F 12 42 BRAKES Anti Lock Brake System How to Read Service Codes OService codes are shown by a series of long and short blinks of the ABS indicator light LED as shown below ORead 10th digit and unit digit as the ABS indicator light LED blinks OWhen there are a number of faults a maximum of six 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 six service codes starting with the last one stored then the display is repeated from the start code once again Start Last service Fifth service Second service First service He See a code 12 code stored code stored code stored code stored Repeat _ GLi4016BWi C Olf there is no fault only the start code is shown Indication of Service Code Exp 1 Start Code 12 ABS is normal is shown Start Code 12 ABS Indi
324. ll the removed parts see appropriate chapters e Adjust Throttle Cables see Throttle Control System Inspection in the Periodic Maintenance chapter Clutch Cable see Clutch Operation Inspection in the Pe riodic Maintenance chapter Drive Chain see Drive Chain Slack Adjustment in the Periodic Maintenance chapter e Fill the engine with engine oil see Engine Oil Change in the Periodic Maintenance chapter e Fill the engine with coolant and bleed the air from the cool ing system see Coolant Change in the Periodic Mainte nance chapter e Adjust the idling see Idle Speed Adjustment in the Peri odic Maintenance chapter CRANKSHAFT TRANSMISSION 9 1 Crankshaft Transmission Table of Contents Exploded WiSW e Special Tools and 5 ie lagu estt 5 Spliftig core oi e E a I deus a c GrankCase ASSEM D y E Crankshaft and Connecting ROS Crankshaft Installation 9 9
325. lly charged OThe output voltage changes according to the inlet air temperature e Remove the ECU see ECU Removal Do not disconnect the ECU connectors e Connect a digital voltmeter to the ECU connector using needle adapter set Special Tool Needle Adapter Set 57001 1457 e Measure the sensor output voltage with the engine stopped and the connector joined e Turn the ignition switch ON Inlet Air Temperature Sensor Output Voltage Connections to ECU Connector Meter Y lead terminal 26 Meter BR BK lead terminal 28 Standard About 2 25 2 50 V at inlet air temperature 20 C 68 F e Turn the ignition switch OFF x lf the output voltage is out of the standard remove the fuel tank and check the wiring And if the output voltage is 4 8 V the ECU is normal x If the output voltage is within the standard check the ECU for its ground and power supply see ECU Power Supply Inspection x lf the wiring is good check the sensor resistance e Remove the needle adapter set and apply silicone sealant to the seals of the connector for waterproofing Sealant Kawasaki Bond Silicone Sealant 56019 120 80170020651 FUEL SYSTEM DFI 3 53 Inlet Air Temperature Sensor Service Code 13 Inlet Air Temperature Sensor Resistance Inspection Remove the inlet air temperature sensor see Inlet Air Temperature Sensor Removal Installation e Suspend the sensor A in a c
326. lots in the nut do not align with the cotter pin hole in the axle tighten the nut clockwise B up to next alignment Olt should be within 30 OLoosen once and tighten again when the slot goes past the nearest hole e Bend the cotter pin A over the nut B A WARNING If the rear axle nut is not securely tightened or the cotter pin is not installed an unsafe riding condi tion may result e Adjust the drive chain slack after installation see Drive Chain Slack Inspection in the Periodic Maintenance chap ter e Install the rear brake caliper see Caliper Installation in the Brakes chapter e Install the rear wheel rotation sensor see Rear Wheel Ro tation Sensor Installation in the Brakes chapter EX650B Models e Check the rear brake effectiveness see Brake Operation Inspection in the Periodic Maintenance chapter A WARNING Do not attempt to drive the motorcycle until a full brake pedal is obtained by pumping the brake pedal until the pads are against the disc The brake will not function on the first application of the pedal if this is not done HJ07007BS1 HJ07008BS1 10 10 WHEELS TIRES Wheels Rims Wheel Inspection Raise the front rear wheel off the ground with jack Special Tools Jack 57001 1238 Jack Attachment 57001 1608 Spin the wheel lightly and check for roughness or binding lf roughness or binding is found replace the hub bearings e Inspec
327. lowing parts Plug Hole Gaskets A Dowel Pins B GE11187BS1 5 20 ENGINE END Camshaft Camshaft Chain e Apply molybdenum disulfide oil solution to all cams A journals B and thrust blocks C with x marks e If a new camshaft is to be used apply a thin coat of molyb denum disulfide grease to the cam surfaces NOTE OThe exhaust camshaft has a 2 412 EX mark D and the inlet camshaft has a 2 412 IN mark E Be careful not to mix up these shafts UO SC rns BS SOOT 55d 200000 0050 K 29504 if Nt 6255559 20042 x GE 11538W2 C e Position the crankshaft as follows e Pull the tension side exhaust side of the chain taut to install the chain e Engage the camshaft chain with the camshaft sprockets so that the timing marks on the sprockets are positioned as shown OUsing a wrench on the crankshaft rotation bolt turn the crankshaft clockwise until the 2 T mark line A on the tim ing rotor is aligned with the notch B in the edge of the upper hole C in the clutch cover GE11186BS1 o e f the clutch cover is removed perform the next proce dure OUsing a wrench on the crankshaft rotation bolt turn the crankshaft clockwise until the 1 T mark line A on the timing rotor is aligned with the wating surface B of the crankcase halves GE11159BS1 o ENGINE
328. ls and tools for rejoining the chain e Using a suitable tool cut the drive chain by removing the link pins Recommended Tool EK Joint Tool 50 CAUTION Read the Tool Manual before removing Body A Handlebar B Cutting and Riveting Pin C For Cutting D For Riveting E Plate Holder a F Plate Holder b G Gauge H e Grind A the pin head to make it flat Set the cutting and riveting pin as shown GKO4016BS1 GKO4017BS1 FINAL DRIVE 11 7 Drive Chain 5 the pin holder until it touches chain pin e Be sure that the cutting pin hits center of chain pin Screw the handlebar A into body Turn the pin holder with wrench clockwise to extract chain pin Drive Chain Installation e Engage the new drive chain to the old drive chain and pull the end of the old drive chain until they are changing the position Remove the old drive chain from the new drive chain e Apply grease to the link pins A and grease seals B C e Engage the drive chain on the rear sprocket through the swingarm e Insert the link pins in the drive chain ends e Install the grease seals C e Install the link plate so that the mark D faces out e Push the link plate by hand or plier to fix it case of grease seal chain be sure to set the grease seals correctly Set the plate holder a A and plate holder b on the body
329. ly brake fluid to the new parts and to the inner wall of the cylinder e Take care not to scratch the piston or the inner wall of the cylinder e Tighten the brake lever pivot bolt and locknut e Apply silicone grease Brake Lever Pivot Bolt e Tighten Torque Brake Lever Pivot Bolt 1 0 N m 0 10 kgf m 9 in Ib Brake Lever Pivot Bolt Locknut 5 9 N m 0 60 kgf m 52 in Ib 2 54 PERIODIC Periodic Maintenance Procedures 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 e Using compressed air remove the pistons OCover the piston area with a clean thick cloth A OBlow compressed air B into the hole for the banjo bolt to remove the piston A WARNING To avoid serious injury never place your fingers or palm in front of the piston If you apply compressed air into the caliper the piston may crush your hand or fingers OPull out the pistons by hand Remove the dust seals A and fluid seals e Remove the bleed valve C and rubber D NOTE Olf compressed air is not available with the brake hose still attached apply the brake lever to remove the pis ton The remaining process is as described above Front Caliper Assembly e Clean the caliper parts except for the pads CAUTION For cleaning the parts use only disc brake fl
330. ly 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 insufficient 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 Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating pr
331. m is considered to be working normally x lf the charging voltage is much higher than the values specified in the table the regulator rectifier is defective or the regulator rectifier leads are loose or open x If the charging voltage does not rise as the engine speed increases then the regulator rectifier is defective or the alternator output is insufficient for the loads Check the alternator and regulator rectifier to determine which part is defective ELECTRICAL SYSTEM 16 39 Charging System Charging System Circuit TON PARK IGNITION BATTERY Galan Got 2 Galan Galan IGNITION UGNITION Gat GP09144BW2 1 Ignition Switch 2 Alternator 3 Regulator Rectifier 4 Water proof Joint C 5 Main Fuse 30 A 6 Battery 12 V 10 Ah 7 Load 16 40 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 Torque Limiter Shafts e Turn the starter motor clutch gear A by hand The starter motor clutch gear should turn clockwise B freely but should not turn counterclockwise C x If the starter motor clutch does not operate as it should or if it makes noise go to the next step e Disassemble the starter motor clut
332. m position e Start the engine The low beam headlight should go on x If the low beam headlight does not go on inspect or re place the following item Headlight Low Beam Bulb see Headlight Bulb Replace ment in the Electrical System chapter Headlight Fuse 10 A see Fuse Inspection in the Electri cal System chapter Dimmer Switch see Switch Inspection in the Electrical System chapter Headlight Relay in Relay Box see Relay Circuit Inspec tion in the Electrical System chapter Harness see Wiring Inspection in the Electrical System chapter e Set the dimmer switch to high beam position The low beam A and high beam headlights should go on The high beam indicator light LED should go on x If the high beam headlight and or high beam 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 off the engine stop switch e The low beam and high beam headlights should stay go ing on x If the headlights and high beam indicator light LED does go off inspect or replace the following item Headlight Relay in Relay Box see Relay Circuit Inspec tion in the Electrical System chapter e Turn off the ignition switch e The headlights and high beam indicator light LED should go off Headlight Aiming Inspection
333. m sda thas than led Geet Tete Eaa Starter Motor Clutch Removal Installation Starter Motor Clutch Inspection Ne Starter Motor Clutch Disassembly Starter Motor Clutch Assembly eot eee Igitnr SV SUC s std x cec eta ams oed rs Atc eS Ete Delito Crankshaft Sensor Removal ue ee Pe YR ore Coe ae Crankshaft Sensor Installation pp Crankshaft Sensor Inspectigom Crankshaft Sensor Peak Voltage Inspection pp 16 42 Timing Rotor Removal ie rr eate tet ceder 16 43 Timing tete endete ttti Bande 16 43 Stick Coil Ignition Coil together with Spark Plug Cap Remowval 16 43 Stick Coil Ignition Coil together with Spark Plug Cap Installation 16 43 Stick Coil Ignition Coil together with Spark Plug Cap 16 44 Suck Coil Primary Peak Voltage aet eoe dh cia eee eee 16 44 spark Pl g Ierioval iot eto er n eden e eit erase A ta PA Ead 16 45 Sp rk M aches 16 45 Spark Plug Condition 9 16 45 Interlock Operation Inspection pp 16 45 IC Igniter
334. mbly on the upper crankcase half OAlign A the timing mark on the balancer gear B with the timing mark on the balancer drive gear C of the crank shaft e Be sure to hang the camshaft chain A on the crankshaft e Be sure that the dowel pins A are in position Set the bearing groove A on the positioning ring as shown 9 14 CRANKSHAFT TRANSMISSION Crankcase Splitting e Apply liquid gasket A to the mating surface of the lower crankcase half Sealant Kawasaki Bond 92104 1064 NOTE OEspecially apply a liquid gasket carefully so that it shall be filled up on the grooves CAUTION Do not apply liquid gasket around the crankshaft main bearing inserts and oil passage holes ODo not apply liquid gasket to the oil passage 6104217882 C CRANKSHAFT TRANSMISSION 9 15 Crankcase Splitting e 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 OMoreover fit the case and tighten the case bolts just after finishing the application of the liquid gasket OThe M9 bolts 1 6 see the next figure have copper plated washers Replace them with new ones e Apply molybdenum disulfide oil solution t
335. mbustion chamber Fuel poor quality or incorrect Use the gasoline recommended in the Owner s Manual Spark plug incorrect Stick coil trouble IC igniter in ECU trouble Inspect and replace see chapter 5 Inspect and repair or replace see chapter 5 see chapter 5 Change fuel see chapter 3 Replace it with the correct plug see chapter 16 Inspect see chapter 16 Inspect see chapter 16 Inlet air temperature sensor trouble Inspect see chapter 3 Miscellaneous Subthrottle sensor trouble Inspect see chapter 3 Subthrottle valve actuator trouble Inspect see chapter 3 Speed sensor trouble Inspect see chapter 3 Throttle valves won t fully open Inspect throttle cable and lever linkage see chapter 3 Brake dragging Clutch slipping Engine overheating Water temperature sensor crankshaft sensor or speed sensor trouble Engine oil level too high Engine oil viscosity too high Inspect caliper fluid seal damage or clogging of master cylinder relief and supply ports see chapter 12 Inspect friction plates for wear see chapter 6 see Overheating of Troubleshooting Guide in chapter 17 Repair see chapter 7 Change see chapter 2 3 36 FUEL SYSTEM DFI DFI System Troubleshooting Guide Symptoms or Possible Causes Actions chapter Drive train trouble Inspect drive chain see chapter 2 and sprockets see chapter 1
336. me with the hole on the radiator OTighten the radiator bolt C ONote the baffle plate on the cylinder head cover when installing the radiator OPosition the radiator hose clamp screws D as shown Radiator Inspection e Check the radiator core x If there are obstructions to air flow remove them the corrugated fins A are deformed carefully straighten them x lf the air passages of the radiator core are blocked more than 20 by unremovable obstructions or irreparably de formed fins replace the radiator with a new one 6007010451 C CAUTION When cleaning the radiator with steam cleaner be careful of the following to prevent radiator damage Keep the steam gun A away more than 0 5 m 1 6 ft B from the radiator core Hold the steam gun perpendicular C not oblique D to the core surface Run the steam gun following the core fin direction Radiator Cap Inspection e Remove Reserve Tank see Coolant Change in the Periodic Main tenance chapter Radiator Cap e Check the condition of the bottom A and top B valve seals and valve spring C x If any one of them shows visible damage replace the cap with a new one 6007013851 C COOLING SYSTEM 4 15 Radiator Install the A on a cooling system pressure tester NOTE OWet the cap sealing surfaces with water or coolant to prevent pressure leaks e Watching the pressure gauge pump the pressure teste
337. mm 0 05846 0 05866 in Connecting Rod Big End Bearing Insert Selection Crankpin Diameter Bearing Insert Marking Marking Size Color Part Number None Brown 92139 0116 None None Black 92139 0115 Blue 92139 0114 Connecting Rod Bolt Stretch Usable Range New Connecting Rod 0 24 0 36 mm 0 0094 0 0142 in Used Connecting Rod 0 20 0 32 mm m 0 0079 0 0126 in Crankshaft Side Clearance 0 05 0 20 mm 0 40 mm 0 0020 0 0079 in 0 0157 in CRANKSHAFT TRANSMISSION 9 7 Specifications Standard Service Limit Crankshaft Runout TIR 0 02 mm 0 0008 in TIR 0 05 mm or less 0 0020 in Crankshaft Main Bearing Insert Journal Clearance 0 012 0 036 mm 0 07 mm 0 0005 0 0014 in 0 0028 in Crankshaft Main Journal Diameter 37 984 38 000 mm 37 96 mm 1 4954 1 4961 in 1 4945 in Marking None 37 984 37 992 mm 1 4954 1 4957 in 1 37 993 38 000 mm 1 4958 1 4961 in 41 000 41 016 mm MEE 1 6142 1 6148 in Crankcase Main Bearing Inside Diameter Marking 41 000 41 008 mm 1 6142 1 6145 in None 41 009 41 016 mm eo 1 6145 1 6148 in Crankshaft Main Bearing Insert Thickness Brown 1 490 1 494 mm 0 0587 0 0588 in Black 1 494 1 498 mm 0 0588 0 0590 in Blue 1 498 1 502 mm 0 0590 0 0591 in Crankshaft Main
338. mponents 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 LIST ABBREVIATIONS ampere S pound s ABDC after bottom dead center m meter s AC alternating current min minute s ATDC after top dead center N newton s BBDC before bottom dead center Pa pascal s BDC bottom dead center PS horsepower BTDC before top dead center psi pound s per square inch C degree s Celsius r revolution DC direct current rpm revolution s per minute F farad s TDC top dead center F degree s Fahrenheit TIR total indicator reading ft foot feet V volt s g gram s W watt s h hour s Q ohm s L liter s COUNTRY AND AREA CODES AT Austria DE Germany CA Canada GB United Kingdom CAL California US United States CH Switzerland WVTA Whole Vehicle Type Approval GENERAL INFORMATION 1 1 General Information Table of Contents pee E 1 2 Model Me Ta li ez Li o a REM 1 7 General Specifications cedet tete e ere ede rea def 1 10 Technical Information Cassette Type Transmission pp 1 13 Technical Information Inlet Air Pressure Sensor pp 1 14 Technical Information ABS Anti Lock Brake 1 15 Unit Conversion Table pp 1 27 1 2 GENERAL INFORMATION Before Servicing Bef
339. n Mod 7 Date problem occurred Mileage Environment when problem occurred Weather Temperature Problem frequency Road Altitude Dfine Ocloudy Orain Osnow always other hot Owarm Ocold Overy cold always often Ostreet highway Omountain road Ouphill downhil bumpy pebble normal high about 1 000 m or more Motorcycle conditions when problem occurred Fl indicator light LED light up immediately after ignition switch ON and goes off after 1 2 seconds normal lights blinks immediately after ignition switch ON and stays on DFI problem Olights up immediately after ignition switch ON but goes off after about 10 seconds DFI problem unlights light LED ECU or its wiring fault Osometimes lights up probably wiring fault 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 Ono spark other Engine stops Poor running at low speed Oright after starting Owhen opening throttle grip Ospark plug dirty broken or gap maladjusted remedy it overheating clutch slipping 3 28 FUEL SYSTEM DFI Troubleshooting th
340. n a digital meter Special Tool Hand Tester 57001 1394 x If the sensor the wiring and connections are good inspect the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good the ECU is suspect Replace the ECU 9017970852 C 8017971 52 3 26 FUEL SYSTEM Troubleshooting the DFI System DFI Diagnosis Flow Chart Problem occurs Confirm problems Gather information from rider The ignition switch is turned on and the state of the Fl indicator light LED is seen Conduct non self diagnosis Conduct self diagnosis inspection inspection Conduct general fuel system inspection General fuel system throttle assy air cleaner fuel tank etc 60179978 F Inquiries to Rider Inquiries to Rider OEach rider reacts to problems in different ways so it is important to confirm what kind of symptoms the rider has encountered OTry to find out exactly what problem occurred under exactly what conditions by asking the rider knowing this information may help you reproduce the problem OThe following sample diagnosis sheet will help prevent you from overlooking any areas and will help you decide if it is a DFl system problem or a general engine problem FUEL SYSTEM DFI 3 27 Troubleshooting the DFI System Sample Diagnosis Sheet Registration No license plate Year of initial registratio
341. n as shown Press C the bearing so that the bearing surface D is flushwith the housing end of clutch cover E GF05032BS1 e Apply water to the rubber of the oil gauge A and press B it so that the ring C face outside GF05031BS1 C CLUTCH 6 11 Clutch Clutch Removal e Remove Engine Oil Drain see Engine Oil Change in the Periodic Maintenance chapter Clutch Cover see Clutch Cover Removal Clutch Spring Bolts A Clutch Springs Clutch Spring Plate B with thrust bearing and pusher e Remove Friction Plates Steel Plates Clutch Hub Nut A OHolding the clutch hub B remove the nut and washer Special Tool Clutch Holder C 57001 1243 e Remove Clutch Hub Spacer Remove the oil pump sprocket bolt A NOTE OThe oil pump sprocket bolt has a left hand threads e Using the hole B pull out the sleeve C Remove the following as a set Clutch Housing D Oil Pump Chain E Oil Pump Sprocket F e Unscrew the bolts A and remove the oil pump chain guide B Clutch Installation e Apply a non permanent locking agent to the oil pump chain guide bolts and tighten them Torque Oil Pump Chain Guide Bolts 12 N m 1 2 kgf m 106 in Ib e Put the oil pump chain A on the clutch housing gear B and the oil pump sprocket C 6 12 CLUTCH Clutch e sure that the spacer A is in position Insert the following on the drive shaf
342. n the ignition switch ON and push the starter button OThen the starter motor should turn when the starter sys tem circuit is normality x If the starter motor is not turn inspect the starter lockout switch neutral switch and relay box x lf their parts are normality replace the ECU 3rd Check Inspect the engine for its secure stop after the following operations are completed e Run the engine to the following conditions Condition Transmission Gear 1st Position Clutch Lever Pulled in Sidestand Up e Set the sidestand on the ground then the engine will stop x lf whichever may not be stopped inspect the neutral switch starter lockout switch sidestand switch and relay box x lf their parts are normality replace the ECU IC Igniter Inspection OThe IC igniter is built in the ECU A e Refer to the Interlock Operation Inspection Ignition Sys tem Troubleshooting chart and Fuel System DFI chapter for ECU Power Supply Inspection ELECTRICAL SYSTEM 16 47 Ignition System Ignition System Troubleshooting Faulty ignition No spark No good Battery Inspection Charge or replace battery Good Ignition system wiring and connector NO 9006 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 9008 Voltage is less specified value Inspect
343. nal light Turn Signal Relay Inspection e Remove Left Upper Inner Fairing see Upper Inner Fairing Re moval 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 flash for one minute Turn Signal Relay A Turn Signal Lights B 12 V Battery C x If the lights do not flash as specified replace the turn sig nal relay Testing Turn Signal Relay Flashing Times The Number of Turn c m Signal Lights Wanags qu em 21 oF 23 140 250 2 42 or 46 75 95 Cycle s per minute Corrected to one light burned out 8 12040251 C 16 60 ELECTRICAL SYSTEM Lighting System Turn Signal Light Circuit INITIO b INI i SS 22 5 E E i Ed 5 pg 9 t el 11 ed 55 3 Zo P GP12206BW3 C Meter Unit Water proof Joint A Water proof Joint B Front Right Turn Signal Light Front Left Turn Signal Light Turn Signal Relay Hazard Button Turn Signal Switch Fuse Box 10 Turn Signal Relay Fuse 10 A 11 Main Fuse 30 A 12 Battery 12 V 10 Ah 13 Frame Ground 14 Rear Right Turn Signal Light 15 Rear Left Turn Signal Light 16 Joint Connector 17 Water proof Joint C 18 Ignition Switch 19 Frame Ground ELECTRICA
344. ncreased first the tappet of inlet solenoid valve opens normally open The brake fluid flows through the valve body as shown in the diagram below to increase the brake fluid pressure in the caliper The master cylinder pressurizes to the brake caliper directly increasing the braking force Increase Mode GL14018BW3 C Brake Lever Front Inlet Solenoid Valve Pump Motor Pump Front Reservoir Front Outlet Solenoid Valve Front Caliper NOORWN GENERAL INFORMATION 1 23 Technical Information ABS Anti Lock Brake System Hold Mode When the caliper fluid pressure is to be hold the tappet of inlet solenoid valve closes and the passage master cylinder side to the valve body is intercepted No matter how hard the brake lever is pulled the brake fluid pressure in the caliper is maintained at a given level Hold Mode GL14017BW3 C Brake Lever Front Inlet Solenoid Valve Pump Motor Pump Front Reservoir Front Outlet Solenoid Valve Front Caliper 1 24 GENERAL INFORMATION Technical Information ABS Anti Lock Brake System Decrease Mode When the caliper fluid pressure is to be decreased the tappet of inlet solenoid valve closes and the passage to the valve body is intercepted The valve of outlet solenoid valve is opened by the operation of the armature and the brake fluid flows to the reservoir ECU operates pump and the pump returns th
345. nd Rear Fender Rear Removal e Remove Seat see Seat Removal Seat Covers see Seat Cover Removal Tail Brake Light A see Tail Brake Light Removal in the Electrical System chapter e Remove Nuts A and Bolts B Flap with License Plate Light e Remove Seat Lock Cable Lower End A Quick Rivet B e Free the clamps from the rear fender rear Pull out the rear fender rear backward and downward Flap and Rear Fender Rear Installation e Installation is the reverse of removal 15 16 FRAME Fenders Rear Fender Front Removal e Remove Rear Fender Rear see Flap and Rear Fender Rear Re moval Battery see Battery Removal in the Electrical System chapter Relay Box see Relay Box Removal in the Electrical Sys tem chapter Starter Relay see Starter Relay Inspection in the Elec trical System chapter Remove the fuse box from the rear fender front e Remove Bolt A Clamp B Free the clamp from the rear fender front e Remove the rear fender front A backward and upward Rear Fender Front Installation Installation is the reverse of removal e Install the removed parts see appropriate chapters 15 17 Frame Inspection e Visually inspect the frame for cracks dents bending or warp Olf there is any damage to the frame replace it A WARNING A repaired frame may fail in use possibly causing an accident If the frame is bent dented cracked
346. nd chapter Muffler Body see Muffler Body Removal in the Engine Top End chapter Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Air Switching Valve and Hose see Air Switching Valve Removal in the Engine Top End chapter Air Cleaner Housing see Air Cleaner Housing Removal in the Fuel System DFI chapter Throttle Body Assy see Throttle Body Assy Removal in the Fuel System DFI chapter Clutch Cable see Clutch Cable Removal in the Clutch chapter e Remove Stick Coils A Baffle Plate B Hose C e Remove or Disconnect Water Temperature Sensor Lead Connector A Starter Motor Cable B Engine Ground Cable Terminal Bolt C Alternator Lead Connector D Sidestand Switch Lead Connector E Speed Sensor Lead Connector F 8 6 ENGINE REMOVAL INSTALLATION Engine Removal Installation e Remove the engine sprocket cover see Engine Sprocket Removal in the Final Drive chapter e Remove the shift pedal A see Shift Pedal Removal in the Crankshaft Transmission chapter e Disconnect Oxygen Sensor Lead Connector B Europe Models Neutral Switch Lead Terminal C Remove the bracket and the engine sprocket E see Engine Sprocket Removal in the Final Drive chapter e Support the engine with a stand or jack A OPut a wooden board B on the suitable stand Remove the engine mounting bolts e Remove the engine mounting bracket bolts both sides D and remove the brackets
347. nder Head Bolts M6 12 1 2 106 in Ib S Cylinder Bolts M6 12 1 2 106 in Ib S Throttle Body Holder Bolts 12 1 2 106 in Ib Rear Camshaft Chain Guide Bolt 20 2 0 15 L Camshaft Chain Tensioner Mounting Bolts 9 8 1 0 87 in lb Camshaft Chain Tensioner Cap Bolt 20 2 0 15 Camshaft Sprocket Bolts 15 1 5 11 L Spark Plugs 15 1 5 11 Exhaust Pipe Manifold Holder Nuts 17 1 7 12 Muffler Body Mounting Bolt Front 20 2 0 15 PERIODIC MAINTENANCE 2 7 Torque and Locking Agent Torque Engine Lubrication Engine Oil Drain Bolt Filter Plate Bolts Oil Filter Holder Mounting Bolt Oil Pan Bolts Oil Pump Chain Guide Bolts Oil Pipe Plate Bolt Oil Pressure Relief Valve Oil Pressure Switch Oil Pump Cover Bolts Lower Fairing Bracket Bolts Oil Pump Sprocket Bolt Oil Passage Plug Oil Plate Bolts Engine Removal Installation Rear Engine Mounting Nuts Engine Mounting Bracket Bolts Front Engine Mounting Bolts 17 2 25 12 12 9 8 15 15 9 8 12 12 20 9 8 3 0 1 0 1 75 2 5 1 2 1 2 1 0 1 5 1 5 1 0 1 2 1 2 2 0 1 0 22 87 13 18 106 in Ib 106 in Ib 87 11 11 87 106 in Ib 106 in Ib 15 89 in lb Fastener es kgf m ftlb Remarks Muffler Body Mounting Bolt Rear 20 2 0 15 Baffle Plate Bolts 5 9 0 60 52 in lb Clutch Upper Cap on Clutch Cover 3 9 0 40 35 in lb Lower Cap on Clutch Cover Hand tighten Oil Filler Plug Hand tighten Clutch Cover Mounting Bolt
348. ne and measure the peak voltage of the crankshaft sensor see Crankshaft Sensor Inspection in the Electrical System in order to check the sensor e Check the wiring for continuity using the following dia gram Crankshaft Sensor Circuit T3 30 1 80179786842 1 ECU 2 Crankshaft Sensor FUEL SYSTEM DFI 3 57 Speed Sensor Service Code 24 25 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 OBe sure the battery is fully charged e Turn the ignition switch OFF e Remove the left center fairing see Center Fairing Re moval in the Frame chapter e Disconnect the speed sensor connector and connect the harness adapter A between the harness connector and speed sensor connector e Connect a digital meter to the harness adapter leads Special Tool Throttle Sensor Setting Adapter 1 57001 1400 e Measure the sensor input voltage with the engine stopped and with the connector joined e Turn the ignition switch ON Speed Sensor Input Voltage Connection to Adapter Meter BL sensor P lead C Meter BK sensor BK Y lead D Standard About 9 11 V DC at Ignition Switch ON xIf the reading is
349. ne is started with 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 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 e Determine the fault using the self diagnosis function e 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 80171210651 BRAKES 12 35 Anti Lock Brake System eVisually inspect the wiring for signs of burning or fraying x If any wiring is poor replace the damaged wiring Pull each connector A apart and inspect it for corrosion dirt and damage x lf the connector is corroded or dirty clean it carefully If it is damaged replace it Check the wiring for continuity OUse the wiring diagram to find the ends of
350. necting rod held vertically use a height gauge to measure the difference in the height of the arbor above the surface plate over a 100 mm 3 94 in length to determine the amount of connecting rod bend x If connecting rod bend exceeds the service limit the con necting rod must be replaced 6105040881 C Connecting Rod Bend Service Limit TIR 0 2 100 mm 0 008 3 94 in 9 22 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Twist e With the big end arbor A still on V block C hold the connecting rod horizontally and measure the amount that the arbor B varies from being paralleled with the surface plate over a 100 mm 3 94 in length of the arbor to de termine the amount of connecting rod twist x 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 e Measure connecting rod big end side clearance Olnsert a thickness gauge A between the big end and ei ther crank web to determine clearance Connecting Rod Big End Side Clearance Standard 0 13 0 38 mm 0 0051 0 0150 in Service Limit 0 58 mm 0 023 in x If the clearance exceeds the service limit replace the con necting rod with new one and then check clearance again If clearance is too large after connecting rod replacement the crankshaft also must be replaced Connecting R
351. nector and the fuel pump relay remove the fuel tank see Fuel Tank Removal and the left side cover see Side Cover Removal in the Frame chapter xIf the power source voltage is normal check the output voltage of the injectors 80170120651 86617013651 80170140651 3 92 FUEL SYSTEM DFI Fuel Injectors Fuel Injector Output Voltage Inspection e Turn the ignition switch OFF Remove the ECU see ECU Removal e Connect a digital voltmeter A to the ECU connector B with the needle adapter set C Special Tool Needle Adapter Set 57001 1457 Injector Output Voltage Connections to Injector 1 Meter BL R lead terminal 42 Meter Battery Terminal Connections to Injector 2 Meter BL G lead terminal 41 Meter Battery Terminal e Turn the ignition switch ON Output Voltage at Injector Connector Standard Battery Voltage 12 8 V or more x If the output voltage is normal perform Injector Signal Test x If the output voltage is out of the standard turn the ignition switch OFF remove the fuel tank and check the injector wiring for continuity Injector Wiring Inspection ECU Connector Injector Connectors Terminal 42 Injector 1 Terminal BL R Terminal 41 Injector 2 Terminal BL G x If the wiring is good inspect the resistance of the injectors see Injector Resistance Inspection e Remove the needle adapter
352. ng ELECTRICAL SYSTEM 16 27 Battery Initial Charge e Place the strip A of caps loosely over the filler ports e Newly activated sealed batteries require an initial charge Standard Charge 1 2 A x 5 10 hours xlf using a recommended battery charger follow the charger s instructions for newly activated sealed battery Kawasaki recommended chargers Optimate 111 6 08019851 C Yuasa 1 5 Amp Automatic Charger Battery Mate 150 9 x lf the above chargers are not available use equivalent one NOTE OCharging rates will vary depending on how long the battery has been stored temperature and the type of charger used Let battery sit 30 minutes after initial charge then check voltage using a voltmeter If it is not at least 12 8 V repeat charging cycle e After charging is completed press down firmly with both hands to seat the strip of caps A into the battery don t pound or hammer When properly installed the strip of the caps will be level with the top of the battery S n3 CAUTION Once the strip of the caps A is installed onto the battery never remove the caps nor add water or electrolyte to the battery 8 08012851 C GPOSO10BS1 C NOTE 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 repea
353. ng 3 625 3 775 V DC at full throttle opening GC17998BS2 C 3 64 FUEL SYSTEM DFI Subthrottle Sensor Service Code 32 xIf the output voltage is out of the standard inspect the subthrottle sensor resistance x If the output voltage is normal check the wiring for conti nuity Wiring Connection ECU Connector A Subthrottle Sensor Connector BL W lead terminal 24 BR BK lead terminal 28 x lf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection Subthrottle Sensor Resistance Inspection e Turn the ignition switch OFF e Disconnect the subthrottle sensor connector e Connect a digital meter A to the subthrottle sensor con nector B e Measure the subthrottle sensor resistance Throttle Sensor Resistance Connections BL lead C BK lead D Standard 4 6 x If the reading is out of the range replace the throttle body assy xIf the reading is within the range but the problem still exists replace the ECU see ECU Removal Installation 9617006652 GC17293BS1 C FUEL SYSTEM DFI 3 65 Subthrottle Sensor Service Code 32 Subthrottle Sensor Circuit O TU FTTTFTTTTTTTTTTTTTTTTT a GC17979BW2 1 2 Water proof Joint 3 Water proof Joint 4 Subthrottle Sensor 3 66 FUEL SYSTEM Oxygen Sensor not
354. ngine 5 To the Water Temperature Sensor 6 Oxygen Sensor Lead Connector 7 Clamp Through the sidestand switch lead and oxygen sensor lead in the clamp 8 Oxygen Sensor Lead 9 Clamp Through the drain hose in the clamp 10 Drain Hose 11 Sidestand Switch Lead 12 Corrugated Tube 13 14 15 16 17 18 19 Alternator Lead Connector Sidestand Switch Lead Connector Speed Sensor Lead Connector Main Throttle Sensor Lead Connector Tube Neutral Switch Lead Drain Hose Through the drain hose between main harness and air cleaner Clamp Insert the clamp in the cross pipe 17 10 APPENDIX Cable Wire Hose Routing APPENDIX 17 11 Cable Wire Hose Routing Clamp Through the right switch housing lead and insert the clamp in the frame Clutch Cable Throttle Cables Clamp Right Switch Housing Lead Clamp Through the clutch cable in the clamp Frame Through the coolant hose in the frame Coolant Hose Clamp 17 12 APPENDIX Cable Wire Hose Routing EX650B Models APPENDIX 17 13 Cable Wire Hose Routing Brake Clutch Cable Throttle Cables Clamp Right Switch Housing Lead Clamp Through the clutch cable in the clamp Frame Through the coolant hose in the frame Coolant Hose Clamp Clamp Clamp the right switch housing lead connector Bra
355. ngine Oil Change e Situate the motorcycle so that it is vertical after warming up the engine e Unscrew the oil filler plug A e Place on oil pan beneath the engine Remove the engine oil drain bolt A to drain the oil OThe oil in the oil filter can be drained by removing the filter see Oil Filter Replacement Replace the drain bolt gasket B with a new one e Tighten the drain bolt Torque Engine Oil Drain Bolt 30 N m 3 0 kgf m 22 ft lb e Pour in the specified type and amount of oil Recommended Engine Oil Type API SE SF or SG API SH SJ or SL with JASO MA Viscosity SAE 10W 40 Capacity 1 7 L 1 8 US qt when filter is not removed 1 9 L 2 0 US qt when filter is removed 2 4 L 2 5 US qt when engine is completely dry NOTE OAlthough 10W 40 engine oil is the recommended oil for most conditions the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area 20W 40 SAE 10W 50 SAE 100 40 SAE 10W 30 20 10 0 10 20 30 40 C 6509011851 C e Check the oil level see Oil Level Inspection the Engine Lubrication System chapter Oil Filter Replacement Drain the engine oil see Engine Oil Change e Remove the oil filter A with the oil filter wrench B Special Tool Oil Filter Wrench 57001 1249 2 50 PERIODIC Periodic Maintenance Procedures
356. ngs should fit perfectly parallel to the groove sides If not replace the piston GE16147BS1 GE16070781 GE16103BS1 C 5 40 ENGINE END Cylinder Pistons Piston Ring End Gap e Place the piston ring A inside the cylinder using the pis ton to locate the ring squarely in place Set it close to the bottom of the cylinder where cylinder wear is low Measure the gap between the ends of the ring with a thickness gauge Piston Ring End Gap Top Standard 0 25 0 40 mm 0 0098 0 0157 in Service Limit 0 7 mm 0 028 in Second Standard 0 40 0 55 mm 0 0157 0 0217 in Service Limit 0 8 mm 0 031 in x lf the end of either ring is greater than the service limit replace all the rings GE16148BS1 ENGINE END 5 41 Throttle Body Holder Throttle Body Holder Installation e Be sure to install the O rings A e Install the clamps B as shown and so that their projec tions fit C on the holes of the holders OBe sure that the clamp bolt heads D face outwards e Tighten Torque Throttle Body Holder Bolts E 12 N m 1 2 kgf m 106 in Ib GE17015BS1 5 42 ENGINE END Muffler Muffler Body Removal A WARNING To avoid a serious burn do not remove the muffler when the engine is still hot Wait until the muffler cool down e Remove Right Frame Cover see F
357. njection 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 3 44 FUEL SYSTEM Main Throttle Sensor Service Code 11 Main Throttle Sensor Removal Adjustment CAUTION Do not remove or adjust the main throttle sensor A since it has been adjusted and set with precision at the factory Never drop the throttle body assy especially on a hard surface Such a shock to the sensor can dam age it Main Throttle Sensor Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Remove the left center fairings see Center Fairing Re moval in the Frame chapter e Disconnect the main throttle sensor connector and con nect the harness adapter A between these connectors e Connect a digital meter to the harness adapter lead Special Tool Throttle Sensor Harness Adapter 57001 1538 e Measure the sensor input voltage with the engine stopped and with the connector joined e Turn the ignition switch ON Main Throttle Sensor Input Voltage Connections to Adapter Meter R sensor BL lead Meter BK sensor BR BK lead Standard 4 75 5 25 V DC e Turn the ignition switch OFF x lf the input voltage is normal check the sensor output voltage x lf the input voltage is less than the
358. nkcase e Install a new gasket and the alternator cover Tighten Torque Alternator Cover Bolts 9 8 1 0 kgf m 87 in Ib Stator Coil Removal e Remove Alternator Cover see Alternator Cover Removal Holding Plate Bolt A and Plate Alternator Lead Grommet B Stator Coil Bolts C e Remove the stator coil D from the alternator cover 16 32 ELECTRICAL SYSTEM Charging System Stator Coil Installation e Apply a non permanent locking agent to the threads of the stator coil bolts and tighten them Torque Stator Coil Bolts 12 N m 1 2 kgf m 106 in Ib e Secure the alternator lead with a holding plate tighten the bolt OApply a non permanent locking agent to the threads of the holding plate bolt Torque Alternator Lead Holding Plate Bolt 9 8 N m 1 0 kgf m 87 in lb e Apply silicone sealant to the circumference of the alter nator lead grommet and fit the grommet into the notch of the cover securely Sealant Kawasaki Bond Silicone Sealant 92104 0004 e Install the alternator cover see Alternator Cover Installa tion Alternator Rotor Removal e Remove the alternator cover see Alternator Cover Re moval Remove the starter idle gear torque limiter and shafts e Wipe oil off the outer circumference of the rotor e Hold the alternator rotor steady with the rotor holder A and remove the rotor bolt B and washer Special Tools Grip 57001 1591 Rotor Holder 57001 1
359. nlet air duct and make sure does not flow the blown air from the outlet air duct B Disconnect the 12 V battery e Blow the air to the inlet air duct A and make sure does not flow the blown air from the outlet air duct B xIf the air switching value 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 cleaner hose C GP18142BS1 GP18144BS1 C ELECTRICAL SYSTEM 16 63 Radiator Fan System Fan Motor Inspection e Disconnect the connector A e Using an auxiliary leads supply battery power to the fan motor x If the fan does not rotate the fan motor is defective and must be replaced Radiator Fan Circuit Jon PARK IGNITION IGSS AIL IN WAIL JOS BATTERY IGS TAILS Ice e GPi5034BW3 C 1 Relay Box 10 Joint Connector 2 Radiator Fan Relay 11 ECU 3 ECU Main Relay 12 Water Temperature Sensor 4 Fuse Box 13 Water proof Joint E 5 Fan Fuse 15 A 14 Water proof Joint C 6 ECU Fuse 15 A 15 Radiator Fan 7 Main Fuse 30 A 16 Ignition Switch 8 Battery 12 V 10 Ah 17 Water proof Joint A 9 Frame Ground 18 Water proof Joint B 16 64 ELECTRICAL SYSTEM Meter Gauge Indicator Unit Meter Unit Removal Installation e Remove Windshi
360. not inflate the tire to more than 400 kPa 4 0 kgf cm 57 psi Overinflation can explode the tire with possibility of injury and loss of life WHEELS TIRES 10 15 Tires Check to see that the rim lines A on both sides of the tire sidewalls are parallel with the rim flanges x If the rim flanges and tire sidewall rim lines are not parallel remove the valve core e Lubricate the rim flanges and tire beads e Install the valve core and inflate the tire again e After the tire beads seat in the rim flanges check for air leakage Olnflate the tire slightly above standard inflation OUse a soap and water solution or submerge the tire and check for bubbles that would indicate leakage e Adjust the air pressure to the specified pressure see Air Pressure Inspection in the Periodic Maintenance chap ter e Install the air valve cap e Adjust the wheel balance see Balance Adjustment Tire Repair Currently two types of repair for tubeless tires have come into wide use One type is called a temporary external re pair which can be carried out without removing the tire from the rim and the other type is called permanent internal repair which requires tire removal It is generally under stood that higher running durability is obtained by perma nent internal repairs than by temporary external ones Also permanent internal repairs have the advantage of permitting a thorough examination for secondary damage not vi
361. nscrew the mounting bolts and take off the disc Remove the gaskets Brake Disc Installation e Replace the gaskets with new ones e Install the brake disc on the wheel so that the marked side A faces out e Apply a non permanent locking agent to the threads of the front and rear brake disc mounting bolts B e Tighten Torque Brake Disc Mounting Bolts 27 N m 2 8 kgf m 20 ft Ib Brake Disc Wear Measure the thickness of each disc A at the point where it has worn the most x If the disc has worn past the service limit replace it Measuring Area B Brake Discs Thickness Standard Front EX650A Models 4 3 4 7 mm 0 17 0 19 in EX650B Models 4 8 5 2 mm 0 19 0 20 in 6108017851 C Rear 4 8 5 2 mm 0 19 0 20 in Service Limit Front 4 0 mm 0 16 in Rear 4 5 mm 0 18 in Brake Disc Warp e Raise the wheel off the ground with jack see Front Rear Wheel Removal in the Wheels Tires chapter Special Tools Jack 57001 1238 Jack Attachment 57001 1608 OFor front disc inspection turn the handlebar fully to one side e Set up a dial gauge against the disc A as shown and measure disc runout while turning B the wheel by hand x If runout exceeds the service limit replace the disc 9108018851 C Disc Runout Standard 0 15 mm 0 006 in or less Service Limit 0 3 mm 0 01 in BRAKES 12 25 Brake Fluid Brake Fluid Level Inspection e Refer to the
362. nspection First Step e Turn on the ignition switch e Set the neutral position e Turn the engine stop switch to stop position A e Push the starter button e The engine does not start x If the engine starts inspect or replace the following item Engine Stop Switch see Switch Inspection in the Elec trical System chapter Second Step e Turn on the ignition switch e Set the neutral position e Turn the engine stop switch to run position A e Push the starter button and run the engine e Turn the engine stop switch to stop position e Immediately the engine should be stop x If the engine does not stop inspect or replace the follow ing item Engine Stop Switch see Switch Inspection in the Elec trical System chapter xIf the engine stop switch is good condition replace the ECU see ECU Removal Installation in the Fuel System DFI chapter PERIODIC MAINTENANCE 2 43 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
363. nspection e Remove Swingarm see Swingarm Removal in the Suspension chapter e Visually inspect the chain guide A Replace the chain guide if it shows any signs of abnormal wear or damage 2 32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake System Brake Fluid Leak Brake Hose and Pipe Inspection e Apply the brake lever or pedal and inspect the brake fluid leak from the brake hoses A fittings B and pipes C xIf the brake fluid leaked from any position inspect or re place the problem part Brake Hose and Pipe Damage and Installation Condition Inspection e Inspect the brake hoses fittings and pipes for deteriora tion cracks and signs of leakage OThe high pressure inside the brake line can cause fluid to leak A or the hose to burst if the line is not properly main tained Bend and twist the rubber hose while examining it Replace the hose and pipe if any crack B bulge or leakage is noticed Tighten any brake hose banjo bolts and brake pipe joint nuts Torque Brake Hose Banjo Bolts 25 2 5 kgf m 18 ft Ib Brake Pipe Joint Nuts 18 N m 1 8 kgf m 13 ft Ib EX650B Models e Inspect the brake hose routing x If any brake hose routing is incorrect route the brake hose according to Cable Wire and Hose Routing section in the Appendix chapter GL10020181 C PERIODIC MAINTENANCE 2 33 Periodic Maintenance Procedures Brake Operation Inspection
364. nstallation pp 13 16 Rear Shock Absorber Inspection pp 13 16 neri mE 13 17 Re MO Va M THE 13 17 Swingarm nce oiii tetro ttc te 13 17 Swingarm Bearing Removal pp 13 18 Swingarm Bearing Installation pp 13 18 Swingarm Bearing Sleeve Inspection 0400 21 00 1 13 19 Swingarm Bearing Lubrication pp 13 20 Chain Guide Inspectlon s iie i Rete Ha S DERE elt lode die edet rds MEE 13 2 SUSPENSION Exploded View Quy du A 0 0071 2 6GM021468W5 C SUSPENSION 13 3 Exploded View Torque No Fastener kgf m ftlb Remarks 1 Front Axle Clamp Bolt 34 3 5 25 2 Front Fork Bottom Allen Bolts 30 3 1 22 L 3 Front Fork Clamp Bolts Lower 20 2 0 15 AL 4 Front Fork Clamp Bolts Upper 20 2 0 15 5 Front Fork Top Plugs 25 2 5 18 6 Outer Tube EX650B Models AL Tighten the two clamp bolts alternately two times to ensure even tightening torque G Apply grease L Apply a non permanent locking agent R Replacement Parts 13 4 SUSPENSION Exploded View SUSPENSION 13 5 Exploded View Torque No Fastener kgf ftlb Remarks 1 Rear Shock Absorber Bolt 59 6 0 44 2 Shock Absorber Nut 59 6 0 44 3 Swingarm Pivot Shaft Nut 108 11 0 80 G Apply grease R Replacement Parts 13 6 SUSPENSION
365. nt forks rear shock absorber oil leak year fel fel 2 35 Steering play inspect year o 2 36 Steering stem bearings lubricate 2 years e 2 37 Electrical System Spark plug condition inspect 2 37 Lights and switches operation inspect year 2 38 Headlight aiming inspect year 2 40 Sidestand switch operation inspect year 2 41 Engine stop switch operation inspect year e e e 2 42 Others Chassis parts lubricate year e e 2 43 Bolts and nuts tightness inspect e e e 2 44 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 MAINTENANCE 2 5 Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY CHANGE REPLACE ITEM Air cleaner element Fuel hose Whichever comes first ODOMETER READING x 1 000 km x 1 000 mile v Every Coolant Radiator hose and O ring Engine oil Oil filter Brake hose and pipe Brake fluid Rubber parts of master cylinder and caliper Spark plug 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
366. nternal Circuit GP19010BW2 C A Headlight Relay B ECU Main Relay C Fuel Pump Relay D Starter Circuit Relay E Fan Relay 16 80 ELECTRICAL SYSTEM Fuse 30 A Main Fuse Removal e Remove Left Side Cover see Side Cover Removal in the Frame chapter Cover see Starter Relay Inspection Connector A e Pull out the main fuse B from the starter relay with needle nose pliers Fuse Box Fuse Removal e Remove the seat see Seat Removal in the Frame chap ter e Unlock the hook A to lift up the lid B Pull the fuses A straight out of the fuse box with needle nose pliers 15 A ECU Fuse Removal e Remove Seat see Seat Removal in the Frame chapter e Unlock the hook A to pull the lid B e Pull out the ECU fuse A from the fuse box ELECTRICAL SYSTEM 16 81 Fuse 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 e 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 Box 15 A ECU Fuse Removal e Inspect the fuse element xIf it is blown out replace the fuse Before replacing a blown fuse always check the amperage in the affected circuit If the amperage is equal to or greater than the fuse rating check the wiring and related components for a short circuit
367. o ohms OFor the switch housings and the ignition switch refer to the tables in the Wiring Diagram x lf the switch has an open or short repair it or replace it with a new one Special Tool Hand Tester 57001 1394 Rear Brake Light Switch Connections Rear Brake Light Switch Connections Color BR BL When brake pedal is pushed down O o When brake pedal is released Sidestand Switch Connections Sidestand Switch Connections Color BK G When sidestand is down c cns When sidestand is up O 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 Gonnections Color SW Terminal Ground When engine is running Engine lubrication system is in good condition 16 74 ELECTRICAL SYSTEM Switches and Sensors Water Temperature Sensor Inspection e Remove the water temperature sensor see Removal In stallation in the Fuel System DFI chapter e Suspend the sensor A in a container of coolant so that the temperature sensing projection C and threaded por tion C are submerged e Suspend an accurate thermometer B with temperature sensing projection located in almost the same depth NOTE OThe sensor and thermometer must not touch the con tainer side or bottom e Place the con
368. o both sides A of the M9 bolts washers and the threads B of the M9 bolts e Apply molybdenum disulfide oil solution to flange A and the threads B of the M8 bolts which is tightening order is 7 10 only see the next figure 8104216 52 GE14071BS1 A UL 59 B 9104218851 9 16 CRANKSHAFT TRANSMISSION Crankcase Splitting Tighten the lower crankcase bolts using the following steps the sequence numbers on the lower crankcase half tighten the M9 bolts 1 2 L 113 mm 4 45 in with washers Torque Crankcase Bolts M9 44 N m 4 5 kgf m 32 ft Ib OTighten the M9 bolts 3 4 L2 83 mm 3 27 in with wash ers Torque Crankcase Bolts M9 44 N m 4 5 kgf m 32 ft Ib OTighten the M9 bolts 5 6 L 113 mm 4 45 with washers Torque Crankcase Bolts 9 44 N m 4 5 kgf m 32 ft lb OTighten the M8 bolts 7 10 Torque Crankcase Bolts M8 35 N m 3 6 kgf m 26 ft Ib OTighten the M8 bolts A Do not apply molybdenum oil solution Torque Crankcase Bolts M8 27 5 N m 2 8 kgf m 20 ft Ib OTighten the M6 bolts B Torque Crankcase Bolts M6 19 6 N m 2 0 kgf m 15 ft Ib Tighten the upper crankcase bolts OThe upper crankcase bolts have copper plated washers Replace them with new ones Torque Upper Crankcase Bolts A 27 5 N m 2 8 kgf m 20 16 e After tightening all crankcase bolts check the f
369. ock Brake System ABS Hydraulic Unit The outlet and inlet solenoid valves reservoir pump motor solenoid valve relay motor relay and ECU are built in the ABS hydraulic unit Xe o 8 GL140248W2 C Brake Lever Brake Pedal Pump Motor Rear Inlet Solenoid Valve Rear Outlet Solenoid Valve Rear Reservoir Rear Caliper Front Inlet Solenoid Valve Front Outlet Solenoid Valve Front Caliper Front Reservoir Orifice Filter Check Valve GENERAL INFORMATION 1 19 Technical Information ABS Anti Lock Brake System Inlet Solenoid Valve Inlet solenoid valves control the brake pressure of each wheel by combining the operation of the outlet solenoid valve The ECU changes the electric current in the solenoids of the inlet solenoid valve 2 way 2 position electromagnetic valve to move the tappet and change the fluid pressure to Increase Mode Hold Mode or Decrease Mode LLLI Es 4 22 54 KTITI 08114026841 C 1 Increase 2 Hold and Decrease Mode 3 Tappet 4 Valve Body 5 From Master Cylinder Outlet Solenoid Valve Outlet solenoid valves control the brake pressure of each wheel by combining the operation of the inlet solenoid valve The ECU changes the electri
370. od Big End Bearing Insert Crankpin Wear e Measure the bearing insert crankpin B clearance with plastigage A e Tighten the big end nuts to the specified torque see Con necting Rod Installation NOTE ODo not move the connecting rod and crankshaft during clearance measurement CAUTION After measurement replace the connecting rod bolts Connecting Rod Big End Bearing Insert Crankpin Clearance Standard 0 017 0 041 mm 0 0001 0 0016 in Service Limit 0 08 mm 0 0031 in x If the clearance is within the standard no bearing replace ment is required xIf the clearance is between 0 042 mm 0 00165 and the service limit 0 08 mm 0 0031 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 6105040781 6105041881 C 6105041781 CRANKSHAFT TRANSMISSION 9 23 Crankshaft and Connecting Rods x If any crankpin has worn past the service limit replace the crankshaft with a new one If the measured crankpin diameters are not less than the service limit but do not
371. ode 44 e Do the 1st step test OMeasure the air gap between the rear wheel rotation sen sor and sensor rotor Thickness Gauge A Air Gap Standard 1 mm 0 04 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 2nd step e Do the 2nd step test 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 bad condition remove the any deposits Install the properly or replace faulty part xIf the all correct 3rd step e Do the 3rd step test 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 ABS indicator light LED A lit faulty ECU in the ABS hydraulic unit Replace the ABS hydraulic unit xIf the ABS indicator light LED A unlit ABS system is normal service code is not stored temporary failure GL14004BS1 BRAKES 12 51 Anti Lock Brake System Rear Wheel Rotation Sensor Wiring Inspection Service Code 45 e Do the 1st step test ODisconnect the ABS hydraulic unit connector and rea
372. oints are correct in the con nector noting the position of the lock D and the lead color before measurement Do not reverse connections of the hand tester or a digital meter e Be careful not to short circuit the leads of the DFI or elec trical system parts by contact between adapters e Turn the ignition switch ON and measure the voltage with the connector joined CAUTION Incorrect reverse connection or short circuit by needle adapters could damage the or electrical system parts OAfter measurement remove the needle adapters and ap ply silicone sealant to the seals A of the connector B for waterproofing Sealant Kawasaki Bond Silicone Sealant 56019 120 e Always check battery condition before replacing the parts A fully charged battery is a must for conducting accurate tests of the DFI system e Trouble may involve one or in some cases all items Never replace a defective part without determining what CAUSED the problem If the problem was caused by some other item or items they too must be repaired or replaced or the new replacement part will soon fail again e Measure coil winding resistance when the DFI part is cold at room temperature e Make sure all connectors in the circuit are clean and tight and examine wires for signs of burning fraying short etc Deteriorated wires and bad connections can cause reappearance of problems and unstable operation of the DFI system x If any
373. oken or weak Inspect and replace see chapter 5 Valve not seating properly valve bent worn or Inspect and repair or replace see chapter 5 carbon accumulating on seating surface Camshaft cam worn Inspect and replace see chapter 5 Hesitation Too low fuel pressure Inspect see chapter 3 Clogged fuel line Inspect and repair see chapter 3 Cracked or obstructed inlet air pressure sensor Inspect and repair or replace see chapter 3 hose inspect sec chapter 3 inspect see chapter 3 inspect see chapter 3 inspect see chapter 3 inspect see chapter 3 inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Inlet air pressure sensor trouble Inspect see chapter 3 Loose injector connectors Remedy see chapter 3 Crankshaft sensor trouble Inspect and repair or replace see chapter 16 Stick coil trouble Inspect and repair or replace see chapter 16 FUEL SYSTEM DFI 3 33 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions chapter Loose terminal of battery cable or engine Inspect and repair see chapter 16 ground lead Delay of ignition timing Inspect crankshaft sensor and IC igniter in ECU see chapter 16 Pooraccelerations yO Too low fuel pressure Inspect see chapter 3 Water or foreign matter in fuel Change fuel Inspect and clean fuel system see chapter 3 Clogged fuel filter or pump
374. oles B e Apply a non permanent locking agent to the camshaft sprockets bolts and tighten them Torque Camshaft Sprockets Bolts 15 N m 1 5 kgf m 11 ft lb x If a new camshaft is to be used apply a thin coat of a molybdenum disulfide grease to the cam surfaces Camshaft Camshaft Cap Wear e Remove Camshaft Caps see Camshaft Removal e Cut strips of plastigage to journal width Place a strip on each journal parallel to the camshaft installed in the correct position Measure each clearance between the camshaft journal and the camshaft cap using plastigage press gauge A Tighten Torque Camshaft Cap Bolts 12 N m 1 2 kgf m 106 in Ib NOTE not turn the camshaft when the plastigage is be tween the journal and camshaft cap Camshaft Journal Camshaft Cap Clearance Standard 0 028 0 071 mm 0 0011 0 0028 in Service Limit 0 16 mm 0 0063 in x If any clearance exceeds the service limit measure the diameter of each camshaft journal with a micrometer Camshaft Journal Diameter Standard 23 950 23 972 mm 0 9429 0 9438 in Service Limit 23 92 mm 0 942 in x If the camshaft journal diameter is less than the service limit replace the camshaft with a new one and measure the clearance again x If the clearance still remains out of the limit replace the cylinder head unit 11156851 C GE11072BS1 C ENGINE END 5 23 Camshaft Camshaft Ch
375. ollowing items OCrankshaft and balancer shafts turn freely 9104219852 C 9104207851 CRANKSHAFT TRANSMISSION 9 17 Crankshaft and Connecting Rods Crankshaft Removal Split the crankcase see Crankcase Splitting Remove the crankshaft A Crankshaft Installation CAUTION If the crankshaft bearing inserts or crankcase halves are replaced with new ones select the bear ing inserts and check clearance with a plastigage press gauge before assembling engine to be sure the correct bearing inserts are installed e Apply molybdenum disulfide oil solution to the crankshaft 8104279851 main bearing inserts OAlign A the timing mark on the balancer gear with the timing mark on the balancer drive gear C of the crank shaft e Install the crankshaft with the camshaft chain A hanging on it Connecting Rod Removal Split the crankcase see Crankcase Splitting Remove the connecting rod nuts A Remove the crankshaft NOTE OMark and record the locations of the connecting rods and their big end caps so that they can be reassembled in their original positions e Remove the connecting rods from the crankshaft peur CAUTION Discard the connecting rod bolts To prevent dam age to the crankpin surfaces do not allow the con necting rod bolts to bump against the crankpins 9 18 CRANKSHAFT TRANSMISSION Cran
376. ombustion chamber Engine load faulty Clutch slipping Engine oil level too high 17 48 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 unevenly worn No clutch lever play Clutch inner cable trouble Clutch release mechanism trouble Clutch not disengaging properly Clutch plate warped or too rough Clutch spring compression uneven Engine oil deteriorated Engine oil viscosity too high Engine oil level too high Clutch housing frozen on drive shaft Clutch hub nut loose Clutch hub spline damaged Clutch friction plate installed wrong Clutch lever play exc
377. ome out of the output shaft when moving it up and down by hand e Check that each gear spins or slides freely on the trans mission shafts without binding after assembly 9 38 CRANKSHAFT TRANSMISSION Transmission BS T 15 16 p Ca 2217 8 19 GI1324 BW3 C E Ss XO X p Chie ee 1st Gear 2nd Gear 3rd Gear 4th Gear 5th Gear 6th Top Gear Ball Bearing Bushing Toothed Washer 34 mm 1 34 Circlip Bushing Thrust Washer p30 mm 1 18 in Needle Bearing Circlip 15 Oil Seal Collar Washer Nut O ring Bearing Spacer 39 mm 1 54 in Positioning Ring Washer 40 mm 1 57 in Bushing Toothed Washer 38 mm 1 50 Shim 28 mm 1 10 in Steel Ball Circlip 632 2 mm 1 268 Thrust Washer 25 mm 0 98 CRANKSHAFT TRANSMISSION 9 39 Transmission Shift Drum and Fork Removal e Remove the transmission assy see Transmission Assy Removal Remove the shift forks A and shift drum see Trans mission Assy Disassembly Shift Drum and Fork Installation Refer to the Transmission Assy Assembly and Installa tion Shift Drum Disassembly e Refer to the Transmission Assy Removal and Disassem bly Shift Drum Assembly Refer to the Transmission Assy Assembly and Installa tion Shift Fork Bending e Visually inspect the shift forks
378. on Control System routes fuel va pors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped Al though no adjustments are required a thorough visual in spection must be made at the intervals specified by the Pe riodic Maintenance Chart Parts Removal Installation A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light CAUTION If gasoline solvent water or any other liquid enters the canister the canister s vapor absorbing capac ity is greatly reduced If the canister does become contaminated replace it with a new one e To prevent the gasoline from flowing into or out of the canister hold the separator perpendicular to the ground e Connect the hoses according to the diagram of the sys tem see Cable Wire and Hose Routing section in the Appendix chapter Make sure they do not get pinched or kinked Hose Inspection e Refer to the Evaporative Emission Control System In spection in the Periodic Maintenance chapter Separator Inspection e Refer to the Evaporative Emission Control System In spection in the Periodic Maintenance chapter Separator A FUEL SYSTEM DFI 3 109 Evaporative Emission Control System California Model
379. onnectthe 12 V battery and terminals in the same man ner as specified in the Liquid Crystal Display LCD Seg ments check Neutral Indicator Light LED A Fl Indicator Light LED B Oil Pressure Warning Indicator Light LED C Right Turn Signal Indicator Light LED D Left Turn Signal Indicator Light LED E High Beam Indicator Light LED F Fuel Level Warning Indicator Light LED Water Temperature Warning Indicator Light LED H ABS Indicator Light LED EX650B Models I e Using the auxiliary leads connect a 12 V battery to the meter unit connector as follows Water Temperature Warning Indicator Light LED Battery Negative Terminal to Terminal 8 GP17391BS1 C Pressure Warning Indicator Light LED Battery Negative Terminal to Terminal 11 GP17392BS1 Fuel Level Warning Indictor Light LED Battery Negative Terminal to Terminal 2 GP17393BS1 C 16 70 ELECTRICAL SYSTEM Meter Gauge Indicator Unit High Beam Indicator Light LED Battery Positive Terminal to Terminal 15 GP17394BS1 C Neutral Indicator Light LED Battery Negative Terminal to Terminal 5 GP17395BS1 C Right and Left Turn Signal Indicator Light LED For Right Turn Signal Indicator Light LED Battery Positive Terminal to Terminal 13 For Left Turn Signal Indicator Light LED Battery P
380. ontainer of machine oil so that the heat sensitive portion is submerged e Suspend a thermometer B with the heat sensitive por tion C located in almost the same depth with the sensor NOTE OThe sensor and thermometer must not touch the con tainer side or bottom e Place the container over a source of heat and gradually raise the temperature of the oil while stirring the oil gently for even temperature e Using a digital meter measure the internal resistance of the sensor across the terminals at the temperatures shown in the table Inlet Air Temperature Sensor Resistance Standard 5 4 6 6 at 0 68 F Vern 0 29 0 39 at 80 C 176 F x If the measurement is out of the range replace the sensor x If the measurement is within the specified replace the ECU Inlet Air Temperature Sensor Circuit Y BR BK BR BK Y L 6C179748W2 1 ECU 2 Inlet Air Temperature Sensor 3 Water proof Joint E 3 54 FUEL SYSTEM DFI Water Temperature Sensor Service Code 14 Water Temperature Sensor Removal Installation CAUTION Never drop the sensor especially on a hard surface Such a shock to the sensor can damage it e Drain the coolant see Coolant Change in the Periodic Maintenance chapter Remove the left center fairing see Center Fairing Re moval in the Frame chapter e Disconnect the sensor connector A and unscrew the water temperature sensor
381. ontents Brake Hose Removal Installation Brake Hose Inspection Anti Lock Brake System ABS Servicing Precautions ABS Troubleshooting Outline Inquiries to Rider Self diagnosis Outline Self diagnosis Procedures Service Code Clearing How to Read Service Codes How to Erase Service Codes ABS Indicator Light LED ABS Indicator Light LED is Unlit When the Ignition Switch turned to ON pp Solenoid Valve Inspection Service Code 13 14 17 18 ABS Solenoid Valve Relay Inspection Service Code 19 Front Rear Wheel Rotation Difference Abnormal Service Code 25 tte ABS Pump Motor Relay Inspection Service Code 35 Front Wheel Rotation Sensor Signal Abnormal Service Code cis Front Wheel Rotation Sensor Wiring Inspection Service Code Rear Wheel Rotation Sensor Signal Abnormal Service Code AY escaso Livin doas td eese ea Rear Wheel Rotation Sensor Wiring Inspection Service Code Power Supply Voltage Abnormal Under Voltage Service Code D2 ou de Power Supply Voltage Abnormal Over Voltage Service Code Donius ECU Inspection Service Code BD
382. operly 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 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 c
383. operly adjusted incorrectly routed or damaged cables could result in an unsafe riding condition e Check idle speed lf the idle speed is out of the specified range adjust it Idle Speed Standard 1 300 50 r min rpm 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 65058793 PERIODIC MAINTENANCE 2 19 Periodic Maintenance Procedures Fuel Hose Inspection fuel leak damage installation condition OThe fuel hose is designed to be used throughout the mo torcycle s life without any maintenance However if the motorcycle is not properly handled the high pressure in side the fuel line can cause fuel to leak A or the hose to burst Remove the fuel tank see Fuel Tank Removal in the Fuel System DFI chapter and check the fuel hose x Replace the fuel hose if any fraying cracks B or bulges C are noticed Dyan e Check that the hoses are routed according to Cable Wire and Hose Routing section in the Appendix chapter x Replace the hose if it has been sharply bent or kinked Hose Joints A Fuel Hose B 9505083851 e Check that the hose joints are securely connected OPush and pull A the hose joint B back and forth more than two times and make sure it
384. or joined Vehicle down Sensor Input Voltage Standard 4 75 5 25 V DC e Turn the ignition switch OFF xIf the reading of input voltage is less than the standard check the ECU for its ground power supply and wiring shorted x If the power source is normal check the output voltage 80171166052 C 3 60 FUEL SYSTEM DFI Vehicle down Sensor Service Code 31 e Remove the sensor see Vehicle down Sensor Removal Connect a digital volt meter A to the connector with nee dle adapter set B Special Tool Needle Adapter Set 57001 1457 Vehicle down Sensor Output Voltage Connections to Sensor Meter Y G lead E Meter BR BK lead Hold the sensor vertically e Turn the ignition switch ON and measure the output volt age with the connector joined OTilt the sensor 60 70 or more C right or left then hold the sensor almost vertical with the arrow mark pointed up D and measure the output voltage Output Voltage at Sensor 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 OFF and then ON e Turn the ignition switch OFF e Remove the needle adapter set and apply silicone sealant to the seals of the connector for waterproofing Sealant Kawasaki Bond Silicone Sealant 56019 120 the output voltage is normal the wiring i
385. or more without plugs 0 2 V or less the oxygen sensor is good x If the reading is without range replace the oxygen sensor see Oxygen Sensor Removal Installation in the Electrical System chapter Oxygen Sensor Circuit x e c 3 BRvBK 1 1 6GC179868W2 C ECU Oxygen Sensor Water proof Joint E Water proof Joint D Oxygen Sensor Heater Fuse 10 A Main Fuse 30 A Battery Frame Ground Joint Connector AON 3 68 FUEL SYSTEM DFI Stick Coils 1 2 Service Code 51 52 Stick Coil 1 Service Code 51 Stick Coil 2 Service Code 52 Stick Coil Removal Installation CAUTION Never drop the stick coils especially on a hard sur face Such a shock to the stick coil can damage it e Refer to the Stick Coil Ignition Coil together with Spark Plug Cap Removal Installation in the Electrical System chapter Stick Coil Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Remove the ECU see ECU Removal Do not disconnect the ECU connector e Connect a digital voltmeter A as shown with the needle adapter set B OMeasure the input voltage to each primary winding of the ignition coils with the engine stopped and with the con nectors joined e Turn the ignition switch ON Stick Coil Input Voltage at ECU Connections for Stick Coil 1 Meter BK
386. ore 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 QA gt ptt 2 gine from accidentally turning over Disconnect the ground AOA ad cable first and then the positive When completed 6620 Se with the service first connect the positive cable to the positive terminal of the battery then the negative ca L ble to negative terminal DISASSEMBLY ASSEMBLY 68020248 5 Edges of Parts Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts Solvent Use a high flush point solvent when cleaning parts High flush point solvent should be used according to directions of the solvent manufacturer 08020058 5 Cleaning Vehicle before Disassembly Clean the vehicle thoroughly before disassembly Dirt or other foreign materials entering into sea
387. ored temporary failure Front Wheel Rotation Sensor Wiring Inspection Service Code 43 Do the 1st step test ODisconnect the ABS hydraulic unit connector and front wheel rotation sensor connector OShort the white and black lead terminals of the main har ness side connector A with a jumper lead and check for continuity between the white and black lead terminals of the main harness side connector B x If there is the continuity in the lead 2nd step x lf there is not the continuity in the lead replace or repair the main harness e Do the 2nd step test O Check for continuity between the white lead terminal of the sensor connector A and ground and black 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 3rd step GL14004BS1 C S GL14038BS1 GL14039BS1 C 12 50 BRAKES Anti Lock System e Do the 3rd step test ORecheck the service code indication erase the service code perform the pre diagnosis inspection 1 and 2 and retrieve the service code lf the ABS indicator light LED A lit faulty ECU in the ABS hydraulic unit Replace the ABS hydraulic unit x lf the ABS indicator light LED A unlit ABS system is normal service code is not stored temporary failure Rear Wheel Rotation Sensor Signal Abnormal Service C
388. ormal wear and may result in an unsafe riding condition e Tighten both chain adjuster locknuts securely Tighten the axle nut Torque Rear Axle Nut 108 N m 11 0 80 16 Turn the wheel measure the chain slack again at the tight est position and readjust if necessary 2 30 PERIODIC Periodic Maintenance Procedures e Insert a new cotter pin NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle tighten the nut clockwise B up to next alignment Olt should be within 30 OLoosen once and tighten again when the slot goes past the nearest hole Bend the cotter pin A over the nut A WARNING If the rear axle nut is not securely tightened or the cotter pin is not installed an unsafe riding condi tion may result Wheel Alignment Inspection e Check that the value A on the left wheel alignment ad juster B aligns with the same left or right edge C of inspection window on the swingarm that the right wheel alignment adjuster value aligns with x lf 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 WARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition HJ07007BS1 C HJ07008BS
389. ositive Terminal to Terminal 14 GP17396BS1 C FI Indicator Light LED Battery Negative Terminal to Terminal 6 GP17397BS1 e f each lights LED does not go on replace the meter assembly ELECTRICAL SYSTEM 16 71 Meter Gauge Indicator Unit EX650B Models ABS Indicator Light LED Battery Negative Terminal to Terminal 3 GP17398BS1 e If the light LED keeps going on replace the meter as sembly 16 72 ELECTRICAL SYSTEM Meter Gauge Indicator Unit Meter Circuit GP173768W4 1 Ignition Switch 11 Fuel Reserve Switch 2 Frame Ground 12 Joint Connector 3 Meter Unit 13 ECU 4 Water proof Joint B 14 Oil Pressure Switch 5 ECU Fuse 15A 15 Neutral Switch 6 Ignition Fuse 10 A 16 Water Temperature Sensor 7 Fuse Box 17 Water proof Joint E 8 Main Fuse 30 A 18 Speed Sensor 9 Battery 12 V 10 Ah 19 Water proof Joint C 10 Frame Ground 20 ABS Hydraulic Unit EX650B Models ELECTRICAL SYSTEM 16 73 Switches and Sensors Brake Light Timing Inspection e Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance chapter Brake Light Timing Adjustment e Refer to the Brake Light Switch Operation Inspection in 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 zer
390. ot the continuity in the lead 3rd step e Do the 3rd step test OCheck for continuity between the red white lead terminal of the main harness side connector A and red white lead terminal of the fuse box B x If there is the continuity in the lead replace the fuse x lf there is not the continuity in the lead replace or repair the main harness GL14004BS1 C GL14035BS1 12 48 BRAKES Anti Lock Brake System e Do the 4th step test 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 lf the battery terminal voltage is not within the specifica tion 5th step x lf the battery terminal voltage correct 6th step e Do the 5th step test OCheck for continuity between the positive cable A of the battery and red white lead terminal of the main harness side connector B x If there is the continuity in the lead 4th step x If there is not the continuity in the lead replace or repair the main harness e Do the 6th step test ORecheck the service code indication erase the service code perform the pre diagnosis inspection 1 and 2 and retrieve the service code xIf the ABS indicator light LED A lit faulty ABS pump motor relay in the ABS hydraulic unit Replace the ABS hydraulic unit x If the ABS indicator light LED A unl
391. ound Special Tool Hand Tester 57001 1394 Battery Terminal Voltage Standard Battery Voltage x lf the battery terminal voltage is not within the specifica tion 2nd step x If the battery terminal voltage correct 3rd step e Do the 2nd step test OCheck the battery condition and regulator rectifier see Charging Condition Inspection Regulator Rectifier In spection in the Electrical System chapter GL14036BS1 C GL14004BS1 GL14036BS1 BRAKES 12 53 Anti Lock Brake System e Do the 3rd step test ORecheck the service code indication erase the service code perform the pre diagnosis inspection 1 and 2 and retrieve the service code lf the ABS indicator light LED A lit faulty ECU in the ABS hydraulic unit Replace the ABS hydraulic unit lf the ABS indicator light LED A unlit ABS system is normal service code is not stored temporary failure ECU Inspection Service Code 55 e Do the 1st step test ORecheck the service code indication erase the service code perform the pre diagnosis inspection 1 and 2 and retrieve the service code lf the ABS indicator light LED A lit faulty ECU in the ABS hydraulic unit Replace the ABS hydraulic unit xIf the ABS indicator light LED A unlit ABS system is normal service code is not stored temporary failure ABS Hydraulic Unit Removal CAUTION The ABS hydraulic unit A has been adjusted and set with p
392. 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 lf the outside diameter A of the seating surface is too large make the 32 grind described below x If the outside diameter of the seating surface is within the specified range measure the seat width as described be low e Grind the seat at a 32 angle B until the seat outside diameter is within the specified range OTo make the 32 grind fit a 32 cutter into the holder and slide it into the valve guide OTurn the holder one turn at a time while pressing down very lightly Check the seat after each turn CAUTION The 32
393. ove Left Lower Fairing see Lower Fairing Removal in the Frame chapter Engine Sprocket Cover see Engine Sprocket Removal in the Final Drive chapter e Connect a digital voltmeter A to the oxygen sensor con nector B main harness side using the needle adapter set C Special Tool Needle Adapter Set 57001 1457 Oxygen Sensor Output Voltage Connections to Oxygen Sensor Connector Meter BL Y lead Meter BR BK lead e Remove the air switching valve hose from the fitting e Install the suitable plugs A on the fitting B and shut off the secondary air e Turn the ignition switch ON e Start the engine and let it idle e Measure the output voltage of the sensor with the con nector joined Oxygen Sensor Output Voltage with Plugs Standard 0 7 V or more e Next remove the plugs from the fitting A with idling FUEL SYSTEM 3 77 Oxygen Sensor Incorrect Output Voltage Service Code 94 Europe Models e Measure the output voltage of the sensor with the con nector joined Oxygen Sensor Output Voltage without Plugs Standard 0 2 or less lf the reading is within range with plugs 0 7 V or more without plugs 0 2 V or less the oxygen sensor is good x If the reading is without range inspect the engine and fuel supply system x lf the engine and fuel supply system good replace the oxygen sensor see Oxygen Sensor Removal Installation in the Electrical System cha
394. overheat OConsiderable difference in inner and outer pad wear OSeal and piston are stuck together x If the fluid seal is replaced replace the dust seal B as well Also replace all seals every other time the pads are changed Rear Caliper Dust Boot and Friction Boot Damage e Check that the dust boot A and friction boot are not cracked worn swollen or otherwise damaged x If they show any damage replace it 6513047851 6105097851 C 6105098851 C BRAKES 12 19 Calipers Caliper Piston and Cylinder Damage O e Visually inspect the pistons A and cylinder surfaces B Replace the caliper if the cylinder and piston are badly Scores or rusty 9105117851 C 6105100851 C Rear Caliper Holder Shaft Wear The caliper body must slide smoothly on the caliper holder shafts A If the body does not slide smoothly one pad will wear more than the other pad wear will increase and con stant drag on the disc will raise brake and brake fluid tem perature e Check to see that the caliper holder shafts are not badly worn or stepped and that the rubber friction boots are not damaged x If the rubber friction boot is damaged replace the rubber friction boot To replace the friction boot remove the pads and the caliper bracket x lf the caliper holder shaft is damage replace the caliper bracket 6105101851 C 12 20 BRAKES Brake Pads Front Brake Pad
395. peak voltage adapter A is a more reliable way to determine the condition of the crankshaft sen sorthan crankshaft sensor internal resistance measure ments e Remove 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 adapter to yellow lead and red lead to black lead in the crankshaft sensor connector e Turn the ignition switch and engine stop switch ON ELECTRICAL SYSTEM 16 43 Ignition System e Pushing the starter button turn the engine 4 5 sec onds with the transmission gear in neutral to measure the crankshaft sensor peak voltage Repeat the measurement 5 or more times Crankshaft Sensor Peak Voltage Standard 1 9 V or more Special Tools Hand Tester 57001 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B x If the tester reading is not specified one check the crank shaft sensor Timing Rotor Removal e Remove Clutch Cover see Clutch Cover Removal in the Clutch chapter Crankshaft Sensor see Crankshaft Sensor Removal e Remove the timing rotor A OHolding the timing rotor with the flywheel amp pulley holder B and unscrew the rotor bolt C Special Tool Flywheel amp Pulley Holder 57001 1605 Timing Rotor Installation e Fit the rotor to the crankshaft e Tighten the rotor bolt Torque Timing Rotor Bolt 40 N m 4 1 kgf m 30 ft Ib e Inst
396. ply molybdenum disulfide oil solution to the piston pins and piston journals OWhen installing the piston pin snap ring compress it only enough to install it and no more CAUTION Do not reuse snap rings as removal weakens and deforms them They could fall out and score the cylinder wall e Install the cylinder see Cylinder Installation Cylinder Wear e Since there is a difference in cylinder wear in different di rections take a side to side and a front to back measure ment at each of the two locations total of four measure ments shown in the figure x If any of the cylinder inside diameter measurements ex ceeds the service limit replace the cylinder 10 mm 0 39 in A 60 mm 2 36 in B Cylinder Inside Diameter Standard 82 994 83 006 mm 3 2675 3 2679 in Service Limit 83 10 mm 3 2716 in Piston Wear 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 x 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 2606 in GE16144BS1 Te oil GE16145BS1 C GE16146BS1 C ENGINE END 5 39 Cylinder Pistons Piston Ring Piston Ring Groove Wear e Check for uneven groove wear by inspecting the ring seat in
397. pter Oxygen Sensor Circuit gt ECU Oxygen Sensor Water proof Joint E Water proof Joint D Oxygen Sensor Heater Fuse 10 A Main Fuse 30 A Battery Frame Ground Joint Connector OOND 5 6C179868W2 C 3 78 FUEL SYSTEM DFI Fl Indicator Light LED Inspection Flow Chart Turn the ignition SW ON Repair or replace the meter or wiring NG No Flashes once then oes off or unlit Does the light LED goes on 2 Cnc light and wiring Yes goes on Good Does the light LED go off after Yes goes off DFI and ignition systems are 1 2 seconds considered to be normal No stays on DFI and ignition systems are abnormal Turn the ignition SW OFF End of inspection Go to self diagnosis Does the light LED go off after No stays on 10 20 seconds Run the engine with idling Turn the ignition SW OFF DFI and ignition systems Ask the rider if the problem are normal occurs again Yes occurs Replace the ECU GC17852B F FUEL SYSTEM DFI 3 79 Fl Indicator Light LED Indicator Light LED Inspection e Remove the meter unit see Meter Unit Removal in the Electrical System chapter e Using two auxiliary leads supply battery power to the FI indicator light LED A 12 V Battery B FI Indicator Light LED Check Connector Meter Connector C disconnected Connection W BK Lead T
398. pter Clutch Lever Free Play Adjustment e Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter Clutch Cable Removal e Remove Right Frame Cover see Frame Cover Removal in the Frame chapter Right Center Fairing see Center Fairing Removal in the Frame chapter e Slide the dust cover A at the middle of clutch cable out of place e Loosen the locknut B and turn the adjusting nut C to give the cable plenty of play e Screw in the adjuster Line up the slots A in the clutch lever and adjuster B and then free the cable from the lever e Free the clutch inner cable tip from the clutch release lever e Disconnect the clutch cable clamp A on the cylinder head cover e Pull the clutch cable out of the frame Clutch Cable Installation e Run the clutch cable correctly see Cable Wire and Hose Routing section in the Appendix chapter e Adjust the clutch cable see Clutch Operation Inspection in the Periodic Maintenance chapter Clutch Cable Lubrication e Refer to the Chassis Parts Lubrication in the Periodic Maintenance chapter GF04017BS1 CLUTCH 6 7 Clutch Lever Cable Clutch Lever Installation e Install the clutch lever so that the mating surface B of the clutch lever clamp is aligned with the punch mark A e Tighten the upper clamp bolt first and then the lower clamp bolt There will be a gap at the lower part of the clamp after tightenin
399. r Bend the end of axle cotter pin surely after tightening the axle nut see Rear Wheel Installation in the Wheels Tires chapter Rear Sprocket Removal e Remove the rear wheel see Rear Wheel Removal in the Wheels Tires chapter CAUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place wooden blocks under the wheel so that the disc does not touch the ground Remove the rear sprocket nuts A Remove the rear sprocket Rear Sprocket Installation e Install the sprocket facing the tooth number marking A outward Tighten the rear sprocket nuts Torque Rear Sprocket Nuts 59 N m 6 0 kgf m 44 ft lb e Install the rear wheel see Rear Wheel Installation in the Wheels Tires chapter 11 12 FINAL DRIVE Sprocket Coupling Coupling Installation e Apply high temperature grease to the coupling grease seal lips A e Apply grease to the coupling internal surface B GK05040BS1 C e Grease the following Wheel Flange Portion A O ring B e Install the collar C Coupling Bearing Removal e Remove Coupling Grease Seal Circlip A Special Tool Inside Circlip Pliers 57001 143 e Remove the bearing A by tapping from the wheel side Special Tool Bearing Driver Set B 57001 1129 Coupling Bearing Installation e Replace the bearing with a new one e Press in the bearing A until it is bottom
400. r 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 5 psi x If the cap can not hold the specified pressure or if it holds too much pressure replace it with a new one Radiator Filler Neck Inspection e Remove the reserve tank see Coolant Change in the Pe riodic Maintenance chapter e Remove the radiator cap e Check the radiator filler neck for signs of damage e Check the condition of the top and bottom sealing seats A in the filler neck They must be smooth and clean for the radiator cap to function properly GD07001BS1 C 4 16 COOLING SYSTEM Thermostat Thermostat Removal e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Remove Left Center Fairing see Center Fairing Removal in the Frame chapter Thermostat Hosing Bolts A Thermostat Hosing B e Pull the thermostat A out of the cylinder head Thermostat Installation e Install the thermostat A in the cylinder head so that the air bleeder hole B is on top e Install a new O ring into the housing and apply grease it e Tighten Torque Thermostat Hosing Bolts 9 8 N m 1 0 kgf m 8
401. r wheel rotation sensor connector OShort the red and green lead terminals of the main har ness side connector A with a jumper lead and check for continuity between the red and green lead terminals of the main harness side connector B x If there is the continuity in the lead 2nd step x If there is not the continuity in the lead replace or repair the main harness e Do the 2nd step test OCheck for continuity between the white lead terminal of the sensor connector A and ground and black lead ter minal of the sensor connector and ground x If there is the continuity in the lead replace the rear wheel rotation sensor x lf there is not the continuity in the lead 3rd step e Do the 3rd step test 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 ABS indicator light LED A lit faulty ECU in the ABS hydraulic unit Replace the ABS hydraulic unit xIf the ABS indicator light LED A unlit ABS system is normal service code is not stored temporary failure Power Supply Voltage Abnormal Under Voltage Service Code 52 e Do the 1st step test ODisconnect the ABS Kawasaki self diagnosis system con nector and ABS hydraulic unit connector OCheck for continuity between the brown lead terminal of the main harness side connector A and brown lead ter minal of the main harness side connector B x If there is the
402. r abrasion discoloration or other damage x If the needle bearing and sleeve B show any sings of abnormal wear discoloration or damage replace them as a set 13 20 SUSPENSION Swingarm e Turn the bearing in the swingarm 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 Examine 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 te er dev pe 14 2 Special TOONS 14 4 T serti 14 5 Steering Ins pecllQDis oasis odas shen ended 14 5 Steering 14 5 Steenng Stem 14 6 Stem Stem Bearing Removal 14 6 Stem Stem Bearing Installation pp 14 7 Stem Bearing LUDOM EE 14 9 Steering Sterni Waf D sinnir ieia ce aA kia 14 9 Stem Cap Deterioration Damage pp 14 9 Handlebar sis Avi
403. r solution Replace the headlight bulb e Fit the projection A of the bulb in the hollow B of the headlight e Install the hook C 16 56 ELECTRICAL SYSTEM Lighting System e Fit the dust cover A onto the bulb B firmly as shown Good C Bad D e After installation adjust the headlight aim see Headlight Aiming Inspection in the Periodic Maintenance chapter City Light Bulb Replacement Europe Models e Remove the meter cover see Meter Unit Removal Instal lation e Disconnect the connector A e Pull out the socket B together with the bulb e Pull the bulb A out of the socket CAUTION Do not turn the bulb Pull the bulb out to prevent damage to the bulb Do not use bulb rated for greater wattage then the specified valve e Replace the bulb with a new one Headlight Removal Installation e Remove Upper Fairing see Upper Fairing Removal in the Frame chapter Mounting Bolts A e Installation is the reverse of removal Tail Brake Light Removal e Remove Seat Covers see Seat Cover Removal in the Frame chapter e Disconnect the connector A e Unscrew the mounting bolts B e Remove the tail brake light C Tail Brake Light Installation e Installation is the reverse of removal GP12025BS1 C ELECTRICAL SYSTEM 16 57 Lighting System License Plate Light Bulb Replacement e Remove Screws License Plate Light Cover e Push
404. rame Cover Removal in the Frame chapter e Remove the bolts and lift up the right footpeg stay A pull the muffler body B backward Exhaust Pipe Removal e Remove Lower Fairings see Lower Fairing Removal in the Frame chapter Center Fairings see Center Fairing Removal in the Frame chapter Muffler Body Clamp Bolt A Exhaust Pipe Manifold Holder Nuts B Exhaust Pipe C Gaskets ENGINE END 5 43 Muffler Muffler Body and Exhaust Pipe Installation e Replace the exhaust pipe gaskets A and muffler body connection gasket B with new ones and install them Olnstall the muffler body connection gasket until it is bot tomed so that the chamfer side C feces muffler body D e Install Muffler Body Exhaust Pipe E Tighten Torque Exhaust Pipe Manifold Holder Nut F 17 N m 1 7 kgf m 12 ft lb Muffler Body Mounting Bolts Front and Rear G 20 N m 2 0 kgf m 15 ft Ib Tighten the muffler body clamp bolt Olnstall the muffler body clamp bolt as shown GE 80348W2 e Thoroughly warm up the engine wait until the engine cools down and retighten all the bolts and nuts CLUTCH 6 1 Clutch Table of Contents Exploded 6 2 Jerez EEUU 6 4 Special Tool and sealanit 6 5 Clutch Lever and Cable enne 6 6 Clutch Lever Free Play Inspection pp 6 6 Clutch Lever Free Play Adjustment Ne 6 6 Clutch Cable Remov
405. recision 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 e 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 Left Frame Cover see Frame Cover Removal in the Frame chapter Rear Fender Front see Rear Fender Front Removal in the Frame chapter Regulator Rectifier see Regulator Rectifier Removal in the Electrical System chapter e Clean the ABS hydraulic unit CAUTION 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 GL14004BS1 C 12 54 BRAKES Anti Lock Brake System e Remove Bolts A e Remove Brake Pipe Joint Nuts A B C D Tape the brake line opening to prevent brake fluid leakage or contamination by foreign matter CAUTION Brake fluid quickly ruins painted plastic surfaces any Spilled fluid should be completely washed away immediately Disconnect the connector A OPull the lever as shown e Remove the ABS hydraulic uni
406. replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below Replacement of the original exhaust system or muffler with a component not in compliance with Federal regulations e Removal of the muffler s or any internal portion of the muffler s e Removal of the air box or air box cover e Modifications to the muffler s or air inlet system by cutting drilling or other means if such modifications result in increased noise levels Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop However it contains enough detail and basic in formation to 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 tex
407. retaining ring into the outer tube e Install the dust seal by hand 6404042081 C SUSPENSION 13 13 Front Fork eApply non permanent locking agent to the threads of the bottom Allen bolt e Hold the front fork horizontally in a vise Hold the cylinder unit with the special tools and tighten the bottom Allen bolt to secure the cylinder in place Torque Front Fork Bottom Allen Bolt 30 N m 3 1 kgf m 22 ft lb Special Tools Fork Cylinder Holder Handle D 57001 183 Fork Cylinder Holder Adapter E 57001 1057 e Pour in the specified type of oil see Front Fork Oil Change Inner Tube Inspection e Visually inspect the inner tube A and repair any dam age e 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 CAUTION If the inner tube is badly bent or creased replace it Excessive bending followed by subsequent straightening can weaken the inner tube e Temporarily assemble the inner and outer tubes and pump them back and forth manually to check for smooth operation e f you feel binding or catching the inner and outer tubes must be replaced A WARNING A straightened inner or outer fork tube may fall
408. revent fuel spillage FUEL SYSTEM DFI 3 105 Fuel Tank e Close the fuel tank cap e Remove the fuel tank and place it on a flat surface ODo not apply the load to the fuel pump outlet portion A especially the outlet pipe made from resin e For California model note the following CAUTION For California model if gasoline solvent water or any other liquid enters the canister the canister s vapor absorbing capacity is greatly reduced If the canister does become contaminated replace it with new sure to plug the evaporative fuel return hose to prevent fuel spilling before fuel tank removal A WARNING For California model be careful not to spill the gasoline through the return hose Spilled fuel is hazardous x If liquid or gasoline flows into the breather hose remove the hose and blow it clean with compressed air OBe careful of fuel spillage from the fuel tank since fuel still remains in the fuel tank and fuel pump A WARNING Store the fuel tank in an area which is well ventilated and free from any source of flame or sparks Do not smoke in this area Place the fuel tank on a flat surface and plug the fuel pipes to prevent fuel leakage Fuel Tank Installation e Note the above WARNING see Fuel Tank Removal e Route the hoses correctly see Cable Wire and Hose Routing in the Appendix chapter Check that the rubber dampers
409. rew lastly Torque Shift Shaft Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib Shift Shaft Cover Screw 4 9 N m 0 50 kgf m 43 in Ib 9113250851 C External Shift Mechanism Inspection e Examine the shift shaft A for any damage x lf 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 x lf the shift mechanism arm D is damaged in any way replace the arm e Check the return spring pin A is not loose x lf it is loose unscrew it apply a non permanent locking agent to the threads and tighten it Torque Shift Shaft Return Spring Pin 29 2 9 kgf m 21 ft Ib 9 32 CRANKSHAFT TRANSMISSION Transmission e Check the gear positioning lever A and its spring for breaks or distortion x lf the lever or spring are damaged any way replace them e Visually inspect the shift drum cam B x If they are badly worn or if they show any damage replace it Transmission Assy Removal e Remove Shift Shaft Assembly see External Shift Mechanism Re moval Neutral Switch Holder Bolt A Neutral Switch Holder B and Pin Shift Drum Holder C and Pin Remove Collar A O ring B e Remove Clutch see Clutch Removal in the Clutch chapter Transmission Case Bolts A x If the transmission assy is to disassembed remove the following Shift Rod Plate Bolt B Shift Rod Pl
410. rinding com pound produces a smooth matched surface on both the seat and the valve ORepeat the process with a fine grinding compound Lapper A Valve Seat B Valve C e The seating area should be marked about in the middle of the valve face x If the seat area is not in the right place on the valve check to be sure the valve is the correct part If it is it may have been refaced too much replace it e Be sure to remove all grinding compound before assem bly e When the engine is assembled be sure to adjust the valve clearance see Valve Clearance Adjustment in the Peri odic Maintenance chapter GE15012381 GE15012081 C ENGINE END 5 35 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 Measure 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
411. ring Bolts 9 8 N m 1 0 kgf m 87 in Ib e Install the clutch cover see Clutch Cover Installation Clutch Plate Wear Damage Inspection e Visually inspect the friction and steel plates for signs of seizure overheating discoloration or uneven wear e Measure the thickness of each friction plate A at several points xIf any plates show signs of damage or if they have worn past the service limit replace them with new ones Friction Plate Thickness Standard 2 92 3 08 mm 0 115 0 121 in Service Limit 2 8 mm 0 110 in GF06125BS1 GF06040181 C GF06123BS1 GF06060281 6 14 CLUTCH Clutch Clutch Plate Warp Inspection e Place each friction plate or steel plate on a surface plate and measure the gap between the surface plate A and each friction plate or steel plate B with a thickness gauge C The gap is the amount of friction or steel plate warp x If any plate is warped over the service limit replace it with a new one Friction and Steel Plate Warp Standard 0 15 mm 0 006 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 x If any spring is shorter than the service limit it must be replaced Clutch Spring Free Length Standard 33 6 mm 1 32 in Service Limit 32 6 mm 1 28 in Clutch Housing Finger Inspection e Visually inspect the clutch housing
412. rottle opening the output voltage is out of the standard inspect the main throttle sensor resistance x If the output voltage is normal check the wiring for conti nuity Wiring Connection ECU Connector A Throttle Sensor Connector B Y W lead ECU terminal 7 lead ECU terminal 28 lf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection 9017999852 C 3 46 FUEL SYSTEM DFI Main Throttle Sensor Service Code 11 Main Throttle Sensor Resistance Inspection e Turn the ignition switch OFF e Disconnect the main throttle sensor connector e Connect a digital meter A to the main throttle sensor connector B Measure the main throttle sensor resistance Main Throttle Sensor Resistance Connections BL lead C 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 O 7 TU FITTTTTTTTTFTTTTTTTTTTTTTTTTTTTTI M Es 1 ECU 2 Water proof Joint E 3 Water proof Joint D 4 Main Throttle Sensor 80170000651 GC17972BW2 FUEL SYSTEM DFI 3 47 Inlet Air Pressure Sensor Service Code 12 CAUTION Never drop the sensor especially on a hard surface Such a
413. rt circuit Housing A Fuse Element B Terminals C Blown Element D CAUTION When replacing a fuse be sure the new fuse matches the specified fuse rating for that circuit Installation of a fuse with a higher rating may cause damage to wiring and components 8 20000151 SUSPENSION 13 1 Suspension Table of Contents deeem E m 13 2 Specifications cerent eer 13 6 opeclal I00lS35 cowie eases ORE obe bed ue e a ands BON RR RERO eda 13 7 menu qM MEME 13 9 Front Fork Removals d nte ee ru in ege deae e Pa UR Aides e e vo tmu 13 9 Front Fork Installation IT 13 9 m 13 9 DISBSSelTDly ise t Eti e teneis atu ab 13 11 Front Fork Assembly ice Tone 13 12 Inner Tube IrnispectlOn ed iti ttt e te LG oro o e Pa de tn 13 13 Dust Seal Inspectlorn irai renti ament e a pert Eid Erie er EH EFE pa TRES 13 13 Fork Spring Inspection iom a a eoe etae eon e em te d o d e ete 13 14 Rear Shock Absorber ire e bti kr M re RERO RE rede d d Re Ire EAR eR 13 15 Spring Preload AGJUSIUEIODU ioni Puteo trt epa det de 13 15 Rear Shock Absorber Removal pp 13 15 Rear Shock Absorber I
414. s 9 8 1 0 87 Clutch Spring Bolts 9 8 1 0 87 Clutch Hub Nut 132 13 5 98 R Clutch Lever Clamp Bolts 7 8 0 80 69 in Ib S Oil Pump Chain Guide Bolts 12 1 2 106 in Ib L Clutch Cable Holder Bolts 9 8 1 0 87 L Clutch Cable Clamp Bolt 9 8 1 0 87 in lb Crankshaft Transmission Oil Plate Bolts Breather Plate Bolts Crankcase Bolts M9 L 113 mm Crankcase Bolts M9 L 83 mm Crankcase Bolts M8 L 73 mm Crankcase Bolts M8 L 60 mm Crankcase Bolts M8 L 110 mm Crankcase Bolts M8 L 50 mm Crankcase Bolts M6 Upper Crankcase Bolts 9 8 9 8 44 44 35 35 27 5 27 5 19 6 27 5 1 0 1 0 4 5 4 5 3 6 3 6 2 8 2 8 2 0 2 8 87 87 32 32 26 26 20 20 15 20 2 8 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Remarks N m kgf m ft Ib Shift Drum Bearing Holder Screw 4 9 0 50 43 in lb L Connecting Rod Big End Nuts see Text lt c MO Timing Rotor Bolt 40 4 1 30 Oil Pressure Switch 15 1 5 11 SS Oil Passage Plug 20 2 0 15 L Gear Positioning Lever Bolt 12 1 2 106 in Ib L Shift Shaft Return Spring pin 29 2 9 22 L Shift Drum Cam Bolt 12 1 2 106 in Ib L Neutral Switch 15 1 5 11 Transmission Case Bolts 20 2 0 15 Shift Rod Plate Bolt 9 8 1 0 87 Neutral Switch Holder Screw 4 9 0 50 43 in Ib L Shift Shaft Cover Bolts 9 8 1 0 87 in lb L 2 Shift Shaft Cover Screw 4 9 0 50 43 in Ib L Wheels Tires Front Axle
415. s suspect Check the wiring xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection xIf the output voltage is out of the specified replace the vehicle down sensor 6617313852 C FUEL SYSTEM DFI 3 61 Vehicle down Sensor Service Code 31 Vehicle down Sensor Circuit 1 ECU 2 Water proof Joint E 3 Vehicle down Sensor 4 Water proof Joint D 6C179788W2 3 62 FUEL SYSTEM Subthrottle Sensor Service Code 32 Subthrottle Sensor Removal Adjustment CAUTION Do not remove or adjust the subthrottle sensor A since it has been adjusted and set with precision at the factory Never drop the throttle body assy especially on a hard surface Such a shock to the sensor can dam age it Subthrottle Sensor Input Voltage Inspection NOTE OBe sure the battery is fully charged e Remove the air cleaner housing see Air Cleaner Housing Removal e Turn the ignition switch OFF e Disconnect the subthrottle sensor connector and connect the harness adapter A between these connectors e Connect a digital meter to the harness adapter lead Special Tool Throttle Sensor Harness Adapter 57001 1400 e Measure the sensor input voltage with the engine stopped and with the connector joined e Turn the ignition switch ON Subthrottle Sensor Input Voltage Connections to Adapter Meter BL sensor BL
416. screen Inspect and replace fuel pump see chapter 3 Fuel pump trouble Inspect see chapter 3 Fuel injector trouble Inspect see chapter 3 Inlet air temperature sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Subthrottle sensor trouble Inspect see chapter 3 Subthrottle valve actuator trouble Inspect see chapter 3 Stick coil trouble Inspect and replace see chapter 16 Engine oil level to high Repair see chapter 7 Spark plug dirty broken or gap maladjusted Replace see chapter 2 Stumble Too low fuel pressure Inspect see chapter 3 Fuel injector trouble Inspect see chapter 3 Main throttle sensor malfunction Inspect see chapter 3 Subthrottle sensor trouble nspect see chapter 3 Subthrottle valve actuator trouble Inspect See chapter 3 Water temperature sensor trouble Inspect See chapter 3 Inlet air pressure sensor trouble Inspect see chapter 3 Unstable fuel pressure Fuel pressure regulator trouble Inspect and replace fuel pump or kinked fuel line Inspect and repair fuel line see chapter 3 Fuel injector trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Backfiring when deceleration Spark plug dirty broken or gap maladjusted Replace see chapter 2 Too low fuel pressure Inspect see chapter 3 Fuel pump trouble Inspect see chapter 3 Main throttle sensor
417. screwdriver A to the injector B Put the grip end onto your ear and listen whether the injector is clicking or not OA sound scope C can also be used e Do the same for the other injectors x lf all the injectors click at a regular intervals the injec tors are good The trouble may be related to the fuel line requiring fuel pressure inspection see Fuel Pressure In spection OThe click interval becomes shorter as the engine speed rises x If any injector s doesn t click the DFI circuit or the injector is suspect Perform Fuel Injector Power Source Voltage Inspection first Fuel Injector Power Source Voltage Inspection e Remove the ECU see ECU Removal ODo not disconnect the ECU connector e Connect a digital meter A to the ECU connector B us ing the needle adapter C Special Tool Needle Adapter Set 57001 1457 OMeasure the power source voltage with the engine stopped and with the connector joined e Turn the ignition switch ON Injector Power Source Voltage at ECU Connections Meter W Y terminal 16 Meter Battery Terminal Service Limit Battery Voltage 12 8 V or more x If the meter doesn t read as specified check the following Main Fuse 30 A see Fuse Inspection in the Electrical System chapter Fuel Pump Relay see Relay Circuit Inspection in the Electrical System chapter Power Source Wiring see wiring diagram below OTo check the W R leads between the injector con
418. selling leasing or trading motor vehicles or motor vehicle engines or who operates a fleet of motor vehicles know ingly to remove or render inoperative any device or element of design installed on or in a 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
419. 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 the output shaft GI132448W2 C Transmission Assy Installation e Assemble the transmission assy see Transmission Assy Assembly e Be sure that the dowel pins A are in position e Apply grease to the O ring B on the oil pipe e Install the transmission assy on the crankcase e Tighten the transmission case bolts Torque Transmission Case Bolts 20 N m 2 0 kgf m 15 ft Ib CRANKSHAFT TRANSMISSION 9 35 Transmission e Install the gear positioning lever see External Shift Mech anism Installation e Install the shift rod plate Torque Shift Rod Plate Bolt 9 8 N m 1 0 kgf m 87 in Ib e Set the gear positioning lever to the neutral position A e Check that the drive and output shaft turn freely e Install Pin A Shift Drum Holder B Pin C Neutral Switch Holder D Neutral Switch Holder Screw E OApply a non permanent locking agent to the neutral switch holder screw and tighten it Torque Neutral Switch Holder Screw 4 9 N m 0 50 kgf m 43 in lb 7 gui E e Apply grease to the O ring A and install its position on the output shaft e Apply grease to the lip of the oil seal C e Install the collar D Transmission Shaft Removal e Remove the tran
420. sible from external inspection of the tire For these reasons Kawasaki does not recommend temporary exter nal repair Only appropriate permanent internal repairs are recommended Repair methods may vary slightly from make to make Follow the repair methods indicated by the manufacturer of the repair tools and materials so that safe results can be obtained n 6J05042BS1 C 10 16 WHEELS TIRES Hub Bearing Hub Bearing Removal Remove the wheel see Front Rear Wheel Removal and take out the following Collars Coupling Out of rear hub Grease Seals e Use the bearing remover to remove the hub bearings A CAUTION 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 20 022 57001 1293 Bearing Remover Shaft 13 57001 1377 Hub Bearing Installation Before installing the hub bearings blow any dirt or foreign particles out of the hub with compressed air to prevent contamination of the bearings e Replace the bearings with new ones NOTE Olnstall the bearings so that the marked side faces out e Install the bearings by using the bearing driver set which does not contact the bearing inner race e Press in each bearing A right until they are bottomed Special Tool Bearing Driver Set B 57001 1129 e Replace
421. smission assy see Transmission Assy Removal e Remove Shift Rods A Shift Forks B Drive Shaft C and Output Shaft D Transmission Shaft Installation e Be sure that the spacer A is on the output shaft B 3 27 60138371 P 9 36 CRANKSHAFT TRANSMISSION Transmission e Install the transmission assy on the crankcase see Trans mission Assy Installation e Press in the oil seal A onto collar B so that the surface of the oil seal is flush with the surface C of the crankcase OApply oil to the outer circumference D of the oil seal so that it will go into place smoothly OApply grease to the lip E of the oil seal Transmission Shaft Disassembly Remove the transmission shafts see Transmission Shaft Removal eRemove the circlips disassemble the transmission shafts Special Tool Outside Circlip Pliers 57001 144 e The 5th gear A on the output shaft has three steel balls i assembled into it for the positive neutral finder mecha nism Remove the 5th gear lt 81130828 5 OSet the output shaft in a vertical position holding the 3rd gear B OSpin the 5th gear quickly C and pull it off upward Transmission Shaft Assembly e Apply engine oil to the bushings needle bearings and shafts e Install the gear bushings A on the shaft with their holes B aligned 6113040851 e Replace any removed with ne
422. ss Connector I Meter BK BL lead 1 Meter lead 2 Il Meter W BL lead 3 Meter G Y lead 4 Measure the actuator input voltage with the engine stopped and with the connector joined e Turn the ignition switch ON Input Voltage at Actuator Standard About 8 5 10 5 V DC x lf the reading is within the standard but the actuator doesn t operate replace it x If the reading is out of the range check the wiring to ECU see wiring diagram in this section x lf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection Subthrottle Valve Actuator Circuit 6017160852 C W BL BK BK BL W BL P P W BL G Y 6GC179818W2 C 1 ECU 2 Subthrottle Valve Actuator FUEL SYSTEM DFI 3 73 Air Switching Valve Service Code 64 Air Switching Valve Removal Installation Refer to the Air Switching Valve Removal Installation in the Engine Top End chapter Air Switching Valve Inspection Refer to the Air Switching Valve Operation Test Unit Test in the Electrical System chapter Remove the fuel tank see Fuel Tank Removal and check the wiring continuity using the following diagram Air Switching Valve Circuit C 1 1 3 He LM 4 o8 PARK BATTERYE 97 6C179888W2 ECU Air
423. surement 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 Crankcase Main Bearing Inside Diameter Marks mark or no mark No 1 Journal A No 2 Journal B No 3 Journal C 9105142852 C e Select the proper bearing insert A in accordance with the combination of the crankcase and crankshaft coding Size Color B 6105041751 Crankcase Main Bearing Crankshaft Main Journal Inside Diameter Marking Diameter Marking Size Color Bearing Insert Part Number 92028 1905 None 1 Black 92028 1904 Blue 92028 1903 The bearing inserts for Nos 1 2 and 3 journals have oil groove 9 26 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods e Install the new inserts the crankcase halves and check insert journal clearance with the plastigage CRANKSHAFT TRANSMISSION 9 27 Balancer Balancer Removal Split the crankcase see Crankcase Splitting Pull the balancer shaft with the balancer gear out of the crankcase Balancer Installation e Apply molybdenum disulfide oil solution to the inside of the balancer shaft bearing insert e 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 9104215851
424. t Clutch Housing A with Chain B and Sprocket C Sleeve D Align E the hole on the oil pump sprocket with the oil pump shaft NOTE Olnsert the sleeve into the clutch housing noting its di rection as shown Sleeve A Oil Holes B Long Distance C Short Distance D Clutch Housing E GF06132BS1 e Install the following parts on the drive shaft Spacer A Clutch Hub B Washer C Nut D Olnstall the washer so that the OUTSIDE mark A faces outward CLUTCH 6 13 Clutch OReplace the clutch hub nut with a new one OHolding the clutch hub tighten the clutch hub nut Special Tool Clutch Holder 57001 1243 Torque Clutch Hub Nut 132 13 5 kgf m 98 16 e Install the friction plates and steel plates starting with a friction plate and alternating them CAUTION If new dry friction plates and steel plates are in stalled apply engine oil to the surfaces of each plate to avoid clutch plate seizure OFor the first steel plate A its thickness is 2 6 mm 0 10 The others 2 3 mm 0 09 Olnstall the last friction plate A fitting the tangs in the grooves in the housing as shown e Apply molybdenum disulfide grease to the pusher ends A and install it in the clutch spring plate OApply engine oil to the bearing C e Install the clutch spring plate and springs D and tighten the clutch spring bolts E Torque Clutch Sp
425. t thor oughly familiarize yourself with the procedures before starting work and then do the work care fully in a clean area Whenever special tools or equipment are specified do not use makeshift tools or equipment Precision measurements can only be made if the proper instruments are used and the use of substitute tools may ad versely affect safe operation For the duration of the warranty period we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty To get the longest life out of your vehicle Follow the Periodic Maintenance Chart in the Service Manual eBe alert for problems and non scheduled maintenance e Use proper tools and genuine Kawasaki Mo torcycle parts Special tools gauges and testers that are necessary when servicing Kawasaki 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
426. t 27 6 27 8 mm 1 087 1 094 in Inlet 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 G too narrow or uneven J repair the seat see Valve Seat Repair Valve Seating Surface Width Standard Exhaust 0 5 1 0 mm 0 020 0 039 in Inlet 0 5 1 0 mm 0 020 0 039 in Valve Seat Repair e Repair the valve seat with the valve seat cutters A Special Tools Valve Seat Cutter Holder Bar 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 Inlet Valve Seat Valve Seat Cutter 45 535 57001 1116 Valve Seat Cutter 32 535 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 5 32 ENGINE END Valves Seat Cutter Operation Care 1 This valve seat cutter is developed to grind the valve for repair Therefore the cutter must not be used for other purposes than seat repair 2 Do not drop or shock the valve seat cutter or the dia mond particles may fall off 3 Do not fail to apply engine oil to the valve seat cutter before grinding the seat s
427. t go on inspect or replace the following item Ignition Switch see Switch Inspection in the Electrical System chapter Third Step e Turn on the turn signal switch A left or right position e The left or right turn signal lights B front and rear ac cording to the switch position should flash e The turn signal indicator light LED C in the meter unit should flash xIf the each light does not flash inspect or replace the following item Turn Signal Light Bulb see Turn Signal Light Bulb Re placement in the Electrical System chapter Meter Unit for Turn Signal Light 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 e Push the turn signal switch e The turn signal lights and indicator light LED should go off x lf the light does not go off inspect or replace the following item Turn Signal Switch see Switch Inspection in the Electri cal System chapter Turn Signal Relay see Turn Signal Relay Inspection in the Electrical System chapter 2 40 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fourth Step Set the dimmer switch A to low bea
428. t oil will penetrate to the rollers and bushings Apply the oil to the O rings so that the O rings will be coated with oil Wipe off any excess oil Oil Applied Areas A O rings B 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 Check the wheel alignment see Wheel Alignment Inspec tion Rotate the rear wheel to find the position where the chain eae is tightest Measure the vertical movement chain slack A midway between the sprockets x lf the chain slack exceeds the standard adjust it Chain Slack Standard 30 40 mm 1 2 1 6 in Drive Chain Slack Adjustment Remove the cotter pin A and loosen the axle nut e Loosen the both chain adjuster locknuts C xIf the chain is too loose turn in the left and right chain adjuster nuts D evenly x lf the chain is too tight turn out the left and right chain adjuster nuts evenly and kick the wheel forward e Turn both chain adjuster nuts evenly until the drive chain has the correct amount of slack To keep the chain and wheel properly aligned the value E on the left wheel alignment adjuster F should align with the same left or right edge G of inspection window on the swingarm that the right wheel alignment adjuster value aligns with A WARNING Misalignment of the wheel will result in abn
429. t the charging cycle and load test If still below 12 8 V the battery is defective 16 28 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 Specifications When a fast charge is inevitably required do it following precisely the maximum charge current and time conditions indicated on the battery CAUTION This battery is designed to sustain no unusual deterioration if refresh charged according to the method specified above However the battery s performance may be reduced no ticeably if charged under conditions other than given above Never remove the seal cap during refresh charge If by chance an excessive amount of gas is generated due to overcharging the relief valve releases the gas to keep the battery normal 3 When you do not use the motorcycle for months Give a refresh charge before you store the motorcycle and store it with the negative cable re moved Give a refresh charge once a month during storage 4 Battery life If the battery will not start the engine even after several refresh charges the batt
430. t the wheel for small cracks dents bending or warp lf there is any damage to the wheel replace the wheel e Remove the wheel and support it without the tire by the axle e Measure the rim runout axial A and radial B with a dial gauge x If rim runout exceeds the service limit check the hub bear ings xIf the problem is not due to the bearings replace the wheel Rim Runout Standard Axial TIR 0 5 mm 0 02 in or less Radial TIR 0 8 mm 0 03 in or less Service Limit Axial TIR 1 0 mm 0 04 in Radial TIR 1 0 mm 0 04 in WARNING Never attempt to repair a damaged wheel If there is any damage besides wheel bearings the wheel must be replaced to insure safe operational condi tion Axle Inspection e Remove the front and rear axles see Front Rear Wheel Removal e Visually inspect the front and rear axle for damages xIf the axle is damaged or bent replace it e Place the axle in V blocks that are 100 mm 3 94 in A apart and set a dial gauge B on the axle at a point halfway between the blocks Turn C the axle to mea sure the runout The difference between the highest and lowest dial readings is the amount of runout x If axle runout exceeds the service limit replace the axle Axle Runout 100 mm 3 94 in Standard TIR 0 03 mm 0 0012 in or less Service Limit TIR 0 2 mm 0 008 in GJ04130BS1 6J04043BS1 C WHEELS TIRES 10 11 Wheels Rims
431. t with bracket e Remove Nuts A and Bracket B CAUTION The ABS hydraulic unit has been adjusted and set with precision at the factory Do not try to disas semble and repair the ABS hydraulic unit ABS Hydraulic Unit Installation e Install the ABS hydraulic unit to the bracket CAUTION Brake fluid quickly ruins painted plastic surfaces any spilled fluid should be completely washed away immediately e Route the lead correctly and join connector A securely OPull the lever B as shown e Route the brake pipes correctly see Cable Wire and Hose Routing section in the Appendix chapter e Tighten the joint nuts Torque Brake Pipe Joint Nuts 18 N m 1 8 kgf m 13 ft Ib e Install the removed parts see appropriate chapters BRAKES 12 55 Anti Lock System ABS Hydraulic Unit Inspection e Remove the ABS hydraulic unit see ABS Hydraulic Unit Removal e Visually inspect the ABS hydraulic unit Replace the ABS hydraulic unit if any of them are cracked or otherwise damaged 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 lf the ABS hydraulic unit connector is clogged with mud or dust blow it off with compressed air Front Wheel Rotation Sensor Removal CAUTION The wheel rotation sensor should be handled care fully never struc
432. tainer 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 x If the hand tester does not show the specified values re place the sensor Water Temperature Sensor Resistance Temperature Resistance kQ 20 4 F 18 80 2 37 0 32 F about 6 544 40 104 F 1 136 0 095 100 C 212 F 0 1553 0 0070 Reference Information Speed Sensor Removal Remove the left center fairing see Center Fairing Re moval in the Frame chapter e Disconnect the speed sensor lead connector A Remove the engine sprocket cover see Engine Sprocket Removal in the Final Drive chapter e Remove Bolt A Speed Sensor B Speed Sensor Installation e Installation is the reverse of removal e Apply a non permanent locking agent to the sensor bolt and tighten it Torque Speed Sensor Bolt 7 8 N m 0 80 kgf m 69 in Ib 8 18055 52 C ELECTRICAL SYSTEM 16 75 Switches and Sensors Speed Sensor Inspection Remove the speed sensor see Speed Sensor Removal Connect the speed sensor connector A with the battery 10 resistor and hand tester 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 OTh
433. tation sensor lead upper the brake hose Rear Wheel Rotation Sensor Lead Through the regulator rectifier lead under the brake fluid reservoir hose Through the vehicle down sensor lead under the brake hose Clamp Clamp the brake hose and rear wheel rotation sensor lead Through the rear wheel rotation sensor lead upper the rear brake light switch lead Through the rear wheel rotation sensor lead under the brake hose 17 30 APPENDIX Cable Wire Hose Routing EX650B Models 253 I i Jl 2 e 9 NS P oM LOS Mb ere A APPENDIX 17 31 Cable Wire Hose Routing 1 Front Wheel Rotation Sensor Lead 2 Ignition Switch Lead 3 Left Switch Housing Lead 4 Clamp Clamp the front wheel rotation sensor lead 5 Main Harness 6 Clamp Clamp the front wheel rotation sensor lead 17 32 APPENDIX Cable Wire Hose Routing APPENDIX 17 33 Cable Wire Hose Routing 1 To Meter Unit 2 Clamp 3 To Front Right Turn Signal Light Lead 4 Left Switch Housing Lead 5 Ignition Switch Lead 6 Main Harness 7 To Front Left Turn Signal Light Lead 17 34 APPENDIX Cable Wire Hose Routing APPENDIX 17 35 Cable Wire Hose Routing 1 Clamp 2 Clamp Insert the clamp to the inner fairing 3 Clamp Insert the clamp to the upper fairing bracket
434. tch Starter Lockout Switch Starter Relay Tachometer FI Indicator Light LED Inlet Air Pressure Sensor Spark Plug Crankshaft Sensor Injector Main Throttle Sensor Delivery Pipe Subthrottle Sensor Subthrottle Valve Main Throttle Valve Subthrottle Valve Actuator Fuel Pump Pressure Regulator Fuel Tank Air Cleaner Element Air Switching Valve Inlet Air Temperature Sensor Air Cleaner Housing Neutral Switch Speed Sensor Vehicle down Sensor Oxygen Sensor Europe Models ECU Electronic Control Unit Battery Air Flow Fuel Flow Water Temperature Sensor 3 12 FUEL SYSTEM DFI DFI System DFI System Wiring Diagram 362 1 69 9 Je aes a ele WIS iil BKZ Y NEN Ep a s R BK BR W x BL W R BL BL e BL R PZBL BR R FUEL SYSTEM DFI 3 13 DFI System Part Name Oxygen Sensor Europe Models Crankshaft Sensor Inlet Air Temperature Sensor Water Temperature Sensor Water proof Joint E Injectors Vehicle down Sensor Water proof Joint D Inlet Air Pressure Sensor Main Throttle Sensor Subthrottle Sensor Subthrottle Valve Actuator Speed Sensor Air Switching Valve Water proof Joint C Stick Co
435. tch Screw Front Reservoir Screws 1 0 Front Caliper Mounting Bolts 34 3 5 25 Front Master Cylinder Clamp Bolts 8 8 i 78 in lb B Apply brake fluid L Apply a non permanent locking agent R Replacement Parts S Follow the specified tightening sequence Si Apply silicone grease ex PBC grease 12 10 BRAKES Exploded View 08102180845 C BRAKES 12 11 Exploded View No Fastener ft lb Remarks 69 in Ib Rear Caliper Mounting Bolts 7 Rear Master Cylinder Mounting Bolts 8 Rear Master Cylinder Push Rod Locknut B Apply brake fluid G Apply grease L Apply a non permanent locking agent R Replacement Parts Si Apply silicone grease ex PBC grease Rear Brake Disc Mounting Bolts _6 EA 12 12 BRAKES Specifications Item Standard Service Limit Brake Lever Brake Pedal Brake Lever Position 5 way adjustable to suit rider Brake Lever Free Play Non adjustable Pedal Free Play Non adjustable Pedal Position About 40 mm 1 6 in below top of footpeg 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 Brake Disc Thickness Front EX650A Models 4 3 4 7 mm 0 17 0 19 in 4 0 mm 0 16 in EX650B Models 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
436. tch Screw Front Brake Reservoir Cap Screws Front Caliper Mounting Bolts Front Master Cylinder Clamp Bolts 1 0 9 27 1 0 1 0 34 8 8 a 0 90 78 L S B Apply brake fluid L Apply a non permanent locking agent R Replacement Parts S Follow the specified tightening sequence Si Apply silicone grease ex PBC grease 12 6 BRAKES Exploded View BRAKES 12 7 Exploded View No Fastener Torque Remarks N m kgf m ft lb Bleed Valve 69 Bolts Brake Pedal Bolt 0 8 in s Rear Brake Disc Mounting Bolts 2 T O L Rear Master Cylinder Mounting Bolts T Rear Caliper Mounting Bolts ES 7 Rear Master Cylinder Push Rod Locknut 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 EX650B Models 6102179 5 C BRAKES 12 9 Exploded View Torque No Fast R k astener Karin ftlb emarks 1 Bleed Valve 7 8 0 80 69 in lb 2 Hose Banjo Bolts 25 2 5 18 Brake Lever Pivot Bolt 9 in Ib Brake Lever Pivot Bolt Locknut 52 in lb 3 4 Brake Pipe Joint Nuts 1 EN 8 Front Brake Disc Mounting Bolts 27 1 0 7 Front Brake Light Swi
437. ter of the tread with a depth gauge A Since the tire may wear unevenly take measurement at several places If any measurement is less than the service limit replace the tire see Tire Removal Installation in the Wheels Tires chapter Tread Depth Standard Front 4 3 mm 0 17 in Rear 7 0 mm 0 28 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 A WARNING To ensure safe handling and stability use only the recommended standard tires for replacement in flated to the standard pressure NOTE OMost countries may have their own regulations a mini mum tire tread depth be sure to follow them OCheck and balance the wheel when a tire is replaced with a new one 2 28 PERIODIC MAINTENANCE Periodic Maintenance Procedures Wheel Bearing Damage Inspection Raise the front wheel off the ground with jack see Front Wheel Removal in the Wheels Tires chapter Turn the handlebar all the way to the right or left e Inspect the roughness of the front wheel bearing by push ing and pulling A the wheel Spin the front wheel lightly and check for smoothly turn roughness binding or noise x If roughness binding 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 of
438. the bearing in serts A with inserts painted blue B Check insert journal clearance with the plastigage The clearance may exceed the standard slightly but it must not be less than the min imum in order to avoid bearing seizure x If the clearance exceeds the service limit measure the diameter of the crankshaft main journal 6105019851 C 9105140851 61050304 5 6105041751 CRANKSHAFT TRANSMISSION 9 25 Crankshaft and Connecting Rods Crankshaft Main Journal Diameter Standard 37 984 38 000 mm 1 4954 1 4961 Service Limit 37 96 mm 1 4945 in x If any journal has worn past the service limit replace the crankshaft with a new one x If the measured journal diameters are not less than the service limit but do not coincide with the original diameter markings on the crankshaft make new marks on it Crankshaft Main Journal Diameter Marks 9105141851 C 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 e 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 or no mark e Tighten the crankcase bolts to the specified torque see Crankcase Assembly NOTE OThe mark already on the upper crankcase half should almost coincide with the mea
439. 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 GJ06039BS1 C 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 E 11 2 Specifications ie ii e ker be ia RE gere eei PCT 11 4 Special OO S 11 5 Drive GAIN EENE EGE 11 6 Drive Chain Slack 11 6 Drive Chain Slack Adjustment
440. 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 2005 Kawasaki Heavy Industries Ltd First Edition 1 Nov 2 2005 M 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 inlet side of the engine While the engine is operating the vapors are drawn into combustion chamber where they are burned along with the fuel and air supplied by the fuel injection system 2 Exhaust Emission
441. ting 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 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 6017029281 FUEL SYSTEM DFI 3 25 Troubleshooting the DFI System OThere are two ways to inspect the DFI system One is voltage Check Method and the other is Resistance Check Method Voltage Check Method OThis method is conducted by measuring the input voltage B to a sensor A first and then the output voltage C from the sensor OSometimes this method can detect a fault of the ECU Refer to each sensor inspection section for detail in this chapter e Use a fully charged battery and a digital meter D which can be read two decimal places voltage or resistance Resistance Check Method OThis method is simple No need for a fully charged battery and the needle adapter Just do the following especially when a sensor A is suspect e Turn the ignition switch OFF and disconnect the connec tors e Inspect the sensor resistance using a digital meter see each sensor inspection e Inspect the wiring and connectors B for continuity using the hand tester C analog tester rather tha
442. tion mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts 11 4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain Drive Chain Slack 30 40 mm 1 2 1 6 in mix Drive Chain Wear 20 link Length 317 5 318 2 mm 12 50 12 53 in 323 mm 12 7 in Standard Chain Make ENUMA Type EK520MVXL1 Link 114 links Sprockets Rear Sprocket Warp 0 4 mm 0 016 in or less 0 5 mm 0 020 in FINAL DRIVE 11 5 Special Tools Inside Circlip Pliers 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 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 sea
443. tion e Install the air suction valve A so that its side where stop per is fixed with the screws B faces the front C e Tighten Torque Air Suction Valve Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib Air Suction Valve Inspection e Remove the air suction valve see Air Suction Valve Re moval e Visually inspect the reeds for cracks folds warps heat damage or other damage x If there is any doubt as to the condition of the reeds A replace the air suction valve as an assembly e Check the reed contact areas B of the valve holder for grooves scratches any signs of separation from the holder or heat damage e If there is any doubt as to the condition of the reed contact areas replace the air suction valve as an assembly e f any carbon or other foreign particles have accumulated between the reed and the reed contact area wash the valve assembly clean with a high flash point solvent CAUTION Do not scrape off the deposits with a scraper as this could damage the rubber requiring replacement of the suction valve assembly Air Switching Valve Removal e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Air Switching Valve Connector A Disconnect Air Switching Valve B Air Switching Valve Installation e Route the hoses correctly see Cable Wire and Hose Routing section in the Appendix chapter GE04048BS1 B 6 048117 P ENGINE E
444. tion in the Electrical System chapter Meter Unit for Neutral Indicator Light LED see Elec tronic Combination Meter Unit Inspection in the Electri cal System chapter Meter Unit for Oil Pressure Warning Indicator Light LED see Electronic Combination Meter Unit Inspec tion in the Electrical System chapter Meter Unit for Fl Indicator Light LED see Electronic Combination Meter Unit Inspection in the Electrical Sys tem chapter Meter Unit for Water Temperature Warning Indicator Light LED see Electronic Combination Meter Unit Inspection in the Electrical System chapter Meter Unit for ABS Indicator Light LED see ABS In dicator Light LED Inspection in the Brakes chapter EX650B Models ECU see ECU Power Supply Inspection in the Fuel Sys tem DFI chapter Main Fuse 30 A and Taillight Fuse 10 A see Fuse In spection in the Electrical System 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 65178129 PERIODIC MAINTENANCE 2 39 Periodic Maintenance Procedures e Turn off the ignition switch e The all lights should go off x If the light does not go off replace the ignition switch Second Step e Turn the ignition switch to P Park position e The city light taillight and license plate light should go on x If the light does no
445. to seal the battery NOTE ODo not pierce or otherwise open the sealed cells B of the electrolyte container Do not attempt to separate individual cells 8 09000851 C e Place the electrolyte container upside down with the six sealed cells into the filler ports of the battery Hold the container level push down to break the seals of all six cells You will see air bubbles rising into each cell as the ports fill NOTE ODo not tilt the electrolyte container gue 8 09000751 C e Check the electrolyte flow x If no air bubbles A are coming up from the filler ports or if the container cells have not emptied completely tap the container B a few times e Keep the container in place for 20 minutes or more Don t remove the container from the battery until it s empty the battery requires all the electrolyte from the container for proper operation CAUTION 8 09000851 C Removal of the container before it is completely empty can shorten the service life of the battery Do not remove the electrolyte container until it is com pletely empty and 20 minutes have elapsed e Gently remove the container from the battery e Let the battery sit for 30 minutes prior to charging to allow the electrolyte to permeate into the plates for optimum performance NOTE OCharging the battery immediately after filling can shorten service life Let the battery sit for at least 30 minutes after filli
446. toe t do euge 10 11 Balance Weight Peroval e ee 10 11 Balance Weight InstellatUol E rote ec eres ete esee 10 11 E ERU EM EEUU 10 13 Air Pressure Inspection Adjustment nemen 10 13 Tire Inspection Hire e Tire Installation TELE PIU BS AIAG Hub Bearing Removal retrato rhe rh eto neant Re Ea ve ER ee lata ERR AM ELS DEED DLE ded 10 16 Hub Bearingdnstallallon 59 2 oie Roa pins cin ie Dev eu oue C 10 16 Hub Bearing Inspection 10 16 H b Bearing EUbFICAon esas 10 17 10 2 WHEELS TIRES Exploded View WHEELS TIRES 10 3 Exploded View No Fastener Remarks N m kgf m ft Ib 1 Front Axle 108 11 0 80 2 Front Axle Clamp Bolt 34 3 5 25 3 Rear Axle Nut 108 11 0 80 4 Caliper Bracket EX650B Models 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 Balance Weights Rim Size
447. tor Terminal Locknut 11 1 1 97 in lb Starter Motor Through Bolts 4 9 0 50 43 in Ib Stator Coil Bolts 12 1 2 106 in Ib L Timing Rotor Bolt 40 4 1 30 Water Temperature Sensor 12 1 2 106 in Ib 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 Torque mm N m kgf m 16 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 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 PERIODIC MAINTENANCE 2 11 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 mm 0 08 0 12 in ura 1 300 50 r min rpm 0 2 1 2 for reference 35 3 1 3 kPa 265 10 mmHg Polyurethane Foam an Cooling System Coolant Type recommended Color Mixed Ratio Freezing Point Total Amount Engine Top End Valve Clearance Exhaust Inlet Clutch Clutch Lever Free Play Permanent type of antifreeze Se Green NON Soft water 5096 Coolant 5096
448. tral whether sidestand up or not Pull the lever in and shift the gear in neutral Though clutch lever pulled in sidestand up and Sidestand down and clutch lever pulled in gear not in neutral whether gear in neutral or not Vehicle down sensor coming off Reinstall see chapter 3 inspect see chapter 3 inspect see chapter 3 Inspect and charge see chapter 16 Replace see chapter 2 Inspect stick coil see chapter 16 Reinstall or inspect stick coil see chapter 16 Replace it with the correct plug see chapter 16 IC igniter in ECU trouble Inspect see chapter 16 Neutral starter lockout or sidestand switch rouble Inspect each switch see chapter 16 Crankshaft sensor trouble Inspect see chapter 16 Stick coil trouble Inspect see chapter 16 Ignition switch shorted Inspect and replace see chapter 16 Engine stop switch shorted Inspect and repair or replace see chapter 2 Starter system wiring shorted or open Inspect and repair or replace see chapter 16 Main 30A or ignition fuse blown Inspect and replace see chapter 16 Fuel air mixture incorrect Air cleaner clogged poorly sealed or missing Clean or reinstall see chapter 3 Leak from oil filler cap crankcase breather hose Inspect and repair or replace see chapter 3 or air cleaner drain hose Water or foreign matter in fuel Change fuel Inspect and clean fuel system see chapter 3 Fuel pressur
449. trouble Inspect see chapter 3 Inlet air temperature sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Inlet air pressure sensor trouble Inspect see chapter 3 Air switching valve broken Inspect and replace see chapter 5 Air suction valve trouble Inspect and replace see chapter 5 After fire Crankshaft sensor trouble Inspect see chapter 16 Spark plug burned or gap maladjusted Replace see chapter 2 3 34 FUEL SYSTEM DFI DFI System Troubleshooting Guide Symptoms or Possible Causes Actions chapter Inlet air temperature sensor trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Inlet air pressure sensor trouble Inspect see chapter 3 Fuel injector trouble Inspect see chapter 3 Run on dieseling Ignition switch trouble Inspect and replace see chapter 16 Engine stop switch trouble Inspect and repair or replace see chapter 2 inspect see chapter 3 Loose terminal of battery cable or ECU Inspect and repair see chapter 16 ground lead Repair see chapter 5 Engine overheating see Overheating of Troubleshooting Guide see chapter 17 Other Engine oil viscosity too high Change see chapter 2 Inspect drive chain see chapter 2 and sprocket see chapter 11 Drive train trouble Inspect caliper fluid seal damage or clogg
450. ts secondly the M8 bolts and lastly the M9 bolts M6 Bolts A M8 Bolts B M9 Bolts C and Washers e Tap lightly around the crankcase mating surface with a plastic mallet and split the crankcase Take care not to damage the crankcase 6104208BS2 C CRANKSHAFT TRANSMISSION 9 11 Crankcase Splitting x If the oil pipe is to be removed follow the next procedure OUnscrew the bolts A and remove the oil pipe B a 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 lf 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 Crankcase Assembly CAUTION The upper and lower crankcase halves are ma chined at the factory in the assembled state so the crankcase halves must be replaced as a set e With a high flash point solvent clean off the mating sur faces of the crankcases halves and wipe dry e Using compressed air blow out the oil passages in the crankcase halves e f the oil plate A on the upper crankcase half was re moved install it as shown e Apply a non permanent locking agent to the oil plate bolts and torque them Torque Oil Plate Bolts B 9 8 N m 1 0 N m 87 in Ib 9104210851 9 12 CRANKSHAFT TRA
451. ttle Valve Actuator Lead Connector Clamp Clamp the harness Clamp Clamp Stick Coil Lead Connector Clamp Clamp the stick coil lead Clamp Push the subthrottle valve actuator lead and clamp the subthrottle sensor lead and subthrottle valve actuator lead to the delivery pipe 17 26 APPENDIX Cable Wire Hose Routing APPENDIX 17 27 Cable Wire Hose Routing CONDO 1 Regulator Rectifier Lead 2 Clamp Insert the clamp in the frame 3 4 Through the rear brake light switch lead and vehicle down sensor lead from the front side of the Rear Brake Light Switch Lead Connector rear shockabsorber installation part Through the regulator rectifier lead to the front opening of the rear fender front Vehicle down Sensor Lead Fuel Pump Lead Connector Through the fuel pump lead to the hook of the rear fender front Routing is done so that there is no slack Through the fuel pump lead to the slit of the cover 17 28 APPENDIX Cable Wire Hose Routing EX650B Models APPENDIX 17 29 Cable Wire Hose Routing A m WN AF ABS Hydraulic Unit Lead ECU Through the lead to the forward of frame cross pipe ABS Hydraulic Unit Through the rear wheel rotation sensor lead upper the starter motor cable and engine ground cable Through the regulator rectifier lead in the clamp Through the rear wheel ro
452. ture 5 9 oF oF 4 32 68 176 212 248 284 40 20 0 20 140 60 20 i 267 104 80 100 120 140 160 180 200 220 240 260 280 300 48 9 80 100 1120 i 1140 71 1 93 3 116 138 320 160 PERIODIC MAINTENANCE 2 1 Periodic Maintenance Table of Contents Periodic Maintenance Chart sss nennen nennen nnne nennen nnn 2 3 Torque and Locking Agent iniri tad chelates 2 6 2 11 Special Tools eicere rr LR XXE REPRE ERR TER GT ENT RR EE CR RR EXER RR Ea 2 13 Periodic Maintenance 2 14 E EcyciCHMiBIDC 2 14 Air Cleaner Element Cleaning nn 2 14 Throttle Control System Inspection 2 15 Engine Vacuum Synchronization Inspection pp 2 16 Idle Speed 2 18 idie Speed Adjustment oreet tio ox ead 2 18 Fuel Hose Inspection fuel leak damage installation condition 2 19 Evaporative Emission Control System California Model 2 19 Evaporative Emission Control System Inspection pp 2 19 Cooling cdaette 2 20 Coolant Level InspectioFi c rrr terit i ette terr Fe
453. uid isopropyl alcohol or ethyl alcohol e Install the bleed valve and rubber cap Torque Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib e Replace the fluid seals A with new ones OApply brake fluid to the fluid seals and install them into the cylinders by hand e Replace the dust seals B with new ones if they are dam aged OApply brake fluid to the dust seals and install them into the cylinders by hand GLO5067BS1 C 6105040251 PERIODIC MAINTENANCE 2 55 Periodic Maintenance Procedures e Apply brake fluid to the outside of the pistons and push them into each cylinder by hand e Check the shaft rubber friction boot A and the dust cover B replace them with new ones if they are damaged e Apply a thin coat of PBC Poly Butyl Cuprysil grease to the caliper holder shafts C and holder holes D PBC is a special high temperature water resistance grease e Install the anti rattle spring A e Install the pads see Front Brake Pad Installation in the Brakes chapter e Wipe up any spilled brake fluid on the caliper with wet cloth Rear Caliper Disassembly e Remove the rear caliper see Rear Caliper Removal in the Brakes chapter e Remove the pads and anti rattle spring see Rear Brake Pad Removal in the Brakes chapter e Using compressed air remove the piston OCover the piston area with a clean thick cloth B OBlow compressed air
454. und with jack Special Tools Jack 57001 1238 Jack Attachment 57001 1608 Pull out the axle to the right and drop the front wheel out of the forks CAUTION Do not lay the wheel on the ground with the discs facing down This can damage or warp the disc Place wooden blocks under the wheel so that the disc does not touch the ground Front Wheel Installation NOTE OThe direction of the wheel rotation A is shown by an arrow B on the wheel spoke e Check the wheel rotation mark on the front wheel and install it 6J04053BS1 C WHEELS TIRES 10 7 Wheels Rims e Apply high temperature grease to the grease seal lips e Fit the collars A on the both sides of the hub e Insert the front axle and tighten the axle Torque Front Axle 108 N m 11 0 kgf m 80 ft Ib e Before tightening the axle clamp bolt on the right front fork leg pump the front fork up and down 4 or 5 times to allow the right front fork leg to seat on the front axle NOTE OPut a block in front of the front wheel to stop moving e Tighten the axle clamp bolt A Torque Front Axle Clamp Bolt 34 N m 3 5 kgf m 25 ft Ib e Install the lower fairing see Lower Fairing Installation in the Frame chapter e Install the front brake calipers see Caliper Installation in the Brakes chapter e Check the front brake effectiveness see Brake Operation Inspection in the Periodic Maintenance chapter A WARNING Do not
455. urface 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 Cutter angle 0931 5 dete Outer diameter of cutter C Operating Procedures e Clean the seat area carefully e Coat the seat with machinist s dye e Fit a 45 cutter into the holder and slide it into the valve guide e Press down lightly on the handle and turn it right or left Grind the seating surface only until it is smooth CAUTION Do not grind the seat too much Overgrinding will reduce valve clearance by sinking the valve into the head If the valve sinks too far into the head it will be impossible to adjust the clearance and the cylin der head must be replaced 8 15011851 C ENGINE END 5 33 Valves e Measure the outside diameter of the seating surface with vernier caliper x If the
456. utch chapter e Remove Bolts A Crankshaft Sensor B e Pull out the grommet C 16 42 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Installation e Route the crankshaft sensor lead correctly see Cable Wire and Hose Routing section in the Appendix chapter e Tighten Torque Crankshaft Sensor Bolts 6 0 N m 0 60 kgf m 53 in Ib e Apply silicone sealant A to the crankshaft sensor lead grommet Sealant Kawasaki Bond Silicone Sealant 92104 0004 e Install the removed parts see appropriate chapters Crankshaft Sensor Inspection e Remove Right Frame Cover see Frame Cover Removal in the Frame chapter Crankshaft Sensor Lead Connector A e Set the hand tester to the x 100 O range and connect lead to the black lead and lead to the yellow lead in the connector Special Tool Hand Tester 57001 1394 x If there is more resistance than the specified value the coil has an open lead and must be replaced Much less than this resistance means the coil is shorted and must be replaced Crankshaft Sensor Resistance 376 564 e Using the highest resistance range of the tester measure the resistance between the crankshaft sensor leads and chassis ground Any tester reading less than infinity 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
457. valve is precision made with no allowance for re placement of individual parts 6008060251 7 12 ENGINE LUBRICATION SYSTEM Oil Pump Oil Pump Removal e Drain Engine Oil see Engine Oil Change in the Periodic Main tenance chapter e Remove Clutch see Clutch Removal in the Clutch chapter Oil Pump Cover Bolts A Oil Pump Cover B e Remove Inner Rotor A for Scavenge Pump Outer Rotor B for Scavenge Pump e Remove Dowel Pin A Pin B Oil Pump Body C with Oil Pump Shaft D and Pin e Remove Inner Rotor A for Feed Pump Outer Rotor B for Feed Pump ENGINE LUBRICATION SYSTEM 7 13 Oil Pump Oil Pump Installation e Apply molybdenum disulfide grease to the portion A of the oil pump shaft as shown e Install Outer Rotor B for Feed Pump Inner Rotor C for Feed Pump Oil Pump Shaft D and Pin E Dowel Pin F Oil Pump Body G Pin and Inner Rotor I for Scavenge Pump Outer Rotor J for Scavenge Pump Oil Pump Cover K NOTE OThe scavenge pump rotors are wider than the feed pump rotors GG09050BS2 C e Apply a non permanent 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 7 14 ENGINE LUBRICATION SYSTEM Oil Pressure Measurement Pressure eRemove the right lower fairing see Lower Fairing Re moval in the Frame chapter
458. valves A open and close smoothly x If the subthrottle valves do not operate check the actuator internal resistance see Subthrottle Valve Actuator Resis tance Inspection Subthrottle Valve Actuator Resistance Inspection e Turn the ignition switch OFF e Remove the air cleaner housing see Air Cleaner Housing Removal e Disconnect the subthrottle valve actuator connector A e Connect a digital meter to the subthrottle valve actuator connector A e Measure the subthrottle valve actuator resistance Subthrottle Valve Actuator Resistance Connections BK lead 1 P lead 2 lead 3 W BL lead 4 Standard About 5 5 7 5 kQ Special Tool Hand Tester 57001 1394 6017159851 xIf the reading is out of the range replace the actuator along with the throttle body assy x lf the reading is within the range check the input voltage see Subthrottle Valve Actuator Input Voltage Inspection 3 72 FUEL SYSTEM DFI Subthrottle Valve Actuator Service Code 62 Subthrottle Valve Actuator Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF e Connect the peak voltage adapter A and a digital meter B to the connector C using the needle adapter set D Special Tools Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Brand KOWA SEIKI Needle Adapter Set 57001 1457 Subthrottle Valve Actuator Input Voltage Connections to Harne
459. w ones e Install the circlips A so that the opening B is aligned with a spline groove C 6113010251 CRANKSHAFT TRANSMISSION 9 37 Transmission e The drive shaft gears can be recognized by size the gear with the smallest diameter is 1st gear and the largest one is 6th gear Be sure that all parts are put back in the cor rect sequence and all circlips and washers are properly in place e Install the 3rd 4th gear onto the drive shaft with their oil holes aligned e Install the 6th gear bushing onto the drive shaft with their oil holes aligned e The output shaft gears can be recognized by size the gear with the largest diameter is 1st gear and the small est one is 6th gear Be sure that all parts are put back in the correct sequence and all circlips and washers are properly in place e Install the 5th and 6th gears onto the output shaft with their oil holes aligned e Install the 3rd 4th gear bushings onto the output shaft with their oil holes aligned e Fit the steel balls into the 5th gear holes in the output shaft aligning three oil holes 5th Gear A Output Shaft B Steel Balls C Oil Holes D CAUTION Do not apply grease to the balls to hold them in 6113033851 C 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 c
460. wel Pin G Connecting Rod Bolts H e Install the cap on the connecting rod aligning the weight and diameter marks e Remove debris and clean the surface of inserts e Apply molybdenum disulfide oil solution MO to the threads and seating surfaces of the big end nuts and bolts 6105060151 6105020651 CRANKSHAFT TRANSMISSION 9 19 Crankshaft and Connecting Rods 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 9105147851 OThe connecting rod big end is bolted using the plastic region fastening method OThis method precisely achieves the needed clamping force without exceeding it unnecessarily allowing the use of thinner lighter bolts further decreasing connecting rod weight OThere are two types of the plastic region fastening One is a bolt length measurement method and other is a rotation angle method Observe one of the following two but the bolt length measurement method is preferable because this is a more reliable way to tighten the big end nuts CAUTION The connecting rod bolts are designed to stretch when tightened Never reuse the connecting rod bolts See the table below for correct bolt and nut usage CAUTION Be
461. y ON or OFF or dropout 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 43 Front wheel rotation sensor wiring wiring shorted or open connector bad connection 44 Rear wheel rotation sensor signal abnormal sensor or rotor missing too large clearance rotor tooth worn or missing Rear wheel rotation sensor wiring wiring shorted or open connector bad connection Power supply voltage abnormal under voltage Power supply voltage abnormal over voltage ONE ECU trouble ECU operation abnormal 12 44 BRAKES Anti Lock Brake System ABS Indicator Light LED Inspection e Turn the ignition switch ON x If the ABS indicator light LED A lights it is normal 1 the ABS indicator light LED does not light go to step ABS Indicator Light LED is Unlit When the Ignition Switch turned to e Turn the ignition switch OFF xIf the ABS indicator light LED A does not light it is normal x If the ABS indicator light LED lights go to step ABS In dicator Light LED Lights When the Motorcycle is Run ning No Service Code ABS Indicator Light LED is Unlit When the Ignition Switch turned to ON e Do the 1st step test O
462. y Circuit seo pe TT HR 16 77 Diode Circuit 16 78 USC ee rc De 16 80 Fuse Removal element 16 80 Fuse Box I i 16 80 19 A EGU Fuse Removals exe 16 80 FUSE INStallation oe 16 81 FUSE INS POCHION m P 16 81 ELECTRICAL SYSTEM 16 3 Exploded View Dummy Page 16 4 ELECTRICAL SYSTEM Exploded View ELECTRICAL SYSTEM 16 5 Exploded View Fastener Remarks N m kgf m ft Ib 1 Front Turn Signal Light Mounting Screws 1 2 0 12 11 in Ib 2 License Plate Light Cover Screws 0 90 0 090 8 in Ib 3 License Plate Light Mounting Screws 1 2 0 12 11 in Ib 4 Meter Screws 1 2 0 12 11 in Ib 5 Meter Unit EX650B Models 6 City Light Europe Models 16 6 ELECTRICAL SYSTEM Exploded View GP022408W5 C ELECTRICAL SYSTEM 16 7 Exploded View No Fastener Torgus Remarks N m kgf m ft Ib 1 Front Brake Light Switch Screw 1 2 0 12 11 in Ib 2 Left Switch Housing Screws 3 5 0 36 31 in Ib 3 Right Switch Housing Screws 3 5 0 36 31 in Ib 4 Starter Motor Cable Terminal Nut 6 0 0 60 53 in Ib 5 Starter Motor Mounting Bolts 9 8 1 0 87 L 6 Starter Motor Terminal Locknut 11 1 1 97
463. yzing the waveform of boost pressure over fixed period The intake stroke is recognized by waveform of boost pressure therefore the system can recognize the difference of each stroke Ignition Switch Inlet Air Pressure Sensor Vacuum Hose 1 Throttle Bore GENERAL INFORMATION 1 15 Technical Information ABS Anti Lock Brake System Outline ABS controls the brake caliper fluid pressure by means of mechatronics a combination of electronic and hydraulic control technology in order to keep the friction force between the tires and the road surfaces close to the maximum value and prevent wheel lock But it does not operate during cruising ABS Total System GL14025BW3 C aS VE ECU ABS Indicator Light LED Pump Motor Pump Front Reservoir Front Inlet Solenoid Valve Front Outlet Solenoid Valve Rear Inlet Solenoid Valve Rear Outlet Solenoid Valve Brake Lever Brake Pedal ABS Hydraulic Unit Front Brake Caliper Front Wheel Rotation Sensor Front Wheel Rotation Sensor Rotor Rear Brake Caliper Rear Wheel Rotation Sensor Rear Wheel Rotation Sensor Rotor ABS Kawasaki Self diagnosis System Con nector ABS Solenoid Valve Relay ABS Motor Relay Rear Reservoir 1 16 GENERAL INFORMATION Technical Information ABS Anti Lock Brake System ABS System Block Diagram

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