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Kawasaki ER6n Service Manual (EN)

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1. Poor running at low speed hito mototh com 3 26 FUEL SYSTEM DFI Troubleshooting the DFI System Oclutch slipping Dother Poor running spark plug loose tighten it or no power at spark plug dirty broken or gap maladjusted remedy it high speed Ospark plug incorrect replace it Eknocking fuel poor quality or incorrect use high octane gasoline hito mototh com FUEL SYSTEM DFI 3 27 DFI System Troubleshooting Guide NOTE OThis is not an exhaustive list giving every possible cause for each problem listed It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties OThe ECU may be involved in the DFI electrical and ignition system troubles If these parts and circuits are checked out good be sure to check the ECU for ground and power supply If the ground and power supply are checked good replace the ECU Engine Doesn t Start Starting Difficulty Starter motor not rotating J S Main 30A or ignition fuse blown Inspect and replace see chapter 16 Starter motor rotating but engine doesn t turn over em z Starter clutch trouble Inspect see chapter 16 Starter idle gear trouble Inspect see chapter 16 Engine won t turn over n see chapter 5 see chapter 9 n Camshaft seizure nspect and replace n Valve seizure spect and replace see chapter 5 Connecting rod small end seizure spect and replace spect and replace see
2. A WARNING Fuel spilled from the carburetors is hazardous e Apply a thin coating of grease to the throttle cable upper ends e Install the upper ends of the throttle cables in the grip e Fit the projection A of the right switch housing into the hole B of the handlebar e Turnthe throttle grip and make sure that the 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 Idle Speed 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 ona hard surface Such a shock to the body assy can damage it hito mototh com 0617013551 FUEL SYSTEM DFI 3 97 Throttle Body Assy e Remove Screws A Delivery Pipe B Fuel Injectors C Throttle Body Assy Assembly OReplace the O rings A
3. htio mototh com 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 DFl system and ignition system by lighting the Fl 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 DFI indicator light LED A goes on NOTE OUse a fully charged battery when conducting self diagnosis Otherwise the light LED blinks very slowly or doesn t blink OKeep the self diagnosis terminal grounded during self diagnosis with an auxiliary lead e Remove the seat see Seat Removal in the Frame chap ter e Ground A the self diagnosis terminal B Orange Black lead to the battery terminal C or battery lead con nector using a wire e Turn on the ignition switch e Connect an
4. Kawasaki ER 6n Motorcycle Service Manual htio mototh com htio mototh com 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 mb mb mb h h k od N oO A IN OO o OO NY OT Oo NO Appendix This quick reference guide will assist you in locating a desired topic or pro cedure Bend the pages back to match the black tab of the desired chapter num ber with the black tab on the edge at each table of contents page Refer to the sectional table of contents for the exact pages to locate the spe cific topic required htio mototh com htio mototh com Kawasaki ER 6n 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
5. al1050417531 E Crankcase Main Bearing Crankshaft Main Journal Bearing Insert Inside Diameter Marking Diameter Marking Part Number 92028 1905 None Black 92028 1904 None 36026 1903 The bearing inserts for Nos 1 2 and 3 journals have oil groove htio mototh com 9 26 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods e Install the new inserts in the crankcase halves and check insert journal clearance with the plastigage hito mototh com CRANKSHAFT TRANSMISSION 9 27 Balancer Balancer Removal e Split the crankcase see Crankcase Splitting e 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 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 astrip 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 Crank
6. 5 19 Muffler Body Removal 5 38 Cylrider Hedd contra 5 20 Exhaust Pipe Removal 5 38 Cylinder Compression Muffler Body and Exhaust Pipe Measurement 5 20 INSTANAUO Mission 5 39 hito mototh com 5 2 ENGINE TOP END Exploded View y m D T an a N LA i get SE a BEGZIS9RRS G hito mototh com ENGINE TOP END 5 3 Exploded View A gs pum 38 i Ar Suction Valve Gover Bois 98 10 87mb 2 OyimderHeadCovrBots 98 10 ain 12 54 49 12 12 20 O Spark Plugs As 1 Camshaft Sprocket Bots 15 12 Baffle Plate Bots 58 L Apply a non permanent locking agent M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts S Follow the specific tightening sequence SS Apply silicone sealant 0 EX EN ET E 10 12 htio mototh com 5 4 ENGINE TOP END Exploded View htio mototh com ENGINE TOP END 5 5 Exploded View A ge RE 4 Exhaust Pipe ManifoldHolderNuts 37 17 12 o 5 Mutter Body Mounting Bolt From 20 20 15 6 Mutier Body Mounting Bot Reay 20 20 15 7 R marked side faces up 8 RN marked side faces up 9 Hollow mark faces forward MO Apply molybdenum disulfide oil solution mixture of the
7. Flap and Hear Fender Rear Installation e Installation is the reverse of removal http mototh com FRAME 15 15 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 e Remove the fuse box from the rear fender front e Remove Bolt A Clamp B e Free the clamp from the rear fender front e Remove the rear fender front A backward and upward Rear Fender Front Installation e Installation is the reverse of removal e Install the removed parts see appropriate chapters hito mototh com 15 16 FRAME Frame Frame Inspection e Visually inspect the frame for cracks dents bending or warp Olf there is any damage to the frame replace it Li WARNING A repaired frame may fail in use possibly causing an accident lf the frame is bent dented cracked or warped replace it htio mototh com FRAME 15 17 Sidestand Sidestand Removal e Raise the rear wheel off the ground with stand e Remove Frame Cover see Frame Cover Removal Bolts A Footpeg Stay B Eu TN a B Ns s EE ul L Nem Ee NA I Guo Y e Remove Sidestand Switch Bolt A with Clamp oidestand Switch B e Remove Spring A oidestand Nut
8. Special Tool Hand Tester 57001 1394 Regulator Rectifier Inspection e Remove Bolts A e Disconnect the connector A e Remove the regulator rectifier B Rectifier Circuit Check e Check conductivity of the following pair of terminals Rectifier Circuit Inspection W BL BK1 W BL BK2 W BL BK3 Tester connection BK Y BK1 BK Y BK2 BK Y BK3 The resistance should be low in one direction and more than ten times as much in the other direction If any two leads are low or high in both directions the rectifier is defective and the regulator rectifier must be replaced NOTE OThe actual meter reading varies with the meter used and the individual rectifier but generally speaking the lower reading should be from zero to one half the scale htio mototh com ELECTRICAL SYSTEM 16 29 BK2 BK 3 0P09143851 C 16 30 ELECTRICAL SYSTEM Charging System 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 test light and the 12 V battery to the regula tor rectifier as shown OCheck the BK1 BK2 and BK3 te
9. aciTi nnB52 c Input Voltage at Actuator Standard about 8 5 10 5 V DC xlf the reading is within the standard but the actuator doesnt operate replace it If the reading is out of the range check the wiring to ECU see wiring diagram in this section lf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection Subthrottle Valve Actuator Circuit BK BX BL G WBE P P TEL GY ac172216N2 C 1 ECU 2 Subthrottle Valve Actuator hito mototh com 3 70 FUEL SYSTEM DFI Air Switching Valve Service Code 64 Air Switching Valve Removal Installation e Refer to Clean Air System section in the Engine Top End chapter Air Switching Valve Inspection e Refer to Air Switching Valve section in the Electrical Sys tem chapter e Remove the fuel tank and check the wiring continuity us ing the following diagram Air Switch Valve Circuit QG173BBHW2 E 1 ECU 7 ECU Main Relay 2 Air Switching Valve 8 Relay Box 3 Water proof Joint C 9 Main Fuse 30 A 4 Ignition Switch 10 Battery 5 Water proof Joint A 11 Frame Ground 6 ECU Fuse 15 A 12 Joint Connector htio mototh com FUEL SYSTEM DFI 3 71 Oxygen Sensor Heater Service Code 67 Europe Model Oxygen Sensor Heater Removal Installation The oxygen sensor heater is bult in the oxygen sensor So the heater itself can not be removed Remove the oxy gen sensor see Oxygen Sensor Removal in the Electr
10. COOLING SYSTEM 4 9 4 10 COOLING SYSTEM Water Pump Water Pump Removal e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e 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 e 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 kgf m 87 in Ib e Replace the O ring A on the water pump cover with a new one and grease it http mototh com 00008067851 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 A Impeller Sealing Seat Surf
11. ST57i1292051 L Hand Tester Sensor Harness Adapter 57001 1394 57001 1561 ST57i139451 sT5715618T Throttle Sensor Setting Adapter 1 Fuel Pressure Gauge Adapter 57001 1400 57001 1593 ST57Ti140085T L SsT15715938T1 Peak Voltage Adapter Fuel Hose 57001 1415 57001 1607 5157141581 STSTIGOTST htio mototh com FUEL SYSTEM DFI 3 17 Special Tools and Sealant Kawasaki Bond Silicone Sealant 56019 120 5156012087 htio mototh com 3 18 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 a 12 V sealed battery as its power source Do not use any other battery except for a 12 V sealed battery as a power source ODo not reverse the battery cable connections This will damage the ECU OTo prevent damage to the DFI parts do not disconnect the battery cables or any other electrical connections when the ignition switch is on or while the engine is running OTake care not to short the leads that are directly con nected to the battery positive terminal to the chassis ground OWhen charging remove the battery from the motorcycle This is to prevent ECU damage by excessive voltage ODo not turn the ignition switch ON while any of the DFI electrical connectors are disconnected The ECU memo rizes service codes ODo n
12. Steering Steering Stem Head Bolt Handlebar Holder Bolts Others Footpeg Stay Bolts Front Fender Bolts Sidestand Bolt hito mototh com PERIODIC MAINTENANCE 2 45 Periodic Maintenance Procedures Replacement Parts Air Cleaner Element Replacement e Refer to the Air Cleaner Element Cleaning Engine 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 e Remove the engine oil drain bolt A to drain the oil OThe oil in the oil filter can be drained by removing the filter see Oil Filter Replacement Replace the drain bolt gasket B with a new one e Tighten the drain bolt Torque Engine Oil Drain Bolt 20 N m 2 0 kgf m 15 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 ED ee A 1 9 L 2 0 US qt when filter is removed 2 4 L 2 5 US qt when engine is use E NEL LEA NE NL completely dry CentOS E NOTE OAlthough 10W 40 engine oil is the recommended oil for most conditions the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area e Check the oil level see Oil Level Inspection in the Engine Lubrication System chapter htio mototh com 2 46 PERIODIC MAINTENANCE Periodic Mainten
13. below from inner tube top with fully compressed without fork spring Fork Spring Free Length 277 8 mm 10 94 in Service limit 272 mm 10 7 in Rear Shock Absorber Spring Preload 3rd position Adjustable Range 1st 7th position Gas Pressure 980 kPa 10 kgf cm 142 psi Non adjustable hito mototh com SUSPENSION 13 7 Special Tools Inside Circlip Pliers Jack 57001 143 57001 1238 ST57TO1438T C i i ST57i123851 Fork Cylinder Holder Handle Fork Oil Seal Driver 41 57001 183 57001 1288 ST57018351 C 3157128831 Fork Cylinder Holder Adapter Fork Oil Level Gauge 57001 1057 57001 1290 35157105731 515712090851 Oil Seal amp Bearing Remover Jack Attachment 57001 1058 57001 1608 ST5T7in05851 L STSTIGGaST L Bearing Driver Set Stem Bearing Driver 28 57001 1129 57001 1610 sT5711298T1 ST5TiB1035T L htio mototh com 13 8 SUSPENSION Special Tools Spacer 028 57001 1663 351571663371 htio mototh com SUSPENSION 13 9 Front Fork Front Fork Removal e Remove Front Wheel see Front Wheel Removal in the Wheels Tires chapter Front Fender see Front Fender Removal in the Frame chapter 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
14. e Insert the following on the drive shaft Clutch Housing A with Chain B and Sprocket C Sleeve D e Align E the hole on the oil pump sprocket with the oil pump shaft 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 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 N m 13 5 kgf m 98 ft lb hito mototh com Clutch 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 in The others are 2 3 mm 0 09 in 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 B 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 Spring 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 frict
15. htio mototh com COOLING SYSTEM 4 3 Exploded View 1 Radiator Hose Clamp Screws 20 020 imb 2 Water Pump impeller Bot 98 10 ermi 3 Water Pump Cover Bots 98 10 ermi 4 Water Pump Drain Bt 70 om 62b 5 Thermostat Housing Bos 98 10 6 Water Temperature Sensor 12 12 10mb C7 Bate Pate Bots se oeo s2mb 1 8 Reserve Tank Baffle Plate 10 Cylinder Head Cover 11 Thermostat 12 Water Pump Impeller 13 Mechanical Seal G Apply grease HG Apply high temperature grease R Replacement Parts htto mototh com 4 4 COOLING SYSTEM Coolant Flow Chart Cylinder Head Jacket Thermostat Housing Cylinder Jacket Reserve Tank we Hose Reserve Tank Radiator Radiator Fan j Radiator Cap Reserve Tank Hose Hot Coolant gt Gold Coolant GO i hito mototh com 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 atthe 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
16. 2006 ER650A6S JKAER650AAA000001 1 This digit in the frame number changes from one machine to another lt Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Consumer Products amp Machinery Company Part No 99924 1360 01 Printed in Japan hito mototh com
17. ECU Removal ECU Installation ECU Power Supply INSDOCHION enri E E E E AA A Fuel ENaren Fuel Pressure Inspection Fuel Flow Rate Inspection UCI PU Delon ve toc EO Fuel Pump Removal Fuel Pump Installation Fuel Pump Operation NS PC CHOM s cocti eto eoa ed Elke E e FR Fricke pe id per Deve e In pane Uds Fuel Pump Operating Voltage Inspection ccccoccncccccncccnnnococononocononononcncnnannnonononononnnnos Pressure Regulator Removal htio mototh com 3 53 3 54 3 54 3 54 3 55 3 55 3 55 3 55 3 55 3 5 3 5 3 5 3 5 3 60 3 60 3 60 3 61 3 62 3 63 3 63 3 63 3 65 3 65 3 65 3 67 3 67 3 67 3 68 3 68 3 68 3 68 3 68 3 69 3 70 3 70 3 70 3 71 3 71 3 71 3 73 3 73 3 73 39 70 3 76 3 17 3 77 3 17 3 78 3 80 3 80 3 82 3 84 3 84 3 84 3 85 3 85 3 86 FUEL SYSTEM DFI 3 3 Pump Screen Fuel Filter Cleaning o saris te acaucteieues E de eco Me Dedicato mile m QM PeMOVal IISTAN ANON ee tt UE PUCIDIC INSPECCION RR TE TEM Fuel Injector Power Source Voltage Inspection occccocnnncccccococoncnccnncnnonanonononcnconanoncnnnoos Fuel Injector Output Voltage Inspection ccccccocccncccccnnncccnonnnncononnncnononcnnnononcnnnnnonccnnnnnns lector Signal Me Sta InjeClOr Resistance Inspeccion ais NEectornunt zr I
18. 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 hito mototh com WHEELS TIRES 10 11 0040758031 E aJ04077851 E aJ04071851 E 0040180851 E 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 004074851 E 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 0040150851 E htio mototh com Tires Air Pressure Inspection Adjustment e Refer to the Air Pressure Inspection in the Periodic Main tenance chapter Tire Inspection e Refer to the Wheel Tire Damage Inspection in the Peri odic Maintena
19. Olncrease the charging voltage to a maximum voltage of 25 V if the battery will not accept current initially Charge for no more than 5 minutes at the increased voltage then check if the battery is drawing current If the battery wil 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 BPURO22B 1 C 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 Judgement 12 0 lower than 12 8 V Charge insufficient Recharge lower than 12 0 V Unserviceable Replace htio mototh com ELECTRICAL SYSTEM 16 25 Charging System Alternator Cover Removal e Remove Lower Fairing see Lower 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 pla
20. Radiator Fan Relay Circuit BCTTSETRR E ECU Water proof Joint C Water proof Joint B Radiator Fan Fuse 15A Relay Box Radiator Fan Relay Main Fuse 30 A Battery Frame Ground Joint Connector OOON DOR WNDN htio mototh com 3 68 FUEL SYSTEM DFI 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 actuator especially on a hard sur face 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 xf the actuator does not work as described above do the visual inspection Subthrottle Valve Actuator Visual Inspection e Remove the throttle body assy see Throttle Body Assy Removal e Turn the ignition switch ON e Check to see that all the subthrottle valves A open and close smoothly x If the subthrottle valves do not operate check the actuator internal resistance see Subthrottle Valve Actuator Resis tance Inspection Subthrottle Valve Actuator Resistance Inspection e Turn the ignition switch OFF e R
21. 1 498 mm 0 0588 0 0590 in Blue 1 498 1 502 mm 0 0590 0 0591 in Crankshaft Main Bearing Insert Selection Crankcase Main Crankshaft Main Bearing Insert Bearing Inside Journal Diameter Diameter Marking Marking Part Number 92028 1905 92028 1904 The bearing inserts for Nos 1 2 and 3 journals have oil grooves Balancer Shaft Balancer Shaft Bearing Insert Journal Clearance 0 011 0 033 mm 0 08 mm 0 0004 0 0013 in 0 0031 in Balancer Shaft Journal Diameter 27 987 28 000 mm 27 96 mm 1 1019 1 1024 in 1 1108 in Marking None 27 987 27 993 mm 1 1019 1 1021 in O 27 994 28 000 mm 1 1021 1 1024 in htio mototh com 9 8 CRANKSHAFT TRANSMISSION Specifications lem O Standard Crankcase Bearing Bore Diameter 31 000 31 016 mm 1 2205 1 2228 in Marking O 31 000 31 008 mm EM 1 2205 1 2208 in None 31 009 31 016 mm 1 2208 1 2211 in Balancer Shaft Bearing Insert Thickness Brown 1 490 1 494 mm HEN 0 0587 0 0588 in Black 1 494 1 498 mm eee ae 0 0588 0 0590 in Blue 1 498 1 502 mm 0 0590 0 0591 in Balancer Shaft Bearing Insert Selection Crankcase Bearing Balancer Shaft Bearing Insert Bore Diameter Journal Diameter Marking Marking Part Number 92139 0119 The bearing inserts for Nos 1 2 journals have oil grooves Transmission Shift Fork Ear Thickness 5 9 6 0 mm 5 8 mm 0
22. 34 N m 3 5 kgf m 25 ft Ib e Check the brake light switch operation see Brake Light Switch Operation Inspection in the Periodic Maintenance chapter hito mototh com BRAKES 12 9 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 B 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 htio mototh com 12 10 BRAKES Brake Lever Brake Pedal e Install the right footpeg stay and tighten the bolts h Torque Footpeg Stay Bolts 34 N m 3 5 kgf m 25 ft Ib l i 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 lb e Check the brake pedal position see Brake Pedal Position Inspection htio mototh com Calipers Front Caliper Removal e
23. 7 Oil Pressure Warning Indicator Light LED Battery Negative Terminal to Terminal 8 hito mototh com BP17311H51 BP17315H51 HP17314H51 LU Meter Gauge Indicator Unit Fuel Level Warning Indictor Light LED Battery Negative Terminal to Terminal 9 High Beam Indicator Light LED Battery Positive Terminal to Terminal 11 Neutral Indicator Light LED Battery Negative Terminal to Terminal 12 Right and Left Turn Signal Indicator Light LED For Right Turn Signal Indicator Light LED Battery Positive Terminal to Terminal 14 For Left Turn Signal Indicator Light LED Battery Positive Terminal to Terminal 15 Fl Indicator Light LED Battery Negative Terminal to Terminal 16 e l each lights LED does not go on replace the meter assembly hito mototh com ELECTRICAL SYSTEM 16 65 HP17318H51 0P17317851 HP17312H51 HP17318H51 HP17313H51 C 16 66 ELECTRICAL SYSTEM Meter Gauge Indicator Unit Meter Circuit J 10 HE0 HG EE A BR E A HH G Tro CI ie T KJT BH E LE T m a4 lo OS GPI72586EN32 G Ignition Switch Frame Ground Meter Unit Water proof Joint B ECU Fuse 15 A lghition Fuse 10 A Fuse Box Main Fuse 30 A Battery 12 V 10 Ah 10 Frame Ground 11 Fuel Reserve Switch 12 Joint Connector 13 ECU 14 Oil
24. DFI 3 49 Inlet Air Pressure Sensor Service Code 12 Inlet Air Pressure Sensor Circuit qQG17373HW2 E 1 ECU 2 Water proof Joint E 3 Water proof Joint D 4 Inlet Air Pressure Sensor htio mototh com 3 50 FUEL SYSTEM DFI Inlet Air Temperature Sensor Service Code 13 Removal nstallation 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 Output Voltage Inspection NOTE OBe sure the battery is fully charged OThe output voltage changes according to the inlet air temperature e Remove the ECU see 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 0617007256541 C Standard about 2 25 2 50 V at inlet air temperature 20 C 68 F e Turn the ignition switch OFF
25. 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 hito mototh com 06170712851 E 06170712851 E FUEL SYSTEM DFI 3 37 Self Diagnosis Turn the ignition switch OFF 44 Turn the ignition switch N 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 Fl 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 Fl indicator light LED doesn t go ON ox Run the engine for several minuies at idling and run the motorcycle at 30 km h 18 NG mph or above in order to confirm no problem 6171666 F htio mototh com 3 38 FUEL SYSTEM DFI 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 Fl indicator light LED blinks
26. Meter BK Y lead terminal 51 061700756514 C Input Voltage at ECU Standard Battery Voltage 12 8 V or more xf 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 htio mototh com 3 66 FUEL SYSTEM DFI Stick Coils 1 2 Service Code 51 52 Stick Coil Circuit BCTTSEGRR E ECU Water proof Joint C Stick Coils Engine Stop Switch Ignition Switch Ignition Fuse 10 A Main Fuse 30 A Battery Frame Ground Joint Connector Oqvo xogonsomc htio mototh com FUEL SYSTEM DFI 3 67 Radiator Fan Relay Service Code 56 Radiator Fan Relay Removal Installation e Radiator fan relay is bult in the relay box e Remove the relay box see Relay Box Removal in the Electrical System chapter Radiator Fan Relay Inspection e See Relay Circuit Inspection in the Electrical System 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 If wiring and radiator fan 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
27. Turn Signal Relay A e Connect one 12 V battery and turn signal lights as indi cated in the figure and count how may times the lights flash for one minute Turn Signal Relay A Turn Signal Lights B 12 V Battery C x If the lights do not flash as specified replace the turn sig nal relay Testing Turn Signal Relay asa Flashing Times The Number of Turn c m Signal Lights Wattage W c m Cycle s per minute Corrected to one light burned out hito mototh com 0P120402531 E ELECTRICAL SYSTEM 16 55 Lighting System Turn Signal Light Circuit GPI2206EN32 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 c 0o Y OOK WN htio mototh com 16 56 ELECTRICAL SYSTEM Air Switching Valve Air Switching Valve Operation Test e 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 Inst
28. Washer 40 mm 1 57 in 9 Toothed Washer 34 mm 1 34 in 24 Bushing 10 Circlip 25 Toothed Washer 38 mm 1 50 in 11 Bushing 26 Shim 28 mm 1 10 in 12 Thrust Washer 30 mm 1 18 in 27 Steel Ball 13 Needle Bearing 28 Circlip 632 2 mm 1 268 in 14 Circlip 29 Thrust Washer 25 mm 0 98 in 15 Oil Seal htio mototh com CRANKSHAFT TRANSMISSION 9 39 Transmission Shift Drum and Fork Removal e Remove the transmission assy see Transmission Assy Removal e Remove the shift forks A and shift drum B see Trans mission Assy Disassembly Shift Drum and Fork Installation e Refer to Transmission Assy Assembly and Installation Shift Drum Disassembly e Refer to Transmission Assy Removal and Disassembly Shift Drum Assembly e Refer to Transmission Assembly and Installation Shift Fork Bending e Visually inspect the shift forks and replace any fork that is bent A bent fork could cause difficulty in shifting or allow the transmission to jump out of gear when under power 90 A A 01171014551 E 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 lf 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 If the gear groove is worn over the service limit the g
29. and seals B with the new ones e Before assembling blow away dirt or dust from the throttle body and delivery pipe by applying compressed air e Apply engine oil to the new O rings of each injector C insert them into the delivery pipe and confirm whether the injectors turn smoothly or not e Install the injectors along with the delivery pipe assy into the throttle bodies n e Install the throttle body assy see Throttle Body Assy In stallation htio mototh com 3 98 FUEL SYSTEM DFI Air Cleaner Air Cleaner Element Removal Installation e Refer to Air Cleaner Element Replacement in the Periodic Maintenance chapter Air Cleaner Element Inspection e Remove the air cleaner element see Air Cleaner Element Replacement in the Periodic Maintenance chapter e Visually check the element A for tears or breaks x If 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 Visually check the drain hose A if the water or oil accu mulates If any water or oil accumulates in the hose remove the plug B from the drain hose and drain it A WARNING Be sure to reinstall the plug in the drain hose after draining Oil on tires will make them slippery and can cause an accident and injury Air Cleaner Housing Removal e Remove disconnect Hose Disconnect A Inl
30. 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 hito mototh com EIMH P Cylinder Pistons e Remove the piston pins Special Tool Piston Pin Puller 57001 1568 A Piston Pin Puller Adapter C 57001 1657 D Center Bolt B Shall of Piston C e Remove the pistons e Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring A to remove it e Remove the 3 piece oil ring with your thumbs in the same manner 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 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 O The oil ring rails have no top or bottom e Do not mix up the top and second ring e Install the top ring A so that the R mark B faces up e Install the second ring C so that the RN
31. cable A e Slide out the positive terminal cap B and then discon nect the positive cable CAUTION Be sure to disconnect the negative cable first e Remove the battery Battery Installation e Put the battery into the rear fender front e Apply a light coat of grease on the terminals to prevent corrosion e Install the positive cable A first e Cover the positive terminal with the cap B e Install the negative cable C Battery Activation Electrolyte Filling e Make sure that the model name A of the electrolyte con tainer matches the model name B of the battery These names must be the same Battery Model Name for ER650A YTX12 BS CAUTION Be sure to use the electrolyte container with the same model name as the battery since the elec trolyte volume and specific gravity vary with the battery type This is to prevent overfilling of the electrolyte shorting the battery life and deteriora aPnBo2D45 E 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 O The battery is vacuum sealed If the sealing sheet has leaked air into the battery it may requ
32. com 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 torque it Torque Neutral Switch Holder Screw 4 9 N m 0 50 kgf m 43 in Ib 0113243851 e Apply grease to the O ring A and install its position B 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 transmission assy see Transmission Assy Removal e Remove Shift Rods A Shift Forks B Drive Shaft C and Output Shaft D cia P Transmission Shaft Installation e Be sure that the spacer A is on the output shaft B htio mototh com 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
33. large make the 32 grind described below xf the outside diameter of the seating surface is within the specified range measure the seat width as described be low e Grind the seat at a 32 angle B until the seat outside diameter is within the specified range OTo make the 32 grind fit a 32 cutter into the holder and slide it into the valve guide OTurn the holder one turn at a time while pressing down very lightly Check the seat after each turn CAUTION The 32 cutter removes material very quickly Check the seat outside diameter frequently to pre vent overgrinding OAfter making the 32 grind return to the seat outside di ameter measurement step above e o 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 xf 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 htio mototh com ENGINE TOP END 5 29 0615511551 E 0E155012151 E daE1580122751 E 5 30 ENGINE TOP END Valves x If the seat width is too wide make the 60 or 55 A grind described below xf 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
34. 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 htio mototh com 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 78 in Ib 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
35. 0 0028 in Service Limit 0 16 mm 0 0063 in xlf 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 hito mototh com HE11158H51 0E110712851 E ENGINE TOP END 5 19 Camshaft Camshaft Chain Camshaft Runout e Remove the camshaft see Camshaft Removal e Set the camshaft in a camshaft alignment jig or on V blocks e Measure runout with a dial gauge at the specified place as shown 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 HE11157H51 Cam Wear e Remove the camshaft see Camshaft Removal e Measure the height A of each cam with a micrometer If the cams are worn down past the service limit replace the camshaft A Cam Height Standard Exhaust 35 843 35 957 mm 1 4111 1 4156 in Inlet 36 543 36 657 mm 1 4387 1 4432 in BETIS REPE SE Service Limit Exhaust 35 74 mm 1 4071 in Inlet 36 44 mm 1 4346 in Camshaft Chain Removal e Split the crankcase see Crankcase Splittin
36. 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 htio mototh com BRAKES 12 15 12 16 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 lb 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 Front Master Cylinder Disassembly e Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter Rear Master Cylinder Disassembly e Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter Master Cylinder Assembly e Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter htio mototh c
37. 232 0 236 in 0 228 in Gear Groove Width 6 05 6 15 mm 6 25 mm 0 238 0 242 in 0 246 in Shift Fork Guide Pin Diameter 6 9 7 0 mm 6 8 mm 0 272 0 276 in 0 268 in Shift Drum Groove Width 7 05 7 20 mm 7 3 mm 0 278 0 283 in 0 287 in htio mototh com CRANKSHAFT TRANSMISSION 9 9 Special Tools and Sealant Outside Circlip Pliers Bearing Driver Set 57001 144 57001 1129 515701448717 C sT5711298T1 Kawasaki Bond 92104 1064 51921064871 htio mototh com 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 M8 A and the wash ers 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 bolts 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 surfa
38. 2679 Cylinder Inside Diameter 83 10 mm 3 2716 in in Piston Diameter EU uU d 82 82 mm 3 2606 in Piston Cylinder Clearance 0 010 0 037 mm 0 0004 0 0015 in Piston Ring Groove Clearance Top 0 03 0 07 mm 0 0012 0 0028 in 0 17 mm 0 0067 in Second 0 02 0 06 mm 0 0008 0 0024 in 0 16 mm 0 0063 in Piston Ring Groove Width Top 0 92 0 94 mm 0 0362 0 0370 in 1 02 mm 0 040 in Second 1 01 1 03 mm 0 0398 0 0406 in 1 11 mm 0 044 in Piston Ring Thickness Top 0 87 0 89 mm 0 0342 0 0350 in 0 80 mm 0 031 in Second 0 97 0 99 mm 0 0382 0 0390 in 0 90 mm 0 035 in Piston Ring End Gap Top 0 25 0 40 mm 0 0098 0 0157 in 0 7 mm 0 028 in Second 0 40 0 55 mm 0 0157 0 0217 in 0 8 mm 0 031 in htio mototh com ENGINE TOP END 5 9 Special Tools and Sealant Compression Gauge 20 kgf cm Valve Seat Cutter 60 530 57001 221 57001 1123 ST57022151 ST57iII2351 Valve Spring Compressor Assembly Valve Seat Cutter Holder Bar 57001 241 57001 1128 Valve Seat Cutter 45 535 Valve Seat Cutter 45 530 57001 1116 57001 1187 5157111681 C Valve Seat Cutter 32 430 Valve Seat Cutter 55 535 57001 1120 57001 1247 ST5TIIBTSTY ST5711208T1 3157124731 Valve Seat Cutter 32 535 Valve Spring Compressor Adapter 21 57001 1121 57001 1272 sT5711218T1 ST5Ti12725T1 htio mototh com 5 10 ENGINE TOP END S
39. 57001 1578 ST57TO1438T C ST5715798T Steering Stem Nut Wrench Pilot Screw Adjuster E 57001 1100 57001 1603 ST5TiI10085T L ST5Ti5BDd5T1 C Jack Jack Attachment 57001 1238 57001 1608 ST57i123851 ST5Ti5BDSET L Oil Filter Wrench 57001 1249 ST5T7iI2495T1 htio mototh com 2 14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System DFI Fuel Hose Inspection fuel leak damage installation condition OThe fuel hose is designed to be used throughout the mo torcycle s life without any 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 Fuel System DFI chapter and check the fuel hose Replace the fuel hose if any fraying cracks B or bulges C are noticed e Check thatthe 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 e Check that the hose joints are securely connected OPush and pull A the hose joint B back and forth more than two times and make sure it is locked x 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 Throttle Control System Inspection e Check
40. 8 15 0 kgf cm 139 213 psi 2400 r min rpm Cylinder Head Warp 0 05 mm 0 002 in Valves Exhaust 0 22 0 31 mm 0 0087 0 0122 in Inlet 0 15 0 21 mm 0 0059 0 0083 in Valve Head Thickness Exhaust 0 8 mm 0 031 in 0 5 mm 0 020 in Inlet 0 5 mm 0 020 in 0 25 mm 0 0098 in Valve Stem Bend TIR 0 01 mm 0 0004 in or less TIR 0 05 mm 0 002 in Valve Stem Diameter Exhaust 4 455 4 470 mm 0 1754 0 1760 in 4 44 mm 0 175 in Inlet 4 475 4 490 mm 0 1762 0 1768 in 4 46 mm 0 176 in Valve Guide Inside Diameter Exhaust 4 500 4 512 mm 0 1772 0 1776 in 4 58 mm 0 180 in Inlet 4 500 4 512 mm 0 1772 0 1776 in 4 58 mm 0 180 in Valve Valve Guide Clearance Wobble Method Exhaust 0 07 0 14 mm 0 0028 0 0055 in 0 27 mm 0 0106 in Inlet 0 02 0 08 mm 0 0008 0 0032 in 0 22 mm 0 0087 in Valve Seat Cutting Angle 45 32 55 60 Valve Seating Surface Width Exhaust 0 5 1 0 mm 0 020 0 039 in Inlet 0 5 1 0 mm 0 020 0 039 in Outside Diameter Exhaust 27 6 27 8 mm 1 087 1 094 in Inlet 32 6 32 8 mm 1 283 1 291 in htio mototh com 5 8 ENGINE TOP END Specifications Mem Standard 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 82 994 83 006 mm 3 2675 3
41. 8 are the cylinder nut and cylinder bolt that are tightened between the cylinder and the crankcase GET15143HW2 E htio mototh com 5 24 ENGINE TOP END Cylinder Head e 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 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 Cylinder Head Warp e Clean the cylinder head elayastraightedge across the lower surface of the cylinder head at several positions e Use athickness 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 hito mototh com 0E14073851 Valves Valve Clearance Inspection e Refer to Valve Clearance Inspection in the Periodic Main tenance chapter Valve Clearance Adjustment e Refer to Valve Clearance Adjustment in the Periodic Maintenance chapter Valve Removal e Remove cylinder head see Cylinder Head Removal e Remove t
42. 9 VAT Ms Medo AA RT OM RH 4 10 Water PUMP REMOV Al assi AA xp vaso b nis id 4 10 Water PurnpunstalldtlOricssssuiduisdodu AA AAA bau Na dc anes 4 10 Mechanical Seal Inspection ane E 4 11 Water Pump Housing Disassembly eese ener nns 4 11 Water Pump Housing Assembly ccoocccconcnonccnccocononcnnnnnnnonannnnnnnnonncnonnnnnnnnnnonnrnonnrnnnananes 4 11 Intler i sp ASSEDI eet p a a 4 12 PUMP impeller Inspector iaa 4 12 miel A 4 13 Radiator and Radiator Fan Removal occooccncccncnccccccncccocnnccanonononnncnnononocnncnnnnnnnonanonenonnnnos 4 13 Radiator and Radiator Fan Installation ccoooncnccccnncononcnnnnonnnccnnnnconarononononcnnnnnncnnnoos 4 14 Radialor e elo APA HS 4 14 Radiator Cap INS IN a e nse 4 14 Radiator Filler Neck Inspeccion urna iii 4 15 Termo sta soe sore UU TOR 4 16 INermostat REMOVA aera a a a ola on cn 4 16 Thermostat instala iutusccieraeieeatabsacalimocesechiinncuesesbdeustssechuielowbasuuartleiecdeswedsaatditerdehagiie 4 16 Thermostat Spec iia 4 16 o o Po 4 18 nose Asta OM E 4 18 FOSS M SpPEN e E TE SOL MT 4 18 Water Temperature SernSOl eetaacoe adi 4 19 Water Temperature Sensor Removal Installation ooocccccocccnccoccnnonanncnnarononanencnnnnos 4 19 Water Temperature Sensor Inspection oocccccccncccocnncconcncnnonononnncnnonannnnnannnonnnrnnonanancnnanos 4 19 htio mototh com 4 2 COOLING SYSTEM Exploded View
43. ADJUSTMENT CHART EXHAUST VALVE EXHAUST PRESENT SHIM Exsaple preset se 5 Exmple ooo Part o 62180 roial rors 1018 1020 2022 1024 1028 1628 1030 1032 1024 1026 1038 1040 1042 1044 1046 1008 1050 1057 1058 wx so ss co esl tol 75 sol as sol ss oo s sol asi zol zal sol as ol asf sol tmicrotess m 2 50 2 55 2 60 2 6sl 2 70 2 75 2 80 2 95 2 90 2 96 5 col 3 05 3 10 3 151 3 20 3 25 3 30l 3 35 3 40 a as 3 58 a a aaa neo laa a la aaa pao mone Prol zea zes zrol zrs 0 ze sof zo nn sos c scs szol asf 130 as heee asa palas llas na aaa aaa lll 0 22 0 31 SPECIF ED CLEARARCE NO CHANGE REGUIRES aa aaa ee ee ee en es ee eee ATAR TIERS EERIPES FED nner neces relanza col col o zs na od se ail o es se on oe eom Mess lara aladas Un AA PEE SETTE IET a e m PE E Ete 3 ese oso ll aoo 208 2 0 asl al is aof aast ao 20 2 0 nal a so E lo so ose 2 05 2 96 2 95 3 00 3 05 a 10 15 3 20 3 25 3 30 3 96 3 40 3 46 3 50 ies oco 2 90 2 95 2 00 3 051 3 10 a 15 2 20 9 25 3 30 0 79 o T 2 95 3 60 2 05 3 10f 3 15 2 201 3 25 a30 3 35 3 40 3 45 3 50 i 0 75 ers s oo 3 06 3 10 s 15 3 20 3 25 3 30 3 351 3 40 3 45 3 50 d oeo oee sos 2 10 2 15 3 201 4 25 a zal 2 08 2 40 2a 2 50 w pss 0 859 310 3 16 3 20 9 25 s 30 s ss 3 40 3 45 3 50 ze 5 9 0 94 9 15 3 20 3 25 3 30 3 95 3 40 3 45 a so INSTALL TH
44. B Sidestand Bolt C oidestand D Sidestand Installation e Apply grease to the sliding area A of the sidestand B e Tighten the bolt and lock them with the nut Torque Sidestand Bolt 44 N m 4 5 kgf m 33 ft Ib e Hook the spring e Install the sidestand switch OApply a non permanent locking agent to the thread of the switch bolt y Torque Sidestand Switch Bolt 8 8 N m 0 90 kgf m 78 0020013851 0 in Ib e Install the footpeg stay e Tighten Torque Footpeg Stay Bolts 34 N m 3 5 kgf m 25 ft Ib htio mototh com 15 18 FRAME 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 htio mototh com Rear View Mirrors Rear View Mirrors Removal e Loosen the lower hexagonal area A for tightening to re move the rear view mirror from the holder CAUTION Do not force to tighten and or loosen the upper hexagonal area adapter B with a pair of span ners Disassembly of this area is Not Available Non permanent locking agent C is already applied to the threads of this inner area Forcible loosen ing may damage the adapter and or the turning mechanism of the stay D Rear View Mirrors Installation e Screw the mounting area of the right rear view mirror into the holder all the way and tighten the lower hexagonal area for ti
45. Be sure to hang the camshaft chain A on the crankshaft e Be sure that the dowel pins A are in position e Set the bearing groove A on the positioning ring B as shown htio mototh com 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 B BIG4217RR htio mototh com CRANKSHAFT TRANSMISSION 9 15 Crankcase Splitting e Fitthe 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 Yl m pr ve E r 3 4104218852 E OThe M9 bolts 1 6 see the next figure have copper plated washers Replace them with new ones e Apply molybdenum disulfide oil solution to both sides A of the M9 bolts washers and the threads B of the M9 bolts 0E14071851 e Apply molyb
46. Bearing Instal lation in the Steering chapter e Adjust the steering see Steering Play Adjustment hito mototh com 051551 851 E oN05540231 E PERIODIC MAINTENANCE 2 37 Periodic Maintenance Procedures Electrical System Spark Plug Condition Inspection e Remove the spark plugs see Spark Plug Replacement e Visually inspect the spark plugs x If the spark plug center electrode A and or side elec trode B are corroded or damaged or if the insulator C is cracked replace the plug xf 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 mM 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 SS iN Z PN i gs N S N Y SA A htio mototh com 2 38 PERIODIC MAINTENANCE Periodic Maintenance Procedures Lights and Switches Operation Inspection First Step e Turn on the ignition switch e Thefollowing lights should go on according to below table License Plate Light C Neutral Indicator Light LED E Oil Pressure Water Temperature Warning Indicator Light LED F Fl Indicator Light LED G goes on about 2 seconds 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 Applicab
47. Brake Line Bleeding e 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 htio mototh com BRAKES 12 11 12 12 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 e Replace the fluid seal if it exhibits any of the conditions listed below OBrake fluid leakage around the pad OBrakes overheat OConsiderable difference in inner and outer pad wear OSeal and piston are stuck together x lf the fluid seal is
48. Clutch Lever Free Play 2 3 mm 0 08 0 12 in Engine Lubrication System Engine Oil Type API S SF or SG API SH SJ or SL with JASO MA Viscosity SAE 10W 40 Capacity RIE s US qt when filter is not remove 1 9 L 2 0 US at 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 6 5 mm 0 26 in 1 mm 0 04 in AT CH DE 1 6 mm 0 06 in Hear 9 0 mm 0 35 in Up to 130 km h 80 mph 2 mm 0 08 in Over 130 km h 80 mph 3 mm 0 12 in Air Pressure when Cold Front Up to 180 kg 397 Ib load 225 kPa 2 25 kgf cm 32 psi Rear Up to 180 kg 397 Ib load 250 kPa 2 50 kgf cm 36 psi htio mototh com 2 12 PERIODIC MAINTENANCE Specifications lem Standad Service Limit Final Drive Drive Chain Slack 30 40 mm 1 2 1 6 in Drive Chain Wear 20 link 317 5 318 2 mm 12 50 12 53 in Length otandard Chain Make ENUMA Type EK520MVXL1 Link 114 links Brakes Brake Fluid Grade Brake Pad Lining Thickness Front 4 5 mm 0 18 in 1 mm 0 04 in Hear 5 0 mm 0 20 in 1 mm 0 04 in Brake Light Timing Front Pulled ON Hear ON after about 10 mm 0 39 in of pedal travel Electrical System AT Austria CH Switzerland DE Germany htio mototh com PERIODIC MAINTENANCE 2 13 Special Tools Inside Circlip Pliers Extension Tube 57001 143
49. 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 e Refer to the Spark Plug Condition Inspection in the Peri odic Maintenance chapter hito mototh com ELECTRICAL SYSTEM 16 39 Ignition System Interlock Operation Inspection e 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 If the engine is start inspect the starter lockout switch neutral switch and relay box x If their parts are normality replace the ECU 2nd Check e Start the engine to the following conditions Condition Transmission Gear 1st Position Clutch Lever Pulled in Sidestand Up OTurn the ignition switch ON and push the starter button OThen the starter motor should turn when the starter sys tem circuit is normality If the starter motor is not turn inspect the starter lockout switch neut
50. Connecting Rod Transmission Shaft Installation 9 35 GICAAING PEDES 9 21 Transmission Shaft Disassembly 9 36 Connecting Rod Bend 9 21 Transmission Shaft Assembly 9 36 Connecting Rod Twist 9 22 Shift Drum and Fork Removal 9 39 Connecting Rod Big End Side Shift Drum and Fork Installation 9 39 GICAL AN CC nn 9 22 Shift Drum Disassembly 9 39 Connecting Rod Big End Bearing Shift Drum Assembly 9 39 Insert Crankpin Wear 9 22 Shift Fork Bending 9 39 Crankshaft Side Clearance 9 24 Shift Fork Gear Groove Wear 9 39 Crankshaft Runout 9 24 Shift Fork Guide Pin Drum Crankshaft Main Bearing Groove Wear esusss 9 40 Insert Journal Wear 9 24 Gear Dog and Gear Dog Hole Balanceo ito io 9 27 Damage intra 9 40 Balancer Remowval 9 27 Ball Bearing Needle Bearing and Oil Balancer Installation 9 27 lolo 9 41 Balancer Shaft Bearing Ball and Needle Bearing Insert Journal Clearance 9 27 Replacement 9 41 TranismlsSsSlObz ioi oucit ete ertet vends 9 29 Ball and Needle Bearing Wear 9 41 Shift Pedal Removal 9 29 Oil Seal Inspection 9 41 Shift Pedal Installation 9 29 htio mototh com 9 2 CRANKSHAFT TRANSMISSION Ex
51. E htio mototh com 6 6 CLUTCH Clutch Lever and Cable Clutch Lever Free Play Inspection e Refer to Clutch Operation Inspection in the Periodic Main tenance chapter Clutch Lever Free Play Adjustment e Refer to Clutch Operation Inspection in the Periodic Main tenance chapter Clutch Cable Removal e Remove the right frame cover see Frame Cover 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 e 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 0F04017851 C 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 Chassis Parts Lubrication in the Periodic Main tenance chapter htio mototh com Clutch Lever and 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 th
52. 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 Between upper and lower level lines Oil Pressure Measurement Oil Pressure 216 294 kPa 2 2 3 0 kgf cm 31 43 psi 4 000 r min rpm Oil Temperature 90 C 194 F hito mototh com ENGINE LUBRICATION SYSTEM 7 7 Special Tools and Sealant Oil Pressure Gauge 10 kgf cm Oil Filter Wrench 57001 164 57001 1249 5157016487 5157124981 Oil Pressure Gauge Adapter PT3 8 x 19 in Kawasaki Bond Silicone Sealant 57001 1233 56019 120 3157123331 51560120857 C htio mototh com 7 8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter A WARNING Motorcycle operation with insufficient deteri orated or contaminated engine oil will cause accelerated wear and may result in engine or trans mission seizure accident and injury Oil Level Inspection e Check that the engine oil level is between the upper A and lower B levels in the gauge NOTE OSituate the motorcycle so that it is perpendicular to the ground Olf the motorcycle has just been used wait several min utes for all the oil to drain down Olf the oil has just been changed start the engine and run it for several minutes at idle speed This fills the oil filter with oil Stop the engine then
53. 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 0c09064854 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 If it comes off reinstall the hose joint e Connect the fuel pump and the fuel level sensor connec tors and the battery cable terminal Fuel Tank and Cap Inspection e Visually inspect the gasket A on the tank cap for any damage Replace the gasket if it is damaged e Check to see if the water drain pipe B 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 C in the tank cap This could cause damage and clogging of the labyrinth in the cap hito mototh com Fuel Tank Fuel Tank Cleaning A WARNING C
54. Hose Routing 609 906 er aes k ME m mm m M s tr 060 EE E htio mototh com APPENDIX 17 5 Cable Wire and Hose Routing Relay 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 battery negative cable 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 00 Y DOOR WD htio mototh com 17 6 APPENDIX Cable Wire and Hose Routing GEDQBSMB htio mototh com APPENDIX 17 7 Cable Wire and Hose Routing 00 Y 0 01 E WN Inlet Pressure Sensor Turn Signal Relay Clamp Insert the clamp in the frame Horn Lead To the Water Temperature Sensor Oxygen Sensor Lead Connector Clamp Through the sidestand switch lead and oxygen sensor lead in the clamp Oxygen Sensor Lead Clamp Through the drain hose in th
55. 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 Model ECU Electronic Control Unit Sealed Battery Air Flow Fuel Flow Water Temperature Sensor htio mototh com FUEL SYSTEM DFI 3 9 3 10 FUEL SYSTEM DFI DFI System DFI System Wiring Diagram 00000 O 4900 m om md na nd omi m ond mm m m m n a m an bnon E ait E E EA TE LL LLLI le ARE EY ULT 4011 A 2 A D aen k Arne eT ee ee ee E E E a Co 1 1p og od p us EE A prat sie n FT TELE t EPET EI al iu TET LE ole TE ee a il ME E SS Fis DA Y AS ISS E NN II AS IS E E IS E o ae HA AA AAA A A DA m A AL des z A E LL IE e uillta re a A es DN HHI p WM I htio mototh com DFI System Part Name Oxygen Sensor Europe Model 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
56. OWhen there are a number of problems all the service codes can be stored and the display will begin starting from the lowest number service code in the numerical order Then after completing all codes the display is repeated until the self diagnosis indicator terminal is open Olf there is no problem no code and unlight OFor example if two problems occurred in the order of 21 12 the service codes are displayed from the lowest number in the order listed 12 21 gt 12 21 5 repeated Self Oisgenesis indicator terminal Grounded Open EN Is ith digit 0 5 6 5s 2 digit Fl Indicatar Light LED B6517353bHMI G 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 Fl 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 htio mototh com FUEL SYSTEM DFI 3 39 Self Diagnosis Service Code Table Service Code Table se FI Indicator LED Light Problems Code ON Main throttle sensor malfunction a gm OFF wiring open or short Inlet ai
57. Periodic Inspection FREQUENCY Whichever ODOMETER READING comes x 1 000 km x 1 000 mile See 12 18 24 a0 36 Page INSPECTION 0 6 7 5 12 15 20 24 fuer system 00000 LT Air Aircleanerelement clean element clean Air cleaner element clean e e e 246 Throttle control system play smooth return no cM EM inspect E fed fel fod pepe Engine vacuum synchronization inspect vacuum synchronization inspect 247 17 rs s pe e E Ts e Fuel leak fuel hose and pipe impe year e e e e eta Fuel and pipe Fuel hose and pipe damage inspect a year year e e e 214 Fuel hose and pipe installation condition pe A Cooling System System Coolant level inspect level Coolant level inspect e o j e o 2 1 249 ADOS n Radiator hose Radiator hose damage inspect inspect year e e o 2 20 Radiator hose installation condition year 2 20 inspect Air Air Suction System Air Suction System Ai suction system damage inspect e e 220 Engine Top End ee Valve clearance inspect Every 42 000 km 26 000 mile Clutch TI O Clutch operation play disengagement IES engagement inspect Wheels and Tires ft Tre air pressure inspect year Je ees Wheelire damage inspect e e 226 Tre vead wear aboomal weer ispest e e ea Wheel bearing damage i
58. Prakeurd Era ol TEET remsor Sensor tron Yehiche ad dryn Fual Sensor eae Wacar peacol Mir doant H Snitching E m Rm 77 73 PE E FARAH um oa ze 2 2 z E pin kn Ingactart OU insit ELECTRICAL SYSTEM 16 15 1k a d Prowaure Wales Inlet mth Oy ren b mperatura hir ss Erenirhall gensar Sansar Tamzarituca Sansar i inaner Raler 2rool kautral Mini F 5 iktzh T S n aic ow a LAS LIE E AAA EY zER BEEN E E ili n a ee DI EE EA EE mee Liluctran c Eonmtrol Bnil ECU Brrb6 DE 14d i TEO VE TE E ee e E HS dj Bn Y PHHAT PU Lisa op LIL ie 1h O Oe TO TES VE E tebe ST Hp dil b E E TE Y o o o f E d d 125 Tl lI HFF daa a uN I DH lH di pl y 1 E di TES 1 0 p DL IL t y 2 BE 1 o pf o 0g D IDpL t pd Cvd 1 Q P DP dg A t IP Ccvid PF 1d QOD Jl Wi BE p 1 NEN NENNEN g i Ty j UL ape a re a easso hf T E emp vide FE Tr ETE CMd dinh MI ERE ES I A KOBE E AN BENS Kod BH vo AS 1 Oe db AS 1L IIS db IO VS EA LI a II VS A LI A 144 1 x II VS EA LI A EL 144 4 5 jy NE II VA LLL Il D ee ee ee PE Bi h l 1 LL Ill Bier dor PS T uU ms CL Sd AAA En TE 1 141 Y Y bd 34 TE FA E po oS A43 4 p OOOO
59. 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 htio mototh com 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 B 0 E 6 WOW dy Inner Rotor C for Feed Pump Oil Pump Shaft D and Pin E Dowel Pin F Oil Pump Body G Pin H and Inner Rotor I for Scavenge Pump Outer Rotor J for Scavenge Pump Oil Pump Cover K OThe scavenge pump rotors are wider than the feed ES pump rotors ND Y A GOO9050RS2 E 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 hito mototh com 7 14 ENGINE LUBRICATION SYSTEM Oil Pressure Measurement Oil Pressure Measurement e Remove the lower fairing see Lower Fairing Removal in the Frame chapter e 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 x 19 in 57001 1233 e Start the engine and warm up the engine e Run the engine at the specified speed and read the oil pressure gauge x If the oi
60. Removal e Remove Seat see Seat Removal Bolts A Grab Rails B 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 and Bolts Torque Grab Rail Mounting Bolts 25 N m 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 htio mototh com 15 14 FRAME Fenders Front Fender Removal e Remove Brake Hose Clamps A Bolts B with Collar Both Side e Remove the front fender C Front Fender Installation e 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 and 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 M e Remove Nuts A and Bolts B Flap with License Plate Light e Remove oeat Lock Cable Lower End A Quick Rivet B e Free the clamps from the rear fender rear e Pull out the rear fender rear backward and downward
61. Remove the following from the oil pan as necessary Filter Plate Bolts A Filter Plate B Filter C e 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 hito mototh com 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 N m 1 5 kgf m 11 ft Ib e Apply grease to the O ring A on the oil screen B and install it on the lower crankcase 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 N m 1 2 kgf m 106 in Ib hito mototh com 1 oa Ey
62. SYSTEM 7 3 Exploded View Engine Oi Drane eo 20 15 HEN A Poire 372 317 19 rs oi Pan Bots 18 12 W6imb 6 TOi Pipe PeBe 10 in 6 ol Pressure Switch 1 15 t8 M S8 9 Ol Pump Cover Bots 1 98 10 erme L 714 oi Plate Bots 98 10 erm t O 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 Kawasaki Bond 56019 120 htio mototh com 7 4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart Inlet Camshaft 011 Passage Exhaust Camshaft y di a 0il Passage Oil Jet Crankshaft E Oil Passages 0il Filter Dil Pressure Switch Main Oil Passage Oi Screen Feeding Oil Flow Scavenge Pump lt Scavenging Oil Flow G3MOGIB 5 http mototh com ENGINE LUBRICATION SYSTEM 7 5 Engine Oil Flow Chart Balancer Shaft Drive Shaft Dil Pipe Oi Passage 0il Passage Crank Room Dutput Shaft Plate Oi Passage Oi Screen Oil Pipe Feed Pump scavenge Pump e tag fa o od od dw s ui M UR M OO Fd a c SS Oil in Transmission Room 011 from Crank Room SHIRE f htto mototh com 7 6 ENGINE LUBRICATION SYSTEM Specifications AI EA
63. TO PERIODIC MAINTENANCE 2 53 Periodic Maintenance Procedures Master Cylinder Rubber Parts Replacement Front Master Cylinder Disassembly e Remove the front master cylinder see Front Master Cylin der Removal in the Brakes chapter e Remove the reservoir cap and diaphragm and pour the brake fluid into a container e Unscrew the locknut and pivot bolt and remove the brake lever e Pull the dust cover A out of place and remove the circlip B 4513111851 Special Tool Inside Circlip Pliers 57001 143 e Pull out the piston C secondary cup D primary cup E and return spring F CAUTION Do not remove the secondary cup from the piston since removal will damage it Rear Master Cylinder Disassembly NOTE ODo not remove the push rod clevis for master cylinder disassembly since removal reguires brake position ad justment e 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 Master Cylinder Assembly e Before assembly clean all parts including the master cylinder with brake fluid or alcohol CAUTION Exc
64. Torque Shift Shaft Return Spring Pin 29 N m 2 9 kgf m 21 ft lb htio mototh com 9 32 CRANKSHAFT TRANSMISSION Transmission e Check the gear positioning lever A and its spring for breaks or distortion xlf the lever or spring are damaged in 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 e 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 be disassembed remove the following Shift Rod Plate Bolt B Shift Rod Plate C Gear Positioning Lever Bolt D Gear Positioning Lever E with Spring Washer and Spacer e Pull the transmission assy A out of the crankcase hito mototh com CRANKSHAFT TRANSMISSION 9 33 Transmission Transmission Assy Disassembly e Remove the transmission assy see Transmission Assy Removal e Remove the following from the transmission case A Shift Rods B Shift Forks C Drive Shaft D Output Shaft E e Remove Shift Drum Cam Bolt A Shift Drum B and Pin Shift Drum C Transmission Assy Assembly e When the new ball bearings A are installed in the trans mission case B press and i
65. a small hole B in the handlebar Torque Left Switch Housing Screws 3 5 N m 0 36 kgf m 31 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 N m 0 36 kgf m 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 htio mototh com STEERING 14 11 htio mototh com FRAME 15 1 Frame Table of Contents z do fojercie VIEW M cR NIE NE 15 2 vrl Rr M HT 15 8 Sod Bero doses aicut entes mee o CU eruit dS oe atte 15 8 Seattle rita 15 8 PAIRINGS T HH HT 15 9 Lower Faing RemoVal TTE DET 15 9 Lower Faning Instala A Ao 15 9 Center Falling Removal dora eR 15 9 Genter Fairing Instala ON titi 15 9 Upper Fainng Removal T TTE EDS Guo 15 10 Upper Faing ASTANA ON ini s 15 10 Upper Fanng Bracket REN e do e de 15 10 Aner Faring REMOVA euses TE 15 11 Inter Falta Instala anales 15 11 Se COVES ax 15 12 A A A 15 12 Side Cover Installation iseni i a e ei 15 12 A E T 15 13 Sea COVE REMOVA cessa eode Su gra Pub E EEEE EEA TE SE IAEA pRRR DE 15 13 Seal Cover Installation a 15 13 melt tus a 15 14 Front Fender TemoValsassscceneen eiat cda 15 14 Front tend
66. are at TDC OThe pistons are numbered beginning with the engine left side e 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 1 T Mark A 2 T Mark B Hole C of Upper Cap Notch D in Edge of Upper Hole 0507071851 C OMeasure the valve clearance of the valves for which the cam 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 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 hito mototh com 2 22 PERIODIC MAINTENANCE 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 If the valve clearance is not wit
67. auxiliary lead E to the self diagnosis terminal G for grounding e To enter the self diagnosis dealer mode 1 ground A the self diagnosis indicator terminal to the battery terminal for more than 2 seconds C and then keep it grounded continuously D OCount the blinks of the light LED to read the service code Keep the auxiliary lead ground until you finish read ing the service code htio mototh com FUEL SYSTEM DFI 3 35 06170271651 C 0617071851 E 3 36 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 O To enter the dealer mode 2 from the dealer mode 1 turn off the ignition switch once Service Code Clearing Procedures Service Code Clearing Procedures eEnter the self diagnosis dealer mode 2 see Self diagnosis Procedures in this chapter NOTE OMake sure to keep the grounding until the following opening and grounding starts e Pull the clutch lever in more than 5 seconds and then release it e Repeat opening B and grounding A the lead self diagnosis terminal more than five times
68. braking power no brake drag and no fluid leakage htio mototh com HLOSOUZSHS2 E OO YH T Brake Fluid WARNING When working with the disc brake observe the pre cautions listed below 1 2 3 Never reuse old brake fluid Do not use fluid from a 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 that no disc brake fluid or any oil gets on them Clean off any fluid or oil that inadvertently gets on the pads or disc with a high flash point solvent Do not use one which will leave an oily residue Replace the pads with new ones if
69. coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action Air however is easily compressed When air enters the brake lines brake lever or pedal movement will be partially used in compressing the air This will make the lever or pedal feel spongy and there will be a loss in braking power A WARNING Be sure to bleed the air from the brake line when ever brake lever or pedal action feels soft or spongy after the brake fluid is changed or when ever a brake line fitting has been loosened for any reason NOTE O The procedure to bleed the front brake line is as follows Bleeding the rear brake line is the same as for the front brake e 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 end of the hose into a container htio mototh com BRAKES 12 19 12 20 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 Pu
70. com Rear Brake Pad Removal Hear 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 iia Rear Master Cylinder Disassembly sso ia err egeris ets Master Cylinder Assembly Master Cylinder Inspection A Eoo e PERSE RU n HUS Brake Disc Removal Brake Disc Installation Brake Disc Wear Brake Disc Warp Brake Fluid esee Brake Fluid Level Inspection Brake Fluid Change Brake Line Bleeding Brake Hose ese Brake Hose Removal Installation Brake Hose Inspection 12 16 12 16 12 16 12 16 1247 12 18 12 18 12 18 12 18 12 18 12 19 12 19 12 19 12 19 12 22 12 22 12 22 128 12 2 BRAKES Exploded View HL B82153H85 G htio mototh com BRAKES 12 3 Exploded View ri BedWe oo iN 2 Brake Hose Banjo Bots 25 25 18 4 Brake Lever Pivot Bolt Locknut 58 060 S2imb 6 Front Brake Light Switch Screw 10 010 omb 7 Front Brake Reservoir Cap Screws 10 040 omb 8 Front Caliper Mountin
71. e Install the brush plate assy to the yoke e Clamp the springs A with the clips B e Fit the armature C to the brush plate assy D e Remove the clips e Install the new O ring A as shown e Install Washers B and Terminal Locknut C e Tighten Torque Starter Motor Terminal Locknut 11 N m 1 1 kgf m 97 in Ib hito mototh com HP110T2H51 Electric Starter System 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 If 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 e Measure the diameter A of the commutator B If the commutator diameter is less than the service limit replace the starter motor with a new one Commwutator Diameter Standard 28 mm 1 10 in Service Limit 27 mm 1 06 in Armature Inspection e Using the x 1 O 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
72. e Turn the ignition switch OFF e Remove the needle adapter set and apply silicone sealant to the seals of the connector for waterproofing Silicone Sealant Kawasaki Bond 56019 120 Seals of Vehicle down Sensor Connector xlf the output voltage is normal the wiring is suspect Check the wiring x lf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the output voltage is out of the specified replace the vehicle down sensor htio mototh com daciTi1l3B52 E FUEL SYSTEM DFI 3 59 Vehicle down Sensor Service Code 31 Vehicle down Sensor Circuit QG179T78HW2 E 1 ECU 2 Water proof Joint E 3 Vehicle down Sensor 4 Water proof Joint D htio mototh com 3 60 FUEL SYSTEM DFI Subthrottle Sensor Service Code 32 Subthrottle Sensor Removal Adjustment CAUTION Do not remove or adjust the subthrottle sensor A since it has been adjusted and set with precision at the factory Never drop the sensor especially on a hard surface Such a shock to the sensor can damage it Subthrottle Sensor Input Voltage Inspection NOTE OBe sure the battery is fully charged e Remove the fuel tank see Fuel Tank 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
73. engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts Exhaust System ER650A6F MANIFOLD SILENCER ITEM NAME ORG PRODUCT Honeycomb Type Catalyst with Oxygen Sensor WVTA FULL A ER650A65 GB WVTA FULL H ER650A6S PiNo 18691 0284 Mark KHI K 492 Non Catalyst dr MAR Honeycomb Type P No 39178 0058 Catalyst without Oxygen Sensor l Australia ERGSOAGF P No 18091 0285 Mark KHI K 492 Honeycomb Type Catalyst without Oxygen Sensor Malaysia ERGSOASF P No 18091 0270 Mark KHI K 499 GEIR F Full Full Power H Honeycomb Type Catalyst GB United Kingdom Model hito mototh com 5 6 ENGINE TOP END Exploded View Silencer C with Hole A for Oxygen Sensor B 002208851 C htio mototh com ENGINE TOP END 5 7 Specifications tem Standard Camshafts Cam Height Exhaust 35 843 35 957 mm 1 4111 1 4156 in 35 74 mm 1 4071 in 36 543 36 657 mm 1 4387 1 4432 Inlet in 36 44 mm 1 4346 in Camshaft Journal Camshaft 0 028 0 071 mm 0 0011 0 0028 in 0 16 mm 0 0063 in Cap Clearance 23 950 23 972 mm 0 9429 0 9438 23 92 mm 0 942 in in Camshaft Bearing Inside 24 000 24 021 mm 0 9449 0 9457 24 08 mm 0 948 in Diameter in Camshaft Runout TIR 0 02 mm 0 0008 in or less TIR 0 1 mm 0 004 in Cylinder Head Camshaft Journal Diameter Usable Range Cylinder Compression 961 1 471 kPa 9
74. flicker at regular intervals the injector circuit in the ECU and the wiring are good Perform the Injector Resistance Inspection Olnjector signals can be also confirmed by connecting the hand tester x 10 V AC instead of the test light set to the injector main harness female connector Crank the engine with the starter motor and check to see if the hand oscillates at regular intervals Special Tool 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 W R lt gt BL R Terminal 2 W R BL G Terminal Standard about 11 7 12 3 O 20 C 68 F Alf the reading is out of the range perform the Injector Unit Test x If the reading is normal perform the Injector Unit Test for confirmation hito mototh com 617024351 FUEL SYSTEM DFI 3 91 Fuel Injectors Injector Unit Test e
75. hand or fingers OPull out the pistons by hand e Remove the dust seals A and fluid seals B e Remove the bleed valve C and rubber cap D NOTE 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 fluid isopropyl alcohol or ethyl alcohol e Install the bleed valve and rubber cap Torque Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib hito mototh com oL05047851 E PERIODIC MAINTENANCE 2 55 Periodic Maintenance Procedures 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 aL05b40231 E 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 Ins
76. 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 hito mototh com htio mototh com CRANKSHAFT TRANSMISSION 9 1 Crankshaft Transmission Table of Contents Exploded View 9 2 External Shift Mechanism SPECIICALIONS iii 9 6 REMOVA ini 9 29 Special Tools and Sealant 9 9 External Shift Mechanism Crankcase Splitting 9 10 Stallone 9 30 Crankcase Splitting 9 10 External Shift Mechanism Crankcase Assembly 9 11 MSPECION me TRENT 9 31 Crankshaft and Connecting Rods 9 17 Transmission Assy Removal 9 32 Crankshaft Removal 9 17 Transmission Assy Disassembly 9 33 Crankshaft Installation 9 17 Transmission Assy Assembly 9 33 Connecting Rod Removal 9 17 Transmission Assy Installation 9 34 Connecting Rod Installation 9 18 Transmission Shaft Removal 9 35 Crankshaft
77. in the reserve tank A with the motorcycle held perpendicular Do not use the sidestand If the coolant level is lower than the L level line B re move the right center fairing see Center Fairing Removal in the Frame chapter and unscrew the reserve tank cap and add coolant to the F level line C L low P 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 htio mototh com 2 20 PERIODIC MAINTENANCE Periodic Maintenance Procedures Radiator Hose and Pipe Inspection coolant leak damage installation condition OThe high pressure inside the radiator hose and pipe can cause coolant to leak A or the hose to burst if the line is not properly maintained e Visually inspect the hoses for signs of deterioration Squeeze the hoses A hose should not be hard and brittle nor should it be soft or swollen x Replac
78. insert the hose smoothly OPut the hose through the fill opening C into the tank and draw the fuel out Front D A WARNING The fuel could not be removed completely from the fuel tank Be careful for remained fuel spillage e Remove Left Side Cover see Side Cover Removal in the Frame chapter e Disconnect the fuel pump lead connector A and the tube B htio mototh com dacnao33851 E Fuel Tank 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 Clon 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 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 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 e Check that the rubber dampers A are on the frame and the fuel tank e Check that the dampers A are in place on the fuel tank as well x lf the dampers are damaged or deteriorated replace them hito mototh com FUEL SYSTEM DFI 3 101 3 102
79. 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 x Indicates a conditional step or what action to take based on the results of the test or inspec tion in the procedural step or sub step it fol lows In most chapters an exploded view illustration of the system components follows the Table of Contents In these illustrations you will find the instructions indicating which parts require spec ified tightening torque oil grease or a locking agent during assembly hito mototh com GENERAL INFORMATION 1 1 General Information Table of Contents BCIE SEIVICIN O NE TEE 1 2 Model ACACIA ea rad et 1 7 General Specill cations ia AA 1 8 Technical Information Cassette Type Transmission oocccnccccccnccononnnnnnnnncnnnnnnnnnnnononcnnnnnnnnons 1 11 Technical Information Inlet Air Pressure Sensor occcccccncccnccccccnncononnnnnnnoncnnnnnnannnnnnnnronnnonaness 1 12 UASD Mm 1 13 htio mototh com 1 2 GENERAL INFORMATION B
80. manufacturer of the repair tools and materials so that safe results can be obtained hito mototh com WHEELS TIRES 10 15 Fs daJn55042851 E 10 16 WHEELS TIRES Hub Bearing Hub Bearing Removal e 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 x 22 B 57001 1293 Bearing Remover Shaft 13 C 57001 1377 Hub Bearing Installation e Before installing the hub bearings blow any dirt or foreign particles out of the hub with compressed air to prevent contamination of the bearings e Replace the bearings with new ones NOTE Olnstall the bearings so that the marked side faces out e Install the bearings by 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 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 Ins
81. mark D faces up hito mototh com ENGINE TOP END 5 33 amp SIK25 0H551 E daE18058B851 E 0E165040051 E 8 D HE18102H51 5 34 ENGINE TOP END Cylinder Pistons NOTE Olf a new piston is used use new piston ring e Install the piston with its marking hollow facing forward e Fit a new piston pin snap ring into the side of the piston so that the ring opening A does not coincide with the slit B of the piston pin hole OApply molybdenum disulfide oil solution to the piston pins and piston journals OWhen installing the piston pin snap ring 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 lf 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 direct
82. muffler body clamp bolt H as shown gGE180243HW2 E e Thoroughly warm up the engine wait until the engine cools down and retighten all the bolts and nuts htio mototh com htio mototh com CLUTCH 6 1 Clutch Table of Contents EXPO iio 6 2 S HU A 6 4 Special TOOl ana Seal dada Clutch Lever and Cable A Clutch Lever Free Play InSpectiON occcccccccncnncccoccncononnnncononncononnnnnononnonnnnnonannnnnnnanennnss Glutch Lever Free Play Adjustment iier e a P CAR pase bie eie tte Pup IDE Reads gcn esI ROSHIOVE aider vans brd A iu A Lp UL LSU Cl tclioableinsrallallOhs umen tecetccatniqu cette ac ds Clutch Gables BWledezio mm lS Clutch ever installation a oe Lead erred ael IR Essen TM 6 7 GUCE COV T cR 6 8 clutch Cover ni ZU UTEM 6 8 Clutch Gover InStallatiOD sed erac to entstehen i onn Hon el ol em estetico bas 6 8 Release onat nie ODE LENTES 6 9 Release SnartdbstallatlOll da 6 9 Clutch Cover DisassSemDIy messan A dd 6 9 Clutch COVE ASSEDI Y apoeni a E a E N 6 10 eiie pu E ELE M TERRE 6 11 Gli Re MOV TETTE 6 11 lc ON e e ll O 6 11 Clutch Plate Wear Damage Inspection occcccoccccccocnncccocnnononnnoconnnnnnnnnnononnnnnnnnononaneninnns 6 13 Clutch Plate Warp InspecHOFiou sepu epi a date ebbe Ee aeos teat ai DEDE ideo cies Sa eade 6 13 Clutch Spring Free Length Measurement occcccnccncccncnnccnccncnnncnnnnnncnnonannnononnnonnncnnonanennnnos 6 14 Clutch HOUSING Finger Inspeccion dod ues ei ete b
83. oe etu ad 11 10 Engine SDrocker InstalatO Mii odas es 11 11 Rear oprocKel REMO Alerta ui dis Rear obprocker IMSLAN My A ie tierra tin as tan three Coupling Instalaciones Coupling Bearing Removal Coupling Bearing InstallatlObi suscita 11 12 Goupling Bearing InsSpDecHOri a 11 13 Coupling Bearing LUDICO iras ais 11 13 Coupling Damper Inspeccion ii 11 13 SDrOCKEL Weal A EI resina 11 13 Rear Sprocket Warp Inspection oocccococcncococonococonocononononcnnononcnnononononannnononnnnonaronennnnons 11 14 htio mototh com 11 2 FINAL DRIVE Exploded View htio mototh com FINAL DRIVE 11 3 Exploded View 2 Rear Ade Nut os M0 8 3 RerSpoketNus s 80 44 5 Speed Sensor Bracket Bois 98 10 87mb G Apply grease HG Apply high temperature grease HO Apply heavy oil L Apply a non permanent locking agent MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts htio mototh com 11 4 FINAL DRIVE Specifications lea Standard Drive Chain Drive Chain Slack 30 40 mm 1 2 1 6 in T 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 E eet Link 114 links AA Sprockets Rear Sprocket Warp 0 4 mm 0 016 in or less 0 5 mm 0 020 in htio mototh com FINAL DRIVE 11 5 Special T
84. 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 em F htio mototh com FUEL SYSTEM DFI 3 85 Fuel Pump e Replace the fuel pump gasket A with a new one 06100458514 C 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 N m 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 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 hito mototh com 3 86 FUEL SYSTEM DFI Fuel Pump e Connec
85. 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 htio mototh com 3 42 FUEL SYSTEM DFI Main Throttle Sensor Service Code 11 Main Throttle Sensor Removal Adjustment CAUTION Do not remove or adjust the main throttle sensor A since it has been adjusted and set with precision at the factory Never drop the sensor especially on a hard surface Such a shock to the sensor can damage it Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF 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 xlf 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 conneciors Wiring Connection ECU Connector A Throttle Se
86. optimum performance NOTE OCharging the battery immediately after filling can shorten service life Let the battery sit for at least 30 minutes after filling htio mototh com aPnBOdgnBS 1 E GPOROODES E ELECTRICAL SYSTEM 16 21 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 lll Yuasa 1 5 Amp Automatic Charger Battery Mate 150 9 xlf the above chargers are not available use equivalent one oP025015851 E 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 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 oP025012851 E oP025010851 E NOTE O To ensure maximum battery life and customer satisfac ti
87. 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 B are not cracked worn swollen or otherwise damaged x If they show any damage replace it htio mototh com 05171047851 E 0L05047851 E oL050480851 E Calipers Caliper Piston and Cylinder Damage e Visually inspect the pistons A and cylinder surfaces B Replace the caliper if the cylinder and piston are badly scores or rusty Rear Caliper Holder Shaft Wear The caliper body must slide smoothly on the caliper holder shafts A If the body does not slide smoothly one pad will wear more than the other pad wear will increase and con stant drag on the disc will raise brake and brake fluid tem perature e Check to see that the caliper holder shafts are not badly worn or stepped and that the rubber friction boots are not damaged xf the rubber friction boot is damaged replace the rubber friction boot To replace the friction boot remove the pads and the caliper bracket If the caliper holder shaft is damage replace the caliper bracket hito mototh com BRAKES 12 13 0L05117851 aL05100851 E oL0510 1851 E 12 14 BRAKES Brake Pads Front Brake Pad Removal e Remove the front caliper with the hose installed see Front Caliper Removal e Draw out the holder shaft pin A and
88. right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously See your Motorcycle dealer for the latest information on product improvements incorporated after this publication All information contained in this publication is based on the latest product information available at the time of publication Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts 2005 Kawasaki Heavy Industries Ltd First Edition 1 Aug 5 2005 K htio mototh com LIST OF ABBREVIATIONS ampere s pound s after bottom dead center meter s alternating current i minute s after top dead center newton s before bottom dead center pascal s bottom dead center horsepower before top dead center pound s per square inch degree s Celsius revolution direct current revolution s per minute farad s top dead center degree s Fahrenheit total indicator reading foot feet volt s gram s watt s hour s ohm s liter s Read OWNER S MANUAL before operating htio mototh com 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 us
89. rim flanges x lf 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 visible from external inspection of the tire For these reasons Kawasaki does not recommend temporary exter nal repair Only appropriate permanent internal repairs are recommended Repair methods may vary slightly from make to make Follow the repair methods indicated by the
90. 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 x If the engine stop switch is good condition replace the ECU see ECU Removal Installation in the Fuel System DFI chapter Bil P htio mototh com PERIODIC MAINTENANCE 2 43 Periodic Maintenance Procedures Others Chassis Parts Lubrication e Before lubricating each part clean off any rusty spots with rust remover and wipe off any grease oil dirt or grime e Lubricate the points listed below with indicated lubricant NOTE OWhenever the vehicle has been operated under wet or rainy conditions or especially after using a high pressure water spray perform the general lubri cation Pivots Lubricate with Grease Brake Lever Brake Pedal Clutch Lever Rear Brake Joint Pin Sidestand Points Lubricate with Grease Clutch Inner Cable Upper and Lower Ends A Throttle Inner Cable Upper and Lower Ends Cables Lubricate with Rust Inhibitor Clutch Cable Throttle Cables e Lubricate the cables by seeping the oil between the cable and housing OThe cable may be lubricated by using a commercially available pressure cable lubricator with an aerosol cable lubricant 06045011451 E e With the cable disconnected at both ends the inner cable should move freely A w
91. should be from zero to one half the scale Tester Connection htio mototh com ELECTRICAL SYSTEM 16 73 Relay Box Relay Box Internal Circuit IMM dAd 19 1900 PM gP19018HW2 E A Headlight Relay B ECU Main Relay C Fuel Pump Relay D Starter Circuit Relay E Fan Relay htio mototh com 16 74 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 Hemoval 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 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 hito mototh com ELECTRICAL SYSTEM 16 75 Fuse Fuse Installation e l 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 x If it is blown out replace the fuse Before replacing a blown fuse alwa
92. so sf eo es sol ssl sol osl sol os oof sl iof asf zoj zs sol 35 ol as so Mess mi 2 s0l 2 5s 2 60 2 85 z o 2 78 2 got 2 esl 2 90 2 95 3 00 3 05 3 10 3 rs 3 20l 3 25 3 30l a as 3 401 3 45 3 50 lo 0 08 2 50 2 55 2 60 2 65 2 70 2 75 2 80 2 85 2 00 2 95 3 00 3 05 3 30 2 15 3 20 2 25 2 30 o o3 oor 2 50 2 55 2 60 2 65 2 20 2 751 2 sol 2 95 2 90 2 05 3 001 8 05 3 201 3 15 3 20 3 25 3 30 3 35 bos 0 3 2 50 2 5s 2 60 2 65 2 70 2 76 2 80 2 as 2 00 2 86 3 00 3 051 3 tol 3 asl 3 20 3 25 3 30 9 35 3 40 i o 2 sol 2 55 2 60 2 65 2 70 2 75 2 90 2 asl 2 9ol 2 95 3 00 8 05 3 10 3 151 3 20 3 25 3 90 9 95 3 40 3 45 SPECIFIED CLEARANCE MO CHANGE REQUIRED 925 007 iz ss z eo 26s 2 70 2 75 2 80 2 85 2 90 2 95 2 00 3 05 3 10 3 15 3 20 5 25 3 30 a as a 40 3 48 3 sof 5 0 28 0 32 z eo 2 65 2 70 2 76 2 00 2 86 2 sol 2 95 3 00 3 05 a 10 3 15 3 20 3 25 9 30 3 35 a dol 3 454 3 60 9 83 0 31 2 65 2 70 2 751 2 80 2 95 2 00 2 95 3 00 2 05 3 10 9 15 3 20 3 25 3 30 3 351 9 40 3 45 3 50 38 0 42 2 20 2 15 2 80 2 85 2 90 2 95 3 09 3 05 3 10 3 15 3 20 3 25 3 30 3 35 3 40 3 45 3 sol 43 0 47 2 75 2 80 2 85 2 00 2 95 3 00 2 05 5 10 a isl 3 20 3 26 2 sol 2 35 3 4ol 3 45 3 50 0 48 0 82 2 85 2 90 z es 3 00 3 05 3 101 3 25 3 20 3 25 3 30 3
93. subthrottle valve by the 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 1 Ignition Coil 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 Stick Coil 2 Ignition Coil Valve Actuator O 1 open the ECU stops the current to the ae 9 actuator The oxygen sensor heater raise Oxygen Sensor temperature of the Europe Model sensor for its earlier activation 12V 6 6W 0 55A The oxygen sensor must send signals output voltage continuously to the EUC If the oxygen sensor heater fails wiring short or open the ECU stops the current to the heater Oxygen Sensor Europe Model If the oxygen sensor output voltage is incorrect the ECU stops oxygen sensor feed back mode Note 1 D J Method and a N Method When the engine load is light like at idling or low speed the ECU determines the injection quantity by calculating from the throttle vacuum inlet air pressure sensor output voltage and engine speed crankshaft sensor output voltage This method is called D J method low speed mode As the engine speed increases and the engine load turns middle to heavy the ECU determines the injection quantity by calculating from the throttle
94. 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 0E17014851 0E17015851 htio mototh com 5 38 ENGINE TOP END Muffler A WARNING To avoid a serious burn do not remove the muffler when the engine is still hot Wait until the muffler cool down Muffler Body Removal e Remove Right Frame Cover see Frame Cover Removal in the Frame chapter e Remove the bolts and lift up the right footpeg stay A e Remove the muffler body mounting bolts A and nut and pull the muffler body B backward Exhaust Pipe Removal e Remove Lower Fairing see Lower Fairing Removal in the Frame chapter Center Fairing see Center Fairing Removal in the Frame chapter Muffler Body Clamp Bolt A Exhaust Pipe Manifold Holder Nuts B Exhaust Pipe C Gaskets hito mototh com ENGINE TOP END 5 39 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 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 e Tighten the muffler body clamp bolts H Olnstall the
95. 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 the radiator and the water jacket expands The excess coolant flows through the radiator cap and hose to the reserve tank to be stored there temporarily Conversely as the engine cools down the coolant in the radiator and the water jacket contracts and the stored coolant flows back to the radiator from the reserve tank The radiator cap has two valves One is a pressure valve which holds the pressure in the system when the engine is running When the pressure exceeds 112 3 141 7 kPa 1 15 1 45 kgf cm 16 3 20 5 psi the pressure valve ope
96. 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 x If the reading is 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 If 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 opeed Sensor Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch OFF htio mototh com FUEL SYSTEM DFI 3 55 06171518851 E 3 56 FUEL SYSTEM DFI Speed Sensor Service Code 24 25 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 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 BK sensor BK Y lead D Standard About 0 05 0 07 V DC NOTE Olf you
97. 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 PI Local Atmospheric Pressure absolute measured by a barometer Pv Vacuum Pressure absolute to Sensor Vv Sensor Output Voltage v htio mototh com FUEL SYSTEM DFI 3 47 Inlet Air Pressure Sensor Service Code 12 then Pv Pl 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 Ne La e AL gt Pv 251764493 C hito mototh com 3 48 FUEL SYSTEM DFI Inlet Air Pressure Sensor Service Code 12 Pv 55 86 cmHg 361764503 C Vv Inlet Air Pressure Sensor Output Voltage V Digital Meter Reading Pv Throttle Vacuum Pressure Absolute Ps Standard Atmospheric Pressure Absolute ID Idling TO Throttle Full Open ST Standard of Sensor Output Voltage v UR Usable Range of Sensor Output Voltage v hito mototh com FUEL SYSTEM
98. the thermostat with a new one htio mototh com Thermostat e To check valve opening temperature suspend the ther mostat A in a container of water and raise the tempera ture of the water OThe thermostat must be completely submerged and must not touch the container sides or bottom Suspend an ac curate thermometer B in the water so that the heat sen sitive portions C are located in almost the same depth lt must not touch the container either xf 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 htio mototh com COOLING SYSTEM 4 17 apu aaQ20252 E 4 18 COOLING SYSTEM Hose and Pipes Hose Installation e Install the hoses and pipes being careful to follow bend IES ASS ing direction Avoid sharp bending kinking flattening or twisting e Run the hoses see Cable Wire and Hose Routing sec tion in the Appendix chapter e Install the clamp A as near as possible to the hose end to clear the raised rib of the fitting This will prevent the hoses from working loose OThe clamp screws should be positioned correctly to pre ieee vent the clamps from contacting the other parts Torque Radiator Hose Clamp Screws 2 0 N m 0 20 kgf m 17 in Ib Hose Inspection e Refer to Cooling Hose and Connection Inspection in the Periodic Maintenance chapter hito mototh com Water Temperature Se
99. valve holder for grooves scratches any signs of separation from the holder or heat damage e f there is any doubt as to the condition of the reed contact areas replace the air suction valve as an assembly e lf 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 Vacuum Switch Valve B im yer 00 41 0d i hc S E htio mototh com 5 12 ENGINE TOP END Clean Air System Air Switching Valve Installation e Install the vacuum switch valve so that the vacuum fitting A faces left side e Route the hoses correctly see Cable Wire and Hose Routing section in the Appendix chapter Air Switching Valve Operation Test e Refer to Air Switching Valve Operation Test in the Electri cal System chapter Air Switching Valve Unit Test e Refer to Air Switching Valve Unit Test in the Electrical Sys tem 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
100. with the inside diameter e Tighten the connecting rod big end nuts to the specified torque see Connecting Rod Installation NOTE O The 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 e 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 92139 0116 Black 92139 0115 e Install the new inserts in the connecting rod and check insert crankpin clearance with the plastigage hito mototh com 0105119851 C 0105040151 E al b5541751 E 9 24 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods Crankshaft Side Clearance e Insert a thickness 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 0
101. 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 Troubleshooting Guide Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head warped Cylinder head gasket damaged Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Other IC igniter in ECU trouble Throttle body assy not synchronizing Engine oil viscosity too high Drive train trouble Brake dragging Air suction valve trouble Air switching valve trouble Engine overheating Clutch slipping Poor Running or No Power at High Speed Firing incorrect Spark plug dirty broken or maladjusted Stick coil wiring trouble Stick coil not in good contact Spark plug incorrect Camshaf
102. x f 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 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 wiring is good check the sensor resistance e Remove the needle adapter set and apply silicone sealant to the seals of the connector for waterproofing Silicone Sealant Kawasaki Bond 56019 120 Seals of ECU Connectors htio mototh com FUEL SYSTEM DFI 3 51 Inlet Air Temperature Sensor Service Code 13 Sensor Resistance Inspection e Remove the inlet air temperature sensor e Suspend the sensor A in a container of machine oil so that the heat sensitive portion is submerged 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 KQ at 0 C 68 F 0 29 0 39 KQ at 80 C 176 F x If the measurement is out of the range replace the sensor 601710285 x If th
103. x If 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 replace the oxygen sensor Oxygen Sensor Circuit BCTTSEGRR E 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 OONDAORWD hito mototh com FUEL SYSTEM DFI 3 65 Stick Coils 1 2 Service Code 51 52 Stick Coil 1 Ignition Coil Service Code 51 Stick Coil 2 Ignition Coil 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 Ignition System section in the Electrical Sys tem chapter Stick Coil Inout 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 lead terminal 43 Meter BK Y lead terminal 51 Connections for Stick Coil 2 Meter BK G lead terminal 52
104. 008 0 0032 in Service Limit Exhaust 0 27 mm 0 0106 in Inlet 0 22 mm 0 0087 in hito mototh com daE15045B51 E 0E15007B32 E ENGINE TOP END 5 27 Valves Valve Seat Inspection e Remove the valve see Valve Removal e Check the valve seating surface A between the valve B and valve seat C OMeasure the outside diameter D of the seating pattern on the valve seat xf the outside diameter is too large or too small repair the seat see Valve Seat Repair Valve Seating Surface Outside Diameter Standard Exhaust 27 6 27 8 mm 1 087 1 094 in 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 If the width is too wide G too narrow H or uneven J repair the seat see Valve Seat Repair Valve Seating Surface Width 0E15011752 Standard Exhaust 0 5 1 0 mm 0 020 0 039 in Inlet 0 5 1 0 mm 0 020 0 039 in Valve Seat Repair e Repair the valve seat with the valve seat cutters A Special Tools Valve Seat Cutter Holder Bar 57001 1128 C Valve Seat Cutter Holder 54 5 57001 1330 B 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 QE1504BBS1 C Valve Seat Cutter 45 535 57001 1116 Valve Seat Cutter 32 535
105. 050508854 e Remove the bypass screw A spring B washer C and O ring D OCheck the bypass screw and its hole for carbon deposits x If any carbon accumulates wipe the carbon off the bypass screw and the hole using a cotton pad penetrated with a high flash point solvent OReplace the O ring with a new one OCheck the tapered portion E of the bypass screw for wear or damage x If the bypass screw is worn or damaged replace it e Turn in the bypass screw until it seats fully but not tightly 0505015851 E htio mototh com PERIODIC MAINTENANCE 2 19 Periodic Maintenance Procedures e Repeat the same procedure for other bypass screws e Repeat the synchronization If 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 xf 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 Cooling System Coolant Level Inspection NOTE OCheck the level when the engine is cold room or ambi ent temperature e Check the coolant level
106. 079 in Service Limit 0 40 mm 0 0157 in Crankshaft Runout e Measure the crankshaft runout x If the measurement exceeds the service limit replace the crankshaft Crankshaft Runout Standard TIR 0 02 mm 0 0008 in or less Service Limit TIR 0 05 mm 0 0020 in Crankshaft Main Bearing Insert Journal Wear e Using a plastigage press gauge A measure the bear ing insert journal B clearance NOTE O Tighten 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 00268 in x f 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 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 htio mototh com 0105015851 E 01051408514 1050 44 5
107. 1 Alternator Output Voltage Tester Reading Range Tester to Tester to at 4 000 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 Tester Connections Heading Range Tester to Tester to One Black lead Another Black lead 0 18 0 27 Q hito mototh com Charging System xf 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 x Any hand tester reading less than infinity indicates a short necessitating stator replacement xf 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
108. 1 E PERIODIC MAINTENANCE 2 47 Periodic Maintenance Procedures 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 If it comes off reinstall the hose joint e Run the fuel hose correctly see Cable Wire and Hose Routing section in the Appendix chapter e Install the removed parts see appropriate chapters e Start the engine and check the fuel hose for leaks Coolant Change A 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 see Center Fairing Removal in the Frame chapter Lower Fairing see Lower Fairing Removal in the Frame chapter e Remove Reserve Tank Bolts A Reserve Tank B hito mototh com 2 48 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Put A the project
109. 1 and 2 throttle body holders and air suction valve covers xlf they are not correct them Replace them if they are damaged hito mototh com ENGINE TOP END 5 13 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 in the Fuel System DFI chapter Air Suction Valve Cover A with Hose B Stick Coils C Baffle Plate Cylinder Head Cover Bolts D Cylinder Head Cover E 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 Cylinder 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 e Install the baffle plate A OPut the insulators B under the baffle plate and the wash ers C on the baffle plate OApply a non permanent locking agent to the baffle plate bolts and torque them Torque Baffle Plate Bolts 5 9 N m 0 60 kgf m 52 in Ib 0E09040854 htto mototh com 5 14 ENGINE TOP END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION This is a non return type camshaft chain tensioner The push rod does not return to its original p
110. 17 23 Cable Wire and Hose Routing 1 Clamp Insert the clamp in the front fender 2 Brake Hose 3 Clamp htio mototh com 17 24 APPENDIX Cable Wire and Hose Routing Q 7 T6 p oo Pp N j EN Aus a ET ki H y N e ADAC mi i y X275 S ff 3 Se A PU RE GS 75 We Jf e htio mototh com APPENDIX 17 25 Cable Wire and Hose Routing 1 Brake Hose 2 Clamp 3 Clamp htio mototh com 17 26 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 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 Stick coil shorted or not in good contact Stick coil trouble Spark plug incorrect IC igniter in ECU trouble Neutral starter lockout or side stand switch trouble Crankshaft sensor trouble Engine Doesn t Start Starting Ignition switch or engine stop switch Difficulty Starter motor not rotating recen m Starter lockout switch or neutral switch trou Ing SMOG or ope Fuse blown ble otarter 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 bl
111. 35 3 40 3 451 3 50 0 53 0 57 2 90 2 96 3 00 s 05 s 10 s 15 3 20 3 25 s 30 3 35 3 40 3 45 3 sol 0 58 0 62 12 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 9 63 0 67 3 00 3 05 3 10 3 15 3 20 3 25 3 30 3 35 s 40 3 45 3 50 oo 3 05 3 10 a 15 3 20 3 261 3 30 3 35 3 40 9 45 3 sol om 0 68 0 72 VALVE CLEARANCE MEASUREMENT ma o Esonpla a w e r ga ad Lo we fal T un Lh 3 Gt 73 0 17 3 10 3 18 220 3 28 3 20 3 35 3 40 3 45 3 50 0 78 0 82 3 15 320 3 25 3 30 9 36 3 40 3 45 3 50 0 83 0 87 3 20 3 25 3 30 3 35 3 40 3 45 3 50 0 88 0 92 3 25 3 301 3 35 3 401 3 45 3 50 INSTALL THE SHIM OF THIS THICKNESS m 0 93 0 97 3 30 3 35 3 40 3 45 3 50 io 98 1 02 3 35 3 45 3 50 fog 1 12 13 117 ey ioca E C a LE i Be O bo 3 3 3 E Measure the clearance when engine is cold Check present shim size WD lt D e O gt o D Q x Q 2 O D 5 lt D C fo C o 3 2 S e gt O x D o D gt ps o gt 3 o N D 5 2 O m N O gt ps E O o 3 2 Example Present shim is 2 95 mm Measured clearance is 0 45 mm Replace 2 95 mm shim with 3 20 mm shim o Remeasure the valve clearance and readjust if necessary htio mototh com 2 24 PERIODIC MAINTENANCE Periodic Maintenance Procedures VALVE CLEARANCE
112. 40 mm 5 5 in 785 mm 30 9 in 174 kg 383 7 lb 98 kg 216 1 Ib 98 kg 216 1 Ib 15 5 L 4 1 US gal Performance Minimum Turning Radius 2 m 8 9 ft Engine Type Cooling System Bore and Stroke Displacement Compression Ratio Maximum Horsepower Maximum Torque Carburetion System Starting System Ignition System Timing Advance Ignition Timing Spark Plug Cylinder Numbering Method Firing Order Valve Timing Inlet Open Close Duration Exhaust Open Close Duration Lubrication System Engine Oil Type 4 stroke DOHC 2 cylinder Liquid cooled 83 x 60 mm 3 3 x 2 4 in 649 cm 39 60 cu in 11 9 54 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 Injection KEIHIN TTK38 x 2 Electric starter Battery and coil transistorized Electronically advanced digital igniter From 10 BTDC 1 300 r min rpm to 35 BTDC 24 800 r min rpm NGK CHR9EIA 9 Left to right 1 2 1 2 31 BTDC 61 ABDC 2 2 50 BBDC 30 ATDC 260 Forced lubrication semi dry sump API SE SF or SG API SH SJ or SL with JASO MA htio mototh com General Specifications GENERAL INFORMATION 1 9 ems ERGSOAGF ERGSOAGS Viscosity Capacity Drive Train Primary Reduction System Type Reduction Ratio Clutch Type Transmission Type Gear Ratios 1st 2nd 3rd 4th oth 6th Final Drive System Type Reduction Ratio Overall Drive Ratio SA
113. 404Res1 E 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 D stop the cylinder unit E from turning by using the special tools and unscrew the Allen bolt HWMO42D08H51 e Remove the cylinder unit A washer and the spring B from the inner tube e 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 hito mototh com 13 12 SUSPENSION Front Fork e Remove the following from the inner tube Inner Guide Bushing A Outer Guide Bushing B Washer C Oil Seal D GMO4117HS1 E e Remove the cylinder base A from the bottom of the outer tube Front Fork Assembly e Check the top plug O ring and replace it with a new one e Replace the following parts with new ones Retaining Ring A Dust Seal B Oil Seal C Inner Guide Bushing D Outer Guide Bushing E Fork Bottom Allen Bolt Gasket F e 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 st
114. 4949 in 37 984 37 992 mm 1 4954 1 4957 in 37 993 38 000 mm E 1 4958 1 4961 in 41 000 41 016 mm 1 6142 1 6148 in 41 000 41 008 mm 1 6142 1 6145 in 41 009 41 016 mm 1 6145 1 6148 in 1 475 1 480 mm 0 05807 0 05827 in 1 480 1 485 mm ee 0 05827 0 05846 in 1 485 1 490 mm 0 05846 0 05866 in Bearing Insert Part Number 92139 0116 92139 0115 92139 0114 Size Color 0 24 0 36 mm 0 0094 0 0142 in 0 20 0 32 mm 0 0079 0 0126 in 0 05 0 20 mm 0 0020 0 0079 in 0 40 mm 0 0157 in htio mototh com CRANKSHAFT TRANSMISSION 9 7 Specifications tem Standard 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 Crankcase Main Bearing Inside Diameter 1 6142 1 6148 in Marking O 41 000 41 008 mm 1 6142 1 6145 in None 41 009 41 016 mm 1 6145 1 6148 in Crankshaft Main Bearing Insert Thickness Brown 1 490 1 494 mm 0 0587 0 0588 in Black 1 494
115. 5 4 Crankshaft Sensor 16 5 ECU Electric Control Unit T 6 Fan Motor 18 7 Front Brake Light Switch 19 8 Fuse Box with ECU Main Fuse 20 9 Ignition Switch 21 10 Meter Unit 22 11 Neutral Switch 23 12 Oil Pressure Switch 24 htio mototh com Air Switching Valve 13 Rear Brake Light Switch Regulator Rectifier Relay Box Sidestand Switch Speed Sensor Starter Lockout Switch Starter Motor Starter Relay with Main Fuse Stick Coils Turn Signal Relay Water Temperature Sensor Oxygen Sensor Europe Models ELECTRICAL SYSTEM 16 13 Parts Location Dummy Page htio mototh com 16 14 ELECTRICAL SYSTEM Wiring Diagram Raoghal mir Houwisk lFronl Breko Lignl Seetch f Cnginu Stop Switch Io GlLerlar Builon Oo i Ignasi pan DLxsteh 3 PAPER TIGR DTT DS b TORT TTL MN dp a wi ie wo T n d deter Unit LoTura Segaal dAdacantae Re phase F tbagh Henma indicatar LightilEb FL park a5 DOG B Bh ae AR D x Watat praanf Joint C T ad h uno dm gm P GP GP UR FerulsLor Rackifier wo mis ULT I A IS J Wwulral Indicator Ligh LED l S 2 000 Prwrkknure Asrning ladicetae Light FO AA 7 5 FI Warning Light E ED B5 6dnecaigr lrim Matar Gleck T ater Temperatura Gauge Fual Tarraing ae be L ij 31110 ee E E E 10 5pondertos Prmil EE E 9 17 E E il pumanatian LightiLLg FED ight
116. 57001 1121 Valve Seat Cutter 55 535 57001 1247 xlf the manufacturer s instructions are not available use the following procedure htio mototh com 5 28 ENGINE TOP END Valves Seat Cutter Operation Care 1 This valve seat cutter is developed to grind the valve for repair Therefore the cutter must not be used for other purposes than seat repair 2 Do not drop or shock the valve seat cutter or the dia mond particles may fall off 3 Do not fail to apply engine oil to the valve seat cutter before grinding the seat surface Also wash off ground particles sticking to the cutter with washing oil NOTE ODo not use a wire brush to remove the metal particles from the cutter It will take off the diamond particles 4 Setting the valve seat cutter holder in position operate the cutter in one hand Do not apply too much force to the diamond portion NOTE OPrior to grinding apply engine oil to the cutter and dur ing the operation wash off any ground particles sticking to the cutter with washing oll 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 A A Cutter angle B DO 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 P
117. 6 in lb L Clutch Cable Holder Bolts 9 8 1 0 87 in lb L Clutch Cable Clamp Bolt 9 8 1 0 87 in lb Engine Lubrication Engine Oil Drain Bolt 20 2 0 15 Filter Plate Bolt 9 8 1 0 87 in lb L Oil Filter 17 2 1 75 13 EO R Holder Mounting Bolt 25 2 5 18 L Oil Pan Bolts 12 1 2 106 in lb Oil Pipe Bolts 9 8 1 0 87 in lb Oil Pipe Plate Bolt 9 8 1 0 87 in lb L Oil Pressure Relief Valve 15 1 5 11 L Oil Pressure Switch 15 1 5 11 SS Oil Pump Cover Bolts 9 8 1 0 87 in lb L Oil Pump Sprocket Bolt 12 1 2 106 in lb L Lh Oil Passage Plug 20 2 0 15 L Oil Plate Bolts 9 8 1 0 89 in lb L Engine Removal Installation Engine Mounting Bracket Bolts 25 2 5 18 Front Engine Mounting Bolts 44 4 5 32 Rear Engine Mounting Nuts 44 4 5 32 Crankshaft Transmission Oil Plate Bolts 9 8 1 0 87 in lb L Breather Plate Bolts 9 8 1 0 87 in lb L Crankcase Bolts M9 L 113 mm 44 4 5 32 MO S Crankcase Bolts M9 L 83 mm 44 4 5 32 MO S Crankcase Bolts M8 L 73 mm 35 3 6 26 MO S Crankcase Bolts M8 L 60 mm 35 3 6 26 MO S Crankcase Bolts M8 L 110 mm 27 5 2 8 20 S Crankcase Bolts M8 L 50 mm 27 5 2 8 20 S Crankcase Bolts M6 19 6 2 0 15 S Upper Crankcase Bolts 27 5 2 8 20 S Shift Drum Bearing Holder Screw 4 9 0 50 43 in lb L T Connecting Rod Big End Nuts see Text Timing Rotor Bolt 40 4 1 30 htio mototh com 2 8 PERIODIC MAINTENANCE Torque and Locking Agent os an an RE 15 1 9 11 Oil Pressure Switch SS Oil Passage Plug 20 2 0 15 L Ge
118. 7 in lb Water Pump Impeller Bolt 9 8 1 0 87 in lb Water Pump Cover Bolts 9 8 1 0 87 in lb Water Pump Drain Bolt 7 0 0 70 62 in lb Thermostat Housing Bolts 9 8 1 0 87 in lb Water Temperature Sensor 12 1 2 106 in lb Engine Top End Air Suction Valve Cover Bolts 9 8 1 0 87 in lb Cylinder Head Cover Bolts 9 8 1 0 87 in lb Camshaft Cap Bolts 12 1 2 106 in lb 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 Cylinder Head Bolts M6 12 1 2 106 in lb S Cylinder Bolts M6 12 1 2 106 in lb S Throttle Body Holder Bolts 12 1 2 106 in lb 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 Muffler Body Mounting Bolt Rear 20 2 0 15 Baffle Plate Bolts 5 9 0 60 52 in lb L htio mototh com PERIODIC MAINTENANCE 2 7 Torque and Locking Agent o remm ee 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 Bolts 9 8 1 0 87 in lb Clutch Spring Bolts 9 8 1 0 87 in lb Clutch Hub Nut 132 13 5 98 R Clutch Lever Clamp Bolts 7 8 0 80 69 in lb S Oil Pump Chain Guide Bolts 12 1 2 10
119. 7001 1100 Torque Steering Stem Nut 20 N m 2 0 kgf m 15 ft Ib e Install the claw washer A so that its bent side B faces upward and engage the bent claws with the grooves of stem locknut C e Hand tighten the stem locknut until it touches the claw washer e Tighten the stem locknut clockwise until the claws are aligned with the grooves ranging from 2nd to 4th of stem nut D and bend the 2 claws downward E e Install the stem head 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 O Tighten the upper fork clamp bolts first next the stem head bolt last the lower fork clamp bolts O Tighten 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 lb 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 Stem Bearing Lubrication e Refer to the Steering Stem Bearing Lubrication in the Pe riodic Maintenance chapter hito mototh com 0N055040451 E 0515511851 E ST
120. 9678N2 E Unused Ground to Sensors Oxygen Sensor Heater Signal 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 Fl Indicator LED Light Ground for Fuel System Ground for ignition System Stick Coil 2 Signal FUEL SYSTEM DFI 3 13 DFI Parts Location DFI Digital Fuel Injection Parts 12 Speed Sensor 1 Fl Indicator Light LED DFI 13 Neutral Switch 2 Ignition Switch 14 Water Temperature Sensor 3 Throttle Body Assy 15 Subthrottle Sensor 4 Inlet Air Temperature Sensor 16 Main Throttle Sensor 5 Injectors 17 Subthrottle Valve Actuator 6 Fuel Pump 18 Stick Coils 7 Relay Box ECU Main Relay Fuel Pump 19 Inlet Air Pressure Sensor Relay Radiator Fan Relay 20 Diagnosis Connector 8 Fuse Box ECU Fuse 15 A Oxygen Sen 21 Self diagnosis Terminal sor Heater Fuse 10 A 22 Air Switching Valve 9 ECU 23 Crankshaft Sensor 10 Sealed Battery 24 Vehicle down Sensor 11 Oxygen Sensor hito mototh com 3 14 FUEL SYSTEM DFI Specifications tom EI Digital Fuel Injection System Idle S
121. 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 lb e Install the removed parts see appropriate chapters htio mototh com SUSPENSION 13 17 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 GHOG0R4ARS E e Remove the ball bearing and needle bearings Special Tool Oil Seal amp Bearing Remover A 57001 1058 0408079851 Swingarm Bearing Installation e Replace the ball and needle bearings A with new ones e Install the ball and needle bearings so that the manufac turer s marks face out Special Tools Bearing Driver Set 57001 1129 Stem Bearing Driver 628 B 57001 1610 Spacer 628 57001 1663 HWOB nTI1HS51 hito mototh com Swingarm e Install the needle bearings A ball bearing B 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 in G 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 UR Jl 1 ST LLL Sa Q Swingarm Bearing Sleeve Inspectio
122. AJECIOF FUCKLING lAs DECHON ys Trote GAP Md Cable iia INrotle Grip Free Play Inspeccion diodes Throttle Grip Free Play AdjuStTMeNt occccocnnncccocococononoconnncnnaconononcnnononnnonannnononrnnonananonnnnos Phrotle Cable mstalato ttt Ce Throttle Gable LUbrIGatlOriu uii tuoi uao nct uou Roe CQ eo Dea a M eect reeset Dus REUS llsiesni A2s Zl At lic fel Speed Inspeccion Engine Vacuum Synchronization Inspection AdjustMeNt onccccccnonccncccnoccnnnnnncnnonnnaconnnonos High Altitude Performance AdjUSITMONT ooccccccccnncccccnccnncnnonononnnnnnononnnnnnonnnnnonononconanannnnnons Torote Body ASSy REMOVA es entierran cual Treue Body ASSy InstallallOD 5 nt oe ttu RU as Ed as Throttle Body Assy Disassembly cavas ii Throttle BOU ASS ASSSITIDIV sd e e ea cala AS ANC A a Pe a Air Cleaner Element Removal Installation ooocccconcncocccnncnnoconononenconnnncnnaronononencnnonos Ale Gleaner Element Inspeccion ete a AA A ae T Pl Gleaner HOUSING REMOV Alsacia ie sa Air Cleaner HOUSING InstallatlOTi cui ii E ti m IQ a to ee aa mes TANK REMOVA Em MEET UCT TMK IMNSTAN ATOM voi tl eS Fuel Tank and Cap InSpeGllOl wcnssseoussessc eost ut eno ae a a a i t A tat Se HE hito mototh com 3 86 3 88 3 88 3 88 3 88 3 89 3 89 3 90 3 91 3 91 3 93 3 93 3 93 3 93 3 93 3 94 3 94 3 94 3 94 3 94 3 95 3 96 3 97 3 98 3 98 3 98 3 98 3 98 3 99 3 4 FUEL SYSTEM DFI Exploded View htio mototh com F
123. AS AS AS PAS ASA Ae es o O O D O m n Cylinder head not sufficiently tightened down htio mototh com FUEL SYSTEM DFI 3 29 DFI System Troubleshooting Guide Symptoms or possible Causes Actions chapter 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 Sparkwe S Spark plug dirty broken or gap maladjusted Stick coil shorted or not in good contact Fuel air mixture incorrect 00000 Air cleaner clogged poorly sealed or missing Clean element or inspect sealing see chapter 2 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 Fuel pressure regulator clogged Unstable rough idings J OO nspect see chapter 3 aspect Inlet air temperature sensor trouble Imspectsee chapter 3 Water temperature sensor trouble Imspectsee chapter 3 incorrect idie speed Main throttle sensor trouble Inspect see chapter 3 see chapter 2 A ASS AS AS AS AA xe Ne N Nr m htio mototh com 3 30 FUEL S
124. 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 lead Meter BK sensor BR BK lead Standard 4 75 5 25 V DC e Turn the ignition switch OFF x If 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 x lf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection 017898852 E htio mototh com Subthrottle Sensor Service Code 32 Subthrottle Sensor Output Voltage Inspection e Remove the fuel tank see Fuel Tank 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
125. 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 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 following parts Plug Hole Gaskets A Dowel Pins B 0E11167851 htio mototh com 5 16 ENGINE TOP END Camshaft Camshaft Chain e Apply molybdenum disulfide oil solution to all cams A journals B and thrust blocks C with x marks e f anew camshaft is to be used apply a thin coat of molyb denum disulfide grease to the cam surfaces NOTE O The 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 al Pal da dal da da 1 l ji I 4 pu E531 Le E tt tata tt 4 E E A a a 2 2 5 1 F i TIRAS ALLEE RR E alata A 1 E va aaa F Nest m Lira a b d y tata a i 1 miles a A A i j y l 1 I i GE11153HW2 e Positio
126. 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 hito mototh com APPENDIX 17 29 O ring at the oil passage in the crankcase damaged Exhaust Smokes Excessively White smoke Piston oil ring worn Cylinder worn Valve oil seal damaged Valve guide worn Engine oil level too high Black smoke Air cleaner clogged Brown smoke Air cleaner duct loose Air cleaner O ring damaged Air cleaner poorly sealed or missing Handling and or Stability Unsatisfactory Handlebar hard to turn Cable routing incorrect Hose routing incorrect Wiring routing incorrect Steering stem nut too tight Steering stem bearing damaged Steering stem bearing lubrication inade quate Steering stem bent Tire air pressure too low Handlebar shakes or excessively vibrates Tire worn Swingarm pivot bearing worn Rim warped or not balanced Wheel bearing worn Handlebar hol
127. Connection ECU Connector A Throttle Sensor Connector B Y W lead ECU terminal 7 BR BK lead ECU terminal 28 lf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection 0179899852 E htio mototh com 3 44 FUEL SYSTEM DFI Main Throttle Sensor Service Code 11 Resistance Inspection e Turn the ignition switch OFF e Disconnect the main throttle sensor connector e Connect a digital meter A to the main throttle sensor connector B e Measure the main throttle sensor resistance Main Throttle Sensor Resistance Connections BL lead C BR BK lead D Standard 4 6k0 0017000051 L x If the reading is out of the range replace the throttle body assy x If the reading is within the range but the problem still exists replace the ECU see ECU Removal Main Throttle Sensor Circuit qQG17972HW2 E 1 ECU 2 Water proof Joint E 3 Water proof Joint D 4 Main Throttle Sensor htio mototh com FUEL SYSTEM DFI 3 45 Inlet Air Pressure Sensor Service Code 12 CAUTION Never drop the sensor especially on a hard surface Such a shock to the part can damage it Removal e Remove Left Center Fairing see Center Fairing Removal in the Frame chapter e Disconnect the inlet air pressure sensor connector A and the vacuum hose B e Pull up the inlet air pressure sensor C Installation e Install Vacuum Hose Inlet Air Press
128. D Pd t de PEE IS E A Tf AA DU d Is LH p A en its t1 D oa 14 Pp g9 EE SA 5A4 A T A A E s T E gt aera ir E AAA ios _ 5 T E LH Her ee D 3p ET ee IS O E IS we LL att pro Joint Y dH 1104 1111 t LL 11 ij HA H tr La Fuel Datira 3 h rtr Rear Bravia ighi Snitch Fual Pusp Batiery 123Y1DAh Relay dog Rear Weehe turn Sagral Li Eel Izeo 1K License Plata inr Light 12738 Jarr mot JE A es 2 En Tasl 3rr de Light LED Tarascon TES Zu zr Laft furn MES 3 Eigual laght d vP ilE H ET ua Lis BK BR YT BA E Lara TE ru Diagnoses alf Ceonaetar S di szngdtis Tearmsnal Color Code l Fan almy C Handilighi Eslzy 4 FEM Mean Xalay Fuel Fump Balay Sooke kar LDar amp uil Helay IGNITION lenitionfBattery Tai R T bid ow ommo 5 Aelay Moon Fuse IGA SWITCH li Tail 5larlar R ront Brake Light Switch hito mototh com IGHT SWITCH Hous ING CONNECTIONS Erown Gray Light Blue E tolor WR R color PR REK R pore f o Run cmo 98052 02214 Y Yellow W2R 2T1AWB5 G 16 16 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems Learn and ob serve all the rules below ODo not reverse the battery c
129. E Exploded View 0002153585 G htio mototh com FRAME 15 7 Exploded View O us Wm 86 1 Grab Rai Mounting Bois 25 25 18 2 Lower Fairing Mounting Bots 88 090 Tein htio mototh com 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 htio mototh com FRAME 15 9 Fairings Lower Fairing Removal e Remove the mounting bolts A and lower fairing B Lower Fairing Installation e Install the lower fairing and tighten the mounting bolts Torque Lower Fairing Mounting Bolts 8 8 N m 0 90 kgf m 78 in Ib Center Fairing Removal e Remove the mounting bolts A e Pull the center fairing B evenly outward to clear the stop pers e Disconnect the turn signal lead connector A e Remove the inner fairing see Inner Fairing Removal e Remove the bracket screws 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 hito mototh com 15 10 FRAME Fairings e Connect the turn signal lead connect
130. E 10W 40 2 4 L 2 5 US qt 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 c6 AAA So Ue SS nu A A Chain drive 3 067 46 15 5 473 Top 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 Type Wheel Travel Brake Type Front Rear Electrical Equipment Battery Tubular diamond 24 5 102 mm 4 0 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 Swingarm 125 mm 4 9 in Dual discs Single disc 12V 10 Ah htio mototh com 1 10 GENERAL INFORMATION General Specifications ems ERGSOAGFERGSDAGS 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 05 000 r min rpm opecifications are subject to change without notice and may not apply to every country htio mototh com GENERAL INFORMATION 1 11 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 ER650A enables transmission to be removed from the right
131. E SHIN OF THIS THICKNESS ma 0 95 9 99 s z0 3 25 5 30 3 35 3 40 3 45 3 50 ion 100 azan sasos 30 a ios ros 3 30 3 35 3 40 3 45 3 50 ago 1 14 3 35 0 40 3 45 3 50 1 15 1 19 3 40 3 45 3 50 1 25 1 79 Measure the clearance when engine is cold Check present shim size Match clearance in vertical column with present shim size in horizontal column Install the shim specified where the lines intersect This shim will give the proper clearance po ane Example Present shim is 2 95 mm Measured clearance is 0 47 mm Replace 2 95 mm shim with 3 15 mm shim o Remeasure the valve clearance and readjust if necessary htio mototh com PERIODIC MAINTENANCE 2 25 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 xf 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 e Turn the adjuster A so that 5 6 mm 0 20 0 24 in B of threads are visible 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 Tur
132. EERING 14 9 Steering Stem Steering Stem Warp e Whenever the steering stem is removed or if the steering cannot be adjusted for smooth action check the steering stem for straightness xf the steering stem A is bent replace the steering stem 0105054854 Stem Cap Deterioration Damage x Replace the stem cap if its oil seal A shows damage htio mototh com 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 htio mototh com Handlebar e 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
133. Fusttong Dioda ol Ay mi o Bo E Nalae Unit e ee A AH PEE E f Air ee e ME E NEN EN ZCO TEET aaa eee MO TTT y _ o A ti o dd 1 1 ot Tiel O l am E eee D E E E E td E et o 2 fib did ee AA PILIS j s I Eill NE Ab e If AAA PA d EN ESO i E Y E od d e bor E i i mimm uz Ba ne Boeler pracek pat Jont A HIE AIr HIY I AIr Hi T B T HIT BzsT Watar penol Joint E Bist Hx T B T Front Zightl n Turn 5bsgnal gaye laugh dow iW Right Gite BE A La gh 12457 ek Ket Framt Egit E Turn sgpnal no Ek r Y laghs da ri18 gr Ret Headtighl HI 124553 HB gist Headlight itd 1285595 Ba HT Left Switch Houcing 1 Hern Sutien Fuse Baz 2 Hazard Button Ll Dbaygan Seasar Ha amp ker Fuse 3 lyra Signal Sai lech 7 an uat 154 4 Diemer Switch J LT Futa 154 5 larler Lockout match 4 Turn Signel Xelmy Fuse 104 B Pacaing Bution LEFT SWITCH HOUSING CONNECTIONS 104 Dh c Eh L HH m L AO Zelay H H dlsght Fuse FDA Taillsght use OA pra Fuba 104 Harn Fase OA Horn Button Hazard Button Turn Signal Switch Gimmer Switch Stater Lockout Passing Button Solor BK WBK Golor amp o 6Y cotor a o GY Color R BKBL YR Y Color LLLI I E t remm om E penes htio mototh com E W25L 022 1A8W5 G Wiring Diagram Sub 5ub Int thraitla niet kir Valra aay
134. 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 hito mototh com JMFMIPAH E 06020672851 GENERAL INFORMATION 1 7 Model Identification ER650A6F ER650A6S Left Side View ER650A6F ER650A6S Right Side View ER650A6F Australia Malaysia ER650A6S Europe htio mototh com 1 8 GENERAL INFORMATION General Specifications ems ERGSOAGFERGSDAGS Dimensions Overall Length Overall Width Overall Height Wheelbase Road Clearance Seat Height Dry Mass Curb Mass Front Rear Fuel Tank Capacity 2 100 mm 82 7 in 760 mm 29 9 in 1 095 mm 43 1 in 1 405 mm 55 3 in 1
135. ION 9 17 Crankshaft and Connecting Rods Crankshaft Removal e Split the crankcase see Crankcase Splitting e Remove the crankshaft A Crankshaft Installation CAUTION If the crankshaft bearing inserts or crankcase halves are replaced with new ones select the bear ing inserts and check clearance with a plastigage press gauge before assembling engine to be sure the correct bearing inserts are installed e Apply molybdenum disulfide oil solution to the crankshaft main bearing inserts 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 Install the crankshaft with the camshaft chain A hanging on it Connecting Rod Removal e Split the crankcase see Crankcase Splitting e Remove the connecting rod nuts A e Remove the crankshaft NOTE OMark and record the locations of the connecting rods and their big end caps so that they can be reassembled in their original positions e Remove the connecting rods from the crankshaft CAUTION Discard the connecting rod bolts To prevent dam age to the crankpin surfaces do not allow the con necting rod bolts to bump against the crankpins hito mototh com 9 18 CRANKSHAFT TRANSMISSION Crankshaft 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 Wei
136. Inspection or Cable Wire and Hose Routing section in the Appendix chapter A WARNING Operation with improperly adjusted incorrectly routed or damaged cables could result in an unsafe riding condition e Check idle speed x If 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 hito mototh com 2 16 PERIODIC MAINTENANCE Periodic Maintenance Procedures 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 the fuel tank see Fuel Tank Removal in the Fuel System DFI chapter e Remove Air Switching Valve Hose A Disconnect Air Cleaner Element Screw B Air Cleaner Element C e Remove Upper Plastic Holder A Element B NOTE O The wire screen A is fastened with a
137. 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 lb Rear 25 N m 2 5 kgf m 18 ft Ib Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft lb e Check the fluid level in the brake reservoirs e Bleed the brake line see
138. ORotate the rear wheel by hand OCheck that the soeedometer shows the speed If the speedometer does not work check the speed sen sor electric source voltage and speed sensor x The electric source voltage and speed sensor are normal replace the meter assembly Speed Sensor Electric Source 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 Set the hand tester to the DC 25 V range and connect it to the terminals 10 and 3 xf the voltage is less than 8 V replace the meter assembly Odometer Check e Check the odometer with the speedometer in the same Way If value indicated in the odometer is not added replace the meter assembly NOTE OThe data is maintained even if the battery is discon nected OWhen the figures come to 999999 they are stopped and locked Trip A B Meter Check e Check the trip A or B meters with the speedometer in the same way 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 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 f
139. OTE O To check air flow through the air switching valve just blow through the air cleaner hose C HP18144H51 htio mototh com 16 58 ELECTRICAL SYSTEM 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 GPRI USSENS G 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 hito mototh com ELECTRICAL SYSTEM 16 59 Meter Gauge Indicator Unit Meter Unit Removal e Remove Headlight Assy see Headlight Removal Installation screws A and Cover B e Slide the dust cover A and remove the connector B e Remove the meter unit by taking off the mounting screws C with the washers CAUTION Place the meter unit so that the face is up If a meter unit is left upside down or sideways for any length of time it will malfunction Meter Gauge Disassembly e Remove Meter Unit see Meter Unit Removal Screws A Lower Meter Cover B e Separate the meter assembly A and upper meter cover B http m
140. Pressure Switch 15 Neutral Switch 16 Water Temperature Sensor 17 Water proof Joint E 18 Speed Sensor 19 Water proof Joint C OCOnNOO1FRWND hito mototh com 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 zero ohms OFor the switch housings and the ignition switch refer to the tables in the Wiring Diagram xf 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 Khen brake pedal is pushed down When brake pedal is released Sidestand Switch Connections Colors 8K 8 Mecueud h n er sidertond nu IC Neutral Switch Connections Neutral Switch Connections Color Sli Terminal Ground Khen transmission is in neutral SO When transmission is mot in neutral Oil Pressure Switch Connections Oil Pressure Switch Connections Engine lubrication system is in good condition hito mototh com ELECTRICAL SYSTEM 16 67 16 68 ELECTRICAL SYSTEM Switches and Sensors Water Temperature Sens
141. Recommended Disc Brake Fluid Grade DOT4 e Follow the procedure below to install the rear brake fluid reservoir cap correctly OFirst tighten the rear brake fluid reservoir cap B clock wise C by hand until slight resistance is felt indicating that the cap is seated on the reservoir body then tighten the cap an additional 1 6 turn D while holding the brake fluid reservoir body A OO eee hito mototh com PERIODIC MAINTENANCE 2 33 Periodic Maintenance Procedures Brake Pad Wear Inspection e Check the lining thickness A of the pads in each caliper 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 xf it does not adjust the brake light switch e While holding the switch body turn the adjusting nut A to adjust the switch CAUTION To avoid damaging the electrical connections in side the switch be sure that the switch body does not turn during adjustment xf 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 Bra
142. Stem Bearing Installation daa 14 7 Stem BEAN MG LUDTCA ON spot cast TT MET 14 8 SICSHING Slem VV al De xcctce ceases e P 14 9 Stem Cap Deterioration Damage eiecit adan 14 9 A tate OeereRtn wenn ec eee nT tot en OR Cr eanRT Pen eee 14 10 Handlebar removal oi lisas 14 10 FlanGle Dal Instala sin ii cern eee 14 10 hito mototh com 14 2 STEERING Exploded View htio mototh com STEERING 14 3 Exploded View O a 2 Front Fork Clamp Botts Upper 30 20 15 4 Lett Switch Housing Screws 38 036 Siimb 5 Right Switch Housing Screws 35 036 tin 6 Steering Stem Head Bot 108 no 80 7 SeemgSemNu 1 30 20 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 htio mototh com 14 4 STEERING Special Tools Steering Stem Nut Wrench Steering Stem Bearing Driver 542 5 57001 1100 57001 1344 STSTIMGST L i 51571344481 Bearing Driver Set Steering Stem Bearing Driver Adapter 641 5 57001 1129 57001 1345 5157112981 51571344581 htio mototh com Steering Steering Inspection e Refer to the Steering Play Inspection in the Periodic Main tenance chapter Steering Adjustment e Refer to the Steering Play Adj
143. System Starter Motor Brush Length Commutator Diameter Sealed Battery YTX12 BS 12 V 10 Ah 12 8 V or more Three phase AC 42 V or more at 4 000 r min rpm 0 18 0 27 Q 14 2 15 2 V 376 564 Q 1 9 V or more 11 150 10 8 16 2 kO 88 V or more 0 8 0 9 mm 0 03 0 04 in 12 mm 0 47 in Service limit 6 0 mm 0 24 in 28 mm 1 10 in Service limit 27 mm 1 06 in Air Switching Valve Resistance 18 22 Q at 20 C 68 F Switch and Sensor Rear Brake Light Switch Timing Engine Oil Pressure Switch Connections Water Temperature Sensor Resistance ON after about 10 mm 0 39 in pedal travel When engine is stopped ON When engine is running OFF in the text htio mototh com ELECTRICAL SYSTEM 16 11 Special Tools and Sealants Hand Tester Grip 57001 1394 57001 1591 Y ST51139451 L ST571591851 L Flywheel Puller Assembly M38 x 1 5 M35 x 1 5 Flywheel amp Pulley Holder 57001 1405 57001 1605 ST57i 410551 L ST5TiB60535T L Peak Voltage Adapter Rotor Holder 57001 1415 57001 1658 ST5TiI4M155T1 31571658371 Lead Wire Peak Voltage Adapter Kawasaki Bond Silicone Sealant 57001 1449 56019 120 ST5TiI 44951 L 51560120857 C Needle Adapter Set Kawasaki Bond Silicone Sealant 57001 1457 92104 0004 5157145751 C 31920004371 E htio mototh com 16 12 ELECTRICAL SYSTEM Parts Location F 1 2 Alternator 14 3 Battery 12 V 10 Ah 1
144. 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 xlf 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 If the light does not go off inspect or replace the following item Turn Signal Switch see Switch Inspection in the Electri cal System chapter Turn Signal Relay see Turn Signal Relay Inspection in the Electrical System chapter Fourth Step e Set the dimmer switch A to low beam position e Start the engine e The low beam headlight should go on xf the low beam headlight does not go on inspect or re place the following item Headlight Low Beam Bulb see Headl
145. Tools Inside Circlip Pliers Jack Attachment 57001 143 57001 1608 ST57TO1438T C STSTIGGaST L Jack 57001 1238 ST57i123851 htio mototh com 12 8 BRAKES Brake Lever Brake Pedal Brake Lever Position Adjustment The brake lever adjuster has 5 positions so that the brake lever position can be adjusted to suit the operator s hand e Push the lever forward and turn the adjuster A to align the number with the arrow mark B on the lever holder OThe distance from the grip to the lever is minimum at num ber 5 and maximum at number 1 Brake Pedal Position Inspection e Check that the brake pedal A is in the correct position Footpeg B Pedal Position Standard About 40 mm 1 6 in C below top of footpeg Alf it is incorrect adjust the brake pedal position Brake Pedal Position Adjustment NOTE O Usually 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 lf the length C shown is 70 1 mm 2 76 0 04 in the pedal position will be within the standard range e Tighten Torque Rear Master Cylinder Push Rod Locknut 18 N m 1 8 kgf m 13 ft lb e Install the footpeg stay and tighten the bolts Torque Footpeg Stay Bolts
146. Transmission chapter e Disconnect Oxygen Sensor Lead Connector B Neutral Switch Lead Terminal C e Remove the bracket D and the engine sprocket E see Engine Sprocket Removal in the Final Drive chapter e Remove Horn Leads A Disconnect Horn Bolt B Horn C e Support the engine with a stand or jack A OPut a wooden board B on the suitable stand e Remove the engine mounting bolts C e Remove the engine mounting bracket bolts both sides D and remove the brackets E e Remove the engine F e Insert the rear engine mounting bolts from the left side of the engine and tighten the nuts e Install the engine mounting brackets A with the bolts B e Insert the front engine mounting bolts C and tighten the bolts OPosition the collar D on the right engine mounting bracket HH 4 51H52 E htio mototh com ENGINE REMOVAL INSTALLATION 8 7 Engine Removal Installation e Tighten Torque Rear Engine Mounting Nuts 44 N m 4 5 kgf m 32 ft Ib Font Engine Mounting Bolts 44 N m 4 5 kgf m 32 ft lb Engine Mounting Bracket bolts 25 N m 2 5 kgf m 18 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 Install the removed parts see appropriate chapters e Adjust Throttle Cables see Throttle Control System Inspection
147. UEL SYSTEM DFI 3 5 Exploded View 2 Fl Indicator LED Light 3 Throttle Cable Accelerator 4 Throttle Cable Decelerator 5 Throttle Body Assy 6 Injectors L Apply cable lubricant O Apply engine oil G Apply grease L Apply a non permanent locking agent R Replacement Parts S Follow the specified tightening sequence htio mototh com 3 6 FUEL SYSTEM DFI Exploded View 6002191585 G htio mototh com FUEL SYSTEM DFI 3 7 Exploded View 1 Water Temperature Sensor 12 12 106imb 8 Oxygen Sensor Europe Mode 441 450 325 Inlet Air Pressure Sensor Air Switching Valve Inlet Air Temperature Sensor Crankshaft Sensor Sealed Battery Relay Box Stick Coil Vehicle down Sensor ECU Electronic Control Unit Apply a non permanent locking agent Replacement Parts SS Apply silicone sealant Lo Jr mo o doo 1o0o0 htio mototh com 8 FUEL SYSTEM DFI DFI System DFI System Ar ERA E FH TH HHI A rl da dt nye TRE A eate H Hh hath Fe hito mototh com DFI System O 0O YO 0420mpNy Co 0 NN NNNNNNNNN ib eas 2000 YJO0N 4O0nN O000 yYO0UtsO0ODn O Ignition Switch Starter Lockout Switch Starter Relay Tachometer Fl Indicator Light LED Inlet Air Pressure Sensor Spark Plug Crankshaft Sensor
148. 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 0617074451 E e Connect the test light set to the injector E as shown e Open and connect F the end of the lead to the battery terminal repeatedly The injector should click xf the injector does not click replace the injector If the injector clicks check the wiring again If the wiring is good replace the injector may be clogged or ECU Injector Fuel Line Inspection e Remove Fuel Tank see Fuel Removal 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 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 VOS qersenecti e F and build up the pressure
149. YSTEM DFI DFI System Troubleshooting Guide Engine stans easy SCT Fuel pump trouble imspeal Fuel injector trouble inspeo Main throttle sensor trouble Inspect Fuel pressure too low or too high Imspect Inlet air pressure sensor trouble Inspect see chapter 3 see chapter 3 see chapter 3 see chapter 3 see chapter 3 ATRAS ARS AS ASA 47 xe Re N N gt 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 Crankshaft sensor trouble Inspect see chapter 16 Stick coil trouble Inspect see chapter 16 i Valve spring broken or weak nspect and replace see chapter 5 n J Valve not seating properly valve bent worn or carbon accumulating on seating surface Hesitation o o0 Cracked or obstructed inlet air pressure sensor Inspect and repair or replace see chapter 3 hose Inspect see chapter 3 inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect and repair or replace see chapter 16 Stick coil trouble Inspect and repair or replace see chapter 16 htio mototh com FUEL SYSTEM DFI 3 31 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions chapter Loose terminal of battery lead or engine Inspect and repair see chapter 16 ground lead Delay of ignition timing In
150. a twisting motion work the fork leg down and out Front Fork Installation e Install the fork with the upper end of the inner tube flush A against the top surface of the stem head B e Tighten Torque Front Fork Clamp Bolts Lower 20 N m 2 0 kgf m 15 ft lb Front Fork Top Plug 25 N m 2 5 kgf m 18 ft lb NOTE OTighten the top plug before tightening the upper fork RN clamp bolt O Tighten the two clamp bolts alternately two times to en sure even tightening torque e Tighten Torque Front Fork Clamp Bolt Upper 20 N m 2 0 kgf m 15 ft Ib e Install the removed parts see appropriate chapters Front Fork Oil Change e Remove the front fork see Front Fork Removal e Remove Top Plug A with O ring Collar B Fork Spring Seat C Fork Spring D EC TE E E t or fi aMmn4n4ns52 E hito mototh com 13 10 SUSPENSION Front Fork e Compress A the fork B 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 approx 390 mL 13 2 US oz After disassembly 0404287851 C and completely dry 458 4 mL 15 5 0 14 US oz NOTE OMove the outer tube up and down a few times to remove the air that is trapped in the fork oil in order to stabilize the oil level e Hold the outer tube vertically in a vise and compress the fork comp
151. able connections This will burn out the diodes on the electrical parts OAlways check battery condition before condemning other parts of an electrical system A fully charged battery is a must for conducting accurate electrical system tests OThe electrical parts should never be struck sharply as with a hammer or allowed to fall on a hard surface Such a shock to the parts can damage them OTo prevent damage to electrical parts do not disconnect the battery cables or any other electrical connections when the ignition switch is on or while the engine is running OBecause of the large amount of current never keep the starter button pushed when the starter motor will not turn over or the current may burn out the starter motor wind ings 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 wi
152. ace B Rubber Seal C Mechanical Seal Diaphragm Gon T2 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 0000067854 e Press the mechanical seal A out of the housing with a bearing driver B Special Tool Bearing Driver Set 57001 1129 0000063854 Water Pump Housing Assembly e Apply a 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 0008064851 htio mototh com 4 12 COOLING SYSTEM Water Pump Impeller Assembly e Clean the sliding surface of the mechanical seal with a high flash point solvent and apply a little coolant to the sliding surface to give the mechanical seal initial lubrica tion e Apply coolant to the surfaces of the rubber seal A and sealing seat B and install the rubber seal and sealing seat into the impeller by pressing them by hand until the seat stops at the bottom of the hole Pump Impeller Inspection e Visually check the impeller A x If the surface is corroded or if the blades are damaged replace the impeller htio mototh
153. al b5541751 E CRANKSHAFT TRANSMISSION 9 25 Crankshaft and Connecting Rods Crankshaft Main Journal Diameter Standard 37 984 38 000 mm 1 4954 1 4961 in Service Limit 37 96 mm 1 4945 in If any journal has worn past the service limit replace the crankshaft with a new one 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 8105141851 None 37 984 37 992 mm 1 4954 1 4957 in 1 37 993 38 000 mm 1 4958 1 4961 in O 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 O or no mark e Tighten the crankcase bolts to the specified torque see Crankcase Assembly NOTE O The mark already on the upper crankcase half should almost coincide with the measurement Crankcase Main Bearing Inside Diameter Marks O 41 000 41 008 mm 1 6142 1 6145 in None 41 009 41 016 mm 1 6145 1 6148 in LIED Crankcase Main Bearing Inside Diameter Marks O mark or no mark A No 1 Journal B No 2 Journal Wi C No 3 Journal d1031472B52 E e Select the proper bearing insert A in accordance with the combination of the crankcase and crankshaft coding Size Color B
154. alancer Shaft Journal Diameter Marks O mark or 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 O 31 000 31 008 mm 1 2205 1 2208 in None 31 009 31 016 mm 1 2208 1 2211 in O00 Crankcase Bearing Bore Diameter Marks O mark or no mark A No 1 Journal B No 2 Journal e 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 with a plastigage Balancer Shaft Bearing Insert Selection Crankcase Main Bearing Bore Diameter Mark Crankshaft Main hito mototh com 0105143851 C 106018852 C Bearing Insert Journal Diameter Mark Size Color Part Number 92139 0119 92139 0118 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 b
155. allation 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 Q at 20 C 68 F x f 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 htio mototh com qE04030851 E aEn40332851 E ELECTRICAL SYSTEM 16 57 Air Switching Valve 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 HP18142H51 e 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 x If the air switching value does not operate as described replace it with a new one N
156. ame 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 Prepare a plastic hose of the inside diameter 7 5 mm 0 30 in and a measuring cylinder e Remove the fuel tank bolt see Fuel Tank Removal e Open the 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 e 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 e Temporarily install the fuel tank and close the fuel tank c cap e With the engine stopped turn the ignition switch ON The fuel pump should operate for 3 seconds and then should stop Repeat this several times until the plastic hose is filled with fuel htto mototh com Fuel Line CAUTION Do not drive the fuel pump without the fuel in the fuel
157. ame chapter e Raise the front wheel off the ground with jack Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e 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 O The 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 htio mototh com 004057851 E 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 lb 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 th
158. ance Procedures Oil Filter Replacement e Drain the engine oil see Engine Oil Change e Remove the oil filter A with the oil filter wrench B Special Tool Oil Filter Wrench 57001 1249 e Replace the filter with a new one e Apply engine oil to the gasket A before installation e Tighten the filter with the oil filter wrench Torque Oil Filter 17 2 N m 1 75 kgf m 13 ft 1b NOTE OHand tightening of the oil filter can not be allowed since it does not reach to this tightening torque e Pour in the specified type and amount of oil see Engine Oil Change Fuel Hose Replacement 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 the fuel tank see Fuel Tank Removal in the Fuel System DFI 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 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 hito mototh com ac05b4023
159. and pulling A the wheel e Spin B the front wheel lightly and check for smoothly turn roughness binding or noise If roughness binding or noise is found remove the front wheel and inspect the wheel bearing see Front Wheel Removal Hub Bearing Inspection in the Wheels Tires chapter e Raise the rear wheel off the ground with 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 o
160. and radial B with a dial gauge x If rim runout exceeds the service limit check the hub bear ings xlf 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 A WARNING Never attempt to repair a damaged wheel If there is any damage besides wheel bearings the wheel must be replaced to insure safe operational condi tion Axle Inspection e Remove the front and rear axles see Front Rear Wheel Removal e Visually inspect the front and rear axle for damages x If 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 hito mototh com 0104110854 aJn450423851 E Wheels Rims Balance Inspection e 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
161. ar Positioning Lever Bolt 12 1 2 106 in lb L Shift Shaft Return Spring pin 29 2 9 22 L Shift Drum Cam Bolt 12 1 2 106 in lb L Neutral Switch 15 1 5 11 Transmission Case Bolts 20 2 0 15 Shift Rod Plate Bolt 9 8 1 0 87 in lb Neutral Switch Holder Screw 4 9 0 50 43 in lb L Shift Shaft Cover Bolts 9 8 1 0 87 in lb L see Text Shift Shaft Cover Screw 4 9 0 50 43 in lb L Wheels Tires Front Axle 108 11 0 80 Front Axle Clamp Bolt 34 3 5 25 Rear Axle Nut 108 11 0 80 Final Drive Engine Sprocket Nut 125 12 7 92 MO Rear Axle Nut 108 11 0 80 Rear Sprocket Nuts 59 6 0 44 Speed Sensor Bolt 7 8 0 80 69 in lb L Speed Sensor Bracket Bolts 9 8 1 0 87 in lb Brakes Bleed Valve Brake Hose Banjo Bolts Brake Lever Pivot Bolt Brake Lever Pivot Bolt Locknut Brake Pedal Bolt Front Brake Disc Mounting Bolts Front Brake Light Switch Screw Front Brake Reservoir Cap Screws Front Caliper Mounting Bolts Front Master Cylinder Clamp Bolts Rear Brake Disc Mounting Bolts Rear Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts Rear Master Cylinder Push Rod Locknut Suspension Front Axle Clamp Bolt Front Fork Bottom Allen Bolts Front Fork Clamp Bolts Lower Front Fork Clamp Bolts Upper Front Fork Top Plugs Rear Shock Absorber Bolt htio mototh com 69 in lb 18 9 in lb 52 in lb 78 in lb 20 9 in lb 9 in lb 25 78 in lb 20 18 18 13 PERIODIC MAINTENANCE 2 9 Torque and Locking Agent Fastener Ti pos Remarks Swingar
162. asher A is on the shaft OBe sure that the spring hook portions B are as shown htio mototh com 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 e Install the shift shaft cover OBe sure that the dowel pins A are in position Olnstall new gasket B 0113243851 e Apply a non permanent locking agent to the shift shaft cover screw A and bolts B C and torque them ODo not apply a non permanent locking agent to the shift shaft cover bolts D E 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 0113250851 External Shift Mechanism Inspection e Examine the shift shaft A for any damage xf 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 If the shift mechanism arm D is damaged in any way replace the arm e Check the return spring pin A is not loose xf it is loose unscrew it apply a non permanent locking agent to the threads and tighten it
163. 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 htio mototh com COOLING SYSTEM 4 15 apnrodiBS1 E 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 87 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 xlf the valve is open replace
164. ator Service Code 62 enne nnns S bthrottle Valve Actuator Removal sedes secta usitato o an x ertet oes vetare Er re urea doce Subthrottle Valve Actuator Audible Inspection oooccccccccncccccnnoconcnnonanonononcnononcnnonanononnns Subthrottle Valve Actuator Visual Inspection oooccccoccccccnncconcnoconnncnnnnnonnononnncnannnonnnnss Subthrottle Valve Actuator Resistance Inspection ccccoocccccnccnnccnnnnnonanncononononnnnnnonanonnnnos Subthrottle Valve Actuator Input Voltage Inspection ccococcnncccncnnoconnnoconcnconaronononennnnos Air Switching Valve Service Cod QOO A om s utt Air Switching Valve Removal Installation cooonccccconnncococonononononnnnnnonannnonnncnnononenonnnoos Ar SWITCHING VaVe A DEN dion faeces ade Pu ate tt iunc ebrei o dd Oxygen Sensor Heater Service Code 67 Europe Model cccoocccccccccccccccncconcnnccononoconnnnos Oxygen Sensor Heater Removal Installation oooccccccocconcocooccnnonononncnnnanonnonancnnnoos Oxygen Sensor Heater Inspection sess Oxygen Sensor Incorrect Output Voltage Service Code 94 Europe Model Oxygen Sensor Removal InstallatiON coocoonnnncoconnnnnononnnnnononennnononcnnnnnnncnncnnonennnnnnns Oxygen Sensor Inspection Fl Indicator Light LED Fl inaieator Ligat LED InSpecllOliu uon duex rai a Uu seca Fuerat Dea a coa EC sse danilo
165. case Assembly NOTE ODo not turn the balancer shaft during clearance mea surement ORemove the lower crankcase half and measure the plas tigage width A to determine the bearing insert journal B clearance Balancer Shaft Bearing Insert Journal Clearance Standard 0 011 0 033 mm 0 0004 0 0013 in Service Limit 0 08 mm 0 0031 in SESS x If the clearance is within the standard no bearing insert replacement is required x If 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 x l the clearance exceeds the service limit measure the diameter of the balancer shaft journal Balancer Shaft Journal Diameter n8530281 C Standard 27 987 28 000 mm 1 1019 1 1024 in Service Limit 27 96 mm 1 1008 in htio mototh com 9 28 CRANKSHAFT TRANSMISSION Balancer x If either journal has worn past the service limit replace the balancer shaft 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 balancer shaft write new marks on it Balancer Shaft Diameter Marks None 27 987 27 993 mm 1 1019 1 1021 in O 27 994 28 000 mm 1 1021 1 1024 in A B
166. ce on the crankcase e Install a new gasket and the alternator cover e Tighten Torque Alternator Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib Stator Coil Hemoval 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 htio mototh com 16 26 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 and 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 Ib e Apply silicone sealant to the circumference of the alter nator lead grommet and fit the grommet into the notch of the cover securely Sealant Kawasaki Bond Silicone Sealant 92104 0004 e Install the alternator cover see Alternator Cover Installa tion Alternator Rotor Removal e Remove the alternator cover see Alternator Cover Re moval e 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 Ro
167. ce with a plastic mallet and split the crankcase lake care not to damage the crankcase htio mototh com 0104207851 104208852 E CRANKSHAFT TRANSMISSION 9 11 Crankcase Splitting xf the oil pie is to be removed follow the next procedure OUnscrew the bolts A and remove the oil pipe B OPrepare a 5 mm rod B and insert it to the hole of the upper crankcase half ORemove the oil pipe A tapping C the rod as shown xf 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 0104210851 htio mototh com 9 12 CRANKSHAFT TRANSMISSION Crankcase Splitting e Press and insert A the new needle bearing B for the shift drum until it is bottomed Special Tool Bear
168. chapter 5 nspect and replace see chapter 9 spect and replace see chapter 9 No fuel flow o d O a o A AS PAS PAS PAS AS 4A ne Engine flooded Spark plug dirty broken or gap maladjusted Replace see chapter 2 Starting technique faulty When flooded don t crank engine with throttle fully opened No spark or spark weak BO dt Ignition and engine stop switches not ON Turn both switches ON hito mototh com 3 28 FUEL SYSTEM DFI DFI System Troubleshooting Guide Symptoms or possible Causes Actions chapter whether sidestand up or not gear not in neutral whether gear in neutral or not Spark plug incorrect Replace it with the correct plug see chapter 16 IC igniter in ECU trouble Inspect see chapter 16 hae starter lockout or sidestand switch Inspect each switch see chapter 16 Stick coil shorted or not in good contact Reinstall or inspect stick coil see chapter 16 Fuel air mixture incorrect S 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 pressure regulator trouble Inspect fuel pressure and replace fuel pump see chapter 3 nspect see chapter 3 nspect see chapter nspect see chapter 3 nspect see chapter 3 N nspect see chapter Compression How O O D O m A
169. ck the light LED and the wiring Good DF and ignition systems are considered to be normal DFI and ignition systems are abnormal Turn the ignition SW OFF End of inspection Go to self diagnesis DFI and ignition systems are normal htio mototh com No Ask the rider if ihe problem occurs again Yes occurs Replace the ECU 0114528 F 3 76 FUEL SYSTEM DFI Fl Indicator Light LED FI 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 Fl indicator light LED A 12 V Battery B FI Indicator Light LED Check Connector Meter Connector C disconnected Connection W BK Lead Terminal 1 of the Meter 8017009051 Battery Terminal BR R Lead Terminal 16 of the Meter Battery Terminal Criterion The light LED should light x If the light LED does not go on replace the meter unit FI Indicator Light LED Circuit QG173BEPHW2 E 1 ECU 6 Main Fuse 30 A 2 Water proof Joint C 7 Battery 3 Ignition Switch 8 Frame Ground 4 Meter Unit 9 Joint Connector 5 Ignition Fuse 10 A hito mototh com FUEL SYSTEM DFI 3 77 ECU 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 Covers Removal in the Frame c
170. cnnnncnnconennnonnnnnnnnnnnnannnnnonancnnnnnnannnnns 2 16 Engine Vacuum Synchronization InSpectiON ccccoccnccccnnncccononononcnconorononanonononcnnononencnnonos 2 17 GOONG VSTE ARTE Em TOES 2 19 Goolant Level nein t TES 2 19 Radiator Hose and Pipe Inspection coolant leak damage installation condition 2 20 AS UOGHOIT OV SION Cot danti decas ctetu dies A Gada 2 20 Air Suction System Damage INSpectiON occccccccnccncccnnconoconcnnnonnnanonnnnonenncnonnnnnnnnnnncncnnnns 2 20 ENGINE OP EN od 2 20 Valve Clearance Inspection ccccccccccnnccocnnnccononnnnnononnnnnonncnnonnnnrnnnnnnnnrnnnnnnnrnnnnnannnnnnnenennnss 2 20 Valve Clearance AdjUStMent cccccceccccccsseececeeeeeceeeeeeceeeseeeeeeesaeeeeeeseeeeeeessaeeeeeseaeeeeeeeas 2 22 A M ET 2 25 Olutch Operalon INSPSCUOMN sica ise und peu caja ut Chee po iat edita veu pax te eee eta 2 25 A et ce stum e tau m oracio Mu uui i uL LIH E OT LU TL LU PUE LQe 2 25 Al Pressure DSCHOM taria 2 25 vee Tre Damage Inspection 2 26 Tire Tread Wear Abnormal Wear Inspection oocccoccccoccnccccncoconnconcncnnnncnonnnnnanonnnnnnnnnnnos 2 26 Wheel Bearing Damage Inspection cccccseecceeeecceeeecseeseuceceueeesseessusessusecsueeenseeesees 2 27 Dive Tas O sake 2 27 Drive Chain Lubrication Condition Inspection ccccooccnccccoccnnccconccnnononncncononnnnnononnnoncnnnns 2 27 Drive Ghain Slack INSOCCTON eros ie 2 28 Drive Chain Slack AG
171. com Radiator Radiator and Radiator Fan Removal e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Remove Left Right Center Fairing see Center Fairing in the Frame chapter 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 Cotter Pin B e Pull A the radiator B 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 f necessary remove Radiator Fan Mounting Bolts A Radiator Fan B http mototh com COOLING SYSTEM 4 13 E Es EH c ERR i MM S _ E SS marr tl 4 14 COOLING SYSTEM Radiator Radiator and Radiator Fan Installation e Install the grommet A so that its large side faces the front e Install the radiator B to the frame OAlign C the projection on the radiator with the hole on the frame OAlign D the projection on the frame with the hole on the radiator ONote the baffle plate on the cylinder head cover when intalling the radiator OPosition the radiator hose clamp screws E as shown Radiator Inspection e Check the radiator core x If there are obstructions to air flow remove them xlf the corru
172. d 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 Silicone Sealant Kawasaki Bond 56019 120 Seals of ECU Connectors htio mototh com 0617003551 FUEL SYSTEM DFI 3 53 Water Temperature Sensor Service Code 14 Water Temperature Sensor Circuit ac1797356N2 E 1 ECU 2 Water Temperature Sensor 3 Water proof Joint E 4 Meter Unit Sensor Resistance Inspection e Remove the water temperature sensor see Water Tem perature Sensor Removal Installation e Refer to Water Temperature Sensor Inspection in the Electrical System chapter htio mototh com 3 54 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 crankshaf
173. d gasket or non permanent locking agent Do not apply them exces sively Excessive application can clog oil passages and Cause serious damage htio mototh com ATA E METE E CADA E GENERAL INFORMATION 1 5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place apply small amount of oil to the con tact area Be sure to maintain proper alignment and use smooth movements when installing Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary Replace with new ones whenever removed Press bearings with the manufacturer and size marks facing out Press the bearing into place by putting pressure on the correct bearing race as shown Pressing the incorrect race can cause pressure between the inner and outer race and result in bearing damage Oil Seal Grease Seal Do not remove pressed oil or grease seals unless removal is necessary Replace with new ones whenever removed Press new oil seals with manufacture and size marks facing out Make sure the seal is aligned properly when installing m ee Ua M Apply specified grease to the lip of seal before installing the seal Grease 602504580851 E 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 66020208 htio mototh com 1 6 GENERAL
174. d 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 htio mototh com 3 74 FUEL SYSTEM DFI Oxygen Sensor Incorrect Output Voltage Service Code 94 Europe Model 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 x If 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 Oxygen Sensor Circuit QG179BE5HR2 E 1 ECU 6 Main Fuse 30 A 2 Oxygen Sensor 7 Battery 3 Water proof Joint E 8 Frame Ground 4 Water proof Joint D 9 Joint Connector 5 Oxygen Sensor Heater Fuse 10 A htio mototh com Fl Indicator Light LED Inspection Flow Chart Turn the ignition SW N No Flashes once then oes off or unlit Does the light LED goes on Yes goes on Does the light LED go off after Yes goes off 1 2 seconds No stays on Does the light LED go off after No stays on 10 20 seconds Run the engine with idling Turn the ignition SW OFF FUEL SYSTEM DFI 3 75 Repair or replace the meter or wiring NG Che
175. denum 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 as TO B 0104213851 htio mototh com 9 16 CRANKSHAFT TRANSMISSION Crankcase Splitting e Tighten the lower crankcase bolts using the following steps OFollowing 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 lb OTighten the M9 bolts 3 4 L 83 mm 3 27 in with wash ers Torque Crankcase Bolts M9 44 N m 4 5 kgf m 32 ft lb OTighten the M9 bolts 5 6 L 113 mm 4 45 in with washers Torque Crankcase Bolts M9 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 lb 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 e Tighten the upper crankcase bolts OThe upper crankcase bolts have copper plated washers Replace them with new ones Torque Upper Crankcase Bolts M8 A 27 5 N m 2 8 kgf m 20 ft lb e After tightening all crankcase bolts check the following items OCrankshaft and balancer shafts turn freely hito mototh com 4104219652 E 0104207851 CRANKSHAFT TRANSMISS
176. der 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 30 APPENDIX Troubleshooting Guide Rear shock adjustment too soft Battery Trouble Front fork rear shock absorber spring weak Battery discharged Rear shock absorber oil leaking Brake Doesn t Hold Air in the brake line Pad or disc worn Brake fluid leakage Disc warped Contaminated pad Brake fluid deteriorated Charge insufficient Battery faulty too low terminal voltage Battery lead making poor contact Load excessive e g bulb of excessive wattage Ignition switch trouble Alternator trouble Wiring faulty Regulator rectifier trouble Primary or secondary cup damaged in master Battery overcharged cylinder Master cylinder scratched inside hito mototh com Alternator trouble Regulator rectifier trouble Battery faulty MODEL APPLICATION Beginning Frame No JKAEREA106A000001 one EROSOACF ER650A 000001
177. dms a 606013452 C ENGINE LUBRICATION SYSTEM 7 11 Oil Pressure Relief Valve Oil Pressure Relief Valve Removal e See Oil Pan Removal Oil Pressure Relief Valve Installation e See Oil Pan Installation Oil Pressure Relief Valve Inspection e Check to see if the valve A slides smoothly when push ing it in with a wooden or other soft rod and see if it comes back to its seat by spring B pressure NOTE Olnspect the valve in its assembled state Disassembly and assembly may change the valve performance xlf 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 oc025040231 E A WARNING Clean the oil pressure relief valve in a 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 lf cleaning does not solve the problem replace the oil pressure relief valve as an assembly The oil pressure relief valve is precision made with no allowance for re placement of individual parts hito mototh com 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
178. e Repair see chapter 5 Engine overheating see Overheating of Troubleshooting Guide see chapter 17 Engine oil viscosity too high Change see chapter 2 Inspect drive chain see chapter 2 and sprocket see chapter 11 Inspect caliper fluid seal damage or clogging Brake dragging el master paa relief and supply ports see chapter 12 Clutch slipping Inspect friction plates for wear see chapter 6 see Overheating of Troubleshooting Guide see chapter 17 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 Drive train trouble Engine overheating Poor Running or No Power at High Speed Firing incorrect BEEN UO 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 see chapter 3 htio mototh com FUEL SYSTEM DFI 3 33 DFI System Troubleshooting Guide Fuel pump operates intermittently and often DFI Pump bearings may wear Replace the pump fuse blows se
179. e 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 Q e Using the highest resistance range of the tester measure the resistance between the crankshaft sensor leads and chassis ground x Any tester reading less than infinity indicates a short necessitating replacement of the crankshaft sensor as sembly Crankshaft Sensor Peak Voltage Inspection NOTE OBe sure the battery is fully charged OUsing the peak voltage adapter A is a more reliable way to determine the condition of the crankshaft sen sor than crankshaft sensor internal resistance measure ments e Remove Crankshaft Sensor Lead Connector see Crankshaft Sens
180. e ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU htio mototh com 3 72 FUEL SYSTEM DFI Oxygen Sensor Heater Service Code 67 Europe Model Oxygen Sensor Circuit QG1793BEBHR2 E 1 ECU 6 Main Fuse 30 A 2 Oxygen Sensor 7 Battery 3 Water proof Joint E 8 Frame Ground 4 Water proof Joint D 9 Joint Connector 5 Oxygen Sensor Heater Fuse 10 A htio mototh com FUEL SYSTEM DFI 3 73 Oxygen Sensor Incorrect Output Voltage Service Code 94 Europe Model Oxygen Sensor Removal Installation e Refer to Oxygen Sensor Removal Installation in the Elec trical 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 Center Fairing see Center Fairing Removal in the Frame chapter 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 hoses 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 an
181. e Periodic Maintenance chapter A WARNING Do not attempt to drive the motorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against the disc The brake will not function on the first application of the lever if this is not done htio mototh com 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 e Remove Cotter Pin A Axle Nut B Washer C Axle D with Washer e Remove the drive chain A from the rear sprocket toward the left e 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 htio mototh com WHEELS TIRES 10 9 Wheels Rims e Engage the drive chain with the rear sprocket TA e Install the caliper bracket A onto the swingarm stop B a e Insert the axle from the right side of the wheel and tighten the axle nut Torque Rear Axle Nut 108 N m 11 0 kgf m 80 ft Ib e Insert a new cotter pin A NOTE O When inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle tighten
182. e chapter 3 Cracked or obstructed inlet air pressure sensor Inspect and repair or replace see chapter 3 hose Compression lows o Valve not seating properly valve bent worn or Inspect and repair or replace see chapter 5 carbon accumulating on the seating surface Carbon built up in combustion chamber Repair see chapter 5 Fuel poor quality or incorrect Use the gasoline recommended in the Owner s Manual Miscellaneous Inspect see chapter 3 Throttle valves won t fully open Inspect throttle cable and lever linkage see chapter 3 Brake dragging Inspect caliper fluid seal damage or clogging of master cylinder relief and supply ports see chapter 12 crankshaft sensor or speed sensor trouble chapter 17 htio mototh com 3 34 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 11 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 Exhaust Smokes Excessively O Oo Whitesmoke MIENNE Engine oil level too high Repair see chapter 7 Inspect fuel line and fuel pump see chapter 3
183. e clamp Drain Hose Sidestand Switch Lead Corrugated Tube Alternator Lead Connector Sidestand Switch Lead Connector Speed Sensor Lead Connector Main Throttle Sensor Lead Connector Tube Neutral Switch Lead Clamp Insert the clamp in the engine bracket Clamp Insert the clamp in the cross pipe Drain Hose Through the drain hose between main harness and air cleaner hito mototh com 17 8 APPENDIX Cable Wire and Hose Routing ERE 5 http mototh com APPENDIX 17 9 Cable Wire and Hose Routing Radiator Fan Connector Clamp Through the main harness and radiator fan lead and insert the clamp in the frame Through the horn lead between water pipe and frame To Front Left Turn Signal Light Clamp Insert the clamp in the bracket Clamp Insert the clamp in the frame Clamp Insert the clamp in the engine bracket NOOR ON htio mototh com 17 10 APPENDIX Cable Wire and Hose Routing htio mototh com APPENDIX 17 11 Cable Wire and 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 Insert the clamp in the bracket Clamp Insert the clamp in the frame About 45 Clamp Insert the clamp in the frame 10 Coolant Hose 11 Clamp 12 Clamp Through the clutch cable in the clamp 00 Y OOK WN ht
184. e 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 x If the clearance is between 0 042 mm 0 00165 in 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 x If 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 htio mototh com 0105040731 E al1050418531 E 0105041751 E CRANKSHAFT TRANSMISSION 9 23 Crankshaft and Connecting Rods If any crankpin has worn past the service limit replace the crankshaft with a new one x If the measured crankpin diameters are not less than the service limit but do not coincide with the original diameter markings on the crankshaft make new marks on it Crankpin Diameter Marks None 37 984 37 992 mm 1 4954 1 4957 in O 37 993 38 000 mm 1 4958 1 4961 in A Crankpin Diameter Marks O or no mark e Measure the connecting rod big end inside diameter and mark each connecting rod big end in accordance
185. e 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 combustion chamber Engine load faulty Clutch slipping Engine oil level too high 17 28 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 Gaug
186. e 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 excessive Clutch release mechanism trouble Gear Shifting Faulty Doesn t go into gear shift pedal doesn t return Clutch not disengaging Shift fork bent or seized Gear stuck on the shaft Gear positioning lever binding Shift return spring weak or broken Shift return spring pin loose Shift mechanism arm spring broken Shift mechanism arm broken Shift pawl broken Jumps out of gear Shift fork ear worn bent Gear groove worn Gear dogs and or dog holes worn Shift drum groove worn Gear positioning lever spring weak or bro ken Shift fork guide pin worn Drive shaft output shaft and or gear splines worn Overshifts Gear positioning lever spring weak or bro ken Shift mechanism arm spring broken Abnormal Eng
187. e lower clamp bolt There will be a gap at the lower part of the clamp after tightening Torque Clutch Lever Clamp Bolts 7 8 N m 0 80 kgf m 69 in Ib Clutch Lever Adjustment The adjuster has 5 positions so that the clutch lever posi tion can be adjusted to suit the operator s hand e Push the lever forward and turn the adjuster A to align the number with the arrow mark B on the lever holder OThe distance from the grip to the lever is minimum at num ber 5 and maximum at number 1 htio mototh com CLUTCH 6 7 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 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 e SS rS RET S and tape the release lever to the clutch cover to prevent o E a the release shaft from falling out AN OS 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 Tig
188. e measurement is within the specified replace the ECU Inlet Air Temperature Sensor Circuit er BRS BH Os E qQG179743HW2 E 1 ECU 2 Inlet Air Temperature Sensor 3 Water proof Joint E htio mototh com 3 52 FUEL SYSTEM DFI Water Temperature Sensor Service Code 14 Water Temperature Sensor Removal Installation CAUTION Never drop the sensor especially on a hard surface Such a shock to the sensor can damage it e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Disconnect the sensor connector A and unscrew the water temperature sensor 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 Standar
189. e of tools and workshop proce dures must be understood in order to carry out maintenance and repair satisfactorily When ever the owner has insufficient experience or doubts his ability to do the work all adjust ments maintenance and repair should be car ried out only by qualified mechanics In order to perform the work efficiently and to avoid costly mistakes read the text thor oughly familiarize yourself with the procedures before starting work and then do the work care fully in a clean area Whenever special tools or equipment are specified do not use makeshift tools or equipment Precision measurements can only be made if the proper instruments are used and the use of substitute tools may ad versely affect safe operation For the duration of the warranty period we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty To get the longest life out of your vehicle e Follow the Periodic Maintenance Chart in the Service Manual e Be 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 i
190. e 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 If there is no vacuum pulsation check the hose line for leak If there is no leak check the air switching valve see Air Switching Valve Unit Test in the Electrical Sys tem chapter or air suction valve see Air Suction Valve Inspection in the Engine Top End chapter Engine Top End Valve Clearance Inspection NOTE O Valve clearance must be checked and adjusted when the engine is cold room temperature e Remove the cylinder head cover see Cylinder Head Cover Removal in the Engine Top End chapter e Unscrew the upper A and lower B caps on the clutch cover htio mototh com 05060050851 E PERIODIC MAINTENANCE 2 21 Periodic Maintenance Procedures e Check the valve clearance when the pistons
191. e 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 050505851 htio mototh com 2 18 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Start the engine and warm it up thoroughly e Check the idle speed Tachometer A e Open and close the throttle x If the idle speed is out of the specified range adjust it CAUTION Do not measure the idle speed by the tachometer of the meter unit 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 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 e Open and close the throttle valves after each measure ment and adjust the idle speed as necessary Ds T e Inspect the vacuums as before Mw ni If both vacuums are within the specification finish the en pa gine vacuum synchronization x If any vacuum can not be adjusted within the specification remove the bypass screws 1 2 and clean them
192. ear 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 01111317851 E htio mototh com 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 on any shift fork is less than the service limit the fork must be replaced Shift Fork Guide Pin Diameter Standard 6 9 7 0 mm 0 272 0 276 in Service Limit 6 8 mm 0 268 in xf 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 excessively worn dogs or dog holes htio mototh com 01171134851 E 011711315851 E CRANKSHAFT TRANSMISSION 9 41 Ball Bearing Needle Bearing and 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 o
193. econds If the LCD segments and LED warning lights will not ap pear replace the meter assembly e Disconnect the terminal 2 OAII the LCD segments and LED warning light disappear If the segments do not disappear replace the meter as sembly MODE AND RESET BUTTON Operation 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 Check that the display change to the CLOCK ODO TRIP A and TRIP B displays each time the MODE button A is pressed Olf the fuel level gauge flashed display change to CLOCK ODO TRIP A TRIP B and FUEL x If 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 0P17303851 htio mototh com 16 62 ELECTRICAL SYSTEM Meter Gauge Indicator Unit e In the HOUR MINUTE setting mode press the RESET button again to effect the HOUR setting mode OThe hour display flashes on the display e Press the MODE button to set the hour e In the HOUR setting mode press the RESET button to effect the MINUTE setting mode OThe minute display flashes on the display e Press the MODE button to set the minute e n the MINUTE setting mode press the RESET button to return t
194. ector 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 O range and read the tester x If 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 If the harness is Open repair or replace the harness OWhen checking a harness A for short circuit open one end B and check the continuity between the other end C and ground D If there is continuity the harness has a short circuit to ground and it must be repaired or re placed e Narrow down suspicious locations by repeating the con tinuity tests from the ECU connectors x If no abnormality is found in the wiring or connectors the DFI parts are the next likely suspects Check the part starting with input and output voltages However there is no way to check the ECU itself If an abnormality is found replace the affected DFI part If no abnormality is found in t
195. ed Sensor Removal e Connect the speed sensor connector A with the battery B 10 kO resistor C and hand tester D as shown e Set the tester to the DC 25 V range Special Tool Hand Tester 57001 1394 e Trace A each side of the speed sensor surface with the Screw driver OThen the tester indicator should flick B x If the tester indicator does not flick replace the speed sensor Oxygen Sensor Removal Europe Models e Remove 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 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 http mototh com ELECTRICAL SYSTEM 16 69 0P120310851 E 16 70 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 e Remove the fuel tank
196. efore Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera tion on a motorcycle read the precautions given below To facilitate actual operations notes illustra tions photographs cautions and detailed descriptions have been included in each chapter wherever necessary This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts Especially note the following Battery Ground Before completing any service on the motorcycle discon nect the battery wires from the battery to prevent the engine from accidentally turning over Disconnect the ground wire first and then the positive When completed with the service first connect the positive wire to the positive terminal of the battery then the negative wire to the neg ative terminal ASSEMBLY GEFAER E Edges of Parts Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts GIMFARMB E Solvent Use a high flush point solvent when cleaning parts High flush point solvent should be used according to directions of the solvent manufacturer OMFS E Cleaning Vehicle before Disassembly Clean the vehicle thoroughly before disassembly Dirt or other foreign materials entering into sealed areas during ve hicle disassembly can cause excessive wear and decrease performance of the ve
197. eir 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 lf 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 permanent Locking Agent For applications that require Liquid Gasket or a Non permanent Locking Agent clean the surfaces so that no oil residue remains before applying liqui
198. el System DFI Table of Contents o ae enn nen yaar Bh ee E REM Bia E UU m B2 iicatee im hebr Hc m SDOCIHGATIOD Ser tic id tds Special TO and A a DEI SErVICING PRECAUTION Sisi ds DEI SERVICING Precautions arsin tionoei eiae eii ler t ter antt est cici Troubleshooting the DEIS St Muriano OUG A ee eer nee UM eerie ee nee POE UI UTER In dulrTes to RAO ariel Inge S TOS dais ci aida DFI System Troubleshooting Guide rererere E EES SeIISDISOEIOSIS at SElf GIAGNOSIS QUIN ia Delf GiaGnOsiS QUIN dea s Ae de eal Self diadgnosis Procedures essa ii oSelf diadnosis PIU e la dd Service Code Clearing Procedures ooccccccoccccncccocnnncononnnnnonancnnnnnnancnnnononnnnnnnnnrnnonnnnennnnnnaness Service Code Clearing PrOCeQures cccooocccccccooccncccnocononcnononnnnnnncnnonnnnnnnonnonennnnnnnnnnnonennnnnss Howto Head Service COGOS iiit id How to Read Service Codes ouais aae o a i a A aa a E a HOW to Erase Service Codo iia id Howto Erase Se VICE OCG cadena alada Servico Code Tal m RET Mr SGMC COS Tasso is ti ias DIU o o Nem NT sp Maiti Throttle Sensor service Code Mit Main Throttle Sensor Removal Adgjustment occccoccnnccnccncccnconocnocononannnonononononcnnonnnnnonenennos PUE Voltage INSHE N enana ouv ede ch taste eo Eee a Eidos ue Ero Eee ae Ouiput Voltage InSPECUON emitan ta Resistance INSDECH ON esee sconieetetezen ete et pita tied
199. elay 7 Relay Box 8 Main Fuse 30 A 9 Battery 10 Frame Ground 11 Fuel Pump 3 88 FUEL SYSTEM DFI Fuel Injectors Removal Installation e Refer to the Throttle Body Assy Disassembly Assembly Audible Inspection e Start the engine e Apply the tip of a screwdriver A to the injector C Put the grip end onto your ear and listen whether the injector is clicking or not OA sound scope B can also be used e Do the same for the other injectors x If all the injectors click at a regular intervals the injectors are good The trouble may be related to the fuel line requiring fuel pressure inspection see Fuel Line section 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 Power Supply Inspection 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 Voltage 12 6 V or more x lf the meter doesn t read as specified c
200. emove the throttle body assy see Throttle Body Assy Removal e Disconnect the subthrottle valve actuator connector A e Connect a digital meter to the subthrottle valve actuator connector A e Measure the subthrottle valve actuator resistance Subthrottle Valve Actuator Resistance Connections BK lead 1 P lead 2 G lead 3 W BL lead 4 Standard About 5 5 7 5 kO Special Tool Hand Tester 57001 1394 l the reading is out of the range replace the actuator along with the throttle body assy x If the reading is within the range check the input voltage see Subthrottle Valve Actuator Input Voltage Inspection htio mototh com 06171515851 E FUEL SYSTEM DFI 3 69 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 Harness Connector Il Meter BK BL lead 1 Meter P lead 2 I Meter W BL lead 3 Meter G Y lead 4 e Measure the actuator input voltage with the engine stopped and with the connector joined e Turn the ignition switch ON
201. en trouble occurred in order to know symptom well OBe sure the battery is fully charged e Remove the fuel tank see Fuel Tank Removal 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 wiped up immediately When the fuel hose is disconnected fuel spills out from the hose and the pipe because of residual pressure Cover the hose connection with a piece of clean cloth to prevent fuel spillage e Install the fuel pressure gauge adapter A and fuel hoses between the fuel pump outlet pipe B and the delivery pipe C 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 A WARNING 0617073651 C Do not try to start the engine with the fuel hoses disconnected e Temporarily install the fuel tank E Clamps F htio mototh com FUEL SYSTEM DFI 3 81 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 Igni
202. ength _ Bolt Length E after tightening before tightening Bolt Stretch Connect Usable Range of ing Rod Connecting Rod Assy Bolt Stretch Use the bolts attached to 0 24 0 36 mm 0 0094 0 0142 in Replace the bolts with new ones 0 20 0 32 mm 0 0079 0 0126 in 2 Rotation Angle Method If you don t have a point micrometer you may tighten the nuts using the Rotation Angle Method 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 hito mototh com CRANKSHAFT TRANSMISSION 9 21 Crankshaft and Connecting Rods e Install new bolts in reused connecting rods e Apply a small amount of molybdenum disulfide oil to the following Threads A of Nuts and Bolts Seating Surfaces B of Nuts and Con rods e First tighten the nuts to the specified torque See the table below e Next tighten the nuts 120 15 OMark A the connecting rod big end caps and n
203. ent straightening can weaken the inner tube e Temporarily assemble the inner and outer tubes and pump them back and forth manually to check for smooth operation e f you feel binding or catching the inner and outer tubes must be replaced A WARNING A straightened inner or outer fork tube may fall in use possibly causing an accident Replace a badly bent or damaged inner or outer tube and inspect the other tube carefully before reusing it Dust Seal Inspection e Inspect the dust seal A for any signs of deterioration or damage Replace it if necessary htio mototh com SUSPENSION 13 13 HWO43n2OH51 0404301854 0041726851 E 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 8 mm 10 94 in Service Limit 272 mm 10 7 in htio mototh com 04043072851 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 acce
204. epped 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 641 57001 1288 e Install the retaining ring into the outer tube e Install the dust seal by hand GMO40420s1 E htio mototh com Front Fork e Apply non permanent locking agent to the threads of the bottom Allen bolt A e Hold the front fork horizontally in a vise B e Hold the cylinder unit C 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 x If 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 subsequ
205. ept 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 HLO O04B8EHS2 E 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 hito mototh com 2 54 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Apply brake fluid to the new parts and to the inner wall of the cylinder e Take care not to scratch the piston or the 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 Caliper Rubber Parts Heplacement 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
206. er IristellaliQpls ouo ducket Uo taie cias 15 14 Flap and Rear Fender Rear RemMovVal cccooccncccnccccccccnccconnncnonononnnnonocnncnnonannnononcnnonarnnnnnnos 15 14 Flap and Rear Fender Rear InstallatiON cccooccocococcncccononoconnncnoncnnonoanononnncnnonnnons 15 14 Rear Fender Front Removal wizun lerjeeie me a A glo MNT NUMERO PR S Sidestand i e eZ TNT TT T ERE Sidestand InstallatiOpisssesiacu tee Ene ERE rb ERtrebei mer ixt ie Ue ode meta uide eut b UE Ese tom MEE TAIN GC OV e TONER T ERN IM RPM Frame Cover Removals docete ool ot tub rte tuta deu 6 ia Frame Cover Installation sssssssssesseeeen mm mmm Inneren nere ne rere mre terrere reis Rear iMd Ec TEUER Hear View Mirrors Removal Rear View Mirrors Install al ON tutus deerat px esa ava idu cie bad Deo te cad deut aen 15 19 htio mototh com 15 2 FRAME Exploded View 00021406745 G htio mototh com FRAME 15 3 Exploded View A ee LLL 2 SdeandBoa as 35 3 SdesandSwichBot 88 090 78b G Apply grease L Apply a non permanent locking agent R Replacement Parts htio mototh com 15 4 FRAME Exploded View 0002141885 G htio mototh com FRAME 15 5 Exploded View O us Wim 86 i Front Fender Bots 39 om 35imb 2 Front Fender Bracket Bos ss 090 ein 1 L Apply a non permanent locking agent htto mototh com 15 6 FRAM
207. er 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 Ath 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 D 5th Gear A Output Shaft B Steel Balls C CAUTION Do not apply grease to the balls to hold them in place This will cause the positive neutral finder mechanism to malfunction 011710317851 E OAfter assembling the 5th gear with steel balls in place on the output shaft check the ball locking effect that the 5th gear doesn t come out of the output shaft when moving it up and down by hand e Check that each gear spins or slides freely on the trans mission shafts without binding after assembly htio mototh com 9 38 CRANKSHAFT TRANSMISSION Transmission NAAN CRRA HOH 0 SOL P cdi pa E n a UE T a Drive Shaft TEH EI im LD SEIN E B OQ O E Ej c yA Ud d EE si LE oe em N Qutput Shaft Ds OE A 04 08 08 dy 08 6113247EN32 1 1st Gear 16 Collar 2 2nd Gear 17 Washer 3 3rd Gear 18 Nut 4 4th Gear 19 O ring 5 5th Gear 20 Bearing 6 6th Top Gear 21 Spacer 39 mm 1 54 in 7 Ball Bearing 22 Positioning Ring 8 Bushing 23
208. er 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 0E14103851 Standard 0 97 0 99 mm 0 0382 0 0390 in Service Limit 0 90 mm 0 035 in If any of the measurements is less than the service limit on either of the rings replace all the rings NOTE OWhen using new rings in a used piston check for un even groove wear The rings should fit perfectly parallel to the groove sides If not replace the piston htio mototh com 5 36 ENGINE TOP END Cylinder Pistons Piston Ring End Gap e Place the piston ring A inside the cylinder using the pis ton to locate the ring squarely in place Set it close to the bottom of the cylinder where cylinder wear is low e Measure the gap B 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 xlf the end gap of either ring is greater than the service limit replace all the rings htio mototh com HE18148H51 ENGINE TOP END 5 37 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
209. et Air Temperature Sensor Connector B Screws C Cover D e Disconnect the breather hose A on the upper crankcase hito mototh com FUEL SYSTEM DFI 3 99 Air Cleaner e Unscrew the bolts A and remove the air cleaner housing B 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 HpO 0ilH52 htio mototh com 3 100 FUEL SYSTEM DFI Fuel Tank Fuel Tank Removal A WARNING Gasoline is extremely flammable and can be explo sive under certain conditions Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Turn the ignition switch OFF Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately e Remove Seat see Seat Removal in the Frame chapter Side Covers see Side Covers Removal in the Frame chapter Fuel Tank Bolts A 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 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
210. f 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 N m 15 8 kgf m 114 ft Ib hito mototh com ELECTRICAL SYSTEM 16 27 16 28 ELECTRICAL SYSTEM Charging System e Apply a thin coat of molybdenum disulfide grease to the shafts A and install them e Install the torque limiter B and starter idle gear C 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
211. fraction of a turn NOTE O Turn the stem nut 1 8 turn at time maximum e Install the claw washer A so that its bent side B faces upward and engage the bent claws with the grooves of stem locknut C e Hand tighten the stem locknut until it touches the claw washer e Tighten the stem locknut clockwise until the claws are aligned with the grooves ranging from 2nd to 4th of stem nut D and bend the 2 claws downward E e 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 f 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
212. g Bos 1 934 as 25 9 Front Master Cylinder Clamp Bots 88 090 T8imb S B Apply brake fluid L Apply a non permanent locking agent R Replacement Parts S Follow the specified tightening sequence oi Apply silicone grease ex PBC grease htio mototh com 12 4 BRAKES Exploded View htio mototh com BRAKES 12 5 Exploded View ACI 78 08 Vin 2 Brake Hose Barjo Bos 25 28 18 3 Brake Pedal Bt e 090 Bn 5 Rear Caliper Mounting Bos 25 28 18 L6 Rear Master Cylinder Mounting Bots 25 28 18 7 Rear Master Cylinder Push Rod Locknut 18 18 19 B Apply brake fluid G Apply grease L Apply a non permanent locking agent R Replacement Parts oi Apply silicone grease ex PBC grease htio mototh com 12 6 BRAKES Specifications Mem Standard 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 4 3 4 7 mm 0 17 0 19 in 4 0 mm 0 16 in Rear 4 8 5 2 mm 0 19 0 20 in 4 5 mm 0 18 in Runout 0 15 mm 0 006 in or less 0 3 mm 0 01 in Brake Fluid Grade DOT4 htio mototh com BRAKES 12 7 Special
213. g in the Crank shaft Transmission chapter e Remove the camshaft chain A from the crankshaft sprocket htio mototh com 5 20 ENGINE TOP END Cylinder Head Cylinder Compression Measurement NOTE OUse the battery which is fully charged e Warm up the engine thoroughly e Stop the engine e Remove Seat see Seat Removal in the Frame chapter Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Air Cleaner Housing see Air Cleaner Housing Removal in the Fuel System DFI chapter Stick Coils see Stick Coil Ignition Coil together with Spark Plug Cap Removal in the Electrical System chap ter 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 ps
214. g 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 N m 0 090 kgf m 8 in Ib hito mototh com Lighting System Headlight Tail Light Circuit OOnNOOAFRWDND gt 10 11 Ignition Switch Water proof Joint A Water proof Joint B Position Light Headlight High Beam Headlight Low Beam Dimmer Switch Passing Switch Headlight Relay Relay Box Starter Relay Turn Signal Light Bulb Replacement e Unscrew the screw A and remove the lens B htio mototh com ELECTRICAL SYSTEM 16 53 GPIZ205EN32 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 16 54 ELECTRICAL SYSTEM 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 signal light Turn Signal Relay Inspection e Remove Left Center Fairing see Center Fairing Removal in the Frame chapter
215. gated fins A are deformed carefully straighten them x If the air passages of the radiator core are blocked more than 20 by unremovable obstructions or irreparably de formed fins replace the radiator with a new one CAUTION When cleaning the radiator with steam cleaner be careful of the following to prevent radiator damage Keep the steam gun A away more than 0 5 m 1 6 ft B from the radiator core Hold the steam gun perpendicular C not oblique D to the core surface Run the steam gun following the core fin direction 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 Alf any one of them shows visible damage replace the cap with a new one hito mototh com ah NN CSS x SES KW 5 or MR ET SER S M wea hu pr MN S NE MS We apn7zOl1D4AS E ob076011851 E Radiator e Install the cap A on a cooling system pressure tester B NOTE OWet the cap sealing surfaces with water or coolant to prevent pressure leaks e Watching the pressure gauge pump the pressure tester to build up the pressure until the relief valve opens the gauge needle flicks downward Stop pumping and mea sure leak time at once The relief valve must open within the specified range in the table below and the gauge hand must remain within the same range
216. ght 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 Dowel Pin G Connecting Rod Bolts H e Install the cap on the connecting rod aligning the weight and diameter marks e Remove debris and clean the surface of inserts e Apply molybdenum disulfide oil solution MO
217. ghtening securely Lower Hexagonal Area for Tightening A Upper Hexagonal Area Adapter B Rear View Mirror Right C e Turn the stay A to assure the safe conditions of the rear with the operator sat on the motorcycle e Adjust the rear view mirror slightly with its mirror B Olnstallation and adjustment of the left side are common with those of the right side Follow the procedure speci fied at the right side hito mototh com FRAME 15 19 Sus SS peo ADA AAA Ss T Da Te E a E E kl IE SE In Pl is TERR nm 0022001851 LU htio mototh com ELECTRICAL SYSTEM 16 1 Electrical System Table of Contents deeem a DSC o ed O Special Tools and SealafilS cuisine Fans Localia lili MINO DIAM bos mise cm siiis MATIS ETSI TEE Um Wirmo INSpPECION asotesest x t oa ssiacuta ves e A A A adi Bater REMOVA onenaren ae tt Baten InstallatloEi ennaa E ARER Baten ACUVallOl st a a T Precaution ire a aE E ee Ntra M UU TOR Charging Gonditlon INSPECCION susrasa dere dus cuc wtodacde aca e Remesas E T I ASA ios ala tala a UID LL M MM MD DID LAUDE Alternator Cover PeITiOValssuenussuid tete odeur ritas tttm Mee a cunt EENE EA IEEE Alternator Cover St idu m aru true oiu de e retro amram ane gual Stator Gol BemoVvaluusseduidnqv a Stator Coil InstalldllOlissszaecce tenet anite ee loe ad Alternator Rotor Removal p tr Alternator Botor InstallallOli caia aa i Altemar INSpec h
218. grease to the lip E of the oil seal Transmission Shaft Disassembly e Remove the transmission shafts see Transmission Shaft Removal e Remove the circlips disassemble the transmission shatts Special Tool Outside Circlip Pliers 57001 144 e The 5th gear A on the output shaft has three steel balls assembled into it for the positive neutral finder mecha nism Remove the 5th gear OSet the output shaft in a vertical position holding the 3rd gear 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 e Replace any circlips removed with new ones e Install the circlips A so that the opening B is aligned with a spline groove C htio mototh com 0113248851 61140625 5 01131040831 E 01171010251 E 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 diamet
219. guide hole to about 120 150 C 248 302 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 44 5 57001 1331 e Wait until the cylinder head cools down and then ream the valve guide with the valve guide reamer A even if the old guide is reused OTurn the reamer in a clockwise direction until the reamer turns freely in the guide Never turn the reamer counter clockwise or it will be dulled OOnce the guides are reamed they must be cleaned thor oughly Special Tool Valve Guide Reamer 4 5 57001 1333 Valve to Guide Clearance Measurement Wobble Method If a small bore gauge is not available inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below e Insert a new valve A into the guide B and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface e Move the stem back and forth C to measure valve valve guide clearance e Repeat the measurement in a direction at a right angle to the first x f 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 0
220. h in the specified range first record the clearance and adjust it Valve Clearance Adjustment e lo 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 Es 0507073851 C 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 CAUTION Do not put shim stock under the shim This may cause the shim to pop out at high rpm causing ex tensive engine damage Do not grind the shim This may cause it to fracture causing extensive engine damage htio mototh com PERIODIC MAINTENANCE 2 23 Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART INLET VALVE PRESENT SHIN lt Exsaple preset sat erent O Part No i2130 sota 1018 z019 1020 1022 1024 1026 1028 1020 toaz 1024 1036 1038 1040 1042 1044 1048 1048 20501 1052 2054 w
221. hapter Center Seat Cover B see Seat Covers section in the Frame chapter Seat Covers C see Seat Covers 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 htio mototh com 3 78 FUEL SYSTEM DFI ECU ECU Power Supply Inspection e Visually inspect the terminals A of the ECU connectors x If the connector is clogged with mud or dust blow it off with compressed air Replace the main harness if the terminals of the main harness connectors are cracked bent or otherwise dam aged x 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 gt Battery Terminal 0 Q lt gt Battery Terminal 0 O 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 te
222. he 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 htio mototh com 4P102 1851 ELECTRICAL SYSTEM 16 37 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 kQ range and read the tester Ignition Coil Winding Resistance Primary Windings 1 1 1 50 Secondary Windings 10 8 16 2 kO x If the tester does not read as specified replace the coil 0P1061 1952 E Stick Coil Primary Peak Voltage NOTE OBe sure the battery
223. he 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 57001 241 A Valve Spring Compressor Adapter 21 57001 1272 B 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 coil end faces down wards the side painted in green faces upwards Valve Stem A Oil Seal B Spring Seat C Closed Coil End D Valve Spring E Side Painted in 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 44 5 57001 1331 hito mototh com ENGINE TOP END 5 25 dE15042851 E 0E15115851 0E15045851 E 5 26 ENGINE TOP END Valves Valve Guide Installation e Apply oil to the valve guide outer surface before installa tion e Heat the area around the valve
224. he 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 htio mototh com 06170725251 E Troubleshooting the DFI System OThere are two ways to inspect the DFI system One is voltage Check Method and the other is Resistance Check Method Voltage Check Method OThis method is conducted by measuring the input voltage B to a sensor A first and then the output voltage C from the sensor OSometimes this method can detect a fault of the ECU e Refer to each sensor inspection section for detail in this chapter e Use a fully charged battery and a digital meter D which can be read two decimal places voltage or resistance Resistance Check Method OThis method is simple No need for a fully charged battery and the needle adapter Just do the following especially when a sensor A is Suspect e Turn the ignition switch OFF and disconnect the connec tors e Inspect the sensor resistance using a digital meter see each sensor inspection in this chapter e Inspect the wiring and connectors B for continuity using the hand tester C analog tester rather than a digital meter Special Tool Hand Tester 57001 1394 If the sensor the wiring and connections are good in spect the ECU for its ground and power supply see thi
225. heck the following Main Fuse 30 A see Fuse section in the Electrical Sys tem 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 connector 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 x If the power source voltage is normal check the output voltage of the injectors hito mototh com Y Y o ty 4 Y er i AN 06170172551 0617013551 06170145651 FUEL SYSTEM DFI 3 89 Fuel Injectors Fuel Injector Output Voltage Inspection e Turn the ignition switch OFF e Remove the ECU see ECU Power Supply Inspection 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 ee 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 fue
226. hicle nhs E hito mototh com 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 8020008 5 Replacement Parts Replacement parts must be KAWASAKI genuine or recommended by KAWASAKI Gaskets O rings oil seals grease seals circlips or cotter pins must be replaced with new ones whenever disassembled 20108 E 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 htio mototh com 1 4 GENERAL INFORMATION Before Servicing Tightening Sequence Generally when installing a part with several bolts nuts or screws start them all in th
227. hort Replace the brush plate assy and the terminal bolt assy Starter Relay Inspection e Remove Bolt A and Cover B htio mototh com TT ELECTRICAL SYSTEM 16 47 Electric Starter System 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 B to the starter relay C as shown Special Tool Hand Tester 57001 1394 xf the relay does not work as specified the relay is defec tive Replace the relay Testing Relay Tester Range x 1 Q range Criteria When battery is connected gt 0 Q 0P11015851 E When battery is disconnected Q htio mototh com 16 48 ELECTRICAL SYSTEM Electric Starter System Electric Starter Circuit GRITOTIENS G 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 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 OONAOARWD hito mototh com Lighting Sy
228. hten the clutch cover mounting bolts Torque Clutch Cover Mounting Bolts 9 8 N m 1 0 kgf m 87 in Ib arator sHR E htio mototh com 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 e Remove the clutch cover see Clutch Cover Removal e Pull the lever and shaft assembly straight out of the clutch cover Release Shaft Installation e Apply high temperature grease to the oil seal lips on the upper ridge of the clutch cover e Apply engine oil to the needle bearings in the hole of the clutch cover e Apply molybdenum disulfide grease to the pusher holding portion A on the release shaft e Install the washer B and spring C e Insert the release shaft straight into the upper hole of the clutch cover CAUTION AFOSOFHAS 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 hito mototh com 6 10 CLUTCH Clutch Cover e Remove the oil level gauge A 0FOs0r3854 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 bear
229. htio mototh com WHEELS TIRES 10 1 Wheels Tires Table of Contents Exploded iio A A PA A atten T Cc Fade m RI EE LL TEES Front Whee RemoVa M EET TTE Front VVNCGSI Instala E UU UT Ur Rear Wheel Removal I ds ISA nearineeclInstala iO Narnia A NA Wheel special ini AXIE IMS peCUO qt C D M M RE Balance Aspecto T Balance AUS IM o o ed edad dee ao le et eue Balance Weight Removal ooocccccccccocococccnccncnonnnnnnnnnnonncnononononnnnonnnnnnnnnnnannnonannonananenons Air Pressure Inspection Adjustment A UU HX A O LEER TO RCD e oli o IS wiisRsi idiaeM et P H PUD Bearno emo alas ia A AUD BE AMG gier ie ile aM canario NEMPE HUD BE anna LUDTICaUON E NO E e htio mototh com 10 2 WHEELS TIRES Exploded View htio mototh com WHEELS TIRES 10 3 Exploded View ACT ATT M0 8 2 FotAWeCampBot a 38 25 S RerAweNu os M6 8 G Apply grease HG Apply high temperature grease R Replacement Parts WL Apply soap and water solution or rubber lubricant htio mototh com 10 4 WHEELS TIRES Specifications lem Standard Semvicelimit 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 m
230. i 2400 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 htio mototh com ENGINE TOP END 5 21 Cylinder Head The 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 be necessary indicated by white exhaust smoke Incorrect cylinder head gasket Replace the gasket with a standard thickness part Cylinder compression Gas 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 Fue
231. iator and Hoses see Radiator and Radiator Fan Re moval in the Cooling System chapter e Unscrew the lower fairing bracket bolts both sides A and remove the brackets both sides B e Disconnect the oil pressure switch terminal A hito mototh com 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 End 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 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 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 hito mototh com 3 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
232. ical 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 Q at 20 C 68 F x If the tester reading is not as specified replace the oxygen sensor with a new one 0P120710851 E xf he tester reading is specified check the power source voltage Inspection NOTE OBe sure the battery is fully charged e Connect a digital voltmeter A to the oxygen sensor con nector B using the needle adapter C Special Tool Needle Adapter Set 57001 1457 e Measure the power source voltage with the engine TEE stopped and with the oxygen sensor connector joined Oxygen Sensor Power Source Voltage Connections to Oxygen Sensor Connector Tester W Y lead D Tester 7 Battery Terminal E Standard Battery Voltage Oxygen Sensor F If 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 If the wiring is good inspect th
233. ight 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 hito mototh com 2 40 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Set the dimmer switch to high beam position e The low beam A and high beam B headlights should go on e The high beam indicator light LED C 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 e Inspect the headlight beam for aiming xlf the headlight beam points to one side rather than straight ahead adju
234. ine 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 hito mototh com 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
235. ing 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 LU 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 1207B 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 ees 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 0104214851 htio mototh com CRANKSHAFT TRANSMISSION 9 13 Crankcase Splitting e Install the crankshaft assembly and the balancer shaft as sembly 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
236. ings A and oil seal B position as shown Press C the bearing so that the bearing surface D is flushwith the housing end of clutch cover E 0FOsS0r2854 e Apply water to the rubber of the oil gauge A and press C it so that the ring B face outside 0F0501854 htio mototh com 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 C e Remove Friction Plates Steel Plates Clutch Hub Nut A OHolding the clutch hub B remove the nut and washer Special Tool Clutch Holder C 57001 1243 e Remove Clutch Hub Spacer e Remove the oil pump sprocket boat A NOTE O The oil pump sprocket bolt has a left hand threads e Using the hole B pull out the sleeve C e 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 htio mototh com 6 12 CLUTCH Clutch e Be sure that the spacer A is in position
237. io mototh com 17 12 APPENDIX Cable Wire and Hose Routing GOODS 5 http mototh com APPENDIX 17 13 Cable Wire and Hose Routing 1 Crankshaft Sensor Lead Connector 2 Clamp Insert the clamp in the bracket htio mototh com 17 14 APPENDIX Cable Wire and Hose Routing htio mototh com APPENDIX 17 15 Cable Wire and Hose Routing 2000 YO00420mnNn 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 hito mototh com 17 16 APPENDIX Cable Wire and Hose Routing casa E htio mototh com APPENDIX 17 17 Cable Wire and Hose Routing Right Switch Housing Lead Throttle Cables Headlight LO Connector Headlight HI Connector Brake Hose Clamp Ignition Switch Lead Main Harness Left Switch Housing Lead 10 Clutch Cable 11 City Light Connector 12 Clamp Insert the clamp in the bracket 13 Clamp Aligh the clamp with the white tape of the harness 14 From the left sequentially through the clutch cable left switch housing lead ignition switch lead and main harness 15 Clamp Thro
238. ion B on the reserve tank into the hole C on the frame bracket and place the reserve tank on the right side of frame Soi e Place a container under the water pump drain bolt A then remove the drain bolt e Remove the radiator cap A in two steps First turn the cap counterclockwise to the first stop Then push and turn it further in the same direction and remove the cap OThe coolant will drain from the radiator and engine e 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 e 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 92 in Ib http mototh com PERIODIC MAINTENANCE 2 49 Periodic Maintenance Procedures 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 5096 Coolant 5096 Freezing Point 35 C 31 F Total Amount 1 2 L 1 3 US qt e Fill the radiator up to the filler neck A with coolant NOTE OPour in the coolant slowly so
239. ion and steel plates for signs of seizure overheating discoloration or uneven wear e Measure the thickness of each friction plate A at several points If any plates show signs of damage or if they have worn past the service limit replace them with new ones Friction Plate Thickness Standard 2 92 3 08 mm 0 115 0 121 in Service Limit 2 8 mm 0 110 in Clutch Plate Warp Inspection e Place each friction plate or steel plate on a surface plate and measure the gap between the surface plate A and each friction plate or steel plate B with a thickness gauge C The gap is the amount of friction or steel plate warp x If any plate is warped over the service limit replace it with a new one Friction and Steel Plate Warp Standard 0 15 mm 0 006 in or less Service Limit 0 3 mm 0 012 in htio mototh com CLUTCH 6 13 0F001 5851 C 0F001 3851 AFDATI E 0F11010751 E 6 14 CLUTCH Clutch Clutch Spring Free Length Measurement e Measure the free length of the clutch springs A xlf 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 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 fricti
240. ion 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 hito mototh com HE18144H51 HE18145H51 HE18148H51 LU ENGINE TOP END 5 35 Cylinder Pistons Piston Ring Piston Ring Groove Wear e Check for uneven groove wear by inspecting the ring seat ing x The rings should fit perfectly parallel to groove surfaces If not replace the piston and all the piston rings e With the piston rings in their grooves make several mea surements with a thickness gauge A to determine piston ring groove clearance Piston Ring Groove Clearance HE18147H51 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 Wiath e Measure the piston ring groove width OUse a vernier caliper at several points around the piston Piston Ring Groove Width Top A Standard 0 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 If 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 micromet
241. ios erect ania tec AE 6 14 Clutch Housing Spline IMS PSCHON venscicnicin li 6 14 hito mototh com 6 2 CLUTCH Exploded View arFa2059HR5 G htio mototh com CLUTCH 6 3 Exploded View 1 Upper Cap on Clutoh Cover 89 040 S5imb 2 Lower Cap on Ciutch Cover Hadighen 3 oePug artigo 4 clutch Cover Mounting Bos 98 10 ein 5 clutch Spring Bos 98 10 ain L6 ciutchHub Nut ee 138 98 R 8 clutch Lever Clamp Bois 78 080 69imb S 9 Oi Pump Chain Guide Bos 12 12 tomb L 10 Clutch Cable Holder Bois 98 10 ein rit clutch Cable Clamp Bot ee 10 in CL Apply cable lubricant EO Apply engine oil G Apply grease HG Apply high temperature grease Lh Left hard Threads M Apply molybdenum disulfide grease R Replacement Parts W Apply water hito mototh com 6 4 CLUTCH Specifications o Hem Standard Clutch Lever Free Play 2 3 mm 0 08 0 12 in 2 2 Clutch Friction Plate Thickness 2 92 3 08 mm 0 115 0 121 in 2 8 mm 0 110 in Friction Plate Warp 0 15 mm 0 16 in or less 0 3 mm 0 012 in Steel Plate Warp 0 2 mm 0 008 in or less 0 3 mm 0 012 in Clutch Spring Free Length 33 6 mm 1 32 in 32 6 mm 1 28 in htio mototh com CLUTCH 6 5 Special Tool and Sealant Clutch Holder Kawasaki Bond Silicone Sealant 57001 1243 92104 0004 e ST57T124385T1 31920004371
242. ir Switching Valve Operation TeSt cccccccncnnccccoccnnccnoccnnnnonnnnnononnnnnonnnncnnonnnnnnnnnnnncnncnnnns 16 56 Air Switching Vale Unit Tes Ersan enu uon es bleu meets pae Deas dn 16 56 coa eli RM Tr 16 58 Fan MOON INSPeclON ESO a 16 58 Meter Gauge Indicator Un Erin ab 16 59 Meter UIE Removal ERES 16 59 Meter Gauge DiSasSeMbly ooccccccocncnccccnncnncccnnnnnnnnnncnnnonnncnnnnnnnronnnonanrnnonnnnrnnonnnnennnnnnncens 16 59 Electronic Combination Meter Unit Inspection oocccccconcccncccnonononccocnnncnnaronnconannnnnonons 16 60 SWIICMES ANG oN DIS aae saniui o a DEAL RE DUE 16 67 Brake Light Timing INSOCCUOM iia 16 67 Brake Light Timing Adjustment cccccccseceecseeeecseeecceeseeseuseesseeeeseueeessaeeeeseueessaneeessags 16 67 SWIC ANS a t ETE 16 67 Water Temperature Sensor Inspection occcccconncccoccnccnonnnonononononennnnonononnnnnononrononanenenaness 16 68 opeed Sensor heroVdloss eases a e idc 16 68 Speed oernsor InstallatlQUiossusm enne ott pecia adiioe iet s ecce sete MR SR iE EATEN 16 68 Speed Sensor TnspeceiOlLssscescue con steuert dilu sede tom cioe EIE Depas edes tees teme E eub Upcuie 16 69 Oxygen Sensor Removal Europe Models cooocccccconccncccooncnnccconcnncnnononnnonannnnnonanononos 16 69 Oxygen Sensor Installation Europe Models coooncccccconccncccnoconcnononcnnnnnnncnnnononcnnconannnnnos 16 69 Oxygen Sensor Inspection Europe Models ococccooococcccnococcconococn
243. ir 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 Cil Filler Plug Hand tighten htio mototh com 3 20 FUEL SYSTEM DFI Troubleshooting the DFI System Outline Outline When an abnormality in the system occurs the Fl indica tor LED Light Emitting Diode light goes on to alert the rider on the meter panel In addition the condition of the problem is stored in the memory of the ECU electronic control unit With the engine stopped and turned in the self diagnosis mode the service code A is indicated by the number of times the FI indicator LED light blinks When due to a malfunction the Fl indicator LED light re mains lit ask the rider about the conditions B under which the problem occurred and try to determine the cause C e First conduct a self diagnosis inspection and then a non self diagnosis inspection The non self diagnosis items are not indicated by the Fl indicator LED light Don t rely solely on the DFI self diagnosis function use common sense Even when the DFI system is operating normally the FI indicator LED light A may light up under strong electrical interference No repair needed Turn the ignition switch OFF to stop the indicator light When the FI indicator LED light goes on and the motor cycle is brought in for repair check the service codes When the repair has bee
244. ire a longer initial charge aPngog2851 E htio mototh com 16 20 ELECTRICAL SYSTEM Battery e Remove the electrolyte container from the vinyl bag e Detach the strip of caps A from the container and set aside these will be used later to seal the battery NOTE ODo not pierce or otherwise open the sealed cells B of the electrolyte container Do not attempt to separate individual cells e Place the electrolyte container upside down with the six sealed cells into the filler ports of the battery Hold the container level push down to break the seals of all six cells You will see air bubbles rising into each cell as the ports fill NOTE ODo not tilt the electrolyte container e Check the electrolyte flow x If no air bubbles A are coming up from the filler ports or if the container cells have not emptied completely tap the 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 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
245. 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 opening 3 625 3 775 V DC at full throttle opening x If 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 B BL W lead terminal 7 BR BK lead terminal 28 lf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection hito mototh com FUEL SYSTEM DFI 3 61 Hp1 080252 C 3 62 FUEL SYSTEM DFI Subthrottle Sensor Service Code 32 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 6k0 0017743091 C x If the reading is out of the range replace the throttle body assy x If the reading is within the range but the problem still exists replace the ECU see ECU section Subthrottle Sensor Circuit ac1729798N2 1 ECU 2 Water proof Joint E 3 Water proof Joint D 4 Subthrottle Sensor hi
246. 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 G Special Tools Hand Tester 57001 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Lead Wire Peak Voltage Adapter 57001 1449 Primary Lead Connection ER CL Adapter R to lead wire peak voltage adapter W Adapter BK to lead wire peak voltage adapter R htio mototh com 16 38 ELECTRICAL SYSTEM 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 e Repeat the measurements 5 times for one stick coil Stick Coil Primary Peak Voltage Standard 88 V or more e Repeat the test for the other stick coil lf the reading is less than the specified value check the following Stick Coils see Stick Coil Ignition
247. ithin the cable housing xf cable movement is not free after lubricating if the cable is frayed B or if the cable housing is kinked C replace the cable dagnanzns51 E hito mototh com 2 44 PERIODIC MAINTENANCE 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 l there are loose fasteners retighten them to the spec ified torque following the specified tightening sequence Refer to the appropriate chapter for torque specifications If torque specifications are not in the appropriate chapter see the Standard Torque Table For each fastener first loosen it by 1 2 turn then tighten it x If cotter pins are damaged replace them with new ones Bolt Nut and Fastener to be checked Engine Clutch 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
248. jUSIment scio os pbi espaces br obici add 2 28 Wheel Alignment Inspection unirse 2 29 Drive Chan Wear INSDOCUON sesser ac peo ei E atiauteetesteea eee cect eaacdeee aces 2 30 Chain Guide INS POCHOM distin ita 2 30 OVS I Mecca antec erecta ee se ata m emm 2 31 Brake Fluid Leak Brake Hose and Pipe Inspection coocccconcncoccnccncnccnannnoncnonanononanonnns 2 31 Brake Hose Damage and Installation Condition Inspection 2 31 Brake Operauorn IrnsBeollOFi sse deu decadiodb eaa cubos ir 2 31 Brake Fluid Level Inspection te 2 32 Brake Pad Wear inspeccion a 2 33 Brake Light Switch Operation Inspection ooocccncccoccnccccnncnnccnonnnnnonononononnancnnnonannnnnnnanons 2 33 SUSPENSION e 2 34 Front Forks Rear Shock Absorber Operation Inspection ccccococcccoccccnoconnncnoncnnonononnnnonos 2 34 Pront FOrK ONLeak IRnSDOCHON uci iie ist sitas 2 34 Rear Shock Absorber Oil Leak Inspection essere 2 34 ELA 110 OY E y PRO ORO 2 35 htio mototh com 2 2 PERIODIC MAINTENANCE Steering Play Inspection Steering Play AdIuSmIehlb aria Steering stem Bearing ubica aid Electrical System opark Plug Condition Ins DO CTOMN LR Lights and Switches Operation InSpectiON occcccocccnncoconcnncononcnnnononnnononnnnonnnnoncnnnononcnos Headlight Aiming INSPECHOM e P Sidestand Switch Operatio
249. ke 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 chapter htio mototh com 2 34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Suspensions Front Forks Rear Shock Absorber Operation Inspection e Pump the forks down and up A 4 or 5 times and inspect the smooth stroke If the forks do not smoothly or noise is found inspect the fork oil level or fork clamps See Front Fork Oil Change in the Suspension chapter e Pump the seat down and up A 4 or 5 times and inspect the smooth stroke x If the shock absorber does not smoothly stroke or noise is found inspect the oil leak 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 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 GS heh vn htio mototh com PERIODIC MAINTENANCE 2 35 Periodic Maintenance Procedures Steering System Steering Play Inspection e Raise the fron
250. kwise until tip of riveting pin hits of link pin e Rivet it e Same work for the other link pin 00407580851 E htio mototh com FINAL DRIVE 11 9 Drive Chain e After staking check the staked area of the link pin for cracks e Measure the outside diameter A of the link pin and link plates width B 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 xf 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 HkO4n28H51 htio mototh com 11 10 FINAL DRIVE Sprocket Coupling Engine Sprocket Removal e Remove Engine Sprocket Cover Bolts A Engine Sprocket Cover B e Remove Speed Sensor Bracket Bolts A Speed Sensor Bracket B e Flatten out the bended washer A e Remove the engine sprocket nut B and washer NOTE OWhen loosening the engine sprocket nut hold the rear brake on e Raise the rear wheel off the ground with stand e Remove the axle cotter pin and loosen the rear axle nut e Loosen the drive chain see Drive Chain Slack Adjust ment in the Periodic Maintenance chapter e Remove the drive chain from the rear sprocket toward the right e Pull the engine sprocket A with drive chain B off the out
251. l System DFI chapter Throttle Body Holder Water Hose Water Temperature Sensor Connector A Front Camshaft Chain Guide hito mototh com 5 22 ENGINE TOP END Cylinder Head e Firstly remove the M6 cylinder head bolts and M6 cylinder bolts A e Secondly remove the M8 bolts B e Thirdly remove the M10 nut C e Fourthly remove the M10 bolts D 0E14073851 C Cylinder Head Installation NOTE O The 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 hito mototh com ENGINE TOP END 5 23 Cylinder Head e Apply molybdenum disulfide oil solution A to both sides of washers and the threads of bolts and nut M10 Cylinder Head Bolts B M10 Cylinder Nut C M8 Cylinder Bolt D e Torque 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 ft Ib Final Used Bolts 49 N m 5 0 kgf m 36 ft lb New Bolts 54 N m 5 5 kgf m 40 ft Ib Cylinder Nut M10 49 N m 5 0 kgf m 36 ft lb 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 O The No 6 is the cylinder head bolt that is tightened be tween the cylinder head with the cylinder OThe No 7 and No
252. l pressure is much lower than the standard check the oil pump relief valve and or crankshaft bearing insert wear immediately x If the reading is much higher than the standard check the oil passages for clogging Oil Pressure Standard 216 294 kPa 2 2 3 0 kgf cm 31 43 psi 4 000 r min rpm oil temperature 90 C 194 F e Stop the engine e Remove the oil pressure gauge and adapter A WARNING Take care against burns form hot engine oil that will drain through the oil passage when the gauge adapter is removed e Apply a non permanent locking agent to the oil passage plug and install it Torque Oil Passage Plug Right 20 N m 2 0 kgf m 15 ft Ib hito mototh com ENGINE LUBRICATION SYSTEM 7 15 Oil Pressure Switch Oil Pressure Switch Removal e Remove or drain Engine Oil see Engine Oil Change in the Periodic Main tenance chapter Switch Cover A Switch Terminal Bolt B Oil Pressure Switch C Oil Pressure Switch Installation e Apply silicone sealant to the threads of the oil pressure switch and tighten it Sealant Kawasaki Bond Silicone Sealant 56019 120 Torque Oil Pressure Switch 15 N m 1 5 kgf m 11 ft Ib e Tighten the terminal bolt securely e Apply a small amount grease to the terminal so that grease should not close the holes A of the switch cover 0613007851 htio mototh com htio mototh com ENGINE REMOVAL INSTALLATION 8 1 Engine Removal Insta
253. l tank and check the injector wiring for continuity Injector Wiring Inspection ECU Connector Injector Connectors Terminal 36 Injector 1 Terminal BL R Terminal 35 Injector 2 Terminal BL G x If the wiring is good inspect the resistance of the injectors see Injector Resistance Inspection e Remove the needle adapter e Apply silicone sealant to the seals of the ECU connector for waterproofing Silicone Sealant Kawasaki Bond 56019 120 Seals of ECU Connectors 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 0617074251 E 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 hito mototh com 3 90 FUEL SYSTEM DFI Fuel Injectors e Remove the fuel tank see Fuel Tank Removal e 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 xf the test lights
254. l tank see Fuel Tank Removal in the Fuel System DFI chapter e Slide back the rubber cap 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 i GPiiEXI P kgf m 53 in Ib Starter Motor Disassembly e Remove the starter motor see Starter Motor Removal e lake off the starter motor through bolts A and remove the both end covers B and pull the armature out of the yoke C hito mototh com 16 44 ELECTRICAL SYSTEM Electric Starter System e Remove Terminal Locknut and Washers O ring e Remove the brush plate assy A from the yoke B e Remove the brush plate A from the plate cover B 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
255. lder until it touches chain pin e Be sure that the cutting pin hits center of chain pin e Screw the handlebar A into body e Turn the pin holder with wrench B 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 e 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 e n case of grease seal chain be sure to set the grease seals correctly e Set the plate holder a A and plate holder b B on the body htio mototh com FINAL DRIVE 11 7 00450180851 E 004015851 E 0k04070851 E 00450721851 E 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 e Take off the plate holder a ok0407271851 E e Set the plate holder b A and cutting and riveting pin B as shown e Turn the pin holder until riveting pin touches link pin e Turn the wrench cloc
256. le Bulb see Wiring Diagram in the Electrical oystem chapter Meter Unit for Meter Panel LCD see Electronic Com bination Meter Unit Inspection 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 Water Temperature Warning Indicator Light LED see Electronic Combination Meter Unit Inspection in the Electrical System chapter Meter Unit for Fl Indicator Light LED see Electronic Combination Meter Unit Inspection in the Electrical Sys tem chapter ECU see ECU Power Supply Inspection in the Fuel Sys tem DFI chapter Main Fuse 30 A and Taillight Fuse 10 A see Fuse In spection in the Electrical System chapter Ignition Switch see Switch Inspection in the Electrical oystem chapter Neutral Switch see Switch Inspection in the Electrical oystem chapter Harness see Wiring Inspection in the Electrical System chapter e Turn off the ignition switch e he 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 not go on inspect or replace the following item Ignition Switch see Switch Inspection in the Electrical oystem chapter htio mototh com PERIODIC MAINTENANCE 2 39 Periodic Maintenance Procedures
257. lean the tank in a well ventilated area and take care that there are no sparks or flame anywhere near the working area Because of the danger or highly flammable liquids do not use gasoline or low flash point solvents to clean the tank e Remove the fuel tank see Fuel Tank Removal e Remove the fuel pump inlet hose and the fuel pump see Fuel Pump section 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 htio mototh com FUEL SYSTEM DFI 3 103 htio mototh com COOLING SYSTEM 4 1 Cooling System Table of Contents qlo Me Mtns nen 4 2 Coolant A ES 4 4 Jo o O A A 4 6 Special Toro Scar Pn ME E EC 4 7 Sez ene oees 4 8 Coolant Deterioration InSpecllOn eee ti e eite tex trad um do ea Ds ipe eire a eindos 4 8 Coolant Level INSpectioN occccccocncnncconnoncccnoncnnnnnnnconnnnnnnnnnnnnnnnnnnnnnnrnnnnnnnennnnnannnnnonenennnss 4 8 A o o mm 4 8 SOOT FAG Peer M 4 8 Pressure TOSUMG c rV a aa 4 8 COCINA SY Sten FUSNIN ches espuma aote eU ite eru e de aun Glee 4 9 Coolant Reserve Tank Removal Installation ocooonccccoocnconccononnnnconononnnonononononanonnnss 4
258. letely e Wait until the oil level stabilizes e Use the fork oil level gauge A to measure the distance between the top of the inner tube to the oil level Special Tool Fork Oil Level Gauge 57001 1290 OSet the oil level gauge stopper B so that the distance C from the bottom of the stopper to the lower end of the pipe is the standard oil level distance OA correct measurement can not be obtained unless the level gauge pipe is placed in the center of the inner tube Oil Level fully compressed without spring Standard 115 2 mm 4 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 0404303852 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 aMmn404D4S 1 E htio mototh com 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 CC 2 E NO GMO
259. llation Table of Contents P een 8 2 Engine Removal InstalldllOFis uus ve ae E acid 8 4 mela 8 4 htio mototh com 8 2 ENGINE REMOVAL INSTALLATION Exploded View htio mototh com ENGINE REMOVAL INSTALLATION 8 3 Exploded View 1 Engine Mounting Bracket Bos 25 25 18 2 Front Engine Mounting Bots 44 45 32 3 Rear Engine Mounting Nuts 44 45 32 4 Engine Mounting Brackets 5 Collar htio mototh com 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 removing the engine or the motorcycle may fall over It could cause an accident and injury CAUTION Be sure to hold the front brake when removing the engine or the motorcycle may fall over The engine or the motorcycle could be damaged e Drain Engine Oil see Engine Oil Change in the Periodic Main tenance chapter Coolant see Coolant Change in the Periodic Mainte nance chapter e Remove Seat see Seat Removal in the Frame chapter Lower Fairing and Center Fairing see Fairing section in the Frame chapter Side Covers see Side Cover Removal in the Frame chapter Frame Covers see Frame Cover Removal in the Frame chapter Rad
260. m 3 94 in TIR 0 03 mm 0 0012 in or less TIR 0 2 mm 0 008 in Wheel Balance 10 g 0 35 oz or less Balance Weights 10 g 0 35 oz 20 g 0 71 oz 30g 1 06 oz Rim Size Front 17 x 3 50 Rear 17 x 4 50 Tires Air Pressure when Cold Front Up to 180 kg 397 Ib load 225 kPa 2 25 kgf cm 32 psi Hear Up to 180 kg 397 Ib load 250 kPa 2 50 kgf cm 36 psi Tread Depth Front 6 5 mm 0 26 in 1 mm 0 04 in AT CH DE 1 6 mm 0 06 in 9 0 mm 0 35 in Up to 130 km h 80 mph 2 mm 0 08 in Over 130 km h 80 mph 3 mm 0 12 in Standard Tires Make Type Front DUNLOP SPORTMAX RADIAL 120 70 ZR17 M C 58 W D221FAJ Rear DUNLOP SPORTMAX D221J 160 60 ZR17 M C 69 W AT Austria CH Switzerland DE Germany A WARNING Use the same manufacturer s tires on both front and rear wheels hito mototh com Special Tools Bearing Driver Set 57001 1129 sT5711298T1 57001 1238 ST57i123851 Bearing Remover Head 20 x 22 57001 1293 ST571293151 htio mototh com WHEELS TIRES 10 5 Bearing Remover Shaft 13 57001 1377 ST5TiATYET L Jack Attachment 57001 1608 ST57i680985T L 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 e Remove the front axle B e Remove the lower fairing see Lower Fairing Removal in the Fr
261. m 16 40 Electric Slaten Sy Stuart SNR ts 16 43 otarter Motor Bermevaliisesten o uo Edu d piro o Arn E eee apace D E Du LAE iE 16 43 Starter Motor instala arar 16 43 Starter MOOD e e Led 16 43 Starter Motor ASSeIDly a iae rto e bandera ctae Vrbe cibo ih eu ugue a Duas 16 44 A A 16 45 Commutator Cleaning and InSpectiON oocccccccooccnnccnononnncnononcnnnnncnnnnnnnnnnnononnnncnnanenonos 16 45 Armature InSpECUO Naiara diia 16 45 148 1 10M 0 S DECUO y OPA neta termine anna D Do DEUM 16 46 Brush Plate and Terminal Bolt Inspection coooccccocnnccccnconcncnncononnnncnncncnnnnnonannnnncnonnnos 16 46 otarter Relay Inspeccion aiia cq 16 46 A o E tmn 16 49 Headlight Beam Horizontal Adjustment eese 16 49 Headlight Beam Vertical Adjustment sees 16 49 Headlight B lb ReplacemeN ecseri vetet eine iria 16 49 City Light Bulb Replacement ertet rone ed 16 50 Headlight Removal Installation cin ii tre ea eee orario unito vna Rr arae Enn YO vaR Rara 16 51 Tan Brake bight Remova kassarnir tie Modo ex dor Pob onis oat a tod 16 51 Tal Brake Lignt nstallallO Mustaine PES Ce ma dau Se Pv raro a a 16 51 License Plate Light Bulb Replacement una 16 52 Turn Signal Light Bulb Replacement ccoocnncccocncccoccncccncnnncanononononnonononnonnnnnonannnononennnnanos 16 53 TUN Signal Relay InspecllOleseieicas cond e uci i et ap e deceat umi Cut bete x aem 16 54 AS WITGIMINIG TOR 16 56 A
262. m Pivot Shaft Nut 108 80 mE 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 lb Right Switch Housing Screws 3 5 0 36 31 in lb Steering Stem Head Bolt 108 11 0 80 Steering Stem Nut 20 2 0 15 htio mototh com Frame Footpeg Stay Bolts 34 3 5 25 Front Fender Bolts 3 9 0 40 35 in lb Front Fender Bracket Bolts 8 8 0 90 78 in lb L Grab Rail Mounting Bolts 25 25 18 Lower Fairing Mounting Bolts 8 8 0 90 78 in lb Sidestand Bolt 44 4 5 32 Sidestand Switch Bolt 8 8 0 90 78 in lb L Electrical System Alternator Cover Bolts 9 8 1 0 87 in lb 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 Front Brake Light Switch Screw 1 2 0 12 11 in lb Left Switch Housing Screws 9 5 0 36 31 in lb License Plate Light Cover Screws 0 90 0 090 8 in lb License Plate Light Mounting Screws t2 0 12 11 in lb Meter Screws 1 2 0 12 11 in lb 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 in lb 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 lb L Starter Motor Cable Terminal Nut 6 0 0 60 53 in lb Starter Motor Clutch Bolts 34 3 5 25 L Starter Motor Mounting Bolts 9 8 1 0 87 in lb L Starter Mo
263. met year e 227 C rL LLLI Din aiken _ I EC Tx su hain guide wear inspect e e 200 Brake System E A e EET Dn Inspect htio mototh com 2 4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY Whichever ODOMETER READING comes x 1 000 km first x 1 000 mile See V 1 12 18 24 30 36 Page INSPECTION Every Firs a P AAA DO Brake operation effectiveness play no drag Epa poe fete fe ted ee ef ae Brake tuia tevel inspet 6monns e e e elele e 202 TETU E O Se A O OO SN a ran forks rear shock absorber operation 2 34 damping and smooth stroke inspect Front forks rear shock absorber oil leak year 2 34 inspect alee sb Steering System Steering play mspeot ww Je e Te Jefes Steering stem bearings lubrcate avers e 206 Electrical System O Electrical System AN Spark plug condton inspect e 207 Lights and switches operation inspect year e e 200 Headlight aiming inspect year e e 240 Sidestand switch operation inspect year e e 241 Engine stop switch operation inspect year el e 242 Others 0 0 AN Chassis pars Meme ya e Tel 20 Bots andnutsightness inspect e Tel e 4 Service more frequently when operating in severe conditions dusty wet muddy high speed or frequent
264. minal 14 0617070651 C 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 f 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 e Temporarily install the inlet air pressure sensor OComnect a commercially available digital meter C vac uum gauge D the fork oil level gauge E and the har ness adapter to the inlet air pressure sensor BJ L Special Tools Fork Oil Level Gauge 57001 1290 i Sensor Harness Adapter 57001 1561 I Inlet Air Pressure Sensor Output Voltage Connection to Adapter T Meter G sensor Y BL lead E Meter BK sensor BR BK lead ac17119B52 OTurn the ignition switch ON OMeasure the inlet air pressure sensor output voltage from various vacuum readings while pulling the handle of
265. mospheric pressure see this text for details 5 4 6 6 kQ at 0C 82 F 0 29 0 39 KQ at 80 C 176 about 2 25 2 50 V 20 68 F see Electrical System chapter about 2 80 2 97 V 020 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 hito mototh com FUEL SYSTEM DFI 3 15 Specifications tem Standard Output Voltage with the sensor tilted 60 70 or more 0 65 1 35 V with sensor arrow mark pointed up 3 55 4 45 V Subthrottle Sensor Non adjustable and non removal Input Voltage 4 75 5 25 V DC between BL and BR BK leads Output Voltage at Idle Throttle Opening 0 4 0 6 V DC between BL W and BR BK leads Output Voltage at Full Throttle Opening 3 625 3 775 V DC between BL W and BR BK leads Resistance 4 6k0 Subthrottle Valve Actuator Resistance about 5 5 7 5 Q Input Voltage about 8 5 10 5 V DC Oxygen Sensor Europe Model Output Voltage Rich 0 7 V or more Output Voltage Lean 0 2 V or less Heater Resistance 11 7 14 5 O at 20 C 68 F Throttle Grip and Cables Throttle Grip Free Play 2 3 mm 0 08 0 12 in hito mototh com 3 16 FUEL SYSTEM DFI Special Tools and Sealant Oil Pressure Gauge 5 kgf cm Needle Adapter Set 57001 125 57001 1457 ST57012551 5157145751 C Fork Oil Level Gauge Throttle Sensor Setting Adapter 57001 1290 57001 1538
266. mp 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 O The fluid level must be checked often during the bleed ing operation and replenished with fresh brake fluid as necessary If the fluid in the reservoir runs completely out any time during bleeding the bleeding operation must be done over again from the beginning since air will have entered the line O Tap the brake hose lightly from the caliper to the reser voir for 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 e Tighten the bleed valve and install the rubber cap Torque Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib e Check the fluid level see Brake Fluid Level Inspection in the Periodic Maintenance chapter e After bleeding is done check the brake for good
267. n CAUTION Do not remove the bearings for inspection Re moval may damage them e Inspect the needle bearings A and ball bearing installed in the swingarm OThe rollers and ball in a bearing normally wear very little and wear is difficult to measure Instead of measuring visually inspect the bearing for abrasion discoloration or other damage x If the needle bearing and sleeve B show any sings of abnormal wear discoloration or damage replace them as a set htto mototh com SUSPENSION 13 19 7 01 n A E O O4G60R5RR2 E 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 hito mototh com STEERING 14 1 Steering Table of Contents q o 14 2 Special eol EE m m UN HER 14 4 A ER 0 EE ti snncetelasuihidouchdie nash nest eneneeae ee eea ets 14 5 DlSeCNING INSDSCUON AA EUER S 14 5 SISCCHIMNG AGIOS UMS sii mm 14 5 o ha pes an a ee nc bah eat 14 6 Stem orem DEALING FREMOV ura dial 14 6 Siem
268. n Oonce frequency Ostreet highway Omountain road Hluphill Odownhill Cibumpy Opebble Altitude Onormal Ohigh about 1 000 m or more Motorcycle conditions when problem occurred Fl indicator Olight up immediately after ignition switch ON and goes off after 1 2 seconds light LED normal Olights blinks immediately after ignition switch ON and stays on DFI problem Olights up immediately after ignition switch ON but goes off after about 10 seconds DFI problem Ounlights light LED ECU or its wiring fault 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 Diengine flooded do not crank engine with throttle opened which promotes engine flooding Ono spark Lichoke lever is not pulled fully when using the lever pull it fully when using other Engine stops Oright after starting L1when opening throttle grip Olwhen closing throttle grip LIwhen moving off L1when stopping the motorcycle Owhen cruising L1other Livery low idle speed Overy high idle speed Cirough idle speed Obattery voltage is low charge the battery Ospark plug loose tighten it Ospark plug dirty broken or gap maladjusted remedy it Obackfiring Datfterfiring Dhesitation when acceleration Diengine oil viscosity too high Obrake dragging Diengine overheating
269. n Inspection occcnccccoccnnccconnnncnonnnnnnononcnnnononnnnnnnnannnnnnoncnnnnss Engine Stop Switch Operation INSpecti0N ooocccccccoccnnccconnnncnnnnccnnnnnononconnnnoncnnnnnnnnnnnnns OCS atic eel CE Chassis Pants EUbEICallOFi rs Bolts Nuts and Fasteners Tightness INSpectiON cccooocccccnccnccncncnnnnncnnnoncononnncnnnnncnnnnanenoos Replacement PANS ni iii area Air Cleaner Element Replacement sees ENQINS DIGNA T M OI Filter Replacements OE oo T Fuel Hose i is RIEN EO TTE Coolant Shands ni RUN Radiator Hose and O ring ReplaceMent ooccncccccccnncccnoccnnnconncnnnnonnnnnononccnnnnnnncnncnnnnnnnnnnnos Brake Hose and Pipe Replacement ccccsscccsesccceeecceeeeceseecsuseeseusesesessaeesseeesseneessaees Brake FIG GRAN e ti Master Cylinder Rubber Parts Replacement ooccccccocccncononcncconncnnnnnnnnnnnononcnnnnnnnrennnnnnnens Caliper Rubber Parts Replacement asnes a r Spark Plug Replacement htio mototh com 2 35 2 35 2 36 2 3 2 3 2 38 2 40 2 41 2 42 2 43 2 43 2 44 2 45 2 45 2 45 2 46 2 46 2 47 2 50 2 51 2 51 2 59 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
270. n adhesive for the shaded portion B Do not remove the wire screen 050507851 htio mototh com PERIODIC MAINTENANCE 2 17 Periodic Maintenance Procedures 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 e 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 l 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 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 fairing 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 th
271. n done the LED light doesn t go on But the service codes stored in memory are not erased to preserve the problem history and the LED light can dis play 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 Fl indicator LED light blinks but the service code cannot be displayed The ignition switch is left ON If the starter button is pushed the electric starter turns but the engine doesn t start To start the engine again raise the motorcycle turn the ignition switch OFF and then ON The vehicle down sensor is turned ON and the LED light goes OFF hito mototh com 06175805851 06170715651 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 e Make sure that measuring points are correct in the con nector noting the position of the lock D and the lead color before measurement Do not reverse connections of the hand tester or a digital meter e Be careful not to shor
272. n the adjusting nut C until the free play is correct A WARNING Be sure that the outer cable end at the clutch lever is fully seated in the adjuster at the clutch lever or it could slip into place later creating enough cable play to prevent clutch disengagement e After the adjustment tighten the locknut and start the en gine and check that the clutch does not slip and that it releases properly Wheels Tires Air Pressure Inspection e Remove the air valve cap e Measure the tire air pressure with an air pressure gauge A when the tires are cold that is when the motorcycle has not been ridden more than a mile during the past 3 hours e Install the air valve cap Adjust the tire air pressure according to the specifications if necessary aJ05007851 E 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 htio mototh com 2 26 PERIODIC MAINTENANCE 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 x If any damage is found replace the wheel if necessary Tire Tread Wear Abnormal Wear Inspec
273. n 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 0E11168851 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 HE11159H51 htio mototh com ENGINE TOP END 5 17 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 82 Pin 1 Pin F 2 Pin G 31 Pin H 32 Pin J 0 E111548N2 E e Install the camshaft cap while pushing the camshaft chain tighten all camshaft bolts and chain guide bolts NOTE O The exhaust cap has a EX mark A and the inlet cap has a IN mark B Be careful not to mix up these caps J A OFirst tighten all the camshaft cap bolts evenly to seat the camshaft in place then tighten all bolts following the spec ified tightening sequence Torque Camshaft Ca
274. n this manual care fully Don t take shortcuts e Remember to keep complete records of main tenance and repair with dates and any new parts installed htio mototh com How to Use This Manual In preparing this manual we divided the prod uct into its major systems These systems be came the manual s chapters All information for a particular system from adjustment through disassembly and inspection is located in a sin gle chapter The Quick Reference Guide shows you all of the product s system and assists in locating their chapters Each chapter in turn has its own comprehensive Table of Contents The Periodic Maintenance Chart is located in the Periodic Maintenance chapter The chart gives a time schedule for required maintenance operations If you want spark plug information for exam ple go to the Periodic Maintenance Chart first The chart tells you how frequently to clean and gap the plug Next use the Quick Reference Guide to locate the Periodic Maintenance chap ter Then use the Table of Contents on the first page of the chapter to find the Spark Plug sec tion Whenever you see these WARNING and CAUTION symbols heed their instructions Always follow safe operating and maintenance practices A WARNING This warning symbol identifies special instructions or procedures which if not correctly followed could result in per sonal injury or loss of life CAUTION This caution symbol identifies special
275. nccnnnnnnnnnonnnnnononnnnnnnancnnnnnnnnonnns Vehicle down Sensor Service Gode Sui AO Vehicle down Sensor REMOVA ui Vehicle down Sensor Installation oooccccoonnnncconnnncoonnnocononoconnnnonnnnnononnnononnnnonanonononons Vehicle down Sensor Inspect Tel NET A O ss eta eee o ubthrotle Sensor Service Code 32 iS Subthrottle Sensor Removal AdjUStIMONT occccconccccccccnccccnnnccoonnncnnnnnnnnnonononnnncnannnononeninnns Subthrottle Sensor Input Voltage INSpectiON ccooocccccccnnccconnncconnnnnnononnconnnnonanoncnoncnnnnos Subthrottle Sensor Output Voltage Inspection oooccccccncncocccnnonancnnnnnnononannncnnnrononaninonnns Subthrottle Sensor Resistance Inspection ccccoonccccccccncccocncccnocnnocononnnnononononnnncnnnonononennnnos Oxygen Sensor not activated Service Code 33 Europe Model Oxygen Sensor Removal InstallatiON ccccoocccnnccconnnncncononncononcnnnononnnnnnnnannnnonancnnnoss Oxygen Sensor Inspection SUCK COIS OH H2 Sevice Code Ol 52 S site abt vites aiii Stick Coil Removal Installatio Mi aos Stick Coil Input Voltage INSpectiON ooccccccccccnncccoccnnccconcnnonnnnnnnnononnnnnononnnnnnnnnnnnnonancnnnnss Radiator Fan Relay Service Code iia Radiator Fan Relay Removal InstallatiON occccconcnnccnnnccnoncnnononnnnnoncnononcnnonanononnnnnnos Radiator Fan Relay Inspectio Qe Subthrottle Valve Actu
276. nce chapter Tire Removal e Remove Wheel see Front Rear Wheel Removal Valve Core Let out the air e To maintain wheel balance mark the valve stem position on the tire with chalk so that the tire can be reinstalled in the same position Chalk Mark or Yellow Mark A Air Valve B Align C e Lubricate the tire beads and rim flanges on both sides with a soap and water solution or rubber lubricant This helps the tire beads slip off the rim flanges CAUTION Never lubricate with engine oil or petroleum distil lates because they will deteriorate the tire e Remove the tire from the rim using a suitable commer cially available tire changer NOTE O The 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 hito mototh com WHEELS TIRES 10 13 aJn5504Dn851 E 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
277. ng section in the Appendix chapter e Install the lower ends of the throttle cables in the cable bracket on the throttle assy after installing the upper ends of the throttle cables in the grip e After installation 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 Chassis Parts Lubrication in the Periodic Main tenance chapter hito mototh com FUEL SYSTEM DFI 3 93 3 94 FUEL SYSTEM DFI Throttle Body Assy ldle Speed Inspection e Refer to Idle Speed Inspection in the Periodic Mainte nance chapter Engine Vacuum Synchronization Inspection Adjust ment e Refer to 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 Hemoval 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 immediatel
278. nnecting 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 hito mototh com 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 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 L
279. non permanent locking agent R Replacement Parts htio mototh com 16 8 ELECTRICAL SYSTEM Exploded View qpa2272HWb E htio mototh com ELECTRICAL SYSTEM 16 9 Exploded View i Aerator Cover Bots 98 10 leimb 2 AlternatorLead Holding Plate Bot 98 10 87imb L 4 Crankshaft Sensor Bots 60 oso S3imib 5 Neural switch 15 15 M 6 lO Pressure Swich 15 15 M ss 7 Joggen Senso 44i 480 335 8 RegulatorRectfierBots 88 090 ein 9 sidestand Switch Bot 1 88 090 7 imb L rio Spark Plugs 1 15 M CM Timing Roret J o 41 30 15 Water Temperature Sensor 12 12 onb 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 htio mototh com 16 10 ELECTRICAL SYSTEM Specifications lea Standard Battery Type Model Name Capacity Voltage Charging System Type Alternator Output Voltage Stator Coil Resistance Charging Voltage Regulator Rectifier Output Voltage Ignition System Crankshaft Sensor Resistance Crankshaft Sensor Peak Voltage Stick Coil Primary Winding Resistance Secondary Winding Resistance Primary Peak Voltage Spark Plug Spark Plug Gap Electric Starter
280. nonaronnnonanonononanononos 16 70 Fuel Reserve Switch INSpecti0N oocccccccocnccncccnonnncconancnnnnnononnnnnnnnnnnononcnnnonnnrnnconennnnnnnnnos 16 70 morae E I NER M UNT 16 71 relay Box INGMOVAl erse E N 16 71 mc Ee reuse O 16 71 Diode GS INCUIINIS OC CH ON me 16 72 FUSE ee ee rn T LU T TT 16 74 30 A Main FUSE ROMOV Al sarita ios 16 74 Fuse Box FUSE IREMOV Al seus teriduedia Gunn a e E a e 16 74 TO Pte Gl Fuse IAC MOV al usario ia iodo 16 74 FUSS INSTA AMON aae E E 16 75 FUSE INSPECCION anar e cias 16 75 hito mototh com ELECTRICAL SYSTEM 16 3 Exploded View Dummy Page htio mototh com 16 4 ELECTRICAL SYSTEM Exploded View BPG2270RRS G htio mototh com ELECTRICAL SYSTEM 16 5 Exploded View License Plate Light Cover Screws 090 0 090 8inlb 2 License Plate Light Mounting Screws 12 012 Wimb Ca MeterSoews e 0122 tin hito mototh com 16 6 ELECTRICAL SYSTEM Exploded View BPG22710R5 E htio mototh com ELECTRICAL SYSTEM 16 7 Exploded View 1 Front Brake Light Switch Screw Hinb 2 Left owitch Housing Screws 31 in lb EN 3 Right Switch Housing Screws tind 4 Starter Motor Cable Terminal Nut 60 06 sin 5 Starter Motor Mounting Bots 98 10 ein 6 Starter Motor Terminal Locka n 1 ain 7 Starter Motor Through Bots 49 050 4gimb G Apply grease L Apply a
281. ns 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 htio mototh com 4 6 COOLING SYSTEM Specifications WMem ETE Coolant Provided when Shipping Type Recommended Permanent type of antifreeze soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators Color Green Mixed Ratio Soft water 5096 coolant 5096 Freezing Point 95 0 731 F Total Amount 1 2 L 1 3 US qt reserve tank full level including radiator and engine Radiator Cap Relief Pressure 112 3 141 7 kPa 1 15 1 45 kgf cm 16 3 20 5 psi Thermostat Valve Opening Temperature 80 5 83 5 177 182 F Valve Full Opening Lift 8 mm 0 31 in or more 95 C 203 F htio mototh com COOLING SYSTEM 4 7 Special Tools Bearing Driver Set Oil Seal Driver 57001 1129 57001 1660 sT5711298T1 31571660371 E htio mototh com 4 8 COOLING SYSTEM Coolant Coolant Deterioration Inspection e Remove the right center fairing cover see Center Fairing Removal in the Frame chapter e Visually inspect the coolant A in the re
282. nsert them until they are bot tomed Special Tool Bearing Driver Set 57001 1129 0113245851 htio mototh com 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 and torque 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 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 P is on the output shaft ai EL El OLI Tee IL 0113244882 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 htio mototh
283. nsor 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 Water Temperature Sensor Removal Installation in the Fuel System DFI chapter Water Temperature Sensor A Water Temperature Sensor Inspection e Refer to Water Temperature Sensor Inspection in the Electrical System chapter htio mototh com COOLING SYSTEM 4 19 htio mototh com ENGINE TOP END 5 1 Engine Top End Table of Contents Exploded VIG uda iste se beaten 5 2 Cylinder Head Removal 5 21 Specifications eeeessssse 5 7 Cylinder Head Installation 5 22 Special Tools and Sealant 5 9 Cylinder Head Warp 5 24 Clean Air System 5 11 VEDI TES 5 25 Air Suction Valve Removal 5 11 Valve Clearance Inspection 5 25 Air Suction Valve Installation 5 11 Valve Clearance Adjustment 5 25 Air Suction Valve Inspection 5 11 Valve Removal 5 25 Air Switching Valve Removal 5 11 Valve Installation 5 25 Air Switching Valve Installation 5 12 Valve Guide Removal 5 25 Air Switching Valve Operation Valve Guide Installation 5 26 TOS uno A 5 12 Valve to Guide Clea
284. nsor Connector B BL lead ECU terminal 10 BR BK lead ECU terminal 28 0017998852 C x lf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection hito mototh com FUEL SYSTEM DFI 3 43 Main Throttle Sensor Service Code 11 Output Voltage Inspection e Measure the output voltage at the main throttle sensor in the same way as input voltage inspection Note the following e Disconnect the main throttle sensor 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 1 300 150 r min rpm x f 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 throttle opening x If 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
285. nsor must send 4 signals output signal to the ECU at 24 If the speed sensor system fails no signal the one rotation of the s and opeed Sensor estaca wiring short or open the speedometer shows 25 9 p l 0 and the ECU sets the top 6 gear position The gear position is decided by the signal of the speed sensor If the vehicle down sensor system has failures Vehicle down Sensor the output voltage Vd is more than usable Output Voltage signal range wiring open the ECU shuts off the Vd 0 65 V 4 45 V fuel pump the fuel injectors and the ignition system If the subthrottle sensor system fails the Subthrottle a signal is out of the usable range wiring short S Output Voltage ensor 045 4 85 V or open the actuator locks sub throttle valve Vehicle down Sensor at full open position The oxygen sensor is active and sensor must send signals output voltage continuously to the ECU Oxygen Sensor Europe Model If the oxygen sensor is not activated the ECU stops oxygen sensor feedback mode htio mototh com FUEL SYSTEM DFI 3 41 Self Diagnosis Service Output Signal Usable The stick coil primary winding must send signals output voltage continuously to the ECU The stick coil primary winding must send signals output voltage continuously to the ECU ne e T If the subthrottle valve actuator fails the Subthrottle 2P9 lesa de signal is out of the usable range wiring short
286. nspection occccccccocnncnnnccconoconnnononononnnnnnnonnncnnnnnnnnnrennnnnnnnnos 13 19 Swingarm Bearing LUbriCatlOr ss scio dae aee t RUE ou EE co nO asa RI I Ur uev isa tu Poe me E 13 20 Ghain Guide IMS PCCUON mm em lO alee 13 20 hito mototh com 13 2 SUSPENSION Exploded View qun212THRb htio mototh com SUSPENSION 13 3 Exploded View mef re gt So 4 Front Fork Clamp Bots Upper 2 20 15 5 FrontForkTopPlugs amp 25 25 18 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 htio mototh com 13 4 SUSPENSION Exploded View htio mototh com SUSPENSION 13 5 Exploded View 1 Rear Shock Absorber Bolt 59 A Ez rear Shock AbsorberNut 5 59 4 8 Swingarm Pivot Shaft Nut 108 no 80 G Apply grease R Replacement Parts htio mototh com 13 6 SUSPENSION Specifications lea Standard Front Fork Per One Unit Fork Inner Tube Outside Diameter 41 mm 1 6 in Air Pressure Atmospheric pressure Non adjustable Fork Spring Setting Non adjustable Damper Setting Non adjustable Fork Oil Viscosity KAYABA KHL34 G10 or equivalent Amount approx 390 mL 13 2 US oz when changing oil 458 4 mL 15 5 0 14 US oz after disassembly and completely dry Fork Oil Level 115 2 mm 4 5 0 08 in
287. 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 abnormal wear and may result in an unsafe riding condition e Tighten both chain adjuster locknuts securely e Tighten the axle nut Torque Rear Axle Nut 108 N m 11 0 kgf m 80 ft Ib e Turnthe wheel measure the chain slack again atthe tight est position and readjust if necessary hito mototh com PERIODIC MAINTENANCE 2 29 Periodic Maintenance Procedures e Insert a new cotter pin A NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle tighten the nut clockwise B up to next alignment Olt should be within 30 OLoosen once and tighten again when the slot goes past the nearest hole LU 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 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 alignmen
288. o the HOUR MINUTE setting mode e Press the MODE button to complete the time setting process OThe clock starts counting the seconds as soon as the MODE button is pressed e Indicate the ODO mode e Check that the display A change to the mile and km dis play each time by pushing the RESET button while MODE button pushed in NOTE OMile Km display can alternate between English and metric modes mile and km in the digital meter Make sure that km or mile according to local regulations is correctly displayed before riding x If the display function does not work and adjust replace the meter assembly Speedometer Check e Connect the 12 V battery and terminals in the same man ner as specified in the Liquid Crystal Display LCD Seg ments Check e The speed equivalent to the input frequency Is indicated in the oscillator A if the square wave illustrated as shown would be input into the terminal 5 Olndicates approximately 60 mph in case the input fre quency would be approximately 169 0 Hz Olndicates approximately 60 km h in case the input fre quency would be approximately 105 6 Hz hito mototh com ee am1i178084B851 0P17304851 qox gue e oy 0P17305851 C Meter Gauge Indicator Unit e l the oscillator is not available the speedometer can be checked as follows Olnstall the meter unit ORaise the rear wheel off the ground with stand OTurn on the ignition switch
289. ocedures 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 e There are washers on each side of the brake hose fitting Replace them with new ones when installing e Tighten Torque Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft Ib 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 Fil the brake line after installing the brake hose see Brake Fluid Change Brake Fluid Change NOTE O The procedure to change the front brake fluid is as fol lows Changing the rear brake fluid is the same as for the front brake htio mototh com 2 52 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Level the brake fluid reservoir e Remove the reservoir cap and diaphragm e Remove the rubber cap from the bleed valve A on the caliper e Attach a clear plastic hose B to the bleed valve and run the other end of the hose into a container e Fill the reservoir
290. olt 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 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 0113240851 htio mototh com 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 opacer D Bolt E OFook the spring at gear positioning lever pushing up F the fook portion as shown e Apply a non permanent locking agent to the gear posi tioning lever bolt and torque it Torque Gear Positioning Lever Bolt 12 N m 1 2 kgf m 106 in Ib 0113241851 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 Viewed from D 0113257851 OBe sure that the w
291. oltage Stick coil is defective Replace stick coil Voltage Is zero No geod or almost zero Inspect Replace bad parts or Mo 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 pPIO280B F htio mototh com 16 42 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 DOMONDOOAWD 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 eS 10 A ECU Fuse 15 A htio mototh com e3 er CES 9 O 3 4 Elisa GP10282HWA4 E 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 43 Electric Starter System Starter Motor Removal CAUTION Do not tap the starter motor shaft or body Tapping the shaft or body could damage the motor e Remove the fue
292. oltmeter A e Remove Seat see Seat Removal in the Frame chapter Battery Cable Cap see Battery Removal e Disconnect the battery terminals CAUTION MCCC Be sure to disconnect the negative cable first aPOBO1DBS1 C e Measure the battery terminal voltage NOTE OMeasure with a digital voltmeter which can be read one decimal place voltage x If 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 M4 4H Battery Charge Rate 96 B aL LT LT T ETE 18 Good C Refresh charge is required D iod dde Refreshing Charge e Remove the battery A see Battery Removal e Do refresh charge by following method according to the battery terminal voltage 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 amnmgadgisti E htio mototh com 16 24 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 5Ax1h CAUTION Charge Tima h If possible do not quick charge If quick charge is done unavoidably do standard charge later on Terminal Voltage less than 11 5 V Battery Terminal Volta Charging Method 1 2 A x 20h NOTE 11 8 11 8 12 0 12 2 12 4 12 6 12
293. om BRAKES 12 17 Master Cylinder Master Cylinder Inspection e Remove the master cylinders see Front Rear Master Cylinder Removal e Disassemble the front and rear master cylinders e Check that there are no scratches rust or pitting on the TE inner wall A of each master cylinder and on the outside e REESE of each piston B E Lh t E E HAS If a master cylinder or piston shows any damage replace them e Inspect the primary cup C and secondary cup D ESA If a cup is worn damaged softened rotted or swollen the piston assembly should be replaced to renew the cups x If fluid leakage is noted at the brake lever the piston as sembly should be replaced to renew the cups Front Master Cylinder J e Check the dust covers E for damage x If they are damaged replace them e Check the piston return springs F for any damage x If the springs are damaged replace them e Check that relief port G and supply port H are not plugged x If the relief port becomes plugged the brake pads will drag on the disc Blow the ports clean with compressed air Rear Master Cylinder K d513050B52 E htio mototh com 12 18 BRAKES Brake Disc Brake Disc Hemoval e Remove the wheel see Front Rear Wheel Removal in the Wheels Tires chapter e Unscrew the mounting bolts and take off the disc e Remove the gaskets Brake Disc Installation e Replace the gaskets with new ones e Install the b
294. omnes N id Regulator Rectifier Inspection sirio Gharging Voltage INSPEC lOM soa deae aIv enata eeu e Ip acacia emet e ee eee Starner Motor GUTE cree m Starter Motor Clutch Removal Installation esses otarter Motor Gluich InSpOCLlOFT soi eme e Re ho io astu E Weide t Ro ERE SUR uu treat oue Deu eeu Starter Motor Clutch DISASSEMDIY 2 eret pasar e Starter Motor Clutch Assembly scssi anaana EEEE loa E AA Dtm Grankshiam Sensor REMOVE a Grankshalt SensorinstallatOA iia Grankshiall SEASON IN EN Crankshaft Sensor Peak Voltage INSpecti0N ooocccccconncncccooccnnccnoccnnnonononononononenononenonos 16 35 TAMNO ROLO REMOVA anat rd 16 36 Tmn ROTOR INSTA ALON aes ii in 16 36 Stick Coil Ignition Coil together with Spark Plug Cap Remowval 16 36 Stick Coil Ignition Coil together with Spark Plug Cap Installation oo 16 36 Stick Coil Ignition Coil together with Spark Plug Cap Inspection 16 37 Stick Coil Primary Peak Voltage ooocccccocooconcccooconcncononnconnnnnnnonnoncnnnnnonnnnnnnannnnnonennnnnss 16 37 opark Plug REMOVA do 16 38 Spark Plug Instala consi aa 16 38 Spark Plug Condition InSpectlOn cct oe od hort ense tede aba ede 16 38 Interlock Operation Inspection ecrans aa a a t EE 16 39 hito mototh com 16 2 ELECTRICAL SYSTEM iex mine OU NI m
295. on it is recommended the battery be load tested at three times its amp hour rating for 15 seconds Re check voltage and if less than 12 8 V repeat the charging cycle and load test If still below 12 8 V the battery is defective hito mototh com 16 22 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 Gi
296. on plates if their tangs are damaged 0F081058514 C Clutch Housing Spline Inspection e Visually inspect where the teeth B on the steel plates wear against the clutch hub splines A xlf there are notches worn into the splines replace the clutch hub Also replace the steel plates if their teeth are damaged 0F08104854 C htio mototh com ENGINE LUBRICATION SYSTEM 7 1 Engine Lubrication System Exploded View Engine Oil Flow Chart Specifications ss Special Tools and Sealant Engine Oil and Oil Filter Oil Level Inspection Engine Oil Change Oil Pan Installation Oil Pressure Relief Valve Table of Contents Oil Pressure Relief Valve Removal ccccccccececececececececececececcceccacaccaeceececececeneueceneneaeas Oil Pump Removal Oil Pump Installation Oil Pressure Measurement Oil Pressure Measurement Oil Pressure Switch Oil Pressure Switch Removal Oil Pressure Switch Installation htio mototh com 1 2 7 4 7 6 1 1 7 8 7 8 7 9 7 9 7 10 7 11 7 11 7 11 7A 742 7 12 7 13 7 14 7 14 7 15 7 15 7 15 7 2 ENGINE LUBRICATION SYSTEM Exploded View 0062070675 G htio mototh com ENGINE LUBRICATION
297. ools Inside Circlip Pliers Bearing Driver Set 57001 143 57001 1129 ST57TO1438T C sT5711298T1 htio mototh com 11 6 FINAL DRIVE Drive Chain Drive Chain Slack Inspection e Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter Drive Chain Slack Adjustment e Refer to the Drive Chain Slack Adjustment in the Periodic Maintenance chapter Wheel Alignment Inspection Adjustment e Refer to the Wheel Alignment Inspection in the Periodic Maintenance chapter Drive Chain Wear Inspection e Refer to the Drive Chain Wear Inspection in the Periodic Maintenance chapter Drive Chain Lubrication e Refer to the Drive Chain Lubrication Condition Inspection in the Periodic Maintenance chapter Drive Chain Removal NOTE OSince the drive chain is installed through the swingarm the chain cannot be removed other than by cutting it Prepare the new link pin link plate grease seals and tools for rejoining the chain e Using a suitable tool cut the drive chain by removing the link pins Recommended Tool EK Joint Tool 50 CAUTION Read the Tool Manual before removing Body A Handlebar B Cutting and Riveting Pin C For Cutting D For Riveting E Plate Holder a F Plate Holder b G Gauge H e Grind A the pin head to make it flat e Set the cutting and riveting pin B as shown htio mototh com 00450158851 E 0045017851 E Drive Chain e Screw the pin ho
298. or e Insert the projections A into the holes B e Install the mounting bolts Upper Fairing Removal e Remove Headlight Assy see Headlight Removal Installation in the Electrical System chapter Mounting Bolts A Upper Fairings Upper Fairing Installation e Installation is the reverse of removal Upper Fairing Bracket Removal e Remove Headlight Assy see Headlight Removal Installation in the Electrical System chapter Meter Unit see Meter Unit Removal in the Electrical Sys tem chapter Bolts A e Free the following parts from the bracket Clutch Cable Ignition Switch Lead Main Harness Brake Hose Throttle Cables Switch Housing Leads e Remove the upper fairing bracket B e Remove Clamp A Bolts B Under Bracket C htio mototh com FRAME 15 11 Fairings 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 e Install the center fairings see Center Fairing Installation htio mototh com 15 12 FRAME Side Covers Side Cover Removal e Remove the seat see Seat Removal e Remove the bolt A e Pull the side cover B evenly outward to clear the stop pers Side Cover Installation e Insert the tabs A into the holes B e Tighten the bolt e Install the seat see Seat Installation htio mototh com FRAME 15 13 Seat Covers Seat Cover
299. or 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 container over a source of heat and gradu ally raise the temperature of the coolant while stirring the coolant gently e Using the hand tester measure the internal resistance of the sensor x If the hand tester does not show the specified values re place the sensor Water Temperature Sensor Resistance 20 C 4F 18 80 2 37 0 C 32 about 6 544 40 C 104 F 1 136 0 095 100 C 212 0 1553 0 0070 Reference Information Speed Sensor Removal e Disconnect the speed sensor lead connector A e 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 htio mototh com aPIBOSBBS2 E Switches and Sensors Speed Sensor Inspection e Remove the speed sensor see Spe
300. or 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 hito mototh com ELECTRICAL SYSTEM 16 35 16 36 ELECTRICAL SYSTEM Ignition System e Pushing the starter button turn the engine 4 5 sec onds with the transmission gear in neutral to measure the crankshaft sensor peak voltage e Repeat the measurement 5 or more times Crankshaft Sensor Peak Voltage Standard 1 9 V or more Special Tools Hand Tester 57001 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B x If the tester reading is not specified one check the crank shaft sensor 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 lb e Install 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 t
301. or 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 http mototh com ELECTRICAL SYSTEM 16 33 16 34 ELECTRICAL SYSTEM Ignition System A WARNING The ignition system produces extremely high volt age Do not touch the spark plugs or stick coils while the engine is running or you could receive a severe electrical shock CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition switch is on or while the engine is running This is to prevent ECU 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 Clutch chapter e Remove Bolts A Crankshaft Sensor B e Pull out the grommet C hito mototh com Ignition System Crankshaft Sensor Installation e Route the crankshaft sensor lead correctly se
302. ormally be measured NOTE Olt is not necessary to remove the coupling bearing for inspection If the bearing is removed it will need to be replaced with a new one e Turn the bearing in the coupling back and forth A while checking for plays roughness or binding xf 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 e Remove the rear wheel coupling and inspect the rubber dampers A e Replace the damper if it appears damaged or deterio rated Sprocket Wear Inspection e Visually inspect the engine and rear sprocket teeth for wear and damage If the teeth are worn as illustrated replace the sprocket and inspect the drive chain wear see Drive Chain Wear Inspection in the Periodic Maintenance chapter Worn Tooth Engine Sprocket A Worn Tooth Rear Sprocket B Direction of Rotation C NOTE Olf a sprocket requires replacement the chain is proba bly worn also When replacing a sprocket inspect the chain htio mototh com FINAL DRIVE 11 13 aJ06002851 E 005017851 E 11 14 FINAL DRIVE Sprocket Coupling Rear Sprocket Warp Inspection e Raise the rear wheel off the ground with stand so that it will turn freel
303. osition once it moves out to take up camshaft chain slack Observe all the rules listed below When removing the tensioner do not take out the mounting bolts only halfway Retightening the mounting bolts from this position could damage the tensioner and the camshaft chain Once the bolts are loosened the tensioner must be removed and reset as described in Camshaft Chain Ten sioner Installation Do not turn over the crankshaft while the tensioner is removed This could upset the camshaft chain timing and damage the valves e Remove Cap Bolt A Washer B Spring 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 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 e Turn the crankshaft 2 turns clockwise to allow the ten sioner to expand and recheck the camshaft chain timing hito mototh com iG Pos Cent P ENGINE TOP END 5 15 Camshaft Camshaft Chain Camshaft Removal e Remove Cylinder Head Cover see Cylinder Head Cover Re moval e Position the crankshaft as follows ORemove the upper A and lower
304. ot 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 prevent corrosion and deposits in the fuel system do not add to fuel any fuel antifreeze chemicals htio mototh com 0617038831 E FUEL SYSTEM DFI 3 19 DFI Servicing Precautions OTo maintain the correct fuel a
305. ototh com 01050404531 E 0105040551 E a105040B631 E 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 xf 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 Rod 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 th
306. ototh com 16 60 ELECTRICAL SYSTEM Meter Gauge Indicator Unit Electronic Combination Meter Unit Inspection e Remove the meter unit A see Meter Unit Removal 1 Battery 2 Ignition 3 Ground 4 Unused 5 Speed Sensor Signal 6 Tachometer Signal 7 Water Temperature Sensor 8 Cil Pressure Warning Indicator Light LED 9 Fuel Level Warning Indicator Light LED 10 Speed Sensor Supply Voltage 11 High Beam Indicator Light LED 12 Neutral Indicator Light LED 13 Unused 14 Right Turn Signal Indicator Light LED 15 Left Turn Signal Indicator Light LED 16 FI Indicator Light LED 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 Liquid Crystal Display LCD Segments 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 1 OConnect the battery negative terminal to the terminal 3 e Connect the terminal 2 to the terminal 1 htio mototh com HP17231H52 E HP172B09H51 0P17300851 ELECTRICAL SYSTEM 16 61 Meter Gauge Indicator Unit OWhen the terminals are connected all the LCD segments A and LED warning lights B appear FI warning light appear for two s
307. owing measures to prevent engine damage when the DFI or the ignition system parts have troubles Service Output Signal Usable 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 Main Throttle Sensor ignition timing at closed throttle position and Output Voltage sets the DFI in the D J method 0 20 4 8 V 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 Inlet Air Pressure If the inlet air pressure sensor system fails the Inlet Air se Pressure absolute signal Pv is out of the usable range wiring Pv 150 mmHg 800 short or open the ECU sets the DFI in the a Main Throttle Sensor Sensor mmHg N method Inlet Air If the inlet air temperature sensor fails the Temperature Inlet Air Temperature signal is out of the usable range wiring short P Ta 30 C 20 6 79 pL Sensor or open the ECU sets Ta at 40 C Water If the water temperature sensor system fails Temperature NU E the signal is out of the usable range wiring Tw 2 30C 120 C l Sensor short or open the ECU sets Tw at 80 Crankshaft sensor must Crankshaft send 22 signals output If crankshaft sensor generates other than 22 Sensor signal to the ECU at signals the engine stops by itself the one cranking Speed se
308. own Starter motor rotating but engine doesn t turn over otarter 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 otarter idle gear seizure No fuel flow No fuel in tank Fuel pump trouble Fuel tank air vent obstructed Fuel filter clogged Fuel line clogged Engine flooded Clean spark plug and adjust plug gap Starting technique faulty When flooded do not crank the engine with the throttle fully opened This promotes engine flood because more fuel is supplied automatically by DFI No spark 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 htio mototh com 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
309. p Bolts 1 12 12 N m 1 2 kgf m 106 in Ib y L u i d 0E11155851 e Install Camshaft Chain Tensioner see Camshaft Chain Ten sioner Installation Cylinder Head Cover see Cylinder Head Cover Instal lation hito mototh com 5 18 ENGINE TOP 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 EX side faces to the right side CAUTION Inlet sprocket must use IN marked bolts holes A Exhaust sprocket must use EX marked bolts holes 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 Ib l 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 e Measure each clearance between the camshaft journal and the camshaft cap using plastigage press gauge A e Tighten Torque Camshaft Cap Bolts 12 N m 1 2 kgf m 106 in Ib NOTE ODo not turn the camshaft when the plastigage is be tween the journal and camshaft cap Camshaft Journal Camshaft Cap Clearance Standard 0 028 0 071 mm 0 0011
310. pecial Tools and Sealant Compression Gauge Adapter M10 x 1 0 Piston Pin Puller 57001 1317 57001 1568 E STSTIS6aST C ST5Ti317STY Valve Seat Cutter Holder 54 5 Piston Pin Puller Adapter C 57001 1330 57001 1657 515713430851 Valve Guide Arbor 4 5 Kawasaki Bond Silicone Sealant 57001 1331 92104 0004 35157165731 ST5Ti3315T1 31920004371 E Valve Guide Reamer 54 5 57001 1333 ST57i33351 htio mototh com ENGINE TOP END 5 11 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 in the Fuel System DFI chapter Air Switching Valve with Hoses see Air Switching Valve Removal Air Suction Valve Cover Bolts A and Clamp ap 25 Air Suction Valve Cover B RET Air Suction Valve C Air Suction Valve Installation e Install the air suction valve A so that its side where stop per is fixed with the screws B faces the front C e Tighten Torque Air Suction Valve Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib HEO4048H51 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 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
311. pection 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 hito mototh com 00809854 aJ060090831 E aJ065008031 E aJ06002851 E WHEELS TIRES 10 17 Hub Bearing Hub Bearing Lubrication NOTE OSince the hub bearings are packed with grease and sealed lubrication is not required hito mototh com htio mototh com FINAL DRIVE 11 1 Final Drive Table of Contents sz dofeje sie VIEW cr EN NE 11 2 OS Gill CM e e e 11 4 SO a a 11 5 Dve Cha enore O 11 6 Drive Crain slack MIRIS eR rU IU EET 11 6 Drive Chain Slack AgJUSUTIe TE usc oou onu e gara eme nae cene pad aen itae AE EE NR PERLE vx heces 11 6 Wheel Alignment Inspection Adjustment occcccoccnnccncnnccnocnnonoconononcnnonanonononcncnnarnnonananonnnens 11 6 Drive Chaint Wear INSDeCUON erratas 11 6 Drive Chain LUC AE OM siasaniegns pnchabneetadantnastiesieaaneeds 11 6 Dive Ghain Removal tia 11 6 Drive Chain Installation Ads 11 7 proce COUDINO M 11 10 Engine Socket HerboVdlsss iiec eco nee
312. peed 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 12 000 r min rpm 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 Q at 20 C 68 F Non adjustable and non removable 4 75 5 25 V DC between BL and BR BK leads 1 073 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 6k0 4 75 5 25 V DC between BL and BR BK leads 3 80 4 20 V DC at standard at
313. ploded View i jl E d ld Ld oP Ae meee ee I A dil ESS oe aa 0162140565 G htio mototh com CRANKSHAFT TRANSMISSION 9 3 Exploded View 2 Timing Rotor Bolt 40 4i 30 3 Oi Plate Bois 1 98 10 sSmb Li 4 Breather Piate Bos os 10 ein i 5 Shit Shaft Retur Spring Pn 29 29 22 i OiPpeBos o ene 7 Crankcase Bots MO L namm 44 45 32 MOS Crankcase Bots M9 L 83mm 44 48 32 MOS Crankcase Bots M8 L 73mm 35 36 26 MOS I0 Crankcase Bots M8 L 60 mm 35 36 26 mos H Crankcase Bots MB L 110mm 275 28 2 s 12 Crankcase Bots M8 L S0 mm 275 28 29 s 18 Crankcase Bolts M6 196 20 1 s 14 Upper Crankcase Bots 275 28 20 s 15 Do not apply any grease or oil G Apply grease L Apply a non permanent locking agent LG Apply liquid gasket Kawasaki Bond 92104 1064 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 o Follow the specific tightening sequence SS Apply silicone sealant Three Bond 1207B Z I Z Z zZ nin OJO O O riririr NINII CD CD htio mototh com 9 4 CRANKSHAFT TRANSMISSION Exploded View 01621415885 G htio mototh com CRANKSHAFT TRANSMISSION 9 5 Exploded View 2 Tran
314. proof Joint C Stick Coil 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 htio mototh com FUEL SYSTEM DFI 3 11 3 12 FUEL SYSTEM DFI DFI System Terminal Names 17 ONDAN Subthrottle Valve Actuator Drive Signal 2 Subthrottle Valve Actuator Drive Signal 1 Water Temperature Warning Light Signal Unused Oxygen Sensor Signal Speed Sensor Signal Main Throttle Sensor Signal Inlet Air Pressure Sensor Signal Unused 10 Vehicle down Sensor Signal 12 13 14 15 16 Power Supply to Sensors Neutral Switch Signal Crankshaft Sensor 4 Signal Unused Unused Power Supply to ECU from ECU Main Re lay Power Supply to ECU from Battery 18 19 20 21 22 23 24 25 26 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 Sensor Signal htio mototh com ac17
315. pump e Remove the pressure tester replenish the coolant and install the radiator cap hito mototh com 3 zT rc 0005013851 Coolant Cooling System Flushing Over a period of time the cooling system accumulates rust scale and lime in the water jacket and radiator When this accumulation is suspected or observed flush the cool ing system If this accumulation is not removed it will clog up the water passage and considerable reduce the effi ciency of the cooling system e Drain the cooling system see Coolant Change in the Pe riodic Maintenance chapter e Fill the cooling system with fresh water mixed with a flush ing compound CAUTION Do not use a flushing compound which is harmful to the aluminum engine and radiator Carefully follow the instructions supplied by the manufacturer of the cleaning product e Warm up the engine and run it at normal operating tem perature for about ten minutes e Stop the engine and drain the cooling system 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 hito mototh com
316. put shaft C e Disengage the drive chain from the engine sprocket hito mototh com Sprocket Coupling Engine Sprocket Installation e 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 O Tighten 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 N m 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 chapter e 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 e Remove the rear sprocket nuts A e Remove the rear sprocket B Rear Sprocket Installation e Install the sprocket facing the too
317. r B of the vehicle down sensor A with the needle adapter set D Vehicle down Sensor Power Source Voltage Connections to Sensor Meter BL lead D Meter BR BK lead E e Turn the ignition switch ON and measure the power source voltage with the connector joined Vehicle down Sensor Input Voltage Standard 4 75 5 25 V DC e Turn the ignition switch OFF If the reading of input voltage is less than the standard check the ECU for its ground power supply and wiring shorted xf the power source is normal check the output voltage daciTi1 B52 E htio mototh com 3 58 FUEL SYSTEM DFI Vehicle down Sensor Service Code 31 e Remove the sensor e 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 F e Hold the sensor vertically e Turn the ignition switch ON and measure the output volt age with the connector joined OTilt the sensor 60 70 or more C right or left then hold the sensor almost vertical with the arrow mark pointed up 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
318. r 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 0114040551 E 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 check its condition xf the bearing is noisy does not spin smoothly or has any rough spots replace it e Check the needle bearings OThe rollers in a needle bearing normally wear very little and wear is difficult to measure Instead of measuring inspect the bearing for abrasion color change or other damage If there is any doubt as to the condition of a needle bear ing replace it Oil Seal Inspection e Inspect the oil seals x Replace it if the lips are misshapen discolored indicating that the rubber has deteriorated hardened or otherwise damaged htio mototh com
319. r pressure sensor malfunction wiring open or short Inlet air temperature sensor malfunction wiring open or short Water temperature sensor malfunction 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 Model an Stick Ignition coil 1 malfunction wiring open or short otick Ignition coil 22 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 67 ANA REBEL Oxygen sensor heater malfunction wiring open or short Europe Model MAANANNNN ann Oxygen sensor malfunction wiring open or short Europe Model Notes OThe ECU may be involved in these problems If all the parts and circuits checked out good be sure to check the ECU for ground and power supply If the ground and power supply are checked good replace the ECU OWhen no service code is displayed the electrical parts of the DFI system has no fault and the mechanical parts of the DFI system and the engine are suspect hito mototh com 3 40 FUEL SYSTEM DFI Self Diagnosis Backups Backups OThe ECU takes the foll
320. r 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 htio mototh com 2 28 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Apply oil to the sides of the rollers so that oil will penetrate to the rollers and bushings Apply the oil to the O rings so that the O rings will be coated with oil e Wipe off any excess oll Oil Applied Areas A O rings B m E Jk E CATIA Errata ooo A Hio suse akmn4n0gn 751 Drive Chain Slack Inspection NOTE OCheck the slack with the motorcycle setting on its side stand OClean the chain if it is dirty and lubricate it if it appears dry e Checkthe wheel alignment see Wheel Alignment Inspec tion e Rotate the rear wheel to find the position where the chain is tightest e Measure the vertical movement chain slack A midway between the sprockets x If the chain slack exceeds the standard adjust it Chain Slack Standard 30 40 mm 1 2 1 6 in d512021B851 Drive Chain Slack Adjustment e Remove the cotter pin A and loosen the axle nut B e Loosen the both chain adjuster locknuts C x If the chain is too loose turn in the left and right chain adjuster nuts D evenly x If 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
321. rake 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 LU Brake Disc Wear e 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 4 3 4 7 mm 0 17 0 19 in Rear 4 8 5 2 mm 0 19 0 20 in GL0BOT7BS C 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 Sy aLoguisasi 0 x If runout exceeds the service limit replace the disc Disc Runout Standard 0 15 mm 0 006 in or less Service Limit 0 3 mm 0 01 in htio mototh com Brake Fluid Brake Fluid Level Inspection e Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter Brake Fluid Change e Refer to the Brake Fluid Change in the Periodic Mainte nance chapter Brake Line Bleeding The brake fluid has a very low compression
322. ral switch and relay box xf their parts are normality replace the ECU 3rd Check e Inspect the engine for its secure stop after the following operations are completed e Run the engine to the following conditions Condition Transmission Gear 1st Position Clutch Lever Pulled in Sidestand Up Set the sidestand on the ground then the engine will stop If whichever may not be stopped inspect the neutral switch starter lockout switch sidestand switch and relay box x If their parts are normality replace the ECU htto mototh com 16 40 ELECTRICAL SYSTEM Ignition System IC Igniter Inspection OThe IC igniter is built in the ECU A e Refer to the Interlock Operation Inspection Ignition Sys tem Troubleshooting chart and Fuel System DFI chapter for ECU Power Supply Inspection hito mototh com ELECTRICAL SYSTEM 16 41 Ignition System ignition System Troubleshooting Faulty ignition No spark No good Batiery Inspection Charge or replace battery Good Ignition system wiring and connector NO Sonn 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 Mo good Voltage is less than the specified value Stick coil primary peak voltage inspection Good Inspect 1 Lower resistance in a hand tester Use KAWASAKI Hand Tester 2 Crankshaft sensor peak v
323. rance Air Switching Valve Unit Test 5 12 Measurement Wobble Clean Air System Hose MEMO Seve 5 26 In SDecllon cian co aee oss 5 12 Valve Seat Inspection 5 27 Cylinder Head Cover 5 13 Valve Seat Repair 5 27 Cylinder Head Cover Removal 5 13 Cylinder PISlONS ainia 5 32 Cylinder Head Cover Installation 5 13 Cylinder Remowval 5 32 Camshaft Chain Tensioner 5 14 Cylinder Installation 5 32 Camshaft Chain Tensioner Piston Removal 5 32 FAS MOV A lucena ieget estes quid 5 14 Piston Installation 5 33 Camshaft Chain Tensioner Cylinder Wear 5 34 Installation 5 14 Piston Wear eeesse 5 34 Camshaft Camshaft Chain 5 15 Piston Ring Piston Ring Groove Camshaft Removal 5 15 WOOP iron DH OUO dd 5 35 Camshaft Installation 5 15 Piston Ring Groove Width 5 35 Camshaft and Sprocket Piston Ring Thickness 5 35 ASSOMDIV dan 5 18 Piston Ring End Gap 5 36 Camshaft Camshaft Cap Wear 5 18 Throttle Body Holder 5 37 Camshaft Runout 5 19 Throttle Body Holder Installation 5 97 Cari Westland 5 19 Vu iaa 5 38 Camshaft Chain Removal
324. requency is indicated in the oscillator A if the square wave illustrated as shown would be input into the termi nal 6 Olndicates approximately 6 000 rpm in case the input fre quency would be approximately 200 Hz htio mototh com ELECTRICAL SYSTEM 16 63 HP17308H51 E E co v HP17309H51 16 64 ELECTRICAL SYSTEM Meter Gauge Indicator Unit e f 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 2 to the terminal 6 repeatedly OThen the tachometer needle A should flick B If the needle does not flick replace the meter assembly Indicator Lights Inspection e Connect the 12 V battery and terminals in the same man ner as specified in the Liquid Crystal Display LCD Seg ments check Neutral Indicator Light LED A Fl Indicator Light LED B Oil Pressure Water Temperature 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 G 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
325. res and bad connections will affect electrical system op eration OMeasure coil and winding resistance when the part is cold at room temperature OColor Codes BK Black G Green P Pink BL Blue GY Gray PU Purple BR Brown LB Light Blue R Red CH Chocolate LG Light Green W White DG Dark Green O Orange Y Yellow OElectrical Connectors Female Connectors A htio mototh com APAROS E ELECTRICAL SYSTEM 16 17 Precautions Male Connectors B aP065102531 E htio mototh com 16 18 ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection e Visually inspect the wiring for signs of burning fraying etc x If any wiring is poor replace the damaged wiring e Pull each connector A apart and inspect it for corrosion dirt and damage xf 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 Mu 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 Q the lead is defective Re place the lead or the wiring harness B if necessary HPO DnB8H51 htio mototh com ELECTRICAL SYSTEM 16 19 Battery Battery Removal e Remove Seat see Seat Removal in the Frame chapter e Disconnect the negative
326. ress 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 hito mototh com 0E15501 8531 E Valves e Measure the outside diameter of the seating surface with a vernier caliper xf the outside diameter of the seating surface is too small repeat the 45 grind until the diameter is within the spec ified range Widened Width A of engagement by machining with 45 cutter Ground Volume B by 32 cutter 32 C Correct Width D Ground Volume E by 60 or 55 cutter 60 or 55 F e Measure the outside diameter of the seating surface with a vernier caliper xf 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 9 grinding operation eas ier O When the valve guide is replaced be sure to grind with 45 cutter for centering and good contact x If the outside diameter A of the seating surface is too
327. ressed onto the steering stem with a suitable commercially avail able chisel B Stem Stem Bearing Installation e Replace the bearing outer races with new ones e Apply grease to the outer races and drive them into the head pipe at the same time Special Tool Bearing Driver Set 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 641 5 B 57001 1345 e Apply grease to the lower ball bearing A and install it onto the stem e Apply grease to the upper ball bearing B and inner race 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 hito mototh com STEERING 14 7 0050150851 E 14 8 STEERING Steering Stem e Settle the inner races in place as follows OTighten the steering stem nut with 39 N m 4 0 kgf m 29 ft lb of torque first and loosen it a fraction of a turn until it turns lightly Afterward tighten it again with specified torque using a stem nut wrench A in the direction shown OCheck that there is no play and the steering stem turns smoothly without rattles If not the steering stem bearings may be damaged Special Tool Steering Stem Nut Wrench 5
328. 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 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 e Check the tire rotation mark on the front and rear tires and install them on the rim accordingly Tire Rotation Mark A Rotating Direction B 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 A WARNING Be sure to install the valve core whenever inflating the tire and do not inflate the tire to more than 400 kPa 4 0 kgf cm 57 psi Overinflation can explode the tire with possibility of injury and loss of life htio mototh com 0105041854 aJ05030751 E ajJn55044B851 E Tires e Check to see that the rim lines A on both sides of the tire sidewalls are parallel with the
329. rminal 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 6 V or more Ignition Switch ON Both Battery Voltage 12 6 V or more x If the meter does not read as specified check the follow ing Main Fuse 30 A see Fuse section in the Electrical Sys tem chapter ECU Fuse 15 A see Fuse Inspection in the Electrical System chapter ECU Main Relay see Relay Circuit Inspection in the Electrical System chapter Power Source Wiring see wiring diagram below x If the inspection checks good the ECU is damaged Re place the ECU The ECU itself cannot be checked or ser viced hito mototh com 06170105651 0617011551 LU FUEL SYSTEM DFI 3 79 ECU ECU Power Source Circuit QG173BE3HW2 E 1 ECU 7 Relay Box 2 Water proof Joint C 8 Main Fuse 30 A 3 Ignition Switch 9 Battery 4 Water proof Joint A 10 Frame Ground 5 ECU Main Fuse 15 A 11 Joint Connector 6 ECU Main Relay htio mototh com 3 80 FUEL SYSTEM DFI Fuel Line Fuel Pressure Inspection NOTE OThis inspection can determine which trouble the DFI system has mechanical or electrical trouble Olt is preferable to measure the fuel pressure while run ning the motorcycle just wh
330. rminal respectively x If the test light turns on the regulator rectifier is defective Replace it xf the test light does not turn on continue the test e Do the 2nd step regulator circuit test OConnect the test light and the 12 V battery in the same manner as specified in the Regulator Circuit Test 1st Step OApply 12 V to the voltage BR terminal OCheck the BK1 BK2 and BK3 terminal respectively xf the test light turns on the regulator rectifier is defective Replace it x If the test light does not turn on continue the test e Do the 3rd step regulator circuit test OConnect the test light and the 12 V battery in the same manner as specified in the Regulator Circuit Test 1st 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 lf 24 V is applied for more than a few seconds the regula tor rectifier may be damaged x If the test light did not light when the 24 V was applied momentarily to the voltage monitoring terminal the regu lator rectifier is defective Replace it x If the regulator rectifier passes all of the tests described it may still be defective If the charging system still does not work properly after checking all of the components and the battery test the regula
331. rminals by connecting the hand tester and one 12 V battery to the relay box as shown see Relay Box Internal Circuit in this section xf the tester does not read as specified replace the relay box Relay Circuit Inspection with the battery disconnected A Tester Connection Tester Reading Q AA o ECU Main Relay LO Fuel Pump Relay Starter Circuit Relay Fan Relay The actual reading varies with the hand tester used htio mototh com 16 72 ELECTRICAL SYSTEM Relay Box Relay Circuit Inspection with the battery connected sua e Tester Tester Connection Reading Q ECU Main Relay 48 i Lo Fuel Pump Relay Fan Relay 18 19 Battery Tester Connection Connection 4 3 DC 25 V Range Reading V Starter 16 12 Battery Circuit Relay Voltage Apply positive lead E 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 13 15 x The resistance should be low in one direction and more than ten times as much in the other direction If any diode shows low or high in both directions the diode is defective and the relay box must be replaced NOTE O The actual meter reading varies with the meter or tester used and the individual diodes but generally speaking the lower reading
332. rotate the engine sprocket the output voltage will be increased daciTi4ABS E 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 l the reading speed sensor operation and wiring are good check the ECU for its ground and power supply see ECU Power Supply Inspection Speed Sensor Circuit aGG179TTHW2 E 1 ECU 2 Speed Sensor 3 Meter Unit 4 Water proof Joint B 5 Frame Ground 6 Joint Connector htio mototh com FUEL SYSTEM DFI 3 57 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 s Connection and Vehicle down Sensor B chang P 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 06170046514 C Vehicle down Sensor Inspection NOTE OBe sure the battery is fully charged e Connect a digital volt meter C to the connecto
333. route the brake hose according to Cable Wire and Hose Routing section in the Appendix chapter aL105620151 E Brake Operation Inspection e Inspect the operation of the front and rear brake by run ning the vehicle on the dry road If 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 hito mototh com 2 32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Fluid Level Inspection n AE la oT ey i e Check that the brake fluid level in the front brake reservoir A is above the lower level line B NOTE OHold the reservoir horizontal by turning the handlebar when checking brake fluid level lf 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 e Check that the brake fluid level in the rear brake reservoir A is above the lower level line B x If the fluid level is lower than the lower level line fill the reservoir to the upper level line C A WARNING Change the brake fluid in the brake line completely if the brake fluid must be refilled but the type and brand of the brake fluid that is already in the reser voir are unidentified After changing the fluid use only the same type and brand of fluid thereafter
334. s chapter If the ground and power supply are good the ECU is suspect Replace the ECU hito mototh com FUEL SYSTEM DFI 3 23 Hbi 8TOHS2 E Hb1 8TIES2 C 3 24 FUEL SYSTEM DFI 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 sysiem inspection General fuel system throttle assy air cleaner fuel tank etc DCITSSTR 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 DFI system problem or a general engine problem htio mototh com FUEL SYSTEM DFI 3 25 Troubleshooting the DFI System Sample Diagnosis Sheet Rider name Registration No license plate No Year of initial registration Model MEM Environment when problem occurred Ofine Ocloudy Orain snow Oalways Dother hot warm Ecold Overy cold Oalways Problem Echronic ofte
335. s 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 resistance 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 htio mototh com aLO05b40231 E rl n E Am 15 FP PERIODIC MAINTENANCE 2 57 Periodic Maintenance Procedures 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 lb e Install Stick Coils see Stick Coil Ignition Coil together with Spark Plug Cap Installation in the Electrical System chapter htio mototh com htio mototh com FUEL SYSTEM DFI 3 1 Fu
336. s of Pressure L x 0 2642 gal US kPa x 0 01020 kgf cm L x 0 2200 gal imp kPa x 0 1450 psi L x 1 057 qt US kPa x 0 7501 cmHg L x 0 8799 qt imp kgf cm x 98 07 kPa L x 2 113 pint US kgf cm x 14 22 psi L x 1 816 pint imp cmHg x 1 333 kPa mL x 0 03381 oz US mL x 0 02816 Oz imp Units of Speed mL x 0 06102 cu in km h 06214 mph Units of Force Units of Power N lt 01020 sec kg kW x 1360 PS A EM MEE IN REM NM kW x 1341 HP kg x MODE N PS x 0 7355 kW kg x 2205 lb PS x 0 9863 HP Units of Temperature 9 C 40 5 F 40 9 176 212 248 ceu gos SE 40 2 C F 68 104 284 80 100 120 140 160 1180 200 220 240 260 280 300 320 hito mototh com htio mototh com PERIODIC MAINTENANCE 2 1 Periodic Maintenance Table of Contents FPerOdiC Maintenance Chata a 2 3 TOque ana LOCKING AG CIM seresa doi icra vie a Vt DR EU T ROO cate adn 2 6 e ae nen ee eee D EP 2 11 Special fele e PET T T Rm 2 13 Periodic Maintenance Procedures caia dias 2 14 A e CO AERA 2 14 Fuel Hose Inspection fuel leak damage installation condition 2 14 Throttle Control System INSpectiON cccccccccnccccnnnncononnnnnononcnnnonnannnnnnnncnnnnnonncnnonnnnennnnnos 2 14 Idle Speed INSPEC CHON xac eet edet E tales 2 15 dle Speed ACIUSIM GNM RE io 2 15 Air Cleaner Element Cleanino occccccocccnncccnoccnnononccn
337. 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 Battery BK Lead Terminal Alf 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 If 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 htio mototh com iis P 0P19105851 ELECTRICAL SYSTEM 16 71 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 e Take out the relay box A and disconnect the connectors B Relay Circuit Inspection e Remove the relay box see Relay Box Removal e Check conductivity of the following numbered te
338. serve tank If whitish cotton like wafts are observed aluminum parts in the cooling system are corroded If the coolant is brown iron or steel parts are rusting In either case flush the cooling system lf the coolant gives off an abnormal smell check for a cooling system leak It may be caused by exhaust gas leaking into the cooling system Coolant Level Inspection e Refer to Coolant Level in the Periodic Maintenance chap ter Coolant Draining e Refer to Coolant Change in the Periodic Maintenance chapter Coolant Filling e Refer to 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 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
339. 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 htio mototh com 1 12 GENERAL INFORMATION Technical Information Inlet Air Pressure Sensor Atmospheric pressure sensor and camshaft position sensor are not equipped with the ER650A As a substitute of these sensors above the ER650A 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 analyzing 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 Vaccum Hose 1 Throttle Bore hito mototh com GENERAL INFORMATION 1 13 Unit Conversion Table Prefixes for Units Units of Length IS st mega M x 1000 000 l kilo k x AUDOD mm x 0 08937 in centi C x 0 01 milli m x 0 001 Units of Torque micro u 0 000001 N m x 0 1020 kgf m N m x 0 7376 ftlb N m x 8 851 E in Ib Units of Mass kgf m x 9 807 N m kg x 2 205 Ib kgfm x 7 233 fbb g x 0 03527 oz kgfm x 86 80 inlb Units of Volume Unit
340. smission Case Bots 20 20 15 5 SWtRodPateBot 98 10 B87mb 6 Neutral Switch Holder Screw 49 050 43imb 1 7 Newa swen as 15 6 Sbit Shatt CoverBots os 10 emb 0 gt gt 9 Shit Shatt Cover Sorew 49 oso 43imb 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 htto mototh com 9 6 CRANKSHAFT TRANSMISSION Specifications o lea Standard Crankshaft Connecting Rods Connecting Rod Bend TIR 0 2 100 mm 0 008 3 94 in TIR 0 2 100 mm 0 008 3 94 in Connecting Rod Twist TEE Connecting Rod Big End Side Clearance Connecting Rod Big End Bearing Insert Crankpin Clearance Crankpin Diameter Marking None O Connecting Rod Big End Inside Diameter Marking None O Connecting Rod Big End Bearing Insert Thickness Brown Black Blue Connecting Rod Big End Bearing Insert Selection Con rod Big End Bore Diameter Marking Crankpin Diameter Marking Connecting Rod Bolt Stretch Usable Range New Connecting Rod Used Connecting Rod Crankshaft Side Clearance 0 13 0 38 mm 0 58 mm 0 0051 0 0150 in 0 023 in 0 017 0 041 mm 0 08 mm 0 0007 0 0016 in 0 0031 in 37 984 38 000 mm 37 97 mm 1 4954 1 4961 in 1
341. spect crankshaft sensor and IC igniter in ECU see chapter 16 Poor acceleration PO Too low fuel pressure Inspect see chapter 3 Water or foreign matter in fuel Change fuel Inspect and clean fuel system see chapter 3 Fuel injector trouble Imspectisee chapter 3 A 40 Water temperature sensor trouble Inspect see chapter 3 Subthrottle sensor trouble QS SAO nspect see chapter 3 Stumble O S inspect see chapter 3 inspect see chapter 3 Subthrottle valve actuator trouble Inspect see chapter 3 Water temperature sensor trouble nspect 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 NENNEN inspect see chapter 3 inspect see chapter 3 inspect see chapter 3 inspect see chapter 3 MERE ME Crankshaft sensor trouble Inspect see chapter 16 Spark plug burned or gap maladjusted Replace see chapter 2 htio mototh com 3 32 FUEL SYSTEM DFI DFI System Troubleshooting Guide Runon dieseing Loose terminal of battery cable or ECU Inspect and repair see chapter 16 ground lead Carbon accumulating on valve seating surfac
342. ssories is 3rd position Spring Preload Setting Standard Position 3rd position Adjustable Range 1st to 7th position e f the compression of the spring is not suited to the op erating conditions adjust it to an appropriate position by referring to the table below Spring Preload Adjustment Adjuster Damping Shock Road Driving E Absorber Load lx Position Force Conditions Speed Hardness 1st Weak Soft Light Good Low 1 il 1 1 1 y l y y l otrong Hard Heavy Bad Highway Rear Shock Absorber Hemoval e Remove Frame Covers see Frame Cover Removal in the Frame chapter Muffler Body see Muffler Body Removal in the Engine Top End chapter e Raise the rear wheel off the ground with jack Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Squeeze the brake lever slowly and hold it with a band A A WARNING Be sure to hold the front brake when removing the shock absorber or the motorcycle may tall over It could cause an accident and injury e Remove Right Stay Cover A htio mototh com SUSPENSION 13 15 0H04611 0 1 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 e Remove the shock absorber C from backward Rear Shock Absorber Installation e Installation is the reverse of removal e Apply grease to the lip of oil seals and bearing of rear shock absorber OBe
343. st 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 x If the headlight beam points too low or high adjust the vertical beam Headlight Beam Vertical Adjustment e Turn the vertical adjuster A on the headlight with the screwdriver in or out to adjust the headlight vertically hito mototh com PERIODIC MAINTENANCE 2 41 Periodic Maintenance Procedures 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 Low Beam A Height of Headlight Center B High Beam C 0517055851 0517058851 Sidestand Switch Operation Inspection e Inspect the sidestand switch A operation accordance to below table Sidestand Switch Operation Sidestand ear Clutch V 2 Position Lever d running afi d 2 A are T running Up In Gear Released Poesnt Stops Start running running running Down In Gear Released DOCU Stops start Down In Gear Pulled in oe Stops Start hito mototh com 2 42 PERIODIC MAINTENANCE Periodic Maintenance Procedures x If the sidestand switch operation does not work inspect or replace the following item Battery see Charging Condition Inspection in the Elec trical System chapter Main F
344. starting stopping For higher odometer readings repeat at the frequency interval established here hito mototh com PERIODIC MAINTENANCE 2 5 Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY Whichever ODOMETER READING x 1 000 km x 1 000 mile CHANGE REPLACE ITEM Radiator hose and O ring Brake hose and pipe Brake fluid Rubber parts of master cylinder and caliper 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 hito mototh com 2 6 PERIODIC MAINTENANCE Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non permanent locking agent or liquid gasket Letters used in the Remarks column mean AL Tighten the two clamp bolts alternately two times to ensure even tightening torque EO Apply engine oil L Apply a non permanent locking agent to the threads Lh Left hand threads MO Apply molybdenum disulfide oil solution R Replacement Parts S Tighten the fasteners following the specified sequence Si Apply silicone grease ex PBC grease SS Apply silicone sealant Fuel System Water Temperature Sensor Speed Sensor Bolt Fuel Pump Bolts Oxygen Sensor Cooling System 106 in lb 69 in lb 87 in lb 32 5 Radiator Hose Clamp Screws 2 0 0 20 1
345. stem 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 e Refer to the Headlight Aiming Inspection in the Periodic Maintenance chapter Headlight Bulb Replacement e Remove Headlight Assy see Headlight Removal Installation Headlight Bulb Dust Cover A e Remove Hook A Headlight Bulb B CAUTION When handling the quartz halogen bulb never touch the glass portion with bare hands Always use a clean cloth Oil contamination from hands or dirty rags can reduce bulb life or cause the bulb to explode NOTE OClean off any contamination that inadvertently gets on the bulb with alcohol or soap and water solution e Replace the headlight bulb e Fit the projection A of the bulb in the hollow B of the headlight e Install the hook C hito mototh com ELECTRICAL SYSTEM 16 49 16 50 ELECTRICAL SYSTEM Lighting System e Fit the dust cover A with the Top mark upward onto the b
346. 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 Ib Rear Shock Absorber Nut 59 N m 6 0 kgf m 44 ft Ib e Install the removed parts see appropriate chapters Rear Shock Absorber Inspection e Remove the rear shock absorber see Rear Shock Ab sorber Removal e Visually inspect the following items Smooth Stroke Oil Leakage Crack or Dent x 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 hito mototh com 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 e 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
347. t adjuster value aligns with If they do not adjust the chain slack and align the wheel alignment see Drive Chain Slack Adjustment NOTE OWheel alignment can be also checked using the straightedge or string method A WARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition hito mototh com 2 30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Drive Chain Wear Inspection e Remove Chain Cover see Swingarm Removal in the Suspension chapter e Rotate the rear wheel to inspect the drive chain for dam aged rollers and loose pins and links x If there is any irregularity replace the drive chain x Lubricate the drive chain if it appears dry e Stretch the chain taut by hanging a 98 N 10 kg 20 Ib weight A on the chain e Measure the length of 20 links B on the straight part C of the chain from the pin center of the 1st pin to the pin center of the 21st pin Since the chain may wear unevenly take measurements at several places x If any measurements exceed the service limit replace the chain Also replace the front and rear sprockets when the drive chain is replaced Drive Chain 20 link Length Standard 317 5 318 2 mm 12 50 12 53 in Service Limit 323 mm 12 7 in 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 e
348. t circuit the leads of the DFI or elec trical system parts by contact between adapters e Turn the ignition switch ON and measure the voltage with the connector joined CAUTION Incorrect reverse connection or short circuit by needle adapters could damage the DFI or electrical system parts OAfter measurement remove the needle adapters and ap ply silicone sealant to the seals A of the connector B for waterproofing Silicone Sealant Kawasaki Bond 56019 120 Seals of Connector e Always check battery condition before replacing the DFI parts A fully charged battery is a must for conducting accurate tests of the DFl 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 If any wiring is deteriorated replace the wiring hito mototh com FUEL SYSTEM DFI 3 21 0617045851 E 6170317151 E 3 22 FUEL SYSTEM DFI Troubleshooting the DFI System e Pull each conn
349. t 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 hito mototh com APPENDIX 17 27 Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Knocking Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect IC igniter in ECU trouble Crankshaft sensor trouble Miscellaneous Throttle valve wont 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 engin
350. t sensor In this case turn off the igni tion switch and turn it on again to enter the Dealer 2 mode In this mode the system tells all the troubles which the DFI system had in both static and dynamic conditions Crankshaft Sensor Removal Installation e See the Ignition System section in the Electrical System chapter Crankshaft Sensor Inspection OThe crankshaft sensor has no power source and when the engine stops the crankshaft sensor generates no sig nals e Crank the engine and measure the peak voltage of the crankshaft sensor see 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 ac1729766N2 E 1 ECU 2 Crankshaft Sensor hito mototh com Speed Sensor Service Code 24 25 Speed Sensor Removal Installation e See the Switches and Sensors section in the Electrical System chapter Speed Sensor Inspection e See Speed Sensor Inspection section 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 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
351. t 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 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 x If the reading stays on battery voltage and never shows O V Check the ECU and fuel pump relay xlf the voltage is in specification but the pump doesnt work replace the pump x If 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 xf the fuel filter is suspected of clogging or being damaged replace it with the fuel pump as a set chia P hito mototh com Fuel Pump Fuel Pump Circuit 1 ECU 2 Water proof Joint C 3 Engine Stop Switch 4 Ignition Switch 5 Ignition Fuse 10 A hito mototh com FUEL SYSTEM DFI 3 87 BCTTSE4RR E 6 Fuel Pump R
352. t wheel off the ground with jack Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e With the front wheel pointing straight ahead alternately tap each end of the handlebar The front wheel should swing fully left and right from the force of gravity until the fork hits the stop xf the wheel binds or catches before the stop the steering is too tight e Feel for steering looseness by pushing and pulling the forks 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 Headlight Assy see Headlight Removal Installation in the Electrical System 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 Straighten the claws A of the claw washer e Remove the steering stem locknut B and claw washer C htio mototh com 2 36 PERIODIC MAINTENANCE Periodic Maintenance Procedures 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 If the steering is too loose tighten the stem nut a
353. take off the holder shaft B e Remove the pad C on the piston side e Push the holder D towards the piston and remove the pad of the other side E from the holder shaft F 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 A WARNING Do not attempt to drive the motorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against the disc The brake will not function on the first application of the lever if this is not done Rear Brake Pad Removal e Remove the 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 e Remove the pad C on the piston side e Push the holder D towards the piston and remove the pad of the other side E from the holder shaft F Rear Brake Pad Installation e Push the caliper piston in by hand as far as it will go e Install the anti rattle spring in its correct position e Install the pad on the piston side first then install the other pad on the holder e Install the rear caliper see Caliper Installation A WARNING Do not attempt to drive the motorcycle until a full brake pedal is obtained by pumping the brake pedal
354. tallation 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 A into the hole for the banjo bolt to remove the piston A WARNING To avoid serious injury never place your fingers or palm inside the caliper opening If you apply com pressed air into the caliper the piston may crush your hand or fingers e Remove the dust seal and fluid seal e Remove the bleed valve and rubber cap NOTE Olf compressed air is not available with the brake hose still attached apply the brake pedal to remove the pis ton The remaining process is as described above hito mototh com 2 56 PERIODIC MAINTENANCE Periodic Maintenance Procedures Rear Caliper Assembly e Clean the caliper parts except for the pads CAUTION For cleaning of the parts use only disc brake fluid isopropyl alcohol or ethyl alcohol e Install the bleed valve and rubber cap Torque Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib 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 i
355. tank e 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 x If the fuel flow is much less than the specified check the battery condition see Battery section in the Electri cal System chapter If the battery is good replace the fuel pump e After inspection install the fuel tank see Fuel Tank In stallation e Start the engine and check for fuel leakage htio mototh com FUEL SYSTEM DFI 3 83 3 84 FUEL SYSTEM DFI Fuel Pump Fuel Pump Removal CAUTION Never drop the fuel pump especially on a hard sur face Such a shock to the pump can damage it A WARNING Gasoline is extremely flammable and can be explo sive under certain conditions Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Turn the ignition switch OFF Disconnect the battery terminal To make fuel spillage minimum draw the fuel out from the fuel tank when the engine is cold Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately e Draw the fuel out from the fuel tank with a commercially available electric pump e Remove the fuel tank see Fuel Tank Removal OBe careful of fuel spillage from the fuel tank since fuel still remains in the fuel tank and fuel pump Plug the fuel pipe
356. teaganindcnindhatent aueatedtis Inlet Air Pressure Sensor Service Code 12 ias dai la REMOVA NOMEN HC Treo SAM E m S Inipdt Voltage InsSpecllODmonussuico escis u Iudbr Aba Omput Voltage Insecta T D T DH Inlet Air Temperature Sensor Service Code 13 occcoonncccccccnccconococononononcnnocononncnnnnnonnnnnononenonnns PIGMOVAIAINSTAN ANION NEUE PE Quip t Voltage Inspector BER OES uen tu dde sana iore SENSO RESISTANCE Water Temperature Sensor Service Code 14 occcooccccccnnncccoconococcnnnoonnnonnnnncnonnncnonnnnnconnnnnnns Water Temperature Sensor Removal Installation sees Water Temperature Sensor Output Voltage InspectioN ccccoccccccoccncccnnococononoconenononos htio mototh com 3 2 FUEL SYSTEM DFI Sensor AeSIStaNnCe INSHSCUON e nace Crankshaft Sensor Service Code 21 ooocccconnnccccnccccconcnoconnncconcnnncnnnnonnnrononannnononnnnnnnnnnonannnns Crankshaft Sensor Removal InstallatiON oooccccooncococonnnocononcnoonnnccannncnnaconononenonnos Grankshall Sensor INSDCCIION asse see etin din Speed Sensor Service Gode a4 25 suisse ii Speed Sensor Removal InstallatiON cccococcccnnoconcnncnconnnncononnonnnonononnnonannnnnonanenonos Speed Sensor Inspection Speed Sensor Input Voltage InSpectioN cccccconccnccconcnnccconnnncnnnnnonnnnnnnnnnnnnnnnnnnonanennnos Speed Sensor Output Voltage Inspection ccccoocccncccccccn
357. th number marking A outward e 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 htio mototh com FINAL DRIVE 11 11 HN 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 aknbo4na8tS1 E 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 bottomed Special Tool Bearing Driver Set B 57001 1129 e Replace the circlip with a new one Special Tool Inside Circlip Pliers 57001 143 aknbo3BBS51 E htio mototh com 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 n
358. 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 e Temporarily install the reserve tank to the frame with two mounting 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 x f 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 F level line htio mototh com 2 50 PERIODIC MAINTENANCE Periodic Maintenance Procedures Radiator Hose and O ring Replacement e Drain the coolant see Coolant Change in the Periodic Maintenance chapter 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 Instal the new hoses and tighten the clamps securely e Fill the coolant see Coolant Change in the Periodic Main tenance chapter e Check the cooling system for leaks htio mototh com gs B amp z8HRJ E PERIODIC MAINTENANCE 2 51 Periodic Maintenance Pr
359. 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 If the throttle grip doesn t return properly check the throt tle cable routing grip free play and cable damage Then lubricate the throttle cable e Check the throttle grip free play A x If the free play is incorrect adjust the throttle cable Throttle Grip Free Play Standard 2 3 mm 0 08 0 12 in htio mototh com 05050872851 PERIODIC MAINTENANCE 2 15 Periodic Maintenance Procedures If necessary 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 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 ldle Speed Inspection e Start the engine and warm it up thoroughly e With the engine idling turn the handlebar to both sides A xlf 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
360. 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 grinding com pound produces a smooth matched surface on both the seat and the valve ORepeat the process with a fine grinding compound Lapper A Valve Seat B Valve C e he 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 htio mototh com daE158012251 E 01550120851 E ENGINE TOP END 5 31 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 OD Tool Vernier Caliper Purpose check seat O D against spec Results 45 Grind Machinist s Tool 45 Cutter d
361. 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 LU 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 HJ 008H51 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 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 htio mototh com 10 10 WHEELS TIRES Wheels Rims Wheel Inspection e Raise the front rear wheel off the ground with jack Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Spin the wheel lightly and check for roughness or binding xf roughness or binding is found replace the hub bearings e Inspect the wheel for small cracks dents bending or Warp x If there is any damage to the wheel replace the wheel e Remove the wheel and support it without the tire by the axle e Measure the rim runout axial A
362. 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 htio mototh com ELECTRICAL SYSTEM 16 31 16 32 ELECTRICAL SYSTEM Charging System Charging System Circuit MGHITION ory BATTERY CE3ICEO Ale Cot TAIL KOD BATTERY I TALE fomi IGN TIM CS ETRE TE Ignition Switch Alternator Regulator Rectifier Water proof Joint C Main Fuse 30 A Battery 12 V 10 Ah Load NN O 7091 WD htio mototh com 0P091448N2 E 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 clutch 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 Alternat
363. 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 hito mototh com BRAKES 12 21 12 22 BRAKES Brake Hose Brake Hose RemovalInstallation 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 htio mototh com SUSPENSION 13 1 Suspension Table of Contents de Lolo cio i i e AP Ro A 13 2 SPECI CALOMS nr lia 13 6 Special TOS tia 13 7 A o m 13 9 FOME FO CMO Val odias 13 9 PLONE FOR INSTANAOM ainia A E T 13 9 ROMs ON ONC MAING ainia aia 13 9 ELM FOR BISas Seniat reia oda 13 11 mien mend ASS daria iia 13 12 Jess ag lea aieo m m 13 13 Dust SE alINSOC CH ON urnas 13 13 FOLK SPA INSPECCION siao o de Dd 13 14 Rear MOCK ADSOIDEN sti deis o 0 o TET 13 15 Spri a Preload Ad USIME Ml 13 15 Rear Shock Absorber HOMO soii ios 13 15 Rear Shock Abosorper INSTalla OM nuit ia 13 16 Rear Shock Absorber Inspection irradia coto SURE U CU tav heb 13 16 SP ale teste ct E PERAE AA OENE A T E TEN SWING ANIM REMOVA lerini anann o OS SWING AMS TAN ATO Miass dcir Aaa Swingarm Bearing Removal ies Swingarm Bearing Installation Swingarm Bearing Sleeve I
364. 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 If the wheel rotates and the weight goes up replace the weight with the next heavier size lfthe 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 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 x If it does discard it A WARNING
365. tion As the tire tread wears down the tire becomes more sus ceptible to puncture and failure An accepted estimate is that 9096 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 center of the tread with a depth gauge A Since the tire may wear unevenly take measurement at several places xlf any measurement is less than the service limit replace the tire see Tire Removal Installation in the Wheels Tires chapter Tread Depth Standard Front 6 5 mm 0 26 in Rear 9 0 mm 0 35 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 htio mototh com PERIODIC MAINTENANCE 2 27 Periodic Maintenance Procedures Wheel Bearing Damage Inspection e Raise the front wheel off the ground with jack see Front Wheel Removal in the Wheels Tires chapter e Turn the handlebar all the way to the right or left e Inspect the roughness of the front wheel bearing by push ing
366. tion 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 e Measure the fuel pressure with the engine idling Fuel Pressure Idling Standard 333 kPa 3 4 kgf cm 48 psi NOTE OThe gauge needle will fluctuate Read the pressure at the average of the maximum and minimum indications xf 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 If 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 xf 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 fuel tank see Fuel Tank Installation htio mototh com 3 82 FUEL SYSTEM DFI 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 fl
367. to mototh com FUEL SYSTEM DFI 3 63 Oxygen Sensor not activated Service Code 33 Europe Model Oxygen Sensor Removal Installation e Refer to Switches and Sensors section 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 Center Fairing see Center Fairing Removal in the Frame chapter 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 hoses 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 htio mototh com 3 64 FUEL SYSTEM DFI Oxygen Sensor not activated Service Code 33 Europe Model 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
368. to the threads and seating surfaces of the big end nuts and bolts htio mototh com 0105040151 E 0105070551 E 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 O lnstall 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 0105147851 C OThe connecting rod big end is bolted using the plastic region fastening method OThis method precisely achieves the needed clamping force without exceeding it unnecessarily allowing the use of thinner lighter bolts further decreasing connecting rod weight OThere are two types of the plastic region fastening One is a bolt length measurement method and other is a rotation angle method Observe one of the following two but the bolt length measurement method is preferable because this is a more reliable way to tighten the big end nuts CAUTION The connecting rod bolts are designed to stretch when tightened Never reuse the connecting rod bolts See the table below for correct bolt and nut usage CAUTION Be careful not to overtighten the nuts The bolts must be positioned on the seating surface correctly to prevent the bolt heads from hitting the crankcase 1 Bolt Length Measurement Method e Be sure to clean the bolts nuts and co
369. tor Holder 57001 1658 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 hito mototh com HPOS8142H51 Charging System e Install the starter gear A and washer B 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 e Remove the rotor bolt and washer e Check the tightening torque with flywheel puller If the rotor is not pulled out with 20 N m 2 0 kgf m 15 ft lb of drawing torque it is installed correctly x If the rotor is pulled out with under 20 N m 2 0 kgf m 15 ft lb o
370. tor Terminal Locknut 11 1 1 97 in lb Starter Motor Through Bolts 4 9 0 50 43 in lb Stator Coil Bolts 12 1 2 106 in lb L 2 10 PERIODIC MAINTENANCE Torque and Locking Agent The table below relating tightening torque to thread diameter lists the basic torque for the bolts and nuts Use this table for only the bolts and nuts which do not require a specific torque value All of the values are for use with dry solvent cleaned threads Basic Torque for General Fasteners Threads Diameter mm Nm km ftb 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 94 72 115 155 11 5 16 0 83 115 165 225 17 0 23 0 125 165 229 325 23 0 33 0 165 240 hito mototh com PERIODIC MAINTENANCE 2 11 Specifications Wem Standard Fuel System Throttle Grip Free Play 2 3mm 0 08 0 12 in Idle Speed 1 300 50 r min rpm Bypass Screws Turn Out O 3 1 2 for reference Engine Vacuum 35 3 11 3 kPa 265 10 mm Hg Air Cleaner Element Polyurethane Foam Cooling System Coolant Type recommended Permanent type of antifreeze Color Green Mixed Ratio Soft water 5096 Coolant 50 Freezing Point 35 C 31 F Total Amount 1 2 L 1 3 US at Engine Top End Valve Clearance Exhaust 0 22 0 31 mm 0 0087 0 0122 in Inlet 0 15 0 21 mm 0 0059 0 0083 in Clutch
371. tor rectifier by replacing it with a known good unit htio mototh com 0P10000451 E aP10000551 E aP10000B531 E 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 readings should also rise But they must be kept under the specified voltage Charging Voltage Tester Range Heading Tester to Tester to 25 V DC Battery 4 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 system is considered to be working normally If the charging voltage is much higher than the values specified in the table the regulator rectifier is defective or the regulator rectifier leads are loose or open xf
372. ts 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 Inspection e Remove Swingarm see Swingarm Removal in the Suspension chapter e Visually inspect the chain guide A x Replace the chain guide if it shows any signs of abnormal wear or damage htio mototh com GKO408RRS1 E PERIODIC MAINTENANCE 2 31 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 and fittings B If the brake fluid leaked from any position inspect or re place the problem part Brake Hose Damage and Installation Condition Inspection e Inspect the brake hoses and fittings for deterioration cracks and signs of leakage OThe high pressure inside the brake line can cause fluid to leak A or the hose to burst if the line is not properly main tained Bend and twist the rubber hose while examining it Replace the hose if any crack B bulge C or leakage is noticed x Tighten any brake hose banjo bolts Torque Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft Ib e Inspect the brake hose routing x If any brake hose routing is incorrect
373. ugh the ignition switch lead and insert the clamp in the bracket c O0 Y OOK WN htio mototh com 17 18 APPENDIX Cable Wire and Hose Routing RE o EE 5 http mototh com APPENDIX 17 19 Cable Wire and Hose Routing Clamp Clamp Clamp Clamp Clamp the main harness subthrottle sensor lead and subthrottle valve actuator lead to the delivery pipe Ground Lead Clamp Subthrottle Sensor Lead Connector Subthrottle Valve Actuator Lead Connector Clamp Clamp the harness 10 Clamp 11 Clamp 12 Stick Coil Lead Connector 13 Clamp Clamp the stick coil lead WD cO 0 Y O Ol htio mototh com 17 20 APPENDIX Cable Wire and Hose Routing Es 5 htio mototh com APPENDIX 17 21 Cable Wire and Hose Routing WD cO 0 Y Ol Regulator Rectifier Lead Clamp Insert the clamp in the frame Rear Brake Light Switch Lead Connector Through the rear brake light switch lead and vehicle down sensor lead from the front side of the 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 Through the fuel pump lead to the slit of the cover hito mototh com 17 22 APPENDIX Cable Wire and Hose Routing htio mototh com APPENDIX
374. ulb B firmly as shown Good C Bad D Top Mark E e After installation adjust the headlight aim see Headlight Aiming Inspection in the Periodic Maintenance chapter City Light Bulb Replacement e Remove the headlight assy see Headlight Removal In stallation e Pull out the socket A together with the bulb e Pull the bulb A out of the socket CAUTION Do not turn the bulb Pull the bulb out to prevent damage to the bulb Do not use bulb rated for greater wattage then the specified valve e Replace the bulb with a new one htio mototh com 0P12075851 E Lighting System Headlight Removal Installation e Remove Mounting Bolts A e Disconnect the headlight connectors A and city light con nector B e Remove the headlight assy e Remove the upper fairings see Upper Fairing Removal in the Frame chapter e Installation is the reverse of removal Tail Brake Light Hemoval 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 htio mototh com ELECTRICAL SYSTEM 16 51 16 52 ELECTRICAL SYSTEM Lighting System License Plate Light Bulb Replacement e Remove Screws A License Plate Light Cover B e Push and turn the bulb counterclockwise and remove it e Insert the new bulb A by alignin
375. 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 e Watch the gauge for at least 6 seconds x If the pressure holds steady the system is good 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 htio mototh com 3 92 FUEL SYSTEM DFI Fuel Injectors Fuel Injector Circuit 40172982 E 1 ECU 7 Fuel Pump Relay for fuel pump and injec 2 Fuel Injectors tors 3 Water proof Joint C 8 Relay Box 4 Engine Stop Switch 9 Main Fuse 30 A 5 Ignition Switch 10 Battery 6 Ignition Fuse 10 A 11 Frame Ground 12 Joint Connector htio mototh com Throttle Grip and Cables Throttle Grip Free Play Inspection e Refer to Throttle Control System Inspection in the Peri odic Maintenance chapter Throttle Grip Free Play Adjustment e Refer to Throttle Control System Inspection in the Peri odic Maintenance chapter Throttle Cable Installation e Install the throttle cables in accordance with Cable Wire and Hose Routi
376. ure Sensor Input Voltage Inspection NOTE OBe sure the battery is fully charged O The inspection is the same as Input Voltage Inspection of the main throttle sensor J 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 0017001051 0 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 If the reading is within the standard range check the sen sor output voltage xf the reading is less than the standard range remove the ECU and check the wiring between these connectors If the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection hito mototh com 3 46 FUEL SYSTEM DFI Inlet Air Pressure Sensor Service Code 12 Output Voltage Inspection NOTE O The output voltage changes according to the local at mospheric pressure e Measure the output voltage at the ECU in the same way as input voltage inspection Note the following Inlet Air Pressure Sensor Output Voltage Connections to ECU Meter Y BL lead terminal 17 Meter BR BK lead ter
377. use 30 A see Fuse Inspection in the Electrical oystem chapter Ignition Fuse 10 A see Fuse Inspection in the Electrical oystem chapter Ignition Switch see Switch Inspection in the Electrical oystem chapter Sidestand Switch see Switch Inspection in the Electrical oystem chapter Engine Stop Switch see Switch Inspection in the Elec trical System chapter Starter Button see Switch Inspection in the Electrical oystem chapter Neutral Switch see Switch Inspection in the Electrical oystem chapter otarter Control Relay see Starter Relay Inspection in the Electrical System chapter Relay Box see Relay Circuit Inspection in the Electrical oystem chapter otarter Circuit Relay see Relay Circuit Inspection in the Electrical System chapter Harness see Wiring Inspection in the Electrical System chapter x If the all parts are good condition replace the ECU see ECU Removal Installation in the Fuel System DFI chap ter Engine Stop Switch Operation Inspection 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
378. ustment in the Periodic Maintenance chapter htio mototh com STEERING 14 5 14 6 STEERING Steering Stem Stem Stem Bearing Removal e Remove Front Wheel see Front Wheel Removal in the Wheels Tires chapter Headlight Assy see Headlight Removal Installation in the Electrical System 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 Remove Under Bracket A see Upper Fairing Bracket Removal in the Frame chapter Front Forks see Front Fork Removal in the Suspension chapter e Straighten the claws A of the claw washer e Remove the steering stem locknut B and claw washer C e Pushing up the stem base and remove the steering stem nut A with stem cap 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 e 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 0105055854 htio mototh com Steering Stem e Remove the lower bearing inner race A which is p
379. uts so that nuts can be turned 120 B properly Eee Torque Angle ing Rod Bolt Nut l i Assy N m kgf m ft lb Use the bolts Attached to 18 1 8 13 0 j4 120 attached to t con rod new con rod 2 0 14 5 120 Replace the Moe 95 17 4 120 bolts with new ones New 25 2 6 18 8 120 Crankshaft Connecting Rod Cleaning e After removing the connecting rods from the crankshaft clean them with a high flash point solvent e Blow the crankshaft oil passages with compressed air to remove any foreign particles or residue that may have accumulated in the passages Connecting Rod Bend e Remove the connecting rod big end bearing inserts and reinstall the connecting rod big end cap e Select an arbor A of the same diameter as the connect ing rod big end and insert the arbor through the connect ing rod big end e Select an arbor of the same diameter as the piston pin and at least 100 mm 3 94 in long and insert the arbor B through the connecting rod small end e On a surface plate set the big end arbor on V block C e With the connecting rod held vertically use a height gauge to measure the difference in the height of the arbor above the surface plate over a 100 mm 3 94 in length to determine the amount of connecting rod bend If connecting rod bend exceeds the service limit the con necting rod must be replaced Connecting Rod Bend Service Limit TIR 0 2 100 mm 0 008 3 94 in hito m
380. ve a refresh charge once a month during storage 4 Battery life If the battery will not start the engine even after several refresh charges the battery has ex ceeded its useful life Replace it Provided however the vehicle s starting system has no prob lem A 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 htio mototh com ELECTRICAL SYSTEM 16 23 Battery Charging Condition Inspection OBattery charging condition can be checked by measuring battery terminal voltage with a digital v
381. 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 If the oil level is too high remove the excess oil using a syring or some other suitable device xlf 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 of the 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 Engine Oil Change in the Periodic Maintenance chapter Oil Filter Replacement e Refer to Oil Filter Replacement in the Periodic Mainte nance chapter htio mototh com 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 e
382. winding is open and the starter motor must be replaced e Using the highest hand tester range measure the resis tance between the segments and the shaft B x If there is any reading at all the armature has a short and the starter motor must be replaced htio mototh com ELECTRICAL SYSTEM 16 45 T Me ALO A A DA G ory 0P11081051 E 011040831 E 16 46 ELECTRICAL SYSTEM Electric Starter System 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 e Using the x 1 O 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 f there is not close to zero ohms the brush lead has an 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 Negative Brush Holders B Terminal Bolt and Yoke C Special Tool Hand Tester 57001 1394 x If there is any reading the brush plate assy and or termi nal bolt assy have a s
383. with fresh specified brake fluid e Change the brake fluid ORepeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes 1 Open the bleed valve A 2 Apply the brake and hold it B 3 Close the bleed valve C 4 Release the brake D NOTE O The fluid level must be checked often during the chang ing operation and replenished with fresh brake fluid If the fluid in the reservoir runs out any time during the changing operation the brakes will need to be bled since air will have entered the brake line OFront Brake Repeat the above steps for the other caliper e Remove the clear plastic hose 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 e Tighten the bleed valve and install the rubber cap Torque Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib e After changing the fluid check the brake for good braking power no brake drag and no fluid leakage x If necessary bleed the air from the lines hito mototh com 4513130652 E OO
384. y e Remove Fuel Tank see Fuel Tank Removal e Disconnect Main Throttle Sensor Connector A Fuel Hose Lower End B Vacuum Hose C Subthrottle Sensor Actuator D Connector e Disconnect 1 2 Injector Connector A Subthrottle Sensor Connector B e Loosen Holder and Duct Clamp Bolts C hito mototh com FUEL SYSTEM DFI 3 95 Throttle Body Assy e Loosen the locknut and screw in the throttle cable adjuster fully to give the cables plenty of play e 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 screw 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 0617017551 C htto mototh com 3 96 FUEL SYSTEM DFI Throttle Body Assy e Fit the accelerator cable end A and the decelerator cable end B into the throttle pulley e Check fuel leakage from the throttle body assy
385. y 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 hito mototh com ork05000851 E BRAKES 12 1 Brakes Table of Contents Exploded VIEW sion ias Specifications pempei aittir Special TOOlS aia Brake Lever Brake Pedal Brake Lever Position Adjustment Brake Pedal Position Inspection Brake Pedal Position Adjustment Brake Pedal Removal Brake Pedal Installation Gali OVS eS Front Caliper Removal Rear Caliper Removal 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 coccccccocococococococonononononos Front Brake Pad Removal Front Brake Pad Installation 12 2 12 6 12 7 12 8 12 8 12 8 12 8 12 9 12 9 12 11 htio mototh
386. ye on seat Purpose Increase O D of seat area to spec 32 Grind Tool 32 Cuter Purpose reduce O D of seat area to spec Measure Seat Width Tool Vernier Caliper Purpose check seat width against spec Results 45 Grind Machinist s Tool 45 Cutter dye on seat Purpose increase width of seat area beyond spec io increase OD 60 or 55 Grind Tool 60 Cutter Purpose reduce seat width to specification Tools Valve Lapper Grinding Compound Purpose perfectly match valve FINISHED and seat area check valve head for damage htio mototh com 5 32 ENGINE TOP END Cylinder Pistons Cylinder Removal e Remove Cylinder Head see Cylinder Head Removal Horn e Remove 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 in 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
387. ys check the amperage in the affected circuit If the amperage is equal to or greater than the fuse rating check the wiring and related components for a short circuit Housing A Fuse Element B Terminals C Blown Element D CAUTION When replacing a fuse be sure the new fuse GP2000Rts1 E matches the specified fuse rating for that circuit Installation of a fuse with a higher rating may cause damage to wiring and components hito mototh com htio mototh com APPENDIX 17 1 Appendix Table of Contents Cable Wire and Hose ROMINA 17 2 Troubleshooting GUIAS sessi 17 26 htio mototh com 17 2 APPENDIX Cable Wire and Hose Routing GoyMOB htio mototh com APPENDIX 17 3 Cable Wire and Hose Routing O OND Of W PO Clamp From the on sequentially through the left switch housing lead ignition switch 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 10 Clamp Insert the clamp from air cleaner side 12 13 Inlet Temperature Sensor Lead Connector Ignition Switch Lead Connector Clamp Clamp the left switch housing lead main harness side and ignition switch lead main harness side htio mototh com 17 4 APPENDIX Cable Wire and

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