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2012 ZX-14R manual - Brocks Performance

Contents

1. 3 98 Radiator Fan Relay 3 98 Radiator Fan Relay Inspector 3 98 Subthrottle Valve Actuator Service Code 62 3 99 Subthrottle Valve Actuator Removal pp 3 99 Subthrottle Valve Actuator 04 4 0 0 0 3 99 Subthrottle Valve Actuator Resistance 3 99 Subthrottle Valve Actuator Input Voltage 3 100 Air Switching Valve Service Code 64 3 102 Air Switching Valve Removal Installation mn 3 102 Air Switching Valve InSpecllohr i eto eere t et rai tide eod e flaps 3 102 Oxygen Sensor Heater Service Code 67 Equipped 3 103 Oxygen Sensor Heater 3 103 Oxygen Sensor Heater Resistance 3 103 Oxygen Sensor Heater Power Source Voltage Inspection 3 104 Idle Speed Control Valve Actuator Service Code 10 3 106 Idle Speed Control Valve Actuator 2 1 3 106 Idle Speed Control Valve Actuator 2 24 0 04 0 3 106
2. 12 29 Brake Hose and Pipe RemovalVlnstallatigm 12 29 Brake Hose and Pipe Inspectiom 12 29 Anti Lock Brake System Equipped Models pt 12 30 ABS Servicing PFIecautlOlis bu uc ta gut 12 33 ABS Troubleshooting Outline essi reor tt at b ade pe e lam dre toca 12 35 12 2 5 Inquirigs oboe No Meck capa ti Mos 12 38 S lf diagnosis 8 Via E 12 40 Self diagnosis Procedures be eu e 12 40 Service Code Clearing Procedures 12 41 How to Head Service 00405 pp 12 44 How to Erase Service Codes ore GR le di lx e eeu gia 12 44 Yellow ABS Indicator Light LED 12 45 Solenoid Valve Inspection Service Code 13 14 17 18 12 46 ABS Solenoid Valve Relay Inspection Service Code 19 12 46 Front Rear Wheel Rotation Difference Abnormal Inspection Service Code 25 12 46 ABS Motor Relay Inspection Service Code 35 11 12 46 Front Wheel Rotation Sensor Signal Abnormal Service Code 42 12 47 Front Wheel Rotation Sensor Wiring Inspection Service Code 43 12 48
3. 186 GP30058CS1 GP30059CS1 C 0 3second am LIL UU UU UU GP30080CS1 C 0 5second 0 5second GP30058CS1 16 92 ELECTRICAL SYSTEM Immobilizer System Equipped Models Olf there is any problem in the registration the red warning indicator light LED and immobilizer warning symbol A blinks to display the collation error Immobilizer Amplifier Failure When Registered Ignition Key is Inserted Ignition Key Collation Error The ignition key 1 is successfully registered in the ECU OThe red warning indicator light LED and immobilizer warning symbol A blinks 3 times and stops for 1 second and then repeats this cycle 0 2second GP30059CS1 C 0 5second 0 5second bu GP30058CS1 C 0 3second UUUUUUUUUUU OLS 0 GP30080CS1 C 0 30 30 3 0 3 0 3 1second 9 UUL SUUL GP30081CS1 C Immobilizer System Equipped Models ELECTRICAL SYSTEM 16 93 e Turn the ignition key 1 OFF and remove the ignition key 15 OThe red warning indicator light LED and immobilizer warning symbol A blinks to display the registration mode NOTE O Turn OFF the ignition switch and wait for the period of 15 seconds or more The registration mode automatically finishes and the r
4. 3 119 ECU Main Relay Removal Installation pp 3 119 ECU Main Relay Inspection pp 3 119 tc EL 3 120 Fuel Pressure Inspection ER 3 120 Fuel Flow Rate Inspeclort u code tee ee enters deae las toa 3 121 PUMP 3 123 Piel UM Removal oie HER eb 3 123 Fuel Pump Installation pp 3 124 Fuel Pump Operation Inspection pp 3 124 Fuel Pump Operating Voltage Inspection 0 24000 1000 3 124 Pressure Regulator Removal 3 125 Fuel Filter 6 3 126 i i ec pr Cc 3 127 Fuel Injector Removal lnstallation pp 3 127 Fuel Injector Audible Inspection inier ertet pntat 3 127 Fuel Injector Resistance Inspector uso de tance eter dee eS en kun 3 127 Fuel Injector Power Source Voltage Inspection pp 3 128 Fuel Injector Output Voltage 2202 enn 3 129 Fuel Injector Fuel Line Inspection tete eter n tuetur 3 130 Throttl Grip and 3 132 Free Play Inspection ish to olt 3 132 Free Play uM me EIER 3 132 Cable InstallallOn cs
5. BR l 1 idl cu Sieg Pah T v qur IS 6C17225FW5 C DFI System FUEL SYSTEM 3 17 Part Names ECU Rear Wheel Rotation Sensor Immobilizer Equipped Models Kawasaki Diagnostic System Connector Joint Connector B Frame Ground Battery Starter Relay Main Fuse 30 A ECU Fuse 15A Frame Ground 3 Frame Ground 2 Frame Ground 1 Frame Ground 4 Fuel Pump ABS Hydraulic Unit Relay Box Fuel Pump Relay ECU Main Relay Fuse Box 1 Joint Connector A Meter Unit Yellow Engine Warning Indicator Light LED Front Wheel Rotation Sensor Joint Connector F Vehicle down Sensor Immobilizer Antenna Equipped Models Immobilizer Amplifier Equipped Models Ignition Switch Engine Stop Switch Starter Button Stick Coil 1 2 3 4 Spark Plugs Intake Air Temperature Sensor Joint Connector C Joint Connector D Idle Speed Control Valve Actuator Crankshaft Sensor Fuel Injector 1 Fuel Injector 2 Fuel Injector 3 Fuel Injector 4 Joint Connector H Subthrottle Valve Actuator Main Throttle Sensor Subthrottle Sensor Intake Air Pressure Sensor 1 Intake Air Pressure Sensor 2 Joint Connector J Joint Connector Air Switching Valve Water Temperature Sensor Oxygen Sensor Equipped Models Gear Pos
6. Headlight Low is dn 12 55 Fuse Box 1 ern ight m LI E ow 12 558 a ii umm 1 1 Headlight pill a 1265 Il City Light 1258 Front Left Turn Signal Light 12V2iw Fuse B 1 1 lgnition Fuse 15 2 Headlight Relay Fuse 15 3 Brake Light Horn Fuse 10 4 Turn Signal Relay Fuse 10 ife Signal Headlight Headlight Relay Relay L9 Relay HI Fuse Box 2 l Metre Fuse 10 2 Fan Fuse 15 3 Headlight Relay Fuse 15 Left Switch Housing Left Switch Housing 1 Button 5 Dimmer Switch 2 Wazard Button 6 Starter Lockout Switch 3 Tura Signal Switch 7 Button 4 Passing Button 8 Upper and Lower Button Relay Box Relay Box 1 Radiator Fan Relay 2 Headlight Circuit Relay 4 Fuel Relay LEFT SWITCH HOUSING CONNECTIONS Horn Buton Hazard Button ng Buitoni mmer Sw 3030 e o ev e Ter toter a t Turn Signal Switch teh Starter Lockout Switch 5 Starter 3 ECU Main Relay Pump Relay Circuit Multifunction Color sk pis Color P pyv oqv7n es Lever Push Released Released R Lo Pulled In Lower 2106546 5 C ELECTRICAL SYSTEM 16 17 Wiring Diagram US CA and CAL Models Intake Air Pressure iet ub Senso
7. 2 39 2 2 PERIODIC MAINT Steering Play Inspection Steering Play Adjustment ENANCE Steering Stem Bearing Lubrication eene nnne Electrical System Lights and Switches Operation Headlight Aiming Inspecti cecus eder aor P rx ve EM VR VA RE Ca Sidestand Switch Operation Inspection Engine Stop Switch Operation Chassis Parts Lubrication Bolts Nuts and Fasteners Tightness 1111 Replacement Parts Air Cleaner Element Repl Fuel Hose Replacement Coolant Change e Radiator Hose and O ring Clutch Hose Replacemen Clutch Fluid Change Rubber Parts of Clutch Master Cylinder Slave Cylinder Replacement Engine Oil Change Oil Filter Replacement Brake Hose Replacerfieri Brake Fluid Change Master Cylinder Rubber Parts Replacement Caliper Rubber Parts Replacement ppp Spark
8. 12 56 BRAKES 12 3 This page intentionally left blank 12 4 5 Exploded View 08102495845 C BRAKES 12 5 Exploded View Torque Fastener Remarks kgf m ft Ib 8 1 Bleed Valves 7 0 80 6 Brake Lever PvotBot 10 910 9 S 8 Brake Lever Pivot Bolt Locknut 5 9 0 60 9 Front Brake Light Switch Screw 12 912 tin B Apply brake fluid L Apply a non permanent locking agent R Replacement Parts S Follow the specified tightening sequence Si Apply silicone grease 12 6 BRAKES Exploded View 01024968845 C Exploded View BRAKES 12 7 Fastener Rear Master Cylinder Push Rod Locknut Brake Pedal Bolt Rear Brake Disc Mounting Bolts 27 Bleed Valves 7 8 0 80 Rear Caliper Assembly Bolts N 36 8 Torque kgf m m Brake Hose Banjo Bolts 25 2 5 Rear Master Cylinder Mounting Bolts 25 2 5 17 2 8 8 1 75 0 90 2 8 3 75 Remarks ft lb 69 in lb 27 1 L Rear Caliper Mounting Bolts 25 2 5 9 Rear Brake Pad Pin B Apply brake fluid G Apply grease L Apply a non permanent locking agent R Replacement Parts Si Apply silicone grease 17 2 1 75 12 8 5 Exploded View ABS Equipped Models BRAKES 12 9 Exploded View EX Brake Pipe Joint Nuts E E 3 ABS Hydraulic Unit 4 White Paint Marks 5 Blue Pai
9. 2 20 Evaporative Emission Control System Inspection CAL and SEA B1 Models 2 20 Cooling System s ose sus teet 2 21 Coolant Level ISPS CU OM raa he und tee vro lay Riba eee 2 21 Radiator Hose and Pipe Inspection Er cete pr epe eer ek a peek poen 2 22 Engine Top End 2 22 Valve Clearance ie P D ES HE 2 22 Valve Clearance Adjustment enero rer pts pk tia ote dE A exuit RD RAS RR AE 2 23 Air Suction System Damage eine re teo citi 2 26 M M 2 26 Clutch Operation Inspector ed pose soc bue o ea esee a 2 26 Clutch Fluid Level 0 ener nen 2 27 Cl tch Fluid Leak dg fu Rs 2 27 Clutch Hose and Pipe Damage and Installation Condition Inspection 2 27 La daz ARI c HE 2 28 Tire Air Pressure ils d es 2 28 Wheel Tire Damage ee xo neret ee ett eee eg ex kb ee 2 28 Tire Tread Wear Inspection dais Este ete toques Ede p e aac Probe REDE gusten 2 28 Wheel Bearing Damage Inspection 2 29
10. Blue Hose Clamps Fuel Tank Green Hose Fittings Canister Purge Valve Camps APPENDIX 17 53 17 54 APPENDIX Troubleshooting Guide NOTE ORefer to the Fuel System chapter for most of DFI trouble shooting guide OThis is not an exhaustive list giving every possible cause for each problem listed It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties Engine Doesn t Start Starting Difficulty Starter motor not rotating Ignition and engine stop switch not ON Starter lockout switch or gear position switch trouble Starter motor trouble Battery voltage low Starter relay not contacting or operating Starter button not contacting Starter system wiring shorted or open Ignition switch trouble Engine stop switch trouble Main 30 A or ignition fuse blown Starter motor rotating but engine doesn t turn over Vehicle down sensor DFI coming off Immobilizer system trouble Equipped Mod els Starter clutch trouble Starter idle gear trouble Engine won t turn over Valve seizure Valve lifter seizure Cylinder piston seizure Crankshaft seizure Connecting rod small end seizure Connecting rod big end seizure Transmission gear or bearing seizure Camshaft seizure Starter idle gear seizure Balancer bearing seizure No fuel flow No fuel in tank Fuel pump trouble Fuel tank air vent obstructed Fuel filter clogged Fuel line clogged No s
11. 2 30 Drive Chain Lubrication Condition Inspection 2 30 Drive Ghalm Slack INSPECHON 2 30 Drive Chain Slack Adjustment pp 2 31 Wheel Alignment InspectlOri des ett Eten baee 2 32 Drive Chain Wear Inspection 42242441 1 1 21 0100 nennen nennen nnne 2 32 Drive Chain Guide Wear e eese etr tecla els ahem ce prb dts 2 33 ipio 2 33 Brake Fluid Leak Brake Hose and Pipe Inspection 2 33 Brake Hose and Pipe Damage and Installation Condition 2 34 Brake Operation ende e CR p c bk eg 2 35 Brake Fluid Level usine Io ete has 2 35 Brake Pad Wear Inspection tne et ee Mane x Ru PORRO 2 36 Brake Light Switch Operation Inspection een 2 36 lieri s m 2 37 Front Forks Rear Shock Absorber Operation Inspection ppp 2 37 Front Fork Oil Leak e ee nena 2 38 Rear Shock Absorber Leak Inspection Ne 2 38 Rocker Arm Operation Inspection 2 38 Tie Rod Operation Inspection pp 2 38 imc
12. Swingarm Installation Swingarm Bearing Removal 13 33 Swingarm Bearing oi pe cum ee Eier dii 13 33 Swingarm Bearing Sleeve 13 34 Swingarm Bearing Lubrication Nt 13 35 Guide Inspectigon A d ces 13 35 Tie Bod ATIIG dua Pee Ye are Debe rr ROLE EET 13 36 e e Eee Co tl 13 36 TIesRod Installation iss goes oerte Re t ER RU n Ma Mu MEM ARE 13 36 Hocker Arm Removal d hist bim ot tee El usu kae rts 13 37 Hocker Arm Installation sse ninn e 13 37 Tie Rod and Rocker Arm Bearing 13 38 Tie Rod and Rocker Arm Bearing Installation see 13 38 Rocker Arm Tie Rod Bearing Sleeve Inspection 2 44 10000 13 40 Rocker Arm Tie Rod Bearing Lubrication 444 24444 222 13 40 13 2 SUSPENSION Exploded View 0 07 72070000 _ D o 7 D 49555 QW A GM023548W5 C Exploded View SUSPENSION 13 3 No Fastener Front Fork Clamp Bolts N m Torque kgf m Front Fork Clamp Bolts Upper R
13. 4 7 9 4 8 Coolant Deterioration InspectiOn 2 eerte teri a oed 4 8 Coolant Level Inspection c oie e eere nare puede 4 8 Coolant Draining tmp 4 8 COOLING FINA acess ents cena CPP REA 4 8 4 8 Cooling System 4 9 Coolant Reserve Tank Removal Installation 2 4 9 Water PMD cT 4 10 Water Pump Remova 4 10 Water Pump ER ua PU RE UE aad 4 10 Water Pump Inspector aono ctl ies eI ER s 4 11 Water Pump Impeller 4 11 RTT 4 12 Radiator and Radiator Fan Removal pp 4 12 Radiator and Radiator Fan Installation pp 4 13 Radiator Inspection siias 4 13 Radiator Cap Inspection 4 14 Radiator Filler Neck InspecliGIi ra ust 4 14 Radiator over Hemoval su oon pete Decet 4 15 Radiator Cover Installatig pe 4 15 Thermostat E 4 16 Thermostat Removal a
14. 81704109842 C ECU Frame Ground Battery Starter Relay Main Fuse 30 A ECU Fuse 15A Frame Ground 1 Relay Box ECU Main Relay Fuse Box 1 Ignition Fuse 15 A Joint Connector A Joint Connector F lgnition Switch Oxygen Sensor c la o FUEL SYSTEM 3 91 Immobilizer Amplifier Service Code 35 Equipped Models Antenna Resistance Inspection e Turn the ignition switch to OFF e Remove the left inner cover see Inner Cover Removal in the Frame chapter e Disconnect the antenna lead connector A Measure the antenna resistance Antenna Resistance Connections BK lead lt gt BK lead Standard About 3 0 4 6 x If the reading is out of the standard replace the antenna see Immobilizer System Parts Replacement in the Elec trical System chapter If the reading is within the standard check the wiring to the amplifier see Immobilizer System Circuit x If the wiring is good check the input voltage of the ampli fier see Amplifier Input Voltage Inspection Amplifier Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch to OFF Remove the windshield see Windshield Removal in the Frame chapter e Connect a digital meter to the amplifier connector A with needle adapter set Special Tool Needle Adapter Set 57001 1457 61048103
15. Throttle Body Assy Holder Installation pp MuUffler eer Muffler Body Removal Muffler Body Installation Exhaust Pipe Removal Exhaust Pipe Installation 5 2 5 6 5 8 5 9 5 11 5 11 5 11 5 12 5 12 5 13 5 13 5 13 5 13 5 14 5 14 5 14 5 16 5 16 5 16 5 18 5 18 5 19 5 22 5 22 5 23 5 23 5 23 5 24 5 24 5 24 5 25 5 27 5 28 5 28 5 29 5 30 5 31 5 31 5 36 5 36 5 36 5 37 5 37 5 37 5 39 5 39 5 2 ENGINE END Exploded View COP 2 S A ps 357271 SS Sasi C o 9 AK d p A Y j 9 2 gt GE025378W5 C Exploded View ENGINE TOP END 5 3 No Fastener Cylinder Head Cover Bolts Torque kgf m ft Ib 87 in lb Remarks Air Suction Valve Cover Bolts 1 0 87 L Camshaft Sprocket Mounting Bolts 11 Front Camshaft Chain Guide Bolt Upper 18 Front Camshaft Chain Guide Bolt Lower 106 in lb Engine Bracket Bolts M8 18 Front Engine Mounting Bolts M10 44 Oo AJOIN Camshaft Chain Tensioner Mounting Bolts 87 in lb Cylinder Head Bolts M11 Cylinder Head Bolts 6 106 in Ib Water Passage Plugs 14 5 Camshaft Cap Bolts 106 in Ib Upper Camshaft Chain Guide Bolts 106 in Ib Throttle Body Assy Holder Bolts 87 in lb Throttle Body Assy Holder Clamp Bolts 18 S
16. 16 72 Air Switching Valve Operation Test ate 16 72 Switching Valve Unit TeSt see ii oett ptr ped ege b 16 72 Radiator Fan seco tecti oen bcc Utt un esie eut io deus 16 74 Fari Motor Inspecetlopt asser to 16 74 Meter Gauge Indicator rtr E wer a ccc nb RA AER P RR Ke ER ER 16 75 Meter Unit Removal seio bte te tr oor tt tee neta Bode tee eant eda 16 75 Meter Unit Installation oorr re 16 75 Meter Unit Disassermibly Lee eeepc 16 76 Meter Operation nnne nnne nnn nnne 16 76 Meter System 16 82 Meter Unit Inspection dex be xor cde Rod i sabes c sais 16 85 Immobilizer System Equipped Models Dn 16 90 Operational Cautions pt 16 90 Myself eE 16 90 Immobilizer System Parts Replacement 16 108 ECU Replacemierit ere nu cba ee Ub Ro Eai 16 108 Immobilizer System Equipped 16 110 Immobilizer System Inspection 16 110 Switches 5 16 111 Brake Light Timing Inspection rete
17. 16 59 Commutator Cleaning and 16 59 Armat re Inspector 16 59 Brush Lead Deben dete 16 60 Right hand End Cover Assembly Inspection pp 16 60 Starter Relay mete tere e cud er Rote UA RR EE ERR 16 60 Systems Ee Moto saab tans 16 62 Headlight Beam Horizontal 16 62 Headlight Beam Vertical 0 16 62 Headlight Bulb Replacement pp 16 62 City Light Bulb HeplacertBnt o ue Sui eroe tete 16 63 Headlight Removal Installation 40 0 16 63 Headlight Relay Inspection 16 64 Tail Brake Light LED Removal ed n Er erc 16 64 Tail Brake Light LED Installation 16 65 License Plate Light Bulb Replacement pp 16 65 Turn Signal Light Bulb Replacement pp 16 66 Rear Turn Signal Light Disassembly pp 16 68 Rear Turn Signal Light Assembly pp 16 68 Turn Signal Relay 16 69 2
18. Outside BL Temperature BK Y Front Right KH Turn sime el Light BK Y BK Y 12 21 City Light 12458 doint Connector Connector 6 Headlight High 12965 Headlight Low wy 12 55 Headlight ay Low the cco 120550 Headlight xr 129658 City Light 12058 ki Front Left Turn Signal 12 21 4 ition Fuse 15 ght Relay Fuse 15 3 Brake Light Horn Fuse 10A 4 Turn Signal Relay Fuse 10 Turn Signal yx be Headlight Headlight Relay 1 Fuse 10A 2 Fan Fuse 15 Relay LO Relay HI 3 Headlight Relay Fuse 15A 4 ABS Solenoid Valve Rolay Fuse 15 8 5 Motor Relay Fuse 20 6 ABS ECU Fuse 10A Left Switch Housing Relay Box ABS Hydraulic Unit Left Switch Housing Relay Box 1 Button 5 Dimmer Switch 1 Radiat Rel 3 ECU Mai Rel 2 Hazard Button 6 Starter Lockout Switch tiree A FUSTO BUMD RELAY 3 Turn Signal Switch 7 SEL Button 5 Starter Circuit 4 Passing Button 8 Upper and Lower Button Relay LEFT SWITCH HOUSING CONNECTIONS Horn Buton Hazard Button Turn Signal Switch Passing Button ch Starter Lockout Switch Multifunction patton e Ter footer e o 5t estee Picoto estan BE Rene Clutch Lever Push Released Released R Lo Pulled I
19. 15 21 Equipped Models 15 10 Front Fender Installation 15 21 Single Seat Cover Installation Flap and Rear Fender Removal 15 21 Equipped Models 15 10 Flap and Rear Fender Installation 15 22 15 11 Windshield 15 23 Lower Fairing Removal 15 11 Windshield Removal 15 23 Lower Fairing Installation 15 11 Windshield Installation 15 23 Fairing Cover Removal 15 11 wid ch e edic E pee quee 15 24 Fairing Cover Installation 15 12 Rear Frame Removal 15 24 Middle Fairing Removal 15 12 Rear Frame Installation 15 24 Middle Fairing Installation 15 13 Frame Inspection 15 24 Middle Fairing Disassembly 15 14 15 25 Middle Fairing Assembly 15 15 Fuel Tank Cover Removal 15 25 Upper Fairing Removal 15 15 Fuel Tank Cover Installation 15 25 Upper Fairing Installation 15 15 Left Inner Rubber Cover Removal 15 26 Upper Fairing Disassembly 15 15 Left Inner Rubber Cover Upper Fairing Assembly 15 15 Installation 15 26 Inner Cover Removal 15 16 Right Inner Rubber Cover In
20. 3 132 Cable 3 132 PET 3 133 Idle Speed Inspection uot t eee Hata ngs 3 133 Throttle Bore Cleaning ette bao oaa sane etae E er Pacino o dace 3 133 Synchronization 22 000 3 133 Throttle Body Assy 3 133 Throttle Body Assy Installation rcr e ERR 3 136 Throttle Body Assy Disassembly cie oe eni eoe per ttd bete tengas tnde 3 139 Throttle Body Assy Assembly cerent Sees emere 3 140 Air CIB CIS enirn 3 142 Air Cleaner Element 4 4 0 3 142 Air Cleaner Element Installatig edet argo de dee ped 3 142 Air Cleaner Element Inspection 3 142 Cleaner Oil Draining a 3 142 C 3 143 Rear Air Intake Duct Removal pp 3 143 Rear Air Intake Duct Installation eode ehe rte Ea Fro eub te Rt os pco eR 3 143 Front and Middle Air Intake Duct Removal 3 144 Front and Middle Air Intake Duct Installation 3 144 We 3 146 TH 3 146 Fuel Tank Iristallal
21. 3 87 Oxygen Sensor not activated Service Code 33 Equipped Models 3 88 Oxygen Sensor Removal lnstallation pp 3 88 Oxygen Sensor Inspection ie a tnt 3 88 Immobilizer Amplifier Service Code 35 Equipped Models 3 91 Antenna Resistance Inspection pp 3 91 Amplifier Input Voltage eee eee raid e t Rae ede et 3 91 Blank Key Detection Service Code 36 Equipped Models 3 92 Ignition Key Ins peetlortesus iue eere bate rb undi eee nam 3 92 ECU Communication Error Service Code 39 pp 3 93 ECU Communication Line Inspection pp 3 93 Fuel Pump Relay Service Code 46 3 95 Fuel Pump Relay Removal Installatiorr 1 tote 3 95 F el P mp Relay iss 3 95 Stick Coils 1 2 3 4 Service Code 51 52 53 54 3 96 Stick Coil REMOval Stall AiO 3 96 Stick Coil Primary Winding Resistance Inspection 3 96 Stick Coil Input Voltage Inspectigom 3 96 Radiator Fan Relay Service Code 56
22. e Turn the engine stop switch to run position e Turn the ignition switch to ON OThe fuel pump should operate for 3 seconds and then should stop NOTE OAfter turning on the engine stop switch and ignition switch inspect the fuel leakage from the connected portion of the special tools Do not drive the fuel pump for 3 seconds or more without the fuel in the fuel tank If the fuel pump is driven without the fuel it may be damaged Fuel Line FUEL SYSTEM DFI 3 121 e Start the engine and let it idle Measure the fuel pressure with the engine idling Fuel Pressure with Engine Idling Standard 294 kPa 3 0 kgf cm 43 psi NOTE OThe gauge needle will fluctuate Read the pressure at the average of the maximum and minimum indications e Turn the ignition switch to OFF x If the fuel pressure is much higher than specified replace the fuel pump because the fuel pressure regulator in the fuel pump have been clogged or stuck xIf the fuel pressure is much lower than specified check the following Fuel Line Leakage see Fuel Injector Fuel Line Inspec tion Amount of Fuel Flow see Fuel Flow Rate Inspection e After above checks measure the fuel pressure again e Remove the fuel pressure gauge hoses and adapter e Install Fuel Hose see Fuel Hose Replacement in the Periodic Maintenance chapter Fuel Tank see Fuel Tank Installation e Start the engine and check for fuel leakage Fuel Flow R
23. sensor lead 2 Oxygen Sensor Lead 3 Crankshaft Sensor Lead 4 Clamp Hold the crankshaft sensor lead and oxygen sensor lead at the black painted mark of the oxygen sensor lead Oxygen Sensor Equipped Models 17 38 APPENDIX Cable Wire and Hose Routing APPENDIX 17 39 Cable Wire and Hose Routing PO N AH HAH UN Radiator Clamps Face the knob of the clamp as shown in the figure Air Bleeder Hose for Thermostat Housing Right Side View Clamp Screw Face the screw head as shown in the figure Thermostat Housing Rear Side View Clamps Water Hose Reserve Tank Hose Reserve Tank Overflow Hose Reserve Tank Air Bleeder Hose for Water Pump Right Side View Water Pump Water Hose Water Hose Cil Cooler Inlet Hose Outlet Hose About 45 Align the white paint mark on the hose with the mark on the thermostat housing cover Insert the air bleeder hose into the water pump fitting so that it point to the center of the impeller shaft 17 40 APPENDIX Cable Wire and Hose Routing APPENDIX 17 41 Cable Wire and Hose Routing Front Side View Install the clamp as shown in the figure Air Bleeder Hose for Water Pump Gear Position Switch Lead Clamp Hold the air bl
24. 10 11 Balance Weight Removal et tado Rie 10 11 Balance Weight ImStalla non 10 12 Qj ctc 10 14 Air Pressure Inspection Adjustment 10 14 Tire Inspection Minuit Tct Tire Installation Tire Repair tud repas Hub BEARING Rr Lr Hub Bearing Removal 10 17 Hub Bearing Installation erret re 10 17 Hub Bearing lere CU c 10 17 Hub Bearing LubriGatlort oeste 10 18 10 2 WHEELS TIRES Exploded View WHEELS TIRES 10 3 Exploded View Torque We mee ouium 1 Front Axle Clamp Bolts 15 AL 2 Front Axle Nut 8 Rear Axle Nut AL Tighten the two clamp bolts alternately two times to ensure even tightening torque HG Apply high temperature grease R Replacement Parts WL Apply soap and water solution or rubber lubricant 10 4 WHEELS TIRES Specifications Item Standard Service Limit Wheels Rims Rim Runout Axial TIR 0 5 mm 0 02 in or less TIR 1 0 mm 0 04 in Radial TIR 0 8 mm 0 03 in or less TIR 1 0 mm 0 04 in Axle Runout 100 mm 3 94 in Wheel Balance Balance Weights Rim Size Front Rear Tires Air Pressure when Cold Front Rear Tread Depth Front ZX1400E ZX1400F Rear 7 1400 ZX1400F Standard Tires Front ZX1400E ZX1400F Rear ZX1400E ZX1400F TIR 0 03 m
25. 4 16 Thermostat Installationm 4 16 Thermostat Inspector ceto 4 16 Hoses PIPES pe 4 18 Pede Dora bos dtt dise EDU 4 18 MM C d 4 18 Water Temperature Sensor eoe t 4 19 Water Temperature Sensor rennene 4 19 Water Temperature Sensor Inspection te De reete oret tege boe bula diu 4 19 4 2 COOLING SYSTEM Exploded View COOLING SYSTEM 4 3 Exploded View EE Water Hose Clamp Screws 0 31 27 Coolant Fitting Bolts 8 8 0 90 78 in lb L Thermostat Housing Mounting Bolts 9 8 87 in lb ES Thermostat Housing Cover Bolts 0 60 52 in lb 5 Oil Cooler Mounting Bolts 1 2 106 S 6 Cylinder Fitting Mounting Bolts 9 8 1 0 87 in lb 7 Water Pump Cover Bolts 9 8 1 0 87 in lb 8 Coolant Drain Bolt 10 1 0 89 in Ib 9 Water Temperature Sensor 12 1 2 106 in Ib L Apply a non permanent locking agent LG Apply liquid gasket R Replacement Parts S Follow the specified tightening sequence 4 4 COOLING SYSTEM Coolant Flow Chart 60041518 6 COOLING SYSTEM 4 5 Coolant Flow Chart Thermostat Housing Cylinder Jacket Air Bleeder Hose for Water Pump Cylinder Head Jacket Air Bleeder Hose for Thermostat Housing
26. ELECTRICAL SYSTEM 16 77 Meter Gauge Indicator Unit Check 1 2 Left Switch Housing Switching Inspection e Turn the ignition switch to ON e By pushing the SEL button A each time check that the display selects main display B power mode C and KTRC mode D x If the display does not work check the following parts Left Switch Housing see Switch Inspection Wiring see Meter Unit Circuit x If the above parts is good replace the meter unit and or ECU e Select the main display e By pushing the upper button A each time check that the display B changes as follows OThis display is ordinary indication CURRENT AVERAGE gt RANGE gt BATTERY OUTSIDE x lf the display function does not work check the following parts Left Switch Housing see Switch Inspection Wiring see Meter Unit Circuit x f the above parts is good replace the meter unit AVERAGE 12 16 78 ELECTRICAL SYSTEM Meter Gauge Indicator Unit e Select the main display e By pushing the lower button A each time check that the display B changes as follows OThis display is ordinary indication 000 TRIP TRIP GP17959CN3 C x lf the display function does not work check the following parts Left Switch Housing see Switch Inspection Wiring see Meter Unit Circuit x If the above parts is good replace the meter unit e
27. 15 4 FRAME Exploded View 08002558845 C 15 5 Exploded View Tor que Remarks kgf m ft lb Rear Footpeg Bracket Bolts 25 2 5 18 Rear Frame Bolts 44 4 5 32 L Rear Frame Pipe Bolts 44 4 5 32 Rear Frame Pipe Nuts 44 4 5 32 R 5 PH Models G Apply grease L Apply a non permanent locking agent R Replacement Parts 15 6 FRAME Exploded View 08002559845 C 15 7 Exploded View R k N m enm 12 11 ilb 2 Rear Fender Mounting Screws 1 2 0 12 11 in lb Seat Lock Bracket Screws 1 2 0 12 11 in Ib 4 Grab Rail Mounting Bolts Equipped Models 25 2 5 18 5 Seat Cover Equipped Models 6 Reflector US CA CAL and AU Models 7 Grab Rail and Rear Hooks Parts Equipped Models 8 PH Model 9 Front Hooks Parts Equipped Models 10 For models equipped with the front hooks tighten the bracket bolts of the front side first G Apply grease R Replacement Parts 15 8 FRAME Exploded View 08002560845 C FRAME 15 9 Exploded View 1 Rear Fairing Equipped Models 15 10 Seat Seat Removal e Insert the ignition key A into the seat lock e Turn the key clockwise and pull up on the rear of seat B e Remove the seat backward Seat Installation e Insert the slots A of the seat into the brackets B of the fuel tank e Insert the
28. GC17227F 5 3 32 FUEL SYSTEM DFI Troubleshooting the DFI System With the engine stopped and turned in the self diagnosis mode the service code error code A is displayed on the LCD by the number of two digits If the problem is with the following parts the ECU can not recognize these problem Therefore the yellow engine warning indicator light LED does not go on and service code is not displayed Fuel Pump Fuel Injectors Stick Coil Secondary Wiring and Ground Wiring ECU Main Relay When the service code A is displayed for first ask the rider about the conditions B of trouble and then start to determine the cause C of problem As a pre diagnosis inspection check the ECU for ground and power supply the fuel line for no fuel leaks and for correct pressure The pre diagnosis items are not indicated by the yellow engine warning indicator light LED Don t rely solely on the DFI self diagnosis function use common sense ERROR E Iu NEC EUN 000 6 POWER zd 0617228 5 8017230 51 Troubleshooting the DFI System FUEL SYSTEM 3 33 Even when the DFI system is operating normally the yel low engine warning indicator light LED goes on be displayed under strong electrical interference Additional measures are not required Turn the ignition switch to OFF to stop the indicator light If the yellow engine
29. BRAKES 12 21 Brake Pads Rear Brake Pad Removal e Loosen the pad pin A e Remove the caliper mounting bolts B e Remove the caliper with the hose installed e Remove Pad Pin A Pad Spring B Brake Pads C Rear Brake Pad Installation e Push the caliper pistons in by hand as far as they will go e Install the outside pad A and insert the pad pin B as shown in the figure Set Inside Pad A Pad Spring B OPushing the pin holder C to hole of the pad and insert the pad pin e Install the caliper see Caliper Installation Tighten the pad pin Torque Rear Brake Pad Pin 17 2 N m 1 75 kgf m 12 7 ft Ib A WARNING After servicing it takes several applications of the brake lever before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the motorcycle until a firm brake lever is obtained by pumping the lever until the pads are against the disc Brake Pad Wear Inspection e Refer to the Brake Pad Wear Inspection in the Periodic Maintenance chapter 12 22 BRAKES Master Cylinder Front Master Cylinder Removal e Remove the reservoir bracket bolt A e Remove the banjo bolt B and remove the brake hose from the master cylinder see Brake Hose Removal In stallation Remove the clamp bolts and take off the master cylin der D as an assembly with the r
30. FUEL SYSTEM DFI 3 131 Fuel Injectors Fuel Injector Circuit OOOO 9998 6617218282 Ignition Switch Engine Stop Switch Fuel Injector 1 Fuel Injector 2 Fuel Injector 3 Fuel Injector 4 Joint Connector H Joint Connector E ECU 10 Frame Ground 11 Battery 12 Starter Relay 13 Main Fuse 30 14 ECU Fuse 15 15 Frame Ground 3 16 Frame Ground 2 17 Relay Box 18 Fuel Pump Relay 19 Fuse Box 1 20 Ignition Fuse 15 A 21 Joint Connector F Oe Et OE p Pons 3 132 FUEL SYSTEM Throttle Grip and Cables Free Play Inspection e Refer to the Throttle Control System Inspection in the Pe riodic Maintenance chapter Free Play Adjustment e Refer to the Throttle Control System Inspection in the Pe riodic Maintenance chapter Cable Installation e Install the throttle cables in accordance with the Cable Wire and Hose Routing section in the Appendix chapter e Install the lower ends of the throttle cables in the throttle pulley on the throttle body assy after installing the upper ends of the throttle cables in the grip e After installation adjust each cable properly see Throttle Control System Inspection in the Periodic Maintenance chapter A WARNING Operation with incorrectly routed or improperly ad justed cables could result in an unsafe riding con dition Be sure the cables are routed correctly and properly adjusted Cable Lu
31. ep CR 16 111 Brake Light Timing 16 111 Switch Inspection ERE 16 111 Water Temperature Sensor 2 16 112 Oxygen Sensor Removal Equipped 16 112 Oxygen Sensor Installation Equipped 16 113 Oxygen Sensor Inspection Equipped 16 113 Fuel Level Sensor Inspection ctr etr e e ERU Rat banc santa Espero 16 113 Fuel Reserve Switch InspebltlOn uscire pt peo 16 114 Gear Position Switch Removal rentre herede tee ka o ER dE ERR ese asc 16 115 Gear Position Switch Installation oer bete perio tcv reti beca Ne d dete eee 16 116 Gear Position Switch Inspection oa Ree rtr Ert ERR n Ee RAE Dre E E Senet 16 116 fem 16 118 Relay BOX Removal de EN due tut Ug pa seen 16 118 Relay CICUIINSDECHON ovde ol en stato 16 118 ELECTRICAL SYSTEM 16 3 Diode Circuit INSpection attt decise 16 119 BIER XR 16 121 30 A 15 ECU Fuse 2 nenne nna 16 121 Fuse Box Fuse Removal Iii ho
32. ENGINE END 5 37 Muffler A WARNING The muffler can become extremely hot during nor mal operation and cause severe burns Do not re move the muffler while it is hot Muffler Body Removal e Remove Rear Fairing see Rear Fairing Removal in the Frame chapter Equipped Models Muffler Body Clamp Bolts A Loosen Bolt B Bracket C Muffler Body Mounting Bolts D and Nuts E Pull the muffler bodies F backward 18160 2 C Muffler Body Installation e Replace the muffler body gaskets A with new ones Olnstall the gaskets until they are bottomed Olnstall the gaskets so that their chamfer sides C faces the front GE18056BS1 5 38 ENGINE END Muffler e Install the muffler body clamps A as shown in the figure Olnsert the projections B into the slots C e Install the muffler bodies D e Replace the nuts E with new ones e Tighten the mounting bolts F and clamp bolts G se curely Torque Muffler Body Mounting Bolts 34 N m 3 5 kgf m 25 ft lb e Install the brackets and tighten the bolts I e Thoroughly warm up the engine wait until the engine cools down retighten all the bolts 181618 2 C e When installing the muffler covers note the following OBe sure that the pads A are in place If the pads are removed install the pads on the inside of the muffler cover as shown in the figure Lef
33. Black 1 494 1 498 mm Sa 0 0588 0 0590 in Blue 1 498 1 502 mm 0 0590 0 0591 Pistons Cylinder Upper Crankcase Inside 83 994 84 006 mm 84 10 mm Diameter 3 3068 3 3073 in 3 3110 in Piston Diameter 83 959 83 974 mm 83 81 mm 3 3055 3 3061 in 3 2996 in Piston Cylinder Clearance 0 020 0 047 mm 0 0008 0 0019 Piston Ring Groove Clearance Top 0 03 0 07 mm 0 17 mm 0 0012 0 0028 in 0 0067 in Second 0 02 0 06 mm 0 16 mm 0 0008 0 0024 in 0 0063 in Piston Ring Groove Width Top 0 92 0 94 mm 1 02 mm 0 0362 0 0370 in 0 040 in Second 1 01 1 03 mm 1 11 mm 0 0398 0 0406 in 0 044 in Piston Ring Thickness Top 0 87 0 89 mm 0 80 mm 0 0343 0 0350 in 0 0315 in Second 0 97 0 99 mm 0 90 mm 0 0382 0 0390 in 0 0354 in Piston Ring End Gap Top 0 20 0 30 mm 0 6 mm 0 0079 0 0118 in 0 024 in Second 0 40 0 55 mm 0 9 mm 0 0157 0 0217 in 0 035 in Transmission Shift Fork Ear Thickness 5 74 6 00 mm 5 6 mm 0 2260 0 2362 in 0 220 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 0 278 0 283 0 287 9 8 CRANKSHAFT TRANSMISSION Specifications Connecting Rod Big End Bearing Insert Selection Con rod Big End Inside Diameter Marking No
34. END Clean Air System Air Suction Valve Inspection e Remove the air suction valve see Air Suction Valve Re moval e Visually inspect the reeds A for cracks folds warps heat damage or other damage x lf there is any doubt as to the condition of the reeds re place the air suction valve as an assembly e Check the reed contact areas B of the valve holder for grooves scratches any sings of separation from the holder or heat damage x If there is any doubt as to the condition of the reed contact areas replace the air suction valve as an assembly x If any carbon or other foreign particles have accumulated between the reed and the reed contact area wash the valve assembly with a high flash point solvent NOTICE Do not scrape off the deposits with a scraper as this could damage the rubber requiring replacement of the suction valve assembly Air Switching Valve Removal e Remove Middle Fairings see Middle Fairing Removal in the Frame chapter Idle Speed Control Valve Actuator see Idle Soeed Con trol Valve Actuator Removal in the Fuel System DFI chapter Connector A Disconnect e Remove the hoses B from the air suction valve covers and frame and remove the air switching valve C Never drop the air switching valve especially on a hard surface Such a shock to the air switching valve can damage it ENGINE END 5 13 Clean Air System Air Switching Valve Insta
35. e Remove Right Middle Fairing see Middle Fairing Removal in the Frame chapter Camshaft Chain Tensioner Mounting Bolts A Camshaft Chain Tensioner B Camshaft Chain Tensioner Installation Opening the snap ring A release it and turn the ten sioner body B clockwise while holding the push rod C e Turning the tensioner body clockwise slide the stopper A into the groove B of the push rod C NOTE OBe careful not to fit the snap ring D into the groove Good E Bad F ENGINE END 5 17 Camshaft Chain Tensioner Replace the gasket A with a new one e Install the tensioner body so that the plug B faces up ward e Tighten Torque Camshaft Chain Tensioner Mounting Bolts 9 8 1 0 kgf m 87 in Ib e Turn the crankshaft 2 turns clockwise to allow the ten sioner to expand and recheck the camshaft chain timing NOTE O You hear the sound from which the push rod moves out Olf you do not hear the sound reassemble the camshaft chain tensioner NOTICE If you start the engine in case that the sound can not be heard the engine may be damaged 5 18 ENGINE END Camshaft Camshaft Chain Camshaft Removal e Remove Cylinder Head Cover see Cylinder Head Cover Re moval Crankshaft Sensor Cover see Crankshaft Sensor Re moval in the Electrical System chapter e Using a wrench on the timing rotor bolt A turn the crank shaft clockwise until the
36. gt 2281400 ABS Ninja ZX 14R Kawasaki zx 14R ABS Motorcycle Service Manual This quick reference guide will assist you in locating a desired topic or pro cedure the pages back to match the black tab of the desired chapter num ber with the black tab on the edge at each table of contents page Refer to the sectional table of contents for the exact pages to locate the spe cific topic required Quick Reference Guide General Information Periodic Maintenance Fuel System DFI Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal Installation Crankshaft Transmission Wheels Tires Final Drive Brakes Suspension Steering Electrical System Om Go Appendix 7781400 ABS Ninja ZX 14R Ninja ZX 14R ABS Kawasaki Motorcycle Service Manual All rights reserved No parts of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Quality Assurance Division Motorcycle amp Engine Company Kawasaki Heavy Industries Ltd Japan No liability can be accepted for any inaccuracies or omissions in this publication although every possible care has been taken to make it as complete and accurate as possible The right is reserve
37. 8 05000851 C BRAKES 12 1 Brakes Table of Contents Exploded mmm 12 4 12 12 ferreo 12 13 Brake Lever Brake dt deii PR OT tr DOG e 12 14 Brake Lever Position Adjustment 12 14 Brake Pedal Position InspeollOTn Rai reet t dese bua tat esed beds 12 14 Brake Pedal Position Adjustment pp 12 14 Brake Pedal Removal e EE 12 14 Brake Pedal Installation 12 15 e c LC 12 16 Front Caliper Removal sce senden tende e eee md du ie num M 12 16 Rear Caliper Removal accio dp E tabat ers ed ler pap 12 16 Caliper Installation tonat emu fede bee deciden 12 17 Front Caliper Disassembly dee tear boe Dade etes dete ense a Bun quede 12 17 Eront Caliper 2 oc tie rte ER Store tn estera timet ted ue 12 17 Rear Caliper Disassembly 12 17 Rear Caliper Assembly su co ete ertet te Dude D 12 17 Caliper Fluid Seal Damage Inspectigm 12 18 Caliper Dust Seal Damage 12 18 Caliper Piston and Cylinder Damage 12 19 Brake I EE Fro
38. Connecting Rod Big End Inside Diameter 41 000 41 016 mm 1 6142 1 6148 in Marking None 41 000 41 008 mm 1 6142 1 6145 in 41 009 41 016 1 6145 1 6148 Connecting Rod Big End Bearing Insert Thickness Brown 1 475 1 480 mm 0 05807 0 05827 Black 1 480 1 485 mm 0 05827 0 05846 Blue 1 485 1 490 mm 0 05846 0 05866 Connecting Rod Bolt Stretch Usable Range 0 29 0 39 mm 0 0114 0 0154 in Crankshaft Side Clearance 0 05 0 24 mm 0 30 mm 0 0020 0 0094 in 0 0118 in Crankshaft 3 Main Journal Width 27 45 27 50 mm 1 0807 1 0827 Crankshaft Runout TIR 0 03 mm 0 0012 in or less TIR 0 08 mm 0 0031 in Crankshaft Main Bearing Insert Journal 0 048 0 086 mm 0 12 mm Clearance 0 0019 0 0034 in 0 0047 in Crankshaft Main Journal Diameter 39 984 40 000 mm 39 96 mm 1 5742 1 5748 in 1 5732 in Marking None 39 984 39 992 mm 1 5742 1 5745 1 39 993 40 000 1 5745 1 5748 Crankcase Main Bearing Inside Diameter 43 000 43 016 mm 1 6929 1 6935 in Specifications CRANKSHAFT TRANSMISSION 9 7 Item Standard Service Limit Marking Crankshaft Main Bearing Insert Thickness 43 000 43 008 mm 1 6929 1 6932 in 43 009 41 016 mm 1 6933 1 6935 in Brown 1 490 1 494 mm 0 0587 0 0588
39. GC17233FS1 Warning Indicator Light LED Circuit 6617251282 1 ECU 2 Joint Connector D 3 Joint Connector C 4 Meter Unit 5 Yellow Engine Warning Indicator Light LED 6 Yellow KTRC Warning Indicator Light LED 7 Red Warning Indicator Light LED 3 112 FUEL SYSTEM DFI ECU ECU Identification OMost countries have their own regulations so each ECU has different characteristic So do not confuse ECU with each other and use only the ECU for your model Other wise the motorcycle cannot clear the regulation ECU Identification Part Number A Specification AU with Immobilizer 9617210751 21175 0712 WVTA FULL with Immobilizer GB WVTA FULL H with Immobilizer 21175 0713 WVTA 78 2 with Immobilizer US without Immobilizer 21175 0714 CA without Immobilizer 21175 0715 CAL without Immobilizer 21175 0717 SEA B1 with Immobilizer PH with Immobilizer 21175 0718 SEA B2 with Immobilizer 21175 0784 BR with Immobilizer ECU Removal Never drop the ECU especially on a hard surface Such a shock to the ECU can damage it e Remove the seat see Seat Removal in the Frame chap ter e Pull the hook A to lift up the lid B of the tool kit case e Remove Tool Kit A Fuse Box 2 B e Remove Bolts A Plate B Tool Kit Case C ECU FUEL SYSTEM 3 113 e Pull
40. vonna 19 Oil Pipe Bolts 87 Oil Passage Plug R1 4 11 Oil Cooler Mounting Bolts 106 in lb Oil Pump Cover Bolts 87 Oil Filter 13 Pan Plate Bolts 87 Filter Holder Mounting Bolt 5 26 Oil Pan Bolts 5 87 Oil Pressure Switch Terminal Bolt 1 13 in lb Oil Pressure Switch 11 Oil Pressure Relief Valve 11 Oil Passage Plug R3 8 15 Engine Oil Drain Bolt l 22 EO Apply engine oil G Apply grease L Apply a non permanent locking agent LG Apply liquid gasket MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts S Follow the specified tightening sequence SS Apply silicone sealant 7 4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart VEN S D 66042288 6 Engine Oil Flow Chart ENGINE LUBRICATION SYSTEM 7 5 Exhaust Camshaft Intake Camshaft Camshaft Oil Passage Camshaft Chain Tensioner Crankshaft Oil Passage Main Oil Passage Oil Pump Screen Oil Pipe Breather Hose for Return Relief Valve Oil Pressure Switch Oil Filter to Oil Jets Oil Cooler 7 6 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart iS s 2 p 1 gt A zi G G j YES xl ECL 2 2
41. 3 120 FUEL SYSTEM Fuel Line Fuel Pressure Inspection NOTE OBe sure the battery is fully charged e Remove Fuel Tank see Fuel Tank Removal Fuel Hose see Fuel Hose Replacement in the Periodic Maintenance chapter OBe sure to place a piece of cloth around the fuel outlet pipe of the fuel pump and the delivery pipe of the throttle body assy WARNING Fuel is flammable and explosive under certain con ditions and can cause severe burns Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is dis connected fuel spills out from the hose and the pipe because of residual pressure Cover the hose connection with a piece of clean cloth to prevent fuel spillage e Install the fuel pressure gauge adapter A and fuel hoses Special Tool 57001 1607 B between the fuel outlet pipe and delivery pipe e Secure the fuel hoses with the clamps e Install the throttle body assy e Connect the following parts temporary Fuel Pump Lead Connector Fuel Level Sensor Lead Connector e Connect the pressure gauge C to the fuel pressure gauge adapter Special Tools Oil Pressure Gauge 5 kgf cm 57001 125 Fuel Pressure Gauge Adapter 57001 1593 Fuel Hose 57001 1607 WARNING Fuel is extremely flammable and can be explosive under certain conditions resulting in serious injury or death Do not try to start the engine with the fuel hoses disconnected
42. 6004040381 C PERIODIC MAINTENANCE 2 47 Periodic Maintenance Procedures Cables Lubricate with Rust Inhibitor Throttle Inner Cables e Lubricate the cables by seeping the oil between the cable and housing OThe cable may be lubricated by using a commercially available pressure cable lubricator with an aerosol cable lubricant e With the cable disconnected at both ends the inner cable should move freely A within the cable housing x If cable movement is not free after lubricating if the cable is frayed B or if the cable housing is kinked C replace the cable Bolts Nuts and Fasteners Tightness Inspection Check the tightness of the bolts and nuts listed here Also check to see that each cotter pin is in place and in good condition NOTE OFor the engine fasteners check the tightness of them when the engine is cold at room temperature x lf there are loose fasteners retorque them to the spec ified torque following the specified tightening sequence Refer to the appropriate chapter for torque specifications If torque specifications are not in the appropriate chapter see the Standard Torque Table For each fastener first loosen it by 1 2 turn then tighten it x lf cotter pins are damaged replace them with new ones 6004011481 C 80904020152 C 2 48 PERIODIC MAINTENANCE Periodic Maintenance Procedures Bolt Nut and Fastener to be checked Engine Clutch Lever Pivot Bolt Lockn
43. 61050304 6105041751 9105335851 9 26 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods Measure the main bearing inside diameter and mark the upper crankcase half in accordance with the inside diam eter A Crankcase Main Bearing Inside Diameter Marks O or no mark e Tighten the crankcase bolts to the specified torque see Crankcase Assembly NOTE OThe mark already on the upper crankcase half should 9105196881 0 almost coincide with the measurement Crankcase Main Bearing Inside Diameter Marks 43 000 43 008 1 6929 1 6932 None 43 009 43 016 1 6933 1 6935 Select the proper bearing insert A in accordance with the combination of the crankcase and crankshaft coding Size Color B 6105041781 Crankcase Main Bearing Crankshaft Main Journal Bearing Insert Inside Diameter Marking Diameter Marking Size Color Part Number Journal Nos 92139 0740 1 3 5 1 Brown 92139 0743 2 4 None 1 92139 0739 1 3 5 Black 92139 0742 2 4 92139 0738 1 3 5 Blue 92139 0741 2 4 The bearing inserts for Nos 2 and 4 journals have an oil groove respectively e Install the new inserts in the crankcase halves and check insert journal clearance with the plastigage CRANKSHAFT TRANSMISSION 9 27 Pistons Piston Removal Split the crankcase see Cr
44. 9 CRANKSHAFT TRANSMISSION 9 3 Exploded View Torque No Fastener Remarks cee Sim mu Breather Cover Bolts L 25 mm __ 87 in lb Breather Cover Bolt L 35 mm 87 in lb Breather Cover Plate Screws 9 8 87 in lb Oil Nozzle Pipe Mounting Bolts 25 18 Oil Passage Plugs R3 8 20 15 Bearing Position Plate Screws 4 9 43 in lb Shift Drum Bearing Holder Screws 4 9 i 43 in lb Clamp Bolts 9 8 i 87 in lb Drive Shaft Cover Bolts 25 18 Timing Rotor Bolt 39 29 Connecting Rod Big End Nuts see the text lt Crankcase Bolts 7 L 60 mm 20 15 Crankcase Bolt M7 L 110 20 15 Crankcase Bolts M7 L 45 mm 20 15 Crankcase Bolts M10 L 90 mm 49 36 Crankcase Bolt M7 L 85 20 15 Crankcase Bolt L 50 15 36 M 26 Do not apply any grease or oil G Apply grease L Apply a non permanent locking agent LG Apply liquid gasket M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts S Follow the specified tightening sequence WL Apply soap and water solution or rubber lubricant AJOIN ololOiololo 5 NIN NI NINN OO 9 4 CRANKSHAFT TRANSMISSION Exploded View 81023658485 C CRANKSHAFT TRANSMISSION 9 5 Explo
45. 6 19 Clutch Plate Warp InspectiOr eto ette e n bert HE x Rx RE 6 19 Clutch Spring Free Length 6 19 Clutch Housing Finger Inspection eere t erre tute reae eer reae P eden pee 6 19 Clutch Housing Splirie InspectiOl ue tei te e t etu eter ed 6 20 Damper Cam Inspection pp 6 20 6 2 CLUTCH Exploded View GF022038W5 C CLUTCH 6 3 Exploded View No Fastener Torque Remarks Nm kgtm fiib 2 Oil Filler Plug Hand tighten 3 Clutch Lever Pivot Bolt 1 0 0 10 8 9 in lb Si 4 Clutch Hose Banjo Bolts 25 2 5 18 5 Clutch Lever Pivot Bolt Locknut 5 9 0 60 52 in lb 6 Clutch Master Cylinder Bleed Valve 5 4 0 55 48 7 Clutch Master Cylinder Clamp Bolts 10 3 1 05 91 in lb 5 8 Starter Lockout Switch Screw 0 70 0 071 6 2 in lb L 9 Clutch Spring Bolts 8 8 0 90 78 in lb 10 Sub Clutch Hub Bolts 25 2 5 18 L 11 Clutch Hub Nut 135 13 8 100 R 12 Clutch Slave Cylinder Bleed Valve 7 8 0 80 69 in lb C Apply clutch fluid EO Apply engine oil L Apply a non permanent locking agent M Apply molybdenum disulfide grease R Replacement Parts S Follow the specified tightening sequence Si Apply silicone grease WL Apply soap and water solution or rubber lubricant 6 4 CLUTCH Specifications Item Standard Service Limit Clutch Leve
46. 6230058651 C Ignition Key Collation Error 0 3second UU GP30080CS1 C e The other remaining ignition key is registered in the ECU OThe red warning indicator light LED and immobilizer warning symbol A blinks 2 times and stops for 1 sec ond and then repeats this cycle to indicate successful registration of ignition key rim umoo mm Turn OFF and remove the other remaining ignition key OThe red warning indicator light LED and immobilizer warning symbol A blinks to display the registration mode codes NOTE Olnsert next key and turn ON within 15 seconds after pre P vious key is turned OFF and removed otherwise regis wee tration mode will be ended and the red warning indicator ON icem light LED goes off 8P30058681 C OTo return to the registration mode start the registered ignition key verification procedure This applies to all ignition key registration e Insert the ignition key 1 to the ignition switch and turn it to ON Immobilizer System Equipped Models ELECTRICAL SYSTEM 16 103 Olf there is any problem in the registration the red warning indicator light LED A blinks to display the collation error code Immobilizer Amplifier Failure When Registered Ignition Key is Inserted Ignition Key Collation Error e The ignition key 1 is registered in the ECU OThe red warning indicator light LED and immobilizer warning symbol A blinks 3 times
47. 7 6 04042851 C 8 04021351 C GM04363BS2 13 22 SUSPENSION Front Fork Screw the fork piston rod puller onto the end of the piston rod Special Tool Fork Piston Rod Puller M12 1 25 57001 1289 e Pull the puller up above the outer tube top e Install the fork spring A with the smaller end B facing upward e Install the collar A so that the cut side B faces down ward e Install the washer on the collar e Install the clamps A as shown in the figure Special Tools Fork Spring Compressor 57001 1540 Fork Spring Compressor 57001 1587 NOTE OSet the clamps so that the cutouts B do not fit the hole C of the washer D pull up the outer tube E to hold it by the clamps and then tighten the two bolts F The outer tube is used as a guide e Set the holder bar A and compression shafts B e Screw in the fork compressor nut come out the piston rod nut OHold up the fork piston rod puller while screwing in the nut 6514020851 0040771 Front Fork SUSPENSION 13 23 e Insert the fork spring stopper A between the piston rod nut B and the clamp C while holding up the fork piston rod puller D Special Tool Fork Spring Stopper 57001 1374 e Remove the fork piston rod puller e Install the rebound damping adjuster rod A Check the distance between the bottom end A of the top plug and rebou
48. OWhen positioning 1 piston TDC at the end of the compression stroke Intake Valve Clearance of 1 and 3 Cylinders Exhaust Valve Clearance of 1 and 2 Cylinders Measuring Valve A Punch Mark IN B Punch Mark EX C OWhen positioning 4 piston TDC at the end of the compression stroke Intake Valve Clearance of 2 and 4 Cylinders Exhaust Valve Clearance of 3 and 4 Cylinders Measuring Valve A Punch Mark IN B Punch Mark EX C x If the valve clearance is not within the specified range first record the clearance and then adjust it Valve Clearance Adjustment e To change the valve clearance remove the camshafts see Camshaft Removal in the Engine Top End chapter and valve lifters e Replace the shim with one of a different thickness NOTE OMark and record the locations of the valve lifters shims so that they can be reinstalled in their original positions GS07024BS1 QM es tte c 9507216851 5999 65 5 9507217851 7102172 6507022851 2 24 PERIODIC MAINTENANCE Periodic Maintenance Procedures Clean the shim to remove any dust or oil e Measure the thickness of the removed shim A e Select a new shim thickness calculation as follows a Present Shim Thickness b Measured Valve Clearance c Specified Valve Clearance Mean Value 0 245 mm Exhaust 0 175 mm Intake d Replace Shim Thickness
49. Run the alternator lead to the inside of the leads and hoses 17 18 APPENDIX Cable Wire and Hose Routing APPENDIX 17 19 Cable Wire and Hose Routing ON 15 16 ABS Equipped Models CAL and SEA B1 Models Pipes Harness Clamp Hold the intake air temperature sensor lead Intake Air Temperature Sensor Intake Air Temperature Sensor Lead Run the intake air temperature sensor lead to the inside of the brake pipes Take care not to pinch the intake air temperature sensor lead by the cover Starter Relay Lead Run the battery ground lead to the inside of the starter relay Battery Negative Cable Starter Motor Cable 10 11 12 13 14 Align the tape portion of the hose with bracket Run the brake pipes under the hoses Blue Hose Align the projection of the damper and hole of the bracket Run the frame ground lead to the left of the motorcycle as shown in the figure Push down the frame ground lead to prevent it from running over the rear fender the frame ground lead over the brake pipes Run the leads to the lower hole of the cover 5 Hydraulic Unit Lead 17 20 APPENDIX Cable Wire and Hose Routing 68099180 6 APPENDIX 17 21 Cable Wire and Hose Routing Clamp Hold the alternator lead at the white painted marks of the alternator lead Alternator Lead Connec
50. A WARNING Mixing brands and types of hydraulic fluid lowers the fluid s boiling point cause rubber part to de teriorate and can reduce the hydraulic clutch sys tem s effectiveness and cause an accident resulting in injury or death Do not mix two brands of brake fluid Change the fluid in the hydraulic clutch sys tem completely if the fluid must be refilled but the type and brand of the hydraulic fluid that is already in the reservoir are unidentified e After changing the fluid check the clutch for good clutch power and no fluid leakage x If necessary bleed the air from the lines see Clutch Line Bleeding in the Clutch chapter e Remove the clear plastic hose e Install the reservoir cap e Tighten the bleed valve and install the rubber cap Torque Clutch Slave Cylinder Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib 2 56 PERIODIC MAINTENANCE Periodic Maintenance Procedures Rubber Parts of Clutch Master Cylinder Slave Cylinder Replacement Clutch Master Cylinder Cup and Dust Seal Replacement Remove the clutch master cylinder see Clutch Master Cylinder Removal in the Clutch chapter Remove the seal cover A circlip B connector C and O ring D Special Tool Inside Circlip Pliers 57001 143 e Remove the locknut E and pivot bolt F and remove the clutch lever e Pull the circlip e Pull out the piston assy H e Replace Seal Cover A Circlip B O ring D Circlip G Pisto
51. Connect the city light connector Headlight Removal Installation e Remove Upper Fairing see Upper Fairing Removal in the Frame chapter Upper Inner Fairing see Upper Inner Fairing Removal in the Frame chapter Bolts A Headlight Mounting Screws B Bracket C Headlights D e Tighten Torque Headlight Mounting Screws 1 2 N m 0 12 kgf m 11 in Ib 16 64 ELECTRICAL SYSTEM Lighting System Headlight Relay Inspection e Remove the inner covers see Inner Cover Removal in the Frame chapter e Take off the headlight relay A both sides e Set the hand tester to the x 1 range and make the measurements shown in the figure Headlight Relay A 12 V Battery B Special Tool Hand Tester C 57001 1394 x lf the tester readings are not as specified replace the headlight relay Testing Relay Criteria When battery is connected 0 When battery is disconnected Tail Brake Light LED Removal e Remove Tool Kit Case see ECU Removal in the Fuel System DFI chapter Relay Box see Relay Box Removal in the Electrical Sys tem chapter ECU see ECU Removal in the Fuel System DFI chap ter Tail Brake Light Mounting Screws A with Washer e Disconnect the connector A e Remove the tail brake light B GP12615BS1 C Lighting System ELECTRICAL SYSTEM 16 65 Tail Brake Light LED Installation Connect the connector e Insert the projectio
52. For Throttle Body Assy Holder For Water Temperature Sensor For Breather Hose Co Cable Wire and Hose Routing 17 34 APPENDIX AD LIB 5 1 an gt at Ay ESO d NEE gt A MY JL ORE 5 Lis g 0 5 65 2 APPENDIX 17 35 Cable Wire and Hose Routing Gear Position Switch Lead Clamp Hold the gear position switch lead Band Hold the gear position switch lead Clamp Oil Pressure Switch Lead Lower Fairing Bracket Clamp Install the clamp to the lower fairing bracket so that the band faces upside and set the position of the clamp as shown in the figure 8 Do not touch the oil pan 9 View from Bottom 10 Clamp Hold the alternator lead 11 Alternator Lead NOOR OND 17 36 APPENDIX Cable Wire and Hose Routing Ip Mot gt m SFr a Sero OR B ERTA Tn 1 1 eo eee A Np 9 Ag AS WEE 7 7 AE eS CR A IA fOr PI N 3 rorem NM NC Ui Na n 0 Os 08809865045 C APPENDIX 17 37 Cable Wire and Hose Routing 1 Clamp Hold the crankshaft sensor lead and
53. Lift up the suitable jack and hold the front fork e Lift up the suitable jack until the piston rod nut A comes out e Insert the fork spring stopper B between the piston rod nut and the holder C while holding up the top plug D Special Tool Fork Spring Stopper 57001 1374 Holding the piston rod nut with a wrench A remove the top plug B from the piston rod Remove the front fork from the fork spring compressor e Remove Washer A Collar B Rebound Damping Adjuster Rod C Fork Spring D Screw the rod nut A onto the piston rod B as shown in the figure 12 mm 0 47 in or more C GM04381BS1 C GM04738BS1 Front Fork SUSPENSION 13 15 Drain the fork oil into a suitable container OUsing the piston rod puller A pump the piston rod B up and down at least ten times to expel the oil from the fork Special Tool Fork Piston Rod Puller M12 x 1 25 57001 1289 e Hold the fork tube upright press the inner tube A and the piston rod all the way down e Pour in the type and amount of fork oil specified Recommended Oil KAYABA 01 KHL15 10 or equivalent Amount Per Side When changing oil Approx 465 mL 15 7 US oz After disassembly and completely dry 548 4 mL 18 5 0 14 US oz x If necessary measure the oil level as follows OHold the inner tube vertically in a vise OUsing the piston rod puller A move the piston rod B u
54. Maximum Torque Carburetion System Starting System Ignition System Timing Advance Ignition Timing Spark Plug Cylinder Numbering Method Firing Order Valve Timing Intake Open Close Duration 4 stroke DOHC 4 cylinder Liquid cooled 84 0 x 65 0 mm 3 31 x 2 56 in 1 441 cm 87 9 cu in 12 3 1 147 2 kW 200 PS 910 000 r min rpm WVTA 78 2 H 78 2 kW 106 PS 28 500 r min rpm CAL US 162 5 16 6 kgf m 120 ft lb 97 500 r min rpm WVTA 78 2 120 1 N m 12 2 kgf m 89 ft lb 94 500 r min rpm CA CAL US FI Fuel Injection MIKUNI 44EIDW x 4 Electric starter Battery and coil transistorized Electronically advanced digital igniter in ECU From 10 BTDC 91 100 r min rpm NGK CR9EIA 9 Left to right 1 2 3 4 1 2 4 3 34 BTDC 72 ABDC 286 1 10 GENERAL INFORMATION General Specifications Primary Reduction System Type Reduction Ratio Clutch Type Transmission Type Gear Ratios 1st 2nd 3rd 4th 5th 6th Final Drive System Type Reduction Ratio Overall Drive Ratio Frame Type Caster Rake Angle Trail Front Tire Type Size Rim Size Rear Tire Type Size Rim Size Front Suspension Type Wheel Travel Items ZX1400EC ZX1400FC Exhaust Open 66 BBDC Close 36 ATDC Duration 282 Lubrication System Forced lubrication wet sump with cooler Engine Oil Type API SG SH SJ SL or SM with JASO MA MA1
55. OFirst tighten the clutch fluid reservoir cap B clockwise 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 clutch fluid reservoir body A e Install the stopper and tighten the screw e After bleeding the clutch line check the clutch for good clutching effectiveness and no fluid leakage necessary bleed the air from the line again Clutch Hose Removal Installation e Refer to the Clutch Hose and Pipe Replacement in the Periodic Maintenance chapter Clutch Hose Inspection e Refer to the Clutch Hose and Pipe Damage and Instal lation Condition Inspection in the Periodic Maintenance chapter C um OT ddan Clutch Cover CLUTCH 6 13 Clutch Cover Removal Remove Engine Oil Drain see Engine Oil Change in the Periodic Maintenance chapter Right Middle Fairing see Middle Fairing Removal in the Frame chapter Clutch Cover Bolts A Clutch Cover B Clutch Cover Installation e Using a cleaning fluid clean off any oil or dirt that may be on the silicone sealant coating area Dry them with a clean cloth e Apply silicone sealant to the area A where the mating surface of the crankcase touches the clutch cover gasket Sealant Liquid Gasket TB1211F 92104 0004 e Replace the clutch cover gasket with a new one Tighten the clutch cover bolts OApply a non permanent lo
56. Remove the right side piston as follows e Using the rear caliper assembly bolt A remove the pis ton B as shown in the figure e Remove Dust Seals A Fluid Seals B Bleed Valves C Rubber Caps D NOTE Olf compressed air is not available do as follows with the brake hose connected to the caliper OPrepare a container for brake fluid and perform the work above it ORemove the pad spring and pads see Rear Brake Pad Removal in the Brakes chapter OPump the brake pedal to remove the caliper piston Rear Caliper Assembly e Clean the caliper parts except for the pads For cleaning the parts use only disc brake fluid isopropyl alcohol or ethyl alcohol e Install the bleed valves and rubber caps Torque Bleed Valves 7 8 N m 0 80 kgf m 69 in Ib 8813157 52 2 68 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Apply brake fluid to the cylinder bores e Replace the fluid seals A with new ones OApply silicone grease to the fluid seals and install them into each cylinder by hand e Replace the dust seals B with new ones e Replace the O ring A e Apply brake fluid to the outside of the pistons and push them into each cylinder by hand e Be sure to install the O ring e Apply a non permanent locking agent to the threads of the rear caliper assembly bolts and tighten them Torque Rear Caliper Assembly Bolts 36 8 3 75 kgf m 27 1 ft lb e Install the
57. Repair see chapter 3 Fuel line clogged Inspect and repair see chapter 3 Fuel pump operates intermittently and often DFI fuse blows Fuel pump bearings may wear Replace the fuel pump see chapter 3 Fuel pump trouble Inspect see chapter 3 Inspect see chapter 3 Intake air pressure sensor 1 trouble Intake air pressure sensor 2 trouble Inspect see chapter 3 Cracked or obstructed intake air pressure sensor 1 and 2 vacuum hose Inspect and repair or replace see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Intake air temperature sensor trouble Inspect see chapter 3 Main throttle sensor trouble Subthrottle sensor trouble Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Subthrottle valve actuator trouble Knocking Fuel change Use the gasoline recommended in Fuel poor quality or incorrect the Owner s Manual Spark plug incorrect Replace it with the correct plug see chapter 2 Stick coil trouble Inspect see chapter 16 ECU trouble Inspect see chapter 3 Engine vacuum not synchronizing Inspect and adjust see chapter 2 FUEL SYSTEM 3 43 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions chapter Intake air pressure sensor 1 trouble Inspect see chapter 3 Intake air pressure sensor 2 trouble Inspect s
58. Reserve Tank Hose Radiator Cap Radiator Radiator Fan 10 Reserve Tank 11 Reserve Tank Overflow Hose 12 Water Pump 13 Oil Cooler 14 Intake Hose 15 Outlet Hose 16 Hot Coolant 17 Cold Coolant Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion When the engine starts the water pump turns and the coolant circulates The thermostat is a wax pellet type which opens or closes with coolant temperature changes The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level When coolant temperature is less than 55 C 131 F the thermostat closes so that the coolant flow is restricted through the air bleeder hole causing the engine to warm up more quickly When coolant temperature is more than 58 62 C 136 144 F the thermostat opens and the coolant flows When the coolant temperature goes up beyond 95 C 203 F the radiator fan relay conducts to op erate the radiator fan The radiator fan draws air through the radiator core when there is not sufficient air flow such as at low speeds This increases up the cooling action of the radiator When the coolant temperature is below 90 C 194 F the fan relay opens and the radiator fan stops In this way this system controls the engine temperature within narrow limits where the engine op erates most efficiently even if the engine load varies The system is pressurized by the
59. Starter Motor Brush Length Standard 10 mm 0 39 in Service Limit 5 0 mm 0 20 in Commutator Cleaning and Inspection e Smooth the commutator surface A if necessary with fine emery cloth B and clean out the grooves Measure the diameter A of the commutator B lf the commutator diameter is less than the service limit replace the starter motor with a new one Commutator Diameter Standard 28 mm 1 10 in Service Limit 27 mm 1 06 in Armature Inspection e Using the x 1 hand tester range measure the resis tance between any two commutator segments A Special Tool Hand Tester 57001 1394 x lf there is high resistance or no reading gt between any two segments a winding is open and the starter motor must be replaced e Using the highest hand tester range measure the resis tance between the segments and the shaft B x If there is any reading at all the armature has a short and the starter motor must be replaced NOTE OEven if the foregoing checks show the armature to be 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 eeu 8 11061051 C 8 11080851 C 16 60 ELECTRICAL SYSTEM Electric Starter System Brush Lead Inspe
60. When changing oil Approx 465 mL 15 7 US oz After disassembly and completely dry 548 4 mL 18 5 0 14 US oz x f necessary measure the oil level as follows OHold the inner tube vertically in a vise OUsing the piston rod puller A move the piston rod B up and down more than ten times in order to expel all the air from the fork oil Special Tool Fork Piston Rod Puller M12 x 1 25 57001 1289 ORemove the piston rod puller OWait until the oil level settles OWith the fork fully compressed and the piston rod fully pushed in insert a tape measure or rod into the inner tube and measure the distance from the top of the inner tube to the oil Oil Level fully compressed without spring Standard 94 2 mm 3 70 0 08 in from the top of the inner tube NOTE OFork oil lever may also be measured using the fork oil level gauge Special Tool Fork Oil Level Gauge A 57001 1290 OWith the fork fully compressed and without fork spring insert the gauge tube into the inner tube B and position the stopper across the top end C of the inner tube OSet the gauge stopper D so that its lower side shows the oil level distance specified E OPull the handle slowly to pump out the excess oil until the oil no longer comes out If no oil is pumped out there is insufficient oil in the inner tube Pour in enough oil then pump out the excess oil as shown above ig lt Wy gt Om
61. Within 12 5S 68114643842 C BRAKES 12 43 Anti Lock Brake System Equipped Models Self diagnosis Flow Chart Turn the ignition switch OFF Connect the ABS self diagnosis terminal to the frame ground Turn the ignition switch ON Self diagnosis mode starts The yellow ABS indicator light LED blinks to display the service code in about 3 6 seconds after entering the self diagnosis mode 1 If no service code is shown drive at 20 km h 12 mph or more for one minute stop and try self diagnosis again Check the faulty point with the service code table and repair according to fault inspection 1 to 14 Erase the service code memorized in the ABS hydraulic unit Start the self diagnosis mode to confirm that erasing has been completed Disconnect the ABS self diagnosis terminal to the frame ground ending the self diagnosis mode Activate the ABS by driving the motorcycle at 20 km h 12 mph or NG lit above order to confirm that the ABS is normal gt Repeat self diagnosis OK Unlit Activate the ABS at a safe place in order to confirm that it operates normally 2 OK 1 The self diagnosis mode ends following When the ignition switch is OFF When the motorcycle is driven while in the self diagnosis mode When the self diagnosis terminal disconnects 2 Apply brake suddenly at 30 km h 19 mph or more to confirm that the motorcycle stops smoothly and steady with pulsation on t
62. indicates short necessitating stator replacement x lf the stator coil has 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 ELECTRICAL SYSTEM 16 43 Charging System Regulator Rectifier Inspection Remove Right Seat Cover see Seat Cover Removal in the Frame chapter Connectors A Regulator Rectifier Bolts B Regulator Rectifier C Set the hand tester to the x 1 range and make the measurements shown in the table Special Tool Hand Tester 57001 1394 e Connect the hand tester to the regulator rectifier x lf the tester readings are not as specified replace the regulator rectifier BK3 2 BKI W BK Y Use only Kawasaki Hand Tester 57001 1394 for this RBS test A tester other than the Kawasaki Hand Tester a may show different readings If a megger or a meter with a large capacity battery is used the regulator rectifier will be damaged Regulator Rectifier Resistance Unit Tester Lead Connection Terminal 1 2 BK3 BK Y 110 270 10 270 10 270 20 750 1 0 5 10 270 20 750 BK2 0 5 10 270 10 270 20 750 BK3 0 5 10 270 10 270 20 750 Tester Lead Connection e Install the regulator rectifier e Tighten Torque Regulator Rectifier Bolts 9 8 1 0 kgf m 87 in Ib e Install the rem
63. 3 72 Rear Wheel Rotation Sensor Signal Service Code 24 3 73 Rear Wheel Rotation Sensor Signal 4 000000 0 3 73 Gear Position Switch Service Code 25 3 75 Gear Position Switch 00 000 eme 3 75 3 2 FUEL SYSTEM DFI Gear Position Switch Resistance 3 75 Gear Position Switch Output Voltage Inspection pp 3 75 Front Wheel Rotation Sensor Signal Service Code 27 3 77 Front Wheel Rotation Sensor Signal Inspection 00000 3 77 Vehicle down Sensor Service Code 31 010 3 79 Vehicle down Sensor Removal 3 79 Vehicle down Sensor 3 79 Vehicle down Sensor Input Voltage 3 80 Vehicle down Sensor Output Voltage 3 81 Subthrottle Sensor Service Code 32 3 84 Subthrottle Sensor 3 84 Subthrottle Sensor Input Voltage 3 84 Subthrottle Sensor Output Voltage 3 85 Subthrottle Sensor Resistance
64. 58099200 6 APPENDIX 17 27 Cable Wire and Hose Routing _ Seat Lock Cable Run the seat lock cable to the outside of the rear left turn signal light lead Rear Left Turn Signal Light Lead Run the relay box leads to the backward of the fuse box 2 Fix the seat lock cable run through in front of the tool case with the clamp as shown in the figure Turn Signal Relay License Plate Light Lead Connector Take care not to pinch the seat lock cable by the cover and frame Insert the seat lock cable in the hook portion of the rear frame and hold it Clamp Hold the rear left turn signal light lead as shown in the figure Put the rear left turn signal light lead connector under the rear frame as shown in the figure 17 28 APPENDIX Cable Wire and Hose Routing 58099210 G APPENDIX 17 29 Cable Wire and Hose Routing 1 Regulator Rectifier Clamp Hold the regulator rectifier leads as shown the figure Make sure that the regula tor rectifier leads do not interfere with the bolt head Run the regulator rectifier leads to the inside of the rear brake reserve tank Fuse Box 1 Run the regulator rectifier leads under the cross bracket Run the regulator rectifier leads to the outside of the fuse box 1 Brake Hose Regulator Rectifier Leads Clamp Hold the rear right turn signal light lea
65. Connect the resistor C to the BL lead and BK Y lead terminals Resistance kQ 6 3 2 Temperature 32 4 F e Turn the ignition switch to ON and read the temperature in the display OThe display range is 20 60 C 4 140 F x If the temperature is out of the range the indication fixes the minimum value or maximum value OWhen the speed is 20 km h 12 mph or less and rising the temperature the indication fixes the value of just before the indication x If the display function does not work check the wiring see Meter Unit Circuit x f the wiring is good replace the meter unit Check 2 4 Fuel Level Warning Inspection e Disconnect the fuel pump lead connector A see Fuel Tank Removal in the Fuel System DFI chapter Main Harness B e Connect the resistor C about 100 O to the fuel pump lead connector terminal as shown in the figure 4 GP17989CS1 C LB BK mt W R GP17987C81 16 84 ELECTRICAL SYSTEM Meter Gauge Indicator Unit e After about 5 seconds check that the E segment and fuel symbol A starts blinking x If the display function does not work check the wiring see Meter Unit Circuit x lf the wiring is good replace the meter unit Check 2 5 Fuel Gauge Inspection e Disconnect the fuel pump lead connector A and fuel level sensor lead connector B see Fuel Tank Removal in
66. NOTICE Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground Special Tools Bearing Remover Head 25 x 28 B 57001 1346 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 e Install the bearings by using the bearing driver set which does not contact the bearing inner race e Press in each right the bearing A until they are bottomed Special Tool Bearing Driver Set B 57001 1129 e Replace the grease seals with new ones e Press in the grease seals A so that the seal surface is flush B with the end of the hole OApply high temperature grease to the grease seal lips Special Tool Bearing Driver Set C 57001 1129 Hub Bearing Inspection Since the hub bearings are made to extremely close tol erances the clearance can not normally be measured NOTE ODo not remove any bearings for inspection If any bear ings are removed they will need to be replaced with new ones e Turn each bearing in the hub back and forth A while checking for plays roughness or binding If bearing play roughness or binding is found replace the bearing e Examine the bearing seal B for tears or leak
67. Starter db Pelay s EA i FARE Regulator 12 12 S gt 585 waged Rectifier i 22 Joint Starter Relay zo E Connector B Diagnosis 55 xz 5 55 Fuse A A Bras 2 ae zi 22 Alternator Engine 2 Fuse 30 ake ABS Kawasaki S Ground S Switch Sfr ur Starter Frame Ground Diagnosis Motor System S Raanester Frame Frane Frame Ground Ground Ground 5 Frame Frame Ground Ground 4 2 RIGHT SWITCH HOUSING CONNECTIONS Front Brake Ligt Srt Engine Stop Switeh Starter Button IGNITION SWITCH CONNECTIONS Battery lgnition Signal fere ow fepe Color er cotor R W R W Color L w OFF Loch Light LED SK Y SK Y z s s License Plate Light 12V5W Rear Left Turn Signal Light 12V21N Color Code BK Black BL Blue BR Brown 78 Green Orange P Pink PU Purple R Res LY White ON Yellow P PARK 98052 0655 W2RO655CW5 C 16 24 ELECTRICAL SYSTEM Wiring Diagram ABS Equipped Models SEA B1 Model Meter Unit 1 Green Left Turn Signal Indicator Light LED 2 Green Right Turn Signal Indicator Light LED 3 Blue High Beam Indicator Light LED Spark Plugs dareen P wu 1 R R T 5 Yellow Engage Shift Up derer Merten X Stick Sidestand Indicator Light LED coils Seiten 6 Red Warning Indicator Light Right Switch Hou
68. e Pull out the throttle body assy B from the holder e Disconnect the fuel hose joint from the delivery pipe of the throttle body assy see Fuel Hose Replacement in the Periodic Maintenance chapter Remove the throttle body assy A to the right side of mo torcycle e After removing the throttle body assy stuff pieces of lint free clean cloths into the throttle body assy holders NOTICE 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 as shown in the figure Bolt Heads B e Connect the fuel hose joint to the delivery pipe of the throt tle body assy see Fuel Hose Replacement in the Periodic Maintenance chapter e Tighten Torque Throttle Body Assy Holder Clamp Bolts 2 0 0 20 kgf m 18 in Ib x If the grommet A was removed install it Olnstall the grommet from the inside of the frame e Insert the duct B to the grommet OApply a soap and water solution or rubber lubricant to the oblique portion C on the duct for easy installation e Fit the projections D of the duct into the holes E in the clamp 8017219 52 C FUEL SYSTEM DFI 3 137 Throttle Body Assy e Install the ducts A to the throttle body assy as shown in the figure Front B Rear View C 8017220 51 e Install the duct clamp bolts A in the direc
69. gine oil that will drain through the oil passage when the gauge adapter is removed e Apply a non permanent locking agent to the threads of the oil passage plug and tighten it Torque Oil Passage Plug R3 8 20 N m 2 0 kgf m 15 ft lb 7 18 ENGINE LUBRICATION SYSTEM Oil Pressure Switch Oil Pressure Switch Removal e Remove Engine Oil Drain see Engine Oil Change in the Periodic Maintenance chapter Left Middle Fairing see Middle Fairing Removal in the Frame chapter Rubber Boot A Switch Terminal Bolt B Oil Pressure Switch C Oil Pressure Switch Installation e Using a high flash point solvent clean off any oil or dirt that may be on the liquid gasket coating area Dry them with a clean cloth e Apply liquid gasket to the threads of the oil pressure switch and tighten it Sealant Liquid Gasket TB1211 56019 120 Torque Oil Pressure Switch 15 1 5 kgf m 11 ft lb e Install the switch lead direction A upward e Apply grease B to the terminal e Tighten the terminal bolt Torque Oil Pressure Switch Terminal Bolt 1 5 0 15 kgf m 13 in Ib NOTE OApply a small amount grease to the terminal so that grease should not close two breather holes A for switch diaphragm 6613005851 C 6613004851 C ENGINE LUBRICATION SYSTEM 7 19 Oil pipe Oil Pipe Removal e Remove Engine Oil Drain see Engine Oil Change in the Periodic Maintenance chapter
70. marks facing out Press the bearing into place by putting RSs pressure on the correct bearing race as shown 3 IE Hh B 1 Pressing the incorrect race can cause pressure between fe 28 in the inner and outer race and result in bearing damage 77 68020188 Oil Seal Grease Seal Do not remove pressed oil or grease seals unless removal is necessary Replace with new ones whenever removed wy Press new oil seals with manufacture and size marks facing out Make sure the seal is aligned properly when installing N v 68020198 Apply specified grease to the lip of seal before installing the seal Grease GBO2046BS1 Circlips Cotter Pins Replace the circlips or cotter pins that were removed with new ones Take care not to open the clip excessively when installing to prevent deformation 68020268 1 6 GENERAL INFORMATION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during mia assembly to minimize wear during initial operation Lubri fi T ony cation points are called out throughout this manual apply A VT gt A the specific oil or grease as specified NJ f 68020218 Direction of Engine Rotation When rotating the crankshaft by hand the free play 1 amount of rotating direction will affect the adjustment Ro Qr eel eS tate the crankshaft to positive direction clockwise viewed from outp
71. oint 1 Fuse 15 Le Color Code i rake Engine 2 Main Fuse 30A brake BK Black Ground n X BL Blue Reserve Fusi Switch Puno Regulator Rectifier ABS Self Diagnosis Terminal Alternator ABS Kawasaki Self re Starter Frame Ground Syston Motor BR Brown Connector Frano Frane Framo amp Green o orange Pink eu Purpie_ Rea White Y Yellow IGNITION SWITCH CONNECTIONS Battery lgnition Signal fere ow fepe RIGHT SWITCH HOUSTNG CONNECTIONS Front Brake Light Switch Foster BH estar ex PEA OFF Loch ON P PARK 98052 06934 W2RO693AW5 C 16 28 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 not reverse the battery cable connections This will burn out the diodes on the electrical parts OAlways check battery condition before condemning other parts of an electrical system A fully charged battery is a must for conducting accurate electrical system tests OThe electrical parts should never be struck sharply as with a hammer or allowed to fall on a hard surface Such a shock to the parts can damage them OTo prevent damage to electrical parts do not disconnect the battery cables or any other electrical connections when the i
72. range and connect it to the terminals in the oil pressure switch gear position switch lead connector B and ground C Internal Circuit 1 Light Green Lead 2 Green Red Lead 3 Black Lead Special Tool Hand Tester 57001 1394 Gear Position Switch Resistance kQ Connections 2 1 Ground 2 Ground 3 Ground Neutral about 0 8 64 9 54 about 0 2 22 2 46 about 0 0 954 1 055 about 0 0 643 0 711 about 0 0 410 0 453 about 0 6th 0 241 0 266 about 0 x lf the tester reading is not as specified replace the gear position switch with a new one N 16 2nd 3rd 4th Sth 6th GP18407BS2 16 118 ELECTRICAL SYSTEM Relay Box The relay box A has relays and diodes The relays and diodes can not be removed Relay Box Removal Never drop the relay box especially on a hard sur face Such a shock to the relay box can damage it e Remove the seat see Seat Removal in the Frame chap ter e Take out the relay box A and disconnect the connectors Relay Circuit Inspection Remove the relay box see Relay Box Removal Check conductivity of the following numbered terminals by connecting the hand tester and one 12 V battery to the relay box as shown in the figure see Relay Box Internal Circuit in this section If the tester does not read as specified replace the relay box Relay Circuit Inspection with the battery disconnected Test
73. 57001 1679 875716795 16 12 ELECTRICAL SYSTEM Special Tools and Sealant Key Registration Adapter 57001 1746 875717465 6 Liquid Gasket TB1211F 92104 0004 879200045 ELECTRICAL SYSTEM 16 13 Parts Location This page intentionally left blank 16 14 ELECTRICAL SYSTEM Parts Location Qa R 67048351 Parts Location ELECTRICAL SYSTEM 16 15 Headlight Relay High Immobilizer Amplifier Immobilizer Equipped Models Ignition Switch Immobilizer Equipped Models Including Immobilizer Antenna Starter Lockout Switch Starter Motor Frame Ground 1 Fuse Box 1 Fuse Box 2 ECU Turn Signal Relay Gear Position Switch Sidestand Switch Alternator Oil Pressure Switch Radiator Fan Motor Relay Box Regulator Rectifier Battery 12 V 14 Ah Frame Ground 2 Idle Speed Control Valve Actuator Air Switching Valve Front Brake Light Switch Meter Unit Headlight Relay Low Stick Coils Spark Plugs Water Temperature Sensor Crankshaft Sensor Oxygen Sensor Equipped Models Engine Ground Starter Relay Rear Brake Light Switch 16 16 ELECTRICAL SYSTEM Wiring Diagram US CA and CAL Models Meter Unit 1 Green Left Turn Signal 1 CAL Wodel Only Indicator Light LEO 2 Green Right Turn Signa
74. 6 Main Fuse 30 A 15 Joint Connector F 7 ECU Fuse 15 A 16 Ignition Switch 8 Frame Ground 2 17 Engine Stop Switch 9 Frame Ground 4 3 96 FUEL SYSTEM DFI Stick Coils 1 2 3 4 Service Code 51 52 53 54 Stick Coil 1 Service Code 51 Stick Coil 2 Service Code 52 Stick Coil 3 Service Code 53 Stick Coil 4 Service Code 54 Stick Coil Removal Installation e Refer to the Stick Coil Removal Installation in the Electri cal System chapter Stick Coil Primary Winding Resistance Inspection e Refer to the Stick Coil Inspection in the Electrical System chapter x lf the reading is within the standard check the input volt age see Stick Coil Input Voltage Inspection Stick Coil Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch to OFF e Remove the ECU see ECU Removal ODo not disconnect the ECU connectors e Connect a digital meter A to the connector B with the needle adapter set Special Tool Needle Adapter Set 57001 1457 Stick Coil Input Voltage Connections to ECU Connector For Stick Coil 1 Digital Meter gt BK lead terminal 65 Digital Meter gt Frame Ground terminal For Stick Coil 2 Digital Meter gt BK R lead terminal 52 Digital Meter gt Frame Ground terminal For Stick Coil 3 Digital Meter gt BK O lead terminal 78 Digital Meter gt Frame Ground terminal For Stick Coil 4 Digital Meter gt BK
75. B so that the sur face of the bushing is flush with the bottom surface C of the cover Special Tool Bearing Driver Set 57001 1129 e Press the bearing D until they are bottomed NOTE the bearing so that sealed E side faces in Special Tool Bearing Driver Set 57001 1129 e Press the new oil seal F so that the oil seal lip G faces to the outside and the oil seal surface is flush with the surface H of the cover Special Tool Bearing Driver Set 57001 1129 e Apply grease to the oil seal lips e Assemble the crankcase e Apply grease to the oil seal lips e Press in the oil seal A to the crankcase so that the sur face of the oil seal is flush with the surface B of the crankcase Transmission Shaft Disassembly e Remove the transmission shafts see Transmission Shaft Removal e Remove the circlips disassemble the transmission shafts 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 e Remove the ball bearing A from output shaft Special Tools Bearing Puller B 57001 135 Bearing Puller Adapter C 57001 317 e Discard the bearing 9113520851 61130828 6113048851 C 9 44 CRANKSHAFT TRANSMISSION Transmission Trans
76. C 25 N m 2 5 kgf m 18 ft Ib e Run the oxygen sensor lead correctly see Cable Wire and Hose Routing section in the Appendix chapter Oxygen Sensor Inspection Equipped Models e Refer to the Oxygen Sensor Inspection in the Fuel System DFI chapter Fuel Level Sensor Inspection e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Clamp A Open Open the clamp A e Remove Bolts A Fuel Level Sensor B 16 114 ELECTRICAL SYSTEM Switches and Sensors e Check that the float moves up and down smoothly without binding It should go down under its own weight x If the float does not move smoothly replace the sensor Float in Full Position A Float in Empty Position B e Using the hand tester A measure the resistance across the terminals in the fuel level sensor lead connector B Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 the tester readings are not as specified or do not change smoothly according as the float moves up and down replace the sensor Fuel Level Sensor Resistance Standard Full position C 9 11 O Empty position 213 219 O e Install a new gasket A on the fuel level sensor as shown in the figure Hollows B Front C e Apply a non permanent locking agent to the threads of the level sensor bolts and tighten them Torque Fuel Level Sensor Bolts 6 9 N m 0 70 kgf m 61 in Ib Fuel Reserve Switch Inspection
77. CAL and SEA B1 Models Specifications FUEL SYSTEM DFI 3 25 Item Standard Digital Fuel Injection System Idle Speed Throttle Assy Throttle Valve Bore Throttle Body Vacuum Bypass Screws ECU Make Type Fuel Pressure High Pressure Line Fuel Pump Type Discharge Fuel Injectors Type Nozzle Type Resistance CAN Communication Line Resistance Main Throttle Sensor Input Voltage Output Voltage Resistance Intake Air Pressure Sensor 1 2 Input Voltage Output Voltage Intake Air Temperature Sensor Output Voltage Resistance Water Temperature Sensor Output Voltage Vehicle down Sensor Input Voltage Output Voltage Subthrottle Sensor Input Voltage Output Voltage 1 100 50 r min rpm Dual throttle valve 44 mm 1 7 in 36 66 1 3 kPa 275 0 10 mmHg 0 1 1 4 for reference Mitsubishi Electric Digital memory type with built in IC igniter sealed with resin 294 kPa 3 0 kgf cm 43 psi with engine idling Wesco pump 67 mL 2 3 US oz or more for 3 seconds INP 258 Fine atomizing type with 4 holes About 11 7 12 3 at 20 C 68 F 122 126 at ECU Connector DC 4 75 5 25 V DC 0 63 0 65 V at idle throttle opening DC 3 76 3 96 V at full throttle opening for reference 4 6 DC 4 75 5 25 V DC 3 80 4 20 V at standard atmospheric pressure see this text for details About DC 2 25 2 50 V at 20 C 68 F 5 4 6 6 at 0 C 32
78. Compression Damping Force Adjustment e To adjust the compression damping force turn the com pression damping adjuster A until you feel a click OThe standard adjuster setting is the 10th click from the 1st click of the fully clockwise position A WARNING If both adjusters are not adjusted equally handling may be impaired and a hazardous condition may result Be sure the adjusters are set equally OThe damping force can be left soft for average riding But it should be adjusted harder for high speed riding or riding with a passenger If the damping feels too soft or too stiff adjust it in accordance with the following table Compression Damping Force Adjustment Position Force 18 1 Counterclockwise STD 151413121110 9 Clockwise Harder Softer T 8 4 7654321 Seated position adjuster turned fully clockwise GM04736BS1 Counterclockwise Softer STD 181716151413121110 9 Clockwise Harder 8765432 Seated position adjuster turned fully clockwise GM04737BS1 Front Fork SUSPENSION 13 11 Spring Preload Adjustment Turn the spring preload adjuster A to change spring preload setting OThe standard adjuster setting is the 14 mm 0 55 in B from top as shown in the figure Adjuster Protrusion from top Standard 14 mm 0 55 in Us
79. Connecting Rod Bend Service Limit TIR 0 2 100 mm 0 008 3 94 in Connecting Rod Twist Inspection e With the big end arbor A still on V block C hold the connecting rod horizontally and measure the amount that the arbor B varies from being paralleled with the surface plate over a 100 mm 3 94 in length of the arbor to de termine the amount of connecting rod twist x If the connecting rod twist exceeds the service limit the connecting rod must be replaced Connecting Rod Twist Service Limit TIR 0 2 100 mm 0 008 3 94 in Connecting Rod Big End Side Clearance Inspection e Measure connecting rod big end side clearance Olnsert a thickness gauge A between the big end and ei ther crank web to determine clearance Connecting Rod Big End Side Clearance Standard 0 13 0 38 mm 0 0051 0 0150 in Service Limit 0 58 mm 0 023 in x If the clearance exceeds the service limit replace the con necting rod with new one and then check clearance again If the clearance is too large after connecting rod replace ment the crankshaft also must be replaced 6105040881 C 6105040781 9 22 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Big End Bearing Insert Crankpin Wear Inspection e Remove the connecting rod big end see Connecting Rod Removal e Cut strips of plastigage press gauge to crankpin width Place a strip on the crankpin parallel to the crankshaft installe
80. Damage 14 9 CLP 14 10 Handlebar REmOVal 14 10 Handlebar 14 10 14 2 STEERING Exploded View STEERING 14 3 Exploded View No Fastener Handlebar Bolts 34 3 5 25 Handlebar Holder Bolts Throttle Case Screws Steering Stem Nut Left Switch Housing Screws 3 5 0 36 31 in lb Front Fork Clamp Bolts Lower 30 3 1 22 AL OQ or AJ AD Apply adhesive AL Tighten the two clamp bolts alternately two times to ensure even tightening torque G Apply grease L Apply a non permanent locking agent R Replacement Parts 14 4 STEERING Special Tools Head Pipe Outer Race Press Shaft 57001 1075 Steering Stem Nut Wrench 57001 1100 N 875710755 C 875711005 C Bearing Driver Set 57001 1129 7571129ST C Steering Stem Bearing Driver 542 5 57001 1344 7571344ST C Steering Stem Bearing Driver Adapter 641 5 57001 1345 7571345ST C Head Pipe Outer Race Driver 55 57001 1446 875714465 C Steering STEERING 14 5 Steering Inspection e Refer to the Steering Play Inspection in the Periodic Main tenance chapter Steering Adjustment e Refer to the Steering Play Adjustment in the Periodic Maintenance chapter 14 6 STEERING Steering
81. F 0 29 0 39 at 80 C 176 F About DC 2 80 2 97 V at 20 C 68 F 4 75 5 25 V with sensor tilted 60 70 or more right or left DC 0 65 1 35 with sensor arrow mark pointed DC 3 55 4 45 DC 4 75 5 25 V DC 4 14 4 34 V at subthrottle valve full close position for reference DC 0 42 0 62 V at subthrottle valve full open position 3 26 FUEL SYSTEM Specifications Input Voltage Output Voltage Rich Output Voltage Lean Heater Resistance Immobilizer Antenna Equipped Models Resistance Idle Speed Control Valve Actuator Resistance Input Voltage Purge Valve Resistance Throttle Grip and Cables Throttle Grip Free Play Oxygen Sensor Equipped Models Item Standard Resistance 4 6 Subthrottle Valve Actuator Resistance About 6 5 8 5 O About DC 9 5 11 5 V and then 0 V or About DC 9 5 11 5 V DC 0 8 V or more DC 0 24 V or less 6 7 10 5 at 20 C 68 F About 3 0 4 6 About 20 About DC 11 13 V and then 0 5 V or About DC 11 13 V 30 34 Q at 20 C 68 2 3 mm 0 08 0 12 in Air Cleaner Element Viscous paper element Special Tools and Sealant Oil Pressure Gauge 5 kgf cm 57001 125 875701255 C Fork Level Gauge 57001 1290 875712905 C Vacuum Gauge 57001 1369 225 222 7571369ST C Hand Tester 57001 1394 7571394
82. Fuel Pump Operation Inspection NOTE OBe sure the battery is fully charged e Turn the engine stop switch to run position e Turn the ignition switch to ON and make sure that the fuel pump operates make light sounds for 3 seconds and then stops e Turn the ignition switch to OFF x If the pump does not operate as described above inspect the operating voltage see Fuel Pump Operating Voltage Inspection Fuel Pump Operating Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch to OFF e Remove the seat see Seat Removal in the Frame chap ter 6610092851 C FUEL SYSTEM DFI 3 125 Fuel Pump Disconnect the fuel pump lead connector and connect the measuring adapter A between these connectors as shown in the figure Main Harness B Fuel Pump C Special Tool Measuring Adapter 57001 1700 e Connect a digital meter D to the measuring adapter leads Fuel Pump Operating Voltage Connections to Adapter Digital Meter pump Y R lead Digital Meter BK pump BK W lead e Measure the operating voltage with engine stopped and with the connector joined Turn the engine stop switch to run position e Turn the ignition switch to ON Operating Voltage Standard Battery Voltage for 3 seconds and then 0 V e Turn the ignition switch to OFF x f the reading stays on battery voltage and never shows 0 V check the fuel pump relay se
83. Handlebar STEERING 14 11 e Install the handlebar holder with handlebar on the steering stem head e Tighten the handlebar holder bolts A following the tight ening sequence 1 2 1 Torque Handlebar Holder Bolts 25 N m 2 5 kgf m 18 ft Ib e Install the front master cylinder see Front Master Cylinder Installation in the Brakes chapter e Install the left and right switch housings OFit the projection A into a hole B in the handlebar Torque Switch Housing Screws 3 5 0 36 kgf m 31 in Ib e Install the clutch lever see Clutch Lever Installation in the Clutch chapter e Install Throttle Grip Throttle Cable Tips A Throttle Cases B OFit the projection into a hole in the handlebar Torque Throttle Case Screws 3 5 N m 0 36 kgf m 31 in Ib e Apply adhesive cement to the inside of the left handlebar grip and install it e Install the left right handlebar weight e Apply a non permanent locking agent to the threads of the handlebar weight bolts and tighten them 15 1 Frame Table of Contents Exploded VieW pp 15 2 Seat Cover Installation 15 19 SIM T 15 10 Seat Cover Disassembly 15 20 Seat Removal 15 10 Seat Cover Assembly 15 20 Seat Installation 15 10 15 21 Single Seat Cover Removal Front Fender Removal
84. Ignition System Crankshaft Sensor Installation e Apply a non permanent locking agent to the threads of the crankshaft sensor bolts A and tighten them Torque Crankshaft Sensor Bolts 5 9 N m 0 60 kgf m 52 in Ib e Using a high flash point solvent clean off any oil or dirt that may be on the silicone sealant coating area Dry them with a clean cloth e Apply silicone sealant to the circumference of the crank shaft sensor lead grommet B and fit the grommet into the notch of the crankcase securely e Apply silicone sealant to the mating surface C of the crankcase halves Sealant Liquid Gasket TB1211F 92104 0004 e Replace the O ring D with a new one e Install the crankshaft sensor cover Apply a non permanent locking agent to only crank shaft sensor cover bolt E as shown in figure Brackets F Clamp G e Tighten the crankshaft sensor cover bolts Torque Crankshaft Sensor Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib e Run the crankshaft sensor lead and oxygen sensor lead equipped models correctly see Cable Wire and Hose Routing section in the Appendix chapter e Install the removed parts see appropriate chapters Crankshaft Sensor Inspection e Remove the right fairing cover see Fairing Cover Re moval in the Frame chapter e Disconnect the crankshaft sensor lead connector B see Crankshaft Sensor Removal e Set the hand tester A to the x 100 O range and connect it to the cran
85. Immobilizer Amplifier down e Sensor Immobilizer Joint Connector F Antenna Front Wheel Rotation Sensor Meter Unit 0000000000 DL Joint I Connector e BK Y 3 Outside itis ETTE m Front Right Turn Signal ipi Light TE 12V21 Gity Light Joint Joint 12V58 Connector Connector 6 A Headlight 3 hi ah oe 12 65 Headlight Low yy 12 55 Headlight Low RT VETT Headlight High Pd 12V65y IL City Light R 5 Turn Signal Light idee a 12 21 Box 1 2 Headlight Relay Fuse 15 3 Light Horn Fuse 10A 4 Tuen Signal Relay Fuse 10 Turn 55 585 5 Signal sid 55 Headlight Headlight Relay 2 Fan Fuse 15 Relay LO Relay HI 3 headlight Relay Fuse 15 4 ABS Solenoid Valve Relay Fuse 15A 5 ABS Motor Relay Fuse 20A 6 ABS ECU Fuse 10 Left Switch Housing Relay Box ABS Hydraulic Unit Left Switch Housing Relay 1 Button 5 Dinmer Switch i Radiator Fan Rel 3 EQU Main Rel 2 Hazard Button Starter Lockout Switch M Psi Pune Relay 3 Turn Signal Switch 7 SEL Button S Clay 5 Starter Circuit 4 Passing Button 8 Upper and Lower Button olay Relay Horn Betton Hazard B
86. OWhen the tongues C of the toothed washer 23 shall be assembled they shall be installed into the notches D of the toothed washer 22 9 46 CRANKSHAFT TRANSMISSION Transmission Shift Drum and Fork Removal e Remove Lower Crankcase Half see Crankcase Splitting Gear Positioning Lever see External Shift Mechanism Removal Screws A Shift Drum Bearing Holder B e Pull out the shift rods C and remove the shift forks e Pull out the shift drum D 9113396851 C Shift Drum and Fork Installation e Apply engine oil to the shift drum forks and rods e Install the shift drum A e Install the shift rods B and shift forks as shown in the figure OPosition the one with shortest ears C on the drive shaft place the in the center groove the shift drum Tineke eset OThe two forks D on the output shaft are identical E SS or NOTE TOSS OThe forks have marks 049 E 050 F and position RT them so that their marks face the engine left side ees 6113522852 C e Install the shift drum bearing holder A as shown in the figure e Apply a non permanent locking agent to the threads of the shift drum bearing holder screws B and tighten them Torque Shift Drum Bearing Holder Screws 4 9 N m 0 50 kgf m 43 in Ib Shift Drum Disassembly e Remove the shift drum see Shift Drum and Fork Re moval e While holding the shift drum with a vise remove the
87. Rear Fairing B Rear Fairing Installation Equipped Models e Installation is the reverse of removal 15 19 Seat Cover Seat Cover Removal e Remove Seat see Seat Removal Bolts A and Hooks B Equipped Models Bolts C and Grab Rail D Equipped Models Bolts E and Washers Screws F and Washers Center Seat Cover G e Remove Quick Rivet A Both Sides OPush the central pin of the quick rivet Remove the bolts A and washer e Clear the side seat covers B from the rear fender e Disconnect the rear turn signal light lead connectors and remove each side seat cover Seat Cover Installation e Connect the rear turn signal light lead connector e Insert the hole A to the projection e Set the quick rivets and push the core of them Tighten the bolts with washers When installing the guards A install it as shown in the figure grab rail equipped models 6007009851 15 20 Seat Cover Insert the projection A into the hole e Tighten the screws with washers e Install the grab rail equipped models Tighten Torque Grab Rail Mounting Bolts 25 N m 2 5 kgf m 18 ft Ib e Install the hooks and tighten the bolts equipped models e Install the seat see Seat Installation Qi A EI Seat Cover Disassembly e Remove Seat Cover see Seat Cover Removal Screws A Rear Turn Signal Light B Seat Co
88. and goes on again after about 4 seconds ECU communication error goes immediately after turning the ignition switch to and stays DFI warning indicator light and ETRE problemi LED does not go on after turning the ignition switch to ON light LED meter unit fault Red warning 0 Starts blinking about 2 seconds after ignition switch and the immobilizer indicator light warning symbol is displayed on the LCD immobilizer system problem LED Does not go on about 2 seconds after ignition switch ON ECU or meter unit fault light up battery oil pressure water temperature immobilizer or meter unit problem engine flooded do not crank engine with throttle opened which promotes engine flooding Engine stalls L1 when stopping the motorcycle when cruising L1 other 3 38 FUEL SYSTEM DFI Troubleshooting the DFI System Poor running at low speed Poor running or no power at high speed very low idle speed O very high idle speed O rough idle speed battery voltage is low charge the battery spark plug loose tighten it spark plug dirty broken or gap maladjusted remedy it backfiring afterfiring hesitation when acceleration engine oil viscosity too high brake dragging engine overheating clutch slipping other spark plug loose tighten it spark plug dirty broken or gap ma
89. assy air cleaner fuel tank etc i GC17232F F Inquiries to Rider OEach rider reacts to problems in different ways so it is important to confirm what kind of symptoms the rider has encountered OTry to find out exactly what problem occurred under exactly what conditions by asking the rider knowing this information may help you reproduce the problem OThe following sample diagnosis sheet will help prevent you from overlooking any areas and will help you decide if it is a DFl system problem or a general engine problem FUEL SYSTEM 3 37 Troubleshooting the DFI System Sample Diagnosis Sheet Rider name Registration No license plate No Year of initial registration Model Engine Frame Date problem occurred Mileage Environment when problem occurred Weather fine cloudy rain snow O always O other Temperature 0 hot warm cold O very cold O always O other Problem chronic often once frequency Road street O highway O mountain road O uphill Ci downhill O0 bumpy O pebble Altitude normal O high about 1 000 m or more Motorcycle conditions when problem occurred Yellow engine goes on immediately after turning the ignition switch to ON and goes off after warning about 1 second normal indicator light goes on immediately after turning the ignition switch to ON goes off after about 1 LED and second
90. counterclockwise and pull out the bulb from the headlight When handling the quartz halogen bulb never touch the glass portion with bare hands Always use a clean cloth Oil contamination from hands or dirty rags can reduce bulb life or cause the bulb to explode NOTE OClean off any contamination that inadvertently gets on the bulb with alcohol or soap and water solution Replace the headlight bulb e Fit the projections A of the bulb in the hollows B of the headlight e Turn the headlight bulb clockwise Connect the headlight connector e After installation adjust the headlight aim see Headlight Aiming Inspection in the Periodic Maintenance chapter OOther Bulbs Repeat the above steps 62125359 ELECTRICAL SYSTEM 16 63 Lighting System City Light Bulb Replacement e Remove the inner covers see Inner Cover Removal in the Frame chapter e Disconnect the city light connector A e Turn the city light bulb counterclockwise and pull out the socket A together with the bulb e Pull out the bulb A straight from the socket Do not turn the bulb Pull the bulb out to prevent damage to the bulb Do not use bulb rated for greater wattage than the specified value e Replace the bulb with a new one e Insert the socket to the headlight OAlign the projections A of the socket and the grooves B of the headlight e Turn the city light bulb clockwise
91. e Fill the fuel tank with fuel Close the fuel tank cap surely Remove the fuel tank see Fuel Tank Removal in the Fuel System DFI chapter Connect the test light A 12 V 3 4 W bulb in a socket with leads and the 12 V battery B to the fuel pump lead connector C Connections Battery 12 V 3 4 W Bulb one side 12 V 3 4 W Bulb other side gt BK R Lead Terminal Battery BK W Lead Terminal Special Tool Needle Adapter Set 57001 1457 x lf the test light turn on the reserve switch is defective Replace the fuel pump GP18626BS1 GP18241BS1 C ELECTRICAL SYSTEM 16 115 Switches and Sensors e Remove the fuel pump see Fuel Pump Removal in the Fuel System DFI chapter Connect the test light 12 V 3 4 W bulb in a socket with leads and the 12 V battery to the fuel pump lead connec tor as shown in the figure 12 V Battery A Test Light B Fuel Pump Lead Connector C Fuel Reserve Switch D x lf the test light doesn t light replace the fuel pump SES 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 Gear Position Switch Removal e Remove the left lower fairing see Lower Fairing Removal in the Frame chapter e Slide out the rubber boot A e Loosen the oil pre
92. faces throttle body assy e Run the fuel hose correctly see Cable Wire and Hose Routing section in the Appendix chapter e Pull B the joint lock C fully as shown in the figure e Insert the fuel hose joint A straight onto the delivery pipe until the hose joint clicks e Push B the joint lock C until the hose joint clicks PERIODIC MAINTENANCE 2 51 Periodic Maintenance Procedures e Push and pull the fuel hose joint A back and forth more than two times and make sure it is locked and doesn t come off A WARNING Leaking fuel can cause a fire or explosion resulting in severe burns Make sure the fuel hose joint is installed correctly on the delivery pipe and that it doesn t leak x If it comes off reinstall the hose joint e Install the throttle body assy see Throttle Body Assy In stallation in the Fuel System DFI chapter e Start the engine and check the fuel hose for leaks Coolant Change A WARNING Coolant can be extremely hot and cause severe burns is toxic and very slippery Do not remove the radiator cap or attempt to change the coolant when the engine is hot allow it cool completely Immediately wipe any spilled coolant from tires frame engine or other painted parts Do not ingest coolant e Remove Right Middle Fairing see Middle Fairing Removal in the Frame chapter Radiator Cap Cover A Radiator Cap B ORemove the radiator cap in two steps First t
93. 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 352 31 F Total Amount 3 2 L 3 4 US qt NOTE OChoose a suitable mixture ratio by referring to the coolant manufacturer s directions G806071BS1 PERIODIC MAINTENANCE 2 53 Periodic Maintenance Procedures e Bleed the air from the cooling system as follows OStart the engine with the radiator cap removed and run it until no more air bubbles A can be seen in the coolant OTap the radiator hoses to force any air bubbles caught inside OStop the engine and add coolant up to the radiator filler neck e Install the radiator cap and radiator cap cover Start the engine warm it up thoroughly until the radiator fan turns on and then stop the engine Check the coolant level in the reserve tank after the en gine cools down If the coolant level is lower than the L level line add coolant to the F level line NOTICE not add more coolant above the level line Radiator Hose and O ring Replacement e Drain the coolant see Coolant Change e Remove Lower Fairings see Lower Fairing Removal in the Frame chapter Middle Fairings see Middle Fairing Removal in the Frame chapter Throttle Body Assy see Throttle Body Assy Removal in the Fuel System DFI c
94. the bearing Coupling Bearing Lubrication e Pack the bearing with good quality bearing grease Turn the bearing around by hand a few times to make sure the grease is distributed uniformly inside the bearing Coupling Damper Inspection Remove the rear wheel coupling and inspect the rubber dampers A e Replace the damper if it appears damaged or deterio rated Sprocket Wear Inspection e Visually inspect the engine and rear sprocket teeth for wear and damage x lf 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 Rear Sprocket Warp Inspection Raise the rear wheel off the ground with the stand so that it will turn freely e Set a dial gauge A against the rear sprocket B near the teeth as shown in the figure and rotate C the rear wheel to measure the sprocket runout warp The difference between the highest and lowest dial gauge readings is the amount of runout warp xIf the runout exceeds the service limit replace the rear sprocket Rear Sprocket Warp Standard TIR 0 4 mm 0 016 in or less Service Limit TIR 0 5 mm 0 020 in 6114010151 GKO5017BS1
95. 0 07 mm 0 0012 0 0028 in Second 0 02 0 06 mm 0 0008 0 0024 in Service Limit Top 0 17 mm 0 0067 in Second 0 16 mm 0 0063 in 9 30 CRANKSHAFT TRANSMISSION Pistons Piston Ring Groove Width Inspection e Measure the piston ring groove width OUse a vernier caliper at several points around the piston Piston Ring Groove Width Standard Top A 0 92 0 94 mm 0 0362 0 0370 in Second B 1 01 1 03 mm 0 0398 0 0406 in Service Limit Top A 1 02 mm 0 040 in Second B 1 11 mm 0 044 in x lf the width of any of the two grooves is wider than the service limit at any point replace the piston Piston Ring Thickness Inspection e Measure the piston ring thickness OUse the micrometer to measure at several points around the ring Piston Ring Thickness Standard Top A 0 87 0 89 mm 0 0343 0 0350 in Second B 0 97 0 99 mm 0 0382 0 0390 in Service Limit Top A 0 80 mm 0 0315 in Second B 0 90 mm 0 0354 in any of the measurements is less than the service limit on either of the rings replace all the rings NOTE OWhen using new rings in a used piston check for un even groove wear The rings should fit perfectly parallel to the groove sides If not replace the piston Piston Ring End Gap Inspection e the piston ring A inside the cylinder upper crankcase using the piston to locate the ring squarely in place Set it close to the bottom of the cylinder whe
96. 0 44 R S 4 Mounting Nuts M12 59 6 0 44 5 Adjusting Collars 15 1 5 11 M Apply molybdenum disulfide grease R Replacement Parts S Follow the specified tightening sequence 8 4 ENGINE REMOVAL INSTALLATION Engine Removal Installation Engine Removal e Support the rear part of the swingarm with a stand e Squeeze the brake lever slowly and hold it with a band A WARNING Motorcycle may fall over unexpectedly resulting in an accident or injury Be sure to hold the front brake when removing the engine 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 Remove Engine Oil Drain see Engine Oil Change in the Periodic Maintenance chapter Coolant Drain see Coolant Change in the Periodic Maintenance chapter Middle Fairings see Middle Fairing Removal in the Frame chapter Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Ducts see Throttle Body Assy Removal in the Fuel Sys tem DFI chapter Coolant Reserve Tank see Coolant Change in the Peri odic Maintenance chapter Clutch Slave Cylinder see Clutch Slave Cylinder Re moval in the Clutch chapter Radiator see Radiator and Radiator Fan Removal in the Cooling System chapter Radiator Cover see Radiator Cover Removal in the Cooling System chapter Muffler Bodies see Muffler Body Removal Installation in the Engine Top
97. 0 60 0 65 4 75 5 00 0 62 Thus the valid range is 0 60 0 62 V e Turn the ignition switch to OFF xIf the reading is out of the standard replace the throttle body assy x If the reading is within the standard remove the ECU and check the wiring for continuity between harness connec tors Special Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Main Throttle Sensor Connector B Y W lead ECU terminal 25 C G lead ECU terminal 13 D x If the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation GT04075BS1 3 56 FUEL SYSTEM Main Throttle Sensor Service Code 11 Main Throttle Sensor Circuit D 5 es d a BL W BL W amp BL Y w Y w amp amp G BL BL BL 1 ECU 2 Main Throttle Sensor 3 Subthrottle Sensor 6T04101BW2 C FUEL SYSTEM 3 57 Intake Air Pressure Sensor 1 Service Code 12 Intake Air Pressure Sensor 1 Removal Never drop the intake air pressure sensor 1 espe cially on a hard surface Such a shock to the sensor can damage it e Remove Throttle Body Assy see Throttle Body Assy Removal Intake Air Pressure Sensor 1 Connector A e Remove the intake air pressure
98. 0 80 kgf m 69 in Ib e Remove the rubber cap A from the bleed valve 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 Bleed the brake line and the caliper ORepeat this operation until no more air be seen com ing out into the plastic hose 1 Pump the brake lever until it becomes hard and apply the brake and hold it A 2 Quickly open and close B the bleed valve while holding the brake applied 3 Release the brake C NOTE OThe fluid level must be checked often during the bleed ing operation and replenished with fresh brake fluid as necessary If the fluid in the reservoir runs completely out any time during bleeding the bleeding operation must be done over again from the beginning since air will have entered the line OTap the brake hose lightly from the caliper to the reser voir for more complete bleeding OFront Brake First bleeding the right caliper then repeat the above steps for the left caliper e Remove the clear plastic hose e Install Diaphragm Diaphragm Plate Front Brake Reservoir Cap Brake Fluid BRAKES 12 27 e Follow the procedure below to install the front rear brake fluid reservoir cap correctly OFirst tighten the brake fluid reservoir cap B clockwise C by hand until slight resistance is felt indicating that the cap is seated on the reservoir body then tighten the cap an additional 1
99. 0 kgf m 36 ft Ib Dy KD 6104309852 C N ABN JN WY SES Wi 6104434851 CRANKSHAFT TRANSMISSION 9 15 Crankcase Splitting OTighten the M7 bolts A Torque Crankcase Bolts M7 20 N m 2 0 kgf m 15 ft Ib 9104427851 Tighten the upper crankcase bolts in the order listed OThe 8 bolts have washers replace them with new ones OTighten 8 Bolts with Washer A M7 Bolt with Clamp B M7 Bolt C M6 Bolts D Torque Crankcase Bolts M8 27 N m 2 8 kgf m 20 ft Ib Crankcase Bolts M7 20 N m 2 0 kgf m 15 ft Ib Crankcase Bolts M6 12 N m 1 2 kgf m 106 in Ib 8104435 52 e After tightening all crankcase bolts check the following items OCrankshaft and transmission shafts turn freely OWhile spinning the output shaft gears shift smoothly from the 1st to neutral and neutral to 1st e Install the removed parts see appropriate chapters 9 16 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods Crankshaft Removal Split the crankcase see Crankcase Splitting e Remove the crankshaft see Connecting Rod Removal Crankshaft Installation 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
100. 06 oz sizes An imbalance of less than 10 grams 0 35 oz will not usually affect running stability ODo not use four or more balance weight more than 90 gram 3 2 oz If the wheel requires an excess balance weight disassemble the wheel to find the cause GJ04158BS2 C Wheels Rims WHEELS TIRES 10 13 Slip the balance weight A on the rib by pushing or lightly hammering C the clip D Olnstall the balance weight at the left side of the motorcycle Left Side E Right Side F Check 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 GJ04160BS2 C 10 14 WHEELS TIRES 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 Maintenance chapter Tire Removal e Remove Wheels see Front Rear Wheel Removal Valve Core Let out the air To maintain wheel balance mark the valve stem position on the tire with chalk so that the tire can be reinstalled in the same position Chalk Mark or Yellow Mark A Air Valve B Align C 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 NOTICE Never lubricate with engine oil or petroleum disti
101. 15 2 V Regulator Rectifier Output Voltage Ignition System Crankshaft Sensor Resistance 376 564 O 2 4 V or more 1 19 1 61 0 8 5 11 5 kO 72 V or more CR9EIA 9 0 8 0 9 mm 0 031 0 035 in 10 mm 0 39 in Service Limit 5 0 mm 0 20 in 28 mm 1 10 in Service Limit 27 mm 1 06 in 20 240 at 20 C 68 F Meter Gauge Indicator Unit Can Communication Line Resistance at Meter Unit 122 126 Switches Sensors Rear Brake Light Switch Timing Engine Oil Pressure Switch Connections Water Temperature Sensor Resistance Gear Position Switch Resistance Fuel Level Sensor Resistance Full Position Empty Position ON after about 10 mm 0 39 in of pedal travel When engine is stopped ON When engine is running OFF in the text in the text 9 110 213 2190 Special Tools and Sealant Hand Tester 57001 1394 7571394ST C Flywheel Puller Assembly M38 x 1 5 M35 x 1 5 57001 1405 s 7571405ST C Peak Voltage Adapter 57001 1415 4 875714155 C Lead Wire Peak Voltage Adapter 57001 1449 7571449ST C Needle Adapter Set 57001 1457 T571457ST C ELECTRICAL SYSTEM 16 11 Key Registration Unit 57001 1582 875715825 C Grip 57001 1591 875715915 C Flywheel amp Pulley Holder 57001 1605 875716055 C Rotor Holder 57001 1672 75716728T Stopper
102. 3 42 FUEL SYSTEM DFI DFI System Troubleshooting Guide Symptoms or Possible Causes Actions chapter Intake air pressure sensor 2 trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Intake air temperature sensor trouble Inspect see chapter 3 Other Intermittent any DFI fault and its recovery Check that DFI connectors are clean and tight and examine leads for signs of burning or fraying see chapter 3 Poor Running or No Power at High Speed Symptoms or Possible Causes Firing incorrect Actions chapter Stick coil shorted or not in good contact Stick coil trouble Inspect or reinstall see chapter 16 Inspect see chapter 16 Spark plug dirty broken or gap maladjusted Spark plug incorrect Inspect and replace see chapter 16 Replace it with the correct plug see chapter 2 ECU trouble Inspect see chapter 3 Fuel air mixture incorrect Clean element or inspect sealing see chapter 2 Air cleaner clogged poorly sealed or missing Air duct loose Reinstall see chapter 3 Throttle body assy holder loose Reinstall see chapter 3 Throttle body assy dust seal damage Replace see chapter 3 Change fuel Inspect and clean fuel system see Water or foreign matter in fuel chapter 3 Fuel injector O ring damage Visually inspect and replace see chapter 3 Fuel injector clogged
103. 30 Meter Unit 15 Frame Ground 2 31 Blue High Beam Indicator Light 16 Frame Ground 1 Turn Signal Light Bulb Replacement Front Turn Signal Light e Remove Middle Fairings see Middle Fairing Removal in the Frame chapter e Turn the socket A counterclockwise and pull out the socket together with the bulb Lighting System ELECTRICAL SYSTEM 16 67 e Push and turn the front turn signal light bulb A counter clockwise and remove it e Replace the bulb with new ones 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 Pushing the socket and turn it clockwise OFit the projections A of the socket into the grooves B of the turn signal light e Install the removed parts see appropriate chapters Rear Turn Signal Light e Remove Seat Cover see Seat Cover Removal in the Frame chapter OTunr the socket A counterclockwise and pull out the Socket together with the bulb e Push and turn the front turn signal light bulb A counter clockwise and remove it e Replace the bulb with new ones 16 68 ELECTRICAL SYSTEM Lighting System 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 Pushing the socket and turn it clockwise OFit
104. 30 30 3 1second OHTE LU UL TUL GP30082CS1 GP30083CS1 C 16 100 ELECTRICAL SYSTEM Immobilizer System Equipped Models e Remove the key registration unit key registration adapter and connect the immobilizer Kawasaki diagnostic system connector NOTE O Turn the ignition switch to ON with the registered ignition key OCheck that the engine can be started using all regis tered ignition keys e Install the new ignition switch see Immobilizer System Parts Replacement Case 3 When the electronic control unit ECU is faulty and has to be replaced e Prepare a new ECU A and current registered ignition key s B NOTE OThe key registration unit is not required OAfter replacing the ECU be sure to register 2 ignition keys If the 2 keys are not registered the engine can not be started e Replace the ECU A see Immobilizer System Parts Re placement e Insert the current registered ignition key into the ignition switch and turn it ON Olf there is any problem in the registration the red warning indicator light LED and immobilizer warning symbol A blinks to display the collation error Immobilizer Amplifier Failure GP30823BS1 C 0 2second GP30059CS1 C ELECTRICAL SYSTEM 16 101 Immobilizer System Equipped Models Registered Ignition Key Collation Error 0 3second GO Be ULL GP30080CS1 e
105. 39 4 0 29 17 Oil Pressure Switch Terminal Bolt 1 5 0 15 13 in lb G 18 Oil Pressure Switch 15 1 5 11 SS G Apply grease L Apply a non permanent locking agent R Replacement Parts S Follow the specified tightening sequence SS Apply silicone sealant WL Apply soap and water solution or rubber lubricant 16 8 ELECTRICAL SYSTEM Exploded View GP026188W5 C ELECTRICAL SYSTEM 16 9 Exploded View s e 2 Starter Lockout Switch Screw 0 70 0 071 6 2 in lb 3 Front Brake Light Switch Scerw 1 2 0 12 11 in lb 4 Fuel Level Sensor Bolts 6 9 0 70 61 in lb L 5 Sidestand Switch Bolt 8 8 0 90 78 in lb L 6 Oxygen Sensor 25 2 5 18 7 Immobilizer Equipped Models 8 Other than US CA and CAL Models L Apply a non permanent locking agent R Replacement Parts 16 10 ELECTRICAL SYSTEM Specifications Alternator Output Voltage Stator Coil Resistance Item Standard Battery Type Sealed battery Model Name FTX14 BS Capacity 12 12 Ah Voltage 12 6 V or more Charging System Type Three phase AC 51 V or more at 4 000 r min rpm 0 05 0 5 at 20 C 68 F Crankshaft Sensor Peak Voltage Stick Coil Primary Winding Resistance Secondary Winding Resistance Primary Peak Voltage Spark Plug Type Gap Electric Starter System Starter Motor Brush Length Commutator Diameter Air Switching Valve Resistance Charging Voltage 14 2
106. 8 0 9 mm 0 031 0 035 in Item Standard Service Limit Air Pressure when Cold Front Up to 175 kg 385 Ib load me 290 kPa 2 9 kgf cm 42 psi Rear Up to 175 kg 385 Ib load 290 kPa 2 9 kgf cm 42 psi Final Drive 1 mm 0 04 in 1 mm 0 04 Special Tools and Sealant Inside Circlip Pliers 57001 143 7570143ST C Steering Stem Nut Wrench 57001 1100 875711005 C Jack 57001 1238 7571238ST C Pilot Screw Adjuster A 57001 1239 875712395 6 Oil Filter Wrench 57001 1249 7571249ST C PERIODIC MAINTENANCE 2 15 Vacuum Gauge 57001 1369 Throttle Sensor Setting Adapter 57001 1538 875713695 C Jack Attachment 3 7571608ST C Liquid Gasket TB1211F 92104 0004 879200045 6 2 16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System DFI Throttle Control System Inspection e Check the throttle grip free play A x If the free play is incorrect adjust the throttle cables Throttle Grip Free Play Standard 2 3 mm 0 08 0 12 in e Check that the throttle grip B moves smoothly from full open to close and the throttle closes quickly and com pletely by the return spring in all steering positions x lf the throttle grip does not return properly check the throt tle cables routing grip free play and cable damage Then lubricate the thr
107. 8 15011752 C GE15133BS1 5 32 ENGINE END Valves Seat Cutter Operation Care 1 This valve seat cutter is developed to grind the valve for repair Therefore the cutter must not be used for other purposes than seat repair 2 Do not drop or shock the valve seat cutter or the dia mond particles may fall off 3 Do not fail to apply engine oil to the valve seat cutter before grinding the seat surface Also wash off ground particles sticking to the cutter with washing oil NOTICE Do not use a wire brush to remove the metal par ticles from the cutter It will take off the diamond particles 4 Setting the valve seat cutter holder in position operate the cutter in one hand Do not apply too much force to the diamond portion NOTE OPrior to grinding apply engine oil to the cutter and dur ing the operation wash off any ground particles sticking to the cutter with washing oil 5 After use wash it with washing oil and apply thin layer of engine oil before storing Marks Stamped on the Cutter The marks stamped on the back of the cutter A represent the following Cutter angle I7 B Outer diameter of cutter Operating Procedures Clean the seat area carefully e Coat the seat with machinist s dye e Fit a 45 cutter into the holder and slide it into the valve guide e Press down lightly on the handle and turn it right or left Grind the seating surface only
108. 9 2 Ke XS B For Cutting D F Q RU For Riveting E Plate Holder A F gt Plate Holder G Gauge H GKO4016BS1 e Grind A the pin head to make it flat Set the cutting and riveting pin B as shown in the figure Screw the pin holder until it touches the link pin e Be sure that the cutting pin hits center of the link pin GK04018BS1 C e Screw the handlebar A into the body e Turn the pin holder with the wrench B clockwise to ex tract the link pin GKO4019BS1 C e Replace the link pin link plate and grease seals e Apply grease to the link pins A and grease seals B C e Engage the drive chain on the engine and rear sprockets e Insert the link pins in the drive chain ends e Install the grease seals 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 Be sure to set the grease seals correctly GK04020BS1 C 11 8 FINAL DRIVE Drive Chain Set the plate holder A A and plate holder B on the body e Fit the plate holder A to the link plate e Turn the pin holder by hand until the plate holder B touches the other link plate e Turn the pin holder by a wrench clockwise until two pins of link come into groove of the plate holder A e Take off the plate holder Set the plate holder A and cutting and riveting pin B as shown in the figure Turn the pin hold
109. 96 B Refresh charge is required C Note D Good E 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 8 08010851 C 5 10060 18180078581 C 8 09001251 ELECTRICAL SYSTEM 16 37 Battery Terminal Voltage 11 5 less than 12 6 V Standard Charge 1 4 5 10 h see following chart Quick Charge 1 NOTICE If possible do not quick charge If quick charge is done unavoidably do standard charge later on Charge Time h 11 8 11 8 12 0 12 2 12 4 12 6 12 8 13 0 Battery Terminal Voltage V Terminal Voltage less than 11 5 V 60802381 6 Charging Method 1 4A x 20h NOTE voB Olncrease the charging voltage to a maximum voltage of TE 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 will accept current decrease the voltage and charge by the standard charging method described on the battery case If the battery will not accept current after 5 min utes replace the battery 8008011381 6 Batter
110. AN OINS RE 13 6 Special TOONS Rs 13 7 EET 13 10 Rebound Damping Force 2221112222111 13 10 Compression Damping Force 13 10 Spring Preload Adjustment a 13 11 Front Fork Removal Each Fork Leg pp 13 11 Front Fork 13 12 Front Fork Oil Change 13 13 Front Fork DISASSOMDIY 13 24 Front Fork Assembly tet PIC 13 24 Inner Tube Outer Tube 13 25 Dust Seal InSpectiOni uei Du 13 26 Spring Tension InspebllOri acce e ce petere iare ades 13 26 Rear Shock Absorber calc 2 LT m 13 27 Rebound Damping Force 13 27 Compression Damping Force 13 27 SDrIng Preload tao Brive a 13 27 Rear Shock Absorber Removal pp 13 28 Rear Shock Absorber Installation pp 13 29 Rear Shock Absorber INSPECTION nesta brote Pul ka encoded 13 29 Rear Shock Absorber Serappirng 5 ore metet 13 30 SWING Swingarm Removal
111. Air Pressure Sensor 2 Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch to OFF e Remove the throttle body assy see Throttle Body Assy Removal ODo not disconnect the connectors of the throttle body assy e Disconnect the intake air pressure sensor 2 connector and connect the measuring adapter A between these connectors B Main Harness C Intake Air Pressure Sensor 2 Special Tool Measuring Adapter 57001 1700 e Connect a digital meter D to the measuring adapter leads Intake Air Pressure Sensor 2 Input Voltage Connections to Adapter Digital Meter gt sensor BL lead Digital Meter gt BK sensor lead e Measure the input voltage with the engine stopped and with the connector joined e Turn the ignition switch to ON GT04085BS1 C Input Voltage Standard DC 4 75 5 25 V e Turn the ignition switch to OFF x If the reading is within the standard check the output volt age see Intake Air Pressure Sensor 2 Output Voltage Inspection x If the reading is out of the standard remove the ECU and check the wiring for continuity between harness tors Special Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector Intake Air Pressure Sensor 2 Connector B BL lead ECU terminal 9 C G lead ECU terminal 13 D x If t
112. All Battery Voltage x If the reading is out of the specification check the follow ing Main Fuse 30 A see Fuse Inspection in the Electrical System chapter ECU Fuse 15 A see Fuse Inspection in the Electrical System chapter ECU Main Relay see Relay Circuit Inspection in the Electrical System chapter Power Source Wiring see wiring diagram in this section 8017250 51 3 116 FUEL SYSTEM DFI ECU ECU Power Source Circuit 2a o Ignition Switch Joint Connector E ECU Frame Ground Battery Starter Relay Main Fuse 30 A ECU Fuse 15A Frame Ground 3 Frame Ground 2 Fuse Box 1 Ignition Fuse 15 Joint Connector F 6617212212 CAN Communication Line FUEL SYSTEM DFI 3 117 CAN Communication Line Resistance Inspection Oln this model resistors for CAN communication line are built in the ECU A and meter unit e Refer to the Meter Unit Inspection in the Electrical System chapter for the resistor in the meter unit e Turn the ignition switch to OFF e Remove ECU see ECU Removal e Connect a digital meter A to the ECU connector black B e Measure the resistance of the CAN communication line resistor Special Tool Hand Tester 57001 1394 CAN Communication Line Resistance at ECU Connector Connections Terminal 27 Terminal 28 Standard 122 126 O xIf the reading is out o
113. Bolts B Slave Cylinder C NOTICE Immediately wash away any clutch fluid that spills It may damage painted surfaces e Perform the following if the clutch slave cylinder is to be removed but not disassembled If the clutch slave cylinder is removed and left alone the piston will be pushed out by spring force and the clutch fluid will drain out ORemove the clutch slave cylinder from the engine with the pipe installed Push A the piston into the cylinder as far as it will go OApply the clutch lever A slowly and hold it with a band OHolding the clutch lever keeps the piston from coming out Clutch Slave Cylinder Installation Apply molybdenum disulfide grease to either end A of the push rod and install the push rod so that the greased end faces in e Replace the spacer B of the clutch slave cylinder with a new one e Install the spacer so that the stepped side C faces out ward 8 10010151 8 10020251 Clutch Slave Cylinder CLUTCH 6 9 Apply a non permanent locking agent to the threads of the slave cylinder bolts A e Finger tighten all the clutch slave cylinder bolts e Remove the band from the clutch lever and release the clutch lever Tighten the clutch slave cylinder bolts e Replace the washers that are on each side of the hose fitting with new ones e Tighten Torque Clutch Hose Banjo Bolt B 25 N m 2 5 kgf m 18 ft
114. Clamp Bolts Lower 30 N m 3 1 kgf m 22 ft lb Front Fork Top Plugs 22 N m 2 2 kgf m 16 ft Ib Front Fork Clamp Bolts Upper 20 N m 2 0 kgf m 15 ft lb NOTE OTighten the two clamp bolts alternately two times to en sure even tightening torque OTighten the top plug before tightening the upper front fork clamp bolt e Install the removed parts see appropriate chapters e Adjust Spring Preload see Spring Preload Adjustment Rebound Damping Force see Rebound Damping Force Adjustment Compression Damping Force see Compression Damp ing Force Adjustment GM04380BS1 Front Fork SUSPENSION 13 13 Front Fork Oil Change e Remove the front fork see Front Fork Removal e Hold the inner tube lower end in a vise e Unscrew the top plug A out of the outer tube e Install the clamps as shown in the figure NOTE OSet the clamps so that the cutout B of the upper side does not touch the tongue shape of stopper pull up the outer tube C to hold it by the clamps and then tighten the two bolts D The outer tube is used as a guide Special Tool Fork Spring Compressor 57001 1540 e Set the spring compressor A and a suitable jack as shown in the figure Special Tool Fork Spring Compressor 57001 1771 e Insert the projection of the protector A into the front fork bottom hole B 13 14 SUSPENSION Front Fork e Set the front fork A under the holder
115. Clutch Fluid Change in the Periodic Maintenance chapter e Remove Clamp Screw A and Stopper Clutch Reservoir Bolt B e Remove the banjo bolt C to disconnect the clutch hose from the master cylinder e Remove the clamp bolts D and take off the master cylin der as an assembly with the clutch reservoir clutch lever and starter lockout switch installed Clutch fluid quickly ruins painted surface any spilled fluid should be completely washed away immediately Clutch Master Cylinder Installation e Install the master cylinder clamp A with the arrow mark B upward Clutch Master Cylinder CLUTCH 6 7 Align the punch mark A on the handlebar with the mating surface B of the master cylinder clamp e Tighten the upper clamp bolt first and then the lower clamp bolt There will be a gap at the lower part of the clamp after tightening Torque Clutch Master Cylinder Clamp Bolts 10 3 N m 1 05 kgf m 91 in Ib e Replace the washers that are on each side of the hose fitting with new ones e Tighten Torque Clutch Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft Ib e Replenish the clutch fluid into the reservoir and bleed the clutch line see Bleeding the Clutch Line Check that the clutch line has proper fluid pressure and no fluid leakage Clutch Master Cylinder Disassembly e Refer to the Rubber Parts of Clutch Master Cylinder Slave Cylinder Replacement in the Periodic Maintenance chap te
116. Diagnostic Systen Connector BK Y BK Y BK Y mall Reserve Fusi Switch wires Pump Regulator Rectifier Alternator IGNITION SWITCH CONNECTIONS RIGHT SM LTOH HOUS ING CONNECTIONS Battery lgnition Signal lgnition Front Brake Light Switch GY fce ior 6r Fen Jester r BLA 98052 06540 06898 W2RO654CW5 C 16 18 ELECTRICAL SYSTEM Wiring Diagram PH and SEA B2 Models Meter Unit ds 2 3 8 9 19 11 12 13 MELED Light Emitting Diode BK BL lonobilizer x Amplifier eee Front Light 124218 Green Neutral Indicator m Light LED Ris Rosi nei ien S 5 N 54 Yellow Engage Shift Up ig witoh Housing Horn Motor Motor X PIS Sidestand Indicator Light LED H coils Red Warning Indicator Light Right Switch Housing tal 1 Front Brake Water Temperature prone Brake FF Battery Immobilizer LED N HH Outside BL Temperature BK Y Sensor Turn Signal BK Y BK Y Green Left Turn Signal Indicator Light LED Green Right Turn Signal Indicator Light LED Blue High Beam Indicator Light LED Switch 2 Engine Stop Switch Red 011 Pressure Warning M M M Indicator Light LED Saf fepter Button 5 tt gt T af 5 ag 5 Yellow KTRC Warning 1 zz 35 zi Indicator Light LED Intake ge Yellow Engine Warning M gt Indicator Light
117. ECU see ECU Removal Installation Subthrottle Sensor Circuit GC17526ES1 D 1 ECU 2 Main Throttle Sensor 3 Subthrottle Sensor GTO41018W2 C 3 88 FUEL SYSTEM Oxygen Sensor not activated Service Code 33 Equipped Models Oxygen Sensor Removal Installation e Refer to the Oxygen Sensor Removal Installation Equipped Models in the Electrical System chapter Oxygen Sensor Inspection e Remove Right Middle Fairing see Middle Fairing Removal in the Frame chapter Oxygen Sensor Lead Connector A e Connect the measuring adapter A between the harness connector and oxygen sensor lead connector as shown in the figure Main Harness B Oxygen Sensor C Special Tool Measuring Adapter 57001 1700 e Connect a digital meter D to the measuring adapter leads Oxygen Sensor Output Voltage Connections to Adapter Digital Meter gt sensor BK lead Digital Meter gt BK sensor lead 6104027851 e Remove the air switching valve A see Air Switching Valve Removal in the Engine Top End chapter ODo not disconnect the air switching valve connector B FUEL SYSTEM DFI 3 89 Oxygen Sensor not activated Service Code 33 Equipped Models e Install the suitable plugs A on the fitting of the air suction valve covers and shut off the secondary air e Warm up the engine thoroughly until the radiator fan
118. ECU terminal 47 Digital Meter Frame Ground terminal For Fuel Injector 2 Digital Meter BL R lead ECU terminal 48 Digital Meter Frame Ground terminal For Fuel Injector 3 Digital Meter BL O lead ECU terminal 49 Digital Meter Frame Ground terminal For Fuel Injector 4 Digital Meter BL G lead ECU terminal 50 Digital Meter Frame Ground terminal e Measure the output voltage with the engine stopped and with the connector joined e Turn the engine stop switch to run position e Turn the ignition switch to ON Output Voltage Standard Battery Voltage for 3 seconds and then 0 V e Turn the ignition switch to OFF x If the reading is in specification check the ECU for its ground and power supply see ECU Power Supply In spection x If the ground and power supply are good replace the ECU see ECU Removal Installation GC17215FS1 3 130 FUEL SYSTEM Fuel Injectors x If the reading is out of the specification remove the ECU and check the wiring for continuity between harness con nector Special Tool Hand Tester 57001 1394 ODisconnect the ECU and injector connector Wiring Continuity Inspection ECU Connector Gray Fuel Injector Connector For Fuel Injector 1 BL BK lead ECU terminal 47 D For Fuel Injector 2 BL R lead ECU terminal 48 For Fuel Injector 3 BL O lead ECU terminal 49 For Fuel Injector 4 B
119. Example Exhaust 2 100 0 33 0 245 2 185 mm OExchange the shim for the 2 200 size shim PERIODIC MAINTENANCE 2 25 Periodic Maintenance Procedures Adjustment Shims Thickness Part Number Mark 92025 1870 0 2 025 92180 0209 3 E 3 92025 1871 5 bur 2 075 92180 0210 8 92025 1872 10 2 125 92180 0211 13 2 150 92025 1873 15 2 175 92180 0212 18 2 200 92025 1874 20 92180 0213 23 2 250 92025 1875 25 92180 0214 28 92025 1876 30 2 325 92180 0215 33 2 375 92180 1058 38 92025 1878 40 2 425 92025 1982 43 2 450 92025 1879 45 2 475 92025 1983 48 2 500 92025 1880 50 92025 1984 53 2 550 92025 1881 55 92025 1985 58 92025 1882 60 2 625 92180 1059 63 92025 1883 65 2 675 92180 1194 68 92025 1884 70 2 725 92180 1195 73 2 750 92025 1885 75 2 775 92180 1196 78 2 800 92025 1886 80 2 825 92180 0216 83 2 850 92025 1887 85 2 875 92180 0217 88 2 900 92025 1888 90 2 925 92180 0218 93 2 950 92025 1889 95 2 975 92180 0219 98 3 000 92025 1890 00 2 26 PERIODIC MAINTENANCE Periodic Maintenance Procedures Be sure to remeasure the clearance after selecting a shim The clearance can be out of the specified range because of the shim tolerance Olf there is no valve clearance use a shim that is a few sizes smaller and remeasure the valve clearance When installing the shim face the marked side toward the valve lifter At this time apply engi
120. Hose Routing section in the Appendix chapter e Install the removed parts see appropriate chapters Steering Stem Bearing Lubrication e Refer to the Steering Stem Bearing Lubrication in the Pe riodic Maintenance chapter Steering Stem Warp Inspection e Whenever the steering stem is removed or if the steering can not be adjusted for smooth action check the steering stem for straightness x lf the steering stem A is bent replace the steering stem Stem Deterioration Damage Inspection Replace the stem cap if its oil seal A shows damage GNOSO085BS1 C 14 10 STEERING Handlebar Handlebar Removal e Remove Clutch Lever Clamp Bolts A Clutch Lever Assembly B Left Switch Housing C Handlebar Weight D e Remove Front Master Cylinder A see Front Master Cylinder Re moval in the Brakes chapter Right Switch Housing B Throttle Case C Handlebar Weight D Throttle Grip E Remove the handlebar holder bolts A Remove each handlebar holder B with handlebar Hold the handlebar a vise and remove the handlebar bolt A and handlebar e Remove Left Handlebar Grip Handlebar Installation e Fit the pin A of the handlebar to the recess B of the handlebar holder e Apply a non permanent locking agent to the threads of the handlebar bolts Tighten Torque Handlebar Bolts 34 N m 3 5 kgf m 25 ft lb GNOGOBOBS1 C
121. Hotar E E X Sidestand 5 Switch Indicator Light LED E E T Coils ore on 8 Red Warning Indicator Light vi Mater Temperature BK Battory Immobitizer LED ir o 7 Red Gil Pressure Warning ef ef wf wt Indicator Light LED R z zz 8 Yellow KTRC Warning a 2 Intak Indicator Light LED as E LI META FH 10 Yellow Engine Warning IT it TI Temperature Indicator Light LED Se eS 55 5 55 Sensor 11 Speedometer 2 Tachometer 13 Multifunction Display 4 tllumination Light LED MLED Light Emitting Diode Ignition Switch BK BL anobilizer V Amplifier s f Vehicle BL down rae sensor _ e Immobilizer BRW Antenna SIRE sut Connector F BR W 5 a i Front Wheel D Rotation Sensor as Meter Unit Bex Y R H Joint Connector Outside BL Temperature BK Y Front Right KH Turn sime e Light BK Y BK Y 12 21 City Light R Joint Joint 2 5 sk Connector Connector Fuse Box 2 Headlight ira 127068 324222 Headlight Low wy 12 55 Headlight M Low 12 554 Headligh
122. Inspection e Remove the spark plugs see Spark Plug Replacement in the Periodic Maintenance Chapter e Visually inspect the spark plugs xlf 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 x f the spark plug is dirtied or the carbon is accumulated replace the spark plug e Measure the gap D with a wire type thickness gauge x the gap is incorrect replace the spark plug Spark Plug Gap 0 8 0 9 mm 0 031 0 035 e Use the standard spark plug or its equivalent Spark Plug CR9EIA 9 Interlock Operation Inspection e Raise the rear wheel off the ground with the stand 1st Check Start the engine to the following conditions Condition Transmission Gear 1st Position Clutch Lever Release Sidestand Down or Up OTurn the ignition switch to ON and push the starter button OThen the starter motor should not turn when the starter system circuit is normality the engine is start inspect the starter lockout switch gear position switch and relay box 2nd Check Start the engine to the following conditions Condition Transmission Gear 1st Position Clutch Lever Pulled in Sidestand Up OTurn the ignition switch to ON and push the starter button OThen the starter motor should turn when the starter sys tem circuit is normality x If the starter motor is not turn inspect the starter loc
123. Joint Pipe Blue Paint Mark Brake Hose Joint Pipe White Paint Mark ABS Hydraulic Unit Brake Hoses View from Front Side Front Wheel Rotation Sensor Lead Clamp Hold the brake hose and front wheel rotation sensor lead and align the clamp with white painted mark of the front wheel rotation sensor lead Clamp Hold the front wheel rotation sensor lead 2a RONDO 17 50 APPENDIX Cable Wire and Hose Routing ABS Equipped Models W S 08809872045 C APPENDIX 17 51 Cable Wire and Hose Routing 1 Clamp Hold the brake hose OF Clamp Hold the brake hose rear wheel rotation sensor lead and align the clamp with white painted mark of the rear wheel rotation sensor lead Rear Wheel Rotation Sensor Lead Brake Hose Touch the brake hose fitting to the stopper Brake Pipe Two Blue Paint Marks Brake Pipe Two White Paint Marks About 71 ABS Hydraulic Unit 10 11 12 13 14 15 16 Rear Wheel Rotation Sensor Brake Hose Two White Paint Marks Brake Hose Two Blue Paint Marks Brake Hose Joint Pipe Two Blue Paint Marks Brake Hose Joint Pipe White Paint Mark Clamp Hold the rear wheel rotation sensor lead Rear View 17 52 APPENDIX Cable Wire and Hose Routing CAL and SEA B1 Models 08809873045 C Cable Wire and Hose Routing
124. L w OFF Loch BK Y Light LED License Plate Light 12758 BK Y R R RAY Rear Left Turn Signal Light 12V21W Color Code BK Black BL Blue BR Brown 78 Green Gray LB Light Blue LG Light Green Orange P Pink PU Purple R Red White ON Yellow P PARK 98052 0691B W2RO6918W5 C 16 26 ELECTRICAL SYSTEM Wiring Diagram ABS Equipped Models BR Model Meter Unit i Green Left Turn Signal Indicator Light LED 2 Green Right Turn Signal indicator Light LED 3 Blue High Beam Indicator Right Switch Housing Light LEB 1 Front gene Spark Plugs Light Switch amp S SN i 3 Starter Button is witch Housing Horn Motor Motor E X Sidestand 5 Yellow Engage Shift Up 2 1 Har Switch Indicator Light LED H oils 6 Red Warning Indicator Light i d S Water Temperature BK Y BX BL Battery Immobi lizer LED a i 7 Red Gil Pressure Warning ue 8 P PES Indicator Light LED ffo r it z H z z 8 Yellow ABS Indicator 5 1 u Light LED ere 55 9 Yellow KTRC Warning z Temperature Indicator Light LEB 5 3 Sensor 10 Yellow Engine Warning Indicator Light LED 11 Speedometer 12 Tachometer 13 Multifunction Display 14 Il lunination Light LED HR LED Light Emitting Diode
125. Left Turn Signal Light Lead Connector Clamp Hold the front left turn signal light lead and insert the clamp into the middle air intake duct Headlight Lead Cover Cover the ignition switch lead and left switch housing lead as shown in the figure 17 16 APPENDIX Cable Wire and Hose Routing 68099160 6 APPENDIX 17 17 Cable Wire and Hose Routing 10 11 12 13 14 Other than CAL and SEA B1 Models Run the engine harness to the outside of the clutch hose and inside of the bracket Stick Coil Lead Connector Clamps Hold the main harness and insert the clamps into the brackets Throttle Body Subharness Connector Clamp Hold the left fan motor lead connector and insert the clamp into the subframe Clamp Hold the left fan motor lead Sidestand Switch Lead Connector Gear Position Switch Lead Connector Clamp Hold the clutch hose sidestand switch lead and gear position switch lead Larger Diameter Sidestand Switch Lead and Gear Position Switch Lead Smaller Diameter Clutch Hose Air Cleaner Drain Tank Put the air cleaner drain tank as shown in the figure Run the sidestand switch lead and gear position switch lead from the notch of the engine sprocket cover to the inside of the cover Run the reserve tank overflow hose and drain hose through the clamp of the sidestand Hold the fuel tank breather hose and clutch hose
126. 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 any wiring is deteriorated replace the wiring Pull each connector A apart and inspect it for corrosion dirt and damage the connector is corroded or dirty clean it carefully If it is damaged replace it Connect the connectors securely Check the wiring for continuity OUse the wiring diagram to find the ends of the lead which is suspected of being a problem OConnect the hand tester between the ends of the leads Special Tool Hand Tester 57001 1394 OSet the tester to the x 1 range and read the tester x lf the tester does not read 0 the lead is defective Re place the lead or the main harness or the subharness 6617037351 9617231252 FUEL SYSTEM 3 35 Troubleshooting the DFI System 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 and ground 0 If there is continuity the harness
127. OTake care not to damage the crankcase G104428BS1 9 12 CRANKSHAFT TRANSMISSION Crankcase Splitting Crankcase Assembly The upper and lower crankcase halves are ma chined at the factory in the assembled state so the crankcase halves must be replaced as a set e With a high flash point solvent clean off the mating sur faces of the crankcase halves and wipe dry A WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the crankcase in a well ventilated area and take care that there are no sparks or flame anywhere near the working area this in cludes any appliance with a pilot light Do not use gasoline or a low flash point solvent to clean the crankcase e Using compressed air blow out the oil passages in the crankcase halves e Press the new drive shaft bearing A so that its stepped side B faces as shown in the figure Special Tool Bearing Driver Set 57001 1129 e Install the bearing position plate C Olnstall the plate so that the stepped hole side faces out side Yellow Paint D e Apply a non permanent locking agent to the threads of the bearing position plate screws E and tighten them Torque Bearing Position Plate Screws 4 9 N m 0 50 kgf m 43 in Ib e Press the new needle bearing A for the shift shaft so that its marked side B faces as shown in the figure OPress the new needle bearing so t
128. Oil Cooler see Oil Cooler Removal Oil Pipe Mounting Bolt A with washers B Oil Pipe C e When disassembling the oil pipe remove the oil pipe bolt OHold the oil pipe in vice Oil Pipe Installation e When assembling the oil pipe replace the O ring A with a new one and apply grease e Apply a non permanent locking agent to the threads of the oil pipe bolt and tighten it OHold the oil pipe in a vice Torque Pipe Bolt 9 8 N m 1 0 kgf m 87 in Ib e Replace the oil pipe O rings with new ones e Apply grease to the oil pipe O rings e Run the oil pipe correctly see Cable Wire and Hose Routing section in the Appendix chapter e Apply a non permanent locking agent to the threads of the oil pipe mounting bolts and tighten them Torque Oil Pipe Mounting Bolts 9 8 N m 1 0 kgf m 87 in Ib e Install the removed parts see appropriate chapters ENGINE REMOVAL INSTALLATION 8 1 Engine Removal Installation Table of Contents 0 aie ad at eased EM 8 2 Engine Removal lnstallation Ne 8 4 Engine Removal ute ute 8 4 Engine 2 E 8 6 8 2 ENGINE REMOVAL INSTALLATION Exploded View GH021828W5 C ENGINE REMOVAL INSTALLATION 8 3 Exploded View Fastener Remarks Engine Bracket Bolts M8 2 Subframe Bolts 23 2 3 17 R 3 Front Engine Mounting Bolts M10 59 6
129. 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 seal cover A circlip B connector C and O ring D Special Tool Inside Circlip Pliers 57001 143 Remove the locknut E and pivot bolt F and remove the brake lever e Remove the circlip G e Pull out the piston assy H e Replace Seal Cover A Circlip B O ring D Circlip G Piston Assy H Diaphragm I 9813150852 C 2 64 PERIODIC MAINTENANCE Periodic Maintenance Procedures Rear Master Cylinder Disassembly e Remove the rear master cylinder see Rear Master Cylin der Removal in the Brakes chapter e Remove the circlip A connector B and O ring C Special Tool Inside Circlip Pliers 57001 143 e Slide the dust cover D out of place and remove the cir clip E e Pull out the push rod assy F e Take off the piston assy G and return spring H Do not remove the secondary cup from the piston since removal will damage it e Replace Circlip A O ring C Circlip E Push Rod Assy F Piston Assy G Diaphragm I Master Cylinder Assembly e Before assembly clean all parts including the master cylinder with brake fluid or alcohol Except for the disc pads and disc use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning brake parts Do not use any other fluid for
130. Plug Replacement 2 39 2 39 2 40 2 41 2 41 2 44 2 45 2 46 2 46 2 46 2 47 2 48 2 48 2 49 2 51 2 53 2 54 2 55 2 56 2 57 2 58 2 59 2 62 2 63 2 65 2 68 PERIODIC MAINTENANCE 2 3 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition The initial maintenance is vitally important and must not be neglected Periodic Inspection FREQUENCY Whichever ODOMETER READING comes x 1 000 km x 1 000 mile See Every 0 6 3 75 7 5 11 25 15 18 75 22 5 Fuel System Throttle control system play year 2 16 smooth return drag inspect Engine vacuum synchronization inspect Idle speed inspect Fuel leak fuel hose and pipe inspect Fuel hose and pipe damage inspect Fuel hose and pipe installation condition inspect Evaporative emission control system function inspect CAL and SEA B1 Models Coolant level inspect Coolant leak water hose and pipe inspect Water hose damage inspect Water hose installation condition year inspect Engine Top End US Models Other than US CA Every 42 000 km 26 250 mile Models Valve clearance inspect Air suction system damage inspect Clutch Clutch operation play disengagement engagement inspect 6 Clutch fluid leak clutch h
131. Rear Wheel Rotation Sensor Signal Abnormal Service Code 44 12 48 Rear Wheel Rotation Sensor Wiring Inspection Service Code 45 12 49 Power Supply Voltage Inspection Low Voltage Service Code 52 12 49 Power Supply Voltage Inspection Over Voltage Service Code 53 12 50 ECU Inspection Service Gode 55 netter 12 50 ABS Hydraulic Unit Removal ohne PRO o ee Pen 12 50 ABS Hydraulic Unit Installation e ooo eia taxe pnl 12 51 ABS Hydraulic Unit Inspection s e odes arre exei depu 12 52 Front Wheel Rotation Sensor 12 53 Front Wheel Rotation Sensor Installation pp 12 53 Rear Wheel Rotation Sensor FHerroVal iiber eser teret heaton Ead ava 12 53 Rear Wheel Rotation Sensor 12 54 Wheel Rotation Sensor Inspectigm oues dh derer res Popes e 12 54 Wheel Rotation Sensor Air Gap Inspection 12 55 Wheel Rotation Sensor Rotor 12 55 ABS Solenoid Valve Relay Fuse 20 A 12 56 ABS Motor Relay Fuse 30 A 12 56 ABS ECGU Puse 10 A Removal 12 56 USE eR RH 12 56 FUSE INSPECTION
132. Stick Coil 1 BK Unused Unused Unused Battery Monitor Voltage Line W R Radiator Fan Relay P BL Fuel Pump Relay BR Y Unused Engine Ground BK Y Engine Ground BK Y Purge Valve CAL and SEA B1 Models R W Oxygen Sensor Heater Equipped Models R Unused Stick Coil 3 BK O KDS Kawasaki Diagnostic System 3 22 FUEL SYSTEM DFI Parts Location Main Throttle Sensor A Subthrottle Sensor B Subthrottle Valve Actuator C Water Temperature Sensor D Battery E Fuel Injectors 1 2 3 4 F Stick Coils 1 2 3 4 A Intake Air Pressure Sensor 1 B Idle Speed Control Valve Actuator C Relay Box Fuel Pump Relay ECU Main Relay A Immobilizer Equipped Models Kawasaki Diagnostic System Connector B ECU C Intake Air Temperature Sensor A Crankshaft Sensor A Oxygen Sensor B Equipped Models 6517579 P FUEL SYSTEM 3 23 DFI Parts Location Gear Position Switch A Immobilizer Amplifier A Equipped Models Vehicle down Sensor B Ignition Key Transponder Immobilizer System Equipped Models A Ignition Switch B Immobilizer Antenna C Equipped Models Yellow Engine Warning Indicator Light LED D Intake Air Pressure Sensor 2 A Fuel Pump A 3 24 FUEL SYSTEM DFI Parts Location Front Wheel Rotation Sensor A Rear Wheel Rotation Sensor A Purge Valve A
133. The registered ignition key is registered in the ECU OThe red warning indicator light LED and immobilizer warning symbol A blinks 1 time and stops for 1 second and the repeats this cycle to indicate successful registra tion of the registered ignition key EA GP30085CS1 C e Turn OFF the registered ignition key and remove it OThe red warning indicator light LED and immobilizer warning symbol A blinks to display the registration mode NOTE _ Olnsert next key and turn ON within 15 seconds after pre 5 2270 vious key is turned OFF and removed otherwise regis m tration mode will be ended and the red warning indicator QN ides cs light LED goes Off GP30058081 C O To return to the registration mode start the registered ignition key verification procedure This applies to all ignition key registration e Insert the other remaining registered ignition key to the ignition switch and turn it to ON NOTE OKeep the other ignition keys away from the immobilizer antenna Olf there is any problem in the registration the red warning indicator light LED and immobilizer warning symbol A blinks to display the collation error Immobilizer Amplifier Failure 0 2second ON On GP30059CS1 C 16 102 ELECTRICAL SYSTEM Immobilizer System Equipped Models When Registered Ignition Key is Inserted 0 5second 0 5second Pee E SE
134. Torque Angle Rod Assy N m ft lb Attached to 33 3 3 4 25 Attached to new con rod 120 New new con rod 39 2 4 0 29 New 120 39 2 4 0 29 Replace the Used 20 ue Used bolts with new ones New ane 6105040451 6105040551 CRANKSHAFT TRANSMISSION 9 21 Crankshaft and Connecting Rods 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 Inspection Remove the connecting rod big end bearing inserts and reinstall the connecting rod big end cap Select an arbor A of the same diameter as the connect ing rod big end and insert the arbor through the connect ing rod big end e Select an arbor of the same diameter as the piston 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 x If the connecting rod bend exceeds the service limit the connecting rod must be replaced
135. Yellow ABS Indicator Light LED Inspection Oln this model the yellow ABS indicator light LED A goes on or blinks by the control of the ABS hydraulic unit e Refer to the meter operation Inspection in the Electrical System chapter ON 5 Power supply voltage abnormal N under voltage 5 N i N 5 te 2 3 JUUL JUUUUL TUUUUL O O O 55 ECU trouble ECU operation abnormal GL14615BS1 12 46 BRAKES Anti Lock Brake System Equipped Models Solenoid Valve Inspection Service Code 13 14 17 18 OThe solenoid valve is built in the ABS Hydraulic Unit A Therefore the solenoid valve cannot be checked directly e Perform the Pre Diagnosis Inspection 1 and 2 see In quiries to Rider any of these service codes appears even if all checks are ended replace the ABS hydraulic unit x If the service code does not appear the ABS system nor mal temporary failure ABS Solenoid Valve Relay Inspection Service Code 19 OThe ABS solenoid valve relay is built in the ABS Hydraulic Unit Therefore the relay cannot be checked directly e Perform the Pre Diagnosis Inspection 1 and 2 see In quiries to Rider x lf this service code appears even if all checks are ended replace the ABS hydraulic unit x If the service code does not appear the ABS system nor mal temporary failure Front Rear Wheel Rotation Difference Abnormal Inspection Service Code 25 C
136. blades are damaged replace the water pump assy 4 12 COOLING SYSTEM Radiator Radiator and Radiator Fan Removal e Remove Middle Fairings see Middle Fairing Removal in the Frame chapter Coolant Drain see Coolant Change in the Periodic Maintenance chapter Right Radiator Fan Motor Lead Connector A Discon nect Clamp B Quick Rivet C Clear the right inner rubber cover D from the hook E of the radiator cover e Free the right radiator fan motor lead e Remove Clamp Screws A Loosen Reserve Tank Hose B Air Bleeder Hose C for Thermostat Housing Water Hose D Oil Cooler Outlet Hose E Upper Radiator Mounting Bolt F e Remove Left Radiator Fan Motor Lead Connector A Discon nect Clamp B Open Quick Rivet C e Clear the left inner rubber cover D from the hook E of the radiator cover e Free the left radiator fan motor lead e Remove Clamp Screw A Loosen Water Hose B Lower Radiator Mounting Bolt C Upper Radiator Mounting Bolt D Radiator E Do not touch the radiator core This could damage the radiator fins resulting in loss of cooling effi ciency Radiator COOLING SYSTEM 4 13 Remove Radiator Fan Mounting Bolts A Left Side Radiator Fan Assy B Right Side Radiator Fan Assy C Radiator and Radiator Fan Installation e Run the radiator fan motor lead correctly see Cable Wire and Hose Routing section in the Appendix chapte
137. broken or weak Clutch hub or housing unevenly worn Clutch master cylinder trouble Clutch slave cylinder 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 slave cylinder trouble Clutch fluid deteriorated Air in clutch fluid line Clutch master cylinder primary or sec ondary cup damage Clutch master cylinder scratched inside Gear Shifting Faulty Doesn t go into gear shift pedal doesn t return Clutch not disengaging Shift fork bent or seized Gear stuck on the shaft Gear positioning lever binding Shift return spring weak or broken Shift return spring pin loose Shift mechanism arm spring broken Shift mechanism arm broken Shift pawl broken Jumps out of gear Shift fork ear worn bent Gear groove worn Gear dogs and or dog holes worn Shift drum groove worn Gear positioning lever spring weak or bro ken Shift fork guide pin worn Drive shaft output shaft and or gear splines worn Overshifts Gear positioning lever spring weak or bro ken Shift mechanism arm spring broken Abnormal Engine Noise Knocking ECU trouble Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Overheating Piston slap Cylinder piston
138. by the manufacturer of the cleaning product e Warm up the engine and run it at normal operating tem perature for about ten minutes Stop the engine and drain the cooling system Fill the system with fresh water e Warm up the engine and drain the system Repeat the previous two steps once more e Fill the system with a permanent type coolant and bleed the air from the system see Coolant Change in the Peri odic Maintenance chapter Coolant Reserve Tank Removal Installation e The coolant reserve tank is removed and installed dur ing coolant change see Coolant Change in the Periodic Maintenance chapter 4 10 COOLING SYSTEM Water Pump Water Pump Removal e Remove Coolant Drain see Coolant Change in the Periodic Maintenance chapter Engine Oil Drain see Engine Oil Change in the Periodic Maintenance chapter Clutch Slave Cylinder see Clutch Slave Cylinder Re moval in the Clutch chapter Engine Sprocket Cover see Engine Sprocket Removal in the Final Drive chapter e Remove Clamp Screw A Loosen Water Hose B Water Pump Cover Bolts C Water Pump Cover D Remove Clamp Screw A Loosen Water Hose B e Pull out the water pump body C with impeller D e Slide the clamp A and remove the air bleeder hose from the water pump body e Remove the water pump body C with impeller Water Pump Installation e Replace the O ring A with a new one e Apply soap and water solution
139. 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 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 Apply silicone grease to the brake lever pivot bolt e Tighten the brake lever pivot bolt and the locknut Torque Brake Lever Pivot Bolt 1 0 N m 0 10 kgf m 8 9 in Ib Brake Lever Pivot Bolt Locknut 5 9 N m 0 60 kgf m 52 in Ib 8813175 52 PERIODIC MAINTENANCE 2 65 Periodic Maintenance Procedures Caliper Rubber Parts Replacement Front Caliper Disassembly e Loosen the front caliper pad pins A and banjo bolt B and tighten them loosely Remove Front Caliper C see Front Caliper Removal in the Brakes chapter Brake Pads see Front Brake Pad Removal in the brakes chapter Front Caliper Assembly Bolts O ring e Using compressed air remove the pistons One way to remove the pistons is as follows Olnstall a rubber gasket A and a wooden board B more than 10 mm 0 4 in thick on the caliper half and fas ten them together with a suitable bolt and nut as shown Leave one of the oil passages C open OLightly apply compressed air D to the oil passage until the pistons hit the r
140. completely Engine Oil Change e Refer to the Engine Oil Change in the Periodic Mainte nance chapter Oil Filtrer Replacement e Refer to the Oil Filter Replacement in the Periodic Main tenance chapter ENGINE LUBRICATION SYSTEM 7 11 Oil Pan Oil Pan Removal Remove Engine Oil Drain see Engine Oil Change in the Periodic Maintenance chapter Muffler Bodies see Muffler Body Removal Installation in the Engine Top End chapter Exhaust Pipe see Exhaust Pipe Removal in the Engine Top End chapter Oil Pressure Switch Terminal A Disconnect Oil Filter B see Oil Filter Replacement in the Periodic Maintenance chapter e Remove the oil pipe bolt C and pull out the pipe fitting e Remove Oil Pan Bolts A with Bracket Oil Pan B Gasket e Remove Oil Pan Plate Bolts A Oil Pan Plate B e Remove Oil Screen A Oil Pipe B e f necessary remove the oil pressure relief valve C see Oil Pressure Relief Valve Removal Do not remove the relief valve with the oil pipe in stalled on the lower crankcase half The oil pipe will be damaged 7 12 ENGINE LUBRICATION SYSTEM Oil Pan Oil Pan Installation e Install the oil pressure relief valve see Oil Pressure Relief Valve Installation e Replace the O ring with a new one e Clean the oil screen e Install the oil screen so that the crankcase rib B fits the notch C of the oil screen e Apply grease to the oil pipe O rin
141. completely washed away immediately e Disconnect the connector A OUnlock the joint lock B as shown in the figure Remove the bolts A Remove the ABS hydraulic unit with bracket e Remove the bolts A and bracket B The ABS hydraulic unit has been adjusted and set with precision at the factory Do not try to disas semble and repair the ABS hydraulic unit ABS Hydraulic Unit Installation e Install the ABS hydraulic unit to the bracket Brake fluid quickly ruins painted plastic surfaces any spilled fluid should be completely washed away immediately e Insert the bolts A into the grommets B 12 52 5 Anti Lock Brake System Equipped Models e Run the lead correctly and fix the connector A securely OLock the joint lock B as shown in the figure e Install the brake pipes correctly as shown in the figure 48 A 71 30 C 38 5 D e Tighten the joint nuts with the flare nut wrench Torque Brake Pipe Joint Nuts 18 1 8 kgf m 13 ft lb e Bleed the brake line see Brake Line Bleeding e Check the brake for good braking power no brake drag and no fluid leakage e Install the removed parts see appropriate chapters ABS Hydraulic Unit Inspection e Remove the ABS hydraulic unit see ABS Hydraulic Unit Removal e Visually inspect the ABS hydraulic unit Replace the ABS hydraulic unit if any of them are cracked or otherwise dam
142. connector and connect the measuring adapter A between these con nectors as shown in the figure Main Harness B Subthrottle Valve Actuator C Special Tool Measuring Adapter 57001 1700 Connect the peak voltage adapter D and a digital meter E to the measuring adapter leads Special Tool Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Subthrottle Valve Actuator Input Voltage Connections to Adapter I Digital Meter gt actuator Y R lead Digital Meter Frame Ground terminal I Digital Meter gt BK actuator G O lead Digital Meter Frame Ground terminal Digital Meter W actuator P BL lead Digital Meter Frame Ground terminal IV Digital Meter gt Y actuator BK lead Digital Meter Frame Ground terminal e Measure the actuator input voltage with the engine stopped and with the connector joined e Turn the ignition switch to ON Input Voltage Standard About DC 9 5 11 5 V and then 0 V or About DC 9 5 11 5 V e Turn the ignition switch to OFF x If the reading is in specification but the actuator does not operate replace the throttle body assy 9704114851 C Subthrottle Valve Actuator Service Code 62 FUEL SYSTEM 3 101 x If the reading is out of the specification remove the ECU and check the wiring for continuity between harness con nector Special Tool Hand Tester 57001 1394 ODisconnect the ECU an
143. e Install the water hoses as shown in the figure White Mark A Tighten Torque Water Hose Clamp Screws 3 0 N m 0 31 kgf m 27 e Replace the oil pipe O ring with a new one e Apply grease to the oil pipe O ring e Install the oil pipe A e Apply a non permanent locking agent to the threads of the oil pipe bolt B and tighten it Torque Oil Pipe Bolt Lower 9 8 N m 1 0 kgf m 87 in Ib e Install the removed parts see appropriate chapters ENGINE LUBRICATION SYSTEM 7 17 Oil Pressure Measurement Oil Pressure Measurement Remove the left middle fairing see Middle Fairing Re moval 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 57001 1233 Start the engine and warm up the engine e Run the engine at the specified speed and read the oil pressure gauge x If the oil pressure is much lower than the standard check the oil pump relief valve and or crankshaft bearing insert wear immediately x If the reading is much higher than the standard check the oil passages for clogging Oil Pressure Standard 245 343 kPa 2 5 3 5 kgf cm 36 50 psi at 4 000 r min rpm oil temperature 90 C 194 F Stop the engine e Remove the oil pressure gauge and adapter A WARNING Hot oil can cause severe burns Beware of hot en
144. gasoline or a low flash point solvent to clean them NOTICE Immediately dry the bolts and nuts with com pressed air after cleaning Clean and dry the bolts and nuts completely e Install new bolts and nuts in reused connecting rod x lf the connecting rod assembly was replaced use the bolts and nuts attached to the new connecting rod assem bly e Apply a small amount of molybdenum disulfide oil solution to the following portions Threads A of Nuts and Bolts Seating Surfaces B of Nuts and Connecting Rods e Dent both bolt head and bolt tip with a punch as shown in the figure e Before tightening use a point micrometer to measure the length of new connecting rod bolts and record the values to find the bolt stretch Connecting Rod A Dent here with a punch B Nuts C Fit micrometer pins into dents D e Tighten the big end nuts until the bolt elongation reaches the length specified as follows Bolt Length after _ Bolt Length before _ Bolt Stretch tightening tightening Connecting Rod Bolt Stretch Usable Range 0 29 0 39 mm 0 0114 0 0154 in Check the length of the connecting rod bolts x If the stretch is more than the usable range the bolt has stretched too much An overelongated bolt may break in use 6105040481 6105330851 9 20 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods 2 Rotation Angle Method If you don t have a point micrometer you may ti
145. inch quart s revolution revolution s per minute top dead center total indicator reading volt s watt s ohm s COUNTRY AND AREA CODES Austria Australia Brazil Canada California Switzerland Germany Europe GB United Kingdom PH Philippine SEA B1 Southeast Asia B1 with Evaporative Emission Control System SEA B2 Southeast Asia B2 US United States WVTA WVTA Model with Honeycomb FULL H Catalytic Converter Full Power GB WVTA WVTA Model with Honeycomb Catalytic FULL H Converter Left Side Traffic Full Power WVTA WVTA Model with Honeycomb Catalytic 78 2 H Converter Restricted Power EMISSION CONTROL INFORMATION To protect the environment in which we all live Kawasaki has incorporated crankcase emis sion 1 and exhaust emission 2 control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board Addi tionally Kawasaki has incorporated an evaporative emission control system 3 in compliance with applicable regulations of the California Air Resources Board on vehicles sold in California only 1 Crankcase Emission Control System This system eliminates the release of crankcase vapors into the atmosphere Instead the vapors are routed through an oil separator to the inlet side of the engine While the engine is operating the vapors are drawn into combustion chamber where they are burned alon
146. istration mode will be ended and the red warning indi cator light LED and immobilizer warning symbol stops blinking O To return to the registration mode start the registered ignition key verification procedure This applies to all ignition key registration OKeep other ignition keys away from the ignition switch Y 0 5second 0 5second 186 GP30058CS1 GP30059CS1 C 0 3second am UUUUUUUUUUU GP30080CS1 C 16 98 ELECTRICAL SYSTEM Immobilizer System Equipped Models Olf there is any problem in the registration the red warning indicator light LED and immobilizer warning symbol A blinks to display the collation error Immobilizer Amplifier Failure When Registered Ignition Key is Inserted Ignition Key Collation Error The ignition key 1 is successfully registered in the ECU OThe warning indicator light LED A blinks 3 times and stops for 1 second and then repeats this cycle to indicate successful registering of ignition key 1 e Turn OFF and remove ignition key 1 OThe red warning indicator light LED and immobilizer warning symbol A blinks to display the registration mode NOTE OTurn OFF the ignition switch and wait for the period more than 15 seconds The registration mode automat ically ends and warning indicator light LED goes off OThis procedure has registered the registered igni
147. lb e Check the gear positioning lever B and spring C for breaks or distortion xIf the lever or spring are damaged in any way replace them e Visually inspect the shift drum cam D lf they are badly worn or if they show any damage replace it 9 42 CRANKSHAFT TRANSMISSION Transmission Transmission Shaft Removal Split the crankcase see Crankcase Splitting e Remove the output shaft A e Remove Shift Forks see Shift Drum and Fork Removal Cover Bolts A Cover B e Pull out the drive shaft Transmission Shaft Installation e Check to see that the set pin A and set ring B are in place e Install the output shaft into the upper crankcase half e Apply engine oil to the bearing OThe bearing set pin and ring must match properly with the hole or groove in the bearing outer race or bearing When they are properly matched there is no clearance between the crankcase and the bearing outer race and bearing e Install the drive shaft into the lower crankcase half e Apply soap and water solution to the new O ring e Install the cover A e Apply a non permanent locking agent to the threads of the drive shaft cover bolts B and tighten them Torque Drive Shaft Cover Bolts 25 2 5 kgf m 18 ft Ib CRANKSHAFT TRANSMISSION 9 43 Transmission x If the cover disassembled install the bearing bushing and oil seal as shown in the figure e Press the new bushing A into cover
148. manufacturer Adjustment of these parts could result in poor performance requiring replacement of the throttle body assy e Remove the throttle body assy see Throttle Body Assy Removal e Disconnect the fuel injector connectors 3 140 FUEL SYSTEM Throttle Body Assy e Disconnect the main throttle sensor A and subthrottle sensor B connectors e Disconnect Subthrottle Valve Actuator Lead Connector A Intake Air Pressure Sensor Connectors B e Cut the clamps e Cut the clamps A Separete the hoses B from the throttle body fittings and intake air pressure sensors e Remove the screws C to pull out the fuel injectors from the throttle body assy together with the delivery pipe D NOTE ODo not damage the insertion portions of the injectors when they are pulled out from the throttle body e Pull out the fuel injectors A from the delivery pipe B NOTE ODo not damage the insertion portions of the injectors when they are pulled out from the delivery pipe Never drop the fuel injector especially on a hard surface Such a shock to the injector can damage 4 it Throttle Body Assy Assembly e Before assembling blow away dirt or dust from the throttle body and delivery pipe by applying compressed air Replace the O rings A of each fuel injector B with new ones e Apply engine oil to the new O rings insert them to the delivery pipe C and c
149. may adversely affect han dling and cause an accident resulting in serious in jury or death To ensure proper handling and sta bility use only the recommended standard tires for replacement inflated to the standard pressure NOTE OMost countries may have their own regulations a mini mum tire tread depth be sure to follow them OCheck and balance the wheel when a tire is replaced with a new one Wheel Bearing Damage Inspection e Raise the front wheel off the ground with the jack see Front Wheel Removal in the Wheels Tires chapter Special Tool Jack 57001 1238 e Turn the handlebar all the way to the right or left e Inspect the roughness of the front wheel bearing by mov ing A the wheel with both hands to both side 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 the stand see Rear Wheel Removal in the Wheels Tires chapter e Inspect the roughness of the rear wheel bearing by mov ing A the wheel with both hands to both side 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 Bear
150. never shows 0 V check the fuel pump relay see Relay Circuit Inspection in the Electrical System chapter xIf the fuel pump relay is normal check the ECU for its ground and power supply see ECU Power Supply In spection x If the ground and power supply are good replace the ECU see ECU Removal Installation x If there is still no battery voltage check the fuel pump re lay see Relay Circuit Inspection in the Electrical System chapter x If the fuel pump relay is normal check the power source wiring see wiring diagram in this section Special Tool Hand Tester 57001 1394 xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation x If the reading is in specification check the output voltage see Fuel Injector Output Voltage Inspection CN 6617214251 Fuel Injectors FUEL SYSTEM DFI 3 129 Fuel Injector Output Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch to OFF e Remove the ECU see ECU Removal ODo not disconnect the ECU connector e Connect a digital meter A to the connector gray B with the needle adapter set Special Tool Needle Adapter Set 57001 1457 Fuel Injector Output Voltage Connections to ECU Connector For Fuel Injector 1 Digital Meter BL BK lead
151. new element A so that screen side B faces backward Use only the recommended air cleaner element Kawasaki part number 11013 0718 Using another air cleaner element will wear the engine prema turely or lower the engine performance e Install the air cleaner element cover A so that arrow mark B faces upward e Tighten the bolts e Install the fuel tank cover see Fuel Tank Installation in the Fuel System DFI chapter Fuel Hose Replacement Pull out the throttle body assy from the holder see Throt tle Body Assy Removal in the Fuel System DFI chapter e Be sure to place a piece of cloth A around the fuel hose joint e Push the joint lock claws B 2 50 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Pull the joint lock A fully as shown in the figure e Pull the fuel hose B out of the delivery pipe e Remove Bolts A Bracket B e Remove the throttle body assy see Throttle Body Assy Removal in the Fuel System DFI chapter e Pull out the fuel hose C to forward WARNING Fuel is flammable and explosive under certain con ditions and can cause severe burns Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is dis connected fuel spills out from the hose and the pipe Cover the hose connection with a clean shop towel to prevent fuel spillage e Install the new fuel hose so that the white mark A side
152. oil seals e Install each tie rod so that the arrow A faces forward e Replace the tie rod nuts with new ones Tighten Torque Tie Rod Nuts 59 N m 6 0 kgf m 44 ft lb GM07058BS1 SUSPENSION 13 37 Tie Rod Rocker Arm Rocker Arm Removal Squeeze the brake lever slowly and hold it with a band e Remove Center Stand see Center Stand Removal in the Frame chapter Equipped Models Rear Fairing see Rear Fairing Removal in the Frame chapter Equipped Models Bracket see Rear Shock Absorber Removal Equipped Models Muffler Bodies see Muffler Body Removal Installation in the Engine Top End chapter e Raise the rear wheel off the ground with the jack Special Tools Jack 57001 1238 Jack Attachment 57001 1608 Remove Lower Rear Shock Absorber Nut and Bolt A Lower Tie Rod Nut and Bolt B Rocker Arm Nut and Bolt C Rocker Arm D Rocker Arm Installation e Apply grease to the inside of the oil seals e Replace the following nuts with new ones Tie Rod Nut Lower Rear Shock Absorber Nut Lower Rocker Arm Nut e Tighten Torque Rocker Arm Nut 34 3 5 kgf m 25 ft lb Tie Rod Nut Lower 59 N m 6 0 kgf m 44 ft lb Rear Shock Absorber Nut Lower 34 N m 3 5 kgf m 25 ft lb e Install the removed parts see appropriate chapters 13 38 SUSPENSION Tie Rod Rocker Arm Tie Rod and Rocker Arm Bearing Removal e Remove Tie Rods see Tie Rod Removal Rocker Arm see Rocker Ar
153. out the following connectors from the connector holder A Immobilizer Equipped Models Kawasaki Diagnostic System Connector B ABS Kawasaki Self diagnosis System Connector C Equipped Models Remove the connector holder e Remove the relay box D from the rubber protector E Lift up the ECU with rubber protector to clear the pro jections e Remove ECU Connectors A ECU with Rubber Protector ECU Installation e Install ECU Connectors A ECU B in Rubber Protector C e Insert the slits of the rubber protector to the projections D of the rear fender e Install Relay Box A Connector Holder B e Put the following connectors on the connector holder Immobilizer Equipped Models Kawasaki Diagnostic System Connector C ABS Kawasaki Self diagnosis System Connector D Equipped Models e Install the plate A to the tool kit case B and tighten the bolts C Insert the stopper D of the fuse box 2 E into the groove F of the tool kit case 3 114 FUEL SYSTEM DFI ECU ECU Power Supply Inspection e Remove the tool kit case see ECU Removal e Visually inspect the ECU connectors x lf the connector is clogged with mud or dust blow it off with compressed air e Remove the ECU see ECU Removal e Visually inspect the terminals A of the ECU and main harness connectors x lf the terminals of the ECU connectors are damaged re place the ECU x If th
154. outer races with new ones e Drive them into the head pipe at the same time Special Tools Head Pipe Outer Race Press Shaft A 57001 1075 Bearing Driver Set 57001 1129 Head Pipe Outer Race Driver 55 57001 1446 e Apply grease to the outer races e Replace the bearing inner races and oil seal with new ones e Apply grease to the oil seal e Install the oil seal A on the steering stem and drive the lower ball bearing inner race B applied the grease onto the stem Special Tools Steering Stem Bearing Driver 642 5 C 57001 1344 Steering Stem Bearing Driver Adapter 41 5 D 57001 1345 e Apply grease to the lower ball bearing A and install it onto the steering stem OThe lower and upper ball bearings are identical e Apply grease to the upper ball bearing B and inner race C e Apply grease to the thread and shaft A as shown in the figure OW GNO5148BS1 C 14 8 STEERING Steering Stem e Install the stem A through the head pipe and install the ball bearing B and inner race C on it e Install Stem Cap D Steering Stem Nut E e Settle the bearings in place as follows OTighten the steering stem nut with 55 N m 5 6 kgf m 41 ft lb of torque first and loosen it a fraction of a turn until it turns lightly Afterward tighten it again with specified torque using a steering stem nut wrench A OCheck that there is no play and the steering stem turns smoothl
155. 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 the stick coils see Stick Coil Removal in the Electrical System chapter e Remove the spark plugs using the 16 mm 0 63 in plug wrench A vertically e Replace the spark plug with a new one Standard Spark Plug Type CR9EIA 9 Insert a new spark plug in the plug hole and finger tighten it first e Using the plug wrench A vertically tighten the plug NOTICE The insulator of the spark plug may break if when the wrench is inclined during tightening Torque Spark Plugs 13 Nm 1 3 kgf m 115 in Ib e Install the stick coils see Stick Coil Installation in the Elec trical System chapter OBe sure the stick coils are installed by pulling up it lightly 8105040251 9513158851 C FUEL SYSTEM DFI 3 1 Fuel System DFI Table of Contents 5 CE EP 3 5 DIR SY SUSI EE EET 3 12 BET Parts EOC SGI tote dd 3 22 Specifications 3 25 Special Tools pa Lao ut duran doa E C atm coutra 3 27 DFI Servicing Precautloris iicet tet E OPI E Ne 3 29 Servicing Precautions s t rere preocupa OR eerte 3 29 Troubleshootin
156. place This will cause the positive neutral finder mechanism to malfunction OAfter assembling the 5th gear with steel balls in place on the output shaft check the ball locking effect that the 5th gear doesn t come out of the output shaft when moving it up and down by hand e Check that each gear spins or slides freely on the trans mission shafts without binding after assembly 6113040851 6113158851 9113447851 CRANKSHAFT TRANSMISSION 9 45 Transmission 1 5 9 9 4 9 s DEDA DRONA I SEX I CA calli Vas pae 9 J WAT TES NS qp iy w OOO COCCO OCCO ODODE 066000006 Oo O 0 09 6006 6113521883 C 1 Output Shaft 13 5th Gear 2 Collar 14 Thrust Washer 35 mm 1 38 in 3 Ball Bearing 15 1st Gear 4 Bushing 16 Needle Bearing 5 2nd Gear 17 Bearing Outer Race 6 Toothed Washer 40 mm 1 57 in 18 Needle Bearing 7 Circlip 19 Snap Ring 25 5 mm 1 00 in 8 6th Top Gear 20 Toothed Washer 35 5 mm 1 40 in 9 4th Gear 21 Snap Ring 33 mm 1 30 in 10 Toothed Washer 43 mm 1 69 in 22 Toothed Washer 40 5 mm 1 59 in 11 Toothed Washer 39 7 mm 1 56 in 23 Toothed Washer 37 mm 1 46 in 12 3rd Gear 24 Drive Shaft OWhen the tongues A of the toothed washer 11 shall be assembled they shall be installed into the notches B of the toothed washer 10
157. projection located in almost the same depth with the sensor NOTE OThe sensor and thermometer must not touch the con tainer side or bottom e Place the container over a source of heat and gradu ally raise the temperature of the coolant while stirring the coolant gently e Using the hand tester measure the internal resistance of the sensor x If the hand tester does not show the specified values re place the sensor Water Temperature Sensor Resistance Temperature Resistance 20 C 4 F 18 80 2 37 0 C 32 F about 6 544 40 C 104 F 1 136 0 095 100 C 212 0 1553 0 0070 Reference Information Oxygen Sensor Removal Equipped Models Never drop the oxygen sensor especially on a hard surface Such a shock to the sensor can damage it Do not pull strongly twist or bend the oxygen sen sor lead This may cause the wiring open e Remove Right Lower Fairing see Lower Fairing Removal in the Frame chapter Oxygen Sensor Lead Connector A Disconnect Oxygen Sensor B 8 18055 52 C ELECTRICAL SYSTEM 16 113 Switches and Sensors Oxygen Sensor Installation Equipped Models Never drop the oxygen sensor A especially on a hard surface Such a shock to the unit can damage it Do not touch the sensing part B of the sensor to prevent oil contact Oil contamination from hands can reduce sensor performance Tighten Torque Oxygen Sensor
158. projections A of the seat into the holes B of the seat lock and insert the seat hook C into the slot D of the frame e Push down the rear part of the seat until the lock clicks Single Seat Cover Removal Equipped Models e Remove Seat see Seat Removal Bolts A and Washers Remove the single seat cover B from the seat 00040068 6 e Remove Wellnuts A 60040078 6 Single Seat Cover Installation Equipped Models e Installation is the reverse of removal Fairings FRAME 15 11 Lower Fairing Removal e Remove Middle Fairing see Middle Fairing Removal Bolt A and Washer Bolt B and Bracket C Clear the hook portions D from the slots and remove the lower fairing E Lower Fairing Installation e Installation is the reverse of removal e When installing the pad A align the edge of the pad with the line B of the lower fairing C e Insert the hook portions A into the slots B e Fit the hole A of the bracket to the projection B of the middle fairing Fairing Cover Removal e Remove Bolts A and Washers e Pulling out the fairing cover B out slowly to clear the projections C and clear the tabs D from the fuel tank cover Clear the inner rubber cover E from the fairing cover and remove the fairing cover backward 6005031851 15 12 FRAME Fairings Fairing Cover Installation e When installing the pad A install
159. radiator cap to suppress boiling and the resultant air bubbles which can cause engine overheating As the engine warms up the coolant in the radiator and the water jacket expands The excess coolant flows through the radiator cap and hose to the reserve tank to be stored there temporarily Conversely as the engine cools down the coolant in the radiator and the water jacket contracts and the stored coolant flows back to the radiator from the reserve tank The radiator cap has two valves One is a pressure valve which holds the pressure in the system when the engine is running When the pressure exceeds 93 123 kPa 0 95 1 25 kgf cm 13 18 psi the pressure valve opens and releases the pressure to the reserve tank As soon as pressure escapes the valve closes and keeps the pressure at 93 123 kPa 0 95 1 25 kgf cm 13 18 psi When the engine cools down another small valve vacuum valve in the cap opens As the coolant cools the coolant contracts to form a vacuum in the system The vacuum valve opens and allows the coolant from the reserve tank to enter the radiator 4 6 COOLING SYSTEM Specifications Item Standard Coolant Provided when Shipping Type Recommended Color Mixed Ratio Freezing Point Total Amount Radiator Cap Relief Pressure Thermostat Valve Opening Temperature Valve Full Opening Lift Permanent type of antifreeze soft water and ethylene glycol plus corrosion an
160. remove the alternator rotor from the crankshaft Special Tool Flywheel Puller Assembly M38 1 5 M35 1 5 57001 1405 NOTICE 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 Install the alternator rotor 16 40 ELECTRICAL SYSTEM Charging System e Using a cleaning fluid clean off any oil or dirt on the washer and dry if with a clean cloth e Install the washer NOTE OConfirm the alternator rotor fit or not to the crankshaft before tightening it with specified torque e Install the washer and rotor bolt Tighten the alternator rotor bolt A while holding the alter nator rotor steadily with the holder B temporary Special Tools Grip C 57001 1591 Rotor Holder 57001 1672 Stopper D 57001 1679 Torque Alternator Rotor Bolt 70 N m 7 0 kgf m 52 ft lb e Install the alternator cover see Alternator Cover Installa tion Remove the rotor bolt and washer e Check the tightening torque with flywheel puller A Special Tool Flywheel Puller Assembly M38 1 5 M35 1 5 57001 1405 xIf the rotor is not pulled out with 20 N m 2 0 kgf m 15 ft Ib of drawing torque it is installed correctly x lf the rot
161. seal whenever the inner tube is repaired or replaced If the inner tube is badly bent or creased replace it Excessive bending followed by subsequent straightening can weaken the inner tube e Temporarily assemble the inner and outer tubes and pump them back and forth manually to check for smooth operation x 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 resulting in seri ous injury or death Replace a badly bent or dam aged inner or outer tube and inspect the other tube carefully before reusing it 8 04042051 GM04386BS1 C 13 26 SUSPENSION Front Fork Dust Seal Inspection e Inspect the dust seal A for any signs of deterioration or damage Replace it if necessary Spring Tension Inspection e Since a spring becomes shorter as it weakens check its free length A to determine its condition the spring of either fork leg is shorter than the service limit it must be replaced If the length of a replacement spring and that of the remaining spring vary greatly the remaining spring should also be replaced in order to keep the fork legs balanced for motorcycle stability Spring Free Length Standard 237 mm 9 33 in Service Limit 232 mm 9 13 in GM04128BS1 C 8 04011851 C Rear Shock Absorber SUSPENSION 13 27 Rebo
162. seat Tool 32 Cutter area to Purpose reduce outside specification Measure Seating Width diameter of seat Tool Vernier Caliper area to Purpose check seat width specification against specification Results 45 Grind Machinist s dye Tool 45 Cutter opsal Purpose increase width of seat area beyond specification to increase outside diameter 60 Grind Tool 60 Cutter Purpose reduce seat Lap Valve Tools Valve Lapper Grinding Compound Purpose perfectly match valve and valve seat area FINISHED check valve head for damage width to specification GEI5143B 5 36 ENGINE END Throttle Body Holder Throttle Body Assy Holder Removal e Remove Throttle Body Assy see Throttle Body Assy Removal in the Fuel System DFI chapter Clamp A Throttle Body Assy Holder Bolts B Throttle Body Assy Holders C Throttle Body Assy Holder Installation e Replace the O rings A with new ones e Apply liquid gasket to any three positions of the O rings and install them Sealant Liquid Gasket TB1211F 92104 0004 Tighten the throttle body assy holder bolts following the tightening sequence 1 3 Upward A Torque Throttle Body Assy Holder Bolts 9 8 N m 1 0 kgf m 87 in Ib e Install the clamps B as shown in the figure e Install Throttle Body Assy see Throttle Body Assy Installation in the Fuel System DFI chapter GE17050BS1 GE17052BS1
163. shift drum cam holder bolt A Shift Drum Cam B Dowel Pin C Ball Bearing D Shift Drum E 9113524851 CRANKSHAFT TRANSMISSION 9 47 Transmission Shift Drum Assembly e Install Ball Bearing A Dowel Pin B and Shift Drum Cam C OAlign the pin with the groove in the shift drum cam e Apply a non permanent locking agent to the threads of the shift drum cam holder bolt D and tighten it Torque Shift Drum Cam Holder Bolt 12 N m 1 2 kgf m 106 in Ib Shift Fork Bending Inspection e Visually inspect the shift forks and replace any fork that is bent A bent fork could cause difficulty in shifting or allow the transmission to jump out of gear when under power 90 A Shift Fork Gear Groove Wear Inspection e Measure the thickness of the shift fork ears A and mea sure the width B of the gear grooves x If the thickness of a shift fork ear is less than the service limit the shift fork must be replaced Shift Fork Ear Thickness Standard 5 74 6 00 mm 0 2260 0 2362 in Service Limit 5 6 mm 0 220 in x If the gear groove is worn over the service limit the gear must be replaced Gear Groove Width Standard 6 05 6 15 mm 0 238 0 242 in Service Limit 6 25 mm 0 246 in Shift Fork Guide Pin Drum Groove Wear Inspection e Measure the diameter of each shift fork guide pin A and measure the width of each shift drum groove B x If the guide pin on any shift fork is less t
164. 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 OThe distance from the grip to the lever is minimum at num ber 6 and maximum at number 1 Brake Pedal Position Inspection Check that the brake pedal A is in the correct position Footpeg B Pedal Position Standard About 45 mm 1 77 in C below top of footpeg x If it is incorrect adjust the brake pedal position Brake Pedal Position Adjustment NOTE OUsually it is not necessary to adjust the pedal position but always adjust it when push rod locknut has been loosened e Loosen the locknut A and turn the push rod with the hex head B to achieve the correct pedal position x lf the length C shown is 80 1 mm 3 15 0 04 in the pedal position will be within the standard range Tighten Torque Rear Master Cylinder Push Rod Locknut 17 2 N m 1 75 kgf m 12 7 ft lb Check the brake light switch operation see Brake Light Switch Operation Inspection in the Periodic Maintenance chapter Brake Pedal Removal e Remove Rear Master Cylinder Mounting Bolts A Right Front Footpeg Bracket Bolts B BRAKES 12 15 Brake Lever Brake Pedal e Remove Cotter Pin A Joint Pin B Rear Brake Light Switch Spring C Return Spring D e Remove the brake pedal bolt E and take out the brake pedal Br
165. 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 ECU trouble 17 56 APPENDIX Troubleshooting Guide Fuel air mixture incorrect Throttle body assy holder loose Air duct holder loose Air cleaner poorly sealed or missing Air cleaner clogged Compression high Carbon built up in combustion chamber Engine load faulty Clutch slipping Engine oil level too high Engine oil viscosity too high Drive train trouble Brake dragging Lubrication inadequate Engine oil level too low Engine oil poor quality or incorrect Oil cooler incorrect Oil cooler clogged Water temperature meter incorrect Water temperature meter broken Water temperature sensor broken Coolant incorrect Coolant level too low Coolant deteriorated Wrong coolant mixed ratio Cooling system component incorrect Radiator fin damaged Radiator clogged Thermostat trouble Radiator cap trouble Radiator fan relay trouble Fan motor broken Fan blade damaged Water pump not turning Water pump impeller damaged Over Cooling Water temperature meter incorrect Water temperature meter broken Water temperature sensor broken Cooling system component incorrect Thermostat trouble Clutch Operation Faulty Clutch slipping Friction plate worn or warped Steel plate worn or warped Clutch spring
166. starts e Measure the output voltage with the connector joined Output Voltage with Plugs Rich Standard DC 0 8 V or more e Turn the ignition switch to OFF e Remove the plugs from the fittings A A WARNING The engine gets extremely hot during normal oper ation and can cause serious burns Never touch a hot engine e Start the engine and let it idle e Measure the output voltage with the connector joined Output Voltage without Plugs Lean Standard DC 0 24 V or less e Turn the ignition switch to OFF x If the reading is out of the standard with plugs 0 8 V or more without plugs 0 24 V or less remove the ECU and check the wiring for continuity between harness connec tors Special Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector Oxygen Sensor Connector B W BL lead ECU terminal 35 C BR BK lead ECU terminal 13 D x If the wiring is good replace the sensor x If the reading is within the standard with plugs 0 8 V or more without plugs 0 24 V or less check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation GT04108BS1 C 3 90 FUEL SYSTEM Oxygen Sensor not activated Service Code 33 Equipped Models Oxygen Sensor Circuit CD
167. that relief port G and supply port H are not plugged x lf the relief port becomes plugged the brake pads will drag on the disc Blow the ports clean with compressed air Front Master Cylinder J Rear Master Cylinder K EU fd 9513050852 C 12 24 BRAKES Brake Disc Brake Disc Removal e Remove the wheels see Front Rear Wheel Removal in the Wheels Tires chapter e Remove the mounting bolts and take off the disc ORemove the sensor rotor ABS Equipped Models e Remove the gaskets Brake Disc Installation e Replace the gaskets with new ones e Install the brake disc on the wheel so that the marked side A faces out Olnstall the sensor rotor on the brake disc so that the marked side faces out ABS Equipped Models e Apply a non permanent locking agent to the threads of the front and rear brake disc mounting bolts B e Tighten Torque Brake Disc Mounting Bolts 27 N m 2 8 kgf m 20 ft Ib Brake Disc Wear Inspection 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 8 5 2 mm 0 19 0 20 in Rear 5 8 6 2 mm 0 23 0 24 in Service Limit Front 4 5 mm 0 18 in Rear 5 5 mm 0 22 in Brake Disc Warp Inspection e Raise the front rear wheel off the ground Special Tools Jack 57001 1238 Jack Attachment 57
168. the Fuel System DFI chapter Main Harness C e Connect the resistor D about 100 to the fuel pump lead connector terminal as shown in the figure e Connect the variable rheostat E to the fuel level sensor lead connector terminal as shown in the figure e After about 15 seconds check that the number of seg ments matches the resistance value of the variable rheo stat Display Segments 10 6 50 5 100 4 140 3 170 2 200 1 x If the display function does not work check the wiring see Meter Unit Circuit x lf the wiring is good replace the meter unit GP17965CS1 Meter Gauge Indicator Unit ELECTRICAL SYSTEM 16 85 Meter Unit Inspection e Remove the meter unit see Meter Unit Removal 1 Blue High Beam Indicator Light LED 2 Red Oil Pressure Warning Indicator Light LED 3 Green Right Turn Signal Indicator Light LED 4 Green Neutral Indicator Light LED b Unused 6 Yellow ABS Indicator Light LED ABS Equipped Models 7 Upper Button 8 Lower Button 9 Ignition 10 Battery 11 Unused 12 Ground 13 Unused 14 Outside Temperature Sensor 15 Fuel Reserve Switch 16 Fuel Level Sensor 17 CAN Communication Line High 18 CAN Communication Line Low 19 Green Left Turn Signal Indicator Light LED 20 SEL Button Do not drop the meter unit Place the meter unit so th
169. the 12 V battery A to the purge valve terminals as shown in the figure Blow the air to the intake air duct A and make sure that the air flows from the outlet air duct B GC17193FS1 C GC17194FS1 C GC17195FS1 C 3 110 FUEL SYSTEM DFI Purge Valve Service Code 3A CAL and SEA B1 Models e Disconnect the 12 V battery e Blow the air to the intake air duct A again and make sure that the air does not flow from the outlet air duct B x If the purge valve dose not operate as described replace it with a new one Purge Valve Circuit 8017196 51 C 87104132842 ECU Frame Ground Battery Starter Relay Main Fuse 30 A ECU Fuse 15A Frame Ground 1 Relay Box ECU Main Relay Fuse Box 1 Ignition Fuse 15 Joint Connector A Joint Connector F Ignition Switch Purge Valve LLL ck FUEL SYSTEM DFI 3 111 Warning Indicator Light LED Yellow Engine Warning Yellow KTRC Warning Red Warning Indicator Light LED Inspection Yellow Engine Warning Indicator Light LED A Yellow KTRC Warning Indicator Light LED B Red Warning Indicator Light LED C Oln this model the above mentioned warning indicator lights LED go on or blink by the data sent from the ECU e Refer to the Meter Operation Inspection in the Electrical System chapter
170. the customer be sure to erase any service codes which might be stored in the ABS hydraulic unit Using the self diagnosis feature make sure that the yellow ABS indicator light LED lights A fully charged battery is a must for conducting reliable self diagnosis Test run the motorcycle at a speed of more than 20 km h 12 mph to see that the yellow ABS indicator light LED does not come on Finally test run the motorcycle at a speed of more than 30 km h 20 mph and brake suddenly to see that the motorcycle stops without loss of steering control and the ABS operates normally The reaction force generated is felt in the brake lever and pedal This completes the final inspection ABS Troubleshooting Outline When an abnormality in the system occurs the yellow ABS indicator light LED lights up to alert the rider In ad dition the nature of the fault is stored in the memory of the ABS hydraulic unit and when in the self diagnosis mode the service code A is indicated by the number of times the yellow ABS indicator light LED blinks The service codes stored in memory are not erased until the mode has been changed to the fault erase mode after the fault has been corrected Therefore after correcting the problem always erase the service codes and then run the self diagnosis pro gram to confirm normal signal output When due to a mal function the yellow ABS indicator light LED remains lit get a thorough understanding of the backgr
171. the ignition switch to ON e The following lights should go on according to below table City Light A goes on Taillight B goes on License Plate Light C goes on Meter Panel Illumination Light LED D goes on Meter Panel LCD E goes on Neutral Indicator Light LED F goes on Oil Pressure Warning Indicator Light LED G goes on ABS Indicator Light LED H ABS Equipped Models lf the light does not go on inspect or replace the following item Battery see Charging Condition Inspection in the Elec trical System chapter Main Fuse 30 A Headlight Relay Fuse 15 A and Brake Light Horn Fuse 10 A see Fuse Inspection in the Elec trical System chapter Applicable Bulb see Wiring Diagram in the Electrical System chapter Meter Unit for Meter Panel LCD see Meter Unit Inspec tion in the Electrical System chapter Meter Unit for Neutral Indicator Light LED see Meter Unit Inspection in the Electrical System chapter Meter Unit for Warning Indicator Light LED see Meter Unit Inspection in the Electrical System chapter Meter Unit for Oil Pressure Warning Indicator Light LED see Meter Unit Inspection in the Electrical Sys tem chapter Meter Unit for Illumination Light LED see Meter Unit Inspection in the Electrical System chapter ECU see ECU Power Supply Inspection in the Fuel Sys tem DFI chapter Ignition Switch see Switch Inspection in the Electrical System chapter Gear Posit
172. the same model name as the battery since the electrolyte volume and specific gravity vary with the battery type GP08135BS1 C Battery ELECTRICAL SYSTEM 16 33 Do not remove the aluminum sealing sheet A from the filler ports B until just prior to use Be sure to use the dedicated electrolyte container for correct electrolyte volume A DANGER Sulfuric acid in battery electrolyte can cause severe burns To prevent burns wear protective clothing and safety glasses when handling electrolyte If the electrolyte comes in contact with your skin or eyes wash the area with liberal amounts of water and seek medical attention for more severe burns e Place the battery on a level surface e Check to see that the sealing sheet has no peeling tears or holes in it e Remove the sealing sheet NOTE OThe battery is vacuum sealed If the sealing sheet has leaked air into the battery it may require a longer initial charge Remove the electrolyte container from the vinyl bag 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
173. 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 Overinflating a tire can cause it to explode causing serious injury or death Be sure to install the valve core whenever inflating the tire and do not inflate the tire to more than 400 kPa 4 0 kgf cm 57 psi GJ05041BS1 6J05030781 6J05044BS1 C 10 16 WHEELS TIRES Tires Check to see that the rim lines A on both sides of the tire sidewalls are parallel with the rim flanges x If the rim flanges and tire sidewall rim lines are not parallel remove the valve core e Lubricate the rim flanges and tire beads e Install the valve core and inflate the tire again e After the tire beads seat in the rim flanges check for air leakage Olnflate the tire slightly above standard inflation OUse a soap and water solution o
174. to the new O ring e Apply soap and water solution to the inside of the air bleeder hose before installation e Install the air bleeder hose B and clamp C to the water pump body as shown in the figure Water Pump COOLING SYSTEM 4 11 e Turn the water pump shaft so that the slot A in its shaft fits onto the projection B of the oil pump drive gear shaft e Install the water hose A and hose clamp B as shown in the figure White Mark C Tighten Torque Water Hose Clamp Screw 3 0 N m 0 31 kgf m 27 in Ib e Replace the O ring D with a new one e Apply grease to the new O ring e Install the water pump cover A e Tighten Torque Water Pump Cover Bolts B 9 8 N m 1 0 kgf m 87 in Ib e Align the projection C of the water pump cover with the white mark D of the water hose E e Install the water hose clamp F as shown in the figure e Tighten Torque Water Hose Clamp Screw 3 0 N m 0 31 kgf m 27 in Ib e Install the remove parts see appropriate chapters Water Pump Inspection e Check the drainage outlet passage A at the bottom of the water pump body for coolant leaks the mechanical seal is damaged the coolant leaks through the seal and drains through the passage Re place the water pump body Water Pump Impeller Inspection e Remove the water pump cover see Water Pump Re moval e Visually inspect the water pump impeller A xIf the surface is corroded or if the
175. until it is smooth Do not grind the seat too much Overgrinding will reduce valve clearance by sinking the valve into the head If the valve sinks too far into the head it will be impossible to adjust the clearance and the cylin der head must be replaced 8 15011851 C Valves ENGINE TOP END 5 33 Measure the outside diameter of the seating surface with a vernier caliper the outside diameter of the seating surface is too small repeat the 45 grind until the diameter is within the spec ified range Widened Width A of engagement by machining with 45 cutter Ground Volume B by 32 cutter 32 C Correct Width D Ground Volume E by 60 cutter 60 F e Measure the outside diameter of the seating surface with a vernier caliper x f the outside diameter of the seating surface is too small repeat the 45 A grind until the diameter is within the specified range Original Seating Surface B NOTE ORemove all pittings of flaws from 45 ground surface OAfter grinding with 45 cutter apply thin coat of machin ist s dye to seating surface This makes seating surface distinct and 32 and 60 grinding operation easier OWhen the valve guide is replaced be sure to grind with 45 cutter for centering and good contact xIf the outside diameter A of the seating surface is too large make the 32 B grind described below x If the outside diameter of the seatin
176. warning indicator light LED of the motorcycle brought in for repair still goes on check the ser vice code When the repair has been done the yellow warning indi cator light LED goes off But the service codes stored in memory of the ECU are not erased to preserve the prob lem history The problem history can be referred using the KDS Kawasaki Diagnostic System when solving unstable problems When the motorcycle is down the vehicle down sensor operates and the ECU shuts off the fuel pump relay fuel in jectors and ignition system The ignition switch is left ON If the starter button is pushed the electric starter turns but the engine does not start When the starter button is pushed the yellow engine warning indicator light LED blinks but the service code is not displayed To start the engine again raise the motorcycle turn the ignition switch to OFF and then ON Much of the DFI system troubleshooting work consists of confirming continuity of the wiring DFI parts assembled and adjusted with precision and it is impossible to disassemble or repair them e When checking the DFI parts use a digital meter which can be read two decimal place voltage or resistance OThe DFI part connectors A have seals B including the ECU When measuring the input or output voltage with the connector joined use the needle adapter set C Insert the needle adapter inside the seal until the needle adapter reaches the termina
177. while parts are being removed Remove Cylinder Head see Cylinder Head Removal in the En gine Top End chapter Clutch see Clutch Removal in the Clutch chapter Timing Rotor see Timing Rotor Removal in the Electrical System chapter Starter Motor see Starter Motor Removal in the Electri cal System chapter External Shift Mechanism see External Shift Mecha nism Removal Oil Pump see Oil Pump Removal in the Engine Lubri cation System chapter Alternator Rotor see Alternator Rotor Removal in the Electrical System chapter Water Pump see Water Pump Removal in the Cooling System chapter Oil Cooler see Oil Cooler Removal in the Engine Lubri cation System chapter Oil Pipe see Oil Pipe Removal in the Engine Lubrication System Oil Pan see Oil Pan Removal in the Engine Lubrication System chapter e Remove Front Balancer Shaft Clamp Lever Bolt A Front Balancer Shaft Clamp Bolt B Loosen Front Balancer Shaft Clamp Lever C 9104425851 CRANKSHAFT TRANSMISSION 9 11 Splitting Remove the upper crankcase bolts OFirst loosen the M6 bolts M6 Bolts A M7 Bolt B M7 Bolt with Clamp C M8 Bolts with Washers D Remove the lower crankcase bolts OFirst loosen the M7 bolts A 9104427851 ONext loosen the M10 bolts 1 10 Sequence numbers e Tap lightly around the crankcase mating surface with a plastic mallet and split the crankcase
178. will see air bubbles rising into each cell as the ports fill NOTE ODo not tilt the electrolyte container 2 112851 GP08139BS1 C ffe L 8 09000751 C 16 34 ELECTRICAL SYSTEM Battery e Check the electrolyte flow x lf no air bubbles A are coming up from the filler ports or if the container cells have not emptied completely tap the container B a few times NOTE OBe careful not to have the battery fall down e Keep the container in place Don t remove the container from the battery the battery requires all the electrolyte from the container for proper operation Removal of the container before it is completely empty can shorten the service life of the battery Do not remove the container until it is completely empty e After filling let the battery sit for 20 60 minutes with the electrolyte container kept in place which is required for the electrolyte to fully permeate into the plates Make sure that the container cells have emptied com pletely and remove the container from the battery e Place the strip of caps A loosely over the filler ports press down firmly with both hands to seat the strip of caps into the battery don t pound or hammer When properly installed the strip of caps will be level with the top of the battery NOTICE Once the strip of caps is installed onto the battery never remove the caps nor add water or electrolyte to th
179. 0 60 52 inrlb 8 Throttle Case Screws 3 5 0 36 31 in lb 9 Sensor Equipped Models 25 2 5 18 10 Oxygen Sensor Equipped Models 11 Throttle Cable Accelerator 12 Throttle Cable Decelerator CL Apply cable lubricant EO Apply engine oil G Apply grease L Apply a non permanent locking agent LG Apply liquid gasket R Replacement Parts S Follow the specified tightening sequence SS Apply silicone sealant WL Apply soap and water solution or rubber lubricant 3 10 FUEL SYSTEM Exploded View FUEL SYSTEM DFI 3 11 Exploded View EE Fuel Level Sensor Bolts 89 070 61 in lb cars Fuel Pump Bolts j 87 L Canister Purge Valve CAL and SEA B1 Models ABS Equipped Models Other than CAL and SEA B1 Models Apply a non permanent locking agent Replacement Parts Follow the specified tightening sequence 3 12 FUEL SYSTEM DFI System DFI System 6017223FW5 C DFI System FUEL SYSTEM DFI 3 13 ECU Battery 12 V 14 Ah Air Switching Valve Idle Speed Control Valve Actuator Intake Air Pressure Sensor 1 Intake Air Pressure Sensor 2 Subthrottle Valve Actuator Intake Air Temperature Sensor Subthrottle Sensor Main Throttle Sensor Fuel Injectors Delivery Pipe Fuel Pump Fuel Filter Pressure Regulator Crankshaft Sensor Water Temperature Sensor Oxygen S
180. 001 1369 Measuring Adapter 57001 1700 Intake Air Pressure Sensor 1 Output Voltage Connections to Adapter Digital Meter Y sensor Y BL lead Digital Meter gt BK sensor lead OTurn the ignition switch to ON OMeasure the intake air pressure sensor 1 output voltage from various vacuum readings while pulling the handle of the fork oil level gauge OCheck the intake air pressure sensor 1 output voltage using the following formula and chart Suppose Pg Vacuum Pressure Gauge of Throttle Body Local Atmospheric Pressure Absolute measured by a barometer Pv Vacuum Pressure Absolute of Throttle Body Vv Sensor Output Voltage V then Pv PI Pg For example suppose the following data is obtained Pg 8 cmHg Vacuum Gauge Reading PI 70 cmHg Barometer Reading Vv 3 2 V Digital Meter Reading then Pv 70 8 62 cmHg Absolute Plot this Pv 62 at a point 1 on the chart and draw a vertical line through the point Then you can get the usable range 2 of the sensor output voltage Usable range 3 08 3 48 V Plot Vv 3 2 V on the vertical line Point 3 Results In the chart Vv is within the usable range and the sensor is normal If the reading is out of the usable range replace the sen sor xIf the reading is within the usable range check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power
181. 001 1608 OFor front disc inspection turn the handlebar fully to one side e Set up a dial gauge against the disc A as shown in the figure and measure disc runout while turning B the wheel by hand runout exceeds the service limit replace the disc Disc Runout Standard TIR 0 15 mm 0 006 in or less Service Limit TIR 0 3 mm 0 01 in 6108017851 C CN 9108018851 C Brake Fluid BRAKES 12 25 Brake Fluid Level Inspection e Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter Brake Fluid Change e Refer to the Brake Fluid Change in the Periodic Mainte nance chapter Brake Line Bleeding The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action Air however is easily compressed When air enters the brake lines brake lever or pedal movement will be partially used in compressing the air This will make the lever or pedal feel spongy and there will be a loss in braking power A WARNING Air in the brake lines diminish braking performance and can cause an accident resulting in injury or death If the brake lever or pedal has a soft or spongy feeling mushy when it is applied there might be air in the brake lines or the brake may be defective Do not operate the vehicle and service the brake system immediately NOTE OThe
182. 091BW2 C Ignition Switch Engine Stop Switch Joint Connector E ECU Joint Connector B Frame Ground Battery Starter Relay Main Fuse 30 A 10 ECU Fuse 15 11 3 12 Frame Ground 2 13 Frame Ground 4 14 Fuel Pump 15 Relay Box 16 Fuel Pump Relay 17 Fuse Box 1 18 Ignition Fuse 15 A 19 Joint Connector F Fuel Injectors FUEL SYSTEM DFI 3 127 Fuel Injector Removal Installation e Refer to the Throttle Body Assy Disassembly Assembly Fuel Injector Audible Inspection NOTE OBe sure the battery is fully charged e Remove the left and right middle fairings see Middle Fair ing Removal in the Frame chapter e Start the engine and let it idle e Apply the tip of a screwdriver A to the fuel injector B Put the grip end onto your ear and listen whether the fuel injector is clicking or not OA sound scope can also be used OThe click interval becomes shorter as the engine speed rises e Do the same for the other fuel injectors x If all the fuel injectors click at a regular intervals the fuel injectors are normal e Turn the ignition switch to OFF If any fuel injector does not click check the fuel injector resistance see Fuel Injector Resistance Inspection Fuel Injector Resistance Inspection e Remove the throttle body assy see Throttle Body Assy Removal e Disconnect the fuel injector connector A e Connect a digi
183. 1 75 12 7 Bleed Valves 7 8 0 80 69 in lb Front Caliper Mounting Bolts 34 3 5 25 Front Brake Reservoir Cap Stopper Screw 1 2 0 12 11 in lb Front Caliper Assembly Bolts 27 2 8 20 L Brake Lever Pivot Bolt 1 0 0 10 8 9 in lb Si Front Brake Master Cylinder Bleed Valve 7 8 0 80 69 in lb Brake Lever Pivot Bolt Locknut 5 9 0 60 52 in lb Front Brake Light Switch Screw 1 2 0 12 11 in lb Front Master Cylinder Clamp Bolts 11 1 1 97 in lb 5 Brake Hose Banjo Bolts 25 2 5 18 Front Brake Disc Mounting Bolts 27 2 8 20 L Rear Master Cylinder Mounting Bolts 25 2 5 18 Rear Master Cylinder Push Rod Locknut 17 2 1 75 12 7 Brake Pedal Bolt 8 8 0 90 78 in lb Rear Brake Disc Mounting Bolts 27 2 8 20 L Rear Caliper Assembly Bolts 36 8 3 75 27 1 L Rear Caliper Mounting Bolts 25 2 5 18 Rear Brake Pad Pin 17 2 1 75 12 7 Td Joint Nuts ABS Equipped 18 18 13 Suspension Front Fork Clamp Bolts Upper 20 2 0 15 Front Fork Clamp Bolts Lower 30 3 1 22 AL Front Fork Top Plugs 22 2 2 16 Piston Rod Nuts 28 2 9 21 Front Axle Clamp Bolts 20 2 0 15 AL Front Fork Bottom Allen Bolts 23 2 3 17 L Rear Shock Absorber Nuts 34 3 5 25 Swingarm Pivot Shaft 20 2 0 15 Swingarm Pivot Shaft Locknut 98 10 0 72 Swingarm Pivot Shaft Nut 108 11 0 79 7 Rocker Arm Nut 34 3 5 25 R Tie Rod Nuts 59 6 0 44 R Steering Handlebar Bolts 34 3 5 25 L Handlebar Holder Bolts 25 2 5 18 AL PERIODIC MAINTENANCE 2 11 Torque and Locking Agent Fastener Remark
184. 12 6 in ENUMA EK530RMX 3D 118 links 0 4 mm 0 016 in or less TIR 0 5 mm 0 020 in FINAL DRIVE 11 5 Special Tools Inside Circlip Pliers Bearing Driver Set 57001 143 57001 1129 7570143ST C 7571129ST C 11 6 FINAL DRIVE Drive Chain Drive Chain Slack Inspection e Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter Drive Chain Slack Adjustment 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 Installation NOTE OSince the drive chain is installed through the swingarm The chain can not be removed other than by cutting it Prepare the new link pin link plate grease seals and tools for rejoining the chain e Remove the screws A e Clear the hook B and remove the chain cover C For safety if the drive chain shall be replaced re place it using a recommended tool Recommended Tool Type EK Joint Tool 50 Brand ENUMA FINAL DRIVE 11 7 Drive Chain Body A Handlebar B A B Cutting and Riveting Pin
185. 2 2 65 Spark plug replace 2 68 Service more frequently when operating severe conditions dusty wet muddy high speed frequent starting stopping For higher odometer readings repeat at the frequency interval established here PERIODIC MAINTENANCE 2 7 Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non permanent locking agent or silicone sealant etc Letters used in the Remarks column mean AL Tighten the two clamp bolts alternately two times to ensure even tightening torque G Apply grease L Apply a non permanent locking agent M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts S Follow the specified tightening sequence Si Apply silicone grease SS Apply silicone sealant Fastener Remarks Fuel System Idle Speed Control Valve Actuator Mounting Bolts 73 in lb Delivery Pipe Mounting Screws 3 44 in lb Crankshaft Sensor Bolts 52 in lb Gear Position Switch Screws 26 in lb Water Temperature Sensor 106 Throttle Body Assy Holder Bolts 87 Throttle Body Assy Holder Clamp Bolts 18 in Ib Vehicle down Sensor Mounting Nuts 52 in lb Throttle Case Screws 31 in lb Oxygen Sensor Equipped Models 18 Fuel Level Senso
186. 2 F G with new ones OTighten Torque Engine Mounting Nuts M12 59 6 0 kgf m 44 ft lb NOTE OHold the mounting bolt at the right side of the frame not to turn when tightening the upper and lower engine mounting nuts at the left side of the frame OMake sure the alignment marks are still matched NOTE Olf the alignment marks do not match repeat the tighten ing process again 8 10 ENGINE REMOVAL INSTALLATION Engine Removal Installation OSeventh install the right engine bracket and tighten the right engine bracket bolts H and the right front engine mounting bolt I OTighten Torque Engine Bracket Bolts M8 25 N m 2 5 kgf m 18 ft lb Front Engine Mounting Bolts M10 59 6 0 kgf m 44 ft lb Subframe Bolts 23 N m 2 3 kgf m 17 ft lb e Run the leads cable and hoses correctly see Cable Wire and Hose Routing section in the Appendix chap ter e Install the removed parts see appropriate chapters e Adjust Throttle Cables see Throttle Control System Inspection in the Periodic Maintenance chapter Drive Chain see Drive Chain Slack Inspection in the Periodic Maintenance chapter e Fill the engine with engine oil see Engine Oil Change in the Periodic Maintenance chapter e Fill the engine with coolant and bleed the air from the cool ing system see Coolant Change in the Periodic Mainte nance chapter CRANKSHAFT TRANSMISSION 9 1 Crankshaft Transmission Table of Cont
187. 2 12 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Torque Remarks Oil Pressure Switch Terminal Bolt 1 5 13 in lb G Oil Pressure Switch 15 11 SS Switch Housing Screws 3 5 31 in lb Starter Lockout Switch Screw 0 70 6 2 in lb L Front Brake Light Switch Screw 1 2 11 in lb Fuel Level Sensor Bolts 6 9 61 in lb L Sidestand Switch Bolt 8 8 78 in lb L Oxygen Sensor Equipped Models 25 18 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 Torque Diameter mm N m kgf m ft lb 5 3 4 4 9 0 35 0 50 30 43 in lb 6 5 9 7 8 0 60 0 80 52 69 in lb 8 14 19 1 4 1 9 10 0 13 5 10 25 34 2 6 3 5 19 0 25 12 44 61 4 5 6 2 33 45 14 73 98 7 4 10 0 54 72 16 115 155 11 5 16 0 83 115 18 165 225 17 0 23 0 125 165 20 225 325 23 0 33 0 165 240 Specifications PERIODIC MAINTENANCE 2 13 Item Standard Service Limit Fuel System DFI Throttle Grip Free Play Idle Speed Throttle Body Vacuum Air Cleaner Element 2 3 mm 0 08 0 12 in 1 100 50 r min rpm 36 66 1 3 kPa 275 0 10 mmHg at idle speed Viscous paper element Cooling System Coolant Type Recommended Color Mixe
188. 30 7571530ST C Fork Spring Compressor 57001 1540 875715405 C Fork Spring Compressor 57001 1587 875715875 C Swingarm Pivot Nut Wrench 57001 1597 875715975 C Jack Attachment 57001 1608 7 7571608ST C Needle Bearing Driver 617 18 57001 1609 7571609ST C Needle Bearing Driver 28 57001 1610 GG 8 5716105 C Spacer 18 57001 1636 eZ T5716368T 28 57001 1663 ST571663ST SUSPENSION 13 9 Special Tools Needle Bearing Driver 20 amp Spacer 28 Fork Spring Compressor 57001 1678 57001 1771 ST571678ST 875717715 6 13 10 SUSPENSION Front Fork Rebound Damping Force Adjustment e To adjust the rebound damping force turn the rebound damping adjuster A until you feel a click OThe standard adjuster setting is the 8th click from the 1st click of the fully clockwise position A WARNING If both adjusters are not adjusted equally handling may be impaired and a hazardous condition may result Be sure the adjusters are set equally OThe damping force can be left soft for average riding But it should be adjusted harder for high speed riding or riding with a passenger If the damping feels too soft or too stiff adjust it in accordance with the following table Rebound Damping Force Adjustment SEE 15 Weak Soft T l 0
189. 32 ft Ib Rear Footpeg Bracket Bolts 25 N m 2 5 kgf m 18 ft Ib e Install the removed parts see appropriate chapters Frame Inspection e Visually inspect the frame for cracks dents bending or warp lf there is any damage to the frame replace it A WARNING A repaired frame may fail in use possibly causing an accident resulting in injury or death If the frame is bent dented cracked or warped replace it 15 25 Cover Fuel Tank Cover Removal Remove Inner Covers see Inner Cover Removal Bolt A Remove the bolt A and washer on both sides e Spread the fuel tank cover B evenly outward to clear the projections C on both sides e Clear the tab D and hook E on both sides e Remove the fuel tank cover to forward F Fuel Tank Cover Installation e Installation is the reverse of removal e When installing the pads A install them as shown in the figure F d 2 Re MU e gt go gt e Be sure that the dampers A in position e Fit the dampers of the fuel tank into the slots B of the fuel tank cover C 15 26 Cover e Insert the slots of the fuel tank cover A into the tabs B of the fairing cover on both sides e Hang the hook C of the fuel tank cover to the bracket on both side e Insert the projections D into the holes on both sides Left Inner Rubber Cover Removal e Remove Left Middle Fairing se
190. 4 Ju TEE ial el x lt v 1 Jet 2 Oil Cooler 3 from Oil Filter 4 Oil Pipe 60042798 6 ENGINE LUBRICATION SYSTEM 7 7 Engine Oil Flow Chart Rear Balancer Oil Passage Front Balancer ss Sa Starter Motor 011 Passage Passage Drive Shaft OZ 4 Output Shaft 011 Passage Oil Passage Breather Hose 7 8 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil Type SG SH SJ SL or SM with JASO MA1 MA2 Viscosity SAE 10W 40 Capacity 3 8 L 4 0 US qt when filter is not removed 4 2 L 4 4 US qt when filter is removed 4 6 L 4 9 US qt when engine is completely dry Level Between upper and lower level lines Wait 2 3 minutes after idling or running Oil Pressure Measurement Oil Pressure 245 343 kPa 2 5 3 5 kgf cm 36 50 psi at 4 000 r min rpm Oil Temperature 90 C 194 F ENGINE LUBRICATION SYSTEM 7 9 Special Tools and Sealants Oil Pressure Gauge 10 kgf cm Liquid Gasket TB1211 57001 164 56019 120 7570164ST C 875601205 Oil Pressure Gauge Adapter PT3 8 57001 1233 875712335 7 10 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter A WARNING Vehicle operation with insufficient deteriorated or contaminated engine oil will cause accelerated wear and may result in engine seizure accident and injury Check the oil le
191. 5 57001 1204 7571204ST C 5 10 ENGINE END Special Tools and Sealants Valve Seat Cutter Holder 5 57001 1208 7571208ST C Valve Seat Cutter 60 33 57001 1334 875713345 6 Valve Guide Driver 57001 1564 7571564ST C Valve Spring Compressor Adapter 24 57001 1586 875715865 Compression Gauge Adapter M10 x 1 0 57001 1601 7T571601ST C L Shape Hose 57001 1606 Valve Guide Driver Attachment 57001 1677 Liquid Gasket TB1211F 92104 0004 s 879200045 8 5716065 C 875716775 6 Liquid Gasket TB1216B 92104 1064 879210645 ENGINE END 5 11 Clean Air System Air Suction Valve Removal Remove Middle Fairings see Middle Fairing Removal in the Frame chapter Air Switching Valve see Air Switching Valve Removal Bolt A e Remove Bolts A e Remove Air Suction Valve Cover Bolts A Air Suction Valve Covers B Air Suction Valves C Air Suction Valve Installation e Install the air suction valve so that opening A of the reed faces the rear and downward e Apply a non permanent locking agent to the threads of the air suction valve cover bolts B and tighten them Torque Air Suction Valve Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib e Install the removed parts see appropriate chapters GE04111BS1 5 12 ENGINE
192. 5 012 mm 0 1969 0 1973 in Valve Valve Guide Clearance Wobble Method Exhaust 0 09 0 16 mm 0 0035 0 0063 in Intake 0 03 0 11 mm 0 0012 0 0043 in Valve Seat Cutting Angle 32 45 60 Valve Seating Surface Width Exhaust 0 8 1 2 mm 0 031 0 047 in Intake 0 5 1 0 mm 0 020 0 039 in Outside Diameter Exhaust 27 6 27 8 mm 1 087 1 094 in Intake 32 6 32 8 mm 1 283 1 291 in Valve Spring Free Length Exhaust 41 03 mm 1 615 in Intake 42 09 mm 1 657 in 0 7 mm 0 028 in 0 3 mm 0 012 in TIR 0 05 mm 0 002 in 4 94 mm 0 194 in 4 96 mm 0 195 in 5 08 mm 0 200 in 5 08 mm 0 200 in 0 36 mm 0 014 in 0 30 mm 0 012 in 39 4 mm 1 551 in 40 4 mm 1 591 in ENGINE END 5 9 Special Tools and Sealants Compression Gauge 20 kgf cm 57001 221 Valve Spring Compressor Assembly 57001 241 7570221ST C 7570241ST C Valve Seat Cutter 45 535 57001 1116 8 5711165 C Valve Seat Cutter 32 530 57001 1120 Valve Seat Cutter 32 535 57001 1121 7571120ST C 7T571121ST C Valve Seat Cutter 60 530 57001 1123 875711235 C Valve Seat Cutter Holder Bar 57001 1128 7571128ST C Valve Seat Cutter 45 30 57001 1187 8 5711875 C Valve Guide Arbor 5 57001 1203 Sue R 7571203ST C Valve Guide Reamer
193. 57001 1582 Key Registration Adapter 57001 1746 Immobilizer System Equipped Models ELECTRICAL SYSTEM 16 91 e Insert the registered ignition key to the ignition switch and turn it to ON Verified OThe red warning indicator light LED and immobilizer warning symbol A blinks to display the registration mode go to the next step Not Verified OThe red warning indicator light LED and immobilizer warning symbol A blinks to display the collation error refer to the following failure illustrations Immobilizer Amplifier Failure Registered Ignition Key Collation Error e Turn the registered ignition key to OFF and remove the registered ignition key x lf there are other registered ignition keys the above pro cedure must be performed for them OThe red warning indicator light LED and the immobilizer symbol A blinks continuously to display that the ECU is in the registration mode for 15 seconds NOTE Olnsert next key and turn ON within 15 seconds after pre vious key is turned OFF and removed otherwise regis tration mode will be ended and the red warning indicator light LED stops flashing OTo return to the registration mode start the registered ignition key s verification procedure This applies to all ignition key registration e Insert the ignition key 1 to the ignition switch and turn it ON NOTE OKeep the other ignition key away from the immobilizer antenna C Y 0 5second 0 5second
194. 6 turn D while holding the brake fluid reservoir body A e Install the stopper and screw Tighten Torque Front Brake Reservoir Cap Stopper Screw 1 2 0 12 kgf m 11 in Ib Tighten the bleed valve and install the rubber cap Torque Bleed Valves 7 8 N m 0 80 kgf m 69 in Ib Check the fluid level see Brake Fluid Level Inspection the Periodic Maintenance chapter e After bleeding is done check the brake for good braking power no brake drag and no fluid leakage 12 28 BRAKES Brake Fluid A WARNING When working with the disc brake observe the pre cautions listed below 1 2 3 Never reuse old brake fluid Do not use fluid from a container that has been left unsealed or that has been open for a long time Do not mix two types and brands of fluid for use in the brake This lowers the brake fluid boiling point and could cause the brake to be ineffective It may also cause the rubber brake parts to deteriorate Don t leave the reservoir cap off for any length of time to avoid moisture contamination of the fluid Don t change the fluid in the rain or when a strong wind is blowing Except for the disc pads and disc use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning of the brake parts Do not use any other fluid for cleaning these parts Gasoline engine oil or any other petroleum distillate will cause deterio ration of the rubbe
195. 7 Clutch Master Cylinder Assembly pt 6 7 Clutch Master Cylinder Inspection ee te th Re been tret Clutch Slave Cylinder suoi e ett nit nt reet e i e ae pen tette rela t Clutch Slave Cylinder Removal pt Clutch Slave Cylinder Installation Re eite bad baci tese Clutch Slave Cylinder Disassembly een 6 9 Clutch Slave Cylinder Assembly oio 6 9 Ee 6 10 Clute Fluid Inspeetlon toto e Rina haat e iae 6 10 Clutch Fluid Change dus 6 10 Bleeding the Clutch LING etr e X eee 6 10 Clutch Hose Removal Installation pt 6 12 Clutch Hose Inspeellorcs sie are ae ede 6 12 TE 6 13 Cover Removal cacti iit eet 6 13 Cluteh Cover 6 13 rio AM Er 6 14 Cl t h Removal ERR M 6 14 PT 6 15 Spring Plate Free Play 0 4400 6 17 Spring Plate Free Play 6 18 Clutch Plate Assembly Length Reference Information Inspection 6 18 Clutch Plate Wear Damage
196. 99 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 0 6214 Units of Force Units of Power N x 0 1020 kg kW x 1360 NE CC l kW x 1341 HP kg x 9 807 N PS x 0 7355 kW kg x 2 205 Ib PS x 0 9863 HP Units of Temperature 9 C 40 40 F 5 F 40 ode oF oF 32 68 104 248 284 40 20 20 40 40 C 20 5 40 i 267 489 i i 100 71 1 93 3 116 1120 176 212 80 100 120 140 160 180 200 220 240 260 280 300 320 1140 160 C 138 PERIODIC MAINTENANCE 2 1 Periodic Maintenance Table of Contents Peri di Maintenance ap m T 2 3 Torque and Locking ACen a 2 7 tolero ee 2 13 Special Tools and Sealant ye 2 15 Periodic Maintenance pp 2 16 System DF 2 16 Throttle Control System Inspection re eI ie emet deal n 2 16 Engine Vacuum Synchronization Inspection pp 2 16 Idle Speed Inspection re ers tue deca pun edet utu ts 2 19 Idle 2 20 Fuel Hose Inspection fuel leak damage installation condition
197. A cam follower B and the torque limiter spring C e Replace the part if it is damaged GF12022BS1 GF06033BS1 C ENGINE LUBRICATION SYSTEM 7 1 Engine Lubrication System Table of Contents CET E EE ER Special Tools and Sealants 5 eoe e te etn Blaue ciega ptu Engine Oil and OWPIgE eode det Oil Level Inspection eH Engine Ir Go IGS oto oasis ru euius Oil Filter Replacement eror en te odo Fere re ERR RM ERR RENE ARE Oil Gooler Oil Pressure 1 irse sana sees saa Oil Pressure Measurement pp Oil Pressure SWITChus tad O Oil Pressure Switch Removal Oil Pressure Switch Installation OI PID P H Ol PIS AS ta AU OM 7 2 ENGINE LUBRICATION SYSTEM Exploded View ENGINE LUBRICATION SYSTEM 7 3 Exploded View Lm 17
198. A for oil leakage x lf the oil leakage is found on it replace the shock absorber with a new one Rocker Arm Operation Inspection Remove the rear fairing see Rear Fairing Removal in the Frame chapter equipped models e Pump the seat down and up 4 or 5 times and inspect the smooth stroke the rocker arm A does not smoothly stroke or noise is found inspect the fasteners and bearings see Rocker Arm Tie Rod Bearing Sleeve Inspection in the Suspen sion chapter Tie Rod Operation Inspection e Remove the rear fairing see Rear Fairing Removal in the Frame chapter equipped models e Pump the seat down and up 4 or 5 times and inspect the smooth stroke x lf the tie rods A do not smoothly stroke or noise is found inspect the fasteners and tie rod bearings see Rocker Arm Tie Rod Bearing Sleeve Inspection in the Suspen sion chapter PERIODIC MAINTENANCE 2 39 Periodic Maintenance Procedures Steering Steering Play Inspection e Raise the front wheel off the ground with the jack see Front Wheel Removal in the Wheel Tire chapter Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e With the front wheel pointing straight ahead alternately tap each end of the handlebar The front wheel should swing fully left and right from the force of gravity until the fork hits the stop x If the wheel binds or catches before the stop the steering is too tight e Feel for steering looseness by pu
199. AL SEA B1 Models Clamp Hold the right fan motor lead connector as shown in the figure and insert the clamp into the radiator cover Run the purge valve lead to the upside of the green hose Run the right switch housing lead horn lead and front wheel rotation sensor lead through the clamp Front Wheel Rotation Sensor Lead Connector Right Switch Housing Lead Connector Clamp Hold the main harness and insert the clamp into the middle air intake duct City Light Lead Connector Headlight Relay Position the main harness near the middle air intake duct 10 Headlight Lead Connector Low 12 13 14 15 Headlight Lead Connector High Green Hose Hose Main Harness Clamp Hold the main harness green hose and blue hose and insert the clamp into the middle air intake duct Clamp Hook the headlight lead Clamp Hold the front right turn signal light lead and insert the clamp into the middle air intake duct Front Right Turn Signal Light Lead Connector 17 10 APPENDIX Cable Wire and Hose Routing sage MINC m Ww ON r J TT e avs HT E N i 4 f i 722 58099130 6 APPENDIX 17 11 Cable Wire and Hose Routing ROD C1 Clamp Hold the reserve tank hose and air bleeder hose as shown in the figure Reserve Tank Hose Air Bleeder Hose
200. Brake Light Sit Engine Stop Seiteh Starter Button Color cotor R W R W Color L w OFF Loch ON P PARK 98052 06924 W2RO692AW5 C 16 22 ELECTRICAL SYSTEM Wiring Diagram ABS Equipped Models Other than SEA B1 and BR Models Meter Unit 1 Green Left Turn Signal Indicator Light LED 2 Green Right Turn Signal Indicator Light LED 3 Blue High Beam Indicator Light LED Spark Plugs E Indicator i 1 a R T ig 5 Yellow Engage Shift Up derer X Stick Sidestand Indicator Light LED Soils Switch 6 Red Warning ilndicator Light Right Switch Housing OFF Water Temperature Front Brake s Light Switch Battery Immobilizer LED WERL duce 18 7 Red Qil Pressure Warning Indicator Light LED 8 Yellow ABS Indicator Light LED 9 Yellow KTRG Warning Indicator Light LED 10 Yellow Engine Warning Indicator Light LED 11 Speedometer 12 Tachometer 13 Multifunction Display 4 illumination Light LED LED Light Emitting Diode Intake Air Temperature Sensor Ignition Switch BR lonobilizer Amplifier ge DE BL down eed Sensor Immobilizer AR Antenna sum 88 4 Connector F BRZW BRIN BRZY Front Wheel C 63 tt BR Rotation Sensor Hes Meter Unit Y R EL i
201. Connect the adapter to the lead wire peak voltage adapter E which is connected between the stick coil connector and stick coil ECU F Battery G Special Tools Hand Tester 57001 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Lead Wire Peak Voltage Adapter 57001 1449 Primary Lead Connection Adapter to lead wire peak voltage adapter W Adapter BK to lead wire peak voltage adapter R A WARNING To avoid extremely high voltage shocks do not touch the spark plugs or tester connections e Turn the engine stop switch to run position e Turn the ignition switch to 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 72 V or more e Repeat the test for the other stick coils x If the reading is less than the specified value check the following Stick Coils see Stick Coil Inspection Crankshaft Sensor see Crankshaft Sensor Inspection ECU see ECU Power Supply Inspection in the Fuel Sys tem DFI chapter Spark Plug Removal e Refer to the Spark Plug Replacement in the Periodic Maintenance chapter Spark Plug Installation e Refer to the Spark Plug Replacement in the Periodic Maintenance chapter GP10283BS1 16 50 ELECTRICAL SYSTEM Ignition System Spark Plug Condition
202. D and immobilizer warning symbol A blinks to display the collation error code Immobilizer Amplifier Failure When Registered Ignition Key is Inserted On LS GP30085CS1 Y 0 5second 0 5second GP30058CS1 C GP30059CS1 C C Y 0 5second 0 5second E Ern paf pes GP30058CS1 16 106 ELECTRICAL SYSTEM Immobilizer System Equipped Models Ignition Key Collation Error 0 3second UL GP30080CS1 e The second ignition key is registered in the ECU OThe red warning indicator light LED and immobilizer warning symbol A blinks 2 times and stops for 1 sec ond and then repeats this cycle to indicate successful registration of ignition key e Turn OFF the ignition switch and wait for period more than 15 seconds e The registration mode automatically ends A Bee The red warning indicator light LED A goes off GP30083CS1 NOTE OTurn the ignition switch ON with the registered ignition key OCheck that the engine can be started using all regis tered ignition keys ELECTRICAL SYSTEM 16 107 Immobilizer System Equipped Models All Keys Initial Registration Flow Chart iore registry acson Cm gt Blinking Patterns and Number gt eg 0 8 4 Second gt 2 3 0 3aecond teecond gt 3 8 9303 0 3 leeeend 8h
203. E 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 Remove the caliper mounting bolts B and detach the caliper C from the disc NOTICE Do not loosen the caliper assembly bolts Take out only the caliper mounting bolts for caliper removal Loosening the caliper assembly bolts will cause brake fluid leakage e Remove the banjo bolt and remove the brake hose D from the caliper see Brake Hose Removal Installation NOTICE 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 Calipers BRAKES 12 17 Caliper Installation e Install the caliper and brake hose lower end OReplace the washers on each side of hose fitting with new ones Tighten Torque Caliper Mounting Bolts Front 34 3 5 kgf m 25 ft lb Rear 25 N m 2 5 kgf m 18 ft lb Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft Ib e Check the fluid level in the brake reservoirs e Bleed the brake line see Brake Line Bleeding e Check the brake for good braking power no brake drag and no fluid leakage A WARNIN
204. End chapter Exhaust Pipe see Exhaust Pipe Removal in the Engine Top End chapter Oil Pipe see Oil Pipe Removal in the Engine Lubrication System chapter Shift Pedal see Shift Pedal Removal in the Crank shaft Transmission chapter e Disconnect Sidestand Switch Lead Connector A Oil Pressure Switch Gear Position Switch Leads Con nector B Alternator Lead Connector see Alternator Cover Re moval in the Electrical System chapter Starter Motor Cable Terminal Nut see Starter Motor Re moval in the Electrical System chapter ENGINE REMOVAL INSTALLATION 8 5 Engine Removal Installation e Remove Bolts A Bolt B Subframe Bracket Bolt C Subframe Bolts D e Remove the subframe E with the clutch pipe F e Remove Throttle Body Subharness Connector A Disconnect Breather Hose B Fuel Hose C on the Delivery Pipe Throttle Cable Lower Ends D e Disconnect Air Switching Valve Lead Connector A Stick Coil Subharness Connector B e For CAL and SEA B1 Models remove the purge valve see Purge Valve Removal in the Fuel System DFI chap ter e Remove Bolts A Idle Speed Control Valve Actuator Lead Connector B Disconnect e Pull the air switching valve hose out of the air cleaner housing e Remove Bolt A Pad B 8 6 ENGINE REMOVAL INSTALLATION Engine Removal Installation e Remove the engine sprocket see Engine Sprocket Re moval in the Final Drive chapter e Support the engi
205. Front Wheel Rotation Sensor Joint Connector F Vehicle down Sensor Immobilizer Antenna Equipped Models Immobilizer Amplifier Equipped Models Ignition Switch Engine Stop Switch Starter Button Stick Coil 1 2 3 4 Spark Plugs Intake Air Temperature Sensor Joint Connector C Joint Connector D Idle Speed Control Valve Actuator Crankshaft Sensor Fuel Injector 1 Fuel Injector 2 Fuel Injector 3 Fuel Injector 4 Joint Connector H Subthrottle Valve Actuator Main Throttle Sensor Subthrottle Sensor Intake Air Pressure Sensor 1 Intake Air Pressure Sensor 2 Joint Connector J Joint Connector Air Switching Valve Water Temperature Sensor Oxygen Sensor Equipped Models Gear Position Switch Joint Connector E 3 16 FUEL SYSTEM System DFI System Wiring Diagram ABS Equipped Models nmm HHHH m OS FAT H iT T PEE T i Bare BE Coe i 3 sk ed Bk met Pitti 1 1 Lu Ni HH TA US CHEERS sk 1 _ D v 2 BK Y BL R n E tud R R M rr BK Y BK Y 8K Y BK Nl is m i
206. G After servicing it takes several applications of the brake lever or pedal before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the motorcycle until a firm brake lever or pedal is obtained by pumping the lever or pedal until the pads are against the disc Front Caliper Disassembly e Refer to the Caliper Rubber Parts Replacement in the Pe riodic Maintenance chapter Front Caliper Assembly e Refer to the Caliper Rubber Parts Replacement in the Pe riodic Maintenance chapter Rear Caliper Disassembly e Refer to the Caliper Rubber Parts Replacement in the Pe riodic Maintenance chapter Rear Caliper Assembly e Refer to the Caliper Rubber Parts Replacement in the Pe riodic Maintenance chapter 12 18 BRAKES Calipers Caliper Fluid Seal Damage Inspection The fluid seal piston seal A is placed around the pis ton to maintain clearance between the pad and the disc If the seal is in a poor condition it could lead the pad to wear excessively or the brake to drag which may cause the tem perature of the discs or the brake fluid to increase e Replace the fluid seal if it exhibits any of the conditions listed below OBrake fluid leakage around the pad OBrakes overheat OConsiderable difference in inner and outer pad wear OSeal and piston are stuck together x If the fluid seal is replaced replace the dust se
207. G lead terminal 51 Digital Meter gt Frame Ground terminal e Measure the input voltage to each primary winding of the stick coils with the engine stopped and with the connec tors joined e Turn the engine stop switch to run position e Turn the ignition switch to ON Input Voltage Standard Battery Voltage GT04096BS1 C FUEL SYSTEM 3 97 Stick Coils 1 2 3 4 Service Code 51 52 53 54 e Turn the ignition switch to OFF x lf the input voltage is out of the standard check the wiring for continuity see Stick Coil Circuit Special Tool Hand Tester 57001 1394 x If the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation x If the input voltage is within the standard check the ECU for its ground and power supply see ECU Power Supply Inspection x lf the ground and power supply are good replace the ECU see ECU Removal Installation Stick Coil Circuit GTO41128W2 C 1 ECU 9 Joint Connector F 2 Frame Ground 10 Ignition Switch 3 Battery 11 Engine Stop Switch 4 Starter Relay 12 Stick Coil 1 5 Main Fuse 30 A 13 Stick Coil 2 6 Frame Ground 2 14 Stick Coil 3 7 Fuse Box 1 15 Stick Coil 4 8 Ignition Fuse 15 A 3 98 FUEL SYSTEM Radiator Fan Relay Service Code 56 Radiator Fan Relay Rem
208. Hydraulic Unit Connector terminal 12 C BK W lead ABS Hydraulic Unit Connector terminal 3 D e For other than ABS equipped models check the wiring for continuity between harness connectors Special Tool Hand Tester 57001 1394 Wiring Continuity Inspection ECU Connector Front Wheel Rotation Sensor Connector B W G lead ECU terminal 58 C BK W lead ECU terminal 4 D 6104130851 9704131851 C 3 78 FUEL SYSTEM Front Wheel Rotation Sensor Signal Service Code 27 x lf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation Wheel Rotation Sensor Circuit ABS Equipped Models 5 M a 0 80 6 a y w BK RAY BK N BK W W G 6T04127BW2 1 ECU 2 Rear Wheel Rotation Sensor 3 ABS Hydraulic Unit 4 Front Wheel Rotation Sensor Wheel Rotation Sensor Circuit other than ABS Equipped Models 2 AO 2 6104128812 1 ECU 2 Rear Wheel Rotation Sensor 3 Front Wheel Rotation Sensor FUEL SYSTEM DFI 3 79 Vehicle down Sensor Service Code 31 This sensor has a weight A with two magnets inside and sends a signal to the ECU But when the motorcycle banks 60 70 or more to eith
209. IC MAINTENANCE Periodic Maintenance Procedures Engine Stop Switch Operation Inspection First Step e Turn the ignition switch to ON e Set the neutral position e Turn the engine stop switch to stop position A e Push the starter button 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 the ignition switch to ON e Set the neutral position e Turn the engine stop switch to run position A e Push the starter button and run the engine e Turn the engine stop switch to stop position e Immediately the engine should be stop x lf the engine does not stop inspect or replace the follow ing item Engine Stop Switch see Switch Inspection in the Elec trical System chapter 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 Center Stand Equipped Models Rear Brake Master Cylinder Joint Pin Sidestand Points Lubricate with Grease Throttle Inner Cable Upper End A
210. Ib Check the fluid level in the master cylinder reservoir and bleed the air in the clutch line e Check the clutch operation e Install the removed parts see appropriate chapters Clutch Slave Cylinder Disassembly e Refer to the Rubber Parts of Clutch Master Cylinder Slave Cylinder Replacement in the Periodic Maintenance chap ter Clutch Slave Cylinder Assembly e Refer to the Rubber Parts of Clutch Master Cylinder Slave Cylinder Replacement in the Periodic Maintenance chap ter 6 10 CLUTCH Clutch Fluid Clutch Fluid Level Inspection e Refer to the Clutch Fluid Level Inspection in the Periodic Maintenance chapter Clutch Fluid Change e Refer to the Clutch Fluid Change in the Periodic Mainte nance chapter Bleeding the Clutch Line A WARNING Air in the clutch lines diminish clutch performance and can cause an accident resulting in injury or death If the clutch lever has a soft or spongy feel ing mushy when it is applied there might be air in the clutch lines or the clutch may be defective Do not operate the vehicle and service the clutch sys tem immediately Clutch fluid quickly ruins painted or plastic sur faces any spilled fluid should be completely wiped up immediately with wet cloth e Remove Screw A Stopper B Clutch Reservoir Cap C Diaphragm Plate Diaphragm e Fill the reservoir with fresh clutch fluid to the upper level line in the reservoir NOTE OTap the clutc
211. Idle Speed Control Valve Actuator Resistance 3 106 Idle Speed Control Valve Actuator Input Voltage 3 107 Purge Valve Service Code CAL and SEA B1 3 109 Purge Valve Removal lnstallation Citer Rr e ee e be t Mon ees s 3 109 Purge Valve amp ER 3 109 Warming Indicator Light LED ap hopes 3 111 Yellow Engine Warning Yellow KTRC Warning Red Warning Indicator Light LED Inspection aet em eet ere 3 111 FUEL SYSTEM DFI 3 3 Cui tek ees erecta DM Mr t 3 112 ECU Identificati N rea er reece 3 112 ECU Removal 3 112 EGU Installation ree e 3 113 ECU Power Supply InspecllOre otio n ETE e ERI Ec Ree aches 3 114 CAN Communication 3 117 CAN Communication Line Resistance 3 117 DFI Power SOUICO AR 3 119 ECU Fuse oe QE bi ED BEN tacet d a adus Meneses 3 119 ECU Fuse NS Tell ANON eC nr 3 119
212. Inspection in the Electrical System chapter e Push the passing button or set the dimmer switch to high beam position The low beam A and high beam 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 Headlight Relay Fuse 15 A see Fuse Inspection in the Electrical System chapter Passing Button Equipped Models see Switch Inspec tion in the Electrical System chapter Dimmer Switch see Switch Inspection in the Electrical System chapter Headlight Circuit Relay in Relay Box see Relay Circuit Inspection in the Electrical System chapter Headlight Relay High see Headlight Relay Inspection SEE the Electrical System chapter 9817209851 Harness see Wiring Inspection in the Electrical System chapter e Turn the engine stop switch to OFF e The low beam and high beam headlights should stay go ing on If the headlights and high beam indicator light LED does go off inspect or replace the following item Headlight Circuit Relay in Relay Box see Relay Circuit Inspection in the Electrical System chapter e Turn the ignition switch to OFF e The headlights and high beam indicator light LED should go off 2 44 PERIODIC MAINTENANCE Periodic Mainten
213. KSHAFT TRANSMISSION Starter Motor Clutch and Torque Limiter e Install the starter clutch and starter clutch shaft e Apply a non permanent locking agent to the threads of the starter clutch shaft plate bolt and tighten it Torque Starter Clutch Shaft Plate Bolt 9 8 N m 1 0 kgf m 87 in Ib Starter Motor Clutch Disassembly e Remove the starter motor clutch see Starter Motor Clutch Removal e Pull the driven gear out off from the drive gear e Remove the needle bearing A and snap ring B 61078129 P e Holding the drive gear A with a hand remove the one way clutch B from the gear by using the standard tip screwdriver C Starter Motor Clutch Assembly e Be sure to install the one way clutch A so that its arrow B faces the side of the snap ring 61078131 P e Install the new snap ring A to the one way clutch 61078132 P CRANKSHAFT TRANSMISSION 9 39 Starter Motor Clutch and Torque Limiter Turn in the driven gear A to the drive gear Counterclockwise C e Install the needle bearing Starter Clutch Inspection e Remove the rear balancer see Rear Balancer Removal e Turn the starter idle gear A by hand When viewed from the rear side of the engine the starter idle gear should turn forward B freely but should not turn backward C lf the clutch does not operate as it should or if it makes noise disassemble the starter clutch examine each part visual
214. L G lead ECU terminal 50 x If the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation Fuel Injector Fuel Line Inspection e Remove the throttle body assy see Throttle Body Assy Removal e Check the fuel injector fuel line for leakage as follows OConnect a commercially available vacuum pressure pump A to the nipple of the delivery pipe B with the fuel hose C both ends connected with the clamps D as shown in the figure OApply soap and water solution to the areas E as shown in the figure OWatching the pressure gauge squeeze the pump lever F and build up the pressure until the pressure reaches the maximum pressure Fuel Injector Fuel Line Maximum Pressure Standard 300 kPa 3 06 kgf cm 43 psi During pressure testing do not exceed the maxi mum pressure for which the system is designed OWatch the gauge for at least 6 seconds x If the pressure holds steady the fuel line is good x If the pressure drops at once or if bubbles are found in the area the 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 throttle body assy see Throttle Body Assy In stallation Start the engine and check for fuel leakage 8017216 51 8017217 52
215. LED 5 5 5 8 5 Speedometer Tachometer Multifunction Display Illumination Light LED Ignition Switch e itus Vehicle Wc down Chie 00 Immobilizer AR Antenna m 88 4 Connector F Front Wheel Rotation Sensor Unit Meter Joint Connector ie Right Joint Joint Connector Connector 6 City Light R 12 5 RLY Headlight High 242 Ill 12 654 H Headlight LI Low wy 12 55 E Headlight ay LI E Low MH 1b Headl High 12965 12 5 BR Y ET ight H Pi BEEN City Light R ia BK Y Torn signs Turn Signal D D Light GIZZ 12218 Fuse Box 1 1 lgnition Fuse 15 2Headlight Relay Fuse 15 3 Brake Light Horn Fuse 10A Signal Relay Fuse 10A Turn Signal APO E Headlight Headlight Relay 2 Fuse 15 Relay LO Relay Hl 3 Headlight Relay Fuse 15 Left Switch Housing Relay Box Left Switch Housing Relay Box 1 Horn Button 5 Dimmer Switch 1 Radiator Fan Rela 3 ECU Main Rela 2 Hazard Button 6 Starter Lockout Switch Leute A FUSTO BUMD RELAY 3 Turn Signal Switch 7 SEL Button 5 Starter Circuit 4 Passing B
216. M 16 61 Electric Starter System Electric Starter Circuit K 2 o H i B 9 GP11231BW3 C Engine Stop Switch Starter Button Gear Position Switch Sidestand Switch Frame Ground Battery 12 V 12 Ah Starter Relay Main Fuse 30 A Starter Motor 10 Frame Ground 2 11 Frame Ground 4 12 Starter Circuit Relay 13 Relay Box 14 Starter Lockout Switch 15 Ignition Fuse 15 16 Fuse Box 1 17 Joint Connector F 18 Ignition Switch 16 62 ELECTRICAL SYSTEM Lighting System This motorcycle adopt the daylight system and have a headlight relay in the relay box The headlight does not go on when the ignition switch and the engine stop switch are first turned on The headlight comes on after the starter button is released and stays on until the ignition switch is turned off The headlight will go out momentarily whenever the starter button is pressed and come back on when the button is released Headlight Beam Horizontal Adjustment 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 the inner covers see Inner Cover Removal the Frame chapter Disconnect the headlight connector A e Turn the headlight bulb A
217. Mark Alphabet C Diameter Mark D O or no mark NOTICE If the connecting rods big end bearing inserts or crankshaft are replaced with new ones select the bearing insert and check clearance with a plasti gage press gauge before assembling engine to be sure the correct bearing inserts are installed Apply molybdenum disulfide oil solution to the inner sur faces of the upper and lower bearing inserts A e Apply molybdenum disulfide oil solution to the threads B and seating surface C of the connecting rod nuts e Install the inserts so that their nails D are on the same side and fit them into the recess of the connecting rod and cap NOTICE Wrong application of oil and grease could cause bearing damage 6105060181 C eO 6105037BS1 C 9 18 CRANKSHAFT TRANSMISSION Crankshaft Connecting Rods OWhen installing the inserts A be careful not to damage the insert surface with the edge of the connecting rod B or the cap C One way to install inserts is as follows Installation D to Cap Installation E to Connecting Rod Push F Spare Dowel Pin G Connecting Rod Bolts H e Remove debris and clean the surface of inserts e Install the cap on the connecting rod aligning the weight and diameter marks e Install the crankshaft see Crankshaft Installation e Install each connecting rod on its original crankpin OThe connecting rod big end is bo
218. 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 Master Cylinder Inspection Visual Inspection Remove the master cylinders see Front Rear Master Cylinder Removal e Disassemble the front and rear master cylinders see Master Cylinder Rubber Parts Replacement in the Peri odic Maintenance chapter e Check that there are no scratches rust or pitting on the inner wall A of each master cylinder and on the outside of each piston x If a master cylinder or piston shows any damage replace them e Inspect the primary cup C and secondary cup D cup is worn damaged softened rotted or swollen the piston assembly should be replaced to renew the cups x If fluid leakage is noted at the brake lever the piston as sembly should be replaced to renew the cups e Check the dust covers E for damage x lf they are damaged replace them e Check the piston return springs F for any damage x If the springs are damaged replace them Check
219. O 3seceand gt 5 8f NOTE 1 Key Substitute Time Insert next key and turn ON within 15 seconds after previous key turned OFF 3 ECU confirms the Immobilizer Amplifier Failure Pattern 1 Ignition Key Collation Error Pattern 5 4 ECU confirms the following Ignition Key or Not O Match the Unique Code 5 ECU confirms the following Immobilizer Amplifier Failure Pattern 1 Second ignition Key Collation Error Pattern 5 Ignition Key is inserted Pattem 2 following Amplifier O Time of Transmitting and Receiving Messages following O Registered 6 ECU confirms the egistered Ignition Key 7 When the ECU registered key is turned OFF ECU keeps the power for two seconds And then in two seconds after the key is ECU turns the power OFF 62300676 16 108 ELECTRICAL SYSTEM Immobilizer System Equipped Models Immobilizer System Parts Replacement Ignition Switch Replacement Remove the left inner cover see Inner Cover Removal in the Frame chapter e Disconnect the lead connectors A e Remove the steering stem head see Stem Stem Bearing Removal in the Steering chapter e Using a small chisel or punch A turn out the Torx bolts Pull out the ignition switch from the steering stem head e Register the more than 2 ignition keys see Key Registra tion e Tighten a new Torx bolt A until the bolt head B is broken Broken Head of Other Side C
220. P Amplifier Input Voltage Connections to Amplifier Connector Digital Meter BR W lead Digital Meter gt BK BL lead e Measure the input voltage with the engine stopped and with the connector joined e Turn the ignition switch to ON Input Voltage Standard Battery Voltage e Turn the ignition switch to OFF If the reading is out of the standard check the wiring see Immobilizer System Circuit x If the reading is within the standard check the wiring to ECU see Immobilizer System Circuit If the wiring is good replace the amplifier see Immobi lizer System Parts Replacement in the Electrical System chapter 3 92 FUEL SYSTEM Blank Key Detection Service Code 36 Equipped Models e This code appears in the following conditions OThe transponder A in the ignition key is malfunction OWhen the spare key of unregistration is used OWhen the ignition key is registered in the registered ECU e Therefore the service code 36 will disappear when the above issue is solved Ignition Key Inspection e Register the ignition key correctly see Key Registration in the Electrical System chapter x lf the service code 36 appears again the transponder in the key is malfunction replace it Immobilizer System Circuit GTO4i110BW3 C 1 ECU 6 Main Fuse 30 A 13 Water Temperature Bat 2 Immobilizer Kawasaki 7 Frame Ground 2 tery Immobilizer Warning In Diagnos
221. Position 52 Valve Valve Switch ail Actuator Joint Connector v Soom t i z PES s z BL aL 58 oz 5 Joint amp 8 Joint ak z Joint Connector E d Connector 2292 a Connector 4 TTTT rrr 22 zi 3 8 Bee 8 5 353 EGU ri Hi M Lj NEN H Hl SA P BL zaz p 21 G R Le aK AK BR W BK G BL o BL R BL BK ee Joint wer Connector BK BL amp Rear Wheel Rotation Immobilizer Kawasaki Diagnostic Systen Connector Sensor Rear Right Turn Signal Light 12V21W Tail Brake BK Y BK Y BK Y Reservep Switch Battery EA 12V124h Joint Connector B uel ump Regulator Rectifier Starter Relay 1 00 Fuse 15A Brake Alternator 2 Wain Fuse 30A proke ABS Kawasaki 5 Switch Self 5 Di re Starter Frame Ground iagnosis 3 otor System Raanester Frame Frane Frame Ground Ground Ground 5 Frame Frane Ground Ground 4 2 IGNITION SWITCH CONNECTIONS Battery lgnition Signal fere ow fepe RIGHT SWITCH HOUSING CONNECTIONS Front Brake Light Siti Engine Stop Switeh Starter Button color cotor R W R W Color
222. Pull out the dust seal C e Remove the retaining ring A from the outer tube e Remove the oil seal B and washer C Front Fork Assembly e Replace the following parts with new ones Oil Seal Bottom Allen Bolt Gasket e Insert the cylinder unit A into the inner tube B e Stop the cylinder from turning by using the fork cylinder holder Special Tool Fork Cylinder Holder 57001 1287 e Apply a non permanent locking agent to the threads of the Allen bolt and tighten it Torque Front Fork Bottom Allen Bolts 23 N m 2 3 kgf m 17 ft lb Front Fork SUSPENSION 13 25 e Apply grease to the oil seal lips e Install the following parts onto the inner tube A temporar ily Dust Seal B Retaining Ring C Oil Seal D Washer E e Insert the inner tube to 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 43 57001 1530 e Install the retaining ring and dust seal into the outer tube e Pour in the specified type of oil see Front Fork Oil Change Inner Tube Outer Tube Inspection e Visually inspect the inner tube A and repair any 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 lf the damage is not repairable replace the inner tube Since damage to the inner tube damages the oil seal replace the oil
223. R mark B faces up e Install the second ring C so that the RN mark D faces up e Apply molybdenum disulfide oil solution to the piston pin and piston journal 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 OWhen installing the piston pin snap ring compress it only enough to install it and no more Do not reuse snap rings as removal weakens and deforms them They could fall out and score the cylinder wall e 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 Upper Oil Ring Steel Rail C Oil Ring Expander D Lower Oil Ring Steel Rail E Dent F 30 40 G GE16060BS1 C GE16061BS1 C GE16284BS1 GE16285BS1 CRANKSHAFT TRANSMISSION 9 29 Pistons Apply molybdenum disulfide oil solution to the cylinder bore and piston skirt e Install the piston with its dent mark A facing exhaust side e Using the piston ring compressor assembly B to install the piston from the cylinder head side Special Tools Piston Ring Compressor Grip 57001 1095 Piston Ring Compressor Belt 80 91 57001 1320 e Install Crankshaft see Crankshaft Installation Connecting Rod Big End Caps see Conne
224. RICAL SYSTEM Meter Gauge Indicator Unit Meter Unit Disassembly e Remove Meter Unit see Meter Unit Removal Screws A Lower Meter Cover B Separate Meter Cover A Meter Assembly B Meter Operation Inspection Check 1 1 Meter Unit Primary Operation Check e Turn the ignition switch to ON e Check that the following items OThe following indicator lights LED blink two times Green Turn Signal Indicator Lights LED A Red Warning Indicator Light LED B Green Neutral Indicator Light LED C Yellow ABS Indicator Light LED D ABS equipped models Yellow Engage Shift Up Indicator Light LED E Blue High Beam Indicator Light LED F Red Oil Pressure Warning Indicator Light LED G OThe yellow KTRC warning indicator light LED H and yellow engine warning indicator light LED I goes on for one second OThe speedometer and tachometer needles J momentar ily point their last readings and back to the minimum po sition OThe animation and Kawasaki mark K appears in the dis play for 4 5 seconds OAfter the Kawasaki mark appeared the ordinary indica tion A Example CURRENT KM L gear position B Example N water temperature C clock D odometer E or trip meter fuel level gauge F power mode indica tor G Example F and KTRC indicator H Example 2 appear in the display x If the meter unit does not work replace the meter assem bly 62179336 6
225. Run the air bleeder hose reserve tank hose and right fan motor lead into the hole of the right inner rubber cover from top to bottom Run the right fan motor lead outside of the two hoses Run the oxygen sensor lead into the holes of the right inner rubber cover Oxygen Sensor Lead Connector Oxygen Sensor Equipped Models 17 12 APPENDIX Cable Wire and Hose Routing 68099140 G APPENDIX 17 13 Cable Wire and Hose Routing Clamp Hold the blue hose and align the clamp with blue painted mark of the blue hose Insert the idle speed control valve hose into the air cleaner until while painted mark on it is hidden a half Battery Positive Cable Battery Negative Cable Battery Ground Lead Run the battery ground lead to the inside of the battery positive cable Fix the battery positive cable and battery ground lead with the band Tighten the battery negative cable engine ground cable and battery ground lead from the frame side as shown in the figure CAL and SEA B1 Models gt OW 17 14 APPENDIX Cable Wire and Hose Routing 68099150 6 APPENDIX 17 15 Cable Wire and Hose Routing CON Clamps Hold the main harness and insert the clamps into the middle air intake duct Main Harness Run the main harness and clutch hose into the hole of the pad Clutch Hose Front
226. SEA B1 models note the following For CAL and SEA B1 models if gasoline solvent water or any other liquid enters the canister the canister s vapor absorbing capacity is greatly re duced If the canister does become contaminated replace it with a new one OBe sure to plug the evaporative fuel return hose to prevent fuel spilling before fuel tank removal A WARNING Spilled fuel is flammable and can be explosive un der certain conditions For CAL and SEA B1 mod els be careful not to spill fuel through the return hose x If liquid or gasoline flows into the breather hose remove the hose and blow it clean with compressed air careful of fuel spillage from the fuel tank since fuel still remains in the fuel tank and fuel pump A WARNING Gasoline is extremely flammable and can be explo sive under certain conditions creating the poten tial for serious burns Store the fuel tank in an area which is well ventilated and free from any source of flame or sparks Do not smoke in this area Place the fuel tank on a flat surface and plug the fuel pipes to prevent fuel leakage Fuel Tank Installation e Note the above WARNING see Fuel Tank Removal e Run the hoses correctly see Cable Wire and Hose Rout ing section in the Appendix chapter e Check that the dampers A and pads B are in place on the fuel tank OFor models equipped with the ABS there is a damper C the dampers
227. ST C Peak Voltage Adapter 57001 1415 875714155 C FUEL SYSTEM DFI 3 27 Needle Adapter Set Throttle Sensor Setting Adapter 57001 1538 57001 1457 T571457ST C Fuel Pressure Gauge Adapter 57001 1593 Fuel Hose 57001 1607 ST571607ST C Measuring Adapter 57001 1700 7571593ST C 875717005 6 3 28 FUEL SYSTEM Special Tools and Sealant Liquid Gasket TB1211 56019 120 875601205 DFI Servicing Precautions FUEL SYSTEM DFI 3 29 DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system OThis DFI system is designed to be used with a 12 V sealed battery as its power source Do not use any other battery except for a 12 V sealed battery as a power source ODo not reverse the battery cable connections This will damage the ECU OTo prevent damage to the DFI parts do not disconnect the battery cables or any other electrical connections when the ignition switch is on or while the engine is running OTake care not to short the leads that are directly con nected to the battery positive terminal to the chassis ground OWhen charging remove the battery from the motorcycle This is to prevent ECU damage by excessive voltage OWhenever the DFI electrical connections are to be dis connected first turn off the ignition switch and disconnect the battery ter
228. Select the power mode e By pushing the upper button A or lower button B each time check that the power mode indicator changes to go ing on x lf the display function does not work check the following parts Left Switch Housing see Switch Inspection Wiring see Meter Unit Circuit the above parts is good replace the meter unit 62179326 6 Meter Gauge Indicator Unit ELECTRICAL SYSTEM 16 79 Select the KTRC mode By pushing the upper button A or lower button each time check that the KTRC indicator changes to going on x If the indicator symbol does not work check the following parts Left Switch Housing see Switch Inspection Wiring see Meter Unit Circuit x f the above parts is good replace the meter unit e Push the SEL button A for more than two seconds e Check that the display changes to the language setting mode A OThis display is system menu indication e By pushing the upper button or lower button each time check that the display selects the ENGLISH or FRAN CAIS x lf the display function does not work replace the meter assembly KTRC 02179386 5 16 80 ELECTRICAL SYSTEM Meter Gauge Indicator Unit e While the language setting mode push the SEL button e Check that the display A changes to the UNIT ENGAGE LAMP SHIFT LAMP LAMP MODE and CLOCK modes e By pushing the upper button or lower button each time check that the
229. Stem Stem Stem Bearing Removal e Remove Upper Fairing see Upper Fairing Removal in the Frame chapter Front Wheel see Front Wheel Removal in the Wheels Tires chapter Handlebars see Handlebar Removal Steering Stem Head Nut A and Washer B Steering Stem Head C Front Forks see Front Fork Removal in the Suspension chapter e Remove Cover Bolts A and Cover B Front Fork Clamp Bolts Lower C Brackets D e Bend the claws A of the claw washer straighten e Remove the steering stem locknut B Special Tool Steering Stem Nut Wrench 57001 1100 e Remove the claw washer 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 Steering Stem D Upper Ball Bearing Inner Race and Ball Bearing e To remove the ball bearing outer races A pressed into the head pipe B insert a bar C into the recesses D of head pipe and applying it to both recess alternately hammer it to drive the race out NOTE Olf either steering stem bearing is damaged it is recom mended that both the upper and lower bearings includ ing outer races should be replaced with new ones STEERING 14 7 Steering Stem Remove the lower ball bearing inner race with its oil seal A which is pressed onto the steering stem with a suitable commercially available chisel B Stem Stem Bearing Installation e Replace the bearing
230. System Troubleshooting Guide Symptoms or Possible Causes Actions chapter Fuel pump trouble Inspect see chapter 3 Fuel injector trouble Inspect see chapter 3 Main throttle sensor trouble Inspect see chapter 3 Subthrottle sensor trouble Inspect see chapter 3 Subthrottle valve actuator trouble Inspect see chapter 3 Intake air pressure sensor 1 trouble Inspect see chapter 3 Intake air pressure sensor 2 trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Intake air temperature sensor trouble Inspect see chapter 3 Spark plug dirty broken or gap maladjusted Inspect and replace see chapter 16 Stick coil trouble Inspect see chapter 16 Stumble sug OOS Unstable fuel pressure Fuel pressure regulator trouble Inspect and replace fuel pump or kinked fuel line Inspect and replace fuel pump see chapter 3 Fuel injector trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 17 Backfiring when deceleration Spark plug dirty broken or gap maladjusted Inspect and replace see chapter 16 Fuel pressure too low Inspect see chapter 3 Air suction valve trouble After fire o y O Spark plug burned or gap maladjusted Replace see chapter 2 Fuel injector trouble Inspect see chapter 3 Intake air pressure sensor 1 trouble Inspect see chapter 3
231. TE ODo not turn the center adjusting screw D e Check the vacuums as before x If all vacuums are within the specification range finish the engine vacuum synchronization x If any vacuum can not be adjusted within the specification replace the bypass screws 1 4 with new ones refer to the following procedure 9505258851 Remove the throttle body assy see Throttle Body Assy Removal in the Fuel System DFI chapter e Turn in the bypass screw A with counting the number of turns until it seals fully but not tightly Record the number of turns e Remove Bypass Screw Spring B Washer C O ring D e Check the bypass screw hole in the throttle body for car bon deposits x If any carbons accumulate wipe the carbons off from the hole using a cotton pad penetrated with a high flash point solvent e Replace the bypass screw spring washer and O ring as a set e Turn in the bypass screw until it seats fully but not tightly 9505161851 C Do not over tighten the bypass screw The tapered portion E of the bypass screw could be damaged PERIODIC MAINTENANCE 2 19 Periodic Maintenance Procedures e Back out the same number of turns counted when first turned in This is to set the screw to its original position NOTE CA throttle body has different turns out of the bypass screw for each individual unit On setting the bypass screw use the turns out determined during d
232. Torque Front Camshaft Chain Guide Bolt Upper F 25 2 5 kgf m 18 ft lb Front Camshaft Chain Guide Bolt Lower G 12 1 2 kgf m 106 in Ib e Install the removed parts see appropriate chapters GE14087BS1 GE14088BS2 Cylinder Head ENGINE TOP END 5 27 Cylinder Head Warp Inspection Clean the cylinder head e Lay astraightedge across the lower surface of the cylinder head at several positions e Use a thickness gauge A to measure the space between the straightedge B and the head Cylinder Head Warp Standard Service Limit 0 05 mm 0 002 in 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 GE14038BS1 C 5 28 ENGINE END Valves Valve Clearance Inspection e Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter Valve Clearance Adjustment e Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter Valve Removal Remove Cylinder Head see Cylinder Head Removal Valve Lifter and Shim NOTE 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 Comp
233. Washer C Special Tool Outside Circrip Pliers 57001 144 e Remove Gear Positioning Lever Bolt A Gear Positioning Lever B Collar and Spring C External Shift Mechanism Installation e Install the gear positioning lever A as shown in the figure Spring B Collar C e Tighten Torque Gear Positioning Lever Bolt D 12 N m 1 2 kgf m 106 in Ib 9113518851 C 9113288851 C CRANKSHAFT TRANSMISSION 9 41 Transmission e Replace the oil seal A with a new one e Apply grease to the lips of the grease seal e Install Shift Shaft Assembly A and Washer OFit the hole B and return spring pin C e Replace the snap ring A with a new one e Install Snap Ring Special Tool Outside Circlip Pliers 57001 144 OFit the snap ring into the groove of the shift shaft securely e Install the removed parts see appropriate chapters External Shift Mechanism Inspection e Examine the shift shaft A for any damage x lf the shaft is bent straighten or replace it x If the serration B are damaged replace the shaft x If the springs C are damaged in any way replace them xIf the shift mechanism arm D is damaged any way replace the shaft e Check the return spring pin A is not loose is loose unscrew it apply a non permanent locking agent to the threads and tighten it Torque Shift Shaft Return Spring Pin 29 3 0 kgf m 21 ft
234. Water Temperature Sensor Resistance Inspection 6104084851 C Water Temperature Sensor Resistance Inspection e Refer to the Water Temperature Sensor Inspection in the Electrical System chapter x If the reading is within the standard but the problem still exists replace the ECU see ECU Removal Installation Water Temperature Sensor Circuit 81904104842 1 ECU 2 Water Temperature Sensor 3 68 FUEL SYSTEM Intake Air Pressure Sensor 2 Service Code 16 Intake Air Pressure Sensor 2 Removal Never drop the intake air pressure sensor 2 espe cially on a hard surface Such a shock to the sensor can damage it e Remove Throttle Body Assy see Throttle Body Assy Removal Intake Air Pressure Sensor 2 Connector A e Remove the intake air pressure sensor 2 B from the bracket C e Remove the vacuum hose D and rubber damper E from the intake air pressure sensor 2 Intake Air Pressure Sensor 2 Installation NOTE OThe intake air pressure sensor 2 is the same part as the intake air pressure sensor 1 e Installation is basically the reverse of removal e Position the intake air pressure sensor 2 A between the projections B on the rubber damper e Install the intake air pressure sensor 2 A on the bracket B as shown in the figure FUEL SYSTEM 3 69 Intake Air Pressure Sensor 2 Service Code 16 Intake
235. YSTEM DFI DFI System Troubleshooting Guide Symptoms or Possible Causes Actions chapter Fuel filter or pump screen clogged Inspect and replace fuel pump see chapter 3 Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump see chapter 3 Fuel line clogged Inspect and repair see chapter 3 Intake air pressure sensor 1 trouble Inspect see chapter 3 Intake air pressure sensor 2 trouble Water temperature sensor trouble Intake air temperature sensor trouble Main throttle sensor trouble Subthrottle sensor trouble Subthrottle valve actuator trouble Unstable rough idling Fuel pressure too low or too high Fuel injector trouble Main throttle sensor trouble Subthrottle sensor trouble Subthrottle valve actuator trouble Engine vacuum not synchronizing Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect Inspect see chapter 3 see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect and adjust see chapter 2 Intake air pressure sensor 1 trouble Inspect see chapter 3 Intake air pressure sensor 2 trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Intake air temperature sensor t
236. ZX1400FC JKBZXT40EFA000001 O This digit in the frame number changes from one machine to another Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Motorcycle amp Engine Company Part No 99924 1450 01 Printed in Japan
237. able Range 4 19 mm 0 16 0 75 in A WARNING If both adjusters are not adjusted equally handling may be impaired and a hazardous condition may result Be sure the adjusters are set equally OThe spring preload can be left soft for average riding But it should be adjusted harder for high speed riding or riding with a passenger If the spring action feels too soft or too stiff adjust it in accordance with the following table Spring Preload Adjustment Adjuster Damping Position Force Setting Load Road Speed un Strong Hard Heavy Bad High Front Fork Removal Each Fork Leg e Remove Middle Fairings see Middle Fairing Removal in the Frame chapter Front Wheel see Front Wheel Removal in the Wheels Tires chapter Front Fender see Front Fender Removal in the Frame chapter Handlebar see Handlebar Removal in the Steering chapter GM04359BS1 C 13 12 SUSPENSION Front Fork Loosen the upper front 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 front fork clamp bolt e Loosen the upper front fork clamp bolt and lower front fork clamp bolts C e With a twisting motion work the fork leg down and out Front Fork Installation e Install the fork so that the top end A of the outer tube is as shown in the figure 21 5 mm 0 85 in B e Tighten Torque Front Fork
238. acket Bolts 49 N m 5 0 kgf m 36 ft Ib Replace the sidestand nut B with a new one e Apply grease to the sliding area C of the sidestand D e Tighten the sidestand bolt E first and then the sidestand nut Torque Sidestand Bolt 44 4 5 32 ft lb Sidestand Nut 44 N m 4 5 kgf m 32 ft Ib Hook the spring F so that the long spring end of it faces upward Olnstall the spring hook direction as shown in the figure e Install the sidestand switch e Apply a non permanent locking agent to the threads of the switch bolt G and tighten it Torque Sidestand Switch Bolt 8 8 N m 0 90 kgf m 78 in Ib 6020060851 Rear View Mirror FRAME 15 29 Rear View Mirror Removal e Remove Inner Cover see Inner Cover Removal Nuts A Rear View Mirror B Rear View Mirror Installation e Installation is the reverse of removal ELECTRICAL SYSTEM 16 1 Electrical System Table of Contents SO UE E 16 4 M REM 16 10 Special Tools and Sealant Dec 16 11 Parts Welcome 16 13 Wiring Diagram US CA and CAL 16 16 Wiring Diagram PH and SEA B2 16 18 Wiring Diagram BR ucc o esie eg emt ote tm aiu 16 20 Wiring Diagram ABS Equipped Models Oth
239. ad Digital Meter gt BK sensor lead e Measure the output voltage with the engine stopped and with the connector joined e Turn the ignition switch to ON 9104078881 Output Voltage Usable Range DC 3 80 4 20 V at standard atmospheric pressure 101 32 kPa 76 cmHg NOTE OThe output voltage changes according to the local at mospheric pressure e Turn the ignition switch to OFF x f the reading is out of the usable range replace the sen Sor x If the reading is within the usable range remove the ECU D C and check the wiring for continuity between harness con LA nectors Special Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor connectors ECU Connector A Intake Air Pressure Sensor 1 Connector B Y BL lead ECU terminal 22 C G lead ECU terminal 13 D 9704079851 C 3 60 FUEL SYSTEM Intake Air Pressure Sensor 1 Service Code 12 lf the wiring is good check the sensor for various vacuum Remove the intake air pressure sensor 1 A and discon nect the vacuum hose from the sensor Connect an auxiliary hose B to the intake air pressure sensor 1 e Temporarily install the intake air pressure sensor 1 OConnect a digital meter C vacuum gauge D the fork oil level gauge E and the measuring adapter to the intake air pressure sensor 1 Special Tools Fork Oil Level Gauge 57001 1290 Vacuum Gauge 57
240. age x If the seal is torn or is leaking replace the bearing GJ06043BS1 6J06008BS1 C 6J06008BS1 C 6J06002BS1 C 10 18 WHEELS TIRES Hub Bearing Hub Bearing Lubrication NOTE OSince the hub bearings are packed with grease and sealed lubrication is not required FINAL DRIVE 11 1 Final Drive Table of Contents Exploded a eee agen 11 2 DOCG ALORS ciclos bas 11 4 ice ie 11 5 I EM 11 6 Drive Chain Slack Inspection REA 11 6 Drive Chain Slack Adjustment pp 11 6 Wheel Alignment Inspection Adjustment 11 6 Drive Chain Wear tarda 11 6 Drive Chain Lubricatig pe 11 6 Drive Chain Removal lnstallation E 11 6 Sprocket COBDIITIQ Leder Lea alta 11 10 Engine SProCke MR 11 10 Engine Sprocket Installation oerte prre ren nne npn nente nnn 11 11 Engine Sprocket Cover nennen nnne 11 11 Engine Sprocket Cover Assembly pp 11 12 Rear Spro
241. age Inspection e Remove any imbedded stones A or other foreign parti cles from tread e Visually inspect the tire for cracks B cuts C and nail D and replace the tire if necessary Swelling or high spots indicate internal damage requiring tire replacement e Visually inspect the wheel for cracks cuts and dents dam age If any damage is found replace the wheel if necessary Tire Tread Wear Inspection As the tire tread wears down the tire becomes more sus ceptible to puncture and failure An accepted estimate is that 90 of all tire failures occur during the last 10 of tread life 90 worn So it is false economy and unsafe to use the tires until they are bald 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 any measurement is less than the service limit replace the tire see Tire Removal Installation in the Wheels Tires chapter Tread Depth Standard Front BRIDGESTONE 3 6 mm 0 14 in METZELER 4 2 mm 0 17 in Rear BRIDGESTONE 4 8 mm 0 19 in METZELER 5 3 mm 0 21 in Service Limit Front 1 mm 0 04 in AT CH DE 1 6 mm 0 06 in Rear 2 mm 0 08 in Up to 130 km h 80 mph 3 mm 0 12 in Over 130 km h 80 mph 6J05007BS1 9511067851 PERIODIC MAINTENANCE 2 29 Periodic Maintenance Procedures A WARNING Some replacement tires
242. aged e Visually inspect the connector terminals A Replace the ABS hydraulic unit or main harness if either of the terminals are cracked bent or otherwise damaged x If the ABS hydraulic unit connector is clogged with mud or dust blow it off with compressed air GL14104BS2 C BRAKES 12 53 Anti Lock Brake System Equipped Models Front Wheel Rotation Sensor Removal wheel rotation sensor should be handled fully never struck sharply with a hammer or al lowed to fall on a hard surface since the wheel rota tion sensor is precision made Be careful not to get water or mud on the wheel rotation sensor Do not try to disassemble or repair the wheel rota tion sensor e Remove Right Middle Fairing see Middle Fairing Removal in the Frame chapter Connector A Disconnect Clamps B e Remove Bolts A Bracket Bolt B Clamps C Front Wheel Rotation Sensor D Front Wheel Rotation Sensor Installation e Installation is the reverse of removal ORun the lead correctly see Cable Wire and Hose Rout ing section in the Appendix chapter Rear Wheel Rotation Sensor Removal The wheel rotation sensor should be handled care fully never struck sharply with a hammer or al lowed to fall on a hard surface since the wheel rota tion sensor is precision made Be careful not to get water or mud on the wheel rotation sensor Do not try to disassemble
243. air cleaner caps see Throttle Body Assy Re moval e Turn the ignition switch to ON e Check to see that all the subthrottle valves A open and close smoothly e Turn the ignition switch to OFF lf the subthrottle valves do not operate check the sub throttle valve actuator resistance see Subthrottle Valve Actuator Resistance Inspection Subthrottle Valve Actuator Resistance Inspection e Turn the ignition switch to OFF e Remove the throttle body assy see Throttle Body Assy Removal e Disconnect the subthrottle valve actuator connector A e Connect a digital meter to the subthrottle valve actuator connector A e Measure the subthrottle valve actuator resistance Subthrottle Valve Actuator Resistance Connections BK lead 1 G Olead 2 Y R lead 3 P BL lead 4 Standard About 6 5 8 5 x If the reading is out of the standard replace the throttle body assy x If the reading is within the standard check the input volt age see Subthrottle Valve Actuator Input Voltage Inspec tion GC17532b81 3 100 FUEL SYSTEM 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 to OFF e Remove the throttle body assy see Throttle Body Assy Removal ODo not disconnect the connectors of the throttle body assy Disconnect the subthrottle valve actuator
244. ake 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 e Install the right front footpeg bracket Torque Front Footpeg Bracket Bolts 25 2 5 kgf m 18 ft lb e Install the rear master cylinder mounting bolts ODepress the brake pedal A and then align the bolts holes of the master cylinder B Torque Rear Master Cylinder Mounting Bolts 25 2 5 kgf m 18 ft lb e Check the brake pedal position see Brake Pedal Position Inspection GL04025BS1 12 16 BRAKES Calipers Front Caliper Removal e Loosen the banjo bolt A at the brake hose lower end and tighten it loosely e Remove the caliper mounting bolts B and detach the caliper C from the disc Do not loosen the caliper assembly bolts Take out only the caliper mounting bolts for caliper removal Loosening the caliper assembly bolts will cause brake fluid leakage e Remove the banjo bolt and remove the brake hoses D from the caliper see Brake Hose Removal Installation Immediately wash away any brake fluid that spills NOT
245. ake System Equipped Models ABS System Wiring Diagram GL14620BW3 C 1 Ignition Switch 14 Frame Ground 5 2 Front Brake Switch 15 ABS Self diagnosis Terminal 3 Front Wheel Rotation Sensor 16 ABS Kawasaki Self diagnosis System Connector 4 Joint Connector C 17 ABS Hydraulic Unit 5 Joint Connector D 18 Brake Light Horn Fuse 10 A 6 Rear Wheel Rotation Sensor 19 Fuse Box 1 7 ECU 20 ABS Motor Relay Fuse 20 A 8 Rear Brake Switch 21 ABS ECU Fuse 10 A 9 Frame Ground 22 Fuse Box 2 10 Battery 12 V 12 Ah 23 ABS Solenoid Valve Relay Fuse 15 A 11 Starter Relay 24 Meter Unit 12 Main Fuse 30 A 25 Yellow ABS Indicator Light LED 13 Frame Ground 2 OColor Codes BK Black GY Gray PU Purple BL Blue LB Light Blue R Red BR Brown LG Light Green V Violet CH Chocolate O Orange W White DG Dark Green P Pink Y Yellow G Green 12 32 5 Anti Lock Brake System Equipped Models Terminal Names 68114107842 C Unused Power Supply to Rear Wheel Rotation Sensor Front Wheel Rotation Sensor Signal Front and Rear Brake Light Switch Unused Unused Unused Power Supply to ABS Solenoid Valve Relay Power Supply to ABS Motor Relay ABS Kawasaki Self diagnosis System Terminal Unused Power Supply to Front Wheel Rotation Sensor ABS Self diagnosis Terminal Unused Unused Power Supply Unuse
246. al B as well Also replace all seals every other time the pads are changed Caliper Dust Seal Damage Inspection e Check that the dust seals A are not cracked worn swollen or otherwise damaged If they show any damage replace the dust seals with new ones Pistons B Fluid Seals C 9105153851 C 9105155851 C GLO5156BS1 C Calipers BRAKES 12 19 Caliper Piston and Cylinder Damage Inspection e Visually inspect the pistons A and cylinder surfaces B Replace the caliper if the cylinder and piston are badly Scores or rusty GLO5158BS1 C 12 20 BRAKES Brake Pads Front Brake Pad Removal e Loosen the pad pins A e Remove Pad Pins A Pad Springs B Brake Pads C Front Brake Pad Installation e Push the caliper pistons in by hand as far as they will go e Install the outside pad A and insert the pad B as shown in the figure Set Inside Pad A Pad Spring B OPushing the pin holder C to hole of the pad and insert the pad pin Torque Front Brake Pad Pins 17 2 N m 1 75 kgf m 12 7 ft lb A WARNING After servicing it takes several applications of the brake lever before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the motorcycle until a firm brake lever is obtained by pumping the lever until the pads are against the disc
247. al in the Electrical System chapter Front and Rear Camshaft Chain Guides see Cylinder Head Removal e Remove the crankshaft sprocket A e Pull out the camshaft chain B downward Camshaft Chain Installation e Install the camshaft chain from head side e Install the crankshaft sprocket on the crankshaft B with their teeth C aligned e Install the removed parts see appropriate chapters GE11012281 GE11096BS1 C 5 24 ENGINE END Cylinder Head Cylinder Compression Measurement NOTE OUse the battery which is fully charged e Warm up the engine thoroughly Stop the engine e Remove Spark Plugs see Spark Plug Replacement in the Peri odic Maintenance chapter e Attach the compression gauge A and adapter B firmly into the spark plug hole e Using the starter motor turn the engine over with the throt tle fully open until the compression gauge stops rising the compression is the highest reading obtainable Special Tools Compression Gauge 20 kgf cm 57001 221 Compression Gauge Adapter M10 1 0 57001 1601 L Shape Hose C 57001 1606 Cylinder Compression Usable Range 1 190 1 798 kPa 12 1 18 3 kgf cm 173 261 psi at 300 r min rpm Repeat the measurement for the other cylinders e Install the spark plugs see Spark Plug Replacement in the Periodic Maintenance chapter OThe following table should be consulted if the obtainable compressio
248. ame time Clutch Plate Assembly Length Reference Information Inspection e Inspect the friction plate thickness see Clutch Plate Wear Damage Inspection e Assemble Clutch Hub A Friction Plates B Spring Seat C Spring D Steel Plates E Sub Clutch Hub F Spring Plate G Clutch Springs H Clutch Spring Holder I Clutch Spring Bolts J Clutch Hub Bolts K Torque Clutch Spring Bolts 8 8 0 90 kgf m 78 in Ib e Measure the clutch plate assembly length L Clutch Plate Assembly Length Reference Standard 54 2 mm 2 13 in NOTE O The length of the clutch plate assembly changes by the steel plate thickness 8 11035 52 C Clutch CLUTCH 6 19 Clutch Plate Wear Damage Inspection e Visually inspect the friction and steel plates for signs of seizure overheating discoloration or uneven wear e Measure the thickness of each friction plate A at several points x lf any plates show signs of damage or if they have worn past the service limit replace them with new ones Friction Plate Thickness 13088 0030 13088 0031 Standard 2 92 3 08 mm 0 115 0 121 in Service Limit 2 7 mm 0 106 in Friction Plate Thickness 13088 0032 Standard 3 72 3 88 mm 0 146 0 153 in Service Limit 3 5 mm 0 138 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 p
249. amshaft Sprocket Mounting Bolts 15 1 5 kgf m 11 ft lb e Apply molybdenum disulfide oil solution oil to all cam parts journals and tappets If anew camshaft is to be used apply a thin coat of molyb denum disulfide grease to the cam surfaces e Using a wrench on the timing rotor bolt A turn the crank shaft clockwise until the line B TDC mark for 41 4 pis tons on the timing rotor C is aligned with the mating sur face D of the crankcase 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 GE11378BS1 5 20 ENGINE END Camshaft Camshaft Chain e Pull the tension side exhaust side A of the chain taut to install the chain e Engage the camshaft chain with the sprockets so that tim ing marks on the sprockets are positioned as shown in the figure OThe timing marks must be aligned with the cylinder head upper surface B Punch Mark EX C Punch Mark IN D 1 Pin E 2 Pin F 30 Pin G 31 Pin H GE11379BW2 C ENGINE END 5 21 Camshaft Camshaft Chain e Install the ten dowel pins on the marks A e Install the camshaft cap following the identification No B and upper camshaft chain guide C e First tighten the all camshaft cap bol
250. ance Procedures Headlight Aiming Inspection Inspect the headlight beam for aiming x lf the headlight beam points to one side rather than straight ahead adjust the horizontal beam Headlight Beam Horizontal Adjustment Remove the inner covers see Inner Cover Removal the Frame chapter e Turn the horizontal adjuster A in both headlights in or out until the beam points straight ahead x lf the headlight beam points too low or high adjust the vertical beam Headlight Beam Vertical Adjustment e Remove the inner covers see Inner Cover Removal in the Frame chapter e Turn the vertical adjuster A in both headlights in or out to adjust the headlight vertically NOTE OON high beam the brightest points should be slightly below horizontal with the motorcycle on its wheels and the rider seated Adjust the headlight to the proper an gle according to local regulations OFor US model the proper angle is 0 4 degrees below horizontal This is 50 mm 2 in drop at 7 6 25 ft measured from the center of the headlight with the motorcycle on its wheels and the rider seated 50 mm 2 in A Center of Brightest Spot B 7 6 m 25 ft C Height of Headlight Center D 65172108 6 PERIODIC MAINTENANCE 2 45 Periodic Maintenance Procedures Sidestand Switch Operation Inspection Inspect the sidestand switch A operation accordance to the following table Sidestand Switch Operation Sidesta
251. and Tester 57001 1394 OSet the tester to the x 1 range and read the tester lf the tester does not read 0 the lead is defective Re place the lead or the wiring harness B if necessary GL14618BS1 16 30 ELECTRICAL SYSTEM Battery Battery Removal e Turn the ignition switch to OFF e Remove Right Fairing Cover see Fairing Cover Removal in the Frame chapter Bolt A with Washer Battery Compartment Cover B OClear the stoppers from the frame e Remove Frame Ground Bolt A and Negative Cables Bracket Bolts B Bracket C NOTICE Be sure to disconnect the negative cable first Slightly pull out the battery tray e Unhook the band Slide the battery cover e Slide the red cap A out e Disconnect the positive cable B e Remove the battery tray with battery C e Disconnect the negative cable A Remove the battery B from the battery tray ELECTRICAL SYSTEM 16 31 Battery Battery Installation e Place the battery in the battery tray A as shown in the figure Connect the negative cable B to the battery e Put alight coat of grease on the terminal C to prevent corrosion e Put the battery cover A on the battery e Insert the battery with the battery tray into the battery com partment Olnsert the projections A on the battery tray into the holes B of the battery compartment e Connect the
252. and stops for 1 sec ond and then repeats this cycle to indicate successful registration of ignition key 1 e Turn OFF the ignition switch and wait for period more than 15 seconds e The registration mode automatically ends The red warning indicator light LED A goes off 0 2second GP30059CS1 C 0 5second 0 5second gt gt 6230058651 C 0 3second UUUUUUUUUUU GP30080CS1 C am 0 30 30 3 0 3 0 3 1second ON OLS UUL SUUL GP30081CS1 C GP30083CS1 C 16 104 ELECTRICAL SYSTEM Immobilizer System Equipped Models NOTE the ignition switch ON with the registered ignition key OCheck that the engine can be started using all regis tered ignition keys Case 4 When all registered ignition keys are faulty or lost The all registered ignition keys replacement is considered very rare case However if it is required the following is necessary NOTE OThe ECU must be replaced with a new one because the registered ignition key code that is registered in the current ECU can not be rewritten Prepare a new ECU A and 2 new ignition keys B NOTE The key registration unit is not required OAfter replacing the ECU be sure to register the 2 ignition keys If the 2 keys are not registered the engine can not be started GP30823BS1 e Insert the fi
253. ankcase Splitting e Remove Connecting Rod Nuts A Connecting Rod Big End Caps e Remove the crankshaft Remove the piston A with connecting rod to the cylinder head side e Remove the piston pin snap ring A e Using the piston pin puller assembly A remove the pis ton pin Special Tool Piston Pin Puller Assembly 57001 910 e Remove the piston from the connecting rod 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 62168320 GE16282BS1 GE16283BS1 9 28 CRANKSHAFT TRANSMISSION Pistons Piston Installation NOTE Olf a new piston is used use new piston ring Apply molybdenum disulfide oil solution to the oil ring ex pander and install the oil ring expander A in the bottom piston ring groove so the ends B not butt together e Apply molybdenum disulfide oil solution to the oil ring steel rails and install the oil ring steel rails one above the ex pander and one below it OSpread the rail with your thumbs but only enough to fit the rail over the piston ORelease the rail into the bottom piston ring groove NOTE OThe oil ring rails have no top or bottom e Apply molybdenum disulfide oil solution to the piston rings NOTE ODo not mix up the top and second ring e Install the top ring A so that the
254. ap maladjusted Inspect and replace see chapter 16 Spark plug incorrect Replace it with the correct plug see chapter 2 ECU ground and power supply trouble Inspect see chapter 3 inspect see chapter 3 Supply fuel see Owner s Manual Inspect and replace see chapter 3 inspect see chapter 3 Inspect and replace see chapter 16 Inspect and replace fuel pump see chapter 3 Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump see chapter 3 Fuel line clogged Inspect and repair see chapter 3 Idle speed control valve trouble Inspect see chapter 3 Poor Running at Low Speed Symptoms or Possible Causes Actions chapter Spark weak Stick coil shorted or not in good contact Inspect or reinstall see chapter 16 Stick coil trouble Inspect see chapter 16 Spark plug dirty broken or gap maladjusted Inspect and replace see chapter 16 Spark plug incorrect Replace it with the correct plug see chapter 2 ECU trouble Inspect see chapter 3 Fuel air mixture incorrect Little fuel in tank Supply fuel see Owner s Manual Air cleaner clogged poorly sealed or missing Clean element or inspect sealing see chapter 2 Air duct loose Reinstall see chapter 3 Throttle body assy holder loose Reinstall see chapter 3 Throttle body assy dust seal damage Replace see chapter 3 Fuel injector O ring damage Replace see chapter 3 3 40 FUEL S
255. ap the coil head while installing the coil e After installation be sure the stick coils are installed se curely by pulling up them lightly e Run the leads correctly see Cable Wire and Hose Rout ing section in the Appendix chapter e Install the removed parts see appropriate chapters Stick Coil Inspection e Remove the stick coils see Stick Coil Removal e Measure the primary winding resistance A as follows OConnect the hand tester between the coil terminals OSet the tester to the x 1 range and read the tester e Measure the secondary winding resistance B as follows OConnect the tester between the plug terminal and coil terminal OSet the tester to the x 1 range and read the tester Stick Coil Winding Resistance Primary Windings 1 2 1 60 Secondary Windings 8 5 11 5 If the tester does not read as specified replace the coil TIS lt mit tW 3E GP10732BS1 GP10589BS2 C Ignition System ELECTRICAL SYSTEM 16 49 Stick Coil Primary Peak Voltage NOTE OBe sure the battery is fully charged e Remove the stick coils see Stick Coil Removal ODo not remove the spark plug e Measure the primary peak voltage as follows Olnstall the new spark plug A into each stick coil B and ground them onto the engine OConnect the peak voltage adapter C to the hand tester D which is set to the DC 250 V range O
256. ard remove the ECU and check the wiring for continuity between main harness con nectors Special Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector Vehicle down Sensor Connector B Y G lead ECU terminal 38 C G lead ECU terminal 13 D xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x lf the ground and power supply are good replace the ECU see ECU Removal Installation 9017786652 C i T ota gt 6104094851 FUEL SYSTEM 3 83 Vehicle down Sensor Service Code 31 Vehicle down Sensor Circuit 81704107842 1 ECU 2 Vehicle down Sensor 3 84 FUEL SYSTEM Subthrottle Sensor Service Code 32 The subthrottle sensor is a rotating variable resistor that change output voltage according to throttle operating The ECU senses this voltage change and determines fuel injec tion quantity and ignition timing according to engine rpm and throttle opening Input Terminal A BL Output Terminal B BL W Ground Terminal C G Subthrottle Sensor Removal Adjustment Do not remove or adjust the subthrottle sensor A since it has been adjusted and set with precision at the factory Never drop the throttle body assy especially on a hard surface Such a shock to the subthrott
257. are damaged or deteriorated replace them GC09116BS2 C FUEL SYSTEM DFI 3 149 Fuel Tank e When installing the dampers A so that the side of it con tacts the bracket as shown in the figure e When installing the trim B install it align the corner C of the bracket 6609117851 e When installing the pads and guard install them as shown in the figure C Align the weld portion of the fuel tank and dents of the pad D View A A 27 e Pull the joint lock A as shown in the figure 3 150 FUEL SYSTEM Fuel Tank Insert the fuel hose joint A straight onto the fuel outlet pipe until the hose joint clicks e Push B the joint lock C until the hose joint clicks 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 Leaking fuel can cause a fire or explosion resulting in serious burns Make sure the hose joint is in stalled correctly on the delivery pipe x If it comes off reinstall the hose joint Connect the fuel pump fuel level sensor lead connectors and the battery terminal see Battery Installation in the Electrical System chapter e For models equipped with an ABS fit the grooves of the damper A on the brake pipes B e Install the removed parts see appropriate chapters Fuel Tank and Cap Inspection e Visually inspect the gasket A o
258. at have a non permanent locking agent applied using an impact driver Use a plastic faced mallet whenever tapping is necessary Gasket O ring Hardening shrinkage or damage of both gaskets and O rings after disassembly can reduce sealing performance Remove old gaskets and clean the sealing surfaces thor oughly so that no gasket material or other material remains Install the new gaskets and replace the used O rings when re assembling Liquid Gasket Non permanent Locking Agent For applications that require Liquid Gasket or a Non permanent Locking Agent clean the surfaces so that no oil residue remains before applying liquid gasket or non permanent locking agent Do not apply them exces sively Excessive application can clog oil passages and cause serious damage ex I Or St 7 d 68020128 68020138 Se N 2724 N I E ims NS LY 68020148 5 68020158 68020168 GENERAL INFORMATION 1 5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place apply small amount of oil to the con 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 n absolutely necessary Replace with new ones whenever S 22 removed Press bearings with the manufacturer and size M
259. at it faces upward If the meter assembly is left up side down or sideways for a long time or dropped it will malfunction Do not short each terminals Check 3 1 CAN Communication Line Resistance In spection e Set the hand tester A to the x1 O range and connect it to the terminal 17 and 18 in the meter unit Special Tool Hand Tester 57001 1394 CAN Communication Line Resistance at Meter Unit Standard 122 126 x lf the tester reading is not specified replace the meter unit Check 3 2 Blue High Beam Indicator Light LED In spection e Using the auxiliary leads the 12 V battery to the meter unit connector as follows OConnect the battery positive terminal to the terminal 9 10 OConnect the battery negative terminal to the terminal 12 e Connect the terminal 1 to the battery terminal 8 17427 52 C GP17544BS1 GP17570BS1 16 86 ELECTRICAL SYSTEM Meter Gauge Indicator Unit Check that the blue high beam indicator light LED A goes on x lf the indicator light does not go on replace the meter unit Check 3 3 Red Oil Pressure Warning Indicator Light LED Inspection e Using the auxiliary leads the 12 V battery to the meter unit connector as follows OConnect the battery positive terminal to the terminal 9 10 OConnect the battery negative terminal to the terminal 12 e Connect the terminal 2 to
260. ate Inspection A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions creating the potential for serious burns Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Turn the ignition switch OFF Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately NOTE OBe sure the battery is fully charged e Turn the ignition switch to OFF e Wait until the engine cools down e Prepare a fuel hose Special Tool 57001 1607 and a measuring cylinder Special Tool Fuel Hose 57001 1607 3 122 FUEL SYSTEM Fuel Line e Remove the fuel tank bolts see Fuel Tank Removal e Open the fuel tank cap A to lower the pressure in the tank e Remove the fuel hose from the fuel pump see Fuel Tank Removal OBe sure to place a piece of cloth around the fuel outlet pipe of the fuel pump A WARNING Fuel is flammable and explosive under certain con ditions and can cause severe burns Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is dis connected fuel spills out from the hose and the pipe because of residual pressure Cover the hose connection with a piece of clean cloth to prevent fuel spillage e Connect the prepared fuel hose A to the fuel outlet pipe of the fuel pump e Secure the fuel hose w
261. ator see Radiator and Radiator Fan Removal e Clear the inner rubber cover A from the hook B of the radiator cover C Both Sides e Remove Clamp A Quick Rivets B Radiator Cover C Radiator Cover Installation e Installation is the reverse of removal 4 16 COOLING SYSTEM Thermostat Thermostat Removal e Remove Coolant Drain see Coolant Change in the Periodic Maintenance chapter Clamp Screw Loosen and Water Hose A Thermostat Housing Cover Bolts B and Clamp C Thermostat Housing Cover D Thermostat Thermostat Installation e Install the thermostat A in the housing so that the air bleeder hole B is on top e Replace the O ring A with a new one e Apply liquid gasket to the new O ring to prevent it from coming off Sealant Liquid Gasket TB1211F 92104 0004 e Install the new O ring into the thermostat housing cover e Install the clamp C as shown in the figure Tighten Torque Thermostat Housing Cover Bolts D 5 9 N m 0 60 kgf m 52 in Ib e Confirm that the thermostat is installed correctly e Install the water hose and tighten the clamp see Cable Wire and Hose Routing section in the Appendix chapter Torque Water Hose Clamp Screw 3 0 N m 0 31 kgf m 27 in Ib e Fill the radiator with coolant see Coolant Change in the Periodic Maintenance chapter Thermostat Inspection e Remove the thermostat see Thermostat Removal and inspect the thermostat valve A a
262. ator lead connector is positioned under the leads Pad Fix the fuel pump lead connector and fuel level sensor lead connector Fuel Level Sensor Lead Connector Fuel Pump Lead Connector Other than CAL and SEA B1 Models CAL and SEA B1 Models APPENDIX 17 23 Cable Wire and Hose Routing This page intentionally left blank 17 24 APPENDIX Cable Wire and Hose Routing 58099270 6 APPENDIX 17 25 Cable Wire and Hose Routing 1 gt CON 11 12 13 14 15 16 17 18 19 ABS Equipped Models Run the immobilizer equipped models Kawasaki diagnostic system connector lead and 5 Kawasaki Self diagnosis system connector lead to the backward of the seat lock and under the tool case Take care not to run the leads above the seat lock ECU Leads Run the diagnostic system connector leads between the tool case and frame Take care not to run the leads above the rear frame ABS Kawasaki Self diagnosis System Connector Fix the immobilizer equipped models Kawasaki diagnostic system connector and ABS Kawasaki Self diagnosis system connector to the connector holder as shown in the figure Make sure that the connectors are securely installed to the connector holder Immobilizer Equipped Models Kawasaki Diagnostic System Connector Tail Brake Light Lead Connector Run the tail brake light lead to the upside of the ECU rubber protector Take care not
263. ator light LED go off No Count the number of times the yellow ABS indicator Ask the rider if the problem light LED blinks in the self diagnosis mode to find the happens again service code 01146458 Self diagnosis Outline When the indicator light has blinked or come on the ABS hydraulic unit memorizes and stores the service code for the service person to troubleshoot easily The service code memory is powered directly by the battery and cannot be canceled by the ignition switch The ABS hydraulic unit can memorize up to all service codes Further service codes are memorized after erasing the preceding all service codes If there is no fault the yellow ABS indicator light LED lights indicating that The ABS is normal Self diagnosis Procedures OWhen a problem occurs with the ABS system the yellow ABS indicator light LED A lights NOTE OUse fully charged battery when conducting self diagnosis Otherwise the light blinks very slowly or doesn t blink OThe motorcycle is stopped SEE OKeep the self diagnosis terminal grounded during self 6L14615BS1 0 diagnosis with an auxiliary lead BRAKES 12 41 Anti Lock Brake System Equipped Models e Remove the seat see Seat Removal in the Frame chap ter e Ground the self diagnosis terminal A Gray to the frame ground using a suitable lead e Turn the ignition switch to ON OCount the blinks of the light to read the service co
264. ause an accident and injury Remove Lower Rear Shock Absorber Nut and Bolt A Upper Tie Rod Nut and Bolt B e Remove the upper rear shock absorber nut and bolt A e Remove the shock absorber downward Rear Shock Absorber Installation e Replace the following nuts with new ones Rear Shock Absorber Nuts Tie Rod Nut Upper e Tighten Torque Rear Shock Absorber Nuts 34 N m 3 5 kgf m 25 ft Ib Tie Rod Nut Upper 59 N m 6 0 kgf m 44 ft lb Rear Shock Absorber Inspection e Remove the rear shock absorber see Rear Shock Ab sorber Removal e Visually inspect the following items Smooth Stroke Oil Leakage Crack or Dent x lf there is any damage to the rear shock absorber replace it e Visually inspect the rubber bushing x lf it show any signs of damage replace it 13 30 SUSPENSION Rear Shock Absorber Rear Shock Absorber Scrapping A WARNING Pressurized nitrogen may explode when heated The rear shock contains nitrogen gas To avoid an explosion do not incinerate the shock body without first releasing the nitrogen and removing the shraeder valve e Remove the rear shock absorber see Rear Shock Ab sorber Removal e Drill the hole A of the reservoir tank using about 2 mm 0 08 in drillbit A WARNING GM05238BS1 Pressurized gas can cause injury Do not point the drill toward your face or body SUSPENSION 13 31 Swingarm Swingarm Removal e Re
265. brication e Refer to the Chassis Parts Lubrication in the Periodic Maintenance chapter Throttle Body Assy FUEL SYSTEM 3 133 Idle Speed Inspection e Refer to the Idle Speed Inspection in the Periodic Main tenance chapter Throttle Bore Cleaning e Check the throttle bore for cleanliness as follows ORemove the throttle body assy see Throttle Body Assy Removal OCheck the main throttle valves A and throttle bores B for carbon deposits by opening the main throttle valves If any carbon accumulates wipe the carbon off the throt tle bores around the throttle bores and the throttle valves using a cotton pad penetrated with a high flash point sol vent Synchronization Inspection Adjustment e Refer to the Engine Vacuum Synchronization Inspection in the Periodic Maintenance chapter Throttle Body Assy Removal A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions creating the potential for serious burns Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Turn the ignition switch OFF Disconnect the battery terminal To avoid fuel spills draw it from the tank when the engine is cold Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately e Remove Middle Fairings see Middle Fairing Removal in the Frame chapter Idle Spee
266. ce the problem part Clutch Hose and Pipe Damage and Installation Condition Inspection e Inspect the clutch hoses and fittings for deterioration cracks corrosion and signs of leakage OThe high pressure inside the clutch line can cause fluid to leak A or the hose to burst if the line is not properly maintained Bend and twist the rubber hose while exam ining it Replace it if any fraying cracks B or bulges C are no ticed e Check that the hoses are securely connected and banjo bolts are tightened correctly Torque Clutch Hose Banjo Bolts 25 2 5 kgf m 18 ft Ib e Inspect the clutch hose routing If any clutch hose routing is incorrect run the hoses ac cording to Cable Wire and Hose Routing section in the Appendix chapter Replace the hose if it has been sharply bent or kinked 6508004851 C 2 28 PERIODIC MAINTENANCE Periodic Maintenance Procedures Wheels Tires Tire 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 Air Pressure when Cold Front Up to 175 kg 385 Ib 290 kPa 2 9 kgf cm 42 psi Rear Up to 175 kg 385 Ib 290 kPa 2 9 kgf cm 42 psi Wheel Tire Dam
267. ch side of the clutch hose fittings Replace them with new ones when installing e Tighten Torque Clutch Hose Banjo Bolts 25 2 5 kgf m 18 ft lb e When installing the hose avoid sharp bending kinking flatting or twisting and Run the hoses according to Cable Wire and Hose Routing section in the Appendix chapter e Fill the clutch line after installing the clutch hose see Clutch Fluid Change PERIODIC MAINTENANCE 2 55 Periodic Maintenance Procedures Clutch Fluid Change e Level the clutch fluid reservoir and remove the reservoir cap e Free the lower fairing see Clutch Slave Cylinder Removal in the Clutch chapter Remove the rubber cap from the bleed valve on the clutch slave cylinder e Attach a clear plastic hose A to the bleed valve and run the other end of the hose into a container e Fill the reservoir with fresh fluid Change the clutch fluid as follows 1 Open B the bleed valve using a wrench 2 Pump the clutch lever and hold C it 3 Close D the bleed valve 4 Release E the clutch lever ORepeat this operation until fresh fluid comes out from the plastic hose or the color of the fluid changes OCheck the fluid level in the reservoir often replenishing it as necessary NOTE Olf the fluid in the reservoir runs completely out any time during fluid changing the bleeding operation must be done over again from the beginning since air will have entered the line
268. cket Remowval tte er e ate i ee ent te RR a De nir Rp c v rue metr rr n ane Hear Sprocket Stall AMO oce teed Coupling Installaatio M Coupling Bearing Remoyales tieu de nas Coupling Bearing Installation gt Coupling Bearing Lubrication Coupling Damper Inspections ipeo Eos pA ERU uae ewe eh es sprocket Wear Inspector yea ede Rear Sprocket Warp Inspection ete ed n tune exo turp erre 11 14 11 2 FINAL DRIVE Exploded View FINAL DRIVE 11 3 Exploded View E Chain Guide Bolt 106 in lb Chain Guide Bolts Engine Sprocket Nut Rear Axle Nut Rear Sprocket Nuts Stud Bolts 14 7 1 5 10 8 L 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 Im L MO 11 4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain Drive Chain Slack Drive Chain Wear 20 link Length Standard Chain Make Type Link Sprockets Rear Sprocket Warp 25 30 mm 1 0 1 2 in 317 5 318 2 mm 12 50 12 53 in 319 mm
269. cking agent to only one clutch cover bolt A shown in figure Torque Clutch Cover Bolts 9 8 Nm 1 0 kgf m 87 in Ib Olf the oil level inspection window A is removed apply soap and water solution to the oil level inspection window and press the oil level inspection window so that its pro jection B faces the inside using lubricant GF11029BS1 C 6 14 Clutch Clutch Removal e Remove Right Middle Fairing see Middle Fairing Removal in the Frame chapter Clutch Cover see Clutch Cover Removal Clutch Spring Bolts A with Spring Holder Clutch Springs Clutch Spring Plate B with Thrust Bearing Pusher C and Washer e Remove Friction Plates and Steel Plates e Hold the sub clutch hub A steady with the clutch holder B and remove the nut C Special Tool Clutch Holder 57001 1243 Remove Torque Limiter Springs Toothed Washer A Sub Clutch Hub B Clutch Hub C Remove Spacer A e Using the two 4 mm 0 16 in bolts A pull out the sleeve B needle bearing C and clutch housing D e Remove the thrust washer GF06010781 Clutch CLUTCH 6 15 Clutch Installation e Install the thrust washer A by facing its chamfered side B towards the crankcase e Engage the clutch housing gear A and oil pump drive gear B with the crankshaft primary gear C and oil pump gear D e Install Needle Bearing Sleeve Spacer A OApply engine o
270. 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 Troubleshooting Guide 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 Engine mounting portions 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 Balancer gear worn or chipped Balancer shaft position maladjusted Balancer bearing worn Balancer rubber damper damaged Abnormal Drive Train Noise Clutch noise Clutch damper weak or damaged Clutch housing friction plate clearance ex cessive Clutch housing gear worn Wrong installation of outside friction plate Transmission noise Bearings worn Transmission gear worn or chipped Metal chips jammed in gear teeth Engine oil insufficient Drive line noise Drive chain adjusted improperly Drive chain worn Rear and or engine sprocket worn Chain lubrication insuffici
271. comes out from the plastic hose or the color of the fluid changes 1 Open the bleed valve A 2 Apply the brake and hold it B 3 Close the bleed valve C 4 Release the brake D NOTE OThe fluid level must be checked often during the chang ing operation and replenished with fresh brake fluid If the fluid in the reservoir runs out any time during the changing operation the brakes will need to be bled since air will have entered the brake line OFront Brake Repeat the above steps for the other caliper e Remove the clear plastic hose e Install the diaphragm and reservoir cap PERIODIC MAINTENANCE 2 63 Periodic Maintenance Procedures e Follow the procedure below to install the front brake fluid reservoir cap correctly OFirst tighten the front rear brake fluid reservoir cap B clockwise C by hand until slight resistance is felt indi cating 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 Install the stopper on the reservoir Tighten Torque Front Brake Reservoir Cap Stopper Screw 1 2 N m 0 12 kgf m 11 in Ib Tighten the bleed valve and install the rubber cap Torque Bleed Valves 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 necessary bleed the air from the lines Master Cylinder Rubber
272. correct bearing inserts are installed Apply molybdenum disulfide oil solution to the crankshaft main bearing inserts e Follow the next procedure to insert the thrust washers on the upper crankcase half after installing connecting rod on the crankshaft see Connecting Rod Installation Apply molybdenum disulfide grease to the outside sur faces A of both thrust washers B e Slide one thrust washer into the upper crankcase half Move the crankshaft to the left or right and then slide the other washer into the upper crankcase half NOTE OSlide the thrust washers so that the oil grooves D face outward Make sure that the red painted edges E are positioned as shown in the figure Front F CRANKSHAFT TRANSMISSION 9 17 Crankshaft and Connecting Rods Connecting Rod Removal Split the crankcase see Crankcase Splitting e Remove Connecting Rod Nuts A 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 piston see Piston Removal Discard the connecting rod bolts and nuts To pre vent damage to the crankpin surfaces do not al low the connecting rod bolts to bump against the crankpins Connecting Rod Installation NOTICE To minimize vibration the connecting rods should have the same weight mark Big End Cap A Connecting Rod B Weight
273. correctly see Cable Wire and Hose Routing section in the Appendix chapter Stator Coil Removal e Remove Alternator Cover see Alternator Cover Removal Alternator Lead Holding Plate Bolts A and Plate B Alternator Lead Grommet C Stator Coil Bolts D e Remove the stator coil E from the alternator cover Charging System ELECTRICAL SYSTEM 16 39 Stator Coil Installation Tighten the stator coil bolts to the specified torque Torque Stator Coil Bolts 12 N m 1 2 kgf m 106 in Ib e Using a high flash point solvent clean off any oil or dirt that may be on the liquid gasket coating area Dry them with a clean cloth Apply liquid gasket to the circumference of the alternator lead grommet and fit the grommet into the notch of the cover securely Sealant Liquid Gasket TB1211F 92104 0004 Secure the alternator lead with a holding plate A and apply a non permanent locking agent to the threads of the plate bolts B and tighten them Torque Alternator Lead Holding Plate Bolts 7 8 N m 0 80 kgf m 69 in Ib e Install the alternator cover see Alternator Cover Installa tion Alternator Rotor Removal e Remove the alternator cover see Alternator Cover Re moval Hold the alternator rotor steady with the rotor holder A and remove the rotor bolt B and washer Special Tools Grip C 57001 1591 Rotor Holder 57001 1672 Stopper D 57001 1679 e Using the flywheel puller A
274. cting Rod In stallation Cylinder Wear Upper Crankcase Inspection Since there is a difference in cylinder wear upper crankcase in different directions take a side to side and a front to back measurement at each of the two locations total of four measurements shown in the figure xIf any of the cylinder inside diameter measurements ex ceeds the service limit replace the crankcase 10 mm 0 39 in A 60 mm 2 36 in B Cylinder Upper Crankcase Inside Diameter Standard 83 994 84 006 mm 3 3068 3 3073 in Service Limit 84 10 mm 3 3110 in GE16063BS1 Piston Wear Inspection e Measure the outside diameter A of each piston 10 mm 0 39 in B up from the bottom of the piston at a right angle to the direction of the piston pin x If the measurement is under service limit replace the pis ton Piston Diameter Standard 83 959 83 974 mm 3 3055 3 3061 in Service Limit 83 81 mm 3 2996 in aE16280881 Piston Ring Piston Ring Groove Wear Inspection e Check for uneven groove wear by inspecting the ring seat ing The rings should fit perfectly parallel to groove surfaces If not replace the piston and all the piston rings e With the piston rings in their grooves make several mea surements with a thickness gauge A to determine piston ring groove clearance Piston Ring Groove Clearance 8616287881 0 Standard Top 0 03
275. ction Check 2 1 Battery Voltage Inspection e Turn the ignition switch to ON Select the battery voltage indication A in the ordinary indication OThe voltage corresponding to a present battery condition is displayed OThe voltage range is 11 16 V x If the display is malfunction check the following parts Battery see Charging Condition Inspection Wiring see Meter Unit Circuit x the wiring is good replace the meter unit Check 2 2 Gear Position Indication Inspection e Turn the ignition switch to ON OThe green neutral indicator light LED A goes on when the transmission gear is neutral position Meter Gauge Indicator Unit ELECTRICAL SYSTEM 16 83 e Set the low gear position and check that the display changes to 1 mark A and the neutral indicator light LED B goes off e Using the suitable stand raise the rear wheel off the ground e Rotate the rear wheel by hand and change the gear po sition Check that the display corresponding to each gear posi tion 1 2 3 4 5 or 6 appears x lf the display function does not work check the following parts Gear Position Switch see Gear Position Switch Inspec tion Wiring see Meter Unit Circuit the above parts is good replace the meter unit and or ECU Check 2 3 Outside Temperature Inspection e Disconnect the outside temperature sensor lead connec tor A see Outside Temperature Sensor Removal Main Harness B
276. ction e Using the x 1 hand tester range measure the resis tance as shown in the figure Terminal Bolt and Positive Brush A Right hand End Cover and Negative Brush B Special Tool Hand Tester 57001 1394 If there is not close to zero ohms the brush lead has open Replace the brush holder assembly Right hand End Cover Assembly Inspection e Using the highest hand tester range measure the resis tance as shown in the figure Terminal and Right hand End Cover A Special Tool Hand Tester 57001 1394 x If there is any reading the right hand end cover assembly have a short Replace the right hand end cover assembly Starter Relay Inspection e Remove the battery see Battery Removal e Disconnectthe starter motor cable A and battery positive cable B from the starter relay e Disconnect the connector C e Pull out the starter relay from the damper e Connect the hand tester A and 12 V battery B to the starter relay C as shown in the figure Special Tool Hand Tester 57001 1394 x lf the relay does not work as specified the relay is defec tive Replace the relay Testing Relay Tester Range 1 range Criteria When battery is connected 0 Q When battery is disconnected gt e Tighten Torque Starter Relay Cable Terminal Bolts 3 9 N m 0 40 kgf m 35 in Ib e Install the removed parts see appropriate chapters 62118870 P GP11202BS1 ELECTRICAL SYSTE
277. ctions in side of the switch be sure that the switch body does not turn during adjustment x If it does not go on inspect or replace the following items Battery see Charging Condition Inspection in the Elec trical System chapter Brake Light see Tail Brake Light Removal in the Electri cal System chapter Main Fuse 30 A and Brake Light Horn Fuse 10 A see Fuse Inspection 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 Suspension Front Forks Rear Shock Absorber Operation Inspection e Pump the forks down and up A 4 or 5 times and inspect the smooth stroke x If the forks do not smoothly or noise is found inspect the fork oil level or fork clamps see Front Fork Oil Change in the Suspension chapter e Pump the seat down and up A 4 or 5 times and inspect the smooth stroke x If the shock absorber does not smoothly stroke or noise is found inspect the oil leak see Rear Shock Absorber Oil Leak Inspection 2 38 PERIODIC MAINTENANCE Periodic Maintenance Procedures 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
278. d Rear Wheel Rotation Sensor Signal Unused Unused ABS Indicator Light LED Unused Unused Ground Ground to Motor NI Anti Lock Brake System Equipped Models BRAKES 12 33 ABS Servicing Precautions There are a number of important precautions that should be followed servicing the ABS system OThis ABS system is designed to be used with a 12 V sealed battery as its power source Do not use any other battery except for a 12 V sealed battery as a power source ODo not reverse the battery cable connections This will damage the ABS hydraulic unit OTo prevent damage to the ABS parts do not disconnect the battery cables or any other electrical connections when the ignition switch is ON or while the engine is running OTake care not to short the leads that are directly con nected to the battery positive terminal to the chassis ground ODo not turn the ignition switch ON while any of the ABS electrical connectors are disconnected The ABS hy draulic unit memorizes service codes ODo not spray water on the electrical parts ABS parts con nectors leads and wiring Olf a transceiver is installed on the motorcycle make sure that the operation of the ABS system is not influenced by electric wave radiated from the antenna Locate the antenna as far as possible away from the ABS hydraulic unit OWhenever the ABS elec
279. d or miss ing Air duct holder loose Water or foreign matter in fuel Throttle body assy holder loose Fuel to injector insufficient Fuel tank air vent obstructed Fuel line clogged APPENDIX 17 55 Fuel pump trouble Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Knocking Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect ECU trouble Miscellaneous Throttle valve wont fully open Brake dragging Clutch slipping Engine overheating Engine oil level too high Engine oil viscosity too high Drive train trouble Camshaft cam worn Air suction valve trouble Air switching valve trouble Catalytic converter melt down due to muffler overheating KLEEN Overheating Firing incorrect Spark plug dirty broken or maladjusted Spark plug incorrect ECU trouble Muffler overheating For KLEEN do not run the engine even if with only one cylinder misfiring or poor running Request the nearest service fa cility to correct it For KLEEN do not push start with a dead battery Connect another full charged battery with jumper cables and start the engine using the electric
280. d Control Valve Actuator see Idle Speed Con trol Valve Actuator Removal Quick Rivet A OPush the central pin of the quick rivet e Clear the left inner rubber cover B from the hooks C of the radiator cover D e Remove Bolts A Subframe Bolts B and Washers 3 134 FUEL SYSTEM Throttle Body Assy e Disconnect the throttle body subharness connector A Remove the connector from the connector bracket Olnsert the standard tip screwdriver into the connector stopper portion from the right side of motorcycle e For CAL and SEA B1 models pull off the vacuum hose from the throttle body assy e Remove Bolt A Bracket B e Disconnect the crankshaft sensor lead connector 62176653 e Loosen the duct clamp bolts on both sides e Remove Fuel Tank see Fuel Tank Removal Heat Insulation Cover A FUEL SYSTEM DFI 3 135 Throttle Body Assy e Remove Screw A Intake Air Temperature Sensor B Bolts C Air Cleaner Caps D ODo not disconnect the intake air temperature sensor lead connector e Remove the duct clamps from the ducts A and pull out the ducts upward ORemove the grommets A as necessary e Remove the throttle case A to make a throttle cable slack e Remove Clamp A Throttle Cable Lower Ends B 3 136 FUEL SYSTEM Throttle Body Assy Loosen the throttle body assy holder clamp bolt A on both sides
281. d Engine Oil Type API SG SH SJ SL or SM with JASO MA MA1 or MA2 Viscosity SAE 10W 40 Capacity 3 8 4 0 US qt when filter is not removed 4 2 L 4 4 US qt when filter is removed 4 6 L 4 9 US qt when engine is completely dry NOTE ODo not add any chemical additive to the oil Oils fulfilling the above requirements are fully formulated and provide adequate lubrication for both the engine and the clutch OAlthough 10W 40 engine oil is the recommended oil for most conditions the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area e Replace the O ring of the oil filler plug with a new one e Apply engine oil to the new O ring e Install the oil filler plug Torque Oil Filler Plug Hand tighten e Check the oil level see Oil Level Inspection in the Engine Lubrication System chapter Oil Filter Replacement e Drain the engine oil see Engine Oil Change e Remove the left lower fairing see Lower Fairing Removal in the Frame chapter Remove the oil filter A with the oil filter wrench Special Tool Oil Filter Wrench 57001 1249 SAE 20W 50 SAE 20W 40 SAE 10W 50 0 SAE 10W 30 10 20 30 40 0 1 50 68 86 104 F 0509010851 PERIODIC MAINTENANCE 2 59 Periodic Maintenance Procedures e Replace the filter with a new one e Apply grease to the gasket A before installation Tighte
282. d Hose Rout ing section in the Appendix chapter OTo prevent corrosion and deposits in the fuel system do not add to fuel any fuel antifreeze chemicals 6617036851 3 30 FUEL SYSTEM DFI Servicing Precautions Olf the motorcycle is not properly handled the high pres sure inside the fuel line can cause fuel to leak or the hose to burst Check the fuel hose A see Fuel Hose Inspec tion fuel leak damage installation condition in the Peri odic Maintenance chapter Replace the fuel hose if any fraying cracks or bulges are noticed OTo maintain the correct fuel air mixture F A there must be no intake air leaks in the DFI system Be sure to install the oil filler plug A after filling the engine oil Torque Oil Filler Plug Hand tighten Troubleshooting the DFI System FUEL SYSTEM DFI 3 31 Outline When a problem occurs with DFI system the yellow en gine warning indicator light LED A goes on to alert the rider OWhen a problem occurs with KTRC system the yellow KTRC warning indicator light LED B goes on the KTRC and POWER mode symbols C blinking on the LCD For models equipped with an immobilizer system the red warning indicator light LED A blinks and immobi lizer warning symbol B is displayed on the LCD when a problem occurs in the system AVERAGE 61041338 E 90 2 amp on 123456 z Py
283. d Models Front Wheel Rotation Sensor Wiring Inspection Service Code 43 Disconnect the front wheel rotation sensor lead connector A see Front Wheel Rotation Sensor Removal e Disconnect the ABS hydraulic unit lead connector see ABS Hydraulic Unit Removal e Check the wiring continuity of the W BK lead and BK W lead Front Wheel Rotation Sensor Lead Connector A ABS Hydraulic Unit Lead Connector B W BK Lead Terminals C BK W Lead terminals D x If the wiring is open replace or repair the harness see ABS System Circuit xIf the wiring is good go to next step e Perform the Pre Diagnosis Inspection 1 and 2 see In quiries to Rider x If this service code appears even if all checks are ended replace the front wheel rotation sensor see Front Wheel Rotation Sensor Removal e Still when it is not good replace the ABS hydraulic unit x If the service code does not appear the ABS system nor mal temporary failure Rear Wheel Rotation Sensor Signal Abnormal Service Code 44 e Measure the air gap between the rear wheel rotation sen sor and sensor rotor Thickness Gauge A Air Gap Standard 0 7 0 9 mm 0 028 0 035 in x the measurement is not the standard check each part for deformation and looseness and correct accordingly x lf the measurement is the standard go to next step e Check that there is iron or other magnetic deposits be tween the sensor and sensor rotor and the sensor rotor slot
284. d Ratio Freezing Point Total Amount Engine Top End Valve Clearance Exhaust Inlet Clutch Clutch Fluid Grade Clutch Lever Free Play Engine Lubrication System Engine Oil Type Viscosity Capacity Wheels Tires Tread Depth Front Rear Permanent type of antifreeze Green Soft water 50 Coolant 50 35 31 F 3 2 L 3 4 US qt 0 22 0 27 mm 0 0087 0 0106 in 0 15 0 20 mm 0 0059 0 0079 in DOT4 Non adjustable API SG SH SJ SL or SM with JASO MA MA1 or MA2 SAE 10W 40 3 8 L 4 0 US qt when filter is not removed 4 2 L 4 4 US qt when filter is removed 4 6 L 4 9 US qt when engine is completely dry Between upper and lower level lines Wait 2 3 minutes after idling or running 4 2 mm 0 17 in 1 mm 0 04 in AT CH DE 1 6 mm 0 06 in Up to 130 km h 80 mph 2 mm 0 08 in Over 130 km h 80 mph 3 mm 0 12 in 5 3 mm 0 21 in 2 14 PERIODIC MAINTENANCE Specifications Drive Chain Slack Drive Chain Wear 20 link Length Standard Chain Make Type Link Brakes Brake Fluid Grade Front Rear Brake Light Timing Front Rear Electrical System Spark Plug Type Gap Brake Pad Lining Thickness 25 30 mm 1 0 1 2 in 317 5 318 2 mm 12 50 12 53 in ENUMA EK530RMX 3D 118 links DOT4 4 0 mm 0 16 in 5 0 mm 0 20 in Pulled ON ON after about 10 mm 0 39 in of pedal travel NGK CR9EIA 9 0
285. d Tester 57001 1394 ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector Intake Air Pressure Sensor 42 Connector B G W lead ECU terminal 11 C G lead ECU terminal 13 D xIf the wiring is good check the sensor for various vac uum see Intake Air Pressure Sensor 1 Output Voltage Inspection GT04087BS1 H 177204 LLL GT04088BS1 FUEL SYSTEM 3 71 Intake Air Pressure Sensor 2 Service Code 16 Intake Air Pressure Sensor 2 Circuit G W 6T04102BW2 C 1 ECU 2 Intake Air Pressure Sensor 1 3 Intake Air Pressure Sensor 2 4 Joint Connector 5 Joint Connector J 3 72 FUEL SYSTEM DFI Crankshaft Sensor Service Code 21 The crankshaft sensor has no power source and when the engine stops the crankshaft sensor generates no sig nals Crankshaft Sensor Removal Installation e Refer to the Crankshaft Sensor Removal Installation in the Electrical System chapter Crankshaft Sensor Resistance Inspection e Refer to the Crankshaft Sensor Inspection in the Electrical System chapter x lf the reading is within the standard check the peak volt age see Crankshaft Sensor Peak Voltage Inspection Crankshaft Sensor Peak Voltage Inspection e Refer to the Crankshaft Sensor Peak Voltage Inspection in the Electrical System chapter
286. d actuator connectors Wiring Continuity Inspection ECU Connector A Subthrottle Valve Actuator Connector B G O lead ECU terminal 15 C P BL lead ECU terminal 14 D Y R lead ECU terminal 1 E BK lead ECU terminal 2 F x If the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see ECU Removal Installation Subthrottle Valve Actuator Circuit 177004 LLL GT04097BS1 Y Y R Y R K BI BK BL GTO41158BW2 C 1 ECU 2 Subthrottle Valve Actuator 3 102 FUEL SYSTEM Air Switching Valve Service Code 64 Air Switching Valve Removal installation e Refer to the Air Switching Valve Removal Installation in the Engine Top End chapter Air Switching Valve Inspection e Refer to the Air Switching Valve Unit Test in the Electrical System chapter lf the air switching valve is normal check the wiring for continuity see Air Switching Valve Circuit Special Tool Hand Tester 57001 1394 x lf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation Air Switching Valve Circuit D GTO41168W2 C 1 ECU 9 Relay Box 2 Fra
287. d as shown in the figure Put the rear right turn signal light lead connector under the rear frame as shown in the figure 17 30 APPENDIX Cable Wire and Hose Routing 68809862844 C Front Grommet About 41 mm 1 61 in Insert the air switching valve hose into the frame until while painted mark on it is hidden a half Air Switching Valve Hose Breather Cover Clamps Breather Hose Align the white painted mark with the end of the plate APPENDIX 17 31 Cable Wire and Hose Routing GER m 4 R ear IL ps E d i C EUN 9 S ES 5 AN Sr He We A Nid me m IAEA AN E 97 die Wee 6809922013 C 1 White Mark 2 Idle Speed Control Valve Actuator 3 Yellow Mark 17 32 APPENDIX Cable Wire and Hose Routing a al rin aim 27 fo a NI 08809863045 C APPENDIX 17 33 Cable Wire and Hose Routing Stick Coil Lead Run the air switching valve lead under the stick coil lead Run the air switching valve lead which is connected to the water temperature sensor lead be tween the throttle body 3 and 4 Heat Insulation Rubber Plate For Air Suction Valve Cover and Stick Coil Insert the tab into the slot
288. d in the correct position Tighten the connecting rod big end nuts to the specified torque see Connecting Rod Installation NOTE ODo not move the connecting rod and crankshaft during clearance measurement e Remove the connecting rod big end again measure each clearance between the bearing insert and crankpin A us ing plastigage NOTICE After measurement replace the connecting rod bolts and nuts Connecting Rod Big End Bearing Insert Crankpin Clearance Standard 0 048 0 086 mm 0 0019 0 0034 in Service Limit 0 12 mm 0 0047 in x lf the clearance is within the standard no bearing replace ment is required the clearance is between 0 087 mm 0 0034 in and the service limit 0 12 mm 0 0047 in replace the bear ing inserts A with inserts painted blue B Check in sert crankpin clearance with the plastigage The clear ance may exceed the standard slightly but it must not be less than the minimum in order to avoid bearing seizure x lf the clearance exceeds the service limit measure the diameter of the crankpins Crankpin Diameter Standard 37 984 38 000 mm 1 4954 1 4961 in Service Limit 37 97 mm 1 4949 in If any crankpin has worn past the service limit replace the crankshaft with a new one x If the measured crankpin diameters A are not less than the service limit but do not coincide with the original di ameter markings B on the crankshaft make new marks on
289. d rust inhibitor chemicals for aluminum engines and radiators Green Soft water 50 coolant 50 35 31 F 3 2 L 3 4 US qt reserve tank full level including radiator and engine 93 123 kPa 0 95 1 25 kgf cm 13 18 psi 58 62 C 136 144 F 8 mm 0 31 in or more at 75 C 167 COOLING SYSTEM 4 7 Sealant Liquid Gasket TB1211F 92104 0004 879200045 4 8 COOLING SYSTEM Coolant Coolant Deterioration Inspection e Visually inspect the coolant in the reserve tank x lf 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 the coolant gives off an abnormal smell check for cooling system leak It may be caused by exhaust gas leaking into the cooling system Coolant Level Inspection e Refer to the Coolant Level Inspection in the Periodic Main tenance chapter Coolant Draining e Refer to the Coolant Change in the Periodic Maintenance chapter Coolant Filling e Refer to the Coolant Change in the Periodic Maintenance chapter Pressure Testing Remove the right middle fairing see Middle Fairing Re moval in the Frame chapter Remove the radiator cap cover and radiator cap and in stall the cooling system pressure tester A on the filler neck NOTE OWet the cap sealing surfaces with water or coolant to prevent
290. d 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 2011 Kawasaki Heavy Industries Ltd First Edition 0 Sep 26 2011 LIST ABBREVIATIONS ABDC AC Ah BBDC BDC BTDC cmHg cu in DC DFI ECU AT AU BR CA CAL CH DE EUR ampere s after bottom dead center alternating current ampere hour after top dead center before bottom dead center bottom dead center before top dead center degree s Celsius centimeters of mercury Cubic inch s direct current Digital Fuel Injection Electronic Control Unit farad s degree s Fahrenheit foot feet gram s gallon s hour s horsepower s inch s Idle Speed Control KDS km h L Ib LCD LED min mph OZ Pa PS psi qt rom TDC TIR V W Q Kawasaki Diagnostic System kilometers per hour liter s pound s Liquid Crystal Display Light Emitting Diode meter s minute s miles per hour newton s ounce s pascal s horsepower pound s per square
291. ddle Air Intake Duct Removal e Remove Upper Fairing see Upper Fairing Removal in the Frame chapter Clamp A Open the clamps B e Remove Outside Temperature Sensor A see Outside Temper ature Sensor Removal in the Electrical System chapter Clamp Open the clamps C e Remove Front Air Intake Duct Mounting Bolt A Both Sides Middle Air Intake Duct Mounting Bolt B Both Sides Front Air Intake Duct C with Rubber Seal D e Loosen the clamp bolt E on both sides e Pull off the left and right middle air intake ducts F to forward Front and Middle Air Intake Duct Installation NOTE OThe left middle air intake duct has L mark A and the right middle air intake duct has a R mark e Insert the middle air intake duct A into the rear air intake duct until the line B align with the duct end C of rear air intake duct D e Tighten the middle air intake duct mounting bolts FUEL SYSTEM 3 145 Air Line e Install the air intake duct clamp bolts in the direction as shown in the figure Bolt Heads A Upper Side B Left Clamp C Right Clamp D About 30 E Rear View F e Tighten the clamp bolts e When installing the rubber seal A note the following Olnstall the rubber seal so that the hollow side B faces forward Front Air Intake Duct C Front D e Install the front air intake duct A together with the rubber seal B and tighten the fron
292. de Keep the auxiliary lead ground until you finish reading the service code Service Code Clearing Procedures Start the service code erase mode with the following pro cedure OThe erase mode starts when the ABS self diagnosis ter minal is disconnected from the frame ground after starting the self diagnosis mode OThe service code can be erased by grounding and un grounding each time for at least one second the ABS self diagnosis terminal three times or more within about 12 5 seconds after starting the erase mode OThe yellow ABS indicator light LED remains lit during the erase mode erasing the yellow ABS indicator light LED blinks and lights OOnce erasing is finished enter the self diagnosis mode again to confirm that the service codes have been erased If the ABS has been reset and all codes have been erased the yellow ABS indicator light LED lights 12 42 5 Anti Lock Brake System Equipped Models Erasing of Service Gode Permit of Service Code Erase End of Service Code Erase 0 Yellow ABS ON 1 Indicator Light LED t 1 1 1 Lf iStart lof 0 45 0 45 0 48 signal to inform of the Erase erase completion pereo ABS Self of service code Open diagnosis Terminal Ground 18 or more OFF 1 1 LJ 1
293. ded View Balancer Shaft Clamp Bolts 1 0 87 in lb 2 Balancer Shaft Clamp Lever Bolts 3 Shift Drum Cam Holder Bolt 12 1 2 106 B L 4 Shift Shaft Return Spring Pin 29 3 0 21 L 5 Gear Position Switch Screws 2 9 0 30 26 in lb L 6 Gear Positioning Lever Bolt 12 1 2 106 in lb 7 Torque Limiter Bolt 25 2 5 18 L 8 Starter Clutch Shaft Plate Bolt 9 8 1 0 87 in lb L 9 Starter Clutch Shaft Bolt 9 8 1 0 87 in lb L 10 Front Balancer 11 Rear Balancer EO Apply engine oil G Apply grease L Apply a non permanent locking agent M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts WL Apply soap and water solution or rubber lubricant Specifications 9 6 CRANKSHAFT TRANSMISSION Item Standard Service Limit Crankcase Crankshaft Connecting Rods Connecting Rod Bend ses TIR 0 2 100 mm 0 008 3 94 in Connecting Rod Twist TIR 0 2 100 mm 0 008 3 94 in Connecting Rod Big End Side Clearance 0 13 0 38 mm 0 58 mm 0 0051 0 0150 in 0 023 in Connecting Rod Big End Bearing 0 048 0 086 mm 0 12 mm Insert Crankpin Clearance 0 0019 0 0034 0 0047 in Crankpin Diameter 37 984 38 000 mm 37 97 mm 1 4954 1 4961 in 1 4949 in Marking None 37 984 37 992 mm 1 4954 1 4957 in O 37 993 38 000 mm 1 4958 1 4961
294. diagnosis inspection 1 2 Conduct self diagnosis Check by other than self diagnosis Check by self diagnosis If harness or connector is faulty If ABS part is faulty Repair or replace Check ABS parts NG Final inspection OK End GLI4011B 12 38 5 Anti Lock Brake System Equipped Models Inquiries to Rider OEach rider reacts to problems in different ways so it is important to confirm what kind of condition the rider is dissatisfied with OTry to find out exactly what problem occurs under exactly what conditions by asking the rider know ing this information may help you reproduce the problem in the shop OThe diagnosis sheet will help prevent you from overlooking any keys so always use it Sample Diagnosis Sheet Rider name Registration No license plate Year of initial registration Model Engine Frame No Date problem occurred Frequency Weather Mileage Phenomenon O Brake lever vibration or noise O Pedal vibration or noise O Yellow ABS indicator light LED blinks O Yellow ABS indicator light LED remains lit up Braking distance too long 1 Abnormal brake lever movement Abnormal pedal movement ABS not working O ABS works but yellow ABS indicator light LED doesn t light up O ABS operating too frequently Engine conditions at O At start up After starting At 5 000 r min rpm or more problem Road conditions S
295. display selects as shown in the figure x lf the display function does not work replace the meter assembly e Select the UNIT A indication e Push the SEL button check that the unit setting menu B blinks e By pushing the upper button or lower button each time check that the display changes as follows 6 KM L L 100KM MPG UK F MPG USA GP17961CN3 C 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 e Check that the unit setting menu is decided by the SEL button pushing the display function does not work replace the meter assembly UNIT A ENGAGE LAMP GP17960CS2 MP OFF ELECTRICAL SYSTEM 16 81 Meter Gauge Indicator Unit e Select the ENGAGE LAMP A indication e Push the SEL button check that the engine speed set ting menu B flashes e By pushing the upper lower button each time check that the display changes as follows OFF gt 1200 lt gt 1300 5900 6000 Do O GP17962CN3 Check that the engine speed setting menu is decided by the SEL button pushing x lf the display function does not work replace the meter assembly e Select the SHIFT LAMP A indication e Push the SEL button check that the engine speed set ting menu B bli
296. e Inspection sssesssseersssrrnrerrereesrrrrrssrrrn 3 59 Intake Air Temperature Sensor Service Code 13 3 63 Intake Air Temperature Sensor 1 3 63 Intake Air Temperature Sensor Installation pp 3 63 Intake Air Temperature Sensor Output Voltage 3 63 Intake Air Temperature Sensor Resistance 3 64 Water Temperature Sensor Service Code 14 3 66 Water Temperature Sensor Removal Installation 22 3 66 Water Temperature Sensor Output Voltage 3 66 Water Temperature Sensor Resistance 3 67 Intake Air Pressure Sensor 2 Service Code 16 sss 3 68 Intake Air Pressure Sensor 2 3 68 Intake Air Pressure Sensor 2 Installation 3 68 Intake Air Pressure Sensor 2 Input Voltage 3 69 Intake Air Pressure Sensor 2 Output Voltage 3 70 Crankshaft Sensor Service Code 21 nennen 3 72 Crankshaft Sensor RemovaWVlnstallatigm pt 3 72 Crankshaft Sensor Resistance 3 72 Crankshaft Sensor Peak Voltage
297. e Middle Fairing Removal Clamp the coolant hose A with a suitable clamper B Remove the coolant reserve tank bolts e Remove the coolant reserve tank D by pulling out the hose with water remains in the reservoir e Remove Quick Rivets A Clamp OPush the central pin of the quick rivet Clear the left inner rubber cover C from the hooks D of the radiator cover e Remove the left inner rubber cover Left Inner Rubber Cover Installation e Run the hose harness and lead correctly see Cable Wire and Hose Routing section in the Appendix chap ter Insert the hooks A of the radiator cover into the slots of the left inner rubber cover e Set the quick rivets and push the core of them e Install the coolant reservoir tank Apply a non permanent locking agent to the threads of the coolant reserve tank bolts and tighten them e Install the removed parts see appropriate chapters Right Inner Rubber Cover Removal e Remove Right Middle Fairing see Middle Fairing Removal Quick Rivets A OPush the central pin of the quick rivet e Clear the right inner rubber cover B from the hooks C of the radiator cover e Clean the right inner rubber cover from the hole D of the engine e Remove the right inner rubber cover 15 27 Cover Right Inner Rubber Cover Installation e Run the hose harness and lead correctly see Cable Wire and Hose Routing section in the Append
298. e Relay Circuit Inspection in the Electrical System chapter x If the fuel pump relay is normal check the ECU for its ground and power supply see ECU Power Supply In spection x If the ground and power supply are good replace the ECU see ECU Removal Installation x lf there is still no battery voltage check the fuel pump re lay see Relay Circuit Inspection in the Electrical System chapter x f the fuel pump relay is normal check the wiring for con tinuity see wiring diagram in this section Special Tool Hand Tester 57001 1394 x If the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see ECU Removal Installation lf the reading is in specification but the pump does not op erate replace the fuel pump see Fuel Pump Removal In stallation Pressure Regulator Removal OThe pressure regulator A is built into the fuel pump and can not be removed C Y R R BK W BK Y th 80178681051 3 126 FUEL SYSTEM DFI Fuel Pump gt gt gt gt 00 Fuel Filter Cleaning OThe fuel filter A is built into the fuel pump can not be cleaned or checked x If the fuel filter is suspected of clogging or being damaged replace it with the fuel pump as a set Fuel Pump Circuit 6C10
299. e Run the leads correctly see Cable Wire and Hose Rout ing section in the Appendix chapter Immobilizer Amplifier Replacement e Remove the windshield see Windshield Removal in the Frame chapter e Disconnect the connector A e Remove the amplifier B from the bracket C ECU Replacement e Refer to the ECU Removal Installation in the Fuel System DFI chapter Immobilizer System Equipped Models ELECTRICAL SYSTEM 16 109 Registered Immobilizer Relational Parts Replacement Chart Failed or Lost Part Ignition Ignition e Keys Switch Amplifier ECU Ignition Key Ignition Switch e Additional Replacement Part 16 110 ELECTRICAL SYSTEM Immobilizer System Equipped Models Immobilizer System Inspection e Refer to the Immobilizer Amplifier and Blank Key Detec tion section in the Fuel System DFI chapter Immobilizer System Circuit GTO4i110BW3 C 1 ECU 10 Fuse Box 1 2 Immobilizer Kawasaki Diagnostic System 11 Ignition Fuse 15 A Connector 12 Meter Unit 3 Frame Ground 13 Red Water Temperature Battery Immobilizer 4 Battery Warning Indicator LED 5 Starter Relay 14 Joint Connector F 6 Main Fuse 30 A 15 Immobilizer Antenna 7 Frame Ground 2 16 Immobilizer Amplifier 8 Joint Connector D 17 Ignition Switch 9 Joint Connector C ELECTRICAL SYSTEM 16 111 Switches and Sensors Brake Light Timing Inspection e Refer to the Brake Ligh
300. e Sensor Connector A Discon nect Screw B Intake Air Temperature Sensor C Intake Air Temperature Sensor Installation e Be sure to install the O ring A e Install the intake air temperature sensor e Tighten the intake air temperature sensor screw Intake Air Temperature Sensor Output Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch to OFF e Remove Fuel tank see Fuel Tank Removal Heat Insulation Cover see Throttle Body Assy Removal e Disconnect the intake air temperature sensor connector and connect the measuring adapter A between these connectors as shown in the figure Main Harness B Intake Air Temperature Sensor C Special Tool Measuring Adapter 57001 1700 e Connect a digital meter D to the measuring adapter leads E 9 Intake Air Temperature Sensor Output Voltage ele Connections to Adapter Digital Meter gt R sensor R BK lead Digital Meter BK sensor lead e Measure the output voltage with the engine stopped and the connector joined e Turn the ignition switch to ON GT04081BS1 Output Voltage Standard About DC 2 25 2 50 V at 20 C 68 F NOTE OThe output voltage changes according to the intake air temperature 3 64 FUEL SYSTEM Intake Air Temperature Sensor Service Code 13 e Turn the ignition switch to OFF x lf the reading is within the standard check the ECU for its g
301. e an explosive gas mixture of hydrogen and oxygen that can cause seri ous injury and burns if ignited Keep the battery away from sparks and open flames during charging When using a battery charger connect the battery to the charger before turning on the charger This procedure prevents sparks at the battery terminals which could ignite any battery gases The electrolyte contains sulfuric acid Be careful not to have it touch your skin or eyes If touched wash it off with liberal amount of water and seek medial at 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 Charging Condition Inspection OBattery charging condition can be checked by measuring battery terminal voltage with a digital voltmeter A e Remove the battery see Battery Removal e Measure the battery terminal voltage NOTE OMeasure with a digital voltmeter which can be read one decimal place voltage x lf the reading is 12 6 V or more no refresh charge is re quired however if the read is below the specified refresh charge is required Battery Terminal Voltage Standard 12 6 V or more Terminal Voltage V A Battery Charge Rate
302. e battery NOTE OCharging the battery immediately after filling can shorten service life 2 114851 e Hm LJ LJ LJ L3 Tf 8 08012851 C 8 08010851 C ELECTRICAL SYSTEM 16 35 Battery Initial Charge e Newly activated sealed batteries require an initial charge Standard Charge 1 4 A 5 10 hours using a recommended battery charger follow the charger s instructions for newly activated sealed battery Kawasaki recommended chargers Battery Mate 150 9 OptiMate PRO 4 S PRO S PRO2 Yuasa MB 2040 2060 Christie C10122S xIf the above chargers are not available use equivalent one e Let battery sit 30 minutes after initial charge then check voltage using a voltmeter Voltage immediately after charging becomes temporarily high For accurate mea suring let the battery sit for given time NOTE OCharging rates will vary depending on how long the battery has been stored temperature and the type of charger used If voltage is not at least 12 6 V repeat charging cycle OTo ensure maximum battery life and customer satisfac tion it is recommended the battery be load tested at three times its amp hour rating for 15 seconds Re check voltage and if less than 12 6 V repeat the charging cycle and load test If still below 12 6 V the battery is defective Precautions 1 No need of topping up No topping up is necessary in this battery until it ends its l
303. e terminals of the main harness connectors are dam aged replace the main harness e Turn the ignition switch to OFF e Disconnect the ECU connectors Gray Connector A e Set the hand tester B to the x 1 O range and check the following wiring for continuity Special Tool Hand Tester 57001 1394 ECU Grounding Inspection Connections BK Y leads ECU terminal 73 or 74 Frame Ground 2 BK BL lead ECU Terminal terminal 40 Frame Ground I Engine Ground Terminal Criteria Both 0 Q If no continuity check the connectors the engine ground lead or main harness and repair or replace them if nec essary 6617211251 C FUEL SYSTEM 3 115 ECU lf the wiring is good check the power source voltage of the ECU NOTE OBe sure the battery is fully charged Connect the ECU connectors e Connect a digital meter A to the connector gray B with the needle adapter set Special Tool Needle Adapter Set 57001 1457 ECU Power Supply Inspection Connections 1 Digital Meter gt Terminal 41 W BK Digital Meter gt Frame Ground terminal Digital Meter gt Terminal 53 BR W Digital Meter gt Frame Ground terminal Digital Meter gt Terminal 54 W BK Digital Meter gt Frame Ground terminal Ignition Switch OFF Terminal 41 W BK Battery Voltage Terminal 53 BR W 0 V Terminal 54 W BK Battery Voltage Ignition Switch ON
304. ead connector A OConnect the hand tester as shown in the table 1 Special Tool Hand Tester 57001 1394 OStart the engine ORun it at the rpm given in the table 1 ONote the voltage readings total 3 measurements Table 1 Alternator Output Voltage Tene E Range Tester to Tester to at 4 000 rpm 250 V AC One Black Lead Another Black Lead 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 Special Tool Hand Tester 57001 1394 ONote the readings total 3 measurement Table 2 Stator Coil Resistance at 20 C 68 F Tester Connections Reading Range Tester to Tester to One Black Lead Another Black Lead 0 05 0 5 x lf there is more resistance than shown in the table or no tester reading infinity for any two leads the stator has an open lead and must be replaced Much less than this resistance means the stator is shorted and must be replaced e Using the highest resistance range of the hand tester measure the resistance between each of the black leads and chassis ground Any hand tester reading less than infinity
305. ection e Measure the output voltage at the main throttle sensor in the same way as input voltage inspection note the follow ing ODisconnect the main throttle sensor connector and con nect the setting adapter A between these connectors Special Tool Throttle Sensor Setting Adapter 57001 1538 Main Throttle Sensor Output Voltage Connections to Adapter Digital Meter gt R sensor Y W lead Digital Meter BK sensor lead GT04074BS1 1048074 P Main Throttle Sensor Service Code 11 FUEL SYSTEM DFI 3 55 Start the engine and warm it up thoroughly Check idle speed to ensure the throttle opening is correct see Idle Speed Inspection in the Periodic Maintenance chapter Idle Speed Standard 1 100 50 r min rpm e Turn the ignition switch to OFF Measure the output voltage with the engine stopped and with the connector joined e Turn the ignition switch to ON Output Voltage Standard DC 0 63 0 65 V at idle throttle opening DC 3 76 3 96 V at full throttle opening for reference NOTE the throttle confirm the output voltage will be raise OThe standard voltage refers to the value when the volt age reading at the Input Voltage Inspection shows 5 V exactly OWhen the input voltage reading shows other than 5 V derive a voltage range as follows Example In the case of a input voltage of 4 75 V 0 63 x 4 75 5 00
306. ector A lt gt Idle Speed Control Valve Actuator Connector B G R lead ECU terminal 56 C G BK lead ECU terminal 42 D G O lead ECU terminal 44 E G Y lead ECU terminal 43 F x If the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation 9704100851 Idle Speed Control Valve Actuator Circuit D 8 0 8 Y G 8K 6 G BK 6 0 6104120812 1 ECU 2 Idle Speed Control Valve Actuator FUEL SYSTEM 3 109 Purge Valve Service Code 3A CAL and SEA B1 Models Purge Valve Removal Installation e Remove Right Middle Fairing see Middle Fairing Removal in the Frame chapter Purge Valve Connector A Disconnect Tubes B Disconnect Bolt C Purge Valve D e Installation is the reverse of removal ORun the tubes correctly see Cable Wire and Hose Rout ing section in the Appendix chapter Purge Valve Inspection e Remove the purge valve see Purge Valve Removal In stallation e Set the hand tester A to the x 1 O range and connect it to the purge valve terminals as shown in the figure Special Tool Hand Tester 57001 1394 Purge Valve Resistance Standard 30 34 at 20 68 F the resistance reading is out of the specified value re place it with a new one Connect
307. ed warning indicator light LED and immobilizer warning symbol will switch off OThis procedure registered the registered ignition key and one ignition key OContinue with the procedure to register the second and later keys before the 15 seconds period has elapsed e Insert the ignition key 2 to the ignition switch and turn it ON Olf there is any problem in the registration the red warning indicator light LED and immobilizer warning symbol A blinks to display the collation error Immobilizer Amplifier Failure When Registered Ignition Key is Inserted Ignition Key Collation Error Y 0 5second 0 5second oe espe qe spe pups GP30058CS1 GP30059CS1 C Y 0 5second 0 5second par GP30058CS1 Y 0 3second A Be ULL GP30080CS1 C 16 94 ELECTRICAL SYSTEM Immobilizer System Equipped Models The ignition key 2 is registered in the ECU OThe red warning indicator light LED and immobilizer warning symbol A blinks 4 times and stops for 1 second and then repeats this cycle OThis procedure has registered the registered ignition key and 2 ignition keys e Continue with the procedure to register an additional 3 ignition keys NOTE OThe ECU can store up the five key codes Ignition Key Indicator Light and Symbol Blinks Indicator Light Stop 1 seconds Indicator Light Blinks 5 times Rema
308. ee chapter 3 Water temperature sensor trouble Inspect see chapter 3 Intake air temperature sensor trouble Inspect see chapter 3 Miscellaneous Subthrottle sensor trouble Inspect see chapter 3 Subthrottle valve actuator trouble Inspect see chapter 3 Throttle valves will not fully open Inspect throttle cables and lever linkage see chapter 3 Engine overheating Water temperature sensor Overheating of Troubleshooting Guide or crankshaft sensor trouble chapter 17 Exhaust Smokes Excessively 7 Becksmke Brown smoke Air duct loose Reinstall see chapter 3 Fuel pressure too low Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Intake air temperature sensor trouble Inspect see chapter 3 3 44 FUEL SYSTEM DFI Self Diagnosis Self Diagnosis Outline The self diagnosis system is monitoring the following mechanisms DFI System and Ignition System KTRC System Immobilizer System Equipped Models The following warning indicator lights LED are used for symbols of below table LED Color Warning Indicator Symbols Oil Pressure Battery Water Temperature Immobilizer Equipped Models Yellow B FI Yellow KTRC C The self diagnosis system has two modes and can be switched to another mode by operating the SEL button of the left switch housing User Mode The ECU notifies the rider of troubles i
309. eedback mode of the oxygen sensor 3 52 FUEL SYSTEM DFI Self Diagnosis Service Parts or Output Signal Usable Codes Function Range or Criteria Backups by ECU The actuator operates open and close of the bypass passage by the pulse signal from the ECU If the ISC actuator fails the signal is out to the usable range wiring short or open the ECU stops the current to the actuator 1 ISC Actuator Purge Valve The purge valve controls CAL and the flow of the fuel vapor SEA B1 gas air by opening and Models shutting the solenoid valve 3A Note 1 D J Method When the engine load is light like at idling or low speed the ECU determines the injection quantity by calculating from the throttle vacuum vacuum sensor output voltage and engine speed crankshaft sensor output voltage This method is called D J method 2 a N Method As the engine speed increases and the engine load turns middle to heavy the ECU determines the injection quantity by calculating from the throttle opening throttle sensor output voltage and the engine speed This method is called a N method This depends on the number of stopped cylinders Main Throttle Sensor Service Code 11 FUEL SYSTEM DFI 3 53 The main throttle sensor is a rotating variable resistor that change output voltage according to throttle operating The ECU senses this voltage change and determines fuel injec tion quantity and ignit
310. eeder hose and gear position switch lead Align the white paint mark of the water hose with the projection on the water pump cover Install the water hose so that white paint mark faces left side Water Hose Install the hose so that white painted mark on the hose faces the front side Insert the hose until it hit the projection of the cylinder fitting Inlet Hose Outlet Hose Clamp 17 42 APPENDIX Cable Wire and Hose Routing 6809868085 C APPENDIX 17 43 Cable Wire and Hose Routing 10 11 12 13 Touch the brake hose fitting to the stopper Clamps Hold the brake hose and insert the clamps into the front fender Brake Hoses Front View Bracket Hold the front wheel rotation sensor lead Front Wheel Rotation Sensor Front Wheel Rotation Sensor Lead Clamp Hold the brake hose only and insert the clamp into the front fender Clamp Hold the brake hose and front wheel rotation sensor lead and align the clamp with white painted mark of the front wheel rotation sensor lead View from A View from B Clamp Hold the front wheel rotation sensor lead AU Model 17 44 APPENDIX Cable Wire and Hose Routing SS TON ON A s 5 6809869015 C APPENDIX 17 45 Cable Wire and Hose Routing 1 Clamp Hold the brake hose OF W Clamp H
311. eel 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 25 30 mm 1 0 1 2 in GK04060781 C 6512021851 PERIODIC MAINTENANCE 2 31 Periodic Maintenance Procedures Drive Chain Slack Adjustment e Remove the cotter pin A and loosen the axle nut B e Loosen the both chain adjuster locknuts C x If the chain is too loose turn out the right and left chain adjusters D evenly the chain is too tight turn in the right and left chain adjusters evenly and kick the wheel forward e Turn both chain adjusters evenly until the drive chain has the correct amount of slack To keep the chain and wheel properly aligned the notch E on the right wheel align ment indicator F should align with the same swingarm mark or position G that the left indicator notch aligns with A WARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition Be sure the wheel is properly aligned e Tighten both chain adjuster locknuts securely e Tighten the axle nut Torque Rear Axle Nut 127 N m 13 0 kgf m 93 7 ft Ib e Turn the wheel measure the chain slack again atthe tight est position and readjust if necessary e Insert a new cotter p
312. ehicle down Sensor Lead Connector A Disconnect Immobilizer Amplifier Lead Connector Equipped Mod els B Disconnect Bolts C e Remove the upper fairing forward Upper Fairing Installation e Installation is the reverse of removal e Run the hoses leads and harness correctly see Cable Wire and Hose Routing section in the Appendix chapter e Fit the front air intake duct A to the upper fairing B Upper Fairing Disassembly e Remove Upper Fairing see Upper Fairing Removal Headlights A see Headlight Removal Installation in the Electrical System chapter Nuts B and Rear View Mirrors Bracket C Upper Fairing Assembly e Installation is the reverse of removal 15 16 FRAME Fairings Inner Cover Removal e Remove Bolts A and Washers e Clear the hooks B and tab C and remove the inner cover D Inner Cover Installation e Be sure that the pads A and damper B are in place 6005032851 e Insert the hooks A of the inner cover under the middle fairing first and then insert the tab B into the slot C of the fuel tank cover e Tighten the bolts with washers Upper Inner Fairing Removal e Remove Quick Rivets A Bolt B and Washer Upper Inner Fairing C OPush the central pin of the quick rivet OSlide out the upper inner fairing backward Fairings FRAME 15 17 Upper Inner Fairing Installation e Insert the tab A of the upper inner fairing
313. el 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 100 mm 3 94 in A apart and set a dial gauge B on the axle at a point halfway between the blocks Turn C the axle to mea sure the runout The difference between the highest and lowest dial readings is the amount of runout x If axle runout exceeds the service limit replace the axle Axle Runout 100 mm 3 94 in Standard TIR 0 03 mm 0 0012 in or less Service Limit TIR 0 2 mm 0 008 in GJ04130BS1 6J04043BS1 C Wheels Rims WHEELS TIRES 10 11 Balance Inspection Remove the front and rear wheels see Front Rear Wheel Removal e Support the wheel so that it can be spun freely e Spin the wheel lightly and mark A the wheel at the top when the wheel stops ORepeat this procedure several times If the wheel stops of its own accord in various positions it is well balanced x If the wheel always stops in one position adjust the wheel balance see Balance Adjustment Balance Adjustment e f the wheel always stops in one position provisionally attach a balance weight A on the rim at the marking using adhesive tape e Rotate the wheel 1 4 turn B and see whether or not the wheel stops in this position If it does the correct balance weight is being used x f the wheel rotates and the weight goes up replace the
314. el Tank see Fuel Tank Removal in the Fuel System DFI chapter Battery see Battery Removal in the Electrical System chapter Bolts A Cover B 2 34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Apply the brake lever or pedal and inspect the brake fluid leak from the brake hoses A pipes B ABS equipped models and fittings C x If the brake fluid leaked from any position inspect or re place the problem part Brake Hose and Pipe Damage and Installation Condition Inspection e For ABS equipped models note the following e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Battery see Battery Removal in the Electrical System chapter Bolts A Cover B PERIODIC MAINTENANCE 2 35 Periodic Maintenance Procedures e Inspect the brake hoses pipes and fittings for deteriora tion cracks and signs of leakage OThe high pressure inside of the brake line can cause fluid to leak A or the hose pipes ABS equipped models to burst if the line is not properly maintained Bend and twist the rubber hose while examining it Replace the hose and pipe ABS equipped models if any crack B bulge C or leakage is noticed Tighten any brake hose banjo bolts Torque Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft Ib Brake Pipe Joint Nuts 18 N m 1 8 kgf m 13 ft Ib ABS Equipped Models e Inspect the brake hose routing If any brake hose and pipe ABS equipped
315. ellow ABS indicator light LED A may light if the tire pressure is incorrect a non recommended tire is in stalled or the wheel is deformed If the indicator light lights remedy the problem and clear the service code A WARNING Use of non recommended tires may cause malfunc tioning of ABS and can lead to extended braking distance resulting in an accident causing serious injury or death Always use recommended stan dard tires for this motorcycle GL14615BS1 Anti Lock Brake System Equipped Models BRAKES 12 35 OThe yellow ABS indicator light LED may come on if the engine is run with the motorcycle on its stand and the transmission in gear If the indicator light comes on just turn the ignition switch OFF then clear service code 42 which indicates a Faulty front wheel rotation sensor OWhen the ABS operates the ABS makes noise and the rider feels the reaction force on the brake lever and brake pedal This is a normal condition It informs the rider that the ABS is operating normally OService codes detected once by the ABS hydraulic unit will be memorized in the ABS hydraulic unit Therefore after maintenance work is finished be sure to erase the service codes Do not erase the service codes during troubleshooting Wait until all the checks and repair work are finished to prevent duplication of previous service codes and unnecessary maintenance work OBefore delivering the motorcycle to
316. em Hose lrispectloh ie peo m den Cylinder Head Cover Cylinder Head Cover Removal iui eti bee poo tet RE eH Debent a LA BP Lee Cylinder Head Cover Installation ssssseeeeenenmeenennmeneenn Camshaft Chain Tensioner Camshaft Chain Tensioner Removal Camshaft Chain Tensioner Installation Camshaft Camshaft Chain Camshaft Removal Camshaft Installation Camshaft Camshaft Cap Wear Camshaft Runout InSpecliOrn pp Cam Wear Inspection GCamshiatt Chain Removal Camshaft Chain Installation Cylinder Cylinder Compression Cylinder Head Removal Cylinder Head installato on n ee ioc Cylinder Head Warp Inspection see eite setae E Doi erste x e Valve Clearance Inspecti Valve Clearance Adjustment pp Valve Removal Valve Installation Valve Guide Removal Valve Guide Installation Valve to Guide Clearance Measurement Wobble Method Valve Seat Inspection Valve Seat Repair Throttle Body Holder Throttle Body Assy Holder Removal
317. emarks ft lb Front Fork Top Plugs Piston Rod Nuts Front Fork Bottom Allen Bolts 20 2 0 Lower 30 3 1 22 2 2 28 2 9 2 2 3 22 AL AL Tighten the two clamp bolts alternately two times to ensure even tightening torque G Apply grease L Apply a non permanent locking agent R Replacement Parts 13 4 SUSPENSION Exploded View Exploded View SUSPENSION 13 5 No Fastener Rear Shock Absorber Nuts 34 35 25 34 3 5 25 20 2 0 15 Swingarm Pivot Shaft Swingarm Pivot Shaft Locknut 98 10 0 72 Swingarm Pivot Shaft Nut 108 11 0 79 7 Rocker Arm Nut 34 3 5 25 Tie Rod Nuts G Apply grease R Replacement Parts 59 6 0 44 13 6 SUSPENSION Specifications Standard Front Fork Per One Unit Fork Inner Tube Diameter 43 mm 1 7 in Air Pressure Atmospheric pressure Non adjustable Rebound Damper Setting 8th click from the 1st click of the fully clockwise position Usable Range 0 lt gt gt 15 clicks Compression Damper Setting 10th click from the 1st click of the fully clockwise position Usable Range 0 18 clicks Fork Spring Preload Setting Adjuster protrusion is 14 mm 0 55 Usable Range 4 19 mm 0 16 0 75 in Fork Oil Type KAYABA 01 KHL15 10 or equivalent Amount Approx 465 mL 15 7 US oz when changing oil 548 4 mL 18 5 0 14 US oz after disa
318. en if the ignition switch is turned OFF the battery or the ABS hydraulic unit are disconnected all service codes remain in the ABS hydraulic unit ORefer to the Service Code Clearing Procedure for the service code erasure BRAKES 12 45 Anti Lock Brake System Equipped Models Service Code Table Service Code 14 17 18 19 25 5 3 Yellow ABS Indicator Light LED JUL JUUUUL IUUUUL JUUUL JUL Problems Rear intake solenoid valve trouble wiring shorted or open Rear outlet solenoid valve trouble wiring shorted or open Front intake solenoid valve trouble wiring shorted or open Front outlet solenoid valve trouble wiring shorted or open ABS solenoid valve relay trouble stuck relay ON or OFF Front rear wheel rotation difference abnormal substandard tire ABS motor relay trouble stuck relay ON or OFF Front wheel rotation sensor signal abnormal sensor or rotor missing too large clearance rotor tooth worn or missing Light State ON ON ON ON ON ON ON 43 JUUUL Front wheel rotation sensor wiring wiring shorted or open connector bad connection ON 44 JUUUL Rear wheel rotation sensor signal abnormal sensor or rotor missing too large clearance rotor tooth worn or missing ON 4 Rear wheel rotation sensor wiring wiring shorted or open connector bad connection Power supply voltage abnormal over voltage
319. ensor Equipped Models Gear Position Switch Vehicle down Sensor Wheel Rotation Sensors 3 14 FUEL SYSTEM DFI System DFI System Wiring Diagram in TE 62 l T p mes ail BLZ BR W PA Holl 61 ey H UE JMO aa E S6 xj xit n T NENNEN f TH gt adi OF ij 111 2 5 0 8 0 LIL E d i BL G In ve Sees I iUd BL R d a Core p ULL we H HI 3 at 1 DFI System FUEL SYSTEM DFI 3 15 Part Names ECU Rear Wheel Rotation Sensor Joint Connector B Immobilizer Equipped Models Kawasaki Diagnostic System Connector Frame Ground Battery Starter Relay Main Fuse 30 A ECU Fuse 15 A Frame Ground 3 Frame Ground 2 Frame Ground 1 Frame Ground 4 Fuel Pump Relay Box Fuel Pump Relay ECU Main Relay Fuse Box 1 Joint Connector A Meter Unit Yellow Engine Warning Indicator Light LED
320. ent 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 APPENDIX 17 57 Caliper trouble Other noise Bracket nut bolt etc mounted or tightened not properly Oil Pressure Warning Indicator Light Goes On Engine oil pump damaged Engine oil screen clogged Engine oil filter clogged Engine oil level too low Engine oil viscosity too low Camshaft bearing worn Crankshaft bearing worn Oil pressure switch damaged Wiring faulty Relief valve stuck open O ring at the oil passage in the crankcase damaged Exhaust Smokes Excessively White smoke Piston oil ring worn Cylinder worn Valve oil seal damaged Valve guide worn Engine oil level too high Black smoke Air cleaner clogged Brown smoke Air duct holder loose Air cleaner poorly sealed or missing Handling and or Stability Unsatisfactory Handlebar hard to turn Cable routing incorrect Hose routing incorrect Wiring routing incorrect Steering stem nut too tight Steering stem bearing damaged Steering stem bearing lubrication inade quate Steering stem bent Tire air pressure too low Handlebar shakes or excessively vibrates Tire worn Swingarm pivot bearing worn Rim warped or not balanced Wheel bearing worn Handlebar holder bolt loose Steering stem nut loose Front rear axle ru
321. ents Exploded View 9 2 Front Balancer Installation 9 31 Specifications pp 9 6 Rear Balancer Removal 9 32 Special Tools and Sealants 9 9 Rear Balancer Installation 9 33 Crankcase Splitting 9 10 Balancer Adjustment 9 35 Crankcase Splitting 9 10 Balancer Damper Inspection 9 36 Crankcase Assembly 9 12 Starter Motor Clutch and Torque Crankshaft and Connecting Rods 9 16 EMITE 9 37 Crankshaft Removal 9 16 Starter Motor Clutch Removal 9 37 Crankshaft Installation 9 16 Starter Motor Clutch Installation 9 37 Connecting Rod Remowval 9 17 Starter Motor Clutch Disassembly 9 38 Connecting Rod Installation 9 17 Starter Motor Clutch Assembly 9 38 Crankshaft Connecting Rod Starter Clutch Inspection 9 39 CIB ARMING e ie 9 21 Torque Limiter Removal 9 39 Connecting Rod Bend Inspection 9 21 Torque Limiter Installation 9 39 Connecting Rod Twist Inspection 9 21 TRANSMISSION 9 40 Connecting Rod Big End Side Shift Pedal Removal 9 40 Clearance Inspection 9 21 Shift Pedal Installation 9 40 Connecting Rod Big End External Shift Mechanism Bearing Insert Crankpin Wear Rem
322. er Connection Tester el Headlight Circuit 1 3 Relay 6 7 ECU Main Relay 4 5 Fuel Pump Rel uel Pump Rela Y 9 10 11 16 Starter Circuit Relay 11 12 17 20 Fan Relay 18 19 The actual reading varies with the hand tester used ELECTRICAL SYSTEM 16 119 Relay Box Relay Circuit Inspection with the battery connected Patery Tester Tester Connection Connection Reading Q ECU Main Relay Fuel Pump Relay Fan Relay 18 19 17 20 Battery Tester Connection Tester 17 DC V MC V Starter Circuit 16 12 12 Battery aa Voltage Apply positive lead Apply negative lead Diode Circuit Inspection e Remove the relay box see Relay Box Removal e Check conductivity of the following pairs of terminals see Relay Box Internal Circuit in this section Diode Circuit Inspection 1 11 2 11 12 13 12 15 12 16 13 14 13 15 The resistance should be low one direction and more than 10 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 The actual meter reading varies with the meter or tester used and the individual diodes but generally speaking the lower reading should be from zero to one half the scale Tester Connection 16 120 ELECTRICAL SYSTEM Relay Box Relay Box Internal Circuit A Headli
323. er side in fact falls down the weight turns and the signal changes The ECU senses this change and stops the fuel pump relay the fuel injectors and the ignition system Hall IC B When the motorcycle is down the ignition switch is left ON If the starter button is pushed the electric starter turns but the engine does not start To start the engine again raise the motorcycle turn the ignition switch to OFF and then turn it to ON Vehicle down Sensor A Ground Terminal B G Output Terminal C Y G Input Terminal D BL Vehicle down Sensor Removal NOTICE Never drop the vehicle down sensor especially on a hard surface Such a shock to the sensor can damage it e Remove Windshield see Windshield Removal in the Frame chapter Bolt A e Remove Connector A Disconnect Bolts B and Nuts Bracket C Vehicle down Sensor D Vehicle down Sensor Installation e Be sure to install the rubber dampers A and collars B on the bracket GC17355BS1 C 3 80 FUEL SYSTEM Vehicle down Sensor Service Code 31 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 for an accident resulting in injury or death Ensure that the vehicle down sensor is held in place by the sensor bracket e Tighten Torque Veh
324. er than SEA B1 and BR Models 16 22 Wiring Diagram ABS Equipped Models SEA B1 Model 16 24 Wiring Diagram ABS Equipped Models BR Model 16 26 16 28 Electrical WIFIPIO suonerie 16 29 Igea mc 16 29 Balla stet ate T La Lco quce aiite T 16 30 Battery Removal rc 16 30 Baltery InStallallglir s a cce ero pen eati o tied cete 16 31 Battery Activation 16 32 Precautions isn 16 35 PLOT PAIS 16 36 Charging Condition Inspection en cse nce eats 16 36 Gharging iic meme Alternator Cover Removal pp Alternator Cover Installatigm Stat r Coll testi bere e Ee ote b Dee Ert e tutte uta Rd ieu Stat r Coll aaa oit ep rele Maen Alternator Rotor Alternator Rotor Installation n cetus o tne cir dese eeu Alternator Inspection ope UN E RR M Ex ER nr Re
325. er until the riveting pin touches the link pin GK04021BS1 C GK04023BS1 C GK04025BS1 C Drive Chain FINAL DRIVE 11 9 e Turn the wrench clockwise until the tip of riveting pin hits of the link pin e Rivet it e Same work for the other link pin e After staking check the staked area of the link pin for cracks e Measure the outside diameter A of the link pin and link plates width B Link Pin Outside Diameter Standard 5 8 6 2 mm 0 23 0 24 in Link Plates Outside Width Standard 22 40 22 55 mm 0 881 0 888 in x If the reading exceeds the specified length cut and rejoin the chain again e Check Movement of the Rollers e Adjust the drive chain slack after installing the chain see Drive Chain Slack Adjustment in the Periodic Mainte nance chapter e Hung the hook A and install the chain cover B e Apply a non permanent locking agent to the screws C and tighten them GK04026BS1 C GK04028BS1 11 10 FINAL DRIVE Sprocket Coupling Engine Sprocket Removal e Pull up the core of the quick rivet A by the thin blade driver and remove it Remove the bolts B and washers Free the lower fairing e Remove Clutch Slave Cylinder A see Clutch Slave Cylinder Re moval in the Clutch chapter Engine Sprocket Cover Bolts B Engine Sprocket Cover C e Flatten out the bended washer A Remove the engine sprocket nut B and wa
326. erse of removal e When installing the pad A install it along the middle fair ing as shown in the figure Right Middle Fairing Only B Y 7 6005028851 6005802981 15 14 Fairings e Insert the tab A of the middle fairing to the inside of the upper fairing B first and then fit the hooks C of the middle fairing on the ribs of the upper fairing OFit the projection D of the middle fairing into the hole E of the upper fairing Hang the hook A of the middle fairing to the bracket e Fit the inner rubber cover to the middle fairing Middle Fairing Disassembly e Remove Middle Fairing see Middle Fairing Removal Lower Fairing see Lower Fairing Removal Inner Fairing see Inner Fairing Removal Screws A Front Turn Signal Light B e Remove Screws A Quick Rivet B Cover C Screws D Bracket E OPush the central pin of the quick rivet Fairings FRAME 15 15 Middle Fairing Assembly e Installation is the reverse of removal e Fit the grooves A of the cover to the projections B of the middle fairing Upper Fairing Removal e Remove Fairing Covers see Fairing Cover Removal Inner Covers see Inner Cover Removal Middle Fairings see Middle Fairing Removal Windshield see Windshield Removal Disconnect City Light Lead Connector A Both Sides Headlight Lead Connectors B Both Sides e Remove V
327. eservoir brake lever and front brake light switch installed e Disconnect the front brake light switch connector E Immediately wash away any brake fluid that spills Front Master Cylinder Installation e Install the master cylinder clamp so that the arrow mark A faces upward e Set the front master cylinder to match its mating surface B to the punch mark C of the handlebar e Tighten the upper clamp bolt first and then the lower clamp bolt Torque Front Master Cylinder Clamp Bolts 11 N m 1 1 kgf m 97 in Ib e Connect the front brake light switch connector e Replace the washers that are on each side of the hose fitting with new ones e Tighten Torque Brake Hose Banjo Bolts 25 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 Rear Master Cylinder Removal e Remove Brake Hose Banjo Bolt A Brake Hose B Cotter Pin C Joint Pin D Bolts E Foot Guard F Rear Master Cylinder e Slide out the clamp e Pull off the reservoir hose lower end and drain the brake fluid into a container BRAKES 12 23 Master Cylinder Rear Master Cylinder Installation e Replace the cotter pin with a new one e Replace the washers that are on each side of hose fitting with new ones Tighten Torque Rear Master Cylinder Mounting Bolts 25 N m 2 5 kgf m 18 ft lb Brake Hose Banjo Bolts 25
328. evel Inspection NOTE OCheck the level when the engine is cold room or ambi ent temperature e Check the coolant level in the reserve tank A with the motorcycle held perpendicularly Do not use the side stand x If the coolant level is lower than the L level line B re move the left fairing cover see Fairing Cover Removal the Frame chapter and then unscrew the reserve tank cap and add coolant to the F level line C L Low F Full NOTICE 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 reserve tank has run completely dry there is probably leakage in the cooling system Check the system for leaks Coolant ruins painted surfaces Immediately wash away any coolant that spills on the frame engine wheels or other painted parts 2 22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Radiator Hose and Pipe Inspection coolant leak damage installation condition OThe high pressure inside the radiator hose can cause coolant to leak A or the hose to burst if the line is not properly maintained e Visually inspect the hoses for signs of deteri
329. f any damage has been found or if the part is be N yond its service limit a 68020098 Replacement Parts Replacement parts must be KAWASAKI genuine or recommended by KAWASAKI Gaskets O rings oil seals grease seals circlips cotter pins or self locking nuts must be replaced with new ones whenever disassembled 68020108 Assembly Order In most cases assembly order is the reverse of disassem oda T bly however if assembly order is provided in this Service s e Manual follow the procedures given lt s Qu 2 9 68020118 1 4 GENERAL INFORMATION Before Servicing Tightening Sequence Generally when installing a part with several bolts nuts or screws start them all in their holes and tighten them to a snug fit Then tighten them according to the specified se quence to prevent case warpage or deformation which can lead to malfunction Conversely when loosening the bolts nuts or screws first loosen all of them by about a quar ter turn and then remove them If the specified tightening sequence is not indicated tighten the fasteners alternating diagonally Tightening Torque Incorrect torque applied to a bolt nut or screw may lead to serious damage Tighten fasteners to the specified torque using a good quality torque wrench Force Use common sense during disassembly and assembly excessive force can cause expensive or hard to repair dam age When necessary remove screws th
330. f the range replace the ECU see ECU Removal Installation x If the reading is within the range resistor of the ECU for CAN communication line is normal Check the wiring for continuity of the CAN communication line see wiring diagram in this section Special Tool Hand Tester 57001 1394 x If the wiring is open repair or replace the main harness GC17787ES1 3 118 FUEL SYSTEM CAN Communication Line CAN Communication Line Circuit 2 3 5 D 5 4 m 5 1 Meter Unit 2 Joint Connector C 3 Joint Connector D 4 ECU 5 Immobilizer Equipped Models Kawasaki Diagnostic System Connector DFI Power Source FUEL SYSTEM 3 119 ECU Fuse Removal Refer to the 30 A Main 15 ECU Fuse Removal in the Electrical System chapter ECU Fuse Installation x If a fuse fails during operation inspect the DFI system to determine the cause and then replace it with a new fuse of proper amperage e Refer to the Fuse Installation in the Electrical System chapter ECU Fuse Inspection e Refer to the Fuse Inspection in the Electrical System chapter ECU Main Relay Removal installation OThe ECU main relay is built in the relay box A e Refer to the Relay Box Removal in the Electrical System chapter ECU Main Relay Inspection e Refer to the Relay Circuit Inspection in the Electrical Sys tem chapter
331. for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation GT04098BS1 GT04099BS1 C FUEL SYSTEM DFI 3 105 Oxygen Sensor Heater Service Code 67 Equipped Models Oxygen Sensor Circuit CD 87104109842 C ECU Frame Ground Battery Starter Relay Main Fuse 30 A ECU Fuse 15 Frame Ground 1 Relay Box ECU Main Relay 10 Fuse Box 1 11 Ignition Fuse 15 12 Joint Connector A 13 Joint Connector F 14 Ignition Switch 15 Oxygen Sensor 3 106 FUEL SYSTEM Idle Speed Control Valve Actuator Service Code 1C Idle Speed Control Valve Actuator Removal Never drop the idle speed control valve actuator es pecially on a hard surface Such a shock to the ac tuator can damage it e Remove Right Middle Fairing see Middle Fairing Removal in the Frame chapter Bolts A Idle Speed Control Valve Actuator Connector B Dis connect e Remove the hoses A from the fitting of the idle speed control valve actuator B Remove Idle Speed Control Valve Actuator Idle Speed Control Valve Actuator Installation e Installation is the reverse of removal e Run the hoses correctly see Cable Wire and Hose Rout ing section in the Appendix chapter e Be sure that the fi
332. g surface is within the specified range measure the seat width as described be low e Grind the seat at a 32 angle until the seat outside diam eter 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 NOTICE The 32 cutter removes material very quickly Check the seat outside diameter frequently to pre vent overgrinding OAfter making the 32 grind return to the seat outside di ameter measurement step above e To measure the seat width use a vernier caliper to mea sure the width of the 45 angle portion of the seat at sev eral places around the seat xIf the seat width is too narrow repeat the 45 grind until the seat is slightly too wide and then return to the seat outside diameter measurement step above 8 15011951 C GE15012181 GE15012281 5 34 ENGINE TOP END Valves x If the seat width is too wide make the 60 A grind de scribed below x lf the seat width is within the specified range lap the valve to the seat as described below e Grind the seat at a 60 angle until the seat width is within the specified range OTo make the 60 grind fit 60 cutter into the holder and slide it into the valve guide OTurn the holder while pressing down lightly OAfter making
333. g symbol B is displayed on the LCD Liquid Crystal Display e Push the SEL button for more than two seconds e The service code A is displayed on the LCD by the num ber of two digits e Any of the following procedures ends self diagnosis OWhen the service code is displayed on the LCD push the SEL button for more than two seconds The display will return to the previous display OWhen the ignition switch is turned to OFF WA D ELTE 01030348 ERROR E 90 12 3 00 123455 POWER zl KTRCl z4 0017228 5 FUEL SYSTEM 3 47 Self Diagnosis Self Diagnosis Flow Chart Turn the ignition switch to OFF Turn the ignition switch to ON Push the SEL button for more than two seconds Then self diagnosis mode starts The service code s is displayed on the LCD Liquid Crystal Display Turn the ignition switch to OFF Locate the problem with the service code table and inspect and repair the faulty system according to inspection procedure on all the service codes Turn the ignition switch to ON Make sure the warning symbols goof Make sure the warning symbols go off OK Run the engine for several minutes at idling and run the motorcycle NG at 30 km h 18 mph or above in order to confirm no problem OK 6103036 F 3 48 FUEL SYSTEM DFI Self Diagnosis Service Code Reading OThe service code s is disp
334. g the DFI System eere rome edm uU ped buie 3 31 eui t cU S 3 31 Inquires 10 FIST s saree ca et dad te e due entes 3 36 DFI System Troubleshooting Guides acide Orne 3 39 onto 3 44 El ACHOSIS cH 3 44 Self Diagnosis Procedures pp 3 45 Self Diagnosis Flow Chart pp 3 47 Service Gode Reading 3 48 Service Code aE a E 3 48 amp 3 50 Main Throttle Sensor Service Code 11 3 53 Main Throttle Sensor 3 53 Main Throttle Sensor Input Voltage 3 53 Main Throttle Sensor Resistance 3 54 Main Throttle Sensor Output Voltage 3 54 Intake Air Pressure Sensor 1 Service Code 12 3 57 Intake Air Pressure Sensor 1 2 3 57 Intake Air Pressure Sensor 1 3 57 Intake Air Pressure Sensor 1 Input Voltage 3 58 Intake Air Pressure Sensor 1 Output Voltag
335. g with the fuel and air supplied by the fuel injection system 2 Exhaust Emission Control System This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this motorcycle The fuel ignition and exhaust systems of this motorcycle have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels The exhaust system of this model motorcycle manufactured primarily for sale in California in cludes a catalytic converter system 3 Evaporative Emission Control System Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere In stead fuel vapors are routed into the running engine to be burned or stored in a canister when the engine is stopped The Clean Air Act which is the Federal law covering motor vehicle pollution contains what is commonly referred to as the Acts tampering provisions Sec 203 a The following acts and the causing thereof are prohibited 3 for any person to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title prior to its sale and delivery to the ultimate purchaser or for any manufacturer or dealer knowingly to remove or render inoperative any such device or element of design after such sale and delivery to the ultimate purchaser 3 B for any person engaged in the business of repai
336. gh no adjustments are required a thorough visual in spection must be made at the intervals specified by the Pe riodic Maintenance Chart Parts Removal Installation WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light If gasoline solvent water or any other liquid enters the canister the canister s vapor absorbing capac ity is greatly reduced If the canister does become contaminated replace it with a new one Connect the hoses according to the diagram of the sys tem see Cable Wire and Hose Routing section in the Appendix chapter Make sure they do not get pinched or kinked Hose Inspection e Refer to the Evaporative Emission Control System In spection CAL and SEA B1 Models in the Periodic Main tenance chapter Purge Valve Inspection e Refer to the Purge Valve Inspection Canister Inspection e Refer to the Evaporative Emission Control System In spection CAL and SEA B1 Models in the Periodic Main tenance chapter COOLING SYSTEM 4 1 Cooling System Table of Contents us 4 2 Coolant Flow Cham mue ios stop cuo teet 4 4 SSC CHICANOMNS M 4 6 sri se
337. ght Circuit Relay B ECU Main Relay C Fuel Pump Relay D Starter Circuit Relay E Fan Relay GPi90108W2 C ELECTRICAL SYSTEM 16 121 Fuse 30 A Main 15 A ECU Fuse Removal Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Bolts A Cover B e Pull out the fuses A from the starter relay with needle nose pliers Fuse Box Fuse Removal e Remove the seat see Seat Removal in the Frame chap ter Unlock the hook A to lift up the lid 16 122 ELECTRICAL SYSTEM Fuse e Pull the fuses A straight out of the fuse box with needle nose pliers Fuse Installation x lf 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 is blown out replace the fuse Before replacing a blown fuse always check the amperage in the affected circuit If the amperage is equal to or greater than the fuse rating check the wiring and related components for a short circuit Housing A Fuse Element B Terminals C Blown Element D 8 20000151 NOTE OA mass current flows to the battery according to the state of the battery which needs refreshing charge when the engine is turned causing ma
338. ghten the nuts using the Rotation Angle Method e Be sure to clean the bolts nuts and connecting rods thor oughly with a high flash point solvent because the new connecting rods bolts and nuts are treated with an anti rust solution A WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the bolts nuts and connecting rods in a well ventilated area and take care that there are no sparks or flame anywhere near the working area this includes any appliance with a pilot light Do not use gasoline or a low flash point solvent to clean them Immediately dry the bolts and nuts with com pressed air after cleaning Clean and dry the bolts and nuts completely e Install new bolts and nuts in reused connecting rod the connecting rod assembly was replaced use the bolts and nuts attached to the new connecting rod assem bly e Apply a small amount of molybdenum disulfide oil solution to the following portions Threads A of Nuts and Bolts Seating Surfaces B of Nuts and Connecting Rods e First tighten the nuts to the specified torque See the table below e Next tighten the nuts 120 OMark A the connecting rod big end caps and nuts so that nuts can be turned 120 B properly OThe nuts can be tightened by using an angle torque gauge For details refer to Cylinder Head Installation in the Engine Top End chapter Connecting
339. gnition switch is ON or while the engine is running OBecause of the large amount of current never keep the starter button pushed when the starter motor will not turn over or the current may burn out the starter motor wind ings OTake care not to short the cables that are directly con nected to the battery positive terminal to the chassis ground OTroubles may involve one or in some cases all items Never replace a defective part without determining what CAUSED the failure If the failure was caused by some other item or items they must be repaired or replaced or the new replacement will soon fail again OMake sure all connectors in the circuit are clean and tight and examine leads for signs of burning fraying etc Poor leads and bad connections will affect electrical system operation OMeasure coil and winding resistance when the part is cold at room temperature Electrical Wiring ELECTRICAL SYSTEM 16 29 Wiring Inspection e Visually inspect the wiring for signs of burning fraying etc lf any wiring is poor replace the damaged wiring Pull each connector A apart and inspect it for corrosion dirt and damage xIf the connector is corroded or dirty clean it carefully If it is damaged replace it Check the wiring for continuity OUse the wiring diagram to find the ends of the lead which is suspected of being a problem OConnect the hand tester between the ends of the leads Special Tool H
340. gs and install the oil pipe e Install the oil pan plate A e Apply a non permanent locking agent to the threads of the oil pan plate bolts B and tighten them Torque Oil Pan Plate Bolts 9 8 Nm 1 0 kgf m 87 in Ib e Replace the oil pan gasket A with a new one e Install the brackets B as shown in the figure e Tighten Torque Oil Pan Bolts 9 8 1 0 kgf m 87 in Ib e Install the removed parts see appropriate chapters HLA SY cy J o J C aat ki ASS Calli r ENGINE LUBRICATION SYSTEM 7 13 Oil Pressure Relief Valve Oil Pressure Relief Valve Removal e Remove Oil Pan see Oil Pan Removal Oil Pipe see Cil Pan Removal e Hold the pipe A in a vise B e Remove the oil pressure relief valve C Oil Pressure Relief Valve Installation e Apply a non permanent locking agent to the threads of the oil pressure relief valve and tighten it NOTICE Do not apply too much non permanent locking agent to the threads This may block the oil pas sage Torque Oil Pressure Relief Valve 15 N m 1 5 kgf m 11 ft lb e Install the removed parts see appropriate chapters Oil Pressure Relief Valve Inspection Check to see if the valve A slides smoothly when push ing itin 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 c
341. gulator Rectifier Inspection DEPUTY SUS Mey ace re sates cau ta NAT Crankshaft Sensor Removal pp Crankshaft Sensor Installation Ne 16 46 Crankshaft Sensor INSPSClOMN cocer ei eee 16 46 Crankshaft Sensor Peak Voltage 16 47 Timing Rotor Removal reir dot 16 47 Timing Rotor IMStallanG pc dete vive 16 47 Stick Coll Eee 16 48 Suck nstallati paetos Ee bec 16 48 Stick Coll INSPSCHOM 16 48 Stick Coil Primary Peak Voltage oe USER 16 49 Spark Plug Removal 16 49 ett Rani td 16 49 Spark Plug Condition Inspection trier ener te 16 50 Interlock Operation Inspection at 16 50 IC Igniter Inspection cc 16 51 Electric Start r gt 16 56 Starter Motor Removal ertet etn Er tonii 16 56 Starter Motor 16 56 16 2 ELECTRICAL SYSTEM Starter Motor Disassembly pp 16 57 Starter Motor Assembly 16 57 Br sh
342. h Hole B for Oxygen Sensor C GE24778BS1 Honeycomb Type Catalyst Positions A Left Muffler Body B Right Muffler Body C 0 24779 52 Manifold D GE24780BS2 5 8 ENGINE END Specifications Camshaft Journal Camshaft 0 038 0 081 mm 0 0015 0 0032 in Cap Clearance Camshaft Journal Diameter 23 940 23 962 mm 0 9425 0 9434 Camshaft Bearing Inside 24 000 24 021 mm 0 9449 0 9457 in Diameter Camshaft Runout TIR 0 02 mm 0 0008 in or less Cylinder Head Cylinder Compression Usable Range 1 190 1 798 kPa 12 1 18 3 kgf cm 173 261 psi at 300 r min rpm Cylinder Head Warp Item Standard Service Limit Camshafts Cam Height Exhaust 35 243 35 357 mm 1 3875 1 3920 in 35 14 1 383 Intake 35 243 35 357 mm 1 3875 1 3920 in 35 14 1 383 0 17 mm 0 0067 in 23 91 mm 0 941 in 24 08 mm 0 948 in TIR 0 1 mm 0 004 in 0 05 mm 0 002 in Valves Valve Clearance Exhaust 0 22 0 27 mm 0 0087 0 0106 in Intake 0 15 0 20 mm 0 0059 0 0079 in Valve Head Thickness Exhaust 0 8 mm 0 031 Intake 0 5 mm 0 020 in Valve Stem Bend TIR 0 01 mm 0 0004 in or less Valve Stem Diameter Exhaust 4 955 4 970 mm 0 1951 0 1957 in Intake 4 975 4 990 mm 0 1959 0 1965 in Valve Guide Inside Diameter Exhaust 5 000 5 012 mm 0 1969 0 1973 in Intake 5 000
343. h hose lightly going from the lower end to upper end and bleed the air off the reservoir Slowly pump the clutch lever several times until no air bubbles can be seen rising up through the fluid from the hole at the bottom of the reservoir e Remove the rubber cap from the bleed valve on the mas ter cylinder e Attach a clear plastic hose A to the bleed valve and run the other end of the hose into a container Clutch Fluid CLUTCH 6 11 e Bleed the clutch line and the master cylinder ORepeat this operation until no more air can be seen com ing out into the plastic hose 1 Pump the clutch lever until it becomes hard and apply the clutch lever and hold it A 2 Quickly open and close B the bleed valve while holding the clutch lever applied 3 Release the clutch lever C NOTE O The fluid level must be checked often during the bleed ing operation and replenished with fresh clutch 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 e Remove the clear plastic hose Tighten the bleed valve and install the rubber cap Torque Clutch Master Cylinder Bleed Valve 5 4 N m 0 55 kgf m 48 in Ib Remove the rubber cap from the bleed valve e Attach a clear plastic hose A to the bleed valve on the clutch slave cylinder and run the other end of the hose i
344. h the chain taut by hanging a 10 kg 22 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 319 mm 12 6 in WARNING A chain that breaks or jumps off the sprockets could snag on the engine sprocket or lock the rear wheel severely damaging the motorcycle and causing it to go out of control Inspect the chain for damage and proper adjustment before each ride If chain wear exceeds the service limit replace it with the standard chain It is an endless type and should not be cut for installation Standard Chain Make ENUMA Type EK530RMX 3D Link 118 links 6 04060651 C PERIODIC MAINTENANCE 2 33 Periodic Maintenance Procedures Drive Chain Guide Wear Inspection e Remove the swingarm see Swingarm Removal in the Suspension chapter e Visually inspect the chain guide A Replace the chain guide if it shows any signs of abnormal wear or damage Brakes Brake Fluid Leak Brake Hose and Pipe Inspection e For ABS equipped models note the following e Remove Fu
345. haft Side Clearance Inspection Move A the crankshaft to the side of the camshaft chain e Insert a thickness gauge B between the thrust washer C and the crank web D at the 3 main journal to deter mine clearance Crankshaft Side Clearance Standard 0 05 0 24 mm 0 0020 0 0094 in Service Limit 0 30 mm 0 0118 in the clearance exceeds the service limit replace the thrust washers as a set Measure the crankshaft 3 main journal width A the measurement exceeds the standard replace the crankshaft B Crankshaft 3 Main Journal Width Standard 27 45 27 50 mm 1 0807 1 0827 in Crankshaft Runout Inspection Measure the crankshaft runout If the measurement exceeds the service limit replace the crankshaft Crankshaft Runout Standard TIR 0 03 mm 0 0012 in or less Service Limit TIR 0 08 mm 0 0031 in 6105334851 CRANKSHAFT TRANSMISSION 9 25 Crankshaft and Connecting Rods Crankshaft Main Bearing Insert Journal Wear Inspection Split the crankcase see Crankcase Splitting e Cut strips of plastigage press gauge to journal width e Place a strip on each journal parallel to the crankshaft installed in the correct position e Tighten the crankcase bolts to the specified torque see Crankcase Assembly NOTE ODo not turn the crankshaft during clearance measure ment OJournal clearance less than 0 025 mm 0 00098 in can not be measu
346. hammer the end of the driver until it bottoms Valve Guide Driver Attachment E A Valve Guide Driver Holder B Valve Guide C Cylinder Head D Valve Guide Installed Height 12 8 13 0 mm 0 50 0 51 in E Special Tools Valve Guide Driver 57001 1564 Valve Guide Driver Attachment E 57001 1677 Ream the valve guide with valve guide reamer A even if the old guide is reused Special Tool Valve Guide Reamer 5 57001 1204 SIZX636581 GE15046BS1 C 5 30 ENGINE END Valves Valve to Guide Clearance Measurement Wobble Method small bore gauge is not available inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below e Insert a new valve A into the guide B and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface e Move the stem back and forth C to measure valve valve guide clearance e Repeat the measurement in a direction at a right angle to the first x If the reading exceeds the service limit replace the guide 8 15007 52 C NOTE OThe reading is not actual valve valve guide clearance because the measuring point is above the guide Valve Valve Guide Clearance Wobble Method Standard Exhaust 0 09 0 16 mm 0 0035 0 0063 in Intake 0 03 0 11 mm 0 0012 0 0043 in Service Limit Exhaust 0 36 mm 0 014 in I
347. han the service limit the fork must be replaced Shift Fork Guide Pin Diameter Standard 6 9 7 0 mm 0 272 0 276 in Service Limit 6 8 mm 0 268 in x If any shift drum groove is worn over the service limit the drum must be replaced Shift Drum Groove Width Standard 7 05 7 20 mm 0 278 0 283 in Service Limit 7 3 mm 0 287 in 6113525851 6113014551 6113161851 6113162851 C 9 48 CRANKSHAFT TRANSMISSION Transmission Gear Dog and Gear Dog Hole Damage Inspection e Visually inspect the gear dogs A and gear dog holes B Replace any damaged gears or gears with excessively worn dogs or dog holes 6113163851 C WHEELS TIRES 10 1 Wheels Tires Table of Contents Exploded VEW eer 10 2 e MR 10 4 Special o t nis 10 5 Wheels RIMS tedeschi tuc 10 6 Front Wheel 10 6 Front Wheel 10 6 Hear Wheel Removal s eredi dea eee rine lote 10 7 Rear Wheel Installation emn ee docu 10 8 Wheel 10 10 Axle MI 10 10 Balance INSPOCT ON 10 11 Balance Adjustment cette aee eios ox
348. hange the valve performance xIf 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 6008060251 A WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the oil pressure relief valve in a well ventilated area and take care that there are no sparks or flame anywhere near the working area this includes any appliance with a pilot light Do not use gasoline or a low flash point solvent to clean the oil pressure relief valve x lf cleaning does not solve the problem replace the oil pressure relief valve as an assembly The oil pressure relief valve is precision made with no allowance for re placement of individual parts 7 14 ENGINE LUBRICATION SYSTEM Oil Pump Oil Pump Removal e Remove Coolant Drain see Coolant Change in the Periodic Maintenance chapter Engine Oil Drain see Engine Oil Change in the Periodic Maintenance chapter Clutch see Clutch Removal in the Clutch chapter Remove the oil pump cover bolts A Remove the oil pump cover B with oil pump drive gear shaft Remove the outer rotor and inner rotor Oil Pump Installation e Apply molybdenum disulfide oil solution to the journal por tions A on the oil pump drive gear shaft B 6609072851 e Insert the o
349. hapter Thermostat Housing A see Thermostat Removal in the Cooling System chapter Oil Cooler B see Cooler Removal in the Engine Lubrication System chapter Fitting C Hoses D O rings E e Replace the hoses and O rings with new ones e Apply liquid gasket to the new O rings Sealant Liquid Gasket TB1211F 92104 0004 e Apply soap and water solution to the inside of the water hoses before installation e Run the new hoses according to Cable Wire and Hose Routing section in the Appendix chapter e Tighten Torque Water Hose Clamp Screws 3 0 0 31 kgf m 27 in Ib e Install the removed parts see appropriate chapters e Fill the coolant see Coolant Change e Check the cooling system for leaks 8005010951 C 85808072883 2 54 PERIODIC MAINTENANCE Periodic Maintenance Procedures Clutch Hose Replacement Clutch fluid quickly ruins painted plastic surfaces any spilled fluid should be completely washed away immediately e Remove the left middle fairing see Middle Fairing Re moval in the Frame chapter e Remove the clutch hose banjo bolts A e When removing the clutch hose take care not to spill the clutch fluid on the painted or plastic parts e When removing the clutch hose B temporarily secure the end of the clutch hose to some high place to keep fluid loss to a minimum e Immediately wash away any clutch fluid that spills e There are washers on ea
350. has a short circuit to ground and it must be repaired or re placed 6017029281 e Narrow down suspicious locations by repeating the con tinuity tests from the ECU connectors If no abnormality is found in the wiring or connectors the DFI parts are the next likely suspects Check the part starting with input and output voltages However there is no way to check the ECU itself If an abnormality is found replace the affected DFI part If no abnormality is found in the wiring connectors and DFI parts replace the ECU 3 36 FUEL SYSTEM DFI Troubleshooting the DFI System DFI Diagnosis Flow Chart Problem occurs Confirm problems Gather information from rider Turn the ignition switch ON Yellow engine warning Yellow engine warning indicator light LED and indicator light LED goes on yellow KTRC warning or yellow engine warning indicator light LED do not go indicator light LED and on or immobilizer warning yellow KTRC warning symbol and red warning indicator light LED go on indicator light LED do not go on or do not blink Red warning indicator light LED blinks and immobilizer warning symbol is displayed on the LCD Conduct non self diagnosis inspection Conduct self diagnosis inspection DFI system Conduct self diagnosis inspection immobilizer system Conduct general fuel system inspection General fuel system throttle body
351. hat its surface is flush with the end of hole C Special Tool Bearing Driver Set 57001 1129 e Press the new oil seal D so that the oil seal lip E faces to the outisde and the oil seal surface is flush with the surface F of the crankcase Special Tool Bearing Driver Set 57001 1129 e Apply grease to the oil seal lips 6104430851 CRANKSHAFT TRANSMISSION 9 13 Crankcase Splitting e When installing the oil passage plugs A note the follow ing OApply a non permanent locking agent to the oil passage plugs OTighten Torque Oil Passage Plugs R3 8 20 N m 2 0 kgf m 15 ft lb When installing the plug B note the following Olnstall the plug so that the chamfered side faces inside e When installing the oil nozzle pipes A note the following OReplace the washers B of oil nozzle pipe with new ones Olnstall Oil Nozzle Pipe Washers OTighten Torque Nozzle Pipe Mounting Bolts C 25 2 5 kgf m 18 ft lb e Be sure to install the following parts Pistons see Piston Installation Crankshaft see Crankshaft Installation Connecting Rod Big End Caps see Connecting Rod In stallation Transmission Shaft see Transmission Shaft Installation Shaft Drum and Shift Fork see Shift Drum and Fork In stallation Front Balancer see Front Balancer Installation Dowel Pins A e Before fitting the lower case on the upper case check the following OCheck to see that the shift d
352. he brake lever and pedal GL14646B 12 44 BRAKES Anti Lock Brake System Equipped Models How to Read Service Codes OService codes are shown by series of long and short blinks of the yellow ABS indicator light LED as shown below ORead 10th digit and unit digit as the yellow ABS indicator light LED blinks OWhen there a number of faults a maximum of all service codes be stored and the display will begin starting from the small number code entered OFor the display pattern first the smallest number code is shown next up to all service codes starting with the last one stored then the display is repeated from the smallest number code once again Service Service Service Service Service gt code 13 code 14 code 17 code 53 code 55 2 4 1 08114114841 C Olf there is no fault the yellow ABS indicator light LED lights as shown in the figure Repeat Start Self diagnosis End Self diagnosis 1 ABS Self diagnosis Terminal Ground Ignition ON Switch OFF 10 digit 10th digit a digit Yellow ABS ON aps 1 0 48 0 45 0 45 0 45 0 45 0 45 0 45 0 48 0 45 0 48 Light LED OFF 0 48 0 45 0 48 0 45 0 45 0 48 4 Service Code 13 Service Code 42 Repetition Yellow ABS ON aps Indicator normal Light LED OFF 1 1 68114644842 C How to Erase Service Codes OEv
353. he stopper 5 Run the ignition switch lead to the upside of the clutch hose 6 Run the clutch hose through the clamp 7 Ignition Switch Lead 17 6 APPENDIX Cable Wire and Hose Routing 68099110 G APPENDIX 17 7 Cable Wire and Hose Routing st Vehicle down Sensor Run the vehicle down sensor lead between the meter bracket and immobilizer amplifier Immobilizer Amplifier Meter Unit Lead Connector Outside Temperature Sensor Clamp Hold the main harness immobilizer amplifier lead and meter unit lead Run the immobilizer amplifier lead to the inside of the clamp as shown in the figure Immobilizer Amplifier Lead Run the vehicle down sensor lead in front of the meter bracket Run the clutch hose between the front fork and head pipe Left Switch Housing Lead Run the left switch housing lead through the clamp after routing the outside of the front fork Run the main harness to the outside of the outside temperature sensor Clamp Hook the main harness from the inside to the outside of the motorcycle Run the vehicle down sensor lead to the outside of the meter unit lead Immobilizer Equipped Models 17 8 APPENDIX Cable Wire and Hose Routing N 7 m i lt 68095250 6 APPENDIX 17 9 Cable Wire and Hose Routing 1 CD 16 17 18 C
354. he wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation 9704077851 3 70 FUEL SYSTEM Intake Air Pressure Sensor 2 Service Code 16 Intake Air Pressure Sensor 2 Output Voltage Inspection e Measure the output voltage at the intake air pressure sen sor 2 in the same way as input voltage inspection note the following ODisconnect the intake air pressure sensor 2 connector and connect the measuring adapter A between these connectors B Main Harness C Intake Air Pressure Sensor 2 D Digital Meter Special Tool Measuring Adapter 57001 1700 Intake Air Pressure Sensor 2 Output Voltage Connections to Adapter Digital Meter Y sensor G W lead Digital Meter BK sensor lead Measure the output voltage with the engine stopped and with the connector joined e Turn the ignition switch to ON Output Voltage Usable Range DC 3 80 4 20 V at standard atmospheric pressure 101 32 kPa 76 cmHg absolute NOTE OThe output voltage changes according to the local at mospheric pressure e Turn the ignition switch to OFF the reading is out of the usable range replace the sen Sor x f the reading is within the usable range remove the ECU and check the wiring for continuity between harness con nectors Special Tool Han
355. heck the following and correct the faulty part Incorrect Tire Pressure Tires not recommended for the motorcycle were installed incorrect tire size Deformation of Wheel or Tire Missing Teeth or Clogging with Foreign Matter of Sensor Rotor see Wheel Rotation Sensor Rotor Inspection in the Brakes chapter x lf the all parts corrected go to next step e Perform the Pre Diagnosis Inspection 1 and 2 see In quiries to Rider x lf this service code appears even if all checks are ended replace the ABS hydraulic unit x If the service code does not appear the ABS system nor mal temporary failure ABS Motor Relay Inspection Service Code 35 e Check the ABS motor relay fuse 20 A A see Fuse Inspection in the Electrical System chapter x If the fuse is good check the wiring continuity as follows ODisconnect Battery Positive Cable see Battery Removal in the Elec trical System chapter ABS Hydraulic Unit Lead Connector see ABS Hydraulic Unit Removal 61048113 Anti Lock Brake System Equipped Models BRAKES 12 47 OCheck the wiring continuity between the positive cable terminal A of the battery and R W lead terminal B in the ABS Hydraulic Unit Lead Connector C x If the wiring is open replace or repair the harness see ABS System Circuit x If the wiring is good go to next step OThe ABS motor relay is built in the ABS Hydraulic Unit Therefore the relay cannot be checked directly e Perf
356. hown in the figure 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 e Install the last friction plate A fitting the tangs in the grooves in the housing as shown in the figure e Apply molybdenum disulfide grease to the outside surface A of the pusher B e Install the pusher into the drive shaft C e Apply engine oil to the needle bearing D e Install Needle Bearing Washer E GF12019BS1 C 6 17 Clutch e Align the wide projections A of the spring plate B with the wide grooves C of the sub clutch hub D to install the spring plate on the sub clutch hub e Install the clutch springs spring holders and tighten the clutch spring bolts Torque Clutch Spring Bolts 8 8 N m 0 90 kgf m 78 in Ib Install the clutch cover see Clutch Cover Installation Spring Plate Free Play Measurement Insufficient clutch free play will cause the engine braking effect to be more sudden resulting in rear wheel hop On the other hand if the free play is excessive the clutch lever may feel spongy or pulsate when pulled Hold an extra drive shaft in a vise and install the following clutch parts on the shaft see Clutch Installation Thrust Washer A Needle Bearing B Sleeve C Clutch Housing D Spacer E Clutch Hub F Sub Clutch Hub G Friction Pla
357. ich could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the motorcycle until a firm brake pedal is obtained by pumping the pedal until the pads are against the disc 10 10 WHEELS TIRES Wheels Rims Wheel Inspection e Raise the front rear wheel off the ground Special Tool Jack 57001 1238 Spin the wheel lightly and check for roughness or binding If roughness or binding is found replace the hub bearings see Hub Bearing Removal Installation e Inspect the wheel for small cracks dents bending warp x If there is any damage to the wheel replace the wheel e Remove the wheel and support it with the tire by the axle e Measure the rim runout axial A and radial B with a dial gauge x If rim runout exceeds the service limit check the hub bear ings see Hub Bearing Inspection xlf the problem is not due to the bearings replace the wheel Rim Runout with tire installed Standard Axial TIR 0 5 mm 0 02 in or less Radial TIR 0 8 mm 0 03 in or less Service Limit Axial TIR 1 0 mm 0 04 in Radial TIR 1 0 mm 0 04 in A WARNING Damaged wheel parts may fail and cause an acci dent resulting in serious injury or death Never at tempt to repair a damaged wheel part If the wheel part is damaged it must be replaced with a new one Axle Inspection Remove the front and rear axles see Front Rear Whe
358. icle down Sensor Mounting Nuts 5 9 N m 0 60 kgf m 52 in Ib Vehicle down Sensor Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch to OFF e Remove the windshield see Windshield Removal in the Frame chapter e Disconnect the vehicle down sensor connector and con nect the measuring adapter A between these connectors as shown in the figure Main Harness B Vehicle down Sensor C Special Tool Measuring Adapter 57001 1700 e Connect a digital meter D to the measuring adapter leads Vehicle down Sensor Input Voltage Connections to Adapter Digital Meter R sensor BL lead Digital Meter BK sensor lead e Measure the input voltage with the engine stopped and with the connector joined e Turn the ignition switch to ON Input Voltage Standard DC 4 75 5 25 V e Turn the ignition switch to OFF x If the reading is within the standard check the output volt age see Vehicle down Sensor Output Voltage Inspec tion GC17356BS1 C GT04091BS1 C Vehicle down Sensor Service Code 31 FUEL SYSTEM DFI 3 81 x If the reading is out of the standard remove the ECU and check the wiring for continuity between main harness connectors Special Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector Vehicle down Sensor Connector B BL lead ECU ter
359. ife under normal use Forcibly prying off the seal cap to add water is very dangerous Never do that 2 Refreshing charge If an engine will not start a horn sounds weak or lamps are dim it indicates the battery has been discharged Give refresh charge for 5 to 10 hours with charge current shown in the specification see Refreshing Charge When a fast charge is inevitably required do it following precisely the maximum charge current and time conditions indicated on the battery NOTICE This battery is designed to sustain no unusual deterioration if refresh charged according to the method specified above However the battery s performance may be reduced no ticeably if charged under conditions other than given above Never remove the seal cap during refresh charge If by chance an excessive amount of gas is generated due to overcharging the relief valve releases the gas to keep the battery normal 3 When you do not use the motorcycle for months Give a refresh charge before you store the motorcycle and store it with the negative cable re moved Give a refresh charge once a month during storage 4 Battery life If the battery will not start the engine even after several refresh charges the battery has ex ceeded its useful life Replace it Provided however the vehicle s starting system has no prob lem 16 36 ELECTRICAL SYSTEM Battery A DANGER tention for more severe burns Interchange Batteries produc
360. il accumulates in the tank any water or oil accumulates in the tank remove the tank and drain it A WARNING Oil on tires will make them slippery and can cause an accident and injury Be sure to reinstall the catch tank after draining FUEL SYSTEM DFI 3 143 Rear Air Intake Duct Removal Left Rear Air Intake Duct e Remove Left Inner Cover see Inner Cover Removal in the Frame chapter Fuel Tank Cover see Fuel Tank Removal e Loosen the clamp bolt A e Remove the mounting bolts B and pull off the left rear air intake duct C backward Right Rear Air Intake Duct e Remove the right middle fairing see Middle Fairing Re moval in the Frame chapter e Loosen the clamp bolt A e Remove the mounting bolts B and pull off the right rear air intake duct C backward Rear Air Intake Duct Installation e Fit the projections A of the holder B into the slots C of rear air intake duct D e Insert the rear air intake duct A until the duct end B align the line C of the middle air intake duct D e Apply a non permanent locking agent to the threads of the mounting bolts and tighten them e Install the air intake duct clamp bolts in the direction as shown in the figure Bolt Heads A Upper Side B Left Clamp C Right Clamp D About 30 E Rear View F e Tighten the clamp bolts GC07085BS1 C 3 144 FUEL SYSTEM Air Line Front and Mi
361. il to the needle bearing and the sleeve be fore installation x f the sub clutch hub bolts were removed install them as follows OApply a non permanent locking agent to the threads of the sub clutch hub bolts and tighten them Torque Sub Clutch Hub Bolts 25 N m 2 5 kgf m 18 ft Ib e Install the clutch hub A on the drive shaft e Align the damper cams B of the sub clutch hub C to the cam followers D of the clutch hub e Install the toothed washer A e Install the four torque limiter springs B as shown in the figure Tangs C ODo not over lap the tang of the springs lt d Ms lt ee m 2 5 Yo 6 118104 P 6 16 Clutch e Replace the clutch hub nut A with a new one Hold the sub clutch hub B steady with the clutch holder C and tighten the clutch hub nut Special Tool Clutch Holder 57001 1243 Torque Clutch Hub Nut 135 N m 13 8 kgf m 100 ft lb e Install the following as shown in the figure Friction Plates A B C Steel Plates D Spring Seat E Spring F Clutch Hub G NOTE OThe lining blocks H of the friction plate A are larger than them of the friction plates B Olnstall the spring seat and spring between first steel plate and second steel plate O The inside diameter of second friction plate C is larger than the others because the spring seat and spring are equipped to decrease the judder noise as s
362. ilures no signal wiring short or open the ECU shuts off the injector 2 to stop fuel to the cylinder 2 though the engine keeps running Stick Coil 3 Stick Coil 4 The ECU sends signals output voltage continuously to the stick coil The ECU sends signals output voltage continuously to the stick coil If the stick coil 3 primary winding has failures no signal wiring short or open the ECU shuts off the injector 3 to stop fuel to the cylinder 3 though the engine keeps running If the stick coil 4 primary winding has failures no signal wiring short or open the ECU shuts off the injector 4 to stop fuel to the cylinder 4 though the engine keeps running Radiator Fan Relay Subthrottle Valve Actuator When the radiator fan relay is OFF the relay is opened The actuator operates open and close of the subthrottle valve by the pulse signal from the ECU If the subthrottle valve actuator fails the signal is out to the usable range wiring short or open the ECU stops the current to the actuator Air Switching Valve Oxygen Sensor Heater Equipped Models The air switching valve controls the flow of the secondary air by opening and shutting the solenoid valve The oxygen sensor heater raises temperature of the sensor for its earlier activation If the oxygen sensor heater fails wiring short or open the ECU stops the current to the heater and it stops the f
363. in A NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle tighten the nut clockwise B up to next alignment Olt should be within 30 degrees OLoosen once and tighten again when the slot goes past the nearest hole e Bend the cotter pin A over the nut A WARNING A loose axle nut can lead to an accident resulting in serious injury or death Tighten the axle nut to the proper torque and install a new cotter pin GJ04082BS1 2 32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Wheel Alignment Inspection e Check that the notch A on the right alignment indicator B aligns with the same swingarm mark or position C that the left alignment indicator notch aligns with x If they do not adjust the chain slack and align the wheel alignment see Drive Chain Slack Adjustment NOTE OWheel alignment can be also checked using the straightedge or string method WARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition Be sure the wheel is properly aligned Drive Chain Wear Inspection e Remove the chain cover see Drive Chain Removal in the Final Drive chapter e Rotate the rear wheel to inspect the drive chain for dam aged rollers and loose pins and links x If there is any irregularity replace the drive chain x Lubricate the drive chain if it appears e Stretc
364. in Throttle Sensor Service Code 11 x If the reading is out of the standard remove the ECU and check the wiring for continuity between harness connec tors Special Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A lt gt Main Throttle Sensor Connector B BL lead ECU terminal 9 C G lead ECU terminal 13 D x If the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation Main Throttle Sensor Resistance Inspection e Turn the ignition switch to OFF e Measure the main throttle sensor resistance in the same way as input voltage inspection note the following ODisconnect the throttle sensor setting adapter A from the connector of the main harness side Special Tool Throttle Sensor Setting Adapter 57001 1538 OConnect the setting adapter B to the sensor connector only OConnect a digital meter A to the setting adapter B Main Throttle Sensor C Main Throttle Sensor Resistance Connections to Adapter W sensor BL lead BK sensor G lead Standard 4 6 kO xIf the reading is out of the standard replace the throttle body assy x If the reading is within the standard check the output volt age see Main Throttle Sensor Output Voltage Inspec tion Main Throttle Sensor Output Voltage Insp
365. in fuse blown out NOTICE When replacing a fuse be sure the new fuse matches the specified fuse rating for that circuit Installation of a fuse with a higher rating may cause damage to wiring and components APPENDIX 17 1 Appendix Table of Contents Cable Wire and Hose Routing Semen awed 17 2 Troubleshooting Guide as coctus ct mcn 17 54 17 2 APPENDIX Cable Wire and Hose Routing 5809090 G APPENDIX 17 3 Cable Wire and Hose Routing 1 Run the right switch housing lead horn lead front wheel rotation sensor lead through the clamp Do not run the horn lead through the clamp on the steering stem Run the left switch housing lead and ignition switch lead through the clamp Pull the leads forward so that they have no slack near the front fork Run the horn lead between the brake hose and front fork Run the throttle cables through the clamp of the front brake reservoir bracket Run the throttle cables to the inside of the brake hose Run the throttle cables through the clamp of the radiator cover 17 4 APPENDIX Cable Wire and Hose Routing 58099100 6 APPENDIX 17 5 Cable Wire and Hose Routing 1 Run the clutch reservoir hose to the inside of the bracket 2 Clutch Reservoir Hose 3 Clutch Hose 4 Touch the clutch hose fitting to t
366. ing e Before installing the brake pipe check to see that there is no damage on the threads of the brake pipe joint nut xIf there is any damage replace the damaged parts with new ones NOTE OHand tighten the brake pipe joint nuts at both ends of the brake pipe temporarily and then tighten them to the specified torque OTighten the brake pipe joint nuts with the flare nut wrench e Tighten Torque Brake Hose Banjo Bolts 25 2 5 kgf m 18 ft lb Brake Pipe Joint Nuts 18 N m 1 8 kgf m 13 ft Ib ABS Equipped Models e When installing the hoses avoid sharp bending kinking flatting or twisting and run the hoses according to Cable Wire and Hose Routing section in the Appendix chapter e Fill the brake line after installing the brake hose see Brake Fluid Change 2 62 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Fluid Change NOTE OThe procedure to change the front brake fluid is as fol lows Changing the rear brake fluid is the same as for the front brake e Level the brake fluid reservoir e Remove Screw A Stopper B Front Brake Reservoir Cap C Diaphragm Plate Diaphragm Remove the rubber cap A from the bleed valve on the caliper e Attach a clear plastic hose B to the bleed valve and run the other end of the hose into a container e Fill the reservoir with fresh specified brake fluid e Change the brake fluid ORepeat this operation until fresh brake fluid
367. ing Inspection in the Wheels Tires chap ter and coupling see Coupling Bearing Inspection in the Final Drive chapter 2 30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Final Drive Drive Chain Lubrication Condition Inspection e special lubricant is not available a heavy oil such as SAE 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication e f the chain appears especially dirty clean it before lubri cation The O rings between the side plates seal in the lu bricant between the pin and the bushing To avoid damaging the O rings and resultant loss of lubri cant observe the following rules Use only kerosene or diesel oil for cleaning of the O ring of the drive chain Any other cleaning solution such as gasoline or trichloroethylene will cause de terioration and swelling of the O ring Immediately blow the chain dry with compressed air after clean ing Complete cleaning and drying the chain within 10 minutes e Apply oil to the sides of the rollers so that oil will penetrate to the rollers and bushings Apply the oil to the O rings so that the O rings will be coated with oil e Wipe off any excess oil Oil Applied Areas A O rings B 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 ary e Checkthe wheel alignment see Wh
368. ing Length C Spring Preload Setting Standard Spring length 175 5 mm 6 909 in Usable Range Spring length 170 0 180 5 mm 6 693 7 106 in OThe standard adjusting nut setting is 175 5 mm 6 9 in spring length Remove the chain cover A see Drive Chain Removal in the Final Drive chapter Remove the bolts B and left foot guard C for turning the hook wrench easily e To adjust the spring preload turn in the adjusting nut and tighten the locknut by using hook wrenches A with the rear shock absorber attached the frame Special Tool Hook Wrench T 3 2 R37 57001 1522 x If the spring action feels too soft or too stiff adjust it Spring Preload Adjustment Adjuster Position Damping Force Setting 180 5 mm Weak Soft 7 106 in l 170 0 mm 6 693 in Rear Shock Absorber Removal Remove Center Stand see Center Stand Removal in the Frame chapter Equipped Models Rear Fairing see Rear Fairing Removal in the Frame chapter Equipped Models Bolt A Both Sides and Bracket B Equipped Models Raise the rear wheel off the ground with the jack Special Tools Jack 57001 1238 Jack Attachment 57001 1608 SUSPENSION 13 29 Rear Shock Absorber Squeeze the brake lever slowly and hold it with a band A A WARNING Be sure to hold the front brake when removing the shock absorber or the motorcycle may fall over It could c
369. ing Nuts A Flap with License Plate Light Tail Brake Light LED see Tail Brake Light LED Re moval in the Electrical System chapter e Pull out the rear fender B backward and downward Flap and Rear Fender Installation e Installation is the reverse of removal e Hang the hook A of the rear fender to the slot B of the rear frame e Tighten Torque Rear Fender Mounting Screws 1 2 0 12 kgf m 11 in Ib e Replace the rear flap mounting nuts with new ones e Run the cables leads harness and hoses correctly see Cable Wire and Hose Routing section in the Appendix chapter Windshield FRAME 15 23 Windshield Removal e Remove Bolts A and Washers Windshield B Windshield Installation e Fit the groove A of the windshield to the outside of the projections B e Tighten the bolts with washers 15 24 Frame Rear Frame Removal e Remove Rear Fender see Flap and Rear Fender Removal Regulator Rectifier A see Regulator Rectifier Inspec tion in the Electrical System chapter Rear Brake Reservoir Bracket Bolt Bolts B and Bracket C Turn Signal Relay D Rear Footpeg Bracket Bolts E Both Sides Rear Frame Bolts F Both Sides Rear Frame OSupport the muffler bodies with a suitable stand Rear Frame Installation Apply a non permanent locking agent to the threads of the rear frame bolt and tighten them Torque Rear Frame Bolts 44 N m 4 5 kgf m
370. ion Switch see Gear Position Switch Inspec tion in the Electrical System chapter Harness see Wiring Inspection in the Electrical System chapter ABS Indicator Light LED ABS Equipped Models see ABS Indicator Light LED Inspection in the Brakes chap ter e Turn the ignition switch to OFF e The all lights should go off e For models equipped with an immobilizer system red warning indicator light LED will blinks Refer to the Im mobilizer System Equipped Models section in the Elec trical System chapter x the light does not go off replace the ignition switch goes on 6817207BS1 2 42 PERIODIC MAINTENANCE Periodic Maintenance Procedures Second Step e Turn the ignition switch to P Park position Other than US and CA models The city light taillight and license plate light should go on x If the light does not go on inspect or replace the following item Ignition Switch see Switch Inspection in the Electrical System chapter Third Step e Turn the ignition switch to ON e Turn on the turn signal switch A left or right position e The left or right turn signal lights B front and rear ac cording to the switch position should blink e The either of turn signal indicator lights LED C in the meter unit should blink xIf the each light does not blink inspect or replace the fol lowing item Turn Signal Light Bulb see Turn Signal Light Bulb Re placement in the Electrical S
371. ion condition and sensor see Wheel Rotation Sensor Inspection Wheel Rotation Sensor Rotor Inspection Remove Wheels see Front Rear Wheel Removal in the Wheels Tires chapter Brake Disc Mounting Bolts A Sensor Rotor B 12 56 5 Anti Lock Brake System Equipped Models e Visually inspect the wheel rotation sensor rotor x lf the rotor is deformed or damaged chipped teeth A replace the sensor rotor with a new one x If there is iron or other magnetic deposits B remove the deposits ABS Solenoid Valve Relay Fuse 20 A Removal e Refer to the Fuse Box Fuse Removal in the Electrical Sys tem chapter ABS Motor Relay Fuse 30 A Removal e Refer to the Fuse Box Fuse Removal in the Electrical Sys tem chapter ABS ECU Fuse 10 A Removal e Refer to the Fuse Box Fuse Removal in the Electrical Sys tem chapter Fuse Installation e f a fuse fails during operation inspect the electrical sys tem to determine the cause and then replace it with a new fuse of proper amperage see Fuse Installation in the Electrical System chapter Fuse Inspection e Remove the fuses see ABS Solenoid Valve Relay Fuse 20 AY ABS Motor Relay Fuse 30 A ABS ECU Fuse 10 A Removal e Refer to the Fuse Inspection in the Electrical System chapter GL14110BS1 C C SUSPENSION 13 1 Suspension Table of Contents Exploded 13 2 ICC IC
372. ion timing according to engine rpm and throttle opening Input Terminal A BL Output Terminal Y W Ground Terminal C G Main Throttle Sensor Removal Adjustment Do not remove or adjust the main throttle sensor A since it has been adjusted and set with precision at the factory Never drop the throttle body assy especially on a hard surface Such a shock to the main throttle sen sor can damage it Main Throttle Sensor Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch to OFF e Remove the right middle fairing see Middle Fairing Re moval in the Frame chapter e Disconnect the main throttle sensor connector A e Connectthe setting adapter A between the harness con nector and main throttle sensor connector Special Tool Throttle Sensor Setting Adapter 57001 1538 e Connect a digital meter to the setting adapter leads Main Throttle Sensor Input Voltage Connections to Adapter Digital Meter gt W sensor BL lead Digital Meter BK sensor lead e Measure the input voltage with the engine stopped and with the connector joined e Turn the ignition switch to ON Input Voltage Standard DC 4 75 5 25 V e Turn the ignition switch to OFF x If the reading is within the standard check the main throt tle sensor resistance see Main Throttle Sensor Resis tance Inspection OBO 6617127851 3 54 FUEL SYSTEM Ma
373. ir 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 Troubleshooting Guide Air duct holder loose Fuel to injector insufficient Fuel line clogged Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Camshaft cam worn Run on dieseling Ignition switch trouble Engine stop switch trouble Fuel injector trouble Loosen terminal of battery cable or ECU ground lead Carbon accumulating on valve seating sur face Engine overheating Other ECU trouble Throttle body assy not synchronizing Engine oil viscosity too high Drive train trouble Brake dragging Clutch slipping Engine overheating Air suction valve trouble Air switching valve trouble Poor Running or No Power at High Speed Firing incorrect Spark plug dirty broken or maladjusted Spark plug incorrect Stick coil shorted or not in good contact trouble Stick coil trouble ECU trouble Fuel air mixture incorrect Air cleaner clogged poorly seale
374. isassem bly e Repeat the same procedure for other bypass screws e Repeat the synchronization 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 Special Tool Throttle Sensor Setting Adapter 57001 1538 Main Throttle Sensor Output Voltage Connections to Adapter Degital Meter gt R sensor Y W lead Degital Meter BK sensor G lead Standard DC 0 63 0 65 V at idle throttle opening x lf the output voltage is out of the standard check the in put voltage of the main throttle sensor see Main Throttle Sensor Input Voltage Inspection in the Fuel System DFI chapter e Remove the vacuum gauge hoses and install the rubber caps on the original position e Install the removed parts see appropriate chapters Idle Speed Inspection e Start the engine and warm it up thoroughly e With the engine idling turn the handlebar to both sides A handlebar movement changes the idle speed the throttle cables may be improperly adjusted or incorrectly routed or damaged Be sure to correct any of these conditions before riding see Throttle Control System Inspection and Cable Wire and Hose Routing section in the Appendix chapter A WARNING Operation with improperly adjusted incorrectly routed or damaged cables could result in an unsafe riding condition Follow the service manual to be
375. ise E until the balancer gear makes a whin ing sound OTurn the shaft counterclockwise F until the balancer gear whining sound disappears and tighten the clamp bolt Torque Balancer Shaft Clamp Bolts 9 8 N m 1 0 kgf m 87 6106054851 C 6106055851 C 8106057 52 C 9 36 CRANKSHAFT TRANSMISSION Balancer Balancer Damper Inspection e Remove the balancer and disassemble the weight and gear assembly e Visually inspect the rubber dampers A lf they appear damaged or deteriorated replace them 61068199 P CRANKSHAFT TRANSMISSION 9 37 Starter Motor Clutch and Torque Limiter Starter Motor Clutch Removal Remove Torque Limiter see Torque Limiter Removal Starter Clutch Shaft Plate Bolt A Pull the starter clutch shaft bolt A with the shaft plate and starter clutch shaft holding the starter clutch C e Remove the starter clutch Starter Motor Clutch Installation x If the shaft bolt A removed hold the shaft to tighten it Apply a non permanent locking agent to the threads of the shaft bolt Torque Starter Clutch Shaft Bolt 9 8 N m 1 0 kgf m 87 in Ib e Replace the O ring A with a new one e Apply molybdenum disulfide grease B to the starter clutch shaft e Assemble Collar Long A Starter Clutch B Collar Short C a A 61078127 61078128 9109007851 9 38 CRAN
376. it Crankpin Diameter Marks None 37 984 37 992 mm 1 4954 1 4957 in 37 993 38 000 1 4958 1 4961 A Crankpin Diameter Marks or no mark 9105236851 6105041751 9105333851 CRANKSHAFT TRANSMISSION 9 23 Crankshaft and Connecting Rods Measure the connecting rod big end inside diameter and mark each connecting rod big end in accordance with the inside diameter e Tighten the connecting rod big end nuts to the specified torque see Connecting Rod Installation NOTE 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 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 or no mark 6105060181 Select the proper bearing insert A in accordance with the combination of the connecting rod and crankshaft coding Size Color B Con rod Big End Inside Diameter Marking Crankpin Bearing Insert Diameter Marking Part Number 92139 0131 Size Color 8105041751 92139 0130 92139 0129 e Install the new inserts in the connecting rod and check insert crankpin clearance with the plastigage 9 24 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods Cranks
377. it as shown in the fig ure e Insert the fairing cover A halfway and fit the inner rubber cover B to the fairing cover as shown in the figure e Insert the front part of the fairing cover A securely e Insert the tabs B on the fairing cover under the fuel tank cover first and then fit the projections C to the holes e Tighten the bolts D with washers Middle Fairing Removal e Remove Fairing Covers see Fairing Cover Removal Inner Covers see Inner Cover Removal Fuel Tank Cover see Fuel Tank Cover Removal Upper Inner Fairing see Upper Inner Fairing Removal Quick Rivet A OPush the central pin of the quick rivet e Remove Bolts A and Washers Quick Rivets OPull up the core of the quick rivet B by the standard tip screwdriver OPush the central pin of the quick rivet C 15 13 Fairings e Remove Bolt A and Washer e Clear the projection B of the middle fairing from the hole C of the upper fairing e Clear the hook D from the bracket e Remove the middle fairing E OWhile pulling backward the middle fairing clear the hooks F and tab G OClear the inner rubber cover from the middle fairing ODisconnect the front turn signal lead connector e For models equipped with an evaporative emission con trol system note the following ORemove the hoses A from the canister B Right Middle Fairing C Middle Fairing Installation e Installation is the rev
378. ith a clamp e Insert the fuel hose into the measuring cylinder B A WARNING Wipe off spilled out fuel immediately Be sure to hold the measuring cylinder vertical e Close the fuel tank cap e Turn the engine stop switch to run position e Turn the ignition switch to ON OThe fuel pump should operate for 3 seconds and then should stop NOTICE Do not drive the fuel pump for 3 seconds or more without the fuel in the fuel tank If the fuel pump is driven without the fuel it may be damaged e Measure the discharge for 3 seconds ORepeat this operation several times Amount of Fuel Flow Standard 67 mL 2 3 US oz or more for 3 seconds e Turn the ignition switch to OFF x lf the fuel flow is much less than the specified replace the fuel pump see Fuel Pump Removal Installation e Install the fuel tank see Fuel Tank Installation e Start the engine and check for fuel leakage Fuel Pump FUEL SYSTEM DFI 3 123 Fuel Pump Removal A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions creating the potential for serious burns Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Turn the ignition switch OFF Disconnect the battery terminal To avoid fuel spills draw it from the tank when the engine is cold Be prepared for fuel spillage any spilled fuel
379. ition Switch Joint Connector E 3 18 FUEL SYSTEM DFI System OColor Codes BK Black BL Blue BR Brown CH Chocolate DG Dark Green G Green GY Gray PU Purple LB Light Blue R Red LG Light Green V Violet O Orange W White P Pink Y Yellow FUEL SYSTEM 3 19 DFI System This page intentionally left blank 3 20 FUEL SYSTEM DFI System Terminal Numbers of ECU Connectors 1D049484 7464044434241 4131211 403020100908 750959493 009 11015141 72111100980 766 38 13 2 9 11109187165 242312212 1120 1 91 81 71 615114 786898483828 19009807 Terminal Names 1 2 OND CI Subthrottle Valve Actuator Y R Subthrottle Valve Actuator BK 3 Front Wheel Rotation Sensor Signal ZX1400F Model G Y Unused ZX1400E Model Front Wheel Rotation Sensor Signal ZX1400E Model BK W Unused ZX1400F Model Unused Starter Lockout Switch R G Gear Position Switch G R Crankshaft Sensor Y BK Power Supply to Sensors BL 10 Intake Air Pressure Sensor 2 G W 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Unused Subthrottle Sensor BLAW Ground for Sensors G Subthrottle Valve Actuator P BL Subthrottle Valve Actuator G O Unused Starter Button BK R Unused Sidestand Switch G BK Ground P Crankshaft Sensor 4 Y Intake Air Pressure Senso
380. ive ca ble to the negative terminal DISASSEMBLY ASSEMBLY 68020248 Edges of Parts Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts 68020048 Solvent Use a high flush point solvent when cleaning parts High flush point solvent should be used according to directions of the solvent manufacturer 68020058 5 Cleaning Vehicle before Disassembly Clean the vehicle thoroughly before disassembly Dirt or 0 other foreign materials entering into sealed areas during ve hicle disassembly can cause excessive wear and decrease performance of the vehicle GENERAL INFORMATION 1 3 Before Servicing Arrangement and Cleaning of Removed Parts Disassembled parts are easy to confuse Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly Storage of Removed Parts After all the parts including subassembly parts have been cleaned store the parts in a clean area Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re assembly 68020088 Inspection Reuse of worn or damaged parts may lead to serious ac cident Visually inspect removed parts for corrosion discol SN oration or other damage Refer to the appropriate sections N of this manual for service limits on individual parts Replace YS AN the parts i
381. ix chap ter Insert the hooks A of the radiator cover into the slots of the right inner rubber cover Insert the projection of the right inner rubber cover into the hole C of the engine Set the quick rivets and push the core of them e Install the removed parts see appropriate chapters 15 28 FRAME Center Stand Sidestand Center Stand Removal Equipped Models e Remove Muffler Bodies see Muffler Body Removal in the Engine Top End chapter Spring A Bolts B Center Stand Bolts C and Nuts D Center Stand E 6020058851 Center Stand Installation Equipped Models e Apply grease to the sliding area A of the center stand Replace the center stand nuts with new ones e Install the center stand bolts D and tighten the center stand bolts and nuts Torque Center Stand Bolts 44 4 5 kgf m 32 ft Ib e Tighten the bolts E e Hook the spring F so that the long spring end of it faces 8020059851 upward Olnstall the spring hook direction as shown in the figure Sidestand Removal e Raise the rear wheel off the ground with the stand e Remove Left Middle Fairing see Middle Fairing Removal Sidestand Switch Bolt A Spring B Sidestand Bolt C and Nut Sidestand D Sidestand Bracket Bolts E Sidestand Installation e Apply a non permanent locking agent to the threads of the sidestand bracket bolts A and tighten them Torque Sidestand Br
382. kout switch sidestand switch relay box and starter relay 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 Release Sidestand Up Set the sidestand on the ground then the engine will stop x If the engine may not be stopped inspect the gear posi tion switch sidestand switch and relay box x lf their parts are normality replace the ECU 6517009851 C ELECTRICAL SYSTEM 16 51 Ignition System IC Igniter Inspection OThe IC igniter is built in the ECU A e Refer to the following items Interlock Operation Inspection see Interlock Operation Inspection Ignition System Troubleshooting see Ignition System d section ECU Power Supply Inspection see ECU Power Supply Inspection in the Fuel System DFI chapter QIS 4 4 gt gt DO n 1 4 16 52 ELECTRICAL SYSTEM Ignition System Ignition System Troubleshooting Faulty ignition No spark No good Battery Inspection Charge or replace battery Good Ignition system wiring and connector 0096 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 Nogpod Voltage is le
383. kshaft sensor lead connector Special Tool Hand Tester 57001 1394 Crankshaft Sensor Resistance 376 564 Q 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 e Using the highest resistance range of the tester measure the resistance between the crankshaft sensor leads and chassis ground Any tester reading less than infinity lt indicates a short necessitating replacement of the crankshaft sensor GP10731BS1 ELECTRICAL SYSTEM 16 47 Ignition System Crankshaft Sensor Peak Voltage Inspection NOTE OBe sure the battery is fully charged OUsing the peak voltage adapter is a more reliable way to determine the condition of the crankshaft sensor than crankshaft sensor internal resistance measurements e Remove the right fairing cover see Fairing Cover Re moval in the Frame chapter e Disconnect the crankshaft sensor lead connector see Crankshaft Sensor Removal e Set the hand tester A to the DC 25 V range and connect the peak voltage adapter B Special Tools Hand Tester 57001 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Connections Crankshaft Sensor Peak Voltage Connector C Adapter Hand Tester Yellow Red Black Black gt C e Turn the engine stop switch to run position e Turn the ignition switch to ON e Pushing the
384. l Special Tool Needle Adapter Set 57001 1457 Insert the needle adapter straight along the terminal in the connector to prevent short circuit between terminals e Make sure that measuring points are correct in the con nector noting the position of the lock D and the lead color before measurement Do not reverse connections of a digital meter e Be careful not to short circuit the leads of the DFI or elec trical system parts by contact between adapters e Turn the ignition switch to ON and measure the voltage with the connector joined Incorrect reverse connection or short circuit by needle adapters could damage the DFI or electrical system parts 9617572051 3 34 FUEL SYSTEM DFI Troubleshooting the DFI System OAfter measurement remove the needle adapters and ap ply silicone sealant to the seals A of the connector B for waterproofing Sealant Liquid Gasket TB1211 56019 120 e Always check battery condition before replacing the DFI parts A fully charged battery is a must for conducting accurate tests of the DFI system e Trouble may involve one or in some cases all items Never replace a defective part without determining what CAUSED the problem If the problem was caused by some other item or items they too must be repaired or replaced or the new replacement part will soon fail again Measure the coil winding resistance when the DFI part is cold at room temperature
385. l lates because they will deteriorate the tire e Remove the tire from the rim using a suitable commer cially available tire changer NOTE OThe tires cannot be removed with hand tools because they fit the rims too tightly Tire Installation A WARNING Some replacement tires may adversely affect han dling and cause an accident resulting in serious in jury or death To ensure proper handling and sta bility use only the recommended standard tires for replacement inflated to the standard pressure 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 NOTICE Replace the air valve whenever the tire is replaced Do not reuse the air valve 6J05040BS1 C Tires WHEELS TIRES 10 15 e Install a new valve in the rim ORemove the valve cap lubricate the stem seal A with a soap and water solution or rubber lubricant and pull B the valve stem through the rim from the inside out until it snaps into place NOTICE Do not use engine oil or petroleum distillates to lu bricate the stem because they will deteriorate the rubber OThe air valve is shown in the figure Valve Cap A Valve Core B Stem Seal C Valve Stem D Valve Seat E Valve Opened F e Checkthe tire rotation mark on the front and rear
386. l Indicator Light LED 3 Blue High Beam Indicator Light LED Spark Plugs Indicator A u a2 3 5 Yellow Engage Shift Up Right Horn Motor Motor X stick Sidestand Indicator Light LED H Coils 6 Warning Indicator Light Right Switch Housing err Water Temperature Hio dd es ig wite Patter lmnop tear GED 2 Engine Stop Switch b Be Red Dil Pressure Warning Indicator Light LED S ef S P 5 8 Yellow KTRO Warning 52 zi Zi Valve Indicator Light LED Intake ge 9 Yellow Engine Warning M X aT Indicator Light LED 5 5 5 8 5 10 Speedometer 83 FE 11 Tachometer ge 12 Multifunction Display 13 Illumination Light LED z LED Light Emitting Diode i parer mE Lu Vehicle down Sensor Joint ym Connector F A Front Wheel V Rotation Sensor Wa Meter Unit Y R Joint Q Connector BL R Outside ht ETTE m ront Rig Turn Signal penser Light BK Y 129218 City Light R Joint Joint 12458 Connector Connector 6 Headlight High 242 12 654 Fuse Box 2
387. l checks are ended replace the ABS hydraulic unit x If the service code does not appear the ABS system nor mal temporary failure ABS Hydraulic Unit Removal The ABS hydraulic unit A has been adjusted and set with precision at the factory Therefore it should be handled carefully never struck sharply with a hammer or allowed to fall on a hard surface Be careful not to get water or mud on the ABS hy draulic unit Drain the brake fluid from the front and rear brake lines ODrain the brake fluid through the bleed valve by pumping the brake lever and pedal e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Battery see Battery Removal in the Electrical System chapter Bolts A Cover B e Clean the ABS hydraulic unit Clean all fittings on the ABS hydraulic unit and the rear master cylinder because dirt around the banjo bolts could contaminate the brake fluid in the line during removal installation Spread out a shop towel around the ABS hydraulic unit before removing the brake line so that brake fluid does not leak on the parts Anti Lock Brake System Equipped Models BRAKES 12 51 e Remove the brake pipe joint nuts A with the flare nut wrench Tape the brake line opening to prevent brake fluid leakage or contamination by foreign matter NOTICE Brake fluid quickly ruins painted plastic surfaces any spilled fluid should be
388. l in the Brakes chapter Service Code 45 see Rear Wheel Rotation Sensor Wiring Inspection in the Brakes chapter e When only service code 24 is displayed do the following inspection procedures e Disconnect ECU Connectors see ECU Removal Rear Wheel Rotation Sensor Lead Connector see Rear Wheel Rotation Sensor Removal in the Brakes chapter e For ABS equipped models check the wiring for continuity between harness connectors Special Tool Hand Tester 57001 1394 Wiring Continuity Inspection ECU Connector ABS Hydraulic Unit Connector B R Y lead ECU terminal 31 ABS Hydraulic Unit terminal 7 C Wiring Continuity Inspection ABS Hydraulic Unit Connector Rear Wheel Rotation Sensor Connector B W G lead ABS Hydraulic Unit Connector terminal 2 C BK O lead ABS Hydraulic Unit Connector terminal 18 D e For other than ABS equipped models check the wiring for continuity between harness connectors Special Tool Hand Tester 57001 1394 Wiring Continuity Inspection ECU Connector Rear Wheel Rotation Sensor Connector B W G lead ECU terminal 58 C BK O lead ECU terminal 34 D Ste mean T1 LL LLLA GT04125BS1 C Se nS 72 9704126851 3 74 FUEL SYSTEM Rear Wheel Rotation Sensor Signal Service Code 24 x If the wiring is good check the ECU for its ground and power
389. lOrk s arde 3 148 Fuel Tank and Cap Inspectloric eoe eco es etaed tabu tereti satt 3 150 3 4 FUEL SYSTEM DFI Fuel Tank Cleaning Se OU 3 151 Evaporative Emission Control System CAL and SEA B1 3 152 Parts Removal Stall tO ata ordei eta o 3 152 ose Inspecetlon M 3 152 PUGS Valve Inspection ctetu d OR a ecd feda 3 152 Canister Inspection FUEL SYSTEM 3 5 Exploded View This page intentionally left blank 3 6 FUEL SYSTEM DFI Exploded View 58002537845 C FUEL SYSTEM DFI 3 7 a kgm ftb Exploded View Idle Speed Control Valve Actuator Mounting Bolts 73 in lb L Apply a non permanent locking agent R Replacement Parts WL Apply soap and water solution or rubber lubricant 3 8 FUEL SYSTEM DFI Exploded View 08002538845 C FUEL SYSTEM 3 9 Exploded View Fastener Remarks 1 2 Crankshaft Sensor Bolts 5 9 0 60 52 in lb L 3 Gear Position Switch Screws 2 9 0 30 26 in lb L 4 Water Temperature Sensor 12 1 2 106 in lb 5 Throttle Body Assy Holder Bolts 9 8 1 0 87 S 6 Throttle Body Assy Holder Clamp Bolts 2 0 0 20 18 in lb 7 Vehicle down Sensor Mounting Nuts 5 9
390. ladjusted remedy it spark plug incorrect replace it knocking fuel poor quality or incorrect use high octane gasoline brake dragging clutch slipping engine overheating engine oil level too high engine oil viscosity too high other FUEL SYSTEM DFI 3 39 DFI System Troubleshooting Guide NOTE OThis is not an exhaustive list giving every possible cause for each problem listed It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties in DFI system OThe ECU may be involved in the electrical and ignition system troubles If these parts and circuits are checked out good be sure to check the ECU for ground and power supply If the ground and power supply are checked good replace the ECU Engine Won t Turn Over Symptoms or possible Causes Actions chapter Gear position starter lockout or sidestand switch Inspect each switch see chapter 16 trouble Immobilizer system trouble Inspect see chapter 3 Vehicle down sensor operated Turn ignition switch OFF see chapter 3 Vehicle down sensor trouble Inspect see chapter 3 Crankshaft sensor trouble Inspect see chapter 16 Stick coil shorted or not in good contact Inspect or Reinstall see chapter 16 Stick coil trouble Inspect see chapter 16 Spark plug dirty broken or g
391. lamp Screws 3 0 0 31 kgf m 27 in Ib Hose Inspection e Refer to the Radiator Hose and Pipe Inspection in the Periodic Maintenance chapter COOLING SYSTEM 4 19 Water Temperature Sensor 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 e Refer to the Water Temperature Sensor Removal Instal lation in the Fuel System DFI chapter Water Temperature Sensor Inspection e Refer to the Water Temperature Sensor Inspection in the Electrical System chapter ENGINE END 5 1 Engine Top End Exploded View Exhaust System Specifications Special Tools and Sealants Clean Air System Table of Contents Par SUCTION Nalve PefTipVals scopo qtd db UR bomo debts Air Suction Valve Installatigm ierit tentent tern netten np emen Finca Air SUCTION Valve INSPECCION sirtarin trn dpa Spa Sade eal Asad Air Switching Valve Removal t QUod en ten p P Bede altae e datis Air Switching Valve Installation 52 reor Air Switching Valve Operation TeSt e ette entere n e Re EX Air Switching Valve Unit Test tek E le Ernte ERR E ra ue Clean Air Syst
392. lancer shaft so that its mark E is in position as shown in the figure e Check that the lever F is in contact with the crankcase e Tighten Torque Balancer Shaft Clamp Bolt G 9 8 N m 1 0 kgf m 87 in Ib 6106040551 9106053851 C CRANKSHAFT TRANSMISSION 9 35 Balancer e When installing the breather cover plate A note the fol lowing Olnstall the breather cover plate to the breather cover B as shown in the figure OApply a non permanent locking agent to the threads of the breather cover plate screws C OTighten Torque Breather Cover Plate Screw 9 8 N m 1 0 kgf m 87 in Ib e When installing the fitting A note the following OPress the fitting so that it is aligned with the line B of the breather cover C e Replace the breather cover gasket A with a new one e Install Breather Cover B Bracket C e Tighten Torque Breather Cover Bolts D 9 8 Nm 1 0 kgf m 87 in Ib Balancer Adjustment Remove Right Middle Fairing see Middle Fairing Removal in the Frame chapter NOTE OFirst adjust the front balancer A next the rear bal ancer B Start the engine and warm it up thoroughly e Adjust the balancer gear backlash with the engine idling The amount of backlash can be changed by turning the balancer shaft which has eccentric journals OStart the engine and let it idle OLoosen the clamp bolt C and turn the balancer shaft D clockw
393. lars on the both sides of the hub Right Side Collar A Left Side Collar B e Engage the drive chain with the rear sprocket e Install the caliper bracket A onto the swingarm stop B e Insert the axle from the left side of the wheel and tighten the axle nut Torque Rear Axle Nut 127 13 0 kgf m 93 7 ft Ib WHEELS TIRES 10 9 Wheels Rims 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 e Bend the cotter pin A over the nut A WARNING A loose axle nut can lead to an accident resulting in serious injury or death Tighten the axle nut to the proper torque and install a new cotter pin GJ04082BS1 e Adjust the drive chain slack after installation see Drive Chain Slack Inspection in the Periodic Maintenance chap ter e Install the rear caliper see Caliper Installation in the Brakes chapter e Install the rear wheel rotation sensor see Rear Wheel Rotation Sensor Installation in the Brakes chapter e Check the rear brake effectiveness see Brake Operation Inspection in the Periodic Maintenance chapter A WARNING After servicing it takes several applications of the brake pedal before the brake pads contact the disc wh
394. late 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 0059 in or less Service Limit 0 3 mm 0 012 in Friction Plate Warp 13088 0030 only Standard 0 2 mm 0 008 in or less Service Limit 0 3 mm 0 012 in Clutch Spring Free Length Measurement Measure the free length of the clutch springs A lf any spring is shorter than the service limit it must be replaced Clutch Spring Free Length Standard 32 1 mm 1 26 in Service Limit 31 0 mm 1 22 in Clutch Housing Finger Inspection e Visually inspect the clutch housing fingers A where the friction plate tangs B hit them x If they are badly worn or if there are groove cuts where the tangs hit replace the housing Also replace the friction plates if their tangs are damaged 6206060251 99999 GF13010781 GF06060381 C GF12020BS1 6 20 Clutch Clutch Housing Spline Inspection e Visually inspect where the teeth A on the steel plates wear against the sub clutch hub splines B x If there are notches worn into the splines replace the sub clutch hub Also replace the steel plates if their teeth are damaged Damper Cam Inspection e Remove the clutch see Clutch Removal e Visually inspect the damper cam
395. layed on the LCD by the number of two digits OWhen there are a number of problems all the service codes can be stored and the display will begin starting from the lowest number service code in the numerical order OThen after completing all codes the display is repeated until the ignition switch is turned to OFF or SEL is pushed for more than two seconds OThe order of the system s appearing is the order of DFl System KTRC System and Immobilizer System equipped models OFor example if three problems occurred in the order of 46 16 33 the service codes are displayed each two seconds from the lowest number in the order listed as shown below 16 33 46 16 33 46 gt repeated ERROR CODE ERROR_ CODE ERROR_CODE N 16 N 33 N 46 CN 1634 of OSOCN 28 af 9025 Z 12 34 em 123455 5 900 123455 ru 008 123455 e TT j EIF KTR 87030408 5 Oln the case more than two service codes are available you may push the upper button or lower button to shift into the other code too Olf the no problem or when the repair has done warning indicator light LED goes off and warning symbol and service code are not displayed Service Code Erasing OWhen repair has been done warning indicator light LED goes off and warning symbol and service code are not displayed But the service codes stored in
396. lb e Replace the swingarm pivot shaft nut A with a new one e Tighten the swingarm pivot shaft nut Torque Swingarm Pivot Shaft Nut 108 11 0 kgf m 79 7 ft lb e Install the removed parts see appropriate chapters 8 06105 51 C Swingarm SUSPENSION 13 33 Swingarm Bearing Removal Remove Swingarm see Swingarm Removal Collar A Oil Seals B Sleeves C Circlip D Right Side Special Tool Inside Circlip Pliers 57001 143 e Remove the ball bearing and needle bearings Special Tool Oil Seal amp Bearing Remover A 57001 1058 Swingarm Bearing Installation e Replace the ball and needle bearings A with new ones e Install the ball and needle bearings so that the manufac turer s marks face out Special Tools Bearing Driver Set 57001 1129 Needle Bearing Driver 28 B 57001 1610 28 C 57001 1663 GM06079BS1 GMO6219BS1 C 13 34 SUSPENSION Swingarm e Install the needle bearings A ball bearing B and oil seals C position as shown in the figure Circlip D 32 mm 1 26 in E 27 5 mm 1 08 in F 9 5 mm 0 37 in G 6GM062208W2 C Swingarm Bearing Sleeve Inspection 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 beari
397. le sen sor can damage it Subthrottle Sensor Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch to OFF e Remove the right middle fairing see Middle Fairing Re moval in the Frame chapter e Disconnect the subthrottle sensor connector and connect the harness adapter A between these connectors Special Tool Throttle Sensor Setting Adapter 57001 1538 e Connect a digital meter to the harness adapter leads Subthrottle Sensor Input Voltage Connections to Adapter Digital Meter W sensor BL lead Digital Meter gt BK sensor lead e Measure the input voltage with the engine stopped and with the connector joined e Turn the ignition switch to ON Input Voltage Standard DC 4 75 5 25 V e Turn the ignition switch to OFF x If the reading is within the standard check the output volt age see Subthrottle Sensor Output Voltage Inspection OBO 6617127851 FUEL SYSTEM DFI 3 85 Subthrottle Sensor Service Code 32 x If the reading is out of the standard remove the ECU and check the wiring for continuity between harness connec tors Special Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector Subthrottle Sensor Connector B BL lead ECU terminal 9 C G lead ECU terminal 13 D x If the wiring is good check the ECU for its ground and power sup
398. line B TDC mark for 41 4 pis tons on the timing rotor C is aligned with the mating sur face D of the crankcase e Remove the camshaft chain tensioner see Camshaft Chain Tensioner Removal eloosen the upper camshaft chain guide bolts and camshaft cap bolts as shown sequence 1 20 in the figure and remove them e Remove Upper Camshaft Chain Guide A Camshaft Caps B Camshafts C e Stuff a clean cloth into the chain tunnel to keep any parts from dropping into the crankcase LE CAEN MP DOOD OOD 8 GE113758W2 C Camshaft Camshaft Chain ENGINE TOP END 5 19 Remove Camshaft Sprocket Bolts A Camshaft Sprockets NOTICE 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 NOTE The exhaust camshaft has a 1093 EX mark A and the intake camshaft has a 1093 IN mark B Be careful not to mix up these shafts e Install the camshaft sprockets as shown in the figure 4 Cam Positions A Intake Camshaft Sprocket B Exhaust Camshaft Sprocket C OThe intake camshaft sprocket and exhaust camshaft sprocket are identical e Apply a non permanent locking agent to the threads of the camshaft sprocket bolts and tighten them Torque C
399. lippery road O snow 1 gravel 1 other Rough surface Other High speed cornering Driving 10 km h 6 mph or above Driving below 10 km h 6 mph When stopping When turning Gradual Abrupt Large brake lever stroke Large pedal stroke Driving conditions Brake application Other conditions 000 000 BRAKES 12 39 Anti Lock Brake System Equipped Models Pre Diagnosis Inspection 1 NG Check brake fluid level in brake reservoir Replenish brake fluid OK NG Check for brake fluid leakage Repair brake line OK NG Check brake lever and brake pedal function Repair or replace master cylinder OK NG Check brake pad and brake disc Replace faulty parts OK Front and rear wheels should rotate smoothly without NG brake drag Repair or replace caliper OK There shouldn t be a lot of play in the wheel bearing There shouldn t be excessive axle bending or disc runout 61140128 12 40 5 Anti Lock Brake System Equipped Models Pre Diagnosis Inspection 2 Check the yellow ABS indicator light LED Unlit Check the power source wiring and meter Does the yellow ABS indicator light LED light unit up with the ignition switch to ON Yes lit Drive at 6 km h 3 7 mph or above for one minute or more Yes When the motorcycle is running does the yellow ABS is normal ABS indic
400. llars C OBe sure that the collar D is in position NOTE OReplace the following bolts with new bolts pre coated with locking agent Engine Bracket Bolts P No 92153 1770 Front Engine Mounting Bolts P No 92153 1769 Subframe Bolts P No 92153 1768 OThird install the left engine bracket A and temporally tighten the left engine bracket bolts B and left front en gine mounting bolt C GH02078BS2 C GH02079BS1 GHO4171BS1 o 8 8 ENGINE REMOVAL INSTALLATION Engine Removal Installation OFourth remove the wrench lever and leave the socket head on the engine mounting bolt A Turn the adjust ing collar F counterclockwise with the socket head to grabbed hands until it becomes hard to turn eliminating a gap B Crankcase C Swingarm D 0 mm 0 in Torque Adjusting Collars 15 N m 1 5 kgf m 11 ft Ib ODo not exceed the specified torque of adjusting collars NOTE Olf the socket cannot be turned by hand adjust the po sition of the engine with a engine lifter to line up the alignment GHO4169BWi C ENGINE REMOVAL INSTALLATION 8 9 Engine Removal Installation Engine Bracket Upper Side GH04170BW3 C OFifth tighten the left engine bracket bolts A and left front engine mounting bolt B OSixth put alignment marks C on upper and lower engine mounting bolt D E and frame OReplace the engine mounting nuts M1
401. llation e Install the air switching valve A with hoses B as shown in the figure Front C 4 41 Right Side View D ingle White Paint E 1 i rur e Run the hoses correctly see Cable Wire and Hose Rout ing section in the Appendix chapter 8 04112 52 C Air Switching Valve Operation Test e Refer to the Air Switching Valve Operation Test in the Electrical System chapter Air Switching Valve Unit Test Refer to the Air Switching Valve Unit Test in the Electrical System chapter Clean Air System Hose Inspection Be certain that all the hoses are routed without being flat tened or kinked and are connected correctly to the air cleaner housing air switching valve and air suction valve covers they are not correct them Replace them if they are damaged 5 14 ENGINE END Cylinder Head Cover Cylinder Head Cover Removal e Remove Middle Fairings see Middle Fairing Removal in the Frame chapter Throttle Body Assy see Throttle Body Assy Removal in the Fuel System DFI chapter Air Switching Valve see Air Switching Valve Removal Radiator Cover see Radiator Cover Removal in the Cooling System chapter Stick Coils see Stick Coil Removal in the Electrical Sys tem chapter Air Suction Valve Covers see Air Suction Valve Re moval e Free the heat insulation rubber plate e Remove Cylinder Head Cover Bolts A with Rubber Wa
402. lted 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 The connecting rod bolts are designed to stretch when tightened Never reuse the connecting rod bolts See the table below for correct bolt and nut usage Be careful not to overtighten the nuts The bolts must be positioned on the seating surface correctly to prevent the bolt heads from hitting the crankcase CRANKSHAFT TRANSMISSION 9 19 Crankshaft and Connecting Rods 1 Bolt Length Measurement Method e Be sure to clean the bolts nuts and connecting rods thoroughly with a high flash point solvent because the new connecting rods bolts and nuts are treated with an anti rust solution A WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the bolts nuts and connecting rods in a well ventilated area and take care that there are no sparks or flame anywhere near the working area this includes any appliance with a pilot light Do not use
403. lutch Lever Pivot Bolt Locknut 5 9 52 in lb Clutch Master Cylinder Bleed Valve 5 4 48 in lb Clutch Master Cylinder Clamp Bolts 10 3 91 5 Starter Lockout Switch Screw 0 70 6 2 in lb L Sub Clutch Hub Bolts 25 18 L Clutch Spring Bolts 8 8 78 in lb Clutch Hub Nut 135 100 R Clutch Slave Cylinder Bleed Valve 7 8 69 in Ib Engine Lubrication System Oil Pipe Mounting Bolts 9 8 87 L Oil Pipe Bolts 9 8 87 in lb L Oil Passage Plug R1 4 15 11 L Oil Cooler Mounting Bolts 12 106 in lb 5 Pump Cover Bolts 9 8 87 in lb Oil Filter 17 13 Oil Pan Plate Bolts 9 8 87 in lb L Oil Filter Holder Mounting Bolt 35 26 L Oil Pan Bolts 9 8 87 Oil Pressure Switch Terminal Bolt 1 5 13 in lb G Oil Pressure Switch 15 11 SS Oil Pressure Relief Valve 15 11 L Oil Passage Plug R3 8 20 15 L Engine Oil Drain Bolt 30 22 Engine Removal Installation Engine Bracket Bolts M8 25 2 5 18 R 5 Subframe Bolts 23 2 3 17 Front Engine Mounting Bolts M10 59 6 0 44 5 PERIODIC MAINTENANCE 2 9 Torque and Locking Agent Fastener Remarks Engine Mounting Nuts M12 Adjusting Collars M Crankshaft Transmission Breather Cover Bolts L 25 mm 9 8 Breather Cover Bolt L 35 mm 9 8 Breather Cover Plate Screws 9 8 Oil Nozzle Pipe Mounting Bolts 25 Oil Passage Plugs R3 8 20 Bearing Position Plate Screws 4 9 Shift Drum Bearing Holder Screws 4 9 Clamp Bolts 9 8 Drive Shaft Cover Bolts 25 18 Timing Rotor Bolt 39 29 Connec
404. ly and replace any worn or damaged parts Torque Limiter Removal e Remove Rear Balancer see Rear Balancer Removal Starter Motor see Starter Motor Removal in the Electri cal System chapter Torque Limiter Bolt A e Holding the torque limiter A remove the torque limiter shaft B and the torque limiter Torque Limiter Installation e Apply molybdenum disulfide grease to the torque limiter shaft A e Install the torque limiter B and shaft OTurn the large hole end of the shaft to inside as shown in the figure e Replace the gasket C with a new one e Apply a non permanent locking agent to the threads of the torque limiter bolt D e Tighten Torque Torque Limiter Bolt 25 2 5 kgf m 18 ft Ib 9110005851 C 9 40 CRANKSHAFT TRANSMISSION Transmission Shift Pedal Removal Remove Shift Pedal Bolt A Shift Pedal B Shift Pedal Installation e Align A the punch mark B on the shift shaft with the upper surface C of shift pedal slit If the punch mark is misaligned with the slit the shift pedal is positioned D as shown in the figure In that case reinstall the shift pedal e Tighten the shift pedal bolt E e After tightening the shift pedal bolt check there is no backlash of the shift pedal External Shift Mechanism Removal e Remove Shift Pedal see Shift Pedal Removal Clutch see Clutch Removal in the Clutch chapter Snap Ring A Shift Shaft Assembly B
405. m 0 0012 in or less 10 g 0 35 oz less 10 g 0 35 oz 20 g 0 71 oz 30 g 1 06 oz J17M C x MT3 50 J17M C x MT6 00 Up to 175 kg 385 Ib load 290 kPa 2 9 kgf cm 42 psi Up to 175 kg 385 Ib load 290 kPa 2 9 kgf cm 42 psi METZELER 4 2 mm 0 17 in BRIDGESTONE 3 6 mm 0 14 in METZELER 5 3 mm 0 21 in BRIDGESTONE 4 8 mm 0 19 in Make Type METZELER TL SPORTEC M5 INTERACT E BRIDGESTONE BATTLAX HYPERSPORT S20F E METZELER TL SPORTEC M5 INTERACT E BRIDGESTONE BATTLAX HYPERSPORT S20R E TIR 0 2 mm 0 008 in 1 mm 0 04 in AT CH DE 1 6 mm 0 06 in Up to 130 km h 80 mph 2 mm 0 08 in Over 130 km h 80 mph 3 mm 0 12 in Size 120 70 2817 58W 190 50 ZR17 M C 73W A WARNING Some replacement tires may adversely affect handling and cause an accident resulting in serious injury or death To ensure proper handling and stability use only the recommended standard tires for replacement inflated to the standard pressure WHEELS TIRES 10 5 Special Tools Bearing Driver Set Bearing Remover Head 25 x 28 57001 1129 57001 1346 7571129ST C 8757134697 Jack Bearing Remover Shaft 013 57001 1238 57001 1377 7571238ST C 875713775 C 10 6 WHEELS TIRES Wheels Rims Front Wheel Removal e Remove Front Caliper Mounting Bolts A Both Sides Front Calipers B Both Sides Loosen Fro
406. m 0 39 in J 5 5 mm 0 22 in K 5 0 mm 0 20 in L GM070608W2 C 13 40 SUSPENSION Tie Rod Rocker Arm Rocker Arm Tie Rod Bearing Sleeve Inspection NOTICE Do not remove the bearings for inspection Re moval may damage them e Visually inspect the locker arm or tie rod sleeves A and needle bearings B e The rollers in a needle bearing normally wear very little and wear is difficult to measure Instead of measuring inspect the bearing for abrasion color change or other damage x If there is any doubt as to the condition of any of the nee dle bearings or sleeve replace the sleeve and needle bearings as a set Rocker Arm Tie Rod Bearing Lubrication NOTE OSince the bearings are packed with grease lubrication is not required GMO7016BS1 C STEERING 14 1 Steering Table of Contents 5 MEAT RECO 14 2 Special 14 4 ijr 14 5 Steering INSPECHON ie 14 5 Steering Adj stMe Nt e edo 14 5 Inge 14 6 Stem Stem Bearing Removal pp 14 6 Stem Stem Bearing Installation teet etri Etude 14 7 Steering Stem Bearing E UbHCALlOR pte 14 9 Steering Stem Warp Inspection 14 9 Stem Cap Deterioration
407. m Removal Sleeves A Oil Seals B Swingarm C see Swingarm Removal e Remove the needle bearings D using the bearing re mover head and bearing remover shaft Special Tools Bearing Remover Head 20 x 22 57001 1293 Bearing Remover Shaft 13 57001 1377 GM070598W2 C Tie Rod and Rocker Arm Bearing Installation e Replace the needle bearings and oil seals with new ones e Apply plenty of grease to the lips of the oil seals e Install the needle bearings and oil seals position as shown in the figure SUSPENSION 13 39 Tie Rod Rocker Arm OScrew the needle bearing driver A into the driver holder Olnsert the needle bearing driver into the needle bearing C and press the needle bearing into the housing until the driver contacts the end surface of the housing Bearing Pressing Depth 5 5 mm 0 22 in D 5 0 mm 0 20 in E NOTE OFor a bearing of inner diameter 18 select the pressing side of the needle bearing driver according to its press ing depth GM07030BS1 Special Tools Bearing Driver Set 57001 1129 Needle Bearing Driver 17 018 57001 1609 Spacer 18 57001 1636 Needle Bearing Driver 520 amp Spacer 28 57001 1678 NOTE Olnstall the needle bearings so that the marked side faces out Needle Bearings A Oil Seals B Front C Right Side D Left Side E Rear Shock Absorber F Tie Rods G Rocker Arm H 7 5 mm 0 30 in I 10 m
408. make sure to correct any of these conditions e Check the idle speed Idle Speed Standard 1 100 50 r min rpm xIf the idle speed is out of the specified range check the idle speed control valve actuator see Idle Speed Control Valve Actuator Inspection in the Fuel System DFI chap ter 2 20 PERIODIC MAINTENANCE Periodic Maintenance Procedures Idle Speed Adjustment NOTE OThis motorcycle is equipped with the idle speed control valve The idle speed is adjusted automatically at the specified value 1 100 r min by the idle speed control valve system Therefore it is not necessary to adjust the idle speed normally Fuel Hose Inspection fuel leak damage installation condition Olf the motorcycle is not properly handled the high pres sure inside the fuel line can cause fuel to leak A or the hose to burst Remove the fuel tank see Fuel Tank Re moval in the Fuel System DFI chapter and left middle fairing see Middle Fairing Removal in the Frame chap ter and check the fuel hose Replace the fuel hose if any fraying cracks B or bulges C are noticed e Check that the hoses are routed according to Cable Wire and Hose Routing section in the Appendix chapter Replace the hose if it has been sharply bent or kinked Hose Joints A Fuel Hose B e Check that the fuel hose joints are securely connected OPush and pull A the fuel hose joint B back and forth more than two ti
409. me Ground Battery 12 V 12 Ah Starter Relay Main Fuse 30 A Frame Ground 2 Fuel Reserve Switch ABS Hydraulic Unit ABS Equipped Models 15 16 17 18 19 20 21 22 23 24 25 26 27 Upper Lower Button SEL Button Fuse Box 1 Ignition Fuse 15A Fuse Box 2 Meter Fuse 10 Dimmer Switch High Beam Turn Signal Switch Left Outside Temperature Sensor Meter Unit Turn Signal Switch Right Joint Connector F Immobilizer Amplifier Equipped Models Immobilizer 16 90 ELECTRICAL SYSTEM Immobilizer System Equipped Models This motorcycle is equipped with an immobilizer system to protect the motorcycle from theft This system provides a theft proof device by means of matching a code between the inbuilt key transponder and ECU Electronic Control Unit If the code does not match ignition system injectors and sub throttle valve actuator will not operate and the engine will not start Abstract e Do not keep more than one immobilizer key of any system on a key ring Jamming of the key code signal may occur and the operation of the system may be affected e The warning indicator light LED will blink for a period of 24 hours once the ignition switch has been switched off and the key removed This blinking can be set to on or off as desired by holding the upper and lower buttons down for 2 seconds within 20 seconds of switching the ignition off e If all coded keys are lost the ECU and ignitio
410. me Ground 10 ECU Main Relay 3 Battery 11 Fuse Box 1 4 Starter Relay 12 Ignition Fuse 15 A 5 Main Fuse 30 A 13 Joint Connector A 6 ECU Fuse 15 A 14 Joint Connector F 7 Frame Ground 2 15 Ignition Switch 8 Frame Ground 1 16 Air Switching Valve FUEL SYSTEM 3 103 Oxygen Sensor Heater Service Code 67 Equipped Models Oxygen Sensor Heater Removal Installation The oxygen sensor heater is built in the oxygen sensor So the heater itself can not be removed Remove the oxy gen sensor see Oxygen Sensor Removal Equipped Mod els in the Electrical System chapter Oxygen Sensor Heater Resistance Inspection e Turn the ignition switch to OFF e Remove the right middle fairing see Middle Fairing Re moval in the Frame chapter e Disconnect the oxygen sensor lead connector A e Connect a digital meter A to the terminals in the oxygen sensor lead connector B e Measure the oxygen sensor heater resistance Oxygen Sensor Heater Resistance Connections W lead C W lead D Standard 6 7 10 5 at 20 68 F x f the reading is out of the standard replace the sensor xIf the reading is within the standard check the power source voltage see Oxygen Sensor Heater Power Source Voltage Inspection 65174300 3 104 FUEL SYSTEM Oxygen Sensor Heater Service Code 67 Equipped Models Oxygen Sensor Heater Power Source Voltage Inspection NOTE OBe sure the batter
411. memory of the ECU are not erased to preserve the problem history In this model the problem history can not be erased Service Code Table OThe service codes of the immobilizer system appear to the system equipped models 2 System Problems 11 FI Main throttle sensor malfunction wiring open or short 12 Fl Intake air pressure sensor 1 malfunction wiring open or short 13 FI Intake air temperature sensor malfunction wiring open or short 14 Fl Water temperature sensor malfunction wiring open or short 16 FI Intake air pressure sensor 2 malfunction wiring open or short 21 Fl Crankshaft sensor malfunction wiring open or short 24 FI KTRC Rear wheel rotation sensor malfunction wiring open or short 25 Fl Gear position switch malfunction wiring open or short Self Diagnosis FUEL SYSTEM DFI 3 49 Service Code System Problems 27 FI KTRC Front wheel rotation sensor signal abnormal sensor or rotor missing too large clearance rotor tooth worn or missing wiring open 31 FI Vehicle down sensor malfunction wiring open or short 32 FI Subthrottle sensor malfunction wiring open or short 33 Fl Immobilizer Immobilizer Fl Fl Fl Fl Fl Fl Fl Fl Fl Oxygen sensor inactivation wiring open or short Equipped Models Immobilizer amplifier malfunction Equipped Models Blank key detection Equipped Models Oxygen sensor heater malfunction wiring open or short E
412. mes and make sure it is locked x If it does not locked reinstall the hose joint A WARNING Leaking fuel can cause a fire or explosion resulting in serious burns Make sure the hose joint is in stalled correctly on the delivery pipe by sliding the joint Evaporative Emission Control System Inspection CAL and SEA B1 Models e Inspect the canister as follows ORemove Right Middle Fairing see Middle Fairing Removal in the Frame chapter Hoses A AA 9505096851 C PERIODIC MAINTENANCE 2 21 Periodic Maintenance Procedures ORemove Inner Fairing see Inner Fairing Remove the Frame chapter Screws A OVisually inspect the canister B for cracks or other dam age x If the canister has any cracks or bad damage replace it with a new one NOTE O The canister is designed to work well through the motor cycle s life without any maintenance if it is used under normal conditions e Inspect the purge valve see Purge Valve Inspection in the Fuel System DFI chapter OCheck that the hoses are securely connected and clips are in position OReplace any kinked deteriorated or damaged hoses ORun the hoses according to Cable Wire and Hose Rout ing section in the Appendix chapter OWhen installing the hoses avoid sharp bending kinking flattening or twisting and run the hoses with a minimum of bending so that the emission flow will not be obstructed Cooling System Coolant L
413. minal Do not pull the lead only the con nector Conversely make sure that all the DFI electrical connections are firmly reconnected before starting the en gine OConnect these connectors until they click A ODo not turn the ignition switch to ON while any of the DFI electrical connectors are disconnected The ECU memo rizes service codes ODo not spray water on the electrical parts DFI parts con nectors leads and wiring Olf a transceiver is installed on the motorcycle make sure that the operation of the DFI system is not influenced by electric wave radiated from the antenna Check operation of the system with the engine at idle Locate the antenna as far as possible away from the ECU OWhen any fuel hose is disconnected do not turn on the ignition switch Otherwise the fuel pump will operate and fuel will spout from the fuel hose ODo not operate the fuel pump if the pump is completely dry This is to prevent pump seizure OBefore removing the fuel system parts blow the outer sur faces of these parts clean with compressed air OWhen any fuel hose is disconnected fuel may spout out by residual pressure in the fuel line Cover the hose joint with a piece of clean cloth to prevent fuel spillage OWhen installing the fuel hoses avoid sharp bending kink ing flattening or twisting and run the fuel hoses with a minimum of bending so that the fuel flow will not be ob structed ORun the hoses according to Cable Wire an
414. minal 9 C G lead ECU terminal 13 D x If the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation Vehicle down Sensor Output Voltage Inspection e Remove the vehicle down sensor e Connect the measuring adapter A to the vehicle down sensor connectors as shown in the figure Special Tool Measuring Adapter 57001 1700 Main Harness B Vehicle down Sensor C e Connect a digital meter D to the measuring adapter leads Vehicle down Sensor Output Voltage Connections to Adapter Digital Meter W sensor Y G lead Digital Meter BK sensor lead GT04074BS1 GT04093BS1 3 82 FUEL SYSTEM Vehicle down Sensor Service Code 31 Hold the sensor vertically e Measure the output voltage with the engine stopped and with the connector joined e Turn the ignition switch to ON e Tilt the sensor 60 70 or more A right or left then hold the sensor almost vertical with the arrow mark pointed up B and measure the output voltage Output Voltage Standard With sensor tilted 60 70 or more right or left DC 0 65 1 35 V With sensor arrow mark pointed up DC 3 55 4 45 V e Turn the ignition switch to OFF x If the reading is out of the standard replace the sensor x If the reading is within the stand
415. mission Shaft Assembly e Apply engine oil to the bushings ball bearing and shafts e Install the gear bushings A on the shaft with their holes B aligned Replace any circlips removed with new ones e Install the circlips A so that the opening B of it is aligned with spline grooves C e Install the circlips so that the mark D on them faces to each gear side 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 correct sequence and all snap rings and washers are properly in place e Install the 3rd 4th gear onto the drive shaft with their oil holes aligned e Install the 5th and 6th gear bushings onto the drive shaft with their oil holes aligned e The output shaft gears can be recognized by size the gear with the largest diameter is 1st gear and the smallest one is 6th gear Be sure that all parts are put back in the correct sequence and all snap ring 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 2nd and 3rd 4th gear bushings onto the output shaft with their oil holes aligned e Fit the steel balls into the 5th gear holes in the output shaft aligning oil holes as shown in the figure 5th Gear A Output Shaft B Steel Balls C Oil Hole D Do not apply grease to the balls to hold them in
416. models rout ing is incorrect run the brake hose and pipe according to Cable Wire and Hose Routing section in the Appendix chapter GL10020181 Brake Operation Inspection e Inspect the operation of the front and rear brake by run ning the vehicle on the dry road xIf the brake operation is insufficiency inspect the brake system A WARNING When test riding the vehicle be aware of surround ing traffic for your safety Brake Fluid Level Inspection Check that the brake fluid level in the front brake reservoir A is above the lower level line B NOTE OHold the reservoir horizontal by turning the handlebar when checking brake fluid level x If the fluid level is lower than the lower level line fill the reservoir to the upper level line C 2 36 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Remove the seat see Seat Removal in the Frame chap ter Check that the brake fluid level in the rear brake reservoir A is above the lower level line B x If the fluid level is lower than the lower level line fill the reservoir to the upper level line C A WARNING Mixing brands and types of brake fluid can reduce the brake system s effectiveness and cause an ac cident resulting in injury or death Do not mix two brands of brake fluid Change the brake fluid in the brake line completely if the brake fluid must be re filled but the type and brand of the brake fluid that is alread
417. move Chain Cover see Drive Chain Removal in the Final Drive chapter Rear Wheel see Rear Wheel Removal in the Wheels Tires chapter Bolts A Clamps B e Remove Upper Tie Rod Nut and Bolt A Rear Shock Absorber B see Rear Shock Absorber Re moval e Unscrew the swingarm pivot shaft nut A e Unscrew the swingarm pivot shaft locknut A using the swingarm pivot nut wrench B Special Tool Swingarm Pivot Nut Wrench 57001 1597 e Unscrew the swingarm pivot shaft A few times OTurn out the swingarm pivot adjusting collar B e Pull out the pivot shaft to the right side of the motorcycle and remove the swingarm 13 32 SUSPENSION Swingarm Swingarm Installation e Apply plenty of grease to the lip of the oil seals A e Install the collar to the left side of the swingarm e Place the adjusting collar A into the frame B as shown in the figure 11 mm 0 43 C e Install the swingarm and insert the swingarm pivot shaft A into the adjusting collar B from the right side and tighten the pivot shaft Torque Swingarm Pivot Shaft 20 N m 2 0 kgf m 15 ft Ib NOTE O Tighten the swingarm pivot shaft until the clearance be tween the ball bearing C and collar comes to 0 mm 0 in e Tighten the swingarm pivot shaft locknut A with the swingarm pivot nut wrench B Special Tool Swingarm Pivot Nut Wrench 57001 1597 Torque Swingarm Pivot Shaft Locknut 98 N m 10 0 kgf m 72 ft
418. mple In the case of a input voltage of 4 75 V 0 42 x 4 75 5 00 0 40 V 0 62 x 4 75 5 00 0 59 V Thus the valid range is 0 40 0 59 V e Turn the ignition switch to OFF x lf the reading is out of the standard check the subthrot tle sensor resistance see Subthrottle Sensor Resistance Inspection x If the reading is within the standard remove the ECU and check the wiring for continuity between harness connec tors Special Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Subthrottle Sensor Connector B BL W lead ECU terminal 12 C G lead ECU terminal 13 D xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation GT04095BS1 C FUEL SYSTEM 3 87 Subthrottle Sensor Service Code 32 Subthrottle Sensor Resistance Inspection e Turn the ignition switch to OFF e Disconnect the subthrottle sensor connector Connect a digital meter A to the subthrottle sensor con nector B Measure the subthrottle sensor resistance Subthrottle Sensor Resistance Connections BL lead C lt gt G lead D Standard 4 6kO xIf the reading is out of the standard replace the throttle body assy x lf the reading is within the standard but the problem still exists replace the
419. must be completely wiped up immediately Never drop the fuel pump especially on a hard sur face Such a shock to the pump can damage it e Draw the fuel out from the fuel tank with a commercially available electric pump e Remove the fuel tank see Fuel Tank Removal OBe careful of fuel spillage from the fuel tank since fuel still remains in the fuel tank and fuel pump Plug the fuel pipe of the fuel tank e Turn the fuel tank upside down e Open the clamp A e Unscrew the fuel pump bolts B and take out the fuel pump C NOTICE Do not pull the leads of the fuel pump and fuel re serve switch If they are pulled the lead terminals may be damaged e Discard the fuel pump gasket A 3 124 FUEL SYSTEM Fuel Pump Fuel Pump Installation e Remove dirt or dust from the fuel pump A by lightly ap plying compressed air e Replace the fuel pump gasket with a new one e Check that the fuel pump terminals A fuel reserve switch terminal B and band C are in place Left D Apply a non permanent locking agent to the threads of the fuel pump bolts Tighten the fuel pump bolts to a snug fit following the tight ening sequence as shown in the figure e Following the tightening sequence tighten the fuel pump bolts to the specified torque Torque Fuel Pump Bolts 9 8 N m 1 0 kgf m 87 in Ib e Tighten the fuel pump bolts again to check the tightness in the order shown
420. n Assy H Diaphragm I e Before assembly clean all parts including the master cylinder with clutch fluid or alcohol Use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning parts Do not use any other fluid for cleaning these parts Gasoline motor 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 eventu ally deteriorate the rubber used in the cylinder e Apply clutch fluid to the parts removed and to the inner wall of the cylinder e Take care not to scratch the piston or the inner wall of the cylinder Torque Clutch Lever Pivot Bolt 1 0 N m 0 10 kgf m 8 9 in Ib Clutch Lever Pivot Bolt Locknut 5 9 N m 0 60 kgf m 52 in Ib e Install the clutch master cylinder see Clutch Master Cylin der Removal in the Clutch chapter 6 08027BS2 C PERIODIC MAINTENANCE 2 57 Periodic Maintenance Procedures Clutch Slave Cylinder Piston Seal Replacement e Remove Left Lower Fairing see Lower Fairing Removal in the Frame chapter Coolant Reserve Tank see Coolant Reserve Tank Re moval Installation in the Cooling System chapter e Loosen the banjo bolt A at the clutch pipe lower end and tighten it loosely e Remove the slave cylinder bolts B and detach the slave cylinder with the pipe installed from the engine e Pump the clutch lever until the piston comes out of the cyli
421. n DFI system ignition system KTRC system and immobilizer system equipped models by lighting or blinking the yellow engine warning indicator light LED A red warning indicator light LED B yellow KTRC warning indicator light LED C and warning symbol D when DFI ignition KTRC and immobilizer system parts are faulty and initiates fail safe function In case of serious troubles ECU stops the injec tion and ignition operations Red A GT03035BS1 07030268 Self Diagnosis FUEL SYSTEM DFI 3 45 Dealer Mode The LCD Liquid Crystal Display displays the service code s A to show the problem s which the above system has at the moment of diagnosis Self Diagnosis Procedures NOTE OUse a fully charged battery when conducting self diagnosis Otherwise the light LED and symbol do not light or blink e Turn the ignition switch to ON OWhen a problem occurs with DFI system and ignition sys tem the yellow engine warning indicator light LED A goes on to alert the rider OWhen a problem occurs with KTRC system the yellow KTRC warning indicator light LED B goes on ERROR CODE 23a ee a 000 00 KTRC faq 0017228 5 9703037851 3 46 FUEL SYSTEM DFI Self Diagnosis OWhen a problem occurs with immobilizer system equipped models the red warning indicator light LED A blinks and immobilizer warnin
422. n Lower 2106556 5 C ELECTRICAL SYSTEM 16 23 Wiring Diagram ABS Equipped Models Other than SEA B1 and BR Models Intake Air ii Pressure iet ub Sensor 2 Intake Water Crank throttle Main Sub Air 2 shaft op Valve Throttle throttle Pressure Sensor Fuel ensor Idle Speed fi i ctuator Sensor Sensor avi Oxygen Control switihing 96 Bear Position Valve Value Switch ais Actuator Joint Fuel Connector Level Ee y Se e Er I I T Sensor 55 ds ge dr e o uel of IB zz z BL BL 2 Hr p gt g Joint Joint 55 x ey z 8 Connector ax 4 BL R Joint Connector E ex o aR Y WR HI R BL L6 8K BRN BK R BK G BL R BL BK ao D BK BL 6 R BK LB GY BL P BK o Y BL Y P BK R e o 6 BL W Gal Y BK R G amp Rear Wheel B Rotation Immobilizer Kawasaki Diagnostic Systen Connector Sensor Rear Right Turn Signal Light 12V21W BL R Tail Brake BK Y a o R a x B lu
423. n reading is not within the us able range Problem Diagnosis Remedy Action Cylinder Carbon accumulation on piston and in Remove the carbon deposits and compression combustion chamber possibly due to replace damaged parts if necessary is higher than damaged valve stem oil seal and or usable range damaged piston oil rings This may be indicated by white exhaust smoke Incorrect cylinder head gasket thickness Replace the gasket with a standard part Cylinder Replace damaged gasket and check Gas leakage around cylinder head compression cylinder head warp is lower than Bag condition of valve seating Repair if necessary usable range Incorrect valve clearance Adjust the valve clearance Incorrect piston cylinder clearance Replace the piston and or cylinder Piston seizure Inspect the cylinder and replace repair the cylinder and or piston as necessary Bad condition of piston ring and or piston Replace the piston and or the piston ring grooves rings Cylinder Head Removal Remove Engine see Engine Removal in the Engine Removal In stallation chapter Cylinder Head Cover see Cylinder Head Cover Re moval Camshafts see Camshaft Removal Water Temperature Sensor Connector see Water Tem perature Sensor Removal Installation in the Fuel System DFI chapter Cylinder Head ENGINE TOP END 5 25 Remove the air bleeder hoses and water hose from the thermostat housing Remove F
424. n switch will have to be replaced e The immobilizer system can not function until the ignition key code is registered in the ECU A total of five keys can be registered in the ECU at any one time Operational Cautions Do not put two keys of any immobilizer system on the same key ring Do not submerge any key in water Do not expose any key to excessively high temperature Do not place any key close to magnet Do not place a heavy item on any key Do not grind any key or alter its shape Do not disassemble the plastic part of any key Do not drop the key and or apply any shocks to the key When ignition key is lost the user should go to his dealer to invalidate the lost key registration in the ECU 10 When the all ignition keys are lost the user should go to his dealer and have a new ECU installed and register the ignition keys M Nr NOTE 9 10 are strongly recommended to the customer to ensure security of the motorcycle Key Registration Case 1 When the ignition key has been lost or addi tional spare ignition key is required e Prepare a new spare ignition key e Cut the key in accordance with the shape of the current ignition key e Remove the seat see Seat Removal in the Frame chap ter e Disconnect the immobilizer Kawasaki diagnostic system connector A e Connect the key registration unit A and key registration adapter B Special Tools Key Registration Unit
425. n the crankshaft at 2 3 position TDC e Insert the pin A as shown in the figure Set the front balancer on the upper crankcase half OAlign the punch mark B on the balancer gear C with the mark D on the balancer drive gear E of crankshaft 08106807841 C e Assemble the crankcase see Crankcase Assembly e Install the new oil seal A so that its surface B is flush with the surface of the crankcase C the oil seal lips with grease e Install the balancer shaft clamp lever e Tighten Torque Balancer Shaft Clamp Lever Bolt D 25 2 5 kgf m 18 ft lb e Turn the balancer shaft so that its mark E is aligned with the crankcase mating line F e Check that the lever G is in contact with the crankcase e Tighten Torque Balancer Shaft Clamp Bolt H 9 8 N m 1 0 kgf m 87 in Ib 08106051841 C Rear Balancer Removal e Remove Engine see Engine Removal in the Engine Removal In stallation chapter Throttle Body Assy see Throttle Body Assy Removal in the Fuel System DFI chapter Breather Cover Bolts A Breather Cover B Breather Cover Gasket C 9106052851 CRANKSHAFT TRANSMISSION 9 33 Balancer Remove Balancer Shaft Clamp Lever Bolt A e Pry off the clamp lever A until the oil seal B removed e Pull the balancer shaft C out of the crankcase The bal ancer weight and gear assembly D come off with needle bearings and wa
426. n the filter with the oil filter wrench Torque Oil Filter 17 1 7 kgf m 13 ft lb NOTE OHand tightening of the oil filter can not be allowed since it does not reach to this tightening torque e Pour in the specified type and amount of oil see Engine Oil Change 6005040251 Brake Hose Replacement Brake fluid quickly ruins painted plastic surfaces any spilled fluid should be completely washed away immediately Remove Upper Inner Fairing see Upper Inner Fairing Removal in the Frame chapter Cover Bolts A Cover B e Remove Bolt A Clamp B 2 60 PERIODIC MAINTENANCE Periodic Maintenance Procedures Remove the brake hose 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 loss to a minimum e Immediately wash away any brake fluid that spills PERIODIC MAINTENANCE 2 61 Periodic Maintenance Procedures e For ABS equipped models note the following e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Battery see Battery Removal in the Electrical System chapter Upper Fairing see Upper Fairing Removal in the Frame chapter Brake Pipe Joint Nuts A Using the flare nut wrench Bolts B Brackets C Cover D e There are washers on each side of the brake hose fitting Replace them with new ones when install
427. n the tank cap for any damage Replace the gasket if it is damaged e Check to see if the water drain pipe B and fuel breather pipe C in the tank are not clogged Check the tank cap breather also x lf they are clogged remove the tank and drain it and then blow the breather free with compressed air NOTICE Do not apply compressed air to the air vent holes D in the tank cap This could cause damage and clogging of the labyrinth in the cap Fuel Tank FUEL SYSTEM 3 151 Fuel Tank Cleaning A WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the tank in a well ventilated area and take care that there are no sparks or flame any where near the working area Do not use gasoline or low flash point solvents to clean the tank e Remove Fuel Tank see Fuel Tank Removal Fuel Pump see Fuel Pump Removal e Pour some high flash point solvent into the fuel tank and shake the tank to remove dirt and fuel deposits e Draw the solvent out of the fuel tank e Dry the tank with compressed air e Install Fuel Pump see Fuel Pump Installation Fuel Tank see Fuel Tank Installation 3 152 FUEL SYSTEM Evaporative Emission Control System CAL and SEA B1 Models The Evaporative Emission Control System routes fuel va pors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped Al thou
428. nal Relay Fuse 10A R Y R BK BK Y Turn 2 Signal Fuse Box 2 l Metre Fuse 10A Headlight Headlight Relay 2 Fan Fuse 15 Reley LO Relay HI 3 Headlight Relay Fuse 15A 4 ABS Solenoid Valve Rolay Fuse 15 8 5 Motor Relay Fuse 20 6 ABS ECU Fuse 10 Left Switch Housing Relay Box ABS Hydraulic Unit Left Switch Housing Relay Box 1 Horn Button 5 Dimmer Switch 1 Radiator Fan Rel 3 ECU Main Rel 2 Hazard Button 6 Starter Lockout Switch tiree A FUSTO BUMD RELAY 3 Turn Signal Switch 7 SEL Button 5 Starter Circuit 4 Passing Button 8 Upper and Lower Button Relay LEFT SWITCH HOUSING CONNECTIONS Horn Buton Hazard Button Turn Signal Switch Passing Button ch Starter Lockout Switch Multifunction patton 5t estee E Picoto EY pk Rene Clutch Lever Push Released Released R Lo Pulled In Lower W2LO691BWS C ELECTRICAL SYSTEM 16 25 Wiring Diagram ABS Equipped Models SEA B1 Model Intake Air ct Pressure iet ub Sensor 2 Intake fet Crank throttle Main Sub Rp T shatt vrusi Yalve Throttle throttle Pressure oe Sensor uel Injectors Sensor 1 Idle Speed 8 ctuator Sensor Sensor x Oxygen Control switihing 96 Bear
429. nd Gear Clutch Engine Position Lever Run running Up Pulled in Continue running start running Up Pulled in Continue running running running Down In Gear Released Stops Down In Gear Pulled in Stops xIf the sidestand switch operation does not work inspect or replace the following item Battery see Charging Condition Inspection in the Elec trical System chapter Main Fuse 30 A see Fuse Inspection in the Electrical System chapter ECU Fuse 15 A see Fuse Inspection in the Electrical System chapter Ignition Fuse 15 A see Fuse Inspection in the Electrical System chapter Ignition Switch see Switch Inspection in the Electrical System chapter Sidestand Switch see Switch Inspection in the Electrical System chapter Starter Lockout Switch see Switch Inspection in the Electrical System chapter Engine Stop Switch see Switch Inspection in the Elec trical System chapter Starter Button see Switch Inspection in the Electrical System chapter Gear Position Switch see Gear Position Switch Inspec tion in the Electrical System chapter Starter Relay see Starter Relay Inspection in the Elec trical System chapter Relay Box see Relay Circuit Inspection in the Electrical System chapter Starter Circuit Relay see Relay Circuit Inspection in the Electrical System chapter Harness see Wiring Inspection in the Electrical System chapter x lf the all parts in good condition replace the ECU 2 46 PERIOD
430. nd connect a suitable measuring leads A between these connectors as shown in the figure Main Harness B Idle Speed Control Valve Actuator C Connect the peak voltage adapter D and a digital meter E to the measuring adapter leads Special Tool Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Idle Speed Control Valve Actuator Input Voltage Connections to Adapter I Digital Meter actuator G Y lead Digital Meter Frame Ground terminal Digital Meter gt W actuator G BK lead Digital Meter Frame Ground terminal Digital Meter gt Y actuator lead Digital Meter Frame Ground terminal IV Digital Meter BK actuator G R lead Digital Meter Frame Ground terminal Measure the actuator input voltage with the engine stopped and with the connector joined e Turn the ignition switch to ON Input Voltage Standard About DC 11 13 V and then 0 5 V or About DC 11 13 V e Turn the ignition switch to OFF GT04118BS1 C R G Y pa 9 3 9704119851 C e 3 108 FUEL SYSTEM Idle Speed Control Valve Actuator Service Code 1C x If the reading is out of the specification remove the ECU and check the wiring for continuity between main harness connector Special Tool Hand Tester 57001 1394 ODisconnect the ECU and actuator connectors Wiring Continuity Inspection ECU Conn
431. nd damping adjuster B with a pair of vernier caliper 13 mm 0 51 in C e Replace the O ring A on the top plug B with a new one e Apply grease to the new O ring e Install the top plug on the piston rod and screw it e Holding the top plug with a wrench tighten the piston rod nut C against the top plug Torque Piston Rod Nuts 28 N m 2 9 kgf m 21 ft Ib e Remove the fork spring stopper e Align the stoppers A of the top plug B with the grooves C of the clamp D and loosen the fork spring compres sor nut e Remove the fork spring compressor and clamps e Raise the outer tube and screw the top plug into it e Install the front fork see Front Fork Installation NOTE OAfter installing the front fork adjust the spring preload and damping force correctly 004224 P GM04409BS1 C 13 24 SUSPENSION Front Fork Front Fork Disassembly e Remove the front fork see Front Fork Removal e Drain the fork oil see Front Fork Oil Change Hold the axle portion of the front fork in vise A Stop the cylinder B from turning by using the fork cylinder holder C Special Tool Fork Cylinder Holder 57001 1287 e Unscrew the Allen bolt D then take the bolt and gasket out of the bottom of the inner tube Remove the cylinder unit A from the inner tube ODo not disassemble the cylinder unit e Separate the outer tube A from the inner tube B e
432. nder e Remove the banjo bolt and remove the slave cylinder C NOTICE Immediately wash away any clutch fluid that spills It may damage painted surfaces NOTE Olf the clutch slave cylinder is removed and left alone the piston will be pushed out by spring force e Remove the spring and piston seal Replace the piston seal with a new one if it was re moved from the piston e Before assembly apply clutch fluid to the outside of the piston and the piston seal e Install the piston seal as shown in the figure Cylinder A Piston B Piston Seal C aes Spring D A WARNING Vehicle operation with insufficient deteriorated or contaminated engine oil will cause accelerated wear and may result in engine seizure accident and injury Check the oil level before each use and change the oil and filter according to the periodic maintenance chart Engine Oil Change e Situate the motorcycle so that it is vertical after warming up 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 e Replace the drain bolt gasket B with a new one e Tighten the drain bolt Torque Engine Oil Drain Bolt 30 N m 3 1 kgf m 22 ft Ib 2 58 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Remove the oil filler plug A e Pour in the specified type and amount of oil Recommende
433. ne None Bearing Insert Crankpin Diameter Marking Crankshaft Main Bearing Insert Selection Crankcase Main Crankshaft Main Bearing Inside Journal Diameter Diameter Marking Marking Size Color 1 Brown Black None None Blue Size Color Brown Black Blue Bearing Insert Part Number 92139 0740 92139 0743 92139 0739 92139 0742 92139 0738 92139 0741 Part Number 92139 0131 92139 0130 92139 0129 Journal Nos 1 3 5 2 4 1 3 5 2 4 1 3 5 2 4 bearing inserts for Nos 2 and 4 journals have oil groove respectively Special Tools and Sealants Bearing Puller 57001 135 Outside Circlip Pliers 57001 144 875701355 C 7570144ST C Bearing Puller Adapter 57001 317 875703175 C Piston Pin Puller Assembly 57001 910 7570910ST C CRANKSHAFT TRANSMISSION 9 9 Piston Ring Compressor Grip 57001 1095 875710955 C Bearing Driver Set 57001 1129 7571129ST C Piston Ring Compressor Belt 80 91 57001 1320 ud 875713205 6 Liquid Gasket TB1216B 92104 1064 879210645 9 10 CRANKSHAFT TRANSMISSION Crankcase Splitting Crankcase Splitting e Remove the engine see Engine Removal in the Engine Removal Installation chapter Set the engine on a clean surface and hold the engine steady
434. ne oil to the shim or the valve lifter to keep the shim in place during camshaft installation 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 e Apply engine oil to the valve lifter surface and install the lifter e Install the camshaft see Camshaft Installation in the En gine Top End chapter Recheck the valve clearance and readjust if necessary e Install the removed parts see appropriate chapters Air Suction System Damage Inspection e Remove the left middle fairing see Middle Fairing Re moval in the Frame chapter Pull the air switching valve hose A out of the frame Start the engine and run it at idle speed e Plug B the air switching valve hose end with your finger and feel vacuum pulsing in the hose x lf there is no vaccum 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 Clutch Clutch Operation Inspection Start the engine and check that the clutch does not slip and that it releases properly x If the clutch operation is insufficiency inspect the clutch system A WARNING When test riding the vehicle be aware of su
435. ne with a suitable stand A OPut a plank B onto the suitable stand for engine balance e Remove Engine Bracket Bolts A Both Sides Front Engine Mounting Bolt B Both Sides Engine Bracket C Both Sides e Remove the engine mounting nuts A NOTE OHold the mounting bolt at the right side of the frame not to turn when loosening the upper and lower engine mounting nuts at the left side of the frame GH04087BS1 e Disconnect the engine ground terminal e Using a Hexagon Wrench turn the engine mounting bolts A clockwise to make the gap between the engine and adjusting collar e Remove the drive chain from the output shaft e Using the stand take out the engine Engine Installation e Support the engine with a suitable stand OPut a plank onto the suitable stand for engine balance e Install the heat insulation rubber plate and run the leads and hoses correctly see Cable Wire and Hose Routing section in the Appendix chapter ENGINE REMOVAL INSTALLATION 8 7 Engine Removal Installation e Install the engine mounting bolts and nuts following the specified installing sequence OApply molybdenum disulfide grease A to the threads of the adjusting collars OFirst tighten the adjusting collars fully by hand Upper Adjusting Collar B Upper Crankcase C Lower Adjusting Collar D Lower Crankcase E OSecond insert the mounting bolts A until they fit B in the adjusting co
436. nect the battery negative terminal to the terminal 12 e Connect the terminal 4 to the battery terminal Check that the green neutral indicator light LED A goes on x lf the indicator light does not go on replace the meter unit GP17574BS1 GP17578BS1 16 88 ELECTRICAL SYSTEM Meter Gauge Indicator Unit Check 3 8 Other Inspection OThe following items are displayed while running AVERAGE CURRENT RANGE Outside Temperature KTRC Level Indicator Odometer Trip A B Meter ECO Mark Water Temperature Engage Lamp Shift Lamp Indication e When the above item is faulty indication check the follow ing items Wiring see Wiring Inspection CAN Communication Line Resistance see Check 1 and CAN Communication Line Resistance Inspection in the Fuel System DFI chapter Fuel Injectors see Fuel Injectors section in the Fuel Sys tem DFI chapter Fuel Level Sensor see Fuel Level Sensor Inspection Fuel Reserve Switch see Fuel Reserve Switch Inspec tion x If the above items are good replace the meter assembly and or ECU Meter Gauge Indicator Unit ELECTRICAL SYSTEM 16 89 Meter Unit Circuit GY BL wy LG BK E MM GPi7932CW3 C 1a o RWNM O Ignition Switch Fuel Level Sensor Water Temperature Sensor Gear Position Switch Oil Pressure Switch ECU Joint Connector B Fra
437. nector and connect the measuring adapter A between these con nectors as shown in the figure Harness B Water Temperature Sensor C Special Tool Measuring Adapter 57001 1700 e Connect a digital meter D to the measuring adapter leads Water Temperature Sensor Output Voltage Connections to Adapter Digital Meter R sensor O lead Digital Meter BK sensor BR lead e Measure the output voltage with the engine stopped and the connector joined e Turn the ignition switch to ON Output Voltage Standard About DC 2 80 2 97 V at 20 C 68 F NOTE OThe output voltage changes according to the coolant temperature in the engine GT04083BS1 FUEL SYSTEM 3 67 Water Temperature Sensor Service Code 14 e Turn the ignition switch to OFF xIf the reading is within the standard check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation x If the reading is out of the standard remove the ECU and D check the wiring for continuity between harness tors Special Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor connectors ECUConnecr A s Water Temperature Sensor Connector O lead ECU terminal 23 C BR lead ECU terminal 13 D If the wiring is good check the water temperature sensor resistance see
438. ner Cover Installation 15 16 Removal cuite chere es 15 26 Upper Inner Fairing Removal 15 16 Right Inner Rubber Cover Upper Inner Fairing Installation 15 17 Installation 15 27 Upper Fairing Bracket Removal 15 17 Center Stand Sidestand 15 28 Upper Fairing Bracket Installation 15 17 Center Stand Removal Equipped Inner Fairing 15 17 Models 15 28 Inner Fairing Installation 15 18 Center Stand Installation Rear Fairing Removal Equipped Equipped 5 15 18 Sidestand Removal Rear Fairing Installation Sidestand Installation 15 28 Equipped Models 15 18 Rear View 15 29 Seat GOVOLD 15 19 Rear View Mirror Removal 15 29 Seat Cover Remowval 15 19 Rear View Mirror Installation 15 29 15 2 FRAME Exploded View FRAME 15 3 Exploded View Remarks 1 Front Footpeg Bracket Bolts 2 Sidestand Nut Sidestand Bolt 4 Sidestand Bracket Bolts 5 6 Sidestand Switch Bolt 0 90 78 in lb L Center Stand Bolts Equipped Models 44 4 5 32 7 Center Stand Equipped Models G Apply grease L Apply a non permanent locking agent R Replacement Parts S Follow the specified tightening sequence
439. ng normally wear very little and wear is difficult to measure Instead of measuring visually inspect the bearing for abrasion discoloration or other damage x lf the needle bearing and sleeve B show any sings of abnormal wear discoloration or damage replace them as a set e Turn the bearing in the swingarm back and forth A while checking for plays roughness or binding bearing play roughness or binding is found replace the bearing e Examine the bearing seal B for tears or leakage x If the seal is torn or is leaking replace the bearing Swingarm SUSPENSION 13 35 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 13 36 SUSPENSION Tie Rod Rocker Arm Tie Rod Removal Squeeze the brake lever slowly and hold it with a band A e Remove Center Stand see Center Stand Removal in the Frame chapter Equipped Models Rear Fairing see Rear Fairing Removal in the Frame chapter Equipped Models Bracket see Rear Shock Absorber Removal Equipped Models e Raise the rear wheel off the ground with the jack Special Tools Jack 57001 1238 Jack Attachment 57001 1608 Remove Upper Tie Rod Nut and Bolt A Lower Tie Rod Nut and Bolt B Tie Rods C Tie Rod Installation e Apply grease to the inside of the
440. nks e By pushing the upper lower button each time check that the display changes as follows OFF 7500 lt gt 7600 10900 lt gt 11000 GP17963CN3 Check that the engine speed setting menu is decided by the SEL button pushing x If the display function does not work replace the meter assembly e Select the LAMP MODE A indication e Push the SEL button check that the lighting mode setting menu B blinks e By pushing the upper lower button each time check that the display changes as follows and the indicator light LED goes on according to message BRIGHT DIM BLINK GP17964CN3 C e Check that the lighting mode setting menu is decided by the SEL button pushing xIf the display function does not work replace the meter assembly 16 82 ELECTRICAL SYSTEM Meter Gauge Indicator Unit e Select the CLOCK A indication e Push the SEL button OThe clock setting menu hour B should blink e By pushing the upper lower button each time check that the hour display changes e By pushing the SEL button check that the hour display decide and minute display A starts blinking e By pushing the upper lower button each time check that the minute display changes e By pushing the SEL button check that the hour and minute display decide x lf the display function does not work replace the meter assembly Meter System Inspe
441. nout excessive Engine mounting portions loose Handlebar pulls to one side Frame bent 17 58 APPENDIX Troubleshooting Guide 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 Rear shock absorber adjustment too soft Front fork rear shock absorber spring weak Rear shock absorber oil leaking Brake Doesn t Hold Air in the brake line Pad or disc worn Brake fluid leakage Disc warped Contaminated pad Brake fluid deteriorated Primary or secondary cup damaged in master cylinder Master cylinder scratched inside Battery Trouble Battery discharged Charge insufficient Battery faulty too low terminal voltage Battery cable making poor contact Load excessive e g bulb of excessive wattage Ignition switch trouble Alternator trouble Wiring faulty Regulator rectifier trouble Battery overcharged Alternator trouble Regulator rectifier trouble Battery faulty MODEL APPLICATION Year Model Beginning Frame No JKBZXNE10CA000001 ae 2 1400 JKBZXT40EEA000001 JKBZXNF1DCA000001 ze
442. ns A of the tail brake light into the holes B of the rear fender e Tighten Torque Tail Brake Light Mounting Screws 1 2 0 12 kgf m 11 in Ib e Install the removed parts see appropriate chapters License Plate Light Bulb Replacement e Remove License Plate Light Cover Mounting Screws A License Plate Light Cover B e Push and turn the bulb A counterclockwise and remove it e Replace the bulb with a new one 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 Tighten Torque License Plate Light Cover Mounting Screws 1 8 0 18 kgf m 16 in Ib GI P 16 66 ELECTRICAL SYSTEM Lighting System Light Circuit 6969 26909 1 Ignition Switch 17 Frame Ground 4 2 Fuse Box 2 18 Headlight Circuit Relay 3 Headlight Relay Fuse 1 15 A 19 Relay Box 4 Fuse Box 1 20 Dimmer Switch 5 Headlight Relay Fuse 2 15 A 21 Passing Button 6 Turn Signal Relay Fuse 10 A 22 Headlight Relay High 7 Tail Brake Light LED 23 Headlight Relay Low 8 License Plate Light 24 Left City Light 9 Joint Connector B 25 Headlight Low Beam 10 Frame Ground 26 Headlight High Beam 11 Battery 12 V 12 Ah 27 Joint Connector G 12 Starter Relay 28 Joint Connector A 13 Main Fuse 30 A 29 Right City Light 14 Alternator
443. nt Axle Clamp Bolts A Right Side Front Axle B Raise the front wheel off the ground Special Tool Jack 57001 1238 Pull out the front axle to the right side and drop the front wheel out of the front forks Do not lay the wheel down on one of the discs This can damage or warp the disc Place blocks un der the wheel so that the disc does not touch the ground Loosen the front axle clamp bolts left side A and re move the front axle nut B Front Wheel Installation NOTE OThe direction of the wheel rotation A is shown by an arrow B on the wheel spoke Check the wheel rotation mark on the front wheel and install it WHEELS TIRES 10 7 Wheels Rims e Apply high temperature grease to the grease seal lips e Fit the collars A on the both sides of the hub OThe oollars are identical e Insert the axle from the right side e Tighten the axle nut B Right Axle Clamp Bolts C Left Axle Clamp Bolts D Viewed from Rear E Torque Front Axle Nut 127 N m 13 0 kgf m 93 7 ft lb e Before tightening the axle clamp bolts on the right front fork leg pump the front fork up and down 4 or 5 times to all on 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 bolts on the right fork leg first Next tighten the axle clamp bolts on the left fork leg NOTE O Tighten the two clamp bolts alternatel
444. nt Brake Pad Removal Front Brake Pad Installation Rear Brake Pad Removal 252 de cea Rear Brake Pad Installation Brake Pad Wear Inspection Master Cylinder ertet eR OR D Front Master Cylinder Removal 2 ite Einb po qe e pon 12 22 Front Master Cylinder Installation pp 12 22 Rear Master Cylinder cito tct bete iere o Done eeux 12 22 Rear Master Cylinder Installation enne 12 23 Front Master Cylinder Disassembly pp 12 23 Rear Master Cylinder Disassembly pp 12 23 Master Cylinder Assembly asuma Ste 12 23 Master Cylinder Inspection Visual 12 23 Brake DiS s use DO tne Ci a dt 12 24 Brake Disc Hermowval tite esto d 12 24 Brake Disc Installation ee rer bete Ha edes e beds eta Deed seid 12 24 Brake Disc Wear Inspection se e eben e d uH Bd s coe 12 24 Brake Disc Warp Inspection eoe ee erar e au pte tcx RARE 12 24 Brake T 12 25 Brake Fluid Level Inspection o 12 25 Brake Pluid MANOS ite Seated 12 25 Brake Line 12 25 BAKE
445. nt Marks R Replacement Parts 12 10 BRAKES Exploded View ABS Equipped Models BRAKES 12 11 Exploded View 1 Brake Pipe 18 1 2 Brake Hose Barjo Bos s 25 18 7 3 ABS Hydraulic Unit 4 Blue Paint Marks 2 Points 5 White Paint Marks 6 White Paint Marks 2 Points 7 Yellow Paint Marks 2 Points R Replacement Parts 12 12 5 Specifications Item Standard Service Limit Brake Lever Brake Pedal Brake Lever Position Brake Lever Free Play Pedal Position Pedal Free Play 6 way adjustable to suit rider Non adjustable About 45 mm 1 77 in below top of footpeg Non adjustable Brake Pads Lining Thickness Front 4 0 mm 0 16 in 1 mm 0 04 in Rear 5 0 mm 0 20 in 1 mm 0 04 in Brake Discs Thickness Front 4 8 5 2 mm 0 19 0 20 in 4 5 mm 0 18 in Rear 5 8 6 2 mm 0 23 0 24 in 5 5 mm 0 22 in Runout TIR 0 15 mm 0 006 in or less TIR 0 3 mm 0 01 in Brake Fluid Grade ABS Equipped Models Wheel Rotation Sensor Air Gap Front Rear 0 7 0 9 mm 0 028 0 035 in 0 7 0 9 mm 0 028 0 035 in BRAKES 12 13 Special Tools Jack Jack Attachment 9 J L 57001 1238 57001 1608 7571238ST C 7571608ST C Hand Tester 57001 1394 7571394ST C 12 14 BRAKES Brake Lever Brake Pedal Brake Lever Position Adjustment The brake lever adjuster has 6 positions
446. ntake 0 30 mm 0 012 in Valves ENGINE TOP END 5 31 Valve Seat Inspection Remove the valve see Valve Removal e Check the valve seating surface A between the valve B and valve seat C OMeasure the outside diameter D of the seating pattern on the valve seat x If the outside diameter is too large or too small repair the seat see Seat Repair Valve Seating Surface Outside Diameter Standard Exhaust 27 6 27 8 mm 1 087 1 094 in Intake 32 6 32 8 mm 1 283 1 291 in OMeasure the seat width E of the portion where there is no build up carbon white portion of the valve seat with a vernier caliper Good F x If the width is too wide G too narrow or uneven J repair the seat see Valve Seat Repair Valve Seating Surface Width Standard Exhaust 0 8 1 2 mm 0 031 0 047 in Intake 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 B 57001 1128 Valve Seat Cutter Holder 5 C 57001 1208 For Exhaust Valve Seat Valve Seat Cutter 45 630 57001 1187 Valve Seat Cutter 32 p30 57001 1120 Valve Seat Cutter 60 p30 57001 1123 For Intake Valve Seat Valve Seat Cutter 45 535 57001 1116 Valve Seat Cutter 32 p35 57001 1121 Valve Seat Cutter 60 633 57001 1334 If the manufacturer s instructions are not available use the following procedure
447. nto a container Bleed the clutch line as follows ORepeat this operation until no more air can be seen com ing out into the plastic hose 1 Pump the clutch lever until it becomes hard and apply the clutch lever and hold it B 2 Quickly open and close C the bleed valve while holding the clutch lever applied 3 Release the clutch lever D NOTE OCheck the fluid level in the reservoir often replenishing it as necessary Olf 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 en tered the line 6 12 CLUTCH Clutch Fluid A WARNING Mixing brands and types of hydraulic fluid lowers the fluid s boiling point cause rubber part to de teriorate and can reduce the hydraulic clutch sys tem s effectiveness and cause an accident resulting in injury or death Do not mix two brands of brake fluid Change the fluid in the hydraulic clutch sys tem completely if the fluid must be refilled but the type and brand of the hydraulic fluid that is already in the reservoir are unidentified Remove the clear plastic hose e Tighten the bleed valve and install the rubber cap Torque Clutch Slave Cylinder Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib e Install Diaphragm Diaphragm Plate Clutch Reservoir Cap e Follow the procedure below to install the clutch fluid reser voir Cap correctly
448. o ees meets 16 121 Fuse Installations i om eto tea e t tree cud 16 122 16 122 16 4 ELECTRICAL SYSTEM Exploded View ELECTRICAL SYSTEM 16 5 Exploded View a Sees re 2 Front Turn Signal Light Mounting Screws 0 12 11 in lb Tail Brake Light Mounting Screws 1 2 0 12 11 in lb 4 License Plate Light Mounting Plate Screws 1 2 0 12 11 in lb 5 License Plate Light Cover Mounting Screws 1 8 0 18 16 in Ib 16 6 ELECTRICAL SYSTEM Exploded View 4 An GP026178W5 C ELECTRICAL SYSTEM 16 7 Exploded View resent N m kgf m ft Ib Lr Saner Motor Through Bos oss fore Starter Motor Cable Terminal Nut 5 9 0 60 52 in lb 3 Starter Motor Terminal Locknut 6 9 0 70 61 in lb 4 Starter Motor Mounting Bolts 9 8 1 0 87 5 Spark Plugs 13 1 3 115 in lb 6 Water Temperature Sensor 12 1 2 106 in lb 7 Ground Terminal Bolt 9 8 1 0 87 in lb 8 Alternator Rotor Bolt 155 15 8 114 5 9 Alternator Cover Bolts 9 8 1 0 87 in lb 10 Alternator Lead Holding Plate Bolts 7 8 0 80 69 in lb L 11 Stator Coil Bolts 12 1 2 106 in lb 12 Gear Position Switch Screws 2 9 0 30 26 in lb L 13 Crankshaft Sensor Bolts 5 9 0 60 52 in lb L 14 Crankshaft Sensor Cover Bolts 9 8 1 0 87 15 Crankshaft Sensor Cover Bolt 9 8 1 0 87 in lb L 16 Timing Rotor Bolt
449. of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below e Replacement of the original exhaust system or muffler with a component not in compliance with Federal regulations e Removal of the muffler s or any internal portion of the muffler s e Removal of the air box or air box cover e Modifications to the muffler s or air inlet system by cutting drilling or other means if such modifications result in increased noise levels Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop However it contains enough detail and basic in formation to make it useful to the owner who de sires to perform his own basic maintenance and repair work A basic knowledge of mechanics the proper use of tools and workshop proce dures must be understood in order to carry out maintenance and repair satisfactorily When ever the owner has insufficient experience or doubts his ability to do the work all adjust ments maintenance and repair should be car ried out only by qualified mechanics In order to perform the work efficiently and to avoid cos
450. old the brake hose and rear wheel rotation sensor lead and align the clamp with white painted mark of the rear wheel rotation sensor lead Rear Wheel Rotation Sensor Lead Brake Hose Face the white paint mark upward Touch the brake hose fitting to the stopper Rear Wheel Rotation Sensor Clamp Hold the rear wheel rotation sensor lead Rear View 17 46 APPENDIX Cable Wire and Hose Routing ABS Equipped Models 500000 0900 08809870045 C APPENDIX 17 47 Cable Wire and Hose Routing ON OD Touch the brake hose fitting to the stopper Clamps Hold the brake hose and insert the clamps into the front fender Brake Hoses Clamp Hold the grommet of the brake hose only and insert the clamp into the front fender Clamp Hold the brake hose and front wheel rotation sensor lead and align the clamp with white painted mark of the front wheel rotation sensor lead Clamp Hold the front wheel rotation sensor lead Front Wheel Rotation Sensor Lead Front Wheel Rotation Sensor View from A View from B 17 48 APPENDIX Cable Wire and Hose Routing ABS Equipped Models APPENDIX 17 49 Cable Wire and Hose Routing About 48 Front Brake Pipe Blue Paint Mark Brake Pipe White Paint Mark Damper Brake Hose Blue Paint Mark Brake Hose White Paint Mark Brake Hose
451. olding the top plug with a wrench tighten the piston rod nut C against the top plug Torque Piston Rod Nuts 28 N m 2 9 kgf m 21 ft Ib e Remove the fork spring stopper e Align the stoppers A of the top plug B with the grooves C of the clamp D and down the suitable jack e Remove the front fork from the fork spring compressor e Raise the outer tube and screw the top plug into it e Install the front fork see Front Fork Installation NOTE OAfter installing the front fork adjust the spring preload and damping force correctly If using the spring compressor 57001 1587 e Install the clamps A as shown in the figure NOTE OSet the clamps so that the cutout B of the upper side does not touch the tongue shape of stopper pull up the outer tube C to hold it by the clamps and then tighten the two bolts D The outer tube is used as a guide Special Tools Fork Spring Compressor 57001 1540 Fork Spring Compressor 57001 1587 e Install the holders E to the clamps as shown in the figure Special Tool Fork Spring Compressor 57001 1587 GM04409BS1 C Front Fork SUSPENSION 13 19 e Insert the holder bar A into the axle hole of the front fork B e Insert the compression shafts A and install the nuts B OSet the other side compression shaft same process e Insert the lower end of the compression shaft A into the hole B of the holder bar e Screw the adj
452. onfirm whether the injectors turn smoothly or not FUEL SYSTEM DFI 3 141 Throttle Body Assy e Replace the dust seals A with new ones e Apply engine oil to the new dust seals e Install the fuel injectors along with the delivery pipe to the throttle body Delivery Pipe Mounting 5 5 0 0 51 Que orque Delivery Pipe Mounting Screws 5 0 N m 0 re ms kgf m 44 in Ib Connect the connectors e Insert the each hoses to the throttle body fittings and in take air pressure sensors e Bind the harness and hoses with clamps e Install the throttle body assy see Throttle Body Assy In stallation 95176571 3 142 FUEL SYSTEM Air Cleaner Air Cleaner Element Removal e Refer to the Air Cleaner Element Replacement in the Pe riodic Maintenance chapter Air Cleaner Element Installation e Refer to the Air Cleaner Element Replacement in the Pe riodic Maintenance chapter Air Cleaner Element Inspection e Remove the air cleaner element see Air Cleaner Element Replacement in the Periodic Maintenance chapter e Visually check the element A for tears or breaks the element has any tears or breaks 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 catch tank A of the drain hose if the water or o
453. or Light 127219 Tail Brake ri umma H ei Light LED License m rud i 55 Rear Loft ano Turn Signal hia Reserve Switch wires Pump Regulator Rectifier B Light 12V21 BK Y BK Y BK Y Starter Relay Battery 12 12 i doint seer Relay Pong je Color Code Engine 2 Fuse 30 Light BK Black S ANNUM BL Blue Starter Frame Ground Wotor BR Brown amp Frame Frame Green 0 Orange P Pink Pu Purple Rk Rea Vets White Y Yellow BK Y BK Y BK BL Alternator IGNITION SWITCH CONNECTIONS Battery lgnition Signal fere ow fepe RIGHT SWITCH HOUSING CONNECTIONS Front Brake Light Sit Engine Stop Switeh Starter Button Color er cotor R W R W Color L W OFF Loch ON P PARK 98052 0690 W2RO690AWS5 C 16 20 ELECTRICAL SYSTEM Wiring Diagram BR Model Meter Unit 1 Green Left Turn Signal Indicator Light LED 2 Green Right Turn Signal Indicator Light LED x 3 Blue High Beam Indicator Right jewitel Housing Light LED i Front Brake Spark Plugs Light Switch 4 Greon Neutral Indicator y u 32 83 24 A 2 Engine Stop Switch Fan Fan GPS a 4 S S 53 S ALS ee Us a 3 Starter Button Rights tek Housing Horn moter
454. or MA2 Viscosity SAE 10W 40 Capacity 4 6 L 4 9 US qt Drive Train Gear 1 556 84 54 Wet multi disc 6 speed constant mesh return shift 2 611 47 18 1 947 37 19 1 545 34 22 1 333 32 24 1 154 30 26 1 036 29 28 Chain drive 2 471 42 17 3 980 Top gear Press backbone 23 93 mm 3 66 in Tubeless 120 70 ZR17 M C 58W J17M C x MT3 50 Tubeless 190 50 ZR17 M C 73W J17M C x MT6 00 Telescopic fork upside down 117 mm 4 61 in General Specifications GENERAL INFORMATION 1 11 Items ZX1400EC ZX1400FC Rear Suspension Type Swingarm uni trak Wheel Travel 124 mm 4 88 in Brake Type Front Dual discs Rear Single disc Electrical Equipment Battery 12 12 Ah Headlight Type Bulb High Low Tail Brake Light Alternator Type Rated Output Semi sealed beam 12 V 55 W 65 W quartz halogen x 2 12 V 55 W quartz halogen x 2 LED Three phase AC 35 A 14 V 5 000 r min rpm Specifications are subject to change without notice and may not apply to every country 1 12 GENERAL INFORMATION Technical Information Evaporative Emission Control System CAL and SEA 1 Models Overview The fuel vapors from the fuel tank contain toxic HC Hydrocarbons In the evaporative emission control system these vapors are kept in the canister temporarily without being released directly into the atmosphere After that the vapors are routed into the throttle body or carburetor b
455. or is pulled out with under 20 N m 2 0 kgf m 15 ft lb of drawing torque clean off any oil dirt or flaw of the crankshaft and rotor tapered portion and washer and dry them with a clean cloth Then confirm that it is not pulled out with above torque e Install the washer and rotor bolt e Tighten the alternator rotor bolt A while holding the alter nator rotor steadily with the holder B Special Tools Grip C 57001 1591 Rotor Holder 57001 1672 Stopper D 57001 1679 Torque Alternator Rotor Bolt 155 N m 15 8 kgf m 114 ft Ib e Install the alternator cover see Alternator Cover Installa tion Charging System ELECTRICAL SYSTEM 16 41 Charging Voltage Inspection Check the battery condition see Charging Condition In spection e Warm up the engine to obtain actual alternator operating conditions e Remove the right fairing cover see Fairing Cover Re moval in the Frame chapter Check that the ignition switch is turned off and connect the hand tester A to the battery terminal and ground Special Tool Hand Tester 57001 1394 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 m
456. or repair the wheel rota tion sensor 12 54 BRAKES Anti Lock Brake System Equipped Models e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Connector A Disconnect Remove the connector from the bracket e Remove Bracket Bolts A Clamps B Bolts C Rear Wheel Rotation Sensor D Rear Wheel Rotation Sensor Installation e Installation is the reverse of removal ORun the lead correctly see Cable Wire and Hose Rout ing section in the Appendix chapter Wheel Rotation Sensor Inspection e Remove the front wheel rotation sensor A from the front fork e Remove the rear wheel rotation sensor B from the caliper bracket e Visually inspect the wheel rotation sensors Replace the wheel rotation sensor if it is cracked bent or otherwise damaged BRAKES 12 55 Anti Lock Brake System Equipped Models Wheel Rotation Sensor Air Gap Inspection e Raise the front rear wheel off the ground see Front Rear Wheel Removal in the Wheels Tires chapter e Measure the air gap between the sensor and sensor rotor at several points by turning the wheel slowly Thickness Gauge A Air Gap Standard Front 0 7 0 9 mm 0 028 0 035 in Rear 0 7 0 9 mm 0 028 0 035 in NOTE O The sensor air gap cannot be adjusted x If the air gap is not within the specification inspect the hub bearing see Hub Bearing Inspection in the Wheels Tires chapter sensor installat
457. oration Squeeze the hoses A hose should not be hard and brittle nor should it be soft or swollen Replace the hose if any fraying cracks B or bulges C are noticed OApply soap and water solution to the inside of the water hoses before installation e Check that the hoses are securely connected and clamps are tightened correctly Torque Water Hose Clamp Screws 3 0 N m 0 31 kgf m 27 in Ib Engine Top End Valve Clearance Inspection NOTE OValve clearance must be checked and adjusted when the engine is cold at room temperature e Remove Crankshaft Sensor Cover see Crankshaft Sensor Re moval in the Electrical System chapter Cylinder Head Cover see Cylinder Head Cover Re moval in the Engine Top End chapter e Turn the crankshaft clockwise align the 1 4 mark on the timing rotor with the crankcase timing mark TDC Mark A for 1 4 Pistons Timing Mark B Crankcase Halves Mating Surface e Using a thickness gauge A measure the valve clearance between the cam and the valve lifter Valve Clearance Standard Exhaust 0 22 0 27 mm 0 0087 0 0106 in Intake 0 15 0 20 mm 0 0059 0 0079 in 6506005851 C PERIODIC MAINTENANCE 2 23 Periodic Maintenance Procedures NOTE OThickness gauge 15 horizontally inserted on the valve lifter Appropriateness A Inadequacy B Thickness Gauge C Horizontally Inserts D Cam E Valve Lifter F Hits the Valve Lifter Ahead G
458. orm the Pre Diagnosis Inspection 1 and 2 see In quiries to Rider x f this service code appears even if all checks are ended replace the ABS hydraulic unit x If the service code does not appear the ABS system nor mal temporary failure Front Wheel Rotation Sensor Signal Abnormal Service Code 42 e Measure the air gap between the front wheel rotation sen sor and sensor rotor Thickness Gauge A Air Gap Standard 0 7 0 9 mm 0 028 0 035 in x lf the measurement is not the standard check each part for deformation and looseness and correct accordingly x lf the measurement is the standard go to next step e Check that there is iron or other magnetic deposits be tween the sensor and sensor rotor and the sensor rotor slots for obstructions e Check the installation condition of the sensor for loose ness e Check the sensor and sensor rotor tip for deformation or damage e g chipped sensor rotor teeth x lf the sensor and sensor rotor in bad condition remove the any deposits Install the proper part or replace faulty part x lf the all items are good go to next step e Perform the Pre Diagnosis Inspection 1 and 2 see In quiries to Rider x lf this service code appears even if all checks are ended replace the ABS hydraulic unit x If the service code does not appear the ABS system nor mal temporary failure GT04121BS1 12 48 5 Anti Lock Brake System Equippe
459. ose and year E 2 e 2 27 pipe inspect inspect 2 4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY Whichever ODOMETER READING comes x 1 000 km first x 1 000 mile See 6 12 18 24 30 7996 ITEM Every 0 6 3 75 7 5 11 25 15 18 75 22 5 installation condition year x 5 2 e 227 Wheels and Tires Tire air pressure inspect year 2 28 Wheel tire damage inspect 2 28 Tire tread wear abnormal wear 2 28 inspect Wheel bearing damage inspect year 2 29 Final Drive Drive chain lubrication condition Every 600 km 400 mile 2 30 inspect Drive chain slack inspect Every 1 000 km 600 mile 2 30 Drive chain wear inspect e e 2 32 Drive chain guide wear inspect 2 33 Brakes Brake fluid leak brake hose and year 2 33 pipe inspect Brake hose and pipe damage year 2 24 inspect Brake hose installation condition 2 34 inspect Brake operation effectiveness year 2 35 play no drag inspect 6 Brake fluid level inspect months 2 35 Brake pad wear inspect 2 36 Brake light switch operation 2 36 inspect Suspension Front forks rear shock absorber operation damping and smooth 2 37 stroke inspect Front forks rear shock absorber year 2 38 oil leak inspect Rocker arm operation inspect 2 38 Tie rod
460. otation sensor see Rear Wheel Rotation Sensor Removal Still when it is not good replace the ABS hydraulic unit x lf the service code does not appear the ABS system nor mal temporary failure Power Supply Voltage Inspection Low Voltage Service Code 52 e Check the battery condition see Charging Condition In spection in the Electrical System chapter x lf the battery is good condition perform the Pre Diagnosis Inspection 1 and 2 see Inquiries to Rider x lf this service code appears even if all checks are ended replace the ABS hydraulic unit x If the service code does not appear the ABS system nor mal temporary failure GT04123BS1 12 50 5 Anti Lock Brake System Equipped Models Power Supply Voltage Inspection Over Voltage Service Code 53 e Check the charging voltage see Charging Voltage In spection in the Electrical System chapter x If the charging voltage is good perform the Pre Diagnosis Inspection 1 and 2 see Inquiries to Rider x lf this service code appears even if all checks are ended replace the ABS hydraulic unit the service code does not appear the ABS system nor mal temporary failure ECU Inspection Service Code 55 OThis ECU is built in the ABS Hydraulic Unit Therefore the ECU cannot be checked directly e Perform the Pre Diagnosis Inspection 1 and 2 see In quiries to Rider x lf this service code appears even if al
461. ottle cable e Run the engine at the idle speed and turn the handlebar all the way to the right and left to ensure that the idle speed does not change x lf the idle speed increases check the throttle cable free play and the cable routing x If necessary adjust the throttle cable as follows e Loosen the locknuts B e Screw both throttle cable adjusters C D to give the throttle grip plenty of play e Turn the decelerator cable adjuster C until 2 3 mm 0 08 0 12 in of throttle grip play is obtained Tighten the locknut A e Turn the accelerator cable adjuster D until 2 3 mm 0 08 0 12 in of throttle grip play is obtained e Tighten the locknut B x If the free play cannot be adjusted with the adjusters re place the cable Engine Vacuum Synchronization Inspection NOTE These procedures are explained on the assumption that the intake and exhaust systems of the engine are in good condition e Situate the motorcycle so that it is vertical e Remove Throttle Body Assy see Throttle Body Assy Removal in the Fuel System DFI chapter Screw A Rubber Caps B for CAL and SEA B1 models three rubber caps PERIODIC MAINTENANCE 2 17 Periodic Maintenance Procedures Connect a vacuum gauge and hoses A Special Tool 57001 1369 to the fittings on the throttle body Special Tool Vacuum Gauge 57001 1369 Tighten the screw without the bracket e Pull off
462. ound before starting the repair work Ask the rider about the conditions B under which the problem occurred and try to determine the cause C Do not rely solely on the ABS self diagnosis function use common sense check the brakes for proper braking power and brake fluid level search for leaks etc 8017230 51 12 36 5 Anti Lock Brake System Equipped Models Even when the ABS is operating normally the yellow ABS indicator light LED may light up under the conditions listed below Turn the ignition switch OFF to stop the indicator light If the motorcycle runs without erasing the service code the light may light up again OAfter continuous riding on a rough road OWhen the engine is started with the stand raised and the transmission engaged and the rear wheel turns OWhen accelerating so abruptly that the front wheel leaves the ground OWhen the ABS has been subjected to strong electrical interference OWhen tire pressure is abnormal Adjust tire pressure OWhen a tire different in size from the standard size is being used Replace with standard size OWhen the wheel is deformed Replace the wheel Much of the ABS troubleshooting work consists of con firming continuity of the wiring The ABS parts are assem bled and adjusted by the manufacturer so there is no need to disassemble or repair them Replace the ABS hydraulic unit The basic troubleshooting procedures are listed below e Carry ou
463. out of the usable range Sensor 5 wiring short or open the ECU sets Ta at 30 C Water If the water temperature sensor system fails 14 Temperaire Water Temperature the signal is out of the usable range wiring Tw 30 120 short or open the ECU sets Tw at 80 C and the radiator fan operates If the intake air pressure sensor 2 system 16 2 2 fails the signal is out of the usable range Sensor 2 Pa 150 800 mmH wiring short or open the ECU sets Pa at 760 9 mmHg the standard atmospheric pressure 21 Crankshaft a If the crankshaft sensor fails the engine stops Sensor gna by itself at the 1 cranking Rear Wheel oe 4 If the rear wheel rotation sensor system fails 24 Rotation the ECU at the 1 of the signal is missing wiring open the ECU Sensor ihe wheel stops the KTRC control Gear If the gear position switch system fails no 25 Position 2 signal wiring short or open the ECU set the Switch top 6th gear position giis take s If the front wheel rotation sensor system fails 27 Sensor lihe ECUAtthe at the signal is missing wiring open the ECU Signal ihawheel stops the KTRC control If the vehicle down sensor system has failures Vehicle O ip t Valiada the output voltage is out of the usable range 31 down 0 Sd 48 V 9 wiring short or open the ECU shuts off the Sensor fuel pump relay the fuel injectors and the ignition system If the subthrottle sensor system fails the
464. output voltage is out of the usable range wiring 32 short or open the ECU drive the subthrottle valve to the closed position and it stops the current to the subthrottle valve actuator Self Diagnosis FUEL SYSTEM DFI 3 51 Parts or Function Output Signal Usable Range or Criteria Backups by ECU Oxygen Sensor Equipped Models Immobilizer Amplifier Equipped Models The oxygen sensor is active and sensor must send signals output voltage continuously to the ECU If the oxygen sensor is not activated the ECU stops the feedback mode of the oxygen sensor If the immobilizer system fails no signal wiring short or open the vehicle is no start and run Ignition Key The ignition key must use register key If the blank key or broken key is used the vehicle is no start and run ECU Fuel Pump Relay The ECU sends the data to the meter unit through the CAN communication line When the fuel pump relay is ON battery monitor voltage is 5 V or more Stick Coil 1 Stick Coil 2 The ECU sends signals output voltage continuously to the stick coil The ECU sends signals output voltage continuously to the stick coil If the stick coil 1 primary winding has failures no signal wiring short or open the ECU shuts off the injector 1 to stop fuel to the cylinder 1 though the engine keeps running If the stick coil 2 primary winding has fa
465. oval 9 40 9 22 External Shift Mechanism Crankshaft Side Clearance Installation terne 9 40 Inspection so ose detent ties cates 9 24 External Shift Mechanism Crankshaft Runout Inspection 9 24 Inspection rre 9 41 Crankshaft Main Bearing Transmission Shaft Removal 9 42 Insert Journal Wear Inspection 9 25 Transmission Shaft Installation 9 42 PISt NS wisi iene 9 27 Transmission Shaft Disassembly 9 43 Piston Remowval 9 27 Transmission Shaft Assembly 9 44 Piston Installation 9 28 Shift Drum and Fork Removal 9 46 Cylinder Wear Upper Crankcase Shift Drum and Fork Installation 9 46 Inspection 9 29 Shift Drum Disassembly 9 46 Piston Wear Inspection 9 29 Shift Drum Assembly 9 47 Piston Ring Piston Ring Groove Shift Fork Bending Inspection 9 47 Wear Inspection 9 29 Shift Fork Gear Groove Wear Piston Ring Groove Width Inspection tet 9 47 IiSpOOllOlTo oed tetas 9 30 Shift Fork Guide Pin Drum Piston Ring Thickness Inspection 9 30 Groove Wear Inspection 9 47 Piston Ring End Gap Inspection 9 30 Gear Dog and Gear Dog Hole 9 31 Damage Inspection 9 48 Front Balancer Removal 9 31 9 2 CRANKSHAFT TRANSMISSION Exploded View T ue Wr
466. oval Installation OThe radiator fan relay is built in the relay box A e Refer to the Relay Box Removal in the Electrical System chapter Radiator Fan Relay Inspection e Refer to the Relay Circuit Inspection in the Electrical Sys tem chapter xIf the radiator fan relay is normal check the wiring for continuity using the wiring diagram in this section Special Tool Hand Tester 57001 1394 xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation Radiator Fan Circuit 0 GTO41138W2 C 1 ECU 10 Fuse Box 1 2 Water Temperature Sensor 11 Ignition Fuse 15 A 3 Frame Ground 12 Fuse Box 2 4 Battery 13 Fan Fuse 15 A 5 Starter Relay 14 Joint Connector F 6 Main Fuse 30 A 15 Ignition Switch 7 Frame Ground 4 16 Fan Motor 2 8 Relay Box 17 Fan Motor 1 9 Fan Relay 18 Frame Ground 2 Subthrottle Valve Actuator Service Code 62 FUEL SYSTEM DFI 3 99 Subthrottle Valve Actuator Removal NOTICE Do not remove the subthrottle valve actuator A since it has been adjusted and set with precision at the factory Never drop the throttle body assy especially on a hard surface Such a shock to the subthrottle valve actuator can damage it Subthrottle Valve Actuator Inspection NOTE OBe sure the battery is fully charged Remove the
467. oved parts see appropriate chapters 16 44 ELECTRICAL SYSTEM Charging System Charging System Circuit Ze n on PARK GNITION OO BR BR BATTERY GD w Ignition Switch Load Frame Ground Battery 12 V 12 Ah Starter Relay Main Fuse 30 A Alternator Regulator Rectifier Frame Ground 3 6209344812 ELECTRICAL SYSTEM 16 45 Ignition System A WARNING The ignition system produces extremely high volt age Do not touch the spark plug ignition coil or ig nition coil lead while the engine is running or you could receive a severe electrical shock NOTICE Do not disconnect the battery cables or any other electrical connections when the ignition switch is ON or while the engine is running This is to pre vent ECU damage Do not install the battery backwards The negative side is grounded This is to prevent damage to the ECU Crankshaft Sensor Removal Never drop the sensor especially on a hard surface Such a shock to the sensor can damage it e Remove Right Middle Fairing see Middle Fairing Removal in the Frame chapter Crankshaft Sensor Lead Connector A e Free the oxygen sensor lead A equipped models from the clamp B Remove Crankshaft Sensor Cover Bolts C Clamp and Bracket Crankshaft Sensor Cover D e Remove Crankshaft Sensor Bolts A Crankshaft Sensor B Grommet C 16 46 ELECTRICAL SYSTEM
468. over the upper fairing on both sides Insert the slots A of the upper inner fairing into the tabs B of the upper fairing Set the quick rivets and push the core of them Tighten the bolt with washer Upper Fairing Bracket Removal e Remove Upper Fairing see Upper Fairing Removal Front and Middle Intake Ducts see Front and Middle Intake Duct Removal in the Fuel System DFI chapter Meter Unit see Meter Unit Removal in the Electrical Sys tem chapter Bolts A and Brackets B Upper Fairing Bracket Bolts C and Nuts Upper Fairing Bracket D Upper Fairing Bracket Installation Installation is the reverse of removal e Run the leads and cables correctly see Cable Wire and Hose Routing section in the Appendix chapter Inner Fairing Removal Left Inner Fairing e Remove Quick Rivets A Screws B Left Inner Fairing C OPush the central pin of the quick rivet 15 18 Fairings Right Inner Fairing e Remove Quick Rivet A Screws B Right Inner Fairing C OPush the central pin of the quick rivet e For models equipped with an evaporative emission con trol system note the following ORemove Screws A Bracket B Canister C Inner Fairing Installation e Installation is the reverse of removal e Fit the slit A of the right inner fairing to the projection B of the cover Rear Fairing Removal Equipped Models e Remove Bolts A and Washers Both Sides
469. p 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 intake hose in order to insert the hose smoothly OPut the hose through the fill opening C into the tank and draw the fuel out Front D A WARNING Spilled fuel is flammable and can be explosive un der certain conditions The fuel can not be removed completely from the fuel tank Be careful for re mained fuel spillage e Be sure to place a piece of cloth A around the fuel hose joint e Push the joint lock claws C Pull the joint lock A as shown in the figure e Pull B the fuel hose joint C out of the fuel outlet pipe A WARNING Fuel is flammable and explosive under certain con ditions and can cause severe burns Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is dis connected fuel spills out from the hose and the pipe because of residual pressure Cover the hose connection with a piece of clean cloth to prevent fuel spillage 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 outlet pipe of the fuel pump 6C09033BS1 C 3 148 FUEL SYSTEM DFI Fuel Tank For CAL
470. p and down more than ten times in order to expel all the air from the fork oil Special Tool Fork Piston Rod Puller M12 x 1 25 57001 1289 ORemove the piston rod puller OWait until the oil level settles OWith the fork fully compressed and the piston rod fully pushed in insert a tape measure or rod into the inner tube and measure the distance from the top of the inner tube to the oil 6M04021281 C x S My gt 8 04042851 C 8 04021351 13 16 SUSPENSION Front Fork Oil Level fully compressed without spring Standard 94 2 mm 3 70 0 08 in from the top of the inner tube NOTE OFork oil lever may also be measured using the fork oil level gauge Special Tool Fork Oil Level Gauge A 57001 1290 OWith the fork fully compressed and without fork spring insert the gauge tube into the inner tube B and position the stopper across the top end C of the inner tube OSet the gauge stopper D so that its lower side shows the oil level distance specified E OPull the handle slowly to pump out the excess oil until the oil no longer comes out If no oil is pumped out there is insufficient oil in the inner tube Pour in enough oil then pump out the excess oil as shown above Screw the fork piston rod puller onto the end of the piston rod Special Tool Fork Piston Rod Puller M12 1 25 57001 1289 e Pull the puller
471. park spark weak Vehicle down sensor DFI coming off Ignition switch not ON Engine stop switch turned OFF Clutch lever not pulled in or gear not in neu tral Battery voltage low Immobilizer system trouble Equipped Mod els Spark plug dirty broken or gap malad justed Spark plug incorrect Stick coil shorted or not in good contact Stick coil trouble ECU trouble Gear position starter lockout or sidestand switch trouble Crankshaft sensor trouble Ignition switch or engine stop switch shorted Starter system wiring shorted or open Main 30 A or ignition fuse blown Fuel air mixture incorrect Bypass screw Air passage clogged Air cleaner clogged poorly sealed or miss ing Leak from oil filler cap crankcase breather hose or air cleaner drain hose Compression Low Spark plug loose Cylinder head not sufficiently tightened down Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak No valve clearance Valve not seating properly valve bent worn or carbon accumulation on the seating surface Poor Running at Low Speed Spark weak Battery voltage low Immobilizer system trouble Equipped Mod els Stick coil trouble Stick coil shorted or not in good contact Spark plug dirty broken or maladjusted Spark plug incorrect ECU trouble Crankshaft sensor trouble Fuel a
472. park Plugs 17 Face the round end outward EO Apply engine oil L Apply a non permanent locking agent LG Apply liquid gasket M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts S Follow the specified tightening sequence 115 in lb 5 4 ENGINE END Exploded View ENGINE END 5 5 Exploded View 1 water Body Mounting Bos 38 5 R Replacement Parts S Follow the specified tightening sequence 5 6 ENGINE TOP END Exhaust System Exhaust System MANIFOLD Honeycomb Type Catalyst with Oxygen Sensor P No 39178 0175 Mark KHI M 139 Honeycomb Type Catalyst without P No 39178 0174 Mark None MUFFLER BODY Honeycomb Type Catalyst P No 18091 0804 P No 18091 0805 Mark KHI K 619 EPA Noise Emission Control Information Honeycomb Type Catalyst P No 18091 0804 P No 18091 0805 Mark KHI K 619 EPA Noise Emission Control Information SPECIFICATION WVTA FULL H GB WVTA FULL H WVTA 78 2 H US CAL CA MARKETING CODE ZX1400FC ZX1400FC ZX1400FC ZX1400FC ZX1400EC ZX1400EC FC ZX1400FC ZX1400EC FC ZX1400EC ZX1400EC ZX1400EC GE24777B F Manifold Mark Position A Muffler Body Mark Position A ENGINE END 5 7 Exhaust System Manifold A wit
473. ply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see ECU Removal Installation Subthrottle Sensor Output Voltage Inspection Measure the output voltage at the subthrottle sensor the same way as input voltage inspection note the fol lowing ODisconnect the subthrottle sensor connector and connect the setting adapter A between these connectors Special Tool Throttle Sensor Setting Adapter 57001 1538 Subthrottle Sensor Output Voltage Connections to Adapter Digital Meter R sensor BL W lead Digital Meter gt BK sensor lead e Disconnect the subthrottle valve actuator connector A 9704074851 3 86 FUEL SYSTEM Subthrottle Sensor Service Code 32 Measure the output voltage with the engine stopped with the connector joined e Turn the ignition switch to ON Measure the output voltage when the subthrottle valves are fully opened by hand Output Voltage Standard DC 4 14 4 34 V at subthrottle valve full close position for reference DC 0 42 0 62 V at subthrottle valve full open position NOTE OOpen the subthrottle valves confirm the output voltage will be raise OThe standard voltage refers to the value when the volt age reading at the Input Voltage Inspection shows 5 V exactly OWhen the input voltage reading shows other than 5 V derive a voltage range as follows Exa
474. positive cable terminal A to the battery e Put a light coat of grease on the terminal to prevent corrosion e Cover the terminal with its red cap B e Fit the cover on the battery and push in the battery tray e Run the cables A and lead B correctly see Cable Wire and Hose Routing section in the Appendix chapter and install them e Hook the band C e Install the negative cables to the frame so that the battery cable terminal D touches the stopper E e Tighten the frame ground bolt F 16 32 ELECTRICAL SYSTEM Battery e Put the holes A of the bracket to the projections B of the battery tray e Tighten the bracket bolts C e Check that the trim seal D are in place on the bracket e Insert the projections A of the battery compartment cover into the holes B of the frame and tighten the bolt e Install Bolt with Washer Right Fairing Cover see Fairing Cover Installation in the Frame chapter 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 ZX1400E F FTX14 BS Each battery comes with its own specific elec trolyte container using the wrong container may overfill the battery with incorrect electrolyte which can shorten battery life and deteriorate battery per formance Be sure to use the electrolyte container with
475. pressure leaks e Build up pressure in the system carefully until the pres sure reaches 123 kPa 1 25 kgf cm 18 psi NOTICE During pressure testing do not exceed the pres sure for which the system is designed The maxi mum pressure is 123 kPa 1 25 kgf cm 18 psi e Watch the gauge for at least 6 seconds x If the pressure holds steady the system is all right the pressure drops and no external source is found check for internal leaks Droplets in the engine oil indicate internal leakage Check the cylinder head gasket and the water pump Remove the pressure tester replenish the coolant and install the radiator cap e Install the right middle fairing see Middle Fairing Installa tion in the Frame chapter 6005011151 C Coolant COOLING SYSTEM 4 9 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 Fill the cooling system with fresh water mixed with a flush ing compound NOTICE Do not use a flushing compound which is harmful to the aluminum engine and radiator Carefully follow the instructions supplied
476. procedure to bleed the front brake line is as follows Bleeding the rear brake line is the same as for the front brake e Remove Screw A Stopper B Front Brake Reservoir Cap C Diaphragm Plate 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 hole at the bottom of the reservoir e Remove the rubber cap from the bleed valve on the front master cylinder e Attach a clear plastic hose A to the bleed valve and run the other end of the hose into a container 12 26 BRAKES Brake Fluid e Bleed the brake line and the master cylinder ORepeat this operation until no more air can be seen com ing out into the plastic hose 1 Pump the brake lever until it becomes hard and apply the brake and hold it A 2 Quickly open and close B the bleed valve while holding 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 Remove the clear plastic hose Tighten the bleed valve and install the rubber cap Torque Front Brake Master Cylinder Bleed Valve 7 8 N m
477. quipped p7 H Models 1C FI Idle Speed Control Valve Actuator malfunction wiring open or short 3A FI Purge valve malfunction wiring open or short CAL and SEA B1 Models Notes OThe ECU may be involved in these problems If all the parts and circuits checked out good be sure to check the ECU for ground and power supply If the ground and power supply are checked good replace the ECU OWhen no service code is displayed the electrical parts of the DFI system has no fault and the mechanical parts of the DFI system and the engine are suspect 3 50 FUEL SYSTEM DFI Self Diagnosis Backups OThe ECU takes the following measures to prevent engine damage when the DFI ignition KTRC or immobilizer system parts have troubles Service Parts or Output Signal Usable Codes Function Range or Criteria Py EGY If the main throttle sensor system fails the output voltage is out of the usable range 11 2 2 wiring short or open the ECU locks ignition timing into the ignition timing at closed throttle position and sets the DFI in the D J method 1 If the intake air pressure sensor 1 system 12 fails the signal is out of the usable range Sensor 1 Pv 150 800 wiring short or open the ECU sets the DFI 5 9 Jin the a N method 2 Intake Air nake Ar Temperature If the intake air temperature sensor system 13 Temperature Ta 30 4 fails the signal is
478. r Clutch Master Cylinder Assembly e Refer to the Rubber Parts of Clutch Master Cylinder Slave Cylinder Replacement in the Periodic Maintenance chap ter Clutch Master Cylinder Inspection e Disassemble the clutch master cylinder see Rubber Parts of Clutch Master Cylinder Slave Cylinder Replace ment in the Periodic Maintenance chapter Special Tool Inside Circlip Pliers 57001 143 e Check that there are no scratches rust or pitting on the inside of the master cylinder A and on the outside of the piston B xIf the master cylinder or piston shows any damage re place them e Inspect the primary cup C and secondary cup D cup is worn damaged softened rotted or swollen the piston assembly should be replaced to renew the cup x If fluid leakage is noted at the clutch lever the piston as sembly should be replaced to renew the cup e Check the dust cover E for damage x If it is damaged replace the piston assembly e Check that the relief F and supply G ports are not plugged x If the small relief port becomes plugged the clutch will drag Blow the ports clean with compressed air e Check the piston return spring H for any damage the spring is damaged replace it GF09005BS1 C 6 8 CLUTCH Clutch Slave Cylinder Clutch Slave Cylinder Removal e Remove Quick Rivet A Bolts B and Washers e Free the lower fairing e Remove Banjo Bolt A Clutch Slave Cylinder
479. r e Be sure that the trim seals A are in position on the radi ator as shown in the figure e Install the dampers B radiator bracket collars C and bolts as shown in the figure e Apply soap and water solution to the inside of the water hoses before installation e Install the each hose and clamps see Cable Wire and Hose Routing section in the Appendix chapter Tighten Torque Water Hose Clamp Screws 3 0 N m 0 31 kgf m 27 in Ib e Check that the pads D are in place on the radiator x If the pads are damage or deteriorated replace them e Install the removed parts see appropriate chapters Radiator Inspection Remove the radiator see Radiator and Radiator Fan Re moval e Check the radiator core x If there are obstructions to air flow remove them the corrugated fins A are deformed carefully straighten them x If the air passages of the radiator core are blocked more than 2096 by unremovable obstructions or irreparably de formed fins replace the radiator with a new one GD07106BS3 C 8007010451 C 4 14 COOLING SYSTEM Radiator 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 In
480. r 1 Y BL Water Temperature Sensor O Unused Main Throttle Sensor Y W Immobilizer Amplifier Equipped Models P BK CAN Communication Line High GY BL CAN Communication Line Low LB Unused Unused Rear Wheel Rotation Sensor Signal ZX1400F Model R Y Unused ZX1400E Model 6GC17735EW2 FUEL SYSTEM DFI 3 21 DFI System 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 Stick Coil 2 BK R Power Supply to ECU from Ignition Switch BR W Power Supply to ECU from Battery W BK External Communication Line Immobilizer System Equipped Models KDS LG BK Idle Speed Control Valve Actuator G R Unused Power Supply to Wheel Rotation Sensors ZX1400E Model W G Unused Unused Rear Wheel Rotation Sensor Signal ZX1400E Model BK O Unused ZX1400F Model Oxygen Sensor Equipped Models W BL Unused Intake Air Temperature Sensor R BK Vehicle down Sensor Y BK Immobilizer Amplifier Equipped Models V Ground for Control System BK BL Power Supply to ECU from Battery W BK Idle Speed Control Valve Actuator G BK Idle Speed Control Valve Actuator G Y Idle Speed Control Valve Actuator G O Unused Unused Fuel Injector 1 BL BK Fuel Injector 2 BL R Fuel Injector 3 BL O Fuel Injector 4 BL G Stick Coil 4 BK G Unused ZX1400F Model Unused Air Switching Valve R BL Unused Unused Unused Unused
481. r 2 Intake Water Crank throttle Main Sub AE Valve Throttle throttle Pressure Sensor Fuel Injectors yaive ensor Idle Speed Pe 8 8 ctuator Sensor Sensor ie Control Switching Gear Position Valve Vales Switch ais Actuator Joint RG FRE are T T Connector S525 F T 4 4 5 ar vv UM BL ow BRZE R BL BR a Y Y 8k Joint Joint Connector 4 1 1 1 Joint Connector ex o BK Y o R BL 2 akset BK BKZ Y BK Y o WR ey mm R BL SS G R BR W BK G BL BK e o D Joint Connector ex o amp Rear Wheel Rotation Sensor Rear Right 2 Light 12 21 Tail Brake Lj ei Light LED License BK AY SK Y Plate 12vsw ES Rear Loft a Ee Signal B Light 12V21 Starter Ti Relay 2 Battery 12 12 i Joint Starter Relay Rear Connector B Color Code Brake Engine 2 Wain Fuse 30A D BK Black Motor BR Brown Frame Frame Green Ground Ground Gray 1 3 Frame Frame Light Blue d vege oun LG light Green 0 Orange Pink PU Purple Violet White Y Yellow Immobilizer Kawasaki
482. r Clutch Lever Position Clutch Lever Free Play Clutch Fluid Grade Clutch Spring Plate Free Play Clutch Plate Assembly Length Friction Plate Thickness 13088 0030 13088 0031 13088 0032 Friction and Steel Plate Warp Friction Plate Warp 13088 0030 only Clutch Spring Free Length 5 way adjustable to suit rider Non adjustable DOT4 Usable Range 0 05 0 70 mm 0 002 0 028 in Reference 54 2 mm 2 13 in 2 92 3 08 mm 0 115 0 121 in 3 72 3 88 mm 0 146 0 153 in 0 15 mm 0 0059 in or less 0 2 mm 0 008 in or less 32 1 mm 1 26 in 2 7 mm 0 106 in 3 5 mm 0 138 in 0 3 mm 0 012 in 0 3 mm 0 012 in 31 0 mm 1 22 in 6 5 Special Tools and Sealant Inside Circlip Pliers Liquid Gasket TB1211F 57001 143 92104 0004 7570143ST C 879200045 Clutch Holder 57001 1243 gt 875712435 C 6 6 CLUTCH Clutch Master Cylinder Clutch Lever Position Adjustment The clutch lever adjuster has 5 positions so that the clutch 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 OThe distance from the grip to the lever is minimum at num ber 5 and maximum at number 1 Clutch Master Cylinder Removal e Disconnect the starter lockout switch connectors A e Drain the clutch fluid from the reservoir see
483. r Bolts 61 Fuel Pump Bolts 87 Cooling System Water Hose Clamp Screws f 27 in lb Coolant Fitting Bolts 78 in lb Thermostat Housing Mounting Bolts 87 Thermostat Housing Cover Bolts 52 in lb Oil Cooler Mounting Bolts 106 in Ib Cylinder Fitting Mounting Bolts s 87 Water Pump Cover Bolts i 87 Coolant Drain Bolt 89 in lb Water Temperature Sensor 106 in lb Engine Top End Air Suction Valve Cover Bolts 9 8 1 0 87 L Cylinder Head Cover Bolts 9 8 1 0 87 Camshaft Sprocket Mounting Bolts 15 1 5 11 L Front Camshaft Chain Guide Bolt Upper 25 2 5 18 Front Camshaft Chain Guide Bolt Lower 12 1 2 106 in lb Engine Bracket Bolts M8 25 2 5 18 5 2 8 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Torque Remarks N m Front Engine Mounting Bolts M10 59 44 R S Camshaft Chain Tensioner Mounting Bolts 9 8 87 Cylinder Head Bolts M11 see the text 5 Cylinder Head Bolts 6 12 106 in lb 5 Water Passage Plugs 19 6 14 5 L Camshaft Cap Bolts 12 106 in lb 5 Upper Camshaft Chain Guide Bolts 12 106 in lb 5 Throttle Body Assy Holder Bolts 9 8 87 in lb 5 Throttle Body Assy Holder Clamp Bolts 2 0 18 in lb Spark Plugs 13 115 in lb Muffler Body Mounting Bolts 34 25 Clutch Clutch Cover Bolts 9 8 87 L 1 Oil Filler Plug Hand tighten Clutch Lever Pivot Bolt 1 0 8 9 in lb Si Clutch Hose Banjo Bolts 25 18 C
484. r parts Oil spilled on any part will be difficult to wash off completely and will eventually deteriorate the rubber used in the disc brake When handling the disc pads or disc be careful that no disc brake fluid or any oil gets on them Clean off any fluid or oil that inadvertently gets on the pads or disc with a high flash point solvent Do not use one which will leave an oily residue Replace the pads with new ones if they cannot be cleaned satisfacto rily Brake fluid quickly ruins painted surfaces any spilled fluid should be completely wiped up imme diately If any of the brake line fittings or the bleed valve is opened at any time the AIR MUST BE BLED FROM THE BRAKE LINE Brake Hose BRAKES 12 29 Brake Hose and Pipe Removal installation e Refer to the Brake Hose and Pipe Replacement in the Periodic Maintenance chapter Brake Hose and Pipe Inspection e Refer to the Brake Hose and Pipe Damage and Instal lation Condition Inspection in the Periodic Maintenance chapter 12 30 5 Anti Lock Brake System Equipped Models Parts Location 61146428 6 ABS Fuse Box ABS Kawasaki Self diagnosis System Connector ABS Hydraulic Unit ABS Indicator Light LED Front Wheel Rotation Sensor Rotor Front Wheel Rotation Sensor Rear Wheel Rotation Sensor Rear Wheel Rotation Sensor Rotor ABS Self diagnosis Terminal OONDABRWN BRAKES 12 31 Anti Lock Br
485. r 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 lt is generally under stood that higher running durability is obtained by perma nent internal repairs than by temporary external ones Also permanent internal repairs have the advantage of permitting a thorough examination for secondary damage not visible from external inspection of the tire For these reasons Kawasaki does not recommend temporary exter nal repair Only appropriate permanent internal repairs are recommended Repair methods may vary slightly from make to make Follow the repair methods indicated by the manufacturer of the repair tools and materials so that safe results can be obtained 6J05042BS1 C Hub Bearing WHEELS TIRES 10 17 Hub Bearing Removal e Remove the wheels see Front Rear Wheel Removal and take out the following Collars Coupling Out of rear hub Grease Seals e Use the bearing remover to remove the hub bearings A
486. rated in the fuel tank flow to the canister and is absorbed into the activated carbon The fuel cap has a valve that prevents a large amount of liquid gasoline from spilling in case the motorcycle turns over Even if a small amount of gasoline flows into the canister the canister will maintain its normal function The purge valve is controlled by the ECU which opens and closes the valve to control the purge timing of the vapors Purge Valve Control The purge valve does not work when the engine is not running Even with the engine running the valve might not always work such as when the vacuum pressure is high idle This can have a large effect on the air fuel ratio and can result in the engine malfunctioning or exhaust deterioration Canister The canister has a pressure control mechanism which prevents an excessive pressure increase 1 14 GENERAL INFORMATION Unit Conversion Table Prefixes for Units Units of Length Prefix Symbol km x 0 6214 mile mega M 1 000 000 i EP o kilo k 1 000 mm x 0 03937 in centi 0 01 milli 0 001 Units of Torque micro u 0 000001 Nm x 01020 x 0 7376 ft lb N m x 8 851 in Ib Units of Mass 9 807 N m kg x 2 205 Ib kgf m x 7 233 ft lb g x 0 03527 OZ 86 80 in Ib Units of Volume Units of Pressure L x 0 2642 gal US kPa x 0 01020 kgf cm L x 0 2200 gal IMP kPa x 0 1450 psi L x 1 057 qt US kPa x 0 7501 cmHg L x 0 87
487. rd DC 4 75 5 25 e Turn the ignition switch to OFF x If the reading is within the standard check the output volt age see Intake Air Pressure Sensor 1 Output Voltage Inspection x If the reading is out of the standard remove the ECU and check the wiring for continuity between harness connec tors Special Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Intake Air Pressure Sensor 1 Connector B BL lead ECU terminal 9 C G lead ECU terminal 13 D xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation GT04076BS1 GT04077BS1 FUEL SYSTEM DFI 3 59 Intake Air Pressure Sensor 1 Service Code 12 Intake Air Pressure Sensor 1 Output Voltage Inspection e Measure the output voltage at the intake air pressure sen sor 1 in the same way as input voltage inspection note the following ODisconnect the intake air pressure sensor 1 connector and connect the measuring adapter A between these connectors B Main Harness C Intake Air Pressure Sensor 1 D Digital Meter Special Tool Measuring Adapter 57001 1700 Intake Air Pressure Sensor 1 Output Voltage Connections to Adapter Digital Meter Y sensor Y BL le
488. re cylinder wear is low e Measure the gap B between the ends of the ring with a thickness gauge Piston Ring End Gap Standard Top 0 20 0 30 mm 0 0079 0 0118 in Second 0 40 0 55 mm 0 0157 0 0217 in Service Limit Top 0 6 mm 0 024 in Second 0 9 mm 0 035 in xlf the end gap of either ring is greater than the service limit replace all the rings GE16070781 GE16070881 GE16066BS1 C CRANKSHAFT TRANSMISSION 9 31 Balancer Front Balancer Removal Split the crankcase see Crankcase Splitting e Remove Front Balancer A Balancer Shaft Oil Seal B Front Balancer Installation e Apply molybdenum disulfide oil solution to the ribs A of the balancer e Apply molybdenum disulfide oil solution to the ribs A of the balancer gear e Check that the rubber dampers B are in place OFace the linked portion C to the bottom e Install the balancer weight A into the gear B OAlign the punch mark C of the balancer weight to the groove D of the gear e Apply molybdenum disulfide oil solution to the needle bearings Insert the needle bearings e Fit the washers A on both ends of the weight and gear assembly The projected sides B face inward 9106058851 C 6106050851 C 61068188 C 61068196 P 6106040551 9 32 CRANKSHAFT TRANSMISSION Balancer e Positio
489. red by plastigage A however using gen uine parts maintains the minimum standard clearance e Split the crankcase again measure each clearance be tween the bearing insert and journal B using plastigage Crankshaft Main Bearing Insert Journal Clearance Standard 0 048 0 086 mm 0 0019 0 0034 in Service Limit 0 12 mm 0 0047 in If the clearance is within the standard no bearing replace ment is required If the clearance is between 0 087 mm 0 0034 in and the service limit 0 12 mm 0 0047 in replace the bearing in serts A with inserts painted blue B Check insert journal clearance with the plastigage The clearance may exceed the standard slightly but it must not be less than the min imum in order to avoid bearing seizure xIf the clearance exceeds the service limit measure the diameter of the crankshaft main journal Crankshaft Main Journal Diameter Standard 39 984 40 000 mm 1 5742 1 5748 in Service Limit 39 96 mm 1 5732 in xIf any journal has worn past the service limit replace the crankshaft with a new one x If the measured journal diameters A are not less than the service limit but do not coincide with the original diameter markings B on the crankshaft make new marks on it Crankshaft Main Journal Diameter Marks None 39 984 39 992 mm 1 5742 1 5745 in 1 39 993 40 000 mm 1 5745 1 5748 in Crankshaft Main Journal Diameter Marks 1 or no mark
490. ressor Assembly A 57001 241 Valve Spring Compressor Adapter 24 B 57001 1586 Valve Installation e Replace the oil seal with a new one Apply a thin coat of molybdenum disulfide grease to the valve stem before valve installation e Install the springs so that the closed coil end faces down wards Valve Stem A Oil Seal B Spring Seat C Closed Coil End D Valve Spring E EX Orange Paint IN Pink Paint Retainer F Split Keepers G Valve Guide Removal e Remove Valve see Valve Removal Oil Seal Spring Seat e Heat the area around the valve guide to 120 150 C 248 302 F and hammer lightly on the valve guide arbor A to remove the guide from the top of the head NOTICE Do not heat the cylinder head with a torch This will warp the cylinder head Soak the cylinder head in oil and heat the oil Special Tool Valve Guide Arbor 5 57001 1203 GE15043BS1 C GE15028BS1 C GE15045BS1 C ENGINE END 5 29 Valves Valve Guide Installation e Apply engine oil to the valve guide outer surface before installation e Heat the area around the valve guide hole to about 120 150 C 248 302 F NOTICE Do not heat the cylinder head with a torch This Will warp the cylinder head Soak the cylinder head and heat the oil e Assembly the valve guide driver parts holder and attach ment E e Insert the rod of the driver into the valve guide bore and
491. ring servicing selling leasing or trading motor vehicles or motor vehicle engines or who operates a fleet of motor vehicles know ingly to remove or render inoperative any device or element of design installed on or a motor vehicle or motor vehicle engine in compliance with regulations under this title follow ing its sale and delivery to the ultimate purchaser NOTE OThe phrase remove or render inoperative any device or element of design has been generally interpreted as follows 1 Tampering does not include the temporary removal or rendering inoperative of de vices or elements of design in order to perform maintenance 2 Tampering could include a Maladjustment of vehicle components such that the emission standards are ex ceeded b Use of replacement parts or accessories which adversely affect the performance or durability of the motorcycle of components or accessories that result in the vehicle exceeding the stan dards d Permanently removing disconnecting or rendering inoperative any component or element of design of the emission control systems WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING 10 000 PER VIOLATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes
492. rks Ignition Key 3 Repeat Turn OFF the ignition switch and wait for period of more than 15 seconds e The registration mode automatically ends The red warning indicator light LED A goes off Remove the key registration unit key registration adapter and connect the immobilizer Kawasaki diagnostic system connector NOTE O Turn the ignition switch to ON with the registered ignition key OCheck that the engine can be started using all regis tered ignition keys 0 30 30 30 3 0 30 30 3 1second A ot LIU UL GP30082CS1 C GP30083CS1 C ELECTRICAL SYSTEM 16 95 Immobilizer System Equipped Models Spare Ignition Key Registration Flow Chart Blinking Patterns and Number 2second m ge 9 Ssecerd 0 2 029 102 03 9 2 gt oW 9 29 2 029 3 9329210259235 1 01 84 gt 4 i 92929 291 01 029203 0 2 teecend gt 5 6 ignition key 2 5 NOTES Red warming inScator ight and symbol goes of 16 96 ELECTRICAL SYSTEM Immobilizer System Equipped Models Case 2 When the ignition switch is faulty and to be replaced e Prepare a new ignition switch A and 2 new ignition keys OThese parts available as set Prepare the current registered ignition key C Remove Ignition Switch see Immobilizer System Parts Replace ment Seat see Sea
493. ront Camshaft Chain Guide Bolt Upper A Remove Front Camshaft Chain Guide Bolt Lower A Collar Front Camshaft Chain Guide B Dowel Pin C Rear Camshaft Chain Guide D Remove the M6 cylinder head bolts A and then the M11 cylinder head bolts B Remove the cylinder head Cylinder Head Installation NOTE OThe camshaft cap is machined with the cylinder head so if a new cylinder head is installed use the cap that is supplied with the new head e Install a new cylinder head gasket and dowel pins e Apply molybdenum disulfide oil solution to both sides A of the cylinder head bolt washers B and the threads of the head bolts C GE14112BS1 GE14189BS1 C 5 26 ENGINE END Cylinder Head Tighten the M11 cylinder head bolts following the tighten ing sequence 1 10 OFirst tighten the bolts specified torque New Bolts One Time Used Bolts Two Times ONext using a angle torque gauge A tighten the bolts specified angle 5 First Torque Second eae N m kgf m Torque N m Angle ft Ib kgf m ft Ib New 30 3 1 22 None 135 5 Used 20 2 0 15 30 3 1 22 110 5 Tighten the M6 cylinder head bolts following the tightening sequence 11 12 Torque Cylinder Head Bolts M6 12 N m 1 2 kgf m 106 in Ib e Install Dowel Pin A Rear Camshaft Chain Guide B Front Camshaft Chain Guide C New O ring D Collar E Tighten
494. rouble Idle speed control valve trouble Inspect see chapter 3 Inspect see chapter 3 Engine stalls easily Spark plug dirty broken or gap maladjusted Inspect and replace see chapter 16 Stick coil trouble Inspect see chapter 16 Main throttle sensor trouble Inspect see chapter 3 Subthrottle sensor trouble Inspect see chapter 3 Subthrottle valve actuator trouble Inspect see chapter 3 Intake air pressure sensor 1 trouble Inspect see chapter 3 Intake air pressure sensor 2 trouble Water temperature sensor trouble Intake air temperature sensor trouble Fuel pump trouble Fuel injector trouble Fuel pressure too low or too high Fuel pressure regulator trouble Fuel line clogged Idle speed control valve trouble Poor acceleration Fuel pressure too low Water or foreign matter in fuel Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect fuel pressure and replace fuel pump see chapter 3 Inspect and repair see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Inspect see chapter 3 Change fuel Inspect and clean fuel system see chapter 3 Fuel filter or pump screen clogged Inspect and replace fuel pump see chapter 3 FUEL SYSTEM DFI 3 41 DFI
495. round and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation xIf the reading is out of the standard remove the ECU D and check the wiring for continuity between main harness connectors Special Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor connectors ECUConnecr A LEES Intake Air Temperature Sensor Connector B R BK lead ECU terminal 37 C G lead ECU terminal 13 D If the wiring is good check the intake air temperature sen sor resistance see Intake Air Temperature Sensor Resis tance Inspection GT04082BS1 Intake Air Temperature Sensor Resistance Inspection e Remove the intake air temperature sensor see Intake Air Temperature Sensor Removal e Suspend the sensor A in a container of machine oil so that the heat sensitive portion is submerged e Suspend a thermometer B with the heat sensitive por tion C located in almost the same depth with the sensor NOTE OThe sensor and thermometer must not touch the con tainer side or bottom e Place the container over a source of heat and gradually raise the temperature of the oil while stirring the oil gently for even temperature e Using a digital meter measure the internal resistance of the sensor across the terminals at the temperatures shown in the following Intake Air Temperature Sen
496. rround ing traffic for your safety PERIODIC MAINTENANCE 2 27 Periodic Maintenance Procedures Clutch Fluid Level Inspection Hold the clutch fluid reservoir A horizontal e Check that the clutch fluid level of the clutch reservoir is between the lower B and the upper C level lines x If the fluid level is lower than the lower level line fill the reservoir to the upper level line in the reservoir OSince the clutch fluid is the same as the brake fluid refer to the Brake Fluid Level Inspection in this chapter for fur ther details e Follow the procedure below to install the clutch fluid reser voir cap correctly OFirst tighten the clutch fluid reservoir cap B clockwise 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 clutch fluid reservoir body A A WARNING Mixing brands and types of fluid can reduce the clutch system s effectiveness and cause an acci dent resulting in injury or death Do not mix two brands of fluid Change the fluid in the clutch line completely if the fluid must be refilled but the type and brand of the fluid that is already in the reservoir are unidentified Clutch Fluid Leak Inspection e Apply the clutch lever and inspect the clutch fluid leak from the clutch hose pipe A and fittings x If the clutch fluid leaked from any position inspect or re pla
497. rst ignition key to the ignition switch and turn it ON Olf there is any problem in the registration the red warning indicator light LED and immobilizer warning symbol A blinks to display the collation error Immobilizer Amplifier Failure GP30059CS1 C Ignition Key Collation Error 0 3second QOO GP30080CS1 C Immobilizer System Equipped Models ELECTRICAL SYSTEM 16 105 The first ignition key is registered in the ECU OThe red warning indicator light LED and immobilizer warning symbol A blinks 1 time and stops for 1 second and then repeats this cycle to indicate successful regis tration of ignition key e Turn OFF and remove the first ignition key and remove it OThe red warning indicator light LED and immobilizer warning symbol A blinks to display the registration mode codes NOTE Olnsert next key and turn ON within 15 seconds after pre vious key is turned OFF and removed otherwise regis tration mode will be ended and the red warning indicator light LED goes OTo return to the registration mode start the registered ignition key verification procedure This applies to all ignition key registration e Insert the second ignition key to the ignition switch and turn it to ON NOTE OKeep the other ignition keys away from the immobilizer antenna Olf there is any problem in the registration the red warning indicator light LE
498. rum and transmission gears are in the neutral position 9104431851 9104432851 9 14 CRANKSHAFT TRANSMISSION Crankcase Splitting e Using a high flash point solvent clean off any oil or dirt that may be on the liquid gasket coating area Dry them with a clean cloth e Apply liquid gasket A to the mating surface of the lower crankcase half as shown in the figure Sealant Liquid Gasket TB1216B 92104 1064 NOTE OMake the application finish within 20 minutes when the liquid gasket to the mating surface of the lower crankcase half is applied OAfter tightening the crankcase bolts wipe up the liquid gasket seeping out the output shaft bearing journal B Do not apply liquid gasket inside of the grooves C near the crankshaft main bearing inserts and bal ancer bearing Do not plug the inside of breather hole D with liq uid gasket e Fit the lower crankcase half to the upper crankcase half e Be sure that the breather hole A on the upper crankcase is not plugged with liquid gasket e The M10 bolts have washers replace them with new ones e Apply molybdenum disulfide oil solution to the seating sur faces A of the washers and the threads B of the M10 bolts e Tighten the lower crankcase bolts using the following steps OFollowing the sequence numbers on the lower crankcase half tighten the M10 bolts 1 10 with washers Torque Crankcase Bolts M10 49 5
499. ry leads supply battery power to the fan motor the fan does not rotate the fan motor is defective and must be replaced Radiator Fan Circuit GTO41138W2 C 1 ECU 10 Fuse Box 1 2 Water Temperature Sensor 11 Ignition Fuse 15 A 3 Frame Ground 12 Fuse Box 2 4 Battery 13 Fan Fuse 15 5 Starter Relay 14 Joint Connector F 6 Main Fuse 30 A 15 Ignition Switch 7 Frame Ground 4 16 Fan Motor 2 8 Relay Box 17 Fan Motor 1 9 Fan Relay 18 Frame Ground 2 ELECTRICAL SYSTEM 16 75 Meter Gauge Indicator Unit Meter Unit Removal Remove Windshield see Windshield Removal in the Frame chapter Immobilizer Amplifier A Equipped Models e Remove Immobilizer Amplifier Bracket Bolt A and Bracket Equipped Models Vehicle down Sensor Bracket Bolt B and Bracket Connector C e Remove Meter Unit Mounting Nuts A and Washers Meter Unit B 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 Meter Unit Installation e Install Meter Unit A Washers B and Meter Unit Mounting Nuts C e Install Connector Vehicle down Sensor Bracket and Bolt A Immobilizer Amplifier Bracket and Bolt Equipped Mod els Immobilizer Amplifier B Equipped Models Windshield see Windshield Installation in the Frame chapter 16 76 ELECT
500. s Right Switch Housing Screws Throttle Case Screws Steering Stem Head Nut Front Fork Clamp Bolts Upper Steering Stem Nut Left Switch Housing Screws Front Fork Clamp Bolts Lower Frame Front Footpeg Bracket Bolts 18 Sidestand Nut 32 Sidestand Bolt 32 Sidestand Bracket Bolts i 36 Sidestand Switch Bolt Center Stand Bolts Equipped Models 5 32 Rear Footpeg Bracket Bolts 18 Rear Frame Bolts 32 Rear Frame Pipe Bolts 32 Rear Frame Pipe Nuts 32 Front Fender Cover Screws 11 in Ib Rear Fender Mounting Screws 11 in lb Seat Lock Bracket Screws 11 in Ib Grab Rail Mounting Bolts Equipped Models 18 Electrical System Headlight Mounting Screws 11 16 Front Turn Signal Light Mounting Screws 11 in lb Tail Brake Light Mounting Screws 11 16 License Plate Light Mounting Plate Screws 11 in lb License Plate Light Cover Mounting Screws 16 in Ib Starter Motor Through Bolts 30 in lb Starter Motor Cable Terminal Nut 52 in lb Starter Motor Terminal Locknut 61 Starter Motor Mounting Bolts 87 Spark Plugs 4 115 in lb Water Temperature Sensor 106 in lb Engine Ground Terminal Bolt 87 Alternator Rotor Bolt 114 Alternator Cover Bolts i 87 in lb Alternator Lead Holding Plate Bolts 69 in lb Stator Coil Bolts 106 in Ib Gear Position Switch Screws 26 in lb Crankshaft Sensor Bolts 52 in lb Crankshaft Sensor Cover Bolts 87 Timing Rotor Bolt 29
501. s e Install the pins A e Install the engine sprocket cover bolt B on the engine sprocket cover C first and then install the engine sprocket cover e Install the other engine sprocket cover bolts and tighten the all bolts e Install the removed parts see appropriate chapters Engine Sprocket Cover Disassembly e Remove the engine sprocket cover see Engine Sprocket Cover Removal e Remove Plate Mounting Bolts A Plate B 11 12 FINAL DRIVE Sprocket Coupling Remove the damper A Engine Sprocket Cover Assembly e Assembly is reverse of disassembly OApply a non permanent locking agent to the threads of the plate mounting bolts Rear Sprocket Removal Remove the rear wheel see Rear Wheel Removal in the Wheels Tires chapter Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground e Remove Rear Sprocket Nuts A Rear Sprocket B Rear Sprocket Installation e Install the sprocket facing the tooth number marking A outward Replace the rear sprocket nuts with new ones Tighten the rear sprocket nuts Torque Rear Sprocket Nuts 69 Nm 7 0 kgf m 51 ft Ib e Install the rear wheel see Rear Wheel Installation in the Wheels Tires chapter Coupling Installation e Apply high temperature grease to the following Coupling Grease Seal Lips A Coupling Internal S
502. s for obstructions e Check the installation condition of the sensor for loose ness e Check the sensor and sensor rotor tip for deformation or damage e g chipped sensor rotor teeth the sensor and sensor rotor in bad condition remove the any deposits Install the proper part or replace faulty part x lf the all items are good go to next step GT04122BS1 Anti Lock Brake System Equipped Models BRAKES 12 49 e Perform the Pre Diagnosis Inspection 1 and 2 see In quiries to Rider x f this service code appears even if all checks are ended replace the ABS hydraulic unit If the service code does not appear the ABS system nor mal temporary failure Rear Wheel Rotation Sensor Wiring Inspection Service Code 45 e Disconnect the rear wheel rotation sensor lead connector A see Rear Wheel Rotation Sensor Removal e Disconnect the ABS hydraulic unit lead connector see ABS Hydraulic Unit Removal e Check the wiring continuity of the W G lead and BK O lead Rear Wheel Rotation Sensor Lead Connector A ABS Hydraulic Unit Lead Connector B W G Lead Terminals C BK O Lead terminals D If the wiring is open replace or repair the harness see ABS System Circuit x If the wiring is good go to next step e Perform the Pre Diagnosis Inspection 1 and 2 see In quiries to Rider x If this service code appears even if all checks are ended replace the rear wheel r
503. s operation inspect 2 38 Steering Steering play inspect year e e e e 2 39 Steering stem bearings lubricate 2 years e 2 40 Electrical System Lights and switches operation year 2 41 inspect PERIODIC MAINTENANCE 2 5 Periodic Maintenance Chart FREQUENCY Whichever ODOMETER READING x 1 000 km x 1 000 mile 30 18 75 ao parts lubricate Bolts and nuts tightness inspect Service more frequently when operating in severe conditions dusty wet muddy high speed or frequent starting stopping For higher odometer readings repeat at the frequency interval established here 2 6 PERIODIC MAINTENANCE Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY Whicheve comes ODOMETER READING x 1 000 km r i x 1 000 mile 5 1 12 24 36 48 Every 0 6 7 5 15 22 5 30 Air cleaner element replace Every 18 000 km 11 250 mile 2 48 Fuel hose replace 2 49 Coolant change 2 51 Radiator hose and O ring replace 2 53 Clutch hose replace 4 years 2 54 Clutch fluid change 2 years 2 55 Pinder api master cylinder slave 4 years 2 56 Engine oil change year 2 57 Oil filter replace year e e e e 258 Brake hose replace 4 years 2 59 Brake fluid change 2 years 2 62 Rubber parts of brake master cylinder caliper 2 63 replace 22
504. sensor 1 B from the bracket C Remove the vacuum hose D and rubber damper E from the intake air pressure sensor 1 Intake Air Pressure Sensor 1 Installation NOTE OThe intake air pressure sensor 1 is the same part as the intake air pressure sensor 2 e Installation is basically the reverse of removal e Position the intake air pressure sensor 1 A between the projections B on the rubber damper e Install the intake air pressure sensor 1 A on the bracket B as shown in the figure 3 58 FUEL SYSTEM DFI Intake Air Pressure Sensor 1 Service Code 12 Intake Air Pressure Sensor 1 Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch to OFF e Remove the throttle body assy see Throttle Body Assy Removal ODo not disconnect the connectors of the throttle body assy e Disconnect the intake air pressure sensor 1 connector and connect the measuring adapter A between these connectors Main Harness C Intake Air Pressure Sensor 1 Special Tool Measuring Adapter 57001 1700 e Connect a digital meter D to the measuring adapter leads Intake Air Pressure Sensor 1 Input Voltage Connections to Adapter Digital Meter R sensor BL lead Digital Meter gt BK sensor lead Measure the input voltage with the engine stopped and with the connector joined e Turn the ignition switch to ON Input Voltage Standa
505. sher NOTE OWhen loosening the engine sprocket nut hold the rear brake on e Remove Chain Guide Bolts A Chain Guide B Raise the rear wheel off the ground with the stand Loosen the drive chain see Drive Chain Slack Adjust ment in the Periodic Maintenance chapter Remove the drive chain from the rear sprocket toward the right e Disengage the drive chain C from the engine sprocket e Pull the engine sprocket off the output shaft E M Lo Sprocket Coupling FINAL DRIVE 11 11 Engine Sprocket Installation e Replace the sprocket washer e Install the engine sprocket onto the output shaft e Apply a non permanent locking agent to the threads of the chain guide bolts e Install the chain guide and tighten the bolts Torque Chain Guide Bolt A 12 N m 1 2 kgf m 106 in Ib Chain Guide Bolts B 9 8 N m 1 0 kgf m 87 in Ib e Apply molybdenum disulfide oil solution to the threads and the seating surface of the engine sprocket nut e Tighten Torque Engine Sprocket Nut 127 N m 13 0 kgf m 93 7 ft Ib NOTE Tighten the nut while applying the rear brake e After torquing the engine sprocket nut bend the one side of the washer A over the nut e Adjust the drive chain slack after installing the engine sprocket see Drive Chain Slack Adjustment in the Pe riodic Maintenance chapter e Apply a non permanent locking agent to the engine sprocket cover bolt
506. shers e Unscrew the balancer shaft clamp bolt and remove the balancer shaft clamp lever and oil seal from the balancer shaft Rear Balancer Installation e Apply molybdenum disulfide oil solution to the ribs A of the balancer 9106050851 C e Apply molybdenum disulfide oil solution to the ribs A of the balancer gear e Check that the rubber dampers B are in place OFace the linked portion C to the bottom e Install the balancer weight A into the gear B OAlign the punch mark C of the balancer weight to the groove D of the gear 61068196 P 9 34 CRANKSHAFT TRANSMISSION Balancer e Apply molybdenum disulfide oil solution to the needle bearings Insert the needle bearings e Fit the washers A on both ends of the weight and gear assembly The projected sides B face inward e Position the crankshaft at 2 3 position TDC or at 1 4 position TDC e Align the mark A on the balancer gear B with the mating surface C of the upper crankcase half e Apply molybdenum disulfide oil solution to the balancer shaft e Install the balancer shaft D and then engage the bal ancer gear and starter motor clutch gear e Install the new oil seal A so that its surface B is flush with the surface of crankcase C OFill the oil seal lips with grease e Install the balancer shaft clamp lever e Tighten Torque Balancer Shaft Clamp Lever Bolt D 25 2 5 kgf m 18 ft lb e Turn the ba
507. shers Cylinder Head Cover B Cylinder Head Cover Installation e Replace the cylinder head cover gasket with a new one e Using a high flash point solvent clean off any oil or dirt that may be on the liquid gasket coating area Dry them with a clean cloth e Apply liquid gasket A to the cylinder head as shown in the figure Sealant Liquid Gasket TB1216B 92104 1064 e Install the new cylinder head cover gasket NOTE OMake the application finish within 20 minutes when the liquid gasket TB1216B to the mating surface of the cylinder head cover is applied e Install Dowel Pins A Plug Hole Gaskets B GE09047BS1 GE09099BS1 C Cylinder Head Cover ENGINE TOP END 5 15 e Install the cylinder head cover e Install the rubber washers A with the metal side faces upward e Tighten the cover bolts following the specified tightening sequence Torque Cylinder Head Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib e Install the heat insulation rubber plate and run the leads correctly see Cable Wire and Hose Routing section in the Appendix chapter e Install the removed parts see appropriate chapters 8 09100851 6 09101851 C 5 16 ENGINE END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal Do not turn over the crankshaft while the tensioner is removed This could upset the camshaft chain timing and damage the valves
508. shing and pulling the forks lf you feel looseness the steering is too loose NOTE OThe cables and wiring will have some effect on the mo tion of the fork which must be taken into account OBe sure the leads and cables are properly routed OThe bearings must be in good condition and properly lubricated in order for any test to be valid Steering Play Adjustment e Remove Handlebars see Handlebar Removal in the Steering chapter Steering Stem Head Nut A and Washer B Upper Front Fork Clamp Bolts C Loosen Steering Stem Head D e Bend the claws A of the claw washer straighten e Remove the steering stem locknut B Special Tool Steering Stem Nut Wrench 57001 1100 e Remove the claw washer C e Adjust the steering using the steering stem nut wrench A Special Tool Steering Stem Nut Wrench 57001 1100 x If the steering is too tight loosen the steering stem nut B a fraction of a turn x lf the steering is too loose tighten the steering stem nut a fraction of a turn NOTE Turn the steering stem nut 1 8 turn at time maximum 2 40 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Install the claw washer A so that its bent side B faces upward and engage the bent claws with the grooves of steering stem locknut C Hand tighten the steering stem locknut until it touches the claw washer Tighten the steering stem locknut clockwise until the claws are aligned with the groo
509. sing OFF Water Temperature Front Brake Battery Immobilizer LED HD Mam yi 7 Red 011 Pressure Warning Indicator Light LED 8 Yellow ABS Indicator Light LED 9 Yellow KTRO Warning Indicator Light LED 10 Yellow Engine Warning Indicator Light LED 11 Speedometer 12 Tachometer 13 Multifunction Display 4 illumination Light LED LED Light Emitting Diode Intake Air Temperature Sensor 6 BR R Y 81 4 81 4 w BK Y lt v 318 11 oa Ignition Switch BR lonobilizer Amplifier Vehicle IE down H Ed Sensor L mobi l izor le Joint Connector F SR N nil Antenna aR Dd Front Wheel i Rotation Sensor Hes Meter Unit Y R EL i Outside BL Temperature BK Y Front Right KH Turn sime el Light BK Y BK Y 12 21 City Light 12458 doint Connector Connector A Headlight High 12965 Headlight Low wy 12558 Headlight Low 0 cco 12 55 Headlight ai gh H aye 129658 IL City Light 12458 Front Left Turn Signal Light 12V2iw 4 ition Fuse 15 n ght Relay Fuse 15A 3 Brake Light Horn Fuse 10A 4 Turn Sig
510. sition Valve Valve Switch ais Actuator Joint Connector 1 Fuel Level Sensor ar Joint Connector Y Y 8k Joint Connector J BKZ Y BK Y BK Y ex o aR Y WR R BL wa L6 8K BRN BK R BK G BL R BL BK ao D BK BL Joint Connector amp Rear Wheel Rotation Sensor Rear Right Light 127219 Tail Brake Lj ei Light LED License BKZ Y BK Y Plate 12 5 Rear Left Light 12V21W Immobilizer Kawasaki Diagnostic Systen Connector g Starter T Relay E Battery 12 12 i doint seer Relay Pong je Color Code Engine 2 Fuse 30 Light BK Black S ANNUM BL Blue Starter Frame Ground Wotor BR Brown amp Frame Frame Green 0 Orange P Pink Pu Purple Rk Red Miei White Y Yellow BK Y BK Y BK Y BR Fuel Reserve Fusi Switch witch Pump Regulator ey Rectifier BK Y BK Y BK BL Alternator IGNITION SWITCH CONNECTIONS Battery lgnition Signal fere ow fepe RIGHT SWITCH HOUSING CONNECTIONS Front
511. sor Resistance Standard 5 4 6 6 at 0 C 32 F 80176808082 C 0 29 0 39 at 80 C 176 x If the reading is out of the standard replace the sensor x lf the reading is within the standard but the problem still exists replace the ECU see ECU Removal Installation FUEL SYSTEM 3 65 Intake Air Temperature Sensor Service Code 13 Intake Air Temperature Sensor Circuit 87104103842 1 ECU 2 Intake Air Temperature Sensor 3 66 FUEL SYSTEM Water Temperature Sensor Service Code 14 Water Temperature Sensor Removal Installation Never drop the water temperature sensor especially on a hard surface Such a shock to the sensor can damage it e Remove the throttle body assy see Throttle Body Assy Removal e Drain the coolant see Coolant Change in the Periodic Maintenance chapter Remove Connector A Water Temperature Sensor B with O ring e Replace the O ring with a new and apply grease to it e Tighten Torque Water Temperature Sensor 12 N m 1 2 kgf m 106 in Ib 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 Turn the ignition switch to OFF e Remove the throttle body assy see Throttle Body Assy Removal e Disconnect the water temperature sensor con
512. spection Remove Right Middle Fairing see Middle Fairing Removal in the Frame chapter Radiator Cap Cover Radiator Cap e Check the condition of the bottom A and top B valve seals and valve spring C any one of them shows visible damage replace the with a new one e Install the cap A on a cooling system pressure tester B NOTE OWet the cap sealing surfaces with water or coolant to prevent pressure leaks e Watching the pressure gauge pump the pressure tester to build up the pressure until the relief valve opens the gauge needle flicks downward Stop pumping and mea sure leak time at once The relief valve must open within the specified range in the table below and the gauge hand must remain within the same range at least 6 seconds Radiator Cap Relief Pressure Standard 93 123 kPa 0 95 1 25 kgf cm 13 18 psi x lf 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 Remove Right Middle Fairing see Middle Fairing Removal in the Frame chapter Radiator Cap Cover Radiator Cap Check the radiator filler neck for signs of damage 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 GDO7013BS1 C GD07001BS1 C COOLING SYSTEM 4 15 Radiator Radiator Cover Removal e Remove Radi
513. ss than the specified value Inspect 1 Lower resistance in a hand tester Use KAWASAKI Hand Tester 2 Crankshaft sensor peak voltage Stick coil primary peak voltage inspection Good Stick coil is defective Replace stick coil Voltage is zero No good or almost zero Inspect Replace bad parts or No good 1 Adapter connection is incorrect or inspect them with adapter is defective KAWASAKI Hand 2 Ignition switch and engine stop switch Tester 3 Crankshaft sensor peak voltage Replace bad parts ECU is defective Replace ECU GP10280B F ELECTRICAL SYSTEM 16 53 Ignition System This page intentionally left blank 16 54 ELECTRICAL SYSTEM Ignition System Ignition System Circuit E Y w o Y BL Y G BK GP10734BW5 C Ignition System ELECTRICAL SYSTEM 16 55 Crankshaft Sensor Main Throttle Sensor Subthrottle Sensor Intake Air Pressure Sensor 2 Intake Air Press Joint Connector Joint Connector J Water Temperature Sensor Gear Position Switch Joint Connector E ECU Frame Ground Battery 12 V 12 Ah Starter Relay Main Fuse 30 A ECU Fuse 15 A Frame Ground 3 Frame Ground 2 Relay Box Starter Lockout Switch lgnition Fuse 15 A Fuse Bo
514. ssembly and completely dry Fork Oil Level 94 2 mm 3 70 0 08 in fully compressed without fork spring below from the top of the inner tube Fork Spring Free Length 237 mm 9 33 in Service Limit 232 mm 9 13 in Rear Shock Absorber Rebound Damper Setting 2 turns out from the fully clockwise position Usable Range 0 2 3 4 turns out Compression Damper Setting 2 3 4 turns out from the fully clockwise position Usable Range 0 turns out Spring Preload Setting Standard Spring length 175 5 mm 6 909 in Usable Range Spring length 170 0 180 5 mm 6 693 7 106 weaker to stronger Gas Pressure 1 080 kPa 11 0 kgf cm 156 psi Non adjustable SUSPENSION 13 7 Special Tools Inside Circlip Pliers Fork Piston Rod Puller M12 x 1 25 57001 143 57001 1289 7570143ST C 7571289ST C Seal amp Bearing Remover Fork Oil Level Gauge 57001 1058 57001 1290 7571058ST C 875712905 C Bearing Driver Set Bearing Remover Head 20 x 22 57001 1129 57001 1293 7571129ST C 7571293ST C Jack Fork Spring Stopper 57001 1238 57001 1374 7571238ST C 875713745 6 Fork Cylinder Holder Bearing Remover Shaft 013 57001 1287 57001 1377 875712875 C 875713775 13 8 SUSPENSION Special Tools Hook Wrench T 3 2 R37 57001 1522 75715228T Fork Oil Seal Driver 43 57001 15
515. ssure switch terminal bolt B and re move the switch lead C e Open the clamps A e Remove Engine Sprocket Cover see Engine Sprocket Removal in the Final Drive chapter Bolt A Clamp B e Disconnect the oil pressure switch gear position switch lead connector C 16 116 ELECTRICAL SYSTEM Switches and Sensors Open the clamp A e Remove Screws B Gear Position Switch C e Remove the pins A and springs from the shift drum Gear Position Switch Installation e Securely place the springs A and pins B into the holes C of the shift drum e Apply grease to the new O ring D e Apply grease to the gear position switch terminals E e Install the gear position switch F e Apply a non permanent locking agent to the threads of the gear position switch screws e Tighten Torque Gear Position Switch Screws 2 9 N m 0 30 kgf m 26 in Ib Gear Position Switch Lead Clamp Bolts 9 8 1 0 kgf m 87 in Ib e Run the gear position switch lead and oil pressure switch lead correctly see Cable Wire and Hose Routing section in the Appendix chapter e Install the removed parts see appropriate chapters Gear Position Switch Inspection NOTE OBe sure the transmission mechanism is good condition e Disconnect the connector A GP18627BS1 rises P Switches and Sensors ELECTRICAL SYSTEM 16 117 e Set the hand tester A to the 1 or x 100
516. 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 2 4 V or more x If the reading is less than the standard inspect the crank shaft sensor see Crankshaft Sensor Inspection Timing Rotor Removal e Remove the crankshaft sensor see Crankshaft Sensor Removal e Remove the timing rotor A OHolding the timing rotor with the flywheel amp pulley holder B and remove the timing 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 39 4 0 kgf m 29 ft lb e Install the removed parts see appropriate chapters 16 48 ELECTRICAL SYSTEM Ignition System Stick Coil Removal i 1 Remove Middle Fairings see Middle Fairing Removal the Frame chapter Air Switching Valve see Air Switching Valve Removal in the Engine Top End chapter e Disconnect the stick coil connectors A e Pull out the stick coils B upward Do not pry the connector part of the coil while re moving the coil Stick Coil Installation e Apply a thin coat of grease A to the stick coils for easy installation e Insert the stick coils so that the coil heads align with the lines B on the cylinder head cover NOTICE Do not t
517. supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation Wheel Rotation Sensor Circuit ABS Equipped Models 5 M a 0 80 6 a y w BK RAY BK N BK W W G 6T04127BW2 1 ECU 2 Rear Wheel Rotation Sensor 3 ABS Hydraulic Unit 4 Front Wheel Rotation Sensor Wheel Rotation Sensor Circuit other than ABS Equipped Models 2 AO 2 6104128812 1 ECU 2 Rear Wheel Rotation Sensor 3 Front Wheel Rotation Sensor Gear Position Switch Service Code 25 FUEL SYSTEM DFI 3 75 Gear Position Switch Removal Installation e Refer to the Gear Position Switch Removal Installation in the Electrical System chapter Gear Position Switch Resistance Inspection e Refer to the Gear Position Switch Inspection in the Elec trical System chapter x lf the reading is as the specified check the output voltage see Gear Position Switch Output Voltage Inspection Gear Position Switch Output Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch to OFF e Remove the left middle fairing see Middle Fairing Re moval in the Frame chapter e Disconnect the oil pressure switch gear position switch lead connector A e Connect the measuring adapter A between the main harness connector and oil puressure
518. supply are good replace the ECU see ECU Removal Installation 6104080852 C Intake Air Pressure Sensor 1 Service Code 12 FUEL SYSTEM DFI 3 61 2 ou 7 1 0 7 P4 7 2 P4 ME MS LUNA T ER RUP A 10 20 30 40 50 60 70 76 80 90 cmHg Ps W 1 1 1 1 20 40 60 80 101 32 120 kPa Ps ID 5T0 gt 5 68017120844 C ID Idling Ps Standard Atmospheric Pressure Absolute Pv Throttle Vacuum Pressure Absolute ST Standard of Sensor Output Voltage V TO Throttle Full Open UR Usable Range of Sensor Output Voltage V Vv Intake Air Pressure Sensor 1 Output Voltage V Digital Meter Reading 3 62 FUEL SYSTEM Intake Air Pressure Sensor 1 Service Code 12 Intake Air Pressure Sensor 1 Circuit MEM coc G W BL Y BL 9 BL G W B 6T04102BW2 C 1 ECU 2 Intake Air Pressure Sensor 1 3 Intake Air Pressure Sensor 2 4 Joint Connector 5 Joint Connector J FUEL SYSTEM 3 63 Intake Air Temperature Sensor Service Code 13 Intake Air Temperature Sensor Removal Never drop the intake air temperature sensor espe cially on a hard surface Such a shock to the sensor can damage it e Remove Fuel Tank see Fuel Tank Removal Heat Insulation Cover see Throttle Body Assy Removal Intake Air Temperatur
519. switch gear position switch lead connector as shown in the figure Main Harness B To Gear Position Switch C To Oil Pressure Switch D Special Tool Measuring Adapter 57001 1700 e Connect a digital meter E to the measuring adapter lead Gear Position Switch Output Voltage Connections to Adapter Digital Meter sensor G R lead Digital Meter gt Frame Ground terminal e Measure the switch input voltage with the engine stopped and with the connector joined e Turn the ignition switch to ON OWhen changing the gear position from lower gear to higher gear raise the rear wheel off the ground with a suitable stand and rotate the rear wheel by hand Output Voltage at 1 6 Gear Positions Standard 1st About DC 3 0 V 2nd About DC 2 5 V 3rd About DC 2 0 V 4th About DC 1 5 V 5th About DC 1 1 V 6th About DC 0 7 V 6104090851 C 3 76 FUEL SYSTEM Gear Position Switch Service Code 25 e Turn the ignition switch to OFF x lf the reading is out of the standard check the wiring for continuity using the wiring diagram in this section Special Tool Hand Tester 57001 1394 x If the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation Gear Position Switch Circuit 81041086842 C 1 2 Frame Ground 2 3 Relay Bo
520. system and assists in locating their chapters Each chapter in turn has its own comprehensive Ta ble of Contents For example if you want ignition coil informa tion use the Quick Reference Guide to locate the Electrical System chapter Then use the Table of Contents on the first page of the chap ter to find the Ignition Coil section Whenever you see symbols heed their in structions Always follow safe operating and maintenance practices A DANGER DANGER indicates a hazardous situa tion which if not avoided will result in death or serious injury A WARNING WARNING indicates a hazardous situa tion which if not avoided could result in death or serious injury NOTICE is used to address practices not related to personal injury This manual contains four more symbols which will help you distinguish different types of information NOTE OThis note symbol indicates points of par ticular interest for more efficient and con venient operation e Indicates a procedural step or work to be done Olndicates a procedural sub step or how to do the work of the procedural step it follows It also precedes the text of a NOTE Indicates a conditional step or what action to take based on the results of the test or inspec tion in the procedural step or sub step it fol lows In most chapters an exploded view illustration of the system components follows the Table of Contents In these illus
521. t Muffler Cover B Right Muffler Cover C GE18162BS2 C ENGINE END 5 39 Muffler OFit the dampers A of the muffler cover B into the slots C of the muffler body D and tighten the bolts Exhaust Pipe Removal e Remove Oxygen Sensor Equipped Models see Oxygen Sen sor Removal Equipped Models in the Electrical System chapter Radiator see Radiator and Radiator Fan Removal in the Cooling System chapter Muffler Bodies see Muffler Body Removal Installation Exhaust Pipe Manifold Holder Nuts A Exhaust Pipe Manifold B Exhaust Pipe Installation e Replace the exhaust pipe gaskets A with new ones and install them GE18183BS1 C e Tighten the exhaust pipe manifold holder nuts following A the tightening sequence 1 8 OOOO View from Front A e Install the removed parts See appropriate chapters GE18184BS1 6 1 Clutch Table of Contents Exploded VEW E 6 2 SSC INC ALONG ssena eem MET 6 4 Special Tools and Sealant tees aoe 6 5 Clutch Master Syll Bra 6 6 Clutch Lever Position 2 6 6 Clutch Master Cylinder Removal pt 6 6 Clutch Master Cylinder Installation 2 6 6 Clutch Master Cylinder Disassembly 6
522. t Removal in the Frame chapter e Remove the immobilizer Kawasaki diagnostic system connector cap e Connect the key registration unit A and key registration adapter B Special Tools Key Registration Unit 57001 1582 Key Registration Adapter 57001 1746 e Connect New Ignition Switch Lead Connector A Immobilizer Antenna Lead Connector B NOTE OKeep the ignition switches more than 15 cm 5 9 in New Ignition Switch C Current Ignition Switch D e Insert the current registered ignition key A at the current ignition switch B e Insert the new ignition key 1 C to the new ignition switch D and turn it to ON Immobilizer System Equipped Models ELECTRICAL SYSTEM 16 97 Verified OThe red warning indicator light LED and immobilizer warning symbol A blinks to display the ECU is in the registration mode go to the next step Not Verified OThe red warning indicator light LED and immobilizer warning symbol A blinks to display the collation error Immobilizer Amplifier Failure Registered Ignition Key Collation Error Turn OFF and remove the new ignition key 1 Disconnect the immobilizer antenna connector then con nect the antenna connector of the new ignition switch e Insert the ignition key 1 A again into the new ignition switch and turn it to ON NOTE Olnsert the next key and turn ON within 15 seconds after previous key is turned OFF and removed otherwise reg
523. t 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 connec tions shown in the table have continuity OFor the switch housings and the ignition switch refer to the tables in the Wiring Diagram x If the switch has an open or short repair it or replace it with a new one Special Tool Hand Tester 57001 1394 Rear Brake Light Switch Connections Rear Brake Light Switch Connections Color BR BL When brake pedal is pushed down When brake pedal is released Sidestand Switch Connections Sidestand Switch Connections Color BK G When sidestand is down When sidestand is up O O Oil Pressure Switch Connections 011 Pressure Switch Connections Color SW Terminal Ground When engine is stopped O When engine is running Engine lubrication system is in good condition 16 112 ELECTRICAL SYSTEM Switches and Sensors Water Temperature Sensor Inspection e Remove the water temperature sensor see Water Tem perature Sensor Removal Installation in the Fuel System DFI chapter e Suspend the sensor A in a container of coolant so that the temperature sensing projection C is submerged Suspend an accurate thermometer with temperature sensing
524. t air intake duct mounting bolts C e Replace the clamps with new ones see Exploded View in this chapter e Run the leads correctly see Cable Wire and Hose Rout ing section in the Appendix chapter 6C07078BS1 3 146 FUEL SYSTEM Fuel Tank Fuel Tank Removal A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions creating the potential for serious burns Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Turn the ignition switch OFF Disconnect the battery terminal To avoid fuel spills draw it from the tank when the engine is cold Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately e Turn the ignition switch to OFF e Wait until the engine cools down e Remove the fairing covers see Fairing Cover Removal in the Frame chapter e Disconnect the battery terminal see Battery Removal in the Electrical System chapter e Remove Inner Covers see Inner Cover Removal in the Frame chapter Fuel Tank Cover see Fuel Tank Cover Removal in the Frame chapter Fuel Tank Bolts A Disconnect Fuel Pump Lead Connector A Fuel Level Sensor Lead Connector B e Remove Fuel Tank Bolts A Drain Hose B Breather Hose C Fuel Tank FUEL SYSTEM DFI 3 147 Open the fuel tank ca
525. t pill High 12658 eit Light fovew IE 1 05 Turn Signs Turn Signal Light 12v2iw Fuse B i 1 Ignition Fuse 15 P Headlight Relay Fuse 15 3 Brake Light Horn Fuse 4 Turn Signal Relay Fuse 10 Turn Signal F Box 2 1 Metre Fuse Headlight Headlight Relay 2 Fan Fuse 15 Relay LO Relay HI 3 Headlight Relay Fuse 15 Left Switch Housing Relay Box Left Switch Housing Relay Box 1 Horn Button 5 Dimmer Switch 1 Radiator Fan Rela 3 ECU Main Rela 2 Hazard Button 6 Starter Lockout Switch Leute A FUSTO BUMD RELAY 3 Turn Signal Switch 7 SEL Button 5 Starter Circuit 4 Passing Button 8 Upper and Lower Button Relay LEFT SWITCH HOUSING CONNECTIONS Horn Buton Hazard Button Turn Signal Switch Passing Button Dimmer Switch Starter Lockout Switch Multifunction oY cotor e o er cotar R Y co tor Clutch Lever Push Released Released R Lo Pulled In Lower 210692 5 C ELECTRICAL SYSTEM 16 21 Wiring Diagram BR Model Intake Air ie Pressure ite ub Sensor 2 Intake Wat Crank throttle Main Sub S Rp Tenperature Valve Throttle throttle Pressure Sensor Sensor Actuat Sensor 1 Oxygen Idle Speed i ctuator Sensor Sensor Ae Control Seicening 2569797 Gear Po
526. t pre diagnosis inspections as a preliminary in spection e Determine the fault using the self diagnosis function e Check wiring and connections from the ABS hydraulic unit connector to the suspected faulty ABS part using the hand tester Special Tool Hand Tester 57001 1394 e Visually inspect the wiring for signs of burning or fraying If any wiring is poor replace the damaged wiring e Pull each connector A apart and inspect it for corrosion dirt and damage If the connector is corroded or dirty clean it carefully If it is damaged replace it e Check the wiring for continuity OUse the wiring diagram to find the ends of the lead which is suspected of being a problem OConnect the hand tester between the ends of the leads Special Tool Hand Tester 57001 1394 OSet the tester to the x 1 O range and read the tester x lf the tester does not read 0 the lead is defective Re place the main harness B if necessary e Narrow down suspicious parts and close in on the faulty ABS part by repeating the continuity tests x If no abnormality is found in the wiring or connectors the ABS parts are the next likely suspects Check each part one by one x If an abnormality is found replace the affected ABS part GL14618BS1 BRAKES 12 37 Anti Lock Brake System Equipped Models ABS Diagnosis Flow Chart Problem occurs Confirm problems Gather information from rider Conduct pre
527. t room temperature x lf the valve is open replace the thermostat with a new one 6D09007BS1 6009024851 Thermostat COOLING SYSTEM 4 17 e 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 must not touch the container either x If the measurement is out of the specified range replace the thermostat with a new one Thermostat Valve Opening Temperature 58 62 C 136 144 6009020252 C 4 18 COOLING SYSTEM Hoses and Pipes Hose Installation e Apply soap and water solution to the inside of the water DD A wg hoses before installation e Install the hoses and pipes being careful to follow bend ing direction Avoid sharp bending kinking flattening or twisting e Run the hoses see Cable Wire and Hose Routing sec tion in the Appendix chapter e Install the clamp as near as possible to the hose end to clear the raised rib of the fitting This will prevent the ico hoses from working loose OThe clamp screws should be positioned correctly to pre vent the clamps from contacting the other parts e Tighten Torque Water Hose C
528. tal meter to the terminals in each fuel injec tor A e Measure the fuel injector resistance Fuel Injector Resistance Standard About 11 7 12 3 at 20 C 68 F x If the reading is out of the standard replace the fuel in jector xIf the reading is within the standard check the power source voltage see Fuel Injector Power Source Voltage Inspection 65175546 3 128 FUEL SYSTEM DFI Fuel Injectors Fuel Injector Power Source Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch to OFF e Remove the throttle body assy see Throttle Body Assy Removal e Connect the throttle body subharness connector A tem porarily e Disconnect the injector connector and connect the mea suring adapter A between these connectors as shown in the figure Harness B Fuel Injector 1 C Special Tool Measuring Adapter 57001 1700 Connect a digital meter D to the measuring adapter lead Fuel Injector Power Source Voltage Connections to Adapter For Fuel Injector 1 2 3 4 Digital Meter R injector W R lead Digital Meter gt Frame Ground terminal Measure the power source voltage with the engine stopped e Turn the engine stop switch to run position e Turn the ignition switch to ON Power Source Voltage Standard Battery Voltage for 3 seconds and then 0 V e Turn the ignition switch to OFF x If the reading stays on battery voltage and
529. te Corrected to one light burned out Lighting System ELECTRICAL SYSTEM 16 71 Turn Signal Light Circuit 5 vam 4 Rear Left Turn Signal Light Joint Connector Frame Ground Battery 12 V 12 Ah Starter Relay Main Fuse 30 A Frame Ground 2 Frame Ground 1 Frame Ground 4 Turn Signal Switch Hazard Button Turn Signal Relay Front Left Turn Signal Light Front Right Turn Signal Light Joint Connector G Joint Connector A Meter Unit Turn Signal Indicator Light LED Right Turn Signal Indicator Light LED Left GPi26148W2 C Ignition Switch For US and CA Models ON Position Only Fuse Box 1 Turn Signal Relay Fuse 10 A Rear Right Turn Signal Light 16 72 ELECTRICAL SYSTEM Air Switching Valve Air Switching Valve Operation Test e Refer to the Air Suction System Damage Inspection in the Periodic Maintenance chapter Air Switching Valve Unit Test e 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 1 range and connect it to the air switching valve terminals as shown in the figure Special Tool Hand Tester 57001 1394 Air Switching Valve Resistance Standard 20 240 at 20 68 F x If the resistance reading is except the specified value re place it with a new one e Connect the 12 V battery A
530. tes H Steel Plates 1 Spring Seat J Spring K Spring Plate L e Engage the clutch hub with the sub clutch hub e To measure the free play set a dial gauge A against the raised center B of the clutch spring plate Move the clutch housing gear back and forth The dif ference between the highest and lowest gauge readings is the amount of free play Drive Shaft D e Measure the spring plate free play Spring Plate Free Play Usable Range 0 05 0 70 mm 0 002 0 028 in x If the free play is not within the usable range change all of the friction plate and measure the free play again x If the free play is not within the usable range adjust the free play see Spring Plate Free Play Adjustment GF11034BS2 C GF12002BS2 C 6 18 Clutch Spring Plate Free Play Adjustment NOTE OThe free play adjustment is performed by replacing the steel plate s e Measure the clutch spring plate free play see Clutch Spring Plate Free Play Measurement and then replace the steel plate s which brings the free play within the usable range Spring Plate Free Play Usable Range 0 05 0 70 mm 0 002 0 028 in OReplace the following steel plate s Thickness Part Number 2 3 mm 0 090 in 13089 0019 2 6 mm 0 102 in STD 13089 0018 2 9 mm 0 114 in 13089 0020 NOTE not use the steel plate of 2 3 mm 0 091 in 2 9 mm 0 114 in thickness at the s
531. the 60 grind return to the seat width mea surement step above Correct Width B e Lap the valve to the seat once the seat width and outside diameter are within the ranges specified above OPut a little coarse grinding compound on the face of the valve in a number of places around the valve head OSpin the valve against the seat until the grinding com pound produces a smooth matched surface on both the seat and the valve ORepeat the process with a fine grinding compound Lapper A Valve Seat B Valve C e The seating area should be marked about in the middle of the valve face x If the seat area is in the right place on the valve check to be sure the valve is the correct part If itis it may have been refaced too much replace it e Be sure to remove all grinding compound before assem bly e When the engine is assembled be sure to adjust the valve clearance see Valve Clearance Inspection in the Periodic Maintenance chapter GE15012381 GE15012081 C ENGINE END 5 35 Valves Valve Seat Repair Machinist s dye on seat 45 Grind Tool 45 Cutter Purpose make seating area smooth and round Measure Seating Area Outside Diameter Tool Vernier Caliper Purpose check seat outside diameter against specification Results Machinist s dye on seat 45 Grind Tool 45 Cutter Purpose increase outside 32 Grind Mars of
532. the air switching valve hose A from the frame e Plug the air switching valve hose end and frame hole e Install the following parts temporarily Throttle Body Assy see Throttle Body Assy Installation in the Fuel System DFI chapter Idle Speed Control Valve Actuator see Idle Speed Con trol Valve Actuator Installation in the Fuel System DFI chapter Fuel Tank see Fuel Tank Installation in the Fuel System DFI chapter e Connect a highly accurate tachometer A to one of the stick coil primary leads e Start the engine and warm it up thoroughly e Check the idle speed using a highly accurate tachometer Idle Speed Standard 1 100 x50 r min rpm x lf the idle speed is out of the specified range inspect the idle speed control valve actuator see Idle Control Valve Actuator Inspection in the Fuel System DFI chapter NOTICE Do not measure the idle speed by the tachometer of the meter unit e While idling the engine inspect the throttle body vacuum using the vacuum gauge B Throttle Body Vacuum Standard 36 66 1 3 kPa 275 0 10 mmHg at idle speed 2 18 PERIODIC MAINTENANCE Periodic Maintenance Procedures lf any vacuum is not within specifications adjust the by pass screws A View from Rear B Special Tool Pilot Screw Adjuster A C 57001 1239 e Adjust the each vacuum 1 4 to the standard value e Open and close the throttle valves after each measure ment NO
533. the battery terminal e Check that the red oil pressure warning light LED A go on x If the indicator light does not go on replace the meter unit Check 3 4 Green Right Turn Signal Indicator Light LED Inspection e Using the auxiliary leads the 12 V battery to the meter unit connector as follows OConnect the battery positive terminal to the terminal 9 10 OConnect the battery negative terminal to the terminal 12 e Connect the terminal 3 to the battery terminal e Check that the green right turn signal indicator light LED A goes on x lf the indicator light does not go on replace the meter unit Meter Gauge Indicator Unit ELECTRICAL SYSTEM 16 87 Check 3 5 Green Left Turn Signal Indicator Light LED Inspection e Using the auxiliary leads the 12 V battery to the meter unit connector as follows OConnect the battery positive terminal to the terminal 9 10 OConnect the battery negative terminal to the terminal 12 e Connect the terminal 19 to the battery terminal e Check that the green left turn signal indicator light LED A goes on x If the indicator light does not go on replace the meter unit Check 3 6 Green Neutral Indicator Light LED Inspec tion e Using the auxiliary leads the 12 V battery to the meter unit connector as follows OConnect the battery positive terminal to the terminal 9 10 OCon
534. the original position e Install the removed parts see appropriate chapters Starter Motor Disassembly e Remove the starter motor see Starter Motor Removal e Take off the starter motor through bolts A and remove the both end covers B e Pull the armature A out of the yoke B e Remove Starter Motor Terminal Locknut Washer and Insulators A Brush Plate Assembly B Starter Motor Assembly e Pry the spring end A and insert the brush B 16 58 ELECTRICAL SYSTEM Electric Starter System e Install the brush plate assembly A into the right hand end cover B e Replace the O ring C with a new one e Install Insulators D Washer E Tighten Torque Starter Motor Terminal Locknut F 6 9 N m 0 70 kgf m 61 in Ib e Install the armature A into the yoke B e Install the thrust washer C e Replace the O rings D with new ones e Put the commutator E among the brushes F e Align the marks A to assemble the yoke and the end covers e Replace the O rings A with new ones e Tighten Torque Starter Motor Through Bolts B 3 4 0 35 kgf m 30 in Ib e Replace the O ring A with a new one e Apply soap and water solution to the new O ring Electric Starter System ELECTRICAL SYSTEM 16 59 Brush Inspection Measure the length A of each brush B If any is worn down to the service limit replace the brush holder assembly
535. the projections A of the socket into the grooves B of the turn signal light e Install the removed parts see appropriate chapters Rear Turn Signal Light Disassembly e Remove Seat Cover see Seat Cover Removal in the Frame chapter Screws A e Pull out the rear turn signal light B from the seat cover e Remove Screw A Rear Turn Signal Light Lens B Rear Turn Signal Light Assembly Fit the projections A of the lens into the grooves B of the turn signal light ELECTRICAL SYSTEM 16 69 Lighting System e Check that the gasket fits into the groove Tighten the screw A e When installing the grommet A face the large diameter side toward rear fender e Install the rear turn signal light Tighten the screws Turn Signal Relay Inspection e Remove Left Seat Cover see Seat Cover Removal in the Frame chapter Turn Signal Relay A e Disconnect the connector B 16 70 ELECTRICAL SYSTEM Lighting System Connect one 12 V battery and turn signal lights as indi cated in the figure and count how may times the lights flash for one minute Turn Signal Relay A Turn Signal Lights B 12 V Battery C x If the lights do not flash as specified replace the turn sig nal relay Testing Turn Signal Relay Load The Number of Turn Flashing Times Signal Lights Wattage W c m 155 21 23 140 250 2 42 or 46 75 95 Cycle s per minu
536. the wiring is good check the meter unit see Meter Unit Inspection in the Electrical System chapter xIf the meter unit is normal replace the ECU see ECU Removal Installation 3 94 FUEL SYSTEM ECU Communication Error Service Code 39 ECU Communication Line Circuit 2 2 I I 3 e 1 2 Joint Connector 3 Joint Connector 4 Meter Unit 5 Yellow Engine Warning Indicator Light LED 6 Yellow KTRC Warning Indicator Light LED FUEL SYSTEM 3 95 Fuel Pump Relay Service Code 46 Fuel Pump Relay Removal installation OThe fuel pump relay is built in the relay box A e Refer to the Relay Box Removal in the Electrical System chapter Fuel Pump Relay Inspection e Refer to the Relay Circuit Inspection in the Electrical Sys tem chapter x If the fuel pump relay is normal check the wiring to the fuel pump relay see Fuel Pump Relay Circuit Special Tool Hand Tester 57001 1394 x If the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection lf the ground and power supply are good replace the ECU see ECU Removal Installation Fuel Pump Relay Circuit O GTO41118W2 1 ECU 10 Fuel Pump 2 Joint Connector B 11 Relay Box 3 Frame Ground 12 Fuel Pump Relay 4 Battery 13 Fuse Box 1 5 Starter Relay 14 Ignition Fuse 15A
537. tic System 8 Joint Connector D dicator Light LED Connector 9 Joint Connector C 14 Joint Connector F 3 Frame Ground 10 Fuse Box 1 15 Immobilizer Antenna 4 Battery 11 Ignition Fuse 15 A 16 Immobilizer Amplifier 5 Starter Relay 12 Meter Unit 17 Ignition Switch FUEL SYSTEM 3 93 ECU Communication Error Service Code 39 ECU Communication Line Inspection OWhen the data is not sent from the ECU to the meter unit for more than about 5 seconds the service code 39 is displayed OThe data is sent through the CAN communication line OThe service code 39 is detected with the meter unit OWhen the user mode this communication error goes on the yellow engine warning indicator light LED A and yellow KTRC warning indicator light LED B and blinks the following items POWER Mode and KTRC Symbols C 12 AVERAGE m i 01041338 Inspect the CAN communication line resistance see Communication Line Resistance Inspection x If the CAN communication line resistance is normal check the wiring according following procedure e Remove the ECU and meter unit check the wiring for continuity between main harness connector ODisconnect the ECU and meter unit connectors Special Tool Hand Tester 57001 1394 Wiring Continuity Inspection ECU Connector Meter Unit Connector B GY BL lead ECU terminal 27 C LB lead ECU terminal 28 D GT04134881 0 x If
538. ting Rod Big End Nuts see the text lt Crankcase Bolts 7 L 60 mm 20 15 Crankcase Bolt M7 L 2 110 mm 20 15 Crankcase Bolts 7 L 45 mm 20 15 Crankcase Bolts M10 L 90 mm 49 36 Crankcase Bolt M7 L 85 mm 20 15 Crankcase Bolt M7 L 50 mm 20 15 Crankcase Bolts M10 L 120 mm 49 36 Crankcase Bolt M6 L 65 mm 12 106 in Ib Crankcase Bolts M8 L 80 mm 27 20 Crankcase Bolts M6 L 25 12 1 106 in Ib Crankcase Bolts M6 L 40 mm 12 106 in lb Crankcase Bolt M6 L 50 mm 12 106 in lb Crankcase Bolts M8 L 70 mm 27 20 Crankcase Bolts M7 L 65 mm 20 15 Balancer Shaft Clamp Bolts 9 8 87 Balancer Shaft Clamp Lever Bolts 25 18 Shift Drum Cam Holder Bolt 12 106 Shift Shaft Return Spring Pin 29 21 Gear Position Switch Screws 2 9 26 Gear Positioning Lever Bolt 12 i 106 in Ib Torque Limiter Bolt 25 18 Starter Clutch Shaft Plate Bolt 9 8 87 Starter Clutch Shaft Bolt 9 8 87 Wheels Tires Front Axle Clamp Bolts 20 2 0 15 AL Front Axle Nut 127 13 0 93 7 Rear Axle Nut 127 13 0 93 7 Final Drive Chain Guide Bolt 12 1 2 106 in Ib L 2 10 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Torque Remarks Chain Guide Bolts 9 8 87 L Engine Sprocket Nut 127 93 7 MO Rear Axle Nut 127 93 7 Rear Sprocket Nuts 69 51 Stud Bolts 14 7 10 8 L Brakes Front Brake Pad Pins 17 2
539. tion key and one ignition key OContinue the procedure to program the second and later keys e Insert the ignition key 2 to the ignition switch and turn it to ON GP30059CS1 C Y 0 5second 0 5second bu 6230058651 0 3second UUUUUUUUUUU OLS 0 GP30080CS1 C 0 30 30 3 0 3 0 3 1second 9 LLL GP30081CS1 C 0 5second 0 5second M Ip pap GP30058CS1 Immobilizer System Equipped Models ELECTRICAL SYSTEM 16 99 Olf there is any problem in the registration the red warning indicator light LED and immobilizer warning symbol A blinks to display the collation error Immobilizer Amplifier Failure When Registered Ignition Key is Inserted Ignition Key Collation Error The ignition key 2 is successfully registered in the ECU OThe red warning indicator light LED and immobilizer warning symbol A blinks 4 times and stops for 1 sec ond and then repeat this cycle to indicate successful programming of ignition key 2 e Turn OFF the ignition switch and wait for period more than 15 seconds e The registration mode automatically ends The red warning indicator light LED A goes off 0 2second GP30059CS1 C 0 5second 0 5second GP30058CS1 C 0 3second UUUUUUUUUUU GP30080CS1 C am 0 30 30 30 3 0
540. tion as shown in the figure Front B Upside View C e Tighten the clamp bolts 80174510651 C e Install the air cleaner caps OThe right air cleaner cap A has a R mark B e Install the intake air temperature sensor and tighten the screw e Install the heat insulation cover A and insert the tabs B into the slots on both sides e Apply a thin coat of grease to the throttle cable lower ends e Fit the accelerator cable end A and the decelerator cable end B into the throttle pulley e Install the clamp securely 3 138 FUEL SYSTEM Throttle Body Assy e Install the removed parts see appropriate chapters e Run the leads and hoses correctly see Cable Wire and Hose Routing section in the Appendix chapter e Adjust Throttle Grip Free Play see Throttle Control System In spection in the Periodic Maintenance chapter FUEL SYSTEM DFI 3 139 Throttle Body Assy Throttle Body Assy Disassembly 6617221282 Throttle Body Assy Intake Air Pressure Sensor 2 Intake Air Pressure Sensor 1 Subthrottle Valve Actuator Main Throttle Sensor Subthrottle Sensor Fuel Injectors Delivery Pipe Throttle Body Subharness Do not remove disassemble or adjust the main throttle sensor subthrottle sensor subthrottle valve actuator throttle link mechanism and throttle body assy because they are adjust or set surely at the
541. tly mistakes read the text thor oughly familiarize yourself with the procedures before starting work and then do the work care fully in 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 in this manual care fully Don t take shortcuts e Remember to keep complete records of main tenance and repair with dates and any new parts installed How to Use This Manual In this manual the product is divided into its major systems and these systems make up the manual s chapters The Quick Reference Guide shows you all of the product s
542. to pinch the tail brake light lead by the ECU rubber protector Fuse Box 2 Put the main harness to the inside of the rear fender rib Take care not to pinch the main harness by the frame rear fender and rib Run the right ECU lead and license plate light lead to the front of the tool box installation position Run the left ECU lead and to the backward of the tool box installation position Mount the tool case while holding the ECU leads by fingers to prevent it from being caught between the tool case and mounting surface After tightening the mounting bolts of the tool case make sure that the ECU leads are not caught between the tool case and mounting surface Run the main harness left ECU lead right ECU lead and diagnostic system connector leads from the left side of the motorcycle Make sure that the leads are not compressed by the frame and rear fender Run the license plate light lead between the ECU connectors Relay Box Leads Run the right ECU lead left ECU lead and license plate light lead to the front of the tool box installation position Run the license plate light lead with slack under the right ECU connector as shown in the figure Make sure that the license plate light lead has no slack above the connecting points and rear wheel Early Models The left ECU lead length is 150 mm 5 91 in Other than Early Models The left ECU lead length is 190 mm 7 48 in 17 26 APPENDIX Cable Wire and Hose Routing
543. to the air switching valve terminals as shown in the figure e Blow the air to the intake air duct A and make sure does not flow the blown air from the outlet air ducts B e Disconnect the 12 V battery e Blow the airto the intake air duct A again and make sure flow the blown air from the outlet air ducts B x lf the air switching valve does not operate as described replace it with a new one NOTE O To check air flow through the air switching valve just blow through the air switching valve hose intake side C GE04030BS1 C GE04033BS1 C GE04031BS1 C lt 7 lt Se GE04032BS1 ELECTRICAL SYSTEM 16 73 Air Switching Valve Air Switching Valve Circuit GTO41168W2 1 ECU 9 Relay Box 2 Frame Ground 10 ECU Main Relay 3 Battery 11 Fuse Box 1 4 Starter Relay 12 Ignition Fuse 15A 5 Main Fuse 30 A 13 Joint Connector A 6 ECU Fuse 15A 14 Joint Connector F 7 Frame Ground 2 15 Ignition Switch 8 Frame Ground 1 16 Air Switching Valve 16 74 ELECTRICAL SYSTEM Radiator Fan System Fan Motor Inspection e Remove the right inner cover see Inner Cover Removal in the Frame chapter e Disconnect the right radiator fan motor lead connector A e Remove the left fairing cover see Fairing Cover Removal in the Frame chapter e Disconnect the left radiator fan motor lead connector A e Using an auxilia
544. to the cylinders by hand e Replace the dust seals B with new ones if they are dam aged OApply silicone grease to the dust seals and install them into the cylinders by hand e Replace the O ring A e Apply brake fluid to the outside of the pistons and push them into each cylinder by hand e Be sure to install the O ring e Apply a non permanent locking agent to the threads of the front caliper assembly bolts and tighten them Torque Front Caliper Assembly Bolts 27 N m 2 8 kgf m 20 ft lb e Install the pads see Front Brake Pad Installation in the Brakes chapter e Wipe up any spilled brake fluid on the caliper with wet cloth Rear Caliper Disassembly e Loosen the rear caliper pad pin A and banjo bolt B and tighten them loosely e Remove Rear Caliper C see Rear Caliper Removal in the Brakes chapter Brake Pads see Rear Brake Pad Removal in the Brakes chapter Rear Caliper Assembly Bolts O ring e Remove the left side piston as follows e Removal of the left side piston is the same as for the front caliper Left Side Caliper A Rubber Gasket B Wooden Board C Bolt D and Nut Apply compressed air E WARNING 8105040251 C 9513154851 9513155851 C The piston the brake caliper crush hands fingers Never place your hand or fingers in front of the piston PERIODIC MAINTENANCE 2 67 Periodic Maintenance Procedures
545. tor Put into the alternator lead connector between the rear fender and rear frame Run the alternator lead under the main harness as shown in the figure Run the alternator lead under the fuel hose Take care not to pinch the alternator lead by the rear fender and main harness Align the gray tape with the end of the battery case to fix main harness position Run the main harness between the rear fender and rib Take care not to run the main harness over the rib Band Hold the main harness at the white painted mark of the main harness with the band and insert the band to the rear fender Run the rear brake light switch lead between the rear fender and frame Run the blue hose under the rear wheel rotation sensor lead connector Rear Wheel Rotation Sensor Lead Connector Insert the rear wheel rotation sensor lead con nector to the bracket Clamp Hold the rear brake light switch lead as shown in the figure CAL and SEA B1 Models 17 22 APPENDIX Cable Wire and Hose Routing w ON Fuel Tank Breather Hose Blue Hose Run the fuel tank breather hose under the rear brake light switch lead and rear wheel rotation sensor lead Run the blue hose over the rear brake light switch lead and rear wheel rotation sensor lead Clamps Fuel Tank Drain Hose Put the alternator lead connector between the clamps as shown in the figure Make sure that the altern
546. trations you will find the instructions indicating which parts require spec ified tightening torque oil grease or a locking agent during assembly GENERAL INFORMATION 1 1 General Information Table of Contents Before Servicing 1 2 IGS 1 7 General SpecificationsS pp 1 9 Technical Information Evaporative Emission Control System CAL and SEA B1 Models 1 12 Unit Conversion Table eT p 1 14 1 2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera tion on a motorcycle read the precautions given below To facilitate actual operations notes illustra tions photographs cautions and detailed descriptions have been included in each chapter wherever necessary This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts Especially note the following Battery Ground Before completing any service on the motorcycle discon nect the battery cables from the battery to prevent the en gt E Sy gine from accidentally turning over Disconnect the ground AOA P cable first and then the positive When completed 38 70 with the service first connect the positive cable to the 2 4 L positive terminal of the battery then the negat
547. trical connections are to be dis connected first turn off the ignition switch OThe ABS parts should never be struck sharply as with a hammer or allowed to fall on a hard surface Such a shock to the parts can damage them OThe ABS parts cannot be disassembled Even if a fault is found do not try to disassemble and repair the ABS parts replace it OThe ABS has many brake lines pipes and leads And the ABS cannot detect problems with the conventional braking system brake disc wear unevenly worn brake pad and other mechanical faults To prevent trouble check the brake lines and pipes for correct routing and connection the wiring for correct routing and the brakes for proper braking power Be sure to check for fluid leak age and bleed the brake line thoroughly 12 34 BRAKES Anti Lock Brake System Equipped Models A WARNING Air in the brake lines diminish braking performance and can cause an accident resulting in injury or death If any of the brake line fittings including the ABS hydraulic unit joint nuts or the bleed valve is opened at any time the air must be bled completely from the brake line If the brake lever has a soft or spongy feeling mushy when it is applied there might be air in the brake lines or the brake may be defective Do not operate the vehicle and service the brake system immediately Do not ride the motorcycle with air in the brake line or the ABS could malfunction OThe y
548. ts evenly to seat the camshaft in place then tighten all bolts following the spec ified tightening sequence Torque Camshaft Cap Bolts 1 18 12 N m 1 2 kgf m 106 in Ib Upper Camshaft Chain Guide Bolts 19 20 12 N m 1 2 kgf m 106 in Ib GE113808W2 C e Install the camshaft chain tensioner see Camshaft Chain Tensioner Installation e Turn the crankshaft 2 turns clockwise to allow the ten sioner to expand and recheck the camshaft chain timing e Install the removed parts see appropriate chapters 5 22 ENGINE END Camshaft Camshaft Chain Camshaft Camshaft Cap Wear Inspection e Remove Upper Chain Guide see Camshaft Removal Camshaft Caps see Camshaft Removal e Cut strips of plastigage press gauge to journal width Place a strip on each journal parallel to the camshaft in stalled in the correct position e Tighten the camshaft cap bolts and upper camshaft chain guide bolts to the specified torque see Camshaft Instal lation NOTE not turn the camshaft when the plastigage is be tween the journal and camshaft cap e Remove the camshaft cap again measure each clear ance between the camshaft journal and the camshaft cap using plastigage A Camshaft Journal Camshaft Cap Clearance Standard 0 038 0 081 mm 0 0015 0 0032 in Service Limit 0 17 mm 0 0067 in any clearance exceeds the service limit measure the diameter of each camshaft journal
549. ttings A are in position on the idle speed control valve actuator as shown in the figure x If the idle speed control valve actuator is replaced be sure to do the following procedures OTurn the ignition switch to ON OTurn the ignition switch to OFF and wait for 2 or 3 sec onds Olnspect the idle speed see Idle Speed Inspection in the Periodic Maintenance chapter GT04117BS1 Idle Speed Control Valve Actuator Resistance Inspection e Turn the ignition switch to OFF e Remove Right Middle Fairing see Middle Fairing Removal in the Frame chapter Bolts A e Disconnect the idle speed control valve actuator connec tor B FUEL SYSTEM DFI 3 107 Idle Speed Control Valve Actuator Service Code 1C Connect a digital meter to the idle speed control valve actuator A e Measure the idle speed control valve actuator resistance Idle Speed Control Valve Actuator Resistance Connections G Y lead 1 lead 2 G BK lead 3 lt gt G R lead 4 Standard About 20 x lf the reading is out of the standard replace the idle speed control valve actuator x If the reading is within the standard check the input volt age see Idle Speed Control Valve Actuator Input Voltage Inspection Idle Speed Control Valve Actuator Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch to OFF e Disconnect the idle speed control valve actuator connec tor a
550. ubber gasket Block the hose joint opening E during this operation if the caliper half has the opening Bolt F and Nut Push down G A WARNING The piston in the brake caliper can crush hands and fingers Never place your hand or fingers in front of the piston 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 e Repeat the previous step to remove the pistons from the other side of the caliper body NOTE Olf compressed air is not available do as follows for both calipers coincidentally with the brake hose connected to the caliper OPrepare a container for brake fluid and perform the work above it ORemove the pad springs and pads see Front Brake Pad Removal in the Brakes chapter OPump the brake lever until the pistons come out of the cylinders and then disassemble the caliper Front Caliper Assembly e Clean the caliper parts except for the pads NOTICE For cleaning the parts use only disc brake fluid isopropyl alcohol or ethyl alcohol e Install the bleed valve and rubber cap Torque Bleed Valves 7 8 N m 0 80 kgf m 69 in Ib 22272422122274222722227222227 22272 72221 27 uel SS 9513152851 9513153851 2 66 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Replace the fluid seals A with new ones OApply silicone grease to the fluid seals and install them in
551. und Damping Force Adjustment Remove the rear fairing see Rear Fairing Removal in the Frame chapter Equipped Models e To adjust the rebound damping force turn the lower damping adjuster A OThe standard adjuster setting is the 2 turns out from the fully clockwise position Rebound Damping Force Adjustment Adjuster Position Damping Force Setting Load 2 3 4 Turns Out Compression Damping Force Adjustment e To adjust the compression damping force turn the upper damping adjuster A OThe standard adjuster setting is the 2 3 4 turns out from the fully clockwise position Compression Damping Force Adjustment Force Adjuster Position T T T T T l 0 Strong Hard Heavy Bad High Spring Preload Adjustment e Remove the rear shock absorber from the frame see Rear Shock Absorber Removal e Loosen the locknut and turn out the adjusting nut to free the spring Special Tool Hook Wrench T 3 2 R37 57001 1522 Counterclockwise Clockwise Softer Harder STD 2 1 ttt Seated position adjuster turned fully clockwise 8 05486851 C Counterclockwise Clockwise Softer Harder STD 6 5 4 3 2 1 mt Seated position adjuster turned fully clockwise 8 05487851 C 13 28 SUSPENSION Rear Shock Absorber e To adjust the spring preload turn in the adjusting nut A and tighten the locknut B Spr
552. up above the outer tube top e Install the fork spring A with the smaller end B facing upward e Install the collar A so that the cut side B faces down ward e Install the washer on the collar Front Fork SUSPENSION 13 17 e Install the clamps as shown in the figure Special Tool Fork Spring Compressor 57001 1540 NOTE OSet the clamps so that the cutouts B do not fit the hole C of the washer D pull up the outer tube E to hold it by the clamps and then tighten the two bolts F The outer tube is used as a guide Set the fork spring compressor A and front fork pro tector suitable jack e Lift up the suitable jack until the piston rod nut comes out Special Tool Fork Spring Compressor 57001 1771 e Hold up the fork piston rod puller e Insert the fork spring stopper A between the piston rod nut B and the holder C while holding up the fork piston rod puller D Special Tool Fork Spring Stopper 57001 1374 e Remove the fork piston rod puller e Install the rebound damping adjuster rod A 13 18 SUSPENSION Front Fork Check the distance between the bottom end A of the top plug and rebound damping adjuster B with a pair of vernier caliper 13 mm 0 51 in C e Replace the O ring A on the top plug B with a new one e Apply grease to the new O ring e Install the top plug on the piston rod and screw it e H
553. urface B Ball Bearing C 9 05066851 C Sprocket Coupling FINAL DRIVE 11 13 e Install Collar A Coupling 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 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 Pack the bearing with high temperature grease e Replace the circlip with a new one Special Tool Inside Circlip Pliers 57001 143 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 GK05087BS1 GKO5068BS1 C 11 14 FINAL DRIVE Sprocket Coupling Coupling Bearing Inspection Since the coupling bearing is made to extremely close tolerances the clearance can not normally be measured NOTE Olt is not necessary to remove the coupling bearing for inspection If the bearing is removed it will need to be replaced with a new one e Turn the bearing in the coupling back and forth A while checking for plays roughness or binding If the bearing play roughness or binding is found replace
554. urn the cap counterclockwise to the first stop Then push and turn it further in the same direction and remove the cap e Remove the left middle fairing see Middle Fairing Re moval in the Frame chapter e Place a container under the drain bolt A at the bottom of the water pump cover e Drain the coolant from the radiator and engine by remov ing the drain bolt 2 52 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Remove Hoses A Bolts B Reserve Tank C Remove the cap D and pour the coolant into a container e Install the reserve tank and reconnect the reserve tank hose and overflow hose correctly see Cable Wire and Hose Routing section in the Appendix chapter e Apply a non permanent locking agent to the threads of the reserve tank bolts and tighten them e Tighten the drain bolt with the gasket OReplace the drain bolt gasket with a new one Torque Coolant Drain Bolt 10 N m 1 0 kgf m 89 in Ib e Fill the radiator up to the radiator filler neck A with coolant and install the radiator cap NOTE O Pour in the coolant slowly so that it can expel the air from the engine and radiator e Fill the reserve tank up to the F level line with coolant and install the radiator cap and radiator cap cover see Coolant Level Inspection Soft or distilled water must be used with the an tifreeze see below for antifreeze in the cooling sys tem If hard water is used in the system
555. ust be kept under the specified voltage Charging Voltage Tester Range Reading Tester to Tester to 25VDC 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 the table the charging system is considered to be working normally x If the charging voltage is much higher than the values specified in the table the regulator rectifier is defective or the regulator rectifier leads are loose or open x f 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 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 16 42 ELECTRICAL SYSTEM Charging System e To check the alternator output voltage do the following procedures OTurn the ignition switch to OFF ORemove the right seat cover see Seat Cover Removal in the Frame chapter ODisconnect the alternator l
556. ust nut A onto the compression shaft as shown in the figure About 20 mm 0 79 in B e Screw the locknut C OSet the other side compression shaft same process e Screw in the nuts A until the piston rod nut B comes out OHold up the top plug C while screwing in the nut 0000407212 P 13 20 SUSPENSION Front Fork Insert the fork spring stopper A between the piston rod nut B and the clamp C while holding up the top plug D Special Tool Fork Spring Stopper 57001 1374 e Holding the piston rod nut with a wrench A remove the top plug B from the piston rod Remove the fork spring compressor from the front fork e Remove Washer A Collar B Rebound Damping Adjuster Rod C Fork Spring D Screw the rod nut A onto the piston rod B as shown in the figure 12 mm 0 47 in or more C Drain the fork oil into a suitable container OUsing the piston rod puller A pump the piston rod B up and down at least ten times to expel the oil from the fork Special Tool Fork Piston Rod Puller M12 1 25 57001 1289 GM04381BS1 C GM04738BS1 6M04021281 Front Fork SUSPENSION 13 21 Hold the fork tube upright press the inner tube A the piston rod all the way down e Pour in the type and amount of fork oil specified Recommended Oil KAYABA 01 KHL15 10 or equivalent Amount Per Side
557. ut Engine Mounting Bolts and Nuts Exhaust Pipe Manifold Holder Nuts Muffler Body Clamp Bolts Muffler Body Mounting Bolts Wheels Front Axle Clamp Bolts Front Axle Nut Rear Axle Nut Rear Axle Nut Cotter Pin Brakes Brake Lever Pivot Bolt Locknut Brake Pedal Bolt Caliper Mounting Bolts Front Master Cylinder Clamp Bolts Rear Master Cylinder Joint Cotter Pin Rear Master Cylinder Mounting Bolts Suspension Front Fork Clamp Bolts Rear Shock Absorber Nuts Swingarm Pivot Shaft Locknut Swingarm Pivot Shaft Nut Tie Rod Nuts Rocker Arm Nut Steering Handlebar Holder Bolts Steering Stem Head Nut Others Center Stand Bolts Equipped Models Footpeg Bracket Bolts Front Fender Mounting Bolts Rear Frame Bolts Sidestand Bolt Replacement Parts Air Cleaner Element Replacement NOTE Oln dusty areas the element should be replaced more frequently than the recommended interval A WARNING If dirt or dust is allowed to pass through into the throttle body assy the throttle may become stuck possibly causing accident Replace the air cleaner element according to the maintenance chart If dirt gets through into the engine excessive en gine wear and possibly engine damage will occur PERIODIC MAINTENANCE 2 49 Periodic Maintenance Procedures e Remove Fuel Tank Cover see Fuel Tank Removal in the Fuel System DFI chapter Bolts A Air Cleaner Element Cover B e Discard the air cleaner element A e Install a
558. ut side 68020228 Electrical Leads A two color lead is identified first by the primary color and then the stripe color Unless instructed otherwise electrical Y R leads must be connected to those of the same color e oar 68020238 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 6802062851 GENERAL INFORMATION 1 7 Model Identification ZX1400EC Left Side View 62038630 7 1400 Right Side View 62038631 1 8 GENERAL INFORMATION Model Identification ZX1400FC Left Side View 68028632 P 7 1400 Right Side View 68038633 P General Specifications GENERAL INFORMATION 1 9 Fuel Tank Capacity Items ZX1400EC ZX1400FC Dimensions Overall Length 2 170 mm 85 43 in Overall Width 770 mm 30 31 Overall Height 1 170 46 06 Wheelbase 1 480 mm 58 27 in Road Clearance 125 mm 4 92 in Seat Height 800 mm 31 50 in Curb Mass ZX1400EC 265 kg 584 3 Ib ZX1400FC 268 kg 591 0 Ib Front 134 kg 295 5 Ib Rear ZX1400EC 131 kg 288 9 Ib ZX1400FC 134 kg 295 5 Ib 22 L 5 8 US gal Performance Minimum Turning Radius 3 1 m 10 2 ft Engine Type Cooling System Bore and Stroke Displacement Compression Ratio Maximum Horsepower
559. uter rotor A and the dowel pin B into the lower crankcase half e Insert the pump cover A washer B pin C and inner rotor D to the oil pump drive gear shaft E 9009071851 C ENGINE LUBRICATION SYSTEM 7 15 Oil Pump e Install the oil pump drive gear shaft with inner rotor OTurn the oil pump drive gear shaft so that the projection in its shaft fits onto the slot of the water pump shaft OFit the hole of the oil pump cover onto the pin on the lower crankcase half e Tighten Torque Pump Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib e Install the removed parts see appropriate chapters 7 16 ENGINE LUBRICATION SYSTEM Oil Cooler Oil Cooler Removal e Remove Coolant Drain see Coolant Change in the Periodic Maintenance chapter Engine Oil Drain see Engine Oil Change in the Periodic Maintenance chapter Exhaust Pipe see Exhaust Pipe Removal in the Engine Top End chapter Oil Pipe Bolt A e Pull out the pipe fitting B e Loosen the clamp screws C Remove the water hoses D from the oil cooler E Remove the oil cooler mounting bolts F and oil cooler Oil Cooler Installation e Replace the O ring A with a new one e Install the oil cooler and tighten the bolts following the specified tightening sequence 1 4 Torque Oil Cooler Mounting Bolts B 12 N m 1 2 kgf m 106 in Ib e Apply soap and water solution to the inside of the water hoses before installation
560. utton ov e Ter Push Released Released R Lo Pulled In Lower W2L0693AW5 C ELECTRICAL SYSTEM 16 27 Wiring Diagram ABS Equipped Models BR Model Intake Air uk Pressure iet ub Sensor 2 Intake Crank throttle Main Sub Air 3 T Valve Throttle throttle Pressure oe Sensor uel Injectors Sensor 1 Idle Speed ctuator Sensor Sensor Oxygen 1 2 4 Air Souter OU em Control Switching Bear Position 52 Valve Valve Switch ais Actuator Joint Connector 1 5 ar Joint Connector E Y Y 8k Joint Connector J BKZ Y BKZ Y BK Y ex o aR Y WR R BL L6 8K BRN BK R BK G BL R BL BK e o D BK BL Joint Connector amp Rear Wheel Rotation Sensor Immobilizer Kawasaki Du Un ystem ay 6 Connector Light 127218 Tail Brake ie e Light LED License BKZ Y BK Y Plate 12 5 Rear Left Light 12V21W o BR Y BK Y BK Y Starter Relay Battery 12V12Ah akzo TE BKZ Y H 4 Starter Relay
561. utton 8 Upper and Lower Button Relay LEFT SWITCH HOUSING CONNECTIONS Horn Button Hazard Button Turn Signal Switch Passing Button Dimmer Switch Starter Lockout Switch Multifunction Button Clutch Lever color o v o GY Color R Y BK R Color R Y BK R Color BK R Color P_BK YIG BK Y R ommo o Released Released R Lo Pulled In Lower W2L0690AW5 C ELECTRICAL SYSTEM 16 19 Wiring Diagram PH and SEA B2 Models Intake Air ar Pressure m ub Sensor 2 Intake Wat throttle Main Sub Air sten Temperature Fuel Injectors Yalve Throttle throttle Pressure ences Idle Speed 7408607 Actuator Sensor Sensor Sensor 1 x Oxygen Y Control switihing 96 Bear Position KE Valve Valve Switch ais Actuator Connector 1 5 ar Joint Connector E Y Y 8k Joint Connector J BKZ Y BKZ Y BK Y ex o aR Y WR R BL wa L6 8K BRN BK R BK G BL R BL BK ao D BK BL Joint Connector amp Rear Wheel Rotation Sensor Immobilizer Kawasaki Diagnostic BEEN i i Rear Right aes 2 Connect
562. vel before each use and change the oil and filter according to the periodic maintenance chart Oil Level Inspection Check that the engine oil level is between the upper A and lower B levels in the oil level inspection window NOTE OSituate the motorcycle so that it is perpendicular to the ground Olf the motorcycle has just been used wait several min utes for all the oil to drain down Olf the oil has just been changed start the engine and run it for several minutes at idle speed This fills the oil filter with oil Stop the engine then wait several minutes until the oil settles Racing the engine before the oil reaches every part can cause engine seizure If the engine oil gets extremely low or if the oil pump or oil passages clog up or otherwise do not function properly the oil pressure warning light will light If this light stays on when the engine is running above idle speed stop the engine immediately and find the cause x lf the oil level is too high remove the excess oil using a syringe or some other suitable device xIf the oil level is too low add the correct amount of oil through the oil filler opening Use the same type and make of oil that is already in the engine NOTE Olf the engine oil type and make are unknown use 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
563. ver Assembly e Installation is the reverse of removal Fenders FRAME 15 21 Front Fender Removal Open the brake hose clamps A e Remove Bolt B with Washer Both Sides Bolt C Both Sides Front Fender Assy D e Remove the front fender cover screws A Separate the front fender covers B and front fender Front Fender Installation e Install the front fender covers to the front fender Olnsert the hooks A of the front fender cover into the slots B of the front fender Tighten Torque Front Fender Cover Screws 1 2 N m 0 12 kgf m 11 in Ib e Install the front fender assy to the front fork and tighten the bolts e Run the hoses and leads correctly see Cable Wire and Hose Routing section in the Appendix chapter Flap and Rear Fender Removal Remove Seat see Seat Removal Seat Covers see Seat Cover Removal Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Tool Kit Case A see ECU Removal in the Fuel System DFI chapter Relay Box B see Relay Box Removal in the Electrical System chapter ECU see ECU Removal in the Fuel System DFI chap ter Rear Wheel C see Rear Wheel Removal in the Wheels Tires chapter Fuse Boxes D Bolts E and Cover F Seat Lock License Plate Light Lead Connector G Disconnect Clamps H Bolts I Rear Fender Mounting Screws J 6008016851 15 22 Fenders e Remove Rear Flap Mount
564. ves ranging from 2nd to 4th of steering stem nut D and bend the 2 claws downward E e Install the steering stem head e Install the washer and tighten the steering stem head nut e Tighten Torque Steering Stem Head Nut 78 N m 8 0 kgf m 58 ft Ib Front Fork Clamp Bolts Upper 20 N m 2 0 kgf m 15 ft Ib e Check the steering again x If the steering is still too tight or too loose repeat the ad justment e Install the handlebars see Handlebar Installation in the Steering chapter Steering Stem Bearing Lubrication e Remove the steering stem see Stem Stem Bearing Re moval in the Steering chapter e Using a high flash point solvent wash the upper and lower ball bearings in the cages and wipe the upper and lower outer races which are press fitted into the frame head pipe clean off grease and dirt e Visually check the outer races and the ball bearings Replace the bearing assemblies if they show wear or damage e Pack the upper and lower ball bearings A in the cages with grease and apply a light coat of grease to the upper and lower outer races e Install the steering stem see Stem Stem Bearing Instal lation in the Steering chapter e Adjust the steering see Steering Play Adjustment 9515034851 gt 65158384 P PERIODIC MAINTENANCE 2 41 Periodic Maintenance Procedures Electrical System Lights and Switches Operation Inspection First Step e Turn
565. weight with the next heavier size If the wheel rotates and the weight goes down replace the weight with the next lighter size Repeat these steps until the wheel remains at rest after being rotated 1 4 turn e Rotate the wheel another 1 4 turn and then another 1 4 turn to see if the wheel is correctly balanced e Repeat the entire procedure as many times as necessary to achieve correct wheel balance e Permanently install the balance weight Balance Weight Removal e Insert standard tip screwdrivers A B between the rib C and weight D as shown in the figure e Pry the balance weight with two screwdrivers and remove the balance weight e Discard the used balance weight NOTICE Do not tap the screwdrivers The rim could be dam aged GJ04291BS1 GJ04292BS1 6J04073BS1 C 10 12 WHEELS TIRES Wheels Rims 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 WARNING Unbalanced wheels can create an unsafe riding condition If the balance weight has any play on the rib of the rim the blade and or clip have been stretched Replace the loose balance weight Do not reuse used balance weight Balance Weight 41075 0007 10 g 0 35 oz 41075 0008 20 g 0 71 oz 41075 0017 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
566. with a micrometer Camshaft Journal Diameter Standard M 23 962 mm 0 9425 0 9434 Service Limit 23 91 mm 0 941 in If the camshaft journal diameter is less than the service limit replace the camshaft with a new one and measure the clearance again x lf the clearance still remains out of the service limit re place the cylinder head unit Camshaft Runout Inspection e Remove the camshafts see Camshaft Removal e Set the camshaft in a camshaft alignment jig or on V blocks e Measure the runout with a dial gauge A at the specified place as shown in the figure the runout exceeds the service limit replace the camshaft Camshaft Runout Standard TIR 0 02 mm 0 00068 in or less Service Limit TIR 0 1 mm 0 004 in y GE11089BS1 C GE11381BS1 Camshaft Camshaft Chain ENGINE TOP END 5 23 Cam Wear Inspection Remove the camshafts see Camshaft Removal e Measure the height A of each cam with a micrometer x If the cams are worn down past the service limit replace the camshaft Cam Height Standard Exhaust 35 243 35 357 mm 1 3875 1 3920 in Intake 35 243 35 357 mm 1 3875 1 3920 in Service Limit Exhaust 35 14 mm 1 383 in Intake 35 14 mm 1 383 in Camshaft Chain Removal e Remove Camshafts see Camshaft Removal Crankshaft Sensor see Crankshaft Sensor Removal in the Electrical System chapter Timing Rotor see Timing Rotor Remov
567. x 4 Meter Unit 5 Gear Position Switch FUEL SYSTEM 3 77 Front Wheel Rotation Sensor Signal Service Code 27 Front Wheel Rotation Sensor Signal Inspection OThe front wheel rotation sensor sends the signal to the ECU through the ABS hydraulic unit ABS equipped mod els For other than ABS equipped models the signal is sent directly to the ECU OThe ECU uses the front wheel rotation sensor signal for KTRC control OThe service code 27 is detected with the ECU e When the service code 27 and following service codes for ABS are displayed at the same time inspect the front wheel rotation sensor Service Code 42 see Front Wheel Rotation Sensor Sig nal Abnormal in the Brakes chapter Service Code 43 see Front Wheel Rotation Sensor Wiring Inspection in the Brakes chapter e When only service code 27 is displayed do the following inspection procedures e Disconnect ECU Connectors see ECU Removal Front Wheel Rotation Sensor Lead Connector see Front Wheel Rotation Sensor Removal in the Brakes chapter e For ABS equipped models check the wiring for continuity between harness connectors Special Tool Hand Tester 57001 1394 Wiring Continuity Inspection ECU Connector ABS Hydraulic Unit Connector B G Y lead ECU terminal 3 ABS Hydraulic Unit terminal 23 C Wiring Continuity Inspection ABS Hydraulic Unit Connector Front Wheel Rotation Sensor Connector B W BK lead ABS
568. x 1 Joint Connector F Vehicle down Sensor Ignition Switch Engine Stop Switch Spark Plugs Stick Coils Sidestand Switch 16 56 ELECTRICAL SYSTEM Electric Starter System Starter Motor Removal Do not tap the starter motor shaft or body Tapping the shaft or body could damage the motor e Remove Engine Sprocket Cover see Engine Sprocket Removal in the Final Drive chapter Left Middle Fairing see Middle Fairing Removal in the Frame chapter Bolts A Reserve Tank Bolts see Coolant Change in the Periodic Maintenance chapter e Take off the heat insulation rubber plate A e Slide out the rubber cap B e Remove the starter motor cable terminal nut C Remove the starter motor mounting bolts A e Pull out the starter motor B from the left side Starter Motor Installation Do not tap the starter motor shaft or body Tapping the shaft or body could damage the motor e Clean the starter motor legs A and crankcase B where the starter motor is grounded e Replace the O ring C with a new one e Apply soap and water solution to the new O ring Tighten Torque Starter Motor Mounting Bolts 9 8 N m 1 0 kgf m 87 in Ib Electric Starter System ELECTRICAL SYSTEM 16 57 e Install the starter motor cable A side by side with starter motor B Tighten Torque Starter Motor Cable Terminal Nut 5 9 N m 0 60 kgf m 52 in Ib e Slide back the rubber cap C to
569. x If the reading is within the standard remove the ECU and check the wiring for continuity between harness connec tors Special Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Crankshaft Sensor Connector B Y BK lead ECU terminal 8 C Y lead ECU terminal 21 D xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation Crankshaft Sensor Circuit D B C vU 1 z aaa MEE D GT04089BS1 C D Y BK Y BK Y BK Y Y GTO41058BW2 C 1 ECU 2 Crankshaft Sensor FUEL SYSTEM 3 73 Rear Wheel Rotation Sensor Signal Service Code 24 Rear Wheel Rotation Sensor Signal Inspection OThe rear wheel rotation sensor sends the signal to the ECU through the ABS hydraulic unit ABS equipped mod els For other than ABS equipped models the signal is sent directly to the ECU OThe ECU uses the rear wheel rotation sensor signal for motorcycle speed and KTRC control OThe service code 24 is detected with the ECU e When the service code 24 and following service codes for ABS are displayed at the same time inspect the rear wheel rotation sensor Service Code 44 see Rear Wheel Rotation Sensor Sig nal Abnorma
570. y 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 6 V Charge insufficient Recharge lower than 12 0 V Unserviceable Replace 16 38 ELECTRICAL SYSTEM Charging System Alternator Cover Removal e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Left Middle Fairing see Middle Fairing Removal in the Frame chapter Alternator Lead Connector A Bolts B and Bracket C e Place a suitable container under the alternator cover A e Remove Alternator Cover Bolts B Alternator Cover e Pull the alternator lead out of between the engine and frame Alternator Cover Installation e Using a high flash point solvent clean off any oil or dirt that may be on the liquid gasket coating area Dry them with a clean cloth e Apply liquid gasket to the alternator lead grommet and crankcase halves mating surface A on the front and rear sides of the cover mount Sealant Liquid Gasket TB1211F 92104 0004 e Check that dowel pins are in place on the crankcase e Install a new gasket and the alternator cover e Tighten Torque Alternator Cover Bolts 9 8 1 0 kgf m 87 in Ib e Run the alternator lead
571. y in the reservoir are unidentified Recommended Disc Brake Fluid Grade DOT4 e Follow the procedure below to install the front rear brake fluid reservoir cap correctly OFirst tighten the brake fluid reservoir cap B clockwise C by hand until slight resistance is felt indicating that the cap is seated on the reservoir body then tighten the cap an additional 1 6 turn D while holding the brake fluid reservoir body A Brake Pad Wear Inspection Remove the brake pads see Front Rear Brake Pad Re moval in the Brakes chapter Check the lining thickness A of the pads in each caliper x If the lining thickness of either pad is less than the service limit B replace both pads in the caliper as a set Pad Lining Thickness Standard Front 4 0 mm 0 16 in Rear 5 0 mm 0 20 in Service Limit 1 mm 0 04 in Brake Light Switch Operation Inspection e Turn the ignition switch to ON e The brake light A should go on when the brake lever is applied or after the brake pedal is depressed about 10 mm 0 39 in p d 65130248 5 9513148851 PERIODIC MAINTENANCE 2 37 Periodic Maintenance Procedures x If it does not adjust the brake light switch e While holding the switch body turn the adjusting nut to adjust the switch Switch Body A Adjusting Nut B Light sooner as the body rises C Light later as the body lowers D To avoid damaging the electrical conne
572. y is fully charged e Turn the ignition switch to OFF e Remove the right middle fairing see Middle Fairing Re moval in the Frame chapter e Disconnect the oxygen sensor lead connector and con nect the measuring adapter A between these connec tors as shown in the figure Main Harness B Oxygen Sensor C Special Tool Measuring Adapter 57001 1700 Connect a digital meter D to the measuring adapter lead Oxygen Sensor Heater Power Source Voltage Connections to Adapter Digital Meter main harness W R lead Digital Meter gt Frame Ground terminal e Measure the power source voltage with the engine stopped and with the connector joined e Turn the ignition switch to ON Power Source Voltage Standard Battery Voltage e Turn the ignition switch to OFF x If the reading is in specification but the problem still ex ists replace the ECU see ECU Removal Installation x If the reading is out of the standard check the following ECU Relay Fuse 15 A see Fuse Inspection in the Elec trical System chapter Power Source Wiring see Oxygen Sensor Circuit xIf the fuse and wiring are good remove the ECU and check the wiring for continuity between harness connec tors Special Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A lt gt Oxygen Sensor Connectors B R lead ECU terminal 76 C xIf the wiring is good check the ECU
573. y the engine vacuum pressure and is then burned by the engine Conventional Evaporative Emission Control System 6806704812 1 Fuel Tank 7 Purge Hose Green 2 Vacuum Hose White 8 Throttle Body or Carburetor 3 SeparatorReturn Pump 9 Canister 4 Breather Hose Blue 10 Flow of Vapor Gas 5 Breather Hose Blue 11 Flow of Liquid Gasoline 6 Return Hose Red Function of Conventional Evaporative Emission Control System The fuel vapors generated in the fuel tank flows to the separator Return Pump and is separated into liquid and gas The liquid gasoline is returned to the fuel tank by the return pump driven by the engine vacuum pressure On the other side the vapor sent to the canister is kept temporarily in the canister by the activated carbon before it is routed to the throttle body or carburetor by the engine vacuum pressure and is burned by the engine GENERAL INFORMATION 1 13 Technical Information Evaporative Emission Control System CAL and SEA B1 Models New Evaporative Emission Control System 6806705812 C 1 Breather Hose Blue 6 Purge Valve 2 Purge Hose Green 7 Purge Hose Green 3 Breather Hose Blue 8 Throttle Body 4 Fuel Tank 9 Flow of Vapor Gas 5 Canister Function of New Evaporative Emission Control System This model is equipped with New Evaporative Emission Control System in which the separator and return hose connected to the fuel tank are eliminated The vapors gene
574. y two times to en sure even tightening torque Torque Front Axle Clamp Bolts 20 N m 2 0 kgf m 15 ft Ib e Install the removed parts see appropriate chapters e Check the front brake effectiveness see Brake Operation Inspection in the Periodic Maintenance chapter A WARNING After servicing it takes several applications of the brake lever before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the motorcycle until a firm brake lever is obtained by pumping the lever until the pads are against the disc Rear Wheel Removal Raise the rear wheel off the ground with the stand A GJ04290BS1 10 8 WHEELS TIRES Wheels Rims Remove Rear Caliper Mounting Bolts A Rear Caliper B e Remove the rear wheel rotation sensor C from the caliper bracket see Rear Wheel Rotation Sensor Re moval in the Brakes chapter e Remove Cotter Pin A Axle Nut B Washer C Axle D from Left Side Remove the drive chain A from the rear sprocket toward the left Move the rear wheel back and remove it Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground Rear Wheel Installation e Apply high temperature grease to the grease seal lips e Fit the col
575. y without rattles If not the steering stem bearings may be damaged Special Tool Steering Stem Nut Wrench 57001 1100 Torque Steering Stem Nut 25 2 5 18 ft lb 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 temporary tighten the stem head nut e Install the front forks see Front Fork Installation in the Suspension chapter GNO5060481 C 9515034851 Steering Stem STEERING 14 9 NOTE OTighten the upper front fork clamp bolts first next the stem head nut last the lower front fork clamp bolts Tighten the two lower front fork clamp bolts alternately two times to ensure even tightening torque Torque Front Fork Clamp Bolts Upper 20 N m 2 0 kgf m 15 ft lb Steering Stem Head Nut 78 N m 8 0 kgf m 58 ft Ib Front Fork Clamp Bolts Lower 30 N m 3 1 kgf m 22 ft Ib A WARNING If the handlebar does not turn to the steering stop it may cause an accident resulting in injury or death Be sure the cables harnesses and hoses are routed properly and do not interfere with handlebar move ment see Cable Wire and
576. ystem chapter Meter Unit for Turn Signal Indicator Light LED see Me ter 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 9517208851 PERIODIC MAINTENANCE 2 43 Periodic Maintenance Procedures Fourth Step e Set the dimmer switch A to low beam position Start the engine e The low beam headlights B should go on xIf the low beam headlight does not go on inspect or re place the following item Headlight Low Beam Bulb see Headlight Bulb Replace ment in the Electrical System chapter Headlight Relay Fuse 15 A see Fuse Inspection in the Electrical System chapter Headlight Circuit Relay in Relay Box see Relay Circuit Inspection in the Electrical System chapter Headlight Relay Low see Headlight Relay Inspection in the Electrical System chapter Harness see Wiring

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