ZXR400 Motorcycle Service Manual Supplement
Contents
1. Remove the left side cover Remove the starter relay Connect the hand tester and 12 V battery to the starter relay as shown If the relay does not work as specified the relay is defective Replace the relay Testing Relay Hand Tester Range x 1 range Criteria When battery is connected 0 When battery is disconnected oo Y R 2 1 Tester 2 12 V Battery 15 24 ELECTRICAL SYSTEM Electric Starter and Fuel Pump Circuit E E 1 Ignition Switch 6 Ignition Coil for 1 4 Cylinder 11 Starter Relay 2 Engine Stop Switch 7 IC Igniter 12 Battery 3 Starter Button 8 Fuel Pump Relay 13 Neutral Switch 4 Junction Box 9 Fuel Pump 14 Starter Motor 5 Starter Circuit Relay 10 Starter Lockout Switch 15 30 A Main Fuse Lighting System The headlight beam is adjustable both horizontally and vertically Headlight aiming must be correctly adjusted both for your safety as well as that of oncoming drivers in most areas it is illegal to ride with an improperly adjusted headlight Headlight Beam Horizontal Adjustment e Turn the adjusting screw the headlight rim in or out until the beam points straight ahead Turning the adjusting screw clockwise makes the headlight beam point to the left A Adjusting Screw Headlight Beam Vertical Adjustment The headlight beam is adjustable vertically If adjusted too low neither low nor high beam will illuminate the roa2. 0 45 0 75 mm 24 mm Fuel Pump Fuel pump pressure 11 16 kPa 0 11 0 16 kg cm 1 6 2 3 psi Switches and Sensors Rear brake light switch Fan switch OFF ON ON OFF Water temperature sensor resistance ON after about 10 mm pedal travel 84 90 C 183 194 F 71 77 C 160 170 F 80 C 175 F 47 57 Q 100 C 212 F 25 300 Special Tools Hand Tester 57001 1394 ELECTRICAL SYSTEM 15 7 Flywheel Holder 57001 1313 Rotor Puller M16 M18 M20 M22 x 1 5 57001 1216 Spark Plug Wrench Hex 16 57001 1262 Rotor Puller M33 x 1 5 57001 1277 m Socket Wrench Hex 8 57001 1268 ins Jack 57001 1238 Sealant Kawasaki Bond Silicone Sealant 56019 120 S 15 8 ELECTRICAL SYSTEM Parts Location 1 Headlight Unit 2 Meter Unit 3 Starter Motor 4 Tail Brake Light 5 License Light 6 Fan Switch 7 Alternator 8 Oil Pressure Switch 9 Neutral Switch 10 Side Stand Switch 11 Cooling Fan 12 Fuel Pump 13 Water Temperature Sensor 14 Turn Signal Light 15 Rear Brake Light Switch 16 Pickup Coil 17 Indicator Light 18 Ignition Switch 19 Front Brake Light Switch 20 Right Grip Switch 21 Starter Lockout Switch 22 Left Grip Switch 23 Ignition Coil 2 3 24 Ignition Coil 1 4 25 Spark Plugs 26 Battery 27 Junction Box 28 Fuel Pump Relay 29 IC Ignit
3. 15 34 ELECTRICAL SYSTEM Water Temperature Sensor Inspection Suspend the sensor in a container of coolant so that the temperature sensing projection and threaded portion are submerged Using an ohmmeter measure the internal resistance of the sensor across the terminal and the body at the temperatures shown in the table Water Temperature Sensor 80 C 175 F 47 570 100 212F 25 300 NOTE OThe sensor and thermometer must not touch the container sides or bottom 1 Water Temperature Sensor 2 Thermometer If the ohmmeter does not show the specified values replace the sensor Fan Switch Inspection Using an ohmmeter check to see that only the connections shown in the table have continuity about zero ohms If the switch has an open or short repair or replace it with new one Fan Switch Resistance ORising temperature From OFF to ON at 84 90 C 183 194 F Falling temperature From ON to OFF at 71 77 C 160 170 F ON Less than 050 OFF More than 1 M Q 1 Fan Switch 2 Thermometer Suspend the switch in a container of coolant so that the temperature sensing projection and threaded portion are submerged Suspend an accurate thermometer in the coolant NOTE OThe switch and thermometer must not touch the container sides or bottom Place the container over a source of heat and gradually raise the temperature of the coolant while stirring the c
4. and check the operation of the gauge Gauge Operation Test Ignition Switch Position ON Wire Location Water temperature female connector disconnected Gauge should read C when sensor wire sensor Results is opened Gauge should read H when sensor wire is grounded to engine CAUTION Do not ground the wiring longer than necessary After the pointer swings to the H position stop the test Otherwise the gauge could be damaged If these readings are not correct the trouble is with the gauge and or wiring A Sensor Connector B Water Temperature Gauge Check the water temperature gauge circuit wiring see Wiring Inspection f all wiring and components other than the water temperature gauge unit check out good the gauge is defective ELECTRICAL SYSTEM 15 33 ES j ET P f Tachometer Circuit 5 e BK BK Y BK Y 4 BR BR 5 2 0x do mes nomen z 1 Ignition Switch 6 Spark Plug 2 6 Pin Connector 7 Ignition Coil 41 44 3 Tachometer 8 4 Pin Connector 4 IC Igniter 9 Engine Stop Switch 5 30A Main Fuse in Starter Relay 10 Battery Water Temperature Gauge Circuit PN BR Yw BK Y _ I 8K Y w BK Y DC BK Y 1 Ignition Switch 5 Water Temperature Sensor 2 6 Pin Connector 6 30A Main Fuse in Starter Relay 3 Water Temperature Gauge 7 Battery 4 4 Pin Connector
5. mv m mm Cow om Amt s x 3 T v odo ee ea 85 a 5 g 7 9805 1 1258A 1259 1261 1285A 1292A 1293A 1294A 15 10 ELECTRICAL SYSTEM Right Handlebar switch 1 Meadiight Switch 2 Front Brate Light switch Switch Engine Stop 4 Starter Button Spark Plugs Wiring Diagram ZX400 L5 ion Box Cool Ing Fan Turn Sign j water Temperature Meter Liont savi Tv Tachometer Tachometer Light 12V3Wx2 UK VIM D O11 Pressure warning Lioht 123v dometor Lisht Neutral indicator Liont 12036 gt Hien Beam indicator Light 12V3v Turn Siem indicator savav Meee tent 12v60 35w Rear Riont Turn Signal Lignt 12V21V Tali erake Light 12 5 210 2 mL Licence Light 12v5 r Left Turn Signal nt 12V21v n Yo n a City Light Pickup Coll 000 ral Pressure Switch Alternator Starter Switch Motor Front wight Turn sional D d Light 12 v 2 Git aif Than Tisi sen wodor sete acter sviten Front Left Turn Signal Light 12 V 21 IGNITION SWITCH CONNECTIONS RIGHT HANDLEBAR SWI
6. or the engine is running 0 not use a meter illumination bulb rated for other than the voltage or wattage specified in the wiring diagram as the meter or gauge panel could be warped by excessive heat radiated from the bulb OTake care not to short the leads that are directly connected 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 too must be repaired or replaced or the new replacement will soon fail again O Make sure all connectors in the circuit are clean and tight and examine wires for signs of burning fraying etc Poor wires and bad connections will affect electrical system operation O Measure coil and winding resistance when the part is cold at room temperature OColor Codes BK Black BL Blue BR Brown CH Chocolate DG Dark green G Green GY Gray LB Light blue LG Light green O Orange P Pink PU Purple R Red W White Y Yellow O Electrical Connectors Female Connectors Male Connectors Exploded View n BO 6 r T ELECTRICAL SYSTEM 15 3 1 Stator Coil 2 Fuel Pump Relay 3 Fuel Pump 4 Starter Relay 5 Pickup Coil 6 IC Igniter 7 Regulator 2 5 N m 0 25 kg m 22 in Ib 5 9 N m 0 6 kg m 52 in Ib 8 3 N m
7. 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 O Connect an ohmmeter between the ends of the leads OSet the meter to the x 1 Q range and read the meter If the meter does not read 0 the lead is defective Replace the lead or the wiring loom if necessary 1 Interlock Diodes J Taillight Fuse 10A
8. Plug Removal e Remove the following Air Cleaner Housing Spark Plug Caps Remove the spark plugs with the box wrench in the tool kit P N 92110 1146 or the spark plug wrench special tool 57001 1262 A Spark Plug Wrench 92110 1146 15 20 ELECTRICAL SYSTEM Spark Plug Installation Note Tighten the spark plugs to the specified torque see Exploded View Run the spark plug leads correctly see Cable Routing section in the General Information chapter Spark Plug Cleaning and Inspection Remove the spark plug and visually inspect Clean the spark plug preferably in a sandblasting device and then clean off any abrasive particles The plug may also be cleaned using a high flash point solvent and a wire brush or other suitable tool x If the spark plug electrodes are corrodes are corroded or damaged or if the insulator is cracked replace the plug Use the standard spark plug or its equivalent Spark Plug Gap Inspection Measure the gap with a wire type thickness gauge If the gap is incorrect carefully bend the side electrode with a suitable tool to obtain the correct gap Spark Plug Gap 0 7 08mm n 2 1 Insulator 3 Plug Gap 2 Center Electrode 4 Side Electrode IC Igniter Inspection Remove the seat Remove the igniter connector Zero an ohmmeter and connect it to terminals of the IC igniter to check the internal resistance of the igniter CAUTION Use only Hand
9. 0 85 kg m 74 in Ib 9 8 N m 1 0 kg m 7 0 ft lb 13 N m 1 3 kg m 9 5 ft Ib 25 N m 2 5 kg m 18 ft Ib 34 N m 3 5 kg m 25 ft Ib 78 N m 8 0 kg m 58 ft Ib Apply a non permanent locking agent to the threads Apply molybdenum disulfide grease Hand Tight 15 4 ELECTRICAL SYSTEM 8 Cooling Fan Switch T9 18 N m 1 8 kg m 13 ft Ib AR Austrian Model FG German Model ELECTRICAL SYSTEM 15 5 9 Speedometer Cable 10 Neutral Switch 11 Oil Pressure Switch 12 Headlight Relay 13 Turn Signal Relay 14 Front Brake Light Switch T10 15 N m 1 5 kg m 11 ft Ib 15 Rear Brake Light Switch T11 7 8 N m 0 8 kg m 69 in Ib 16 Side Stand Switch T12 9 8 N m 1 0 kg m 7 0 ft lb 17 Junction Box G Apply grease 18 Water Temperature Sensor IT Italian Model 15 6 ELECTRICAL SYSTEM Specifications Standard Service Limit Specific gravity 12V8Ah 1 32 20 C 68 F Alternator Charging voltage Output voltage Stator coil resistance Ignition System Pickup coil resistance Ignition coil 3 needle arcing distance Primary winding resistance Secondary winding resistance Spark plug gap UNE 14 5 V Night 4 000 r min rpm Not less than 43 V 4 000 r min rpm 02 090 355 5350 7 mm or more 234350 12 18kQ 0 7 0 8 mm Starter Motor Carbon brush length Commutator groove depth Commutator diameter 7
10. ELECTRICAL SYSTEM 15 1 Electrical System Table of Contents Precaution Exploded View Specifications 6 Special Tools 5 7 Sealant 5 7 Parts Locatioi 5 8 Wiring Diagram ZX400 L1 L4 5 9 Wiring Diagram ZX400 L5 15 10 Battery 15 11 Charging Condition Inspection 15 11 Refreshing Charg 15 11 Charging System 15 12 Alternator Cover Removal Alternator Cover Installation Alternator Rotor Removal Alternator Rotor Installation Notes Stator Coil Removal Stator Installation Notes Alternator Inspection Rectifier Inspection Regulator Inspection Regulator Rectifier Output Voltage Inspection Ignition System Pickup Coil Removal Pickup Coil Installation Pickup Coil Inspection Ignition Coil Removal Ignition Coil Installation Ignition Coil Inspection Spark Plug Removal Spark Plug Installation Note Spark Plug Cleaning and Inspection Spark Plug Gap Inspectioi IC Igniter Inspectiot Electric Starter System Starter Motor Removal Starter Motor Installation Starter Motor Disassembly Starter Motor Assembly Note Brush Inspection Commutator Cleaning an Armature Inspection Brush Lead Inspection Brush Plate and Terminal Bolt Inspection Starter Relay Inspection Lighting System Headlight Beam Horizontal Adjustmen Headlight Beam Vertical Adjustment Headlight Bulb Replacement Notes Headlight Unit Removal Installation N
11. Regulator Rectifier Output Voltage Connections Meter to Meter to Black Yellow Connector 5 Battery Stat the engine and note the voltage readings at various engine speeds with the headlight turned on and then turned off The readings should show nearly battery voltage when the engine speed is low and as the engine speed rises the readings should also rise But they must be kept under the specified voltage e Turn off the ignition switch to stop the engine and disconnect the hand tester XIf the regulator rectifier output voltage is kept between the values given in table the charging system is considered to be working normally If the output 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 If the battery voltage does not rise as the engine speed increases then the regulator rectifier is defective or the alternator output is insufficient for the loads Check the alternator and regulator rectifier to determine which part is defective ELECTRICAL SYSTEM 15 17 Ignition System The ignition system produces extremely high voltage Do not touch the spark plugs ignition coils or spark plug leads while the engine is running or you could receive a severe electrical shock CAUTION Do not disconnect the battery leads or any other electrical connections when the ig
12. TGH CONNECTIONS tas Tui Tui ERES toe sep an com x ww oc com com vm Com Mm io ie OFF coc com E o Sates PARK ON G _ 98051 1515 1517 1518 1519 Battery Charging Condition Inspection Battery charging condition can be checked by measuring battery terminal voltage Remove Seat IC Igniter Junction Box Disconnect the battery terminal leads Measure the battery terminal voltage NOTE Measure with a digital voltmeter which can be read one decimal place voltage If the reading is below the specified refreshing charge is required Battery Terminal Voltage Standard 12 6 V or more 1 Digital Voltmeter Refreshing Charge Remove the battery Refresh charge by following method according to the battery terminal voltage ELECTRICAL SYSTEM 15 11 1 Battery 2 Sealing Cap OTerminal Voltage 11 5 12 6 V or less Standard Charge 0 9A x 5 10h see following chart Quick Charge 40Ax10h If possible do not quick charge If the quick charge is done due to unavoidable circumstances do standard charge later on OTerminal Voltage 11 5 V or less Charging Method 0 9A x 15 20h NOTE ORaise the voltage initially 25 V as maximum and charge for about 5 minutes as a yardstick If ammeter s
13. Tester 57001 983 for this test A tester other than the Kawasaki Hand Tester may show different readings If a megger or a meter with a large capacity battery is used the IC igniter will be damaged Replace the IC igniter if the reading is not the specified value IC Igniter Internal Resistance Range 8 Be 8 Be 39 Be 28 8 8 x 58 3 Be NOTE ONo measurement is needed on H terminal Electric Starter System Starter Motor Removal Remove the fuel tank Remove the terminal nut of starter motor wiring and take out the mounting bolts OUsing the socket wrench special tool 57001 1268 makes work easy Pull the starter motor upwards with twisting motion A Starter Motor B Mounting Bolts Starter Motor Installation CAUTION Do not tap the starter motor shaft or body Tapping the shaft or body could damage the motor When installing the starter motor clean the starter motor legs and crankcase where the starter motor is grounded Apply a small amount of engine oil to the O ring Tighten the following fasteners to the specified torque see Exploded View Starter Motor Mounting Bolts Starter Motor Disassembly Remove both end covers and pull the armature out of yoke ELECTRICAL SYSTEM 15 21 A Bolts B End Covers careful not to lose the brush springs Remo
14. be low in one direction and more than ten times as much in the other direction If any diode shows low or high in both directions the diode is defective and the junction box must be replaced NOTE OThe actual meter reading varies with the meter used and the individual diodes but generally speaking the lower reading should be from zero to one half the scale ELECTRICAL SYSTEM 15 37 Junction Box Internal Circuit U K Model ZX400 L1 L4 _ DBE D 090900 o o g bo 15 A High Beam Headlight Fuse Diodes B 10A Fan Fuse F 10A Taillight Fuse JEL C 10A Low Beam Headlight Fuse G 10A Headlight Fuse D D Hom Fuse 10A 49 O 6 d 15 38 ELECTRICAL SYSTEM Junction Box Internal Circuit ZX400 L5 0000 9 OAO A Accessory Fuse 10A E Ignition Fuse 10A B Fan Fuse 10A F Headlight Fuse 10A C Turn Signal Relay Fuse 10A G Starter Diode D Horn Fuse 10A H Starter Circuit Relay Electrical Wiring Wiring Inspection Visually inspect the wiring for signs of burning fraying etc If any wiring is poor replace the damaged wiring Pull each connector apart and inspect it for corrosion dirt and damage If the connector is corroded or dirty clean it carefully
15. d far enough ahead If adjusted too high the high beam will fail to illuminate the road close ahead and the low beam will blind oncoming drivers Loosen the adjusting bolt and adjust the beam until the beam points straight ahead Tighten the bolt after adjusting the beam NOTE OOn high beam the brightest point should be slightly below horizontal with the motorcycle on its wheels and the rider seated Adjust the headlights to the proper angle according to local regulations ELECTRICAL SYSTEM 15 25 A Adjusting Bolt Headlight Bulb Replacement Notes CAUTION When handling the quartz halogen bulbs 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 install the dust cover so that the TOP mark point up and the cover fits onto the bulb firmly as shown A Top Mark B Up 15 26 ELECTRICAL SYSTEM Good Bad 1 2 1 Dust Cover 2 Headlight Bulb A Pin Closest to Base lnsert the socket by aligning the projection on the triangular mark with the notch and turn the socket clockwise Check the headlight aim after installation Headlight Unit Removal Installation Note Install the headlight unit so that the TOP mark on the lens points up A Triangular Mark C Notch B Projection Turn Signal Light Bulb Replacement Note Be ca
16. d periods Be sure to heed the fluid manufacturer s warnings Alternator Rotor Cleaning Area 1 The tapered portion of the crankshaft 2 The alternator rotor bolt and the threads in the crankshaft 3 The tapered portion of the alternator rotor 4 Chamfer Install the washer so that the chamfer side faces out Tighten the alternator rotor bolt to the specified torque see Exploded View while holding the alternator rotor 15 14 ELECTRICAL SYSTEM steady with the flywheel holder special tool 57001 1313 rdi A Silicone Sealant Applied Areas Install a new gasket and the alternator cover Tighten the cover bolts to the specified torque see Exploded View Fill the engine with engine oil Stator Coil Removal Remove the alternator cover see this chapter Remove the holding plate Remove the stator coil lead grommet out of the notch of cover Unscrew the mounting bolt and take off the stator A Holding Plate B Grommets C Mounting Bolts D Stator Stator Installation Notes Fit the stator coil lead grommet into the notch of cover securely Route the stator coil lead in accordance with the Wire Routing in the General Information chapter 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 lo
17. e dirty terminals and straighten slightly bent terminals Check conductivity of the numbered terminals with the hand tester special tool If the tester dose not read as specified replace the junction box Fuse Circuit Inspection ZX400 L1 L4 Meter Reading Q 0 U K Model 15 36 ELECTRICAL SYSTEM Fuse Circuit Inspection ZX400 L5 o 88 32 5 1 8 18 18 8 Starter Circuit Remove the junction box see Fuse Removal Check conductivity of the following numbered terminal by connecting the hand tester special tool and one 12 V battery to the junction box as shown If the relay does not work as specified replace the junction box Relay Circuit Inspection ZX400 L1 L4 with the battery disconnected Mae Ring with the battery connected Relay Circuit Inspection ZX400 L5 with the battery disconnected Apply positive lead Apply negative lead with the battery connected Apply positive lead Apply negative lead Diode Circuit Inspection Remove the junction box from the motorcycle Pull off the connectors from the junction box Check conductivity of the following pair of terminals Terminals for Diode Circuit Inspection 14 12 14 15 14 16 ZX400 L1 L4 14 12 14 15 14 16 11 12 ZX400 L5 The resistance should
18. e is a high resistance or no reading 20 between any two segments winding is open and the starter motor must be replaced Using the highest ohmmeter range measure the resist ance between the segments and the shaft If there is any reading at all the armature has a short and the starter motor must be replaced 1 Segment 2 Shaft NOTE OEven if the foregoing checks show the armature to be good it may be defective in some manner not readily detectable with an ohmmeter If all other starter motor and starter motor circuit components check good but the starter motor still does not turn over or only turns over weakly replace the starter motor with a new one Brush Lead Inspection Using the x 1 ohmmeter range measure the resist ance as shown Brush and Terminal 7 Brush and End Cover A 7 Brush B Brush C Terminal f there is not close to zero ohms the brush lead has an open Replace the terminal bolt assembly and or the brush holder assembly ELECTRICAL SYSTEM 15 23 Brush Plate and Terminal Bolt Inspection Using the x 1 Q ohmmeter range measure the resist ance as shown between terminal bolt and brush plate between terminal bolt and brush between terminal bolt and end cover If there is any reading the brush holder assembly and or terminal bolt assembly have a short Replace the brush holder assembly and the terminal bolt assembly Starter Relay Inspection
19. er 30 Regulator Rectifier 31 Starter Relay 32 Turn Signal Relay Wiring Diagram ZX400 L1 L4 Water Temperature Gauge Meter Light seva Tv Tachometer Tachometer Light t2vavaz 12 1 wt lont 12V60 35w City Light Li and other than UK 124v L2 L5 and UK 12V5w Front Right Turn Signal Light 12 V 21 V ront Lere Jurn sionat Light 12 V 21 RES rs 011 Pressure warning Liont 12vav fic Fath Speedometer Light 12V1 7vx2 e Neutral indicator Light tavav Migh Beam indicator Light 12V3v mr n Turn Signal indicator Lignt 12vav 02 05 and UK Cooling Fan Sviteh Vater Temoerature Sensor pon ger Riont sandieber sviten SHU prost canine une f Jenition Coll mE e esi ELECTRICAL SYSTEM 15 9 Junction Box IERI E D Rear Right Turn Signal Lignt 12V21v Taii Brate Light 12v8 21wx2 a t Licence Liont Rear Left Turn Signal e Liont 127219 starter E GTL pla n a otnor Then u r s button E Giner than Traian edel Sh pos norn 1292 54 HANDLIBAR CONNECTIONS aie SWITCH CONNECTIONS 77 08 m er zm Cmm 6 o 57 cos tow
20. es Removal Remove the following Upper Fairing Headlight Unit Speedometer Cable Upper End Wiring Connectors Remove the meter unit by taking off the mounting nuts A Meter Mounting Nuts CAUTION Place the meter or gauge so that the face is up If a meter or gauge is left upside down or sideways for any length of time it will malfunction Bulb Replacement To remove the wedge base type bulb pull the bulb out of the socket CAUTION Do not use bulb rated for greater wattage than the specified value Do not turn the bulb to prevent damage to the bulb A Pull the bulb 15 32 ELECTRICAL SYSTEM Meter Gauge Assembly Note Install each lead on the original position shown A Y W Lead B BK Y Lead C BR Lead D BK Lead Tachometer Inspection Check the tachometer circuit wiring see Tachometer Circuit and Wiring Inspection If all wiring and components other than the tachometer unit check out good the unit is suspect Check the unit as shown Remove the air cleaner housing Remove the BK lead of the ignition coil Turn the ignition switch ON Open or connect the BK lead to the battery positive terminal using an auxiliary lead Then the pointer should flick Turn the ignition switch OFF If the pointer does not flick replace the tachometer unit A Tachometer B Pointer flicks Water Temperature Gauge Operation Inspection Prepare an auxiliary wire
21. esistance between each of the yellow leads and chassis ground Any meter reading less than infinity 20 indicates short necessitating stator replacement If the stator coils have normal resistance but the voltage check showed the alternator to be defective then the rotor magnetism have probably weakened and the rotor must be replaced Rectifier Inspection Check the rectifier resistance as follows Remove the regulator rectifier and disconnect the connector 2 see Charging System Wiring Diagram Connect an ohmmeter to the regulator rectifier as shown in the Table and check the resistance in both directions of each diode following the table Rectifier Circuit Inspection Connections Meter to Meter to e o ojlo 2 o m o Charging System Wiring Diagram ELECTRICAL SYSTEM 15 15 1 W Lead Terminal 2 BR Lead Terminal 3 BK Y Lead Terminal 4 Y Lead Terminal 5 Y2 Lead Terminal 6 Ys Lead Terminal NOTE actual meter reading varies with the meter used and the individual diode but generally speaking the lower reading should be from zero to one half the scale 1 Alternator 2 Connector 1 3 Regulator Rectifier 4 Connector 2 5 Diode Rectifier 6 Control Circuit 1 7 Connector 5 8 Main Fuse 30A 9 Connector 3 10 Connector 4 11 Ignition Switch 12 Headlight 10A Fuse Junc
22. he fan does not rotate inspect the following Fan Fuse Junction Box Headlight Circuit Leads and Connectors Main Fuse Fan Fan Inspection Remove the following Air Cleaner Housing Disconnect the 2 pin connector in the fan leads A Fan Connector Using two auxiliary wires supply battery power to the fan If the fan does not rotate at this time the fan is defective and must be replaced ELECTRICAL SYSTEM 15 29 Fan Installation Installation is the reverse of removal Cooling Fan Circuit T 2 BL BL W z x 5 gt x W BL 5 T L 1 Cooling Fan 6 Fan Switch 2 2 pin Connector 7 Radiator 3 Starter Relay 8 Main Fuse 30A 4 Fan Fuse 10A 9 Battery 5 Junction Box 15 30 ELECTRICAL SYSTEM Fuel Pump The pump operates when the starter button is pushed on or the engine is running Refer to the Starter Motor section for the Fuel Pump Wiring Diagram When fuel level in the float bow is low the fuel pump operates to supply fuel into the float bowl When the fuel reaches a certain level the fuel pressure rises and the fuel pump stops A Pump Relay B Fuel Pump Fuel Pomp Relay Inspection Remove the side cover assembly and take out the fuel pump relay Set the hand tester special tool 57001 1394 to the X 1kQ range and make the measurements shown in the table If the tester readings are not as spec
23. he ignition coils Measure the arcing distance with Kawasaki coil tester special tool 57001 1242 to check the condition of the ignition coil NOTE OSince a tester other than the Kawasaki coil tester may produce a different arcing distance the Kawasaki coil tester is recommended for reliable results 1 Ignition Coil Tester 57001 1242 2 Ignition Coil To avoid extremely high voltage shocks do not touch the coil or lead x If the distance reading is less than the specified value the ignition coil or spark plug caps are defective Ignition Coil Arcing Distance 7 mm or more To determine which part is defective measure the arcing distance again with the spark plug caps removed from the ignition coil If the arcing distance is subnormal as before the trouble is with the ignition coil itself If the arcing distance is now normal the trouble is with the spark plug caps Measuring coil resistance If the arcing tester is not available the coil can be checked for a broken or badly shorted winding with an ohmmeter However an ohmmeter cannot detect layer shorts and shorts resulting from insulation breakdown under high voltage Disconnect the primary leads from the coil terminals Measure the primary winding resistance O Connect an ohmmeter between the coil terminals OSet the meter to the x 1 range and read the meter Measure the secondary winding resista
24. hows no change in current after 5 minutes you need a new battery The current if it can flow into the battery tends to become excessive Adjust the voltage as often as possible to keep the current at standard valve 0 9 A L I CAUTION This battery is sealed type Never remove sealing caps even at charging Never add water Charge with current and time as stated below 1 Battery Charger 3 Standard Value 0 9 2 Battery 15 12 ELECTRICAL SYSTEM Battery Standard Charge Time Chart 0 9 A Regular Current Charge For Reference Lr CHARGE TIME Ss 1 8 18 12 0 111 114 126 114 13 00 BATTERY TERMINAL VOLTAGE Determine battery condition after refreshing charge O Determine the condition of the battery 30 minutes after completion of the charge by measuring the terminal voltage according to the table below Criteria Judgement 126 V or higher Good 120 126 V or lower 120 V or lower Charge insufficient Recharge Unserviceable Replace Charging System Alternator Cover Removal Remove the lower fairing Set a suitable container under the engine Remove the alternator cover bolts using the socket wrench special tool 57001 1268 A Alternator Cover Bolt Remove the alternator cover Alternator Cover Installation Replace the gasket with a new one Run the stator lead as sh
25. ified replace the fuel pump relay the tester readings are not normal check the fuel pump operation CAUTION Use only Hand Tester 57001 983 for this test An ohmmeter other than the Kawasaki Hand Tester may show different readings If a megger or a meter with a large capacity battery is used the pump relay will be damaged Fuel Pump Relay Internal Resistance Tester Lead Connection 4 Connection Tester Lead Pump Operation Inspection Remove the fuel pump with the fuel filter Prepare a container filled with kerosene Prepare the rubber hoses and connect them to the pump fittings Connect the suitable pressure gauge to the outlet hose as shown 1 Fuel Pump 6 Kerosene 2 Pressure Gauge 7 2 Pin Connector 3 Outlet Hose 8 Battery 4 Inlet Hose 9 Auxiliary Leads 5 Fuel Filter Connect the pump leads to the battery using auxiliary wires as shown If the pump operates check the pump relay if the pump does not operate the pump is defective the pump operates and the pump relay is normal close the outlet hose while operating the fuel pump When the pump stops read the pressure gauge If the pressure gauge reading is out of the specified pressure the pump is defective Fuel Pump Pressure 11 16 kPa 0 11 0 16 kg cm 1 6 2 3 psi Standard ELECTRICAL SYSTEM 15 31 Meters Gaug
26. l to the battery terminal and the black yellow lead terminal to the battery terminal momentarily The bulb should now light and stay on until the bulb circuit is opened 1 Regulator Rectifier 6 BR Lead Terminal 2 Test Light 7 BK Y Lead Terminal 3 12 V Battery 8 Y Lead Terminal 4 12 V Battery 9 Lead Terminal 5 12 V Battery 10 Y3 Lead Terminal CAUTION Do not apply more than 24 volts If more than 24 volts is applied the regulator rectifier may be damaged Do not apply 24 V more than a few seconds If 24 volts is applied for more than a few seconds the regulator rectifier may be damaged Repeat the above three steps for other two yellow leads in connector 2 which leads to the regulator rectifier Replace the regulator rectifier if the bulb does not light as described above NOTE OThe above test is not foolproof If the above checks show the regulator rectifier is not damaged but there is still trouble in the charging system first carefully inspect the alternator battery wiring and all connections Replace the regulator rectitier if all these other components turn out good Regulator Rectifier Output Voltage Inspection Check the battery condition see Battery section Warm up the engine to obtain actual alternator operat ing conditions Remove the seat Check that the ignition switch is turned off and connect the hand tester as shown in table
27. nce OPull the spark plug cap off the lead O Connect an ohmmeter between the spark plug leads OSet the meter to the x 1 kQ and read the meter If the meter does not read as specified replace the coil Ignition Coil Winding Resistance 2 3 350 12 18 Primary Windings Secondary Windings Ignition Coil Winding Resistance 1 Measure primary winding resistance 2 Measure secondary winding resistance 3 Ignition Coil If the meter reads as specified the ignition coil windings are probably good However if the ignition system still does not perform as it should after all other components have been checked test replace the coil with one known to be good ELECTRICAL SYSTEM 15 19 Check the spark plug leads for visible damage if any spark plug lead is damaged replace the coil Ignition System Wiring Diagram tcia G W 0 BK Y EU 2 1 IC Igniter 9 Starter Switch 17 30A Main Fuse 2 4 Pin Connector 10 Engine Stop Switch 18 Battery 3 6 Pin Connector 11 Ignition Switch 19 2 Pin Connector 4 2 Pin Connector 12 Junction Box 20 9 Pin Connector 5 Pickup Coil 13 Starter Circuit Relay 21 Side Stand Switch 6 Ignition Coil for 41 44 Cylinder 14 Diodes 22 Starter Lockout Switch 7 Ignition Coil for 42 43 Cylinder 15 10 Pin Connector 23 Neutral Switch 8 Spark Plugs 16 Starter Relay Spark
28. nition switch is on or while the engine is running This is to prevent IC igniter damage Do not install the battery backwards The negative Side is grounded This is to prevent damage to the diodes and IC igniter Pickup Coil Removal Remove the pickup coil cover Remove the pickup coil A Pickup Coil B Mounting Bolts Pickup Coil Installation Tighten the pickup coil mounting bolt to the specified torque see Exploded View install the pickup coil cover Pickup Coil Inspection Disconnect the pickup coil connector Zero an ohmmeter and connect it to the pickup coil leads If there is more resistance than the specified value the coil has an open lead and must be replaced Much less than this resistance means the coil is shorted and must be replaced 15 18 ELECTRICAL SYSTEM Pickup Coil Resistance x 100 355 535 O BK Y Lead Using the highest resistance range of the ohmmeter measure the resistance between the pickup coil leads and chassis ground Any meter reading less than infinity o0 indicates a short necessitating replacement of the pickup coil assembly Ignition Coil Removal Remove the air cleaner housing Remove the ignition coil from the bracket Ignition Coil Installation Connect the primary leads to the ignition coil terminals Black Lead to 1 4 Coil Green Lead to 2 3 Coil Red Lead to both Coils gnition Coil Inspection Remove t
29. oolant gently Junction Box The junction box has fuses relays and diodes The relays and diodes can not be removed Fuse Removal Remove the seats and the left side cover Unlock the hook to lift up the locking arm Pull the fuses straight out of the junction box with needle nose pliers Pull out the main fuse from the starter relay A Junction Box B Fuses C Main Fuse Fuse Installation If a fuse fails during operation inspect the electrical system to determine the cause and then replace it with a new fuse of proper amperage ELECTRICAL SYSTEM 15 35 Fuse Inspection Remove the fuse see Fuse Removal Inspect the fuse element If it is blown out replace the fuse Before replacing blown fuse always check the amperage in the affected circuit If the amperage is equal to or greater than the fuse rating check the wiring and related components for short circuit CAUTION When replacing a fuse be sure the new fuse matches the specified fuse rating for that circuit Installation of a fuse with a higher rating may cause damage to wiring and components 1 Housing 2 Fuse Element 3 Terminals 4 Blown Element Junction Box Fuse Circuit Inspection Remove the junction box see Fuse Removal Pull off the connectors from the junction box Make sure all connector terminals are clean and tight and none of them have been bent Clean th
30. ote Tail Brake Light Bulb Replacement Notes Turn Signal Light Bulb Replacement Note Turn Signal Relay Inspection Cooling Fan System Fan System Circuit Inspection Fan Inspection Fan Installation Fuel Pump Fuel Pump Relay Inspection Pump Operation Inspection Meters Gauges Removal Bulb Replacement Meter Gauge Assembly Note Tachometer Inspection Water Temperature Gauge Operation Inspection Water Temperature Sensor Inspection Fan Switch Inspection Junction Fuse Removal Fuse Installation Fuse Inspection Junction Box Fuse Starter Circuit Diode Circuit Inspection Electrical Wiring Wiring Inspection 15 2 ELECTRICAL SYSTEM Precautions There are numbers of important precautions that are musts when servicing electrical systems Learn and observe all the rules below O Do not reverse the battery lead connections This will burn out the diodes in 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 leads or any other electrical connections when the ignition switch is on
31. own Apply silicone sealant to the stator lead grommet 1 Apply silicone sealant Apply silicone sealant to the crankcase halves mating surface on the front and rear sides of the cover mount Silicone Sealant Applied Area Alternator Rotor Removal Place the jack special tool under the frame to steady the motorcycle Place a suitable container under the alternator cover Remove the alternator cover Wipe oil off the outer circumference of the rotor Hold the alternator rotor steady with the flywheel holder special tool and remove the rotor bolt A Flywheel Holder 57001 1313 C Rotor Bolt B Rotor Threads the rotor puller special tool and the rotor puller special tool onto the alternator rotor Holding the rotor puller turn the rotor puller until the alternator rotor is forced off the end of the crankshaft ELECTRICAL SYSTEM 15 13 fs A Rotor Puller 57001 1216 B Rotor Puller 57001 1277 CAUTION If the rotor is difficult to remove turn the puller while tapping the end of the puller covered with the cap Do not attempt to strike the alternator rotor itself Striking the rotor can cause the magnets to lose their magnetism Alternator Rotor Installation Notes Clean the following portions with an oil less cleaning fluid such as trichloroethylene or acetone These cleaning fluids are usually highly flammable and harmful if breathed for prolonge
32. reful not to overtighten the lens mounting screws Tail Brake Light Bulb Replacement Notes the new bulb by aligning the pins with the grooves in the walls of the socket so that the pin closest to the bulb base is to the upper right Turn Signal Relay Inspection Remove the seat and right side cover e Take the turn signal relay out of the bracket A Turn Signal Relay Check the condition or the relay for the following troubles 1 Neither right nor left turn signals come on at all Check that battery voltage is normal Unplug the relay leads and use an ohmmeter to check that there is continuity close to zero ohms between the relay terminals if there is no ohmmeter reading or if there is several ohms resistance replace the relay with a new one Turn the meter to the 25 V DC range connect the meter lead to the brown lead that was disconnected from the relay and connect the meter lead to the orange lead With the ignition switch on first switch the turn signal Switch to the R and then to the L position The meter should register battery voltage at either position If it does not the fuse ignition switch or wiring is at fault 2 Both right or both left turn signals come on and stay on or flash too slowly Check that battery voltage is normal Check that all wiring connections are good Check that the turn signal bulbs and indicator bulbs are of the correct wa
33. tion Box 13 Taillight 10A Fuse Junction Box 14 Battery 15 Load 15 16 ELECTRICAL SYSTEM Regulator Inspection To test the regulator out of circuit use three 12 V batteries and a test light made from 12 V 3 6 W bulb in a socket with leads Remove the regulator rectifier unit from the frame Using auxiliary leads connect one of the yellow lead terminal at the unit to the battery terminal and connect the test light between the black yellow lead terminal at the unit and the battery terminal At this time the bulb should not be lit 5 Y Lead Terminal 6 Y2 Lead Terminal 7 Ys Lead Terminal 1 Regulator Rectifier 2 Test Light 3 12 V Battery 4 BK Y Lead Terminal The test light works as an indicator and also as a current limiter to protect the regulator rectifier from excessive current Do not use an ammeter instead of a test light Connect the brown lead terminal to the other battery terminal and connect the black yellow lead terminal to the battery terminal momentarily At this time the bulb should not be lit L 1 Regulator Rectifier 6 BR Lead Terminal 2 Test Light 7 BK Y Lead Terminal 3 12 V Battery 8 Y Lead Terminal 4 12 V Battery 9 Lead Terminal 5 W Lead Terminal 10 Ys Lead Terminal To apply 24 V to the regulator rectifier connect two 12 V batteries in series and connect the brown lead termina
34. ttage If all of the above check good replace the relay 3 A single light on one side comes on and stays on Either the light that does not come one is burned out of the incorrect wattage or the wiring is broken or improperly connected 4 Neither light on one side comes Unless both lights for that side are burned out the trouble is with the turn signal switch 5 Flashing rate is too fast If this occurs on both the right and left sides check that the battery is not being overcharged If the magneto and the battery voltage are normal replace the turn signal relay If this occurs on only one side one or both of the turn signal bulbs are of too high a wattage ELECTRICAL SYSTEM 15 27 15 28 ELECTRICAL SYSTEM Headlight Circuit U K Model w a 5 9 55 55 EH 5 Headlight Circuit other than U K Model 1 Ignition Switch 5 Headlight Switch 2 High Beam Indicator Light 6 Dimmer Switch 3 Headlight 7 Passing Button 4 City Light 8 10A Taillight Fuse 9 10A Headlight Fuse 10 30A Main Fuse in Starter Relay 11 15A High Beam Fuse 12 Headlight Relay Cooling Fan System Fan System Circuit Inspection Remove the left lower fairing and disconnect the leads from the radiator fan switch A Fan Switch Terminals Using an auxiliary wire connect the radiator fan switch leads If the fan rotates inspect the fan switch If t
35. ve the screw and take out the brushes Unsolder the terminal and take out the brushes A 7 Brushes B Brushes A Soldered Terminal 15 22 ELECTRICAL SYSTEM Starter Motor Assembly Note inspect the O rings if it is not damaged install the brushes and springs into the end cover holder OClamp the brush leads with clips on the end cover and fix the springs NOTE OBe careful not to damage the leads and O rings Pull the armature out from the yoke and install it on the end cover brush side Fit the alignment projection on the yoke into the notches of the end cover Brush Inspection Measure the length of each brush If any is worn down to the service limit replace the carbon brush holder assembly and the terminal bolt assembly Starter Motor Brush Length Standard Service Limit 70 mm 3 5mm Commutator Cleaning and Inspection Smooth the commutator surface if necessary with fine emery cloth and clean out the grooves as illustrated 1 Commutator 2 Emery Cloth Measure the diameter of the commutator Replace the starter motor with a new one if the commutator diameter is less than the service limit 1 Commutator Segment 2 Diameter Commutator Diameter Standard 24 mm Service Limit 23 mm Armature Inspection Using the x 1 ohmmeter range measure the resist ance between any two commutator segments If ther
36. w Output or no output at all 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 To check the alternator output voltage do the following procedures Refer to appropriate chapters and charging system Wiring Diagram Turn off the ignition switch Disconnect connector 1 Connect the hand tester special tool 57001 1394 as shown in table Start the engine Run it at the rpm given in table Note the voltage readings total 3 measurements Alternator Output Voltage Range Meter to Meter to x If the output voltage shows the value in table the alternator operators properly and the regulator rectifier is damaged A much lower reading than that given in the table indicates that the altemator is defective Check the stator coil resistance as follows Stop the engine Connect the hand tester special tool 57001 1394 as shown in table Note the readings total 3 measurement Stator Coil Resistance Range Meter to Meter to Another black lead Connector 1 If there is more resistance than shown the Table or no meter reading infinity for any two leads the stator has an open lead and must be replace Much less than this resistance means the stator is shorted and must be replaced Using the highest resistance range of the hand tester measure the r
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