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Motorcycle Service Manual

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1. 2 2 Transmission Shaft Removal Transmission Shaft Installation Transmission Shaft Disassembly Transmission Shaft Assembly Shift Drum and Fork Removal Shift Drum and Fork Installation Shift Drum Disassembly Shift Drum Assembly Shift Fork Bending Inspection Shift Fork Gear Groove Wear 0 9 7 Shift Fork Guide Pin Drum Groove Wear Inspection Gear Dog and Gear Dog Hole Damage Inspection Ball Bearing Needle Bearing and Oil Ball and Needle Bearing Replacement Ball and Needle Bearing Wear Oil Seal Inspection CRANKSHAFT TRANSMISSION 9 1 9 27 9 27 9 28 9 28 9 28 9 28 9 29 9 30 9 32 9 32 9 32 9 32 9 33 9 38 9 38 9 38 9 38 9 38 9 39 9 39 9 39 9 40 9 40 9 40 9 40 9 2 CRANKSHAFT TRANSMISSION Exploded View CRANKSHAFT TRANSMISSION 9 3 Exploded View 1 Balancer Shaft camps 2 Balancer Shaft Lever Bolt 25 18 L 3 Breather Side Plate Bolt 0 60 52 in lb L 4 Connecting Rod Big End Nuts see the text 5 Breather Plate Bolts 9 8 1 0 87 in lb L 6 Shift Drum Bearing Holder Bolts 12 1 2 106 in Ib L 7
2. us i N m 8 30024651 0 3second poge FU 6230026651 C 0 30 30 30 3 0 30 30 3 1second GP30029CS1 OHTE 16 88 ELECTRICAL SYSTEM Immobilizer System Equipped Models e The red warning indicator light LED A goes off e Remove the key registration unit key registration adapter and install the immobilizer Kawasaki diagnostic system connector cap NOTE OTurm the ignition switch to ON with the registered ignition key OCheck that the engine can be started using all regis tered ignition keys GP30030CS1 ELECTRICAL SYSTEM 16 89 Immobilizer System Equipped Models Spare Ignition Key Registration Flow Chart Blinking Patterns and Number 2secon4 0g O ho O Baesend EJ 2 93923213 9393 2 gt 3 9 02029289 3 010 3 8 2 gt 0 20 22 29 92 3 02 010393 69 3 192 5 1 8 3setand gt 6 Red warning edicator ight LED NOTE and symbol binking NOTES Amplifier Time of Transmitting and Receiving Signals 2 ECU confirms the following immobilizer Amplifier Pattern 1 Registered ignition Key Collation Error Pattern 6 3 ECU confirms the edere mony Smet 4 Key Registration Waiting Time Insert next key and tum ON within CT 5 ECU confirms the following Tum OFF and re
3. Oxygen Sensor Oxygen Sensor Installation Oxygen Sensor Inspection Outside Temperature Sensor Outside Temperature Sensor Installation Outside Temperature Sensor Fuel Level Sensor Inspection 16 109 Relay BOX oa ente p e mee deeds 16 110 Relay Box Removal 16 110 Relay Box Installation 16 110 Relay Circuit Inspection 16 111 Diode Circuit Inspection 16 112 dtes diat iret i gt R a 16 113 30 A Main Fuse Remowval 16 113 15 A ECU Fuse Remowval 16 113 Fuse Box Fuse Remowval 16 113 Fuse Installation 16 113 Fuse Inspection 16 114 ELECTRICAL SYSTEM 16 3 Exploded View This page intentionally left blank 16 4 ELECTRICAL SYSTEM Exploded View ELECTRICAL SYSTEM 16 5 Exploded View IM NL LI kgfm ftib 1 Switch Housing Screws 5 2 Sensor Front Brake Light Switch Screw 1 2 x 11 4 Licence Plate Light Mounting Screws 0 9 0 09 8 in Ib 5 Install the rear brake light switch spring so that the shorter side A faces upward 6 Starter Lockout Switch
4. IGNITION G3 BR JOJO signal Jee ECU Joint Connector D Frame Ground 2 Frame Ground 3 Engine Ground Battery 12 V 8 Ah Starter Relay Main Fuse 30 A ECU Fuse 15 A GCci7098FW2 C Relay Box Fuel Pump Relay ECU Main Relay Fuse Box 1 lgnition Fuse 15 A Joint Connector F lgnition Switch Engine Stop Switch Fuel Injectors 3 114 FUEL SYSTEM DFI 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 Lubrication e Refer to the Chassis Parts Lubrication in the Period
5. 16 10 Special Tools and Sealant 16 11 Parts 16 13 Wiring Diagram BR Model 16 15 Wiring Diagram CA Model 16 18 Wiring Diagram Other than BR and Models t 16 20 00 16 22 Electrical Wiring 16 23 Wiring Inspection 16 23 MM DM RETE 16 24 Battery Removal 16 24 Battery Installation 16 24 Battery Activation 16 24 70 00 16 27 16 28 Charging Condition Inspection 16 28 Refreshing Charge 16 28 Charging System 16 30 Alternator Cover Removal 16 30 Alternator Cover Installation 16 30 Stator Coil Remowval 16 31 Stator Coil Installation 16 31 Alternator Rotor Removal 16 31 Alternator Rotor Installation 16 32 Charging Voltage Inspection 16 35 Alternator Inspection 16 35 Regulator Rectifier Inspection 16 37 Ignition System 16 39 Crankshaft Sensor Removal 16 39 Crankshaft Sensor Installation 16 39 Crankshaft Sensor Inspection
6. Cable Clutch Lever Free Play Inspection e Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter Clutch Lever Free Play Adjustment e Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter Clutch Cable Removal e Remove the right radiator side cover see Radiator and Radiator Fan Removal in the Cooling System chapter e Slide the dust cover A at the clutch cable lower end out of place e Loosen the nuts B and slide the lower end of the clutch cable to give the cable plenty of play e Screw in the adjuster A e Line up the slots B in the clutch lever and adjuster and then free the cable from the lever e Free the clutch inner cable tip from the clutch release lever e Pull the clutch cable out of the frame Clutch Cable Installation e Run the clutch cable correctly see Cable Wire and Hose Routing section in the Appendix chapter e Adjust the clutch cable see Clutch Operation Inspection in the Periodic Maintenance chapter Clutch Cable Lubrication e Refer to the Chassis Parts Lubrication in the Periodic Maintenance chapter Clutch Lever Assembly Installation e Install the clutch lever so that the mating surface A of the clutch lever clamp is aligned with the punch mark B 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
7. 12 37 Self diagnosis Procedures ee AGI 12 37 Service Code Clearing 1 1 1 1 1 41 1 12 38 How to Read Service Codes host aeta ds terapie e tad eua 12 41 How to Erase Service Codes pp 12 41 Yellow ABS Indicator Light LED Inspection 000000 12 44 Solenoid Valve Inspection Service Code 13 14 17 18 12 44 ABS Solenoid Valve Relay Inspection Service Code 19 12 44 Front Rear Wheel Rotation Difference Abnormal Service Code 25 12 45 ABS Motor Relay Inspection Service Code 35 12 45 Front Wheel Rotation Sensor Signal Abnormal Service Code 42 12 46 Front Wheel Rotation Sensor Wiring Inspection Service Code 43 12 47 Rear Wheel Rotation Sensor Signal Abnormal Service Code 44 12 47 Rear Wheel Rotation Sensor Wiring Inspection Service Code 45 12 48 Power Supply Voltage Abnormal Low Voltage Service Code 52 12 48 Power Supply Voltage Abnormal
8. Coolant Flow Specifications d eie Special Tools Coolant sciet er ia ce dat Coolant Deterioration Inspection Coolant Level Coolant Draining Coolant Filling uoi Pressure Testing Cooling System Flushing Coolant Reserve Tank Remowval Installation pp Water 2 2 2 1 21 0 0 0 09 Water Pump Removal Water Pump Installation Water Pump Inspection Water Pump Impeller n Water Pump Impeller Inspection Water Pump Housing Disassembly Water Pump Housing Assembly Mechanical Seal Inspection Fsadiator diee eee tex ides Radiator and Radiator Fan Removal Radiator and Radiator Fan Installation Radiator Inspection Radiator Cap Inspection Radiator Filler Neck Inspection 2 Thermostat Remowval Thermostat Installation Thermostat Inspection Hose and Hose Installation
9. 24 1 68090810 6 APPENDIX 17 5 Cable Wire and Hose Routing Run the clutch cable left switch housing lead into the guide Hold the clutch cable with the clamp Run the brake hose right switch housing lead and throttle cables into the guide Hold the right switch housing lead and throttle cables to the handlebars with the clamp Throttle Cables Left Switch Housing Lead Hold the left switch housing lead to the handlebars with the clamp Clutch Cable Detail A Clamp City Light Lead Connector Run the city light lead to under the meter bracket Left Turn Signal Lead Accessory Lead Connectors Before clamping face the locking portion of the clamp in direction as shown 17 6 APPENDIX Cable Wire and Hose Routing 68098820 6 APPENDIX 17 7 Cable Wire Hose Routing DNAN N 12 13 14 15 16 17 18 Before clamping face the locking portion of the clamp in direction as shown Run the meter unit lead to front of the meter bracket Hold the city light lead to the meter bracket with the clamp Hold the main harness to the meter bracket Run the clutch cable and left switch housing lead into the guide Hold the clutch cable with the clamp Tie the ignition switch lead immobilizer antenna lead equipped models and left switch housing lead with clamp
10. 7 10 ees 7 10 Oil Screen Cleaning 7 10 Uil Pressure Relief Valve tei 7 11 Oil Pressure Relief Valve 7 11 Oil Pressure Relief Valve Installation nnne 7 11 Oil Pressure Relief Valve 9 7 11 LER 7 12 OUMPRUMP REMOVAl ssec ec tate 7 12 Oil4pump Installation etel 7 12 Oil Pump Drive Gear 1 7 13 Oil Pump Drive Gear Installationm 8 7 13 7 14 Qil Gooler Rerrioval ee oe eee eee eed dea Ee EE lees 7 14 7 14 Oil Pressure Measurement 7 15 Oil Pressure Measurement tee tee ee tet coeno 7 15 Oil Pressure Switch ien p EE 7 16 Oil Pressure Switch Removal titer ett te t et aee etc Ete botte ge bebes 7 16 Oil Pressure Switch Installation eeeseeeeeen nnne 7 16 M 7 17 tooth rho EE haee Re Pete lage SERES SERE NERA
11. Thoroughly warm up the engine wait until the engine cools down retighten all the bolts and nuts e Install the removed parts see appropriate chapters END 5 45 Muffler Exhaust Pipe Removal e Remove Muffler Body see Muffler Body Removal Oxygen Sensor see Oxygen Sensor Removal in the Electrical System chapter e Support the premuffler chamber with the suitable stand e Loosen the premuffler chamber mounting bolt A e Remove Exhaust Pipe Holder Nuts A Exhaust Pipe Premuffler Chamber B In the photo the radiator has been removed for clarity Exhaust Pipe Installation e f the premuffler chamber guard has been removed install it and tighten the bolts in sequence 1 4 as shown in the figure Torque Premuffler Chamber Guard Bolts 9 8 1 0 kgf m 87 in Ib e Replace the exhaust pipe gaskets A with new ones and install them e Install the exhaust pipe Tighten the exhaust pipe holder nuts B and mounting bolt C Torque Chamber Mounting Bolt C 34 Nm 3 5 kgf m 25 ft lb e Install the muffler body see Muffler Body Installation e Thoroughly warm up the engine wait until the engine cools down retighten all the bolts and nuts e Install the removed parts see appropriate chapters OWhen installing run the cables and leads correctly see Cable Wire and Hose Routing section in the Appendix chapter
12. P7BL BK Y BK Y Joint SK Y Connector D BK Y BK 0 Rear Wheel Rotation Sensor Rear Right Turn Signal BK BL Light 124104 Diagnostic ABS Hydraulic Unit Self System ABS Self Diagnosis Terminal ABS Kawasaki Diagnosis Connector Starter 525555 Relay Regulator a Rectifier Alternator S Battery N 55 Starter T2V8Ah Enging1 2 3 4 5 oin Motor Frame Ground Rear Brake Light Switch use Box 2 Fan Fuse 15 Heter Fuse 7 5 Starter Relay 2 3 Accessory Fuse 4 5 1 ECU Fuse 15 2 Main Fuse 30A ABS Motor Relay Fuse 284 ABS Solenoid Valve Relay Fuse 15 TGNITION SWITCH CONNECTIONS Batteryflgnitionl Signal RIGHT SWITCH HOUSING CONNECTIONS Front Brake Light Switch Engine Stop_Switeh Starter Button Color Y R R olor BK ABK A OFF Loch i Immobilizer Kawasaki hen esta M hen sts BK Y BK Y License Plate 16 Light 12V5N Rear Left Turn Signal Light 127109 Color Code BK Black BL Blue BR Brown Green Orange P Pink PU Purple R Red W White ON Y Yellow P PARK 98052 06870 W2RO687CW5 C 16 18 ELECTRICAL SYSTEM Wiring Diagram CA Model Right Switch Hou
13. nd Me 8 7 8 2 ENGINE REMOVAL INSTALLATION Exploded View 6 9 rt s lt P d e REMOVAL INSTALLATION 8 3 Exploded View Fastener Upper Engine Bracket Bolts M10 2 Upper Engine Bracket Bolt M8 27 2 8 20 S 3 Lower Engine Bracket Bolts 59 6 0 44 S 4 Upper Adjusting Collar 9 8 1 0 87 in lb S 5 Upper Engine Mounting Bolt L 65 44 4 5 32 S 6 Upper Adjusting Collar Locknut 49 5 0 36 S 7 Upper Engine Mounting Bolt L 54 44 4 5 32 S 8 Engine Bracket Bolts 59 6 0 44 S 9 Middle Engine Bracket Bolts 25 2 5 18 10 Middle Engine Mounting Nut 44 4 5 32 S 11 Lower Engine Mounting Nut 44 4 5 32 S 12 Lower Adjusting Collar Locknut 49 5 0 36 S 13 Lower Adjusting Collar 9 8 1 0 87 in lb S L Apply a non permanent locking agent S Follow the specified tightening sequence 8 4 ENGINE REMOVAL INSTALLATION Special Tool Engine Mount Nut Wrench 57001 1450 7571450ST C REMOVAL INSTALLATION 8 5 Engine Removal Installation Engine Removal e Support the rear part of the swingarm with a stand e Squeeze the brake lever slowly and hold it with a band A A WARNING Motorcycle may fall over unexpectedly resulting in an accident or injury Be sure to hold the front brake when removing the engine NOTICE Be sure to hold the front brak
14. lt gt 70 Pv abs 68017120844 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 FUEL SYSTEM DFI 3 53 Intake Air Pressure Sensor 1 Service Code 12 Intake Air Pressure Sensor 1 Circuit OM 6617079212 C 1 ECU 2 Intake Air Pressure Sensor 1 3 54 FUEL SYSTEM DFI Intake Air Temperature Sensor Service Code 13 Intake Air Temperature Sensor Removal Instal lation Never drop the intake air temperature sensor espe cially on a hard surface Such a shock to the sensor can damage it e Remove the fuel tank see Fuel Tank Removal e Disconnect the connector A from the intake air temper ature sensor B e Remove Screw C Intake Air Temperature Sensor e Be sure to install the O ring A e Install the intake air temperature sensor e Tighten Torque Intake Air Temperature Sensor Mounting Screw 1 2 N m 0 12 kgf m 11 in Ib Intake Air Temperature Sensor Output Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch to OFF e Remove the fuel tank see Fuel Tank Removal e Disconnect the intake air temperature sensor connector and connect the measuring adapter A between these
15. BRAKES 12 13 Calipers Caliper Installation e Install the caliper and brake hose lower end OReplace the washers on each side of hose fitting with new ones OApply silicone grease to the rear caliper pin bolt e Tighten Torque Caliper Mounting Bolts Front 25 2 5 kgf m 18 ft Ib Rear 22 N m 2 2 kgf m 16 ft Ib Rear Caliper Pin Bolt 27 N m 2 8 kgf m 20 ft Ib Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft lb Bleed the brake line see Brake Line Bleeding Check the brake for good braking power no brake drag and no fluid leakage A WARNING After servicing it takes several applications of the brake lever or pedal before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the motorcycle until a firm brake lever or pedal is obtained by pumping the lever or pedal until the pads are against the disc Front Caliper Disassembly e Refer to the Caliper Rubber Parts Replacement in the Pe riodic Maintenance chapter Front Caliper Assembly e Refer to the Caliper Rubber Parts Replacement in the Pe riodic Maintenance chapter Rear Caliper Disassembly e Refer to the Caliper Rubber Parts Replacement in the Pe riodic Maintenance chapter Rear Caliper Assembly e Refer to the Caliper Rubber Parts Replacement in the Pe riodic Maintenance chapter 12 14 BRAKES Calipers
16. Hose Inspection Water Temperature Sensor Water Temperature Sensor Removal Installation 44 42 4242 Water Temperature Sensor Inspection 4 4 4 6 4 7 4 8 4 8 4 8 4 8 4 8 4 8 4 9 4 10 4 10 4 10 4 12 4 12 4 12 4 13 4 13 4 13 4 14 4 14 4 15 4 16 4 16 4 17 4 18 4 18 4 18 4 19 4 20 4 20 4 20 4 21 4 21 4 21 4 2 COOLING SYSTEM Exploded View COOLING SYSTEM 4 3 Exploded View No Fastener Torque Remarks kgf m ft Ib 1 Radiator Water Hose Clamp Screws 2 9 0 30 26 in Ib 2 Coolant By pass Fitting Bolt 8 8 0 90 78 L 3 Thermostat Housing Bolts 0 60 52 L 4 Water Pipe Bolts 1 2 106 in Ib L 5 Water Impeller Bolt CU 6 Water Pump Bolts 97 in lb Coolant Drain Bolt G Apply grease HG Apply high temperature grease L Apply a non permanent locking agent R Replacement Parts 87 97 in lb 4 4 COOLING SYSTEM Coolant Flow Chart Radiator Radiator Fan Radiator Oil Cooler Cylinder Head Jacket Cylinder Jacket Inlet Pipe Water Pump 9 Outlet Pipe 10 Water Temperature Sensor 11 Thermostat Housing 12 Reserve Tank Overflow Hose 13 Reserve Tank 14 Hot Coolant 15 Cold Coolant 00041498 G COOLING SYSTEM 4 5 Coolant Fl
17. 3 70 Subthrottle Sensor Service Code 32 3 72 Subthrottle Sensor Removal Adjustment eese 3 72 Subthrottle Sensor Input Voltage 220 4010 00 000000000000 00 3 72 Subthrottle Sensor Output Voltage Inspection 3 73 Subthrottle Sensor Resistance Inspection pp 3 75 Oxygen Sensor not activated Service Code 33 3 76 Oxygen Sensor 44 10 3 76 Oxygen sederet terret 3 76 Immobilizer Amplifier Service Code 35 Equipped Model 3 79 Antenna Resistance Inspection RN 3 79 Amplifier Input Voltage Inspection pp 3 79 Blank Key Detection Service Code 36 Equipped 3 80 Ignition Key InspectiON iocis Puto nds 3 80 ECU Communication Error Service Code 39 3 81 ECU Communication Line Inspection Nt 3 81 Stick Coils 1 2 3 4 Service Code 51 52 53 54 3 82 Stick Coil 3 82 Stick Coil Primary Winding Resistance Inspection pp 3 82 Stick Coil Inp
18. Re DER 13 24 Rebound Damping Force 2422 2 224 114 13 24 Spring Preload Adjustment 13 24 Rear Shock Absorber Removal 13 24 Rear Shock Absorber Installation pp 13 25 Rear Shock Absorber eee 13 26 Rear Shock Absorber 5 13 26 Rear Shock Absorber Bearing 2 2 21 211 4 1 1 1 1 14 0 13 26 Rear Shock Absorber Bearing Installation 13 26 ice Swingarm Removal Swingarm Installation Swingarm Bearing Removal pp 13 29 Swingarm Bearing Installation pp 13 29 Swingarm Bearing Sleeve Inspection Ne 13 30 Swingarm Bearing Lubrication 13 30 Chain Guide Inspection 13 30 Tie Rod Rocker Arm nore ode cette reet ic e eect ete 13 31 TIG ROG REMOVE 13 31 6 RR m ERRORES ER ERE OR ERE ER FER D RA ER A 13 31 Rocker Arm Removal peee Qe Eo EL qn 13 31 Rocker Arm 13 32 Tie Rod and Rocker Arm Be
19. 6505014 P 2 18 PERIODIC Periodic Maintenance Procedures eTurninthe bypass screw A with counting the number of turns until it seals fully but not tightly Record the number of turns Do not over tighten them They could be damaged requiring replacement e Remove Bypass Screw Spring B Washer C O ring D e Check the bypass screw and its hole for carbon deposits x If any carbons accumulate wipe the carbons off from the bypass screw and the hole using a cotton pad penetrated with a high flash point solvent Replace the O ring with a new one OApply grease to the O ring e Check the tapered portion E of the bypass screw for wear or damage x If the bypass screw is worn or damaged replace it e Turn the bypass screw until it seats fully but not tightly e Back out the same number of turns counted when first turned in This is to set the screw to its original position NOTE OA 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 disassem bly e Repeat the same procedure for other bypass screws e Repeat the synchronization f 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 M
20. i Make sure the yellow engine warning indicator light LED or the red warning indicator light LED and the immobilizer symbols go off at 30 km h 18 mph or above in order to confirm no problem END Run the engine for several minutes at idling and run the motorcycle NG GC17107F Self Diagnosis FUEL SYSTEM DFI 3 39 Service Code Reading OThe service code s is displayed on the LCD by the num ber 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 or der OThen after completing all codes the display is repeated until the ignition switch is turned OFF or upper button is pushed for more than two seconds OFor example if three problems occurred in the order of 56 16 35 the service codes are displayed each two sec onds from the lowest number in the order listed as shown below 16 35 56 5 16 35 56 repeated Olf there is no problem or when the repair has been done yellow engine warning indicator light LED or red warning indicator light LED and immobilizer symbols go off and service code is not displayed Service Code Erasing tb 35 um m h 9 5 9617105252 C OWhen repair has been done yellow engine warning indicator light LED or red warning indicator light LED a
21. 3 107 lieto He 3 109 Fuel Injector 3 109 Fuel Injector Audible 3 109 Fuel Injector Resistance 3 109 Fuel Injector Power Source Voltage Inspection 3 110 Fuel Injector Output Voltage 3 111 Fuel Injector Fuel Line 3 112 Throttle Grip and Cables pp 3 114 Free Play InsSpBeliorzno itane ue elu anak 3 114 Free Play Adjustmierit iie E eH e eik tu aci piene 3 114 Gable Installationi t dort Eb ede pete better Pb ute 3 114 Cable B brication tee eR ER rr IRE DERE REOR 3 114 Throttle B dy ASSY 3 115 Idle Speed 3 115 Synchronization Inspection ACjUStMeNt 3 115 Throttle Body Assy Removal Ne 3 115 Throttle Body Assy Installation pe 3 117 Throttle Body Assy Disassembly 3 nte euge e tetas 3 118 Throttle Body Assy Assembly Ne 3 119 PISCEM 3 120 Air Cleaner Element Removal Installation 3 120 Air Cleaner Element Inspection 3 120 Air Cleaner Oil Drairirg deii a ba 3 120 Air Cleaner Housing Removal oe n ett e ectetuer ep eid eu 3 120
22. 5 19 5 40 Camshaft Removal 5 19 Piston Ring Thickness Inspection 5 41 Camshaft Installation 5 20 Piston Ring End Gap Inspection 5 41 Camshaft Camshaft Cap Wear Throttle Body Assy Holder 5 42 5 23 Throttle Holder Camshaft Runout Inspection 5 23 5 42 Cam Wear Inspection 5 24 Throttle Body Assy Holder Camshaft Chain Removal 5 24 Installation 5 42 Cylinder Head 5 25 MUNG aca 5 43 Cylinder Compression Muffler Body Remowval 5 43 5 25 Muffler Body Installation 5 44 Cylinder Head Removal 5 26 Exhaust Pipe Removal 5 45 Cylinder Head Installation 5 26 Exhaust Pipe Installation 5 45 5 2 END Exploded View os 6 wD T i GE02535BW5 C END 5 3 Exploded View No Fastener Torque Remarks kgf m ft Ib 1 Air Suction Valve Cover Bolts 9 8 1 0 87 L 2 Spark Plugs 13 1 3 115 in Ib 3 Cylinder Head Cover Bolts 9 8 1 0 87
23. GE18159BS2 C CLUTCH 6 1 Clutch Table of Contents Exploded ELM 6 2 Specifications ERR 6 4 Special Tool and Sealant 6 5 Clutch Eever and Cable ise erre teet ette ite eve eed Ae ets 6 6 Clutch Lever Free Play InSpectiQFi nocent tinent nene ertet E nee Ronan ud da Spe sh 6 6 Clutch Lever Free Play Adjustment 6 6 Clutch Cable Removal diete trit e Hee dee cetur 6 6 Clutch Cable Installation 99 nnns 6 6 Clutch Cable E brication n te e ese Tee oderam 6 6 Clutch Lever Assembly 6 6 Clutch COVEN a 6 7 Clutch Cover Removal 99 6 7 Clutch Cover 6 7 Release Shaft Removal 2 2 6 7 Release Shaft Installation pp 6 8 Clutch Cover Disassernbly e eee ier idet cete dern dee 6 8 Clutch Cover ASSermbly rete EU te preces mee id Ay ie aa 6 9 BUG 6 10 Clutch Rermoval etit rre bebe e e E EY ERU ee I Ree ERR REOR RE Reged 6 10 Glutchinstallation uec emt t ERE 6 10 Clutch Plate Assembly Inspectionm eene tnn nna nnne 6 13 Clutch Plate Assembly 1111111 nennen 6 13 Clutch Plate Wear Damage 6 14 Clutch Plat
24. 11 6 Drive Ghainoclack AdjUStMeEnt e dba edere a tat esas 11 6 Wheel Alignment Inspection AdjUStMent enn 11 6 Drive Chain Wear 8 9 9 9 11 6 Drive Chain 11 6 aec eed er Le e etn 11 6 Drive Chain 11 7 Drive Chain 11 7 11 11 Engine Sprocket Cover Removal re ce eo pee nel due 11 11 Engine Sproket Cover InstalldllOlis deos ooi 11 11 Engine Sprocket Removal ier pt eoe e tenta cent ee tg etta eu xe ku detur deu Engine Sprocket Installation Rear Sprocket Rear Sprocket Installation i rtt oet n tt tte Coupling Installation ts Coupling Bearing Removal etae bao Re ag Coupling Bearing Installation Coupling Bearing Inspection Coupling Bearing Lubrication pp 11 14 Coupling Damper Inspection pp 11 14 Sprocket Wear
25. Holding the top plug A with a wrench B tighten the spring preload adjuster C NOTE OAfter tightening lift the top plug to make the space e Install the clamps A as shown in the figure NOTE OSet the cutout B of the clamp to the plate C of top plug 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 Special Tool Fork Spring Compressor 57001 1540 e Set the spring compressor A and suitable jack B as shown in the figure Special Tool Fork Spring Compressor 57001 1771 e Set the front fork A under the holder B 13 12 SUSPENSION Front e Insert the projection of the protector A into the front fork bottom hall B OFor right front fork remove the front axle clamp bolt e Lift up the suitable jack C about 20 mm 0 79 in D e Lift up the suitable jack A until the piston rod nut comes out e While holding the top plug A insert the fork spring stop per B between the piston rod nut C and the slider Special Tool Fork Spring Stopper 57001 1374 e Holding the top plug A with a wrench B loosen the piston rod nut C e Remove Top Plug Rebound Damping Adjuster Rod Right Front Fork Only Washer A Collar B Fork Spring C GM04731BS1 Front SUSPENSION 13 13 e Drain the fork oil into suitable container and remove the sp
26. Periodic Maintenance Procedures 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 Place a container under the coolant drain bolt A then remove the drain bolt and drain bolt gasket e Remove the right middle fairing see Middle Fairing Re moval in the Frame chapter e Remove the radiator cap A in two steps First turn the cap counterclockwise to the first stop Then push and turn it further in the same direction and remove the cap OThe coolant will drain from the radiator and engine e Remove Hose A Reserve Tank Bolts B e Turn over the reserve tank remove the cap and pour the coolant into a suitable container e Install the reserve tank e Replace the drain bolt gasket with a new one e Tighten the drain bolt with the gasket Torque Coolant Drain Bolt 11 N m 1 1 kgf m 97 in Ib PERIODIC MAINTENANCE 2 53 Periodic Maintenance Procedures e When filling the coolant choose a suitable mixture ratio by referring to the coolant manufacturer s directions NOTICE Soft or distilled water must be used with the an tifreeze in the cooling system If hard water is used in the system it causes scales accu
27. dna 7 17 Oil Pipe 7 17 7 2 ENGINE LUBRICATION SYSTEM Exploded View LUBRICATION SYSTEM 7 3 Exploded View No Fastener Torque N m kgf m TjOFePug 2 2 Cooler Bolts 12 1 2 106 in Ib 3 Passage Plugs 20 2 0 15 L 4 Radiator Water Hose Clamp Screws 3 0 0 31 27 5 Oil Pressure Switch 15 1 5 11 55 6 Pressure Switch Terminal Bolt 2 0 0 20 18 in Ib 7 Oil Pressure Relief Valve 15 1 5 11 L 8 Filter 17 1 7 13 9 Oil Filter Pipe 25 2 5 18 L 10 Oil Pan Bolts 12 1 2 106 in Ib S 11 Engine Oil Drain Bolt 29 3 0 21 12 Lower Fairing Bracket Bolts 12 1 2 106 in Ib 13 Apply molybdenum disulfide oil solution to the hole of the oil pump drive gear shaft 14 See the text EO Apply engine oil G Apply grease L Apply a non permanent locking agent LG Apply liquid gasket M Apply molybdenum disulfide grease R Replacement Parts S Follow the specified tightening sequence SS Apply silicone sealant 7 4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart 66042318 G gt gt uo c o o c Yo oor E 9 LOG Go Rn c c Oo A 5 1 d p coc GES UO eoo
28. 13 32 SUSPENSION Tie Rod Rocker Arm Rocker Arm Installation e Apply grease to the inside of the oil seals e Replace the rocker arm nut tie rod nuts and rear shock absorber nut with new ones e Tighten Torque Rocker Arm Nut 34 N m 3 5 kgf m 25 ft lb Tie Rod Nuts 34 N m 3 5 kgf m 25 ft Ib Rear Shock Absorber Nut Lower 34 N m 3 5 kgf m 25 ft lb e Install the removed parts see appropriate chapters Tie Rod and Rocker Arm Bearing Removal e Remove Tie Rods see Tie Rod Removal Rocker Arm see Rocker Arm 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 15 x 17 57001 1267 Bearing Remover Shaft 13 57001 1377 GM070998W2 C SUSPENSION 13 33 Tie Rod Rocker Arm Tie Rod and Rocker Arm Bearing Installation e Replace the needle bearing A and oil seals with new E 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 OScrew the needle bearing driver into the driver holder Olnsert the needle bearing driver into the needle bearing and press the needle bearing 7 5 mm 0 30 in B OFor a bearing of inner diameter 17 select the pressing side of the needle bearing driver according to its press ing depth
29. 4 5 mm 0 18 in 5 5 mm 0 22 in TIR 0 3 mm 0 01 in Special Tools Jack 57001 1238 Attachment Jack 57001 1252 7571238ST C 875712525 6 BRAKES 12 9 Hand Tester 57001 1394 7571394ST C Jack Attachment 57001 1608 7571608ST C 12 10 BRAKES Brake Lever Brake Pedal Brake Lever Position Adjustment The brake lever adjuster has 5 positions so that the brake lever position can be adjusted to suit the operator s hand e Push the lever forward and turn the adjuster A to align the number with the arrow mark B on the lever holder OThe distance from the grip to the lever is minimum at num ber 6 and maximum at number 1 Brake Pedal Position Inspection e Check that the brake pedal A is in the correct position B Footpeg Pedal Position Standard About 54 mm 2 1 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 the 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 If the length C shown is 70 1 mm 2 76 0 04 in the pedal position will be within the standard range e Tighten Torque Rear Master Cylinder Push Rod Locknut 17 1 7 kgf m 13 ft Ib e Check the brake light switch operation
30. Oxygen Sensor Circuit GCi17088FW2 C ECU Frame Ground 3 Engine Ground Battery 12 V 8 Ah Starter Relay Main Fuse 30 ECU Fuse 15 A Relay Box ECU Main Relay Fuse Box 1 lgnition Fuse 15 A Joint Connector F lgnition Switch Oxygen Sensor FUEL SYSTEM DFI 3 79 Immobilizer Amplifier Service Code 35 Equipped Model Antenna Resistance Inspection e Turn the ignition switch to OFF e Remove the left upper side fairing see Upper Side Fairing Removal in the Frame chapter e Slide the rubber cover A and disconnect the antenna lead connector B e Measure the antenna resistance Antenna Resistance Connections BK lead BK W lead Standard About 3 0 4 6 Q x If the reading is out of the standard replace the antenna see Immobilizer System Parts Replacement in the Elec trical System chapter xIf 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 sure the battery is fully charged e Turn the ignition switch to OFF e Remove the meter cover see Meter Cover Removal in the Frame chapter ODo not disconnect the connectors e Connect a digital meter to the ampl
31. 12viow eK R Light Gr 12 5 Headlight Low ne 12058 Hoadlight R BK Hi gh BK Y 120559 Front Left x 8 Turn Signal EXER TES Light 12v108 lt D ey CD we Accessory Connectors Accessory Socket eo 96 12V BR epo Une zig zz m 000 o Left Switch Housing Fuse Box 1 1 Ignition Fuse 15A 2 Headlight Relay Fuse 154 3 Brake Light Horn Fuse 7 54 Accessory 4 Turn Signal Relay Relay Fuse 7 Relay PE Seiten Housing Relay Box T Horn Button i 2 Hazard Button REEL 3 Turn Signal Switch 4 Passing Button 2 Headlight Circuit 5 Dimmer Switch Relay 6 Starter Lockout 3 ECU Main Relay Switch 4 Fuel Pump Relay 7 SEL Button S tarter Circuit B Upper and Lower Relay Button ABS Hydraulic Unit Horn Button Hazard Button BR YpK alGoter ov e at ctor Push Released Released R Lo Pulled In 210650 5 C ELECTRICAL SYSTEM 16 21 Wiring Diagram Other than BR and CA Models Crank shaft Sensor Fuel 2 Injectors Water Neutral 011 Oxygen Temperature Switch Pressure Sensor Troia Sensor Sulton 2 ensor Switch Main Intake Air Intake AE Sub Throttle Pressure Air qhretele Sensor Sensor 2 Pressure Yo Sensor 1 4 etuator
32. ELECTRICAL SYSTEM 16 105 Immobilizer System Equipped Models Immobilizer System Circuit LG BK BL O BK Y GP30033CW3 C 0o00 amp oN2o 10 11 12 13 14 15 16 17 18 19 20 Ignition Switch Joint Connector E ECU Immobilizer Kawasaki Diagnostic System Connector Frame Ground 3 Frame Ground 1 Engine Ground Battery 12 V 8 Ah Starter Relay Main Fuse 30 A ECU Fuse 15A Relay Box ECU Main Relay Fuse Box 1 Ignition Fuse 15 Meter Unit Red Warning Indicator Light LED Battery Oil Pressure Water Temperature Immobilizer Joint Connector F Immobilizer Antenna Immobilizer Amplifier 16 106 ELECTRICAL SYSTEM Switches and Sensors Brake Light Timing Inspection e Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance chapter Brake Light Timing Adjustment e Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance chapter Switch Inspection e Using a hand tester check to see that only the con nections shown in the table have continuity about zero ohms OFor the switch housings and the ignition switch refer to the tables in the Wiring Diagram 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 B
33. 0 2 20 Radiator Hose and Pipe Inspection coolant leak damage installation condition 2 21 Engine Top End bL H 2 21 Valve Clearance Inspection 2 21 Valve Clearance Adjustment eo eroe ote 2 22 Air Suction System Damage 2 26 ec 2 27 Clutch Operation Inspectigom 0 2 27 MICHEL Ae ooh 2 28 Air Pressure 2 28 Wheel Tire Damage Inspection lee Dee cene ete ede dent deus 2 28 Tire Tread Wear rne nnne 2 28 Wheel Bearing Damage Inspection cecinere nnne 2 29 IAE 2 30 Drive Chain Lubrication Condition Inspection 2 30 Drive Chain Slack 2 30 Drive Chain Slack Adjustment retenta cipem ti ben ER HR a HER R 2 31 Wheel Alignment Inspection sue us iie EL dele Rete idee Dane es CER DR eV RA 2 32 Drive Chain Wear 2 32 Chain Guide Wear Inspection 2 33 BIaK6S oret nn 2 34 Brake Fluid Leak Brake Hose and Pipe Ins
34. 16 41 Crankshaft Sensor Peak Voltage 16 41 Timing Rotor Removal 16 42 Timing Rotor Installation 16 42 Stick Coil Removal 16 42 Stick Coil Installation 16 42 Stick Coil 16 43 Stick Coil Primary Peak Voltage 16 43 Spark Plug Removal 16 44 Spark Plug Installation 16 44 Spark Plug Condition Inspection 16 44 Interlock Operation Inspection 16 44 IC Igniter Inspection 16 45 Electric Starter System 16 48 Starter Motor Removal 16 48 Starter Motor Installation 16 48 Starter Motor Disassembly 16 49 Starter Motor Assembly 16 50 Brush Inspection 16 52 Commutator Cleaning and 1 5 16 52 Armature Inspection 16 52 Brush Lead Inspection 16 53 Right hand End Cover Inspection 16 53 Starter Relay Inspection 16 53 Lighting System ee 16 56 Headlight Beam Horizontal Adjustment 16 56 Headlight Beam Vertical Adjustment 16 56 Headlight Bulb Replacement 16 56 City Light Bulb Replacement 16 57 Headlight Cover Removal 16
35. ABS Hydraulic Unit Connector B G Y lead ECU terminal 10 ABS Hydraulic Unit terminal 8 C Wiring Continuity Inspection ABS Hydraulic Unit Connector Front Wheel Rotation Sensor Connector B W BK lead ABS Hydraulic Unit Connector terminal 12 C BK W lead ABS Hydraulic Unit Connector terminal 3 D xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection If the ground and power supply are good replace the ECU see Removal Installation 8017144 81 8017145 81 C FUEL SYSTEM DFI 3 67 Front Wheel Rotation Sensor Signal Service Code 27 Front Wheel Rotation Sensor Circuit 6617085212 C 1 ECU 2 ABS Hydraulic Unit 3 Front Wheel Rotation Sensor 3 68 FUEL SYSTEM DFI 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 either 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 OFF and then ON Vehicle down Sensor A Ground Te
36. gt Kawasaki VERSYS 1000 Motorcycle Service Manual This quick reference guide will assist you in locating a desired topic or pro cedure Bend the pages back to match the black tab of the desired chapter num ber with the black tab on the edge at each table of contents page Refer to the sectional table of contents for the exact pages to locate the spe cific topic required Quick Reference Guide General Information Periodic Maintenance Fuel System DFI Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal Installation Crankshaft Transmission Wheels Tires Final Drive Brakes Suspension Steering Electrical System gt a gt 15 Appendix Kawasaki VERSYS 1000 Motorcycle Service Manual rights reserved parts of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Quality Assurance Division Motorcycle amp Engine Company Kawasaki Heavy Industries Ltd Japan No liability can be accepted for any inaccuracies or omissions in this publication although every possible care has been taken to make it as complete and accurate as possible The right is reserved to make changes at any time without prior notice and without incurring an obligation to ma
37. E E T OTT 10 5 Wheels 10 6 Front Wheel 10 6 Front Wheel 10 6 Rear Wheel Removal ioue QE Mae 10 7 Rear Wheel 10 8 Wheel Inspection ee E teh EE t Ea e Ro PER TERT ERE RET 10 9 Axle Inspectioh reto Ttc I I do FUSE TIRAS 10 10 Balance Inspection atento deret pet ete oet ti ete edere d etd 10 10 Balance Adjustment eee rt a ERR 10 10 Balance Weight Removal 10 10 Balance Weight Installation b 10 11 Mcr 10 12 Air Pressure Inspection Adjustment 10 12 Inspection erc EI IM Tire Installation te d e pde aeneus Bearg os tutte Hub Bearing PREMIO A LU BARS Aot Rute tau Pimp Loa ctas dente ase dd 10 15 Hub Bearing Installation store Rc oet Pte hig Re e A Dai ete keen 10 15 Hub Bearing duci 10 16 H b Bearing EUbri Caton oec
38. Pressing the incorrect race can cause pressure between Ic 5 A the inner and outer race and result in bearing damage 77 orem 68020188 Oil Seal Grease Seal Do not remove pressed oil or grease seals unless removal is necessary Replace with new ones whenever removed L new oil seals with manufacture size marks facing out Make sure the seal is aligned properly when installing NS 2 68020198 Apply specified grease to the lip of seal before installing the seal Grease 6802046851 C 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 assembly to wear during Lubri AH p TN cation points are called out throughout this manual apply A VAT a the specific oil or grease as specified e A x 68020218 Direction of Engine Rotation When rotating the crankshaft by hand the free play MN amount of rotating direction will affect the adjustment Ro tate the crankshaft to positive direction clockwise viewed r from output side UM 68020228 Electrical Wires A two color wire is identified first by the primary co
39. 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 Stem Stem Stem Bearing Removal e Remove Upper Fairing Bracket see Upper Fairing Bracket Re moval in the Frame chapter Handlebars and Lower Handlebar Holder see Handle bar Removal Steering Stem Head Bolt Plug A Steering Stem Head Bolt B and Washer e Remove Front Forks A see Front Fork Removal in the Suspen sion chapter Steering Stem Head Brake Hose Fitting Bolt B e Bend the claws A of claw washer back 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 of head pipe and applying it to both recess alternately ham mer it to drive the race out NOTE Olf either steering stem bearing is damaged it is recom mended that both the upper and lower bearings includ ing outer races should be replaced with new ones 6405055851 C Steering Stem STEERING 14 7 e
40. Tires WHEELS TIRES 10 13 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 Check the tire rotation mark on the front and rear tires and install them on the rim accordingly Tire Rotation Mark A Rotating Direction B e Position the tire on the rim so that the valve A align with the tire balance mark B the chalk mark made during removal or the yellow paint mark on a new tire e Install the tire bead over the rim flange using a suitable commercially available tire changer e Lubricate the tire beads and rim flanges with a soap 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
41. e Connect a digital meter to the subthrottle valve actuator connector A e Measure the subthrottle valve actuator resistance Subthrottle Valve Actuator Resistance Connections Y BK lead 1 P BL lead 2 lead 3 BK O lead 4 Standard About 5 2 7 8 xIf 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 6617168851 C 3 86 FUEL SYSTEM DFI Subthrottle Valve Actuator Service Code 62 Subthrottle Valve Actuator Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch to OFF e Disconnect the subthrottle valve actuator 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 e 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 1 Digital Meter R actuator BK O lead Digital Meter Battery terminal Il Digital Meter BK actuator G lead Digital Meter Battery terminal Digital Meter W actuator P BL lead Digital Meter Battery
42. 5 12 Valve 5 29 Air Suction Valve Removal 5 12 Valve Installation 5 29 Air Suction Valve Installation 5 12 Valve Guide Removal 5 29 Air Suction Valve Inspection 5 13 Valve Guide Installation 5 30 Air Switching Valve Removal 5 13 Valve to Guide Clearance Air Switching Valve Installation 5 13 Measurement Wobble Air Switching Valve Operation Method scutis itis fresa da 5 31 Testen en ene ries 5 13 Valve Seat Inspection 5 31 Air Switching Valve Unit Test 5 14 Valve Seat Repair 5 32 Clean Air System Hose Cylinder Pistons 5 37 Inspection 5 14 Cylinder Removal 5 37 Cylinder Head Cover 5 15 Cylinder Installation 5 37 Cylinder Head Cover Removal 5 15 Piston Remowval 5 38 Cylinder Head Cover Installation 5 15 Piston Installation 5 39 Camshaft Chain Tensioner 5 18 Cylinder Wear Inspection 5 39 Camshaft Chain Tensioner Piston Wear Inspection 5 40 Removal oce dede 5 18 Piston Ring Piston Ring Groove Camshaft Chain Tensioner Wear Inspection 5 40 Installation 5 18 Piston Ring Groove Width Camshaft Camshaft Chain
43. Clutch Cover CLUTCH 6 7 Clutch Cover Removal e Remove Right Lower Fairing see Lower Fairing Removal in the Frame chapter Engine Oil Drain see Engine Oil Change in the Periodic Maintenance chapter Clutch Cable Lower End Clutch Cover Mounting Bolts A e Turn the release lever A toward the rear as shown in the figure and remove the clutch cover B About 907 C Clutch Cover Installation e Be sure to dowel pins A 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 silicone sealant to the area B 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 and install it e Tighten Torque Clutch Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib Release Shaft Removal NOTICE Do not remove the clutch release lever and shaft assembly unless it is absolutely necessary If re moved the oil seal replacement may be required Remove the clutch cover see Clutch Cover Removal e Pull the release lever and shaft assembly A straight out of the clutch cover e Remove the spring B and washer C 6 8 CLUTCH Clutch Cover Release Shaft Installation e Apply grease to the oil seal lips on the upper ridge of the clutch cover e Apply engine oil to the needle bearings in the hole of
44. Fuel Hose Fuel Pump Lead Intake Air Temperature Sensor Lead Connector Run the battery ground cable to under the starter motor cable to outside of the fuel tube and to upside of the alternator lead and brake pipes Hold the battery ground cable and starter motor cable to the main harness with the band at the front of the branching point on the main harness After tying them cut the band excess length and face its knot downward Run the fuel pump lead to inside of the main harness Run the battery ground cable between the main harness and the branched main harness that goes to the ECU Hold the main harness to the rear fender Hold the fuel pump lead connector to the bracket Run the starter motor cable to under the fuse box Fuse Box Starter Relay Run the alternator lead and main harness to regulator rectifier to under the rear frame ECU Hold the main harness to the ECU bracket Insert the clip on the main harness to the tab on the rear fender to hold the main harness Run the battery ground cable to under the relay box Relay Box Accessory Relay Hold the accessory relay and battery positive lead connector to the bracket and insert it into the rear fender Battery Positive Lead Connector Battery Positive Cable Hold the main harness with the clamp so that it positions away from the bracket KLZ1000AC early model only 17 24 APPENDIX Cable Wire a
45. Fuel injector trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Backfiring when deceleration Spark plug dirty broken or gap maladjusted Inspect and replace see chapter 2 Fuel pressure too low Inspect see chapter 3 Fuel pump trouble Inspect see chapter 3 Main throttle sensor trouble Inspect see chapter 3 Subthrottle sensor trouble Inspect see chapter 3 2 S Intake air 1 trouble Intake air 2 trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Intake air temperature sensor trouble Inspect see chapter 3 3 34 FUEL SYSTEM DFI DFI System Troubleshooting Guide Symptoms or Possible Causes Actions chapter 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 Actions chapter Firing incorrect Stick coil shorted or not in good contact Inspect or Reinstall see chapter 16 Stick coil trouble Inspect see chapter 16 Spark plug dirty broken or gap maladjusted Inspect and replace see chapter 2 Spark plug incorrect Replace it with the correct plug see chapter 2 ECU tro
46. Guide shows you all of the products 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 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 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 xIndicates 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 follo
47. Phenome non Engine conditions at problem L1 After starting L1 At 5 000 r min rpm or more Road conditions O Slippery road E1snow Dgravel O other Rough surface O Other Driving conditions L1 High speed cornering Driving 10 km h 6 mph or above Driving below 10 km h 6 mph When stopping O When turning Gradual Abrupt L1 Large brake lever stroke Large pedal stroke Brake application Other conditions 12 36 BRAKES Anti Lock Brake System 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 Replace wheel bedding arse There shouldn t be excessive axle bending or disc runout GLI40012B BRAKES 12 37 Anti Lock System Pre Diagnosis Inspection 2 Check the yellow ABS indicator light LED Goes on Does the yellow ABS indicator light Does the yellow ABS indicator light LED LED go on with the ignition switch blink with the ignition switch to ON to ON Drive at
48. e Apply a thin coat of molybdenum disulfide grease to the shaft A and install it and starter idle gear B e Install the alternator cover see Alternator Cover Installa tion System ELECTRICAL SYSTEM 16 35 Charging Voltage Inspection e Check the battery condition see Charging Condition In spection e Warm up the engine to obtain actual alternator operating conditions e Check that the ignition switch is turned off and connect the hand tester A to the battery terminals B Special Tool Hand Tester 57001 1394 e Start the engine and note the voltage readings at var ious engine speeds with the headlight turned on and then turned off To turn off the headlight disconnect the headlight connector on the headlight unit The readings should show nearly battery voltage when the engine speed is low and as the engine speed rises the readings should also rise But they must be kept under the specified voltage Charging Voltage Connections i Tester Range Reading Tester to Tester to 25 V DC Battery Battery 14 4 15 0 V e Turn off the ignition switch to stop the engine and discon nect the hand tester x If the charging voltage is kept between the values given in the table the charging system is considered to be working normally xIf the charging voltage is much higher than the values specified in the table the regulator rectifier is defective or the regul
49. for any person engaged in the business of repairing servicing selling leasing or trading motor vehicles or motor vehicle engines or who operates a fleet of motor vehicles know ingly to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title follow ing its sale and delivery to the ultimate purchaser NOTE OThe phrase remove or render inoperative any device or element of design has been generally interpreted as follows 1 Tampering does not include the temporary removal or rendering inoperative of de vices or elements of design in order to perform maintenance 2 Tampering could include a Maladjustment of vehicle components such that the emission standards are ex ceeded b Use of replacement parts or accessories which adversely affect the performance or durability of the motorcycle c Addition of components or accessories that result in the vehicle exceeding the stan dards d Permanently removing disconnecting or rendering inoperative any component or element of design of the emission control systems WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING 10 000 PER VIOLATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperat
50. too low Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Intake air temperature sensor trouble Inspect see chapter 3 Exhaust Smokes Excessively Black smoke pur 3 36 FUEL SYSTEM DFI Self Diagnosis Self diagnosis Outline The self diagnosis system has two modes and can be switched to another mode by operating the meter unit User Mode The ECU notifies the rider of troubles in DFI system igni tion system and immobilizer system by goes on or blinking the yellow engine warning indicator light LED A or red warning indicator light LED B and immobilizer warning symbol C when DFI ignition and immobilizer system parts are faulty and initiates fail safe function In case of serious troubles ECU stops the injection and ignition operations Dealer Mode The LCD Liquid Crystal Display display the service code s A to show the problem s which the DFI system ignition system and immobilizer system has at the moment of diagnosis 8017100 52 C 8017101 52 C Self Diagnosis FUEL SYSTEM DFI 3 37 Self diagnosis Procedures OWhen problem occurs with the DFI system and ignition system the yellow engine warning indicator light LED A goes on 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 OFor models equipped
51. 16 50 ELECTRICAL SYSTEM Electric Starter System e Pull out the brushes from the brush holder A e Remove Brush Springs B Starter Motor Terminal C Positive Brush Assy D Screw E Negative Brush Assy F Brush Holder Starter Motor Assembly e Align the hole A of the brush holder B to the boss C of the right hand end cover D e Align the stoppers A of the negative brush assy B to the guides C of the brush holder D e Tighten Torque Bush Holder Screw 3 8 0 39 kgf m 34 in Ib e Insert the jagged porition A on the starter motor terminal B to the slit C on the positive brush assy D e Install the starter motor terminal to the brush holder e Replace the O ring A with a new one OApply grease to the O ring e Install the following parts to the starter motor terminal B New O ring Collar C Washer D Starter Motor Terminal Locknut E Olnstall the collar so that stepped side faces outward e Tighten Torque Starter Motor Terminal Locknut 11 Nm 1 1 kgf m 97 in Ib GP11204BS1 Electric Starter System ELECTRICAL SYSTEM 16 51 e Install the brush springs A and insert the brushes B Apply thin coat of grease to the oil seal A e Replace the O rings A with new ones OApply grease to the O rings e Insert the armature B so that commutator side C faces hollow side D of the yoke E e Align the stopper A and hollo
52. 3 mm 0 12 in Front Up to 220 kg 485 Ib load 250 kPa 2 5 kgf cm 36 psi Rear Up to 220 kg 485 Ib load 290 kPa 2 9 kgf cm 42 psi Final Drive Drive Chain Slack 25 35 mm 1 0 1 4 in PERIODIC MAINTENANCE 2 13 Specifications Item Standard Service Limit Drive Chain Wear 20 link 317 5 318 2 mm 12 50 12 53 in 319 mm 12 6 in Length Standard Chain Make ENUMA EK525RMX Link 116 Links Brakes Brake Fluid Grade DOT4 Brake Pad 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 Light Timing Front Pulled ON after about 10 0 39 of ___ travel Electrical System Spark Plug Type NGK CR9EIA 9 2 14 PERIODIC MAINTENANCE Special Tools Inside Circlip Pliers 57001 143 7570143ST C Steering Stem Nut Wrench 57001 1100 875711005 C Pilot Screw Adjuster A 57001 1239 N 875712395 6 Oil Filter Wrench 57001 1249 7571249ST C Spark Plug Wrench Hex 16 57001 1262 Vacuum Gauge 57001 1369 es 7571369ST C Throttle Sensor Setting Adapter 57001 1538 7571538ST C eo 7571607ST C Fuel Hose 57001 1607 PERIODIC MAINTENANCE 2 15 Periodic Maintenance Procedures Fuel System DFI Throttle Control System Inspe
53. 5 Premuffler Chamber Guard Bolts 9 8 1 0 87 in lb S R Replacement Parts S Follow the specified tightening sequence 5 6 END Exhaust System Identification MANIFOLD MUFFLER BODY Honeycomb Type Catalyst with Oxygen P No 18091 0778 Sensor Mark KHI K 617 P No 39178 0170 EPA Noise Emission Mark 137 Control Information SPECIFICATION WVTA FULL H GB WVTA FULL H WVTA 78 2 H SEA B2 AU BR CA MODEL KLZ1000AC KLZ1000AC KLZ1000AC KLZ1000AC KLZ1000AC KLZ1000AC KLZ1000AC GE24731B F Exhaust Pipe Mark Position A Muffler Body Mark Position A Exhaust System ldentification ENGINE TOP END 5 7 Exhaust A with Hole B for Oxygen Sensor Honeycomb Type Catalyst Positions A GE24764BS2 C GE24765BS2 C 5 8 END Specifications Cap Clearance Diameter Camshaft Runout Camshaft Journal Camshaft Camshaft Journal Diameter Camshaft Bearing Inside 0 038 0 081 mm 0 0015 0 0032 in 23 940 23 962 mm 0 9425 0 9434 in 24 000 24 021 mm 0 9449 0 9457 in TIR 0 02 mm 0 0008 in or less Item Standard Service Limit Camshafts Cam Height Exhaust 32 943 33 057 mm 1 2970 1 3015 in 32 84 mm 1 293 in Intake 32 943 33 057 mm 1 2970 1 3015 in 32 84 mm 1 293 in 0 17 mm 0 0067 in 23 91 mm 0 9413 in 24 08 mm 0 9480 in TIR 0 1 mm 0
54. 6114579893 C Joint Connector E ECU Rear Wheel Rotation Sensor Rear Brake Light Switch Frame Ground 5 Frame Ground 4 Frame Ground 1 Engine Ground Battery 12 V 8 Ah 10 Starter Relay 11 Main Fuse 30 A 12 ECU Fuse 15 A 13 Fuse Box 2 14 ABS Motor Relay Fuse 25 A 15 ABS Solenoid Valve Relay Fuse 15 A OColor Codes OMNATDRWN gt BK Black GY Gray BL Blue LB Light Blue BR Brown LG Light Green CH Chocolate O Orange DG Dark Green P Pink G Green PU Purple V Violet W White Y Yellow ABS Kawasaki Self diagnosis System Con nector ABS Self diagnosis Terminal ABS Hydraulic Unit Fuse Box 1 Brake Light Horn Fure 7 5 Ignition Fuse 15 Meter Unit Yellow ABS Indicator Light LED Joint Connector F Front Wheel Rotation Sensor Ignition Switch Front Brake Light Switch BRAKES 12 29 i Lock System Ant ABS Hydraulic Unit Terminal Names 68114545842 C Ground BK BL Unused Front Wheel Rotation Sensor Signal Input BK W Power Supply BR W ABS Kawasaki Self Daignosis System Terminal P Front and Rear Brake Light Switch Signal BL R ABS Self Daiagnosis Terminal GY Front Wheel Rotation Sensor Signal Output G Y Power Supply to ABS Solenoid Valve Relay R BK Ground to Motor BK Unused Power Supply to Front Wheel Rotation Sensor W BK Power Su
55. 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 seal B as well Also replace all seals every other time the pads are changed Rear Caliper Dust Boot and Friction Boot Damage Inspection e Check that the dust boot A and friction boot B are not cracked worn swollen or otherwise damaged x If they show any damage replace it 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 GLO5295BS1 C 9105296851 C GL05297BS1 Calipers BRAKES 12 15 Rear Caliper Holder Wear Inspection The caliper body must slide smoothly on the rear caliper pin bolt A and sleeve B If the body does not slide smoothly one pad will wear more than the other pad wear will increase and constant drag on the disc will raise brake an
56. GP026128W5 C ELECTRICAL SYSTEM 16 9 Exploded View Torque Fastener Wm Tem Remarks Engine Ground Cable Terminal Bolt E 8 1 0 87 in lb 2 Neutral Switch 1 5 11 3 Sidestand Switch Bolt 22 0 90 78 in lb L 4 Turn Signal Relay 5 Fuel Box 1 6 Fuel Box 2 7 ECU 8 Relay Box 9 Horn 10 Accessory Relay 11 Air Switching Valve L Apply a non permanent locking agent R Replacement Parts 16 10 ELECTRICAL SYSTEM Specifications Item Standard Battery Type Model Name Capacity Voltage Charging System Type Alternator Output Voltage Stator Coil Resistance Charging Voltage Regulator Rectifier Output Voltage Ignition System Crankshaft Sensor Resistance Crankshaft Sensor Peak Voltage Stick Coil Primary Winding Resistance Secondary Winding Resistance Primary Peak Voltage Spark Plug Type Gap Sealed Battery YTX9 BS 12 V 8 Ah 12 8 V or more Three phase AC 44 8 V or more at 4 000 rpm 0 17 0 25 O at 20 C 68 F 14 4 15 0 V 376 564 2 0 V or more 1 1 1 50 10 8 16 2 100 V or more CR9EIA 9 0 8 0 9 mm 0 031 0 035 in Electric Starter System Starter Motor Brush Length 12 mm 0 47 in Service limit 6 5 mm 0 26 in Air Switching Valve Resistance 18 220 at 20 C 68 F Switches and Sensors Rear Brake Light Switch Timing Engine Oil Pressure Switch Connections Water Temperature Senso
57. LUBRICATION SYSTEM Oil Pressure Switch Oil Pressure Switch Removal e Remove Left Lower Fairing Assembly see Lower Fairing Assem bly Removal in the Frame chapter Engine Oil Drain see Engine Oil Change in the Periodic Maintenance chapter Switch Cover 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 silicone sealant to the threads of the oil pressure switch and tighten it Sealant Liquid Gasket TB1211 56019 120 Torque Oil Pressure Switch 15 N m 1 5 kgf m 11 ft Ib e Install the switch lead e Tighten Torque Oil Pressure Switch Terminal Bolt 2 0 N m 0 20 kgf m 18 in Ib e Apply grease to the terminal Oil Pipe ENGINE LUBRICATION SYSTEM 7 17 Oil Pipe Removal e Remove Oil Pan see Oil Pan Removal Oil Pipe A Oil Pipe Installation e Replace the O rings A with new ones e Apply grease to the O rings and install them 65148070 P ENGINE REMOVAL INSTALLATION 8 1 Engine Removal Installation Table of Contents EEE 8 2 Special E 8 4 Engirie FRemoval InstallaliQrs Da aou aM Pad 8 5 Engine REMOVAL sic 8 5 Ernigirie
58. Oxygen Sensor Inspection e Warm up the engine thoroughly until the radiator fan starts e Turn the ignition switch to OFF e Remove the right side cover see Side Cover Removal in the Frame chapter e Open the clamp A and pull out the oxygen sensor lead connector B e Disconnect the oxygen sensor lead connector 4 pins con nector and connect the measuring adapter A between these connectors B Main Harness C Oxygen Sensor 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 R sensor BL Y lead Digital Meter BK sensor lead e Remove Air Cleaner Housing see Air Cleaner Housing Removal e Disconnect the stick coil connectors A e Pull up the rubber cover B forward ODo not disconnect the air switching valve connector C FUEL SYSTEM DFI 3 93 Oxygen Sensor Incorrect Output Voltage Service Code 94 e Separate the air switching valve hoses A from the air suction valve covers e Install the suitable plugs A on the fitting of the air suction valve covers and shut off the secondary air e Reposition the rubber cover and connect the stick coil connectors e Install the air cleaner housing temporarily see Air Cleaner Housing Installation e Remove the fuel hose see Fuel Hose Replacement in the Periodic Mainte
59. Run the main harness ignition switch lead immobilizer antenna lead equipped models and left switch housing lead into the guide Main Harness Clutch Cable 10 11 Hold the main harness to the meter bracket Run the high beam headlight lead through the outside of frame to avoid contact with the meter bracket High Beam Headlight Lead Connector Vehicle down Sensor Intake Air Temperature Sensor Low Beam Headlight Lead Connector Run the main harness ignition switch lead immobilizer antenna lead equipped models left switch housing lead and clutch cable through inside of the left fork tube Run the clutch cable between the radiator upper brackets Run the clutch cable to the outside of the leads and clamp 17 8 APPENDIX Cable Wire and Hose Routing 68098830 6 APPENDIX 17 9 Cable Wire and Hose Routing Hold the main harness to the left engine bracket Run the main harness to the upside of the left engine bracket Run the throttle cables to under the main harness Left Engine Bracket Slide the dust cover over the connectors Run the right switch housing lead ignition switch lead radiator fan motor lead immobilizer an tenna lead equipped models and left switch housing lead to under the throttle cables Hold the right switch housing lead ignition switch lead radiator fan motor lead immobilizer antenna lead equipped models and left switch hou
60. Special Tools Bearing Driver Set 57001 1129 Needle Bearing Driver 17 018 57001 1609 NOTE Olnstall the needle bearings so that the marked side faces in Rocker Arm Tie Rod Bearing Sleeve Inspection B Do not remove the bearings for inspection Re moval may damage them Q e Visually inspect the rocker arm or tie rod sleeves A and needle bearings e The rollers in a needle bearing normally wear very little and wear is difficult to measure Instead of measuring 9107101881 0 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 STEERING 14 1 Steering Table of Contents ET 14 2 Special 14 4 E 14 5 Steering nspectlon 14 5 Steering 14 5 Steering tt 14 6 Stem Stem Bearing 14 6 Stem Stem Bearing Installatiom 8 14 7 Steering Stem Bearing Lubrication
61. x If the ground and power supply are good replace the see Removal Installation Radiator Fan Relay Circuit GCci7092FW2 C 1 ECU 10 Radiator Fan Relay 2 Frame Ground 3 11 Fuse Box 1 3 Engine Ground 12 Ignition Fuse 15 A 4 Battery 12 V 8 Ah 13 Joint Connector F 5 Starter Relay 14 Ignition Switch 6 Main Fuse 30 A 15 Fan Motor 7 Fuse Box 2 16 Joint Connector C 8 Fan Fuse 15 A 17 Water Temperature Sensor 9 Relay Box Subthrottle Valve Actuator Service Code 62 FUEL SYSTEM DFI 3 85 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 air cleaner housing see Air Cleaner Housing Removal Turn the ignition switch to ON Check to see that all the subthrottle valves A open close smoothly Turn the ignition switch to OFF x If 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 Disconnect the subthrottle valve actuator connector A
62. 2 52 Radiator hose O ring replace Engine oil change Oil filter replace Brake hose replace Brake fluid change Rubber parts of master cylinder and caliper replace Spark plug replace 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 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 AD Apply adhesive ThreeBond TB1344N or equivalent AL Tighten the two clamp bolts alternately two times to ensure even tightening torque G Apply grease L Apply a non permanent locking agent MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts S Follow the specified tightening sequence Si Apply silicone grease ex PBC grease SS Apply silicone sealant Torque Fast R k astener Nm ftlb emarks Fuel System DFI Switch Housing Screws 3 5 0 36 31 in Ib Upper Air Cleaner Housing Screws 1 1 0 11 10 in Ib Throttle Body Assy Holder Clamp Bolts 2 9 0 30 26 in Ib Throttle Body Assy Holder Bolts 12 1 2 106 L
63. 4 280 mmHg e With the engine at the correct idle speed equalize higher vacuum of 1 or 2 for example 300 mmHg to higher vacuum of 3 or 4 for example 280 mmHg by turning the center adjusting screw A NOTE OAfter adjustment the final vacuum measurement be tween the highest throttle valves may not be 300 mmHg for example The goal is to have the highest two vac uums between the left 1 and 2 and right 3 and 4 banks be the same e Open and close the throttle after each measurement and adjust the idle speed as necessary e Once the throttle valves have been synchronized inspect output voltage of the main throttle sensor to ensure proper operation procedure is explained at the end of this sec tion xIf any one vacuum measurement is out of the specified range after left 1 2 and right 3 4 synchronization adjust the bypass screws A Special Tool Pilot Screw Adjuster A B 57001 1239 e Adjust the lower vacuum between 1 and 2 to the higher vacuum of 1 and 2 e Adjust the lower vacuum between 3 and 4 to the higher vacuum of 3 and 4 e Open and close the throttle valves after each measure 6505241851 ment and adjust the idle speed as necessary e Check the vacuums as before x If all vacuums are within the specification range finish the engine vacuum synchronization If any vacuum can not be adjusted within the specification remove the bypass screws 1 4 and clean them
64. 9617108251 3 74 FUEL SYSTEM DFI Subthrottle Sensor Service Code 32 eMeasure the output voltage with the engine stopped with the connector joined e Remove the left side cover see Side Cover Removal in the Frame chapter e Turn the ignition switch to ON e Measure the output voltage when the subthrottle valve is completely closed by turning the lever A fully clockwise B Output Voltage Standard DC 1 08 1 12 V at subthrottle valve full close position DC 4 2 4 4 V at subthrottle valve full open position for reference NOTE OTurm the lever counterclockwise confirm the output volt age will be raise OThe standard voltage refers to the value when the volt age reading at the Input Voltage Inspection shows 5 V exactly OWhen the input voltage reading shows other than 5 V derive a voltage range as follows Example In the case of a input voltage of 4 75 V 1 08 x 4 75 5 00 1 03 V 1 12 x 4 75 5 00 1 06 V Thus the valid range is 1 03 1 06 V Turn the ignition switch to OFF x If 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 check the wiring for continuity between main harness con nectors ODisconnect the ECU and sensor connectors Wiring Inspection ECU Connector A Subthrottle Sensor Connector B BL W lead ECU terminal
65. 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 GL14580BS1 12 32 BRAKES Anti Lock Brake System 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 the customer be sure to erase any service codes which
66. Clutch Lever Pulled in Sidestand Up e Setthe sidestand on the ground then the engine will stop xIf the engine does not stop inspect the neutral switch sidestand switch and relay box x If their parts are normality replace the ECU 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 section ECU Power Supply Inspection see ECU Power Supply Inspection in the Fuel System DFI chapter 16 46 ELECTRICAL SYSTEM Ignition System Ignition System Troubleshooting Faulty ignition No spark Good No good Battery Inspection Charge or replace battery Good Ignition system wiring and connector Na good 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 Stick coil primary peak voltage inspection No good Voltage is less than the specified value Inspect 1 Lower resistance in a hand tester Use KAWASAKI Hand Tester 2 Crankshaft sensor peak voltage Good Stick coil is defective Replace stick coil Voltage is zero No good or almost zero No good Inspect 1 Adapter connection is incorrect or adapter is defective 2 Ignition switch and engine stop switch Crankshaft sensor peak vo
67. FUEL SYSTEM DFI 3 45 xIf the reading is out of the standard remove the ECU and check the wiring for continuity between main harness connectors ODisconnect the ECU and sensor connectors Wiring Inspection ECU Connector A Main Throttle Sensor Connector B BL lead ECU terminal 4 C G lead ECU terminal 49 D xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation Main Throttle Sensor Output Voltage Inspection 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 throttle sensor setting adapter A between these connectors Special Tool Throttle Sensor Setting Adapter 57001 1538 Main Throttle Sensor Output Voltage Connections to Adapter Digital Meter R sensor Y W lead Digital Meter BK sensor lead Start the engine and warm it up thoroughly Check idle speed to ensure the throttle opening is correct Idle Speed Standard 1 100 50 r min rpm the idle speed is out of the specified range adjust it see Idle Speed Inspection in the Periodic Maintenance chapter GC17108FS1 3 46 FUEL SYSTEM Main Throttle Sensor Service Code 11 e Turn the igni
68. Problem chronic O often frequency Road street O highway O mountain road O uphill downhill C1 bumpy pebble Altitude normal O high about 1 000 m or more Motorcycle conditions when problem occurred Yellow engine warning indicator light LED and yellow KTRC warning indicator light LED L1 lights go on immediately after ignition switch ON and go off after 1 2 seconds normal light s go on after ignition switch ON DFI and KTRC system problem light s do not go on ECU or meter unit problem sometimes light s go on probably wiring fault Red warning indicator light LED starts go on about seconds after from ignition switch ON and goes off after engine pressure becomes high enough with engine running starts blinking about seconds after from ignition switch ON and the immobilizer warning symbol on the LCD starts blinking immobilizer system problem does not go on about seconds after ignition switch ON ECU or meter unit problem O light up battery oil pressure water temperature or meter unit problem Engine stalls L1 starter motor not rotating L1 ip when closing throttle grip O when stopping the motorcycle when cruising other 3 30 FUEL SYSTEM DFI Troubleshooting the DFI System at low speed Poor running or no power at high speed Poor running O very low id
69. Special Tools Fork Spring Compressor 57001 1587 Fork Spring Compressor 57001 1540 NOTE OSet the cutout of the clamp to the slider e While holding up the piston rod puller insert the fork spring stopper between the piston rod nut and the slider Special Tool Fork Spring Stopper 57001 1374 e Remove the piston rod puller e Insert the rebound damping adjuster rod into the holes of the piston rod Right Side Only e Replace the O ring A on the top plug with a new one e Apply grease to the new O ring e Screw in the top plug until it stops onto the piston rod e Holding the top plug B with a wrench C tighten the piston rod nut D against the top plug Torque Piston Rod Nuts 15 1 5 kgf m 11 ft Ib e While holding up the top plug A pull out the fork spring stopper B e Remove 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 e Adjust the spring preload see Spring Preload Adjust ment e Adjust the rebound damping force see Rebound Damp ing Force Adjustment Right Front Fork Only Front Fork Disassembly e Remove the front fork see Front Fork Removal e Drain the fork oil see Fork Oil Change SUSPENSION 13 21 Front Separate the inner tube from the outer tube as follows OSlide up the dust seal A ORemove the retaining ring B from the outer tube
70. 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 220 kg 485 Ib 250 kPa 2 5 kgf cm 36 psi Rear Up to 220 kg 485 Ib 290 kPa 2 9 kgf cm 42 psi Wheel Tire Damage Inspection e Remove any imbedded stones A or other foreign parti cles B from tread e Visually inspect the tire for cracks and cuts and replace the tire if necessary Swelling or high spots indicate inter nal damage requiring tire replacement e Visually inspect the wheel for cracks cuts and dents dam age x If any damage is found replace the wheel if necessary Tire Tread Wear 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 9096 worn So it is false economy and unsafe to use the tires until they are bald e Measure the tread depth at the center of the tread with a depth gauge A Since the tire may wear unevenly take measurement at several places x If any measurement is less than the service limit replace the tire see Tire Removal Installation in the Wheels Tires chapter 6J050
71. e Set the fork spring compressor on the washer A using the outer tube as a guide Special Tools Fork Spring Compressor 57001 1771 Fork Spring Compressor 57001 1540 NOTE OSet the cutout of the clamp to the slider e While holding up the piston rod puller insert the fork spring stopper between the piston rod nut and the slider Special Tool Fork Spring Stopper 57001 1374 e Remove the piston rod puller e Insert the rebound damping adjuster rod into the holes of the piston rod Right Front Fork Only e Replace the O ring A on the top plug with a new one e Apply grease to the new O ring e Screw in the top plug until it stops onto the piston rod e Holding the top plug B with a wrench C tighten the piston rod nut D against the top plug Torque Piston Rod Nuts 15 1 5 kgf m 11 ft Ib e While holding up the top plug A pull out the fork spring stopper B e Remove 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 e Adjust the spring preload see Spring Preload Adjust ment e Adjust the rebound damping force see Rebound Damp ing Force Adjustment Right Front Fork Only 13 16 SUSPENSION Front If using the spring compressor 57001 1587 e Install the clamps A as shown in the figure NOTE OSetthe cutout B of the clamp to the plate C of top plug D pull
72. grease seals C and circlip D with new ones e Install the needle bearings as shown in the figure E Left Side F Right Side G 27 5 mm 1 1 in H 9 5 mm 0 37 in I 29 5 mm 1 16 in NOTE Olnstall the needle bearings so that the marked side faces out Special Tool Needle Bearing Driver 028 57001 1610 OPress in the ball bearing until it bottomed Special Tool Bearing Driver Set 57001 1129 Olnstall the circlip Special Tool Inside Circlip Pliers 57001 143 OPress in the grease seals so that seal surface is flushed with the end of housing Special Tool Bearing Driver Set 57001 1129 GM06217BS1 GM06218BS1 222 5 GM06197BS1 C 13 30 SUSPENSION Swingarm 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 B in stalled in the swingarm OThe rollers and ball in a bearing normally wear very little and wear is difficult to measure Instead of measuring visually inspect the bearing for abrasion discoloration or other damage xlf the needle bearing and sleeve C 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
73. 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 Valves ENGINE TOP END 5 29 Valve Clearance Inspection e Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter Valve Clearance Adjustment e Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter Valve Removal e Remove Cylinder Head see Cylinder Head Removal Valve Lifter and Shim OMark and record the valve lifter and shim locations so they can be installed in their original positions e Using the valve spring compressor assembly remove the valve Special Tools Valve Spring Compressor Assembly A 57001 241 Valve Spring Compressor Adapter 24 B 57001 1586 Valve Installation e Replace the oil seal with a new one e Apply a thin coat of molybdenum disulfide grease to the valve stem before valve installation e Install the springs so that the closed coil end faces down wards Valve Stem A Oil Seal B Spring Seat C Closed Coil End D Valve Spring E Retainer F Split Keepers 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 cylinde
74. terminal IV Digital Meter gt Y actuator Y BK lead Digital Meter gt Battery terminal e Measure the actuator input voltage with the engine stopped and with the connector joined Turn the ignition switch to ON Input Voltage Standard About DC 11 5 13 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 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 Connector A Subthrottle Valve Actuator Connector B P BL lead ECU terminal 1 C YIBK lead ECU terminal 12 D BK O lead ECU terminal 23 E G lead ECU terminal 24 F xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the see Removal Installation 6617132251 9617133251 C FUEL SYSTEM DFI 3 87 Subthrottle Valve Actuator Service Code 62 Subthrottle Valve Actuator Circuit 2 eu x zz or GCci7093FW2 C 1 ECU 2 Subthrottle Valve Actuator 3 88 FUEL SYSTEM DFI Air Switching Valve Service Code 64 Air Switching Valve Removal Inst
75. terminal as shown Hold the ABS Kawasaki self diagnosis system connector on the bracket ABS Self diagnosis Terminal Fuel Pump Lead Hold the fuel pump lead connector on the bracket ECU Battery Ground Cable Hold the main harness with the clamp so that it positions away from the bracket KLZ1000AC early model only 17 26 APPENDIX Cable Wire and Hose Routing Q 68098920 6 APPENDIX 17 27 Cable Wire Hose Routing Battery Positive Cable Battery Ground Cable Immobilizer Equipped Models Kawasaki Diagnostic System Connector Insert the diagnostic system connector into the pad to hold it on the rear fender Hold the main harness to the rear fender with the blade clips on the main harness Main Harness to Rear Lights Run the main harness to under the rear frame Hold the main harness to the rear fender with clip Rear Right Turn Signal Light Lead Connector License Plate Light Lead Connector Tail Brake Light LED Lead Connector Run the licence plate light lead under the pad on the rear fender Rear Left Turn Signal Light Lead Connector Hold the main harness to the rear fender with clip Rear Right Turn Signal Light Lead Run the license plate light lead to upside of the seat lock cable Seat Lock Cable Run the main harness and tail brake light LED lead to under the seat lock cable Run the rear left t
76. 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 the air cleaner housing see Air Cleaner Housing Removal e Disconnect the sensor connector A e Remove the intake air pressure sensor 2 A from the rubber damper B in the bracket and separate the vac uum hose C 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 the reverse of removal OPosition the intake air pressure sensor 2 A between the projection B on the rubber damper 3 60 FUEL SYSTEM DFI Intake Air Pressure Sensor 2 Service Code 16 Intake 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 air cleaner housing see Air Cleaner Housing Removal 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 R sensor BL lead Digital Meter gt BK sensor lead e Measure the input voltage with the engine stopped and with th
77. 3 40 3 45 3 50 Jc o TEE ENT ENT ETSERT DET ERE DES ERSERES I DETTNIMEEN ENT EXE DES DS ERES DRE ER DES DES 0 85 0 89 5 2513 30 3 35 3 40 3 45 3 50 25 3 30 3 35 3 40 3 45 3 50 30 3 35 3 40 3 45 3 50 35 3 40 3 45 3 50 40 3 45 3 50 45 3 50 INSTALL THE SHIM THIS THICKNESS mm VALVE CLEARANCE 1 20 24 3 45 3 50 1 25 29 3 50 GS07120BW3 C Measure the clearance when engine is cold Check present shim size Match clearance in vertical column with present shim size in horizontal column Install the shim specified where the lines intersect This shim will give the proper clearance Example Present shim is 2 95 mm 5 Measured clearance is 0 47 mm Replace 2 95 mm shim with 3 15 mm shim Remeasure the valve clearance and readjust if necessary 2 26 PERIODIC Periodic Maintenance Procedures Be sure to remeasure the clearance after selecting a shim according to the table If the clearance is out of the specified range use the additional shim Olf there is no valve clearance use a shim that is a few sizes smaller and remeasure the valve clearance e When installing the shim face the marked side toward the valve lifter 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 th
78. 7 Outside Temperature Sensor L Apply a non permanent locking agent 16 6 ELECTRICAL SYSTEM Exploded View GP026118W5 C ELECTRICAL SYSTEM 16 7 Exploded View w No Fastener Nm j kgfm ftib intake Air Temperature Sensor Mounting Screw 12 012 nmo 2 Spark Plugs 9 8 1 0 87 3 Crankshaft Sensor Cover Bolts 12 1 2 106 in Ib 4 Water Temperature Sensor 12 1 2 106 in Ib 5 Timing Rotor Bolt 39 4 0 29 6 Crankshaft Sensor Bolts 5 9 0 60 52 in lb 7 Starter Motor Cable Terminal Nut 5 9 0 60 52 in Ib 8 Starter Motor Terminal Locknut 11 1 1 97 in Ib 9 Starter Motor Mounting Bolts 9 8 1 0 87 in lb 10 Alternator Rotor Bolt 155 15 8 114 11 Stator Coil Bolts 12 1 2 106 L 12 Starter Motor Through Bolts 5 0 0 51 44 in lb 13 Brush Holder Screw 3 8 0 39 34 in ib 14 Oil Pressure Switch 15 1 5 11 55 15 Oil Pressure Switch Terminal Bolt 2 0 0 20 18 16 Alternator Cover Bolts 12 1 2 106 in Ib 17 Alternator Lead Holding Plate Bolt 12 1 2 106 L 18 Immobilizer Model 19 Immobilizer Amplifier 20 Starter Relay 21 WVTA 78 2H and GB WVTA FULL H Models G Apply grease L Apply a non permanent locking agent M Apply molybdenum disulfide grease R Replacement Parts SS Apply silicone sealant WL Apply soap and water solution or rubber lubricant 16 8 ELECTRICAL SYSTEM Exploded View
79. Amplifier Olu GI 111111 uj 91585 121101 BR BK bi Vehicle Jn down Immobilizer Sensor Antenna Front Wheel Rotation Sensor Quom Meter Unit Front Right Ture siens EJ Eus IE Light 12V5w mai ui Joint ia Connector F BR W Joint Sonaeetor Joint Connector Outside Temperature od Sensor 12910 Meter Unit 1 Yellow Engine Warning Indicator Light LED 4 Yellow KIRG Warning Light LED Light LED Water Temperature Inmobilizer 0 11 Tachometer Clock Level Gauge Temperature Gauge Front Left Y 5 Light Headlight Low Y 12V55W Headlight R BK High Fuse 12 55 2 Yellow ABS Indicator Light LED Fuse 7 5 Yellow KIRG Indicator Light LED Indicator Light LED 5 Green Neutral Indicator 6 High Beam Indicator T Green Left Turn Signal Indicator Light LED 8 Green Right Turo Signal Indicator Light LED 9 Red Warning Indicator Battery Oil Pressure 12 0dometer Trip 3 4 Water Temperature Outside 15 Illumination Light LED MLED Light Emitting Diode Light LED Fuse Box 1 i Ignition Fuse 15 2 Headlight Relay Fuse 15
80. B e Tighten Torque Water Pump Impeller Bolt C 9 8 N m 1 0 kgf m 87 in Ib Be sure to install the dowel pins D e Connect the neutral switch connector E e Replace the O ring A with a new one and install it e Install the water pump cover A and clamp B e Tighten Torque Water Pump Cover Bolts C 11 N m 1 1 kgf m 97 in Ib e Install the new O rings A on the water pipe B e Insert the water pipes into the water pump cover 4 12 COOLING SYSTEM Water Pump e Apply a non parmanent locking agent to the threads of 1 the water pipe bolts A and tighten them Torque Water Pipe Bolts 12 N m 1 2 kgf m 106 in Ib e Connect the water hose B to the upper water pipe e Tighten Torque Water Hose Clamp Screw C 2 9 0 30 kgf m 26 in Ib Water Pump Inspection e Remove the left lower fairing see Lower Fairing Removal in the Frame chapter 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 mechanical seal unit Water Pump Impeller Disassembly Assembly e Remove the water pump impeller see Water Pump Re moval e The sealing seat and rubber seal may be removed easily by hand e Apply coolant around the surfaces of the rubber seal and sealing seat e Install the rubber seal A and sealing seat B i
81. Connecting Rod Removal e Split the crankcase see Crankcase Splitting e Remove the connecting rod big end nuts A e Remove the crankshaft NOTE OMark and record the locations of the connecting rods and their big end caps so that they can be reassembled in their original positions e Remove the connecting rods from the crankshaft Discard the connecting rod bolts To prevent dam age to the crankpin surfaces do not allow the con necting rod bolts to bump against the crankpins Connecting Rod Installation To minimize vibration the connecting rods should have the same weight mark Big End Cap A Connecting Rod B Weight Mark Alphabet C Diameter Mark D O or no mark 8105060181 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 CRANKSHAFT TRANSMISSION 9 17 Crankshaft Connecting Rods e Apply molybdenum disulfide oil solution A to the inner surfaces of upper and lower bearing inserts e Do not apply any grease or oil to the cap inside and cap insert outside B e Install the inserts so that their nails C 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
82. 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 20 0 32 mm 0 0079 0 0126 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 C 6105040381 CRANKSHAFT TRANSMISSION 9 19 Crankshaft Connecting Rods 2 Rotation Angle Method do not have a point micrometer you may tighten 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 NOTICE Immediately dry the bolts and nuts with com pressed air after cleaning Clean and dry the bolts and nuts completely e Inst
83. E with new ones e Apply grease to the O rings and install them e Install the hoses and tighten the clamps securely Torque Radiator Water Hose Clamp Screws 2 9 0 30 kgf m 26 in Ib e Fill the coolant see Coolant Change e Check the cooling system for leaks GS06068BW3 C PERIODIC MAINTENANCE 2 55 Periodic Maintenance Procedures 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 with a new one e Tighten Torque Engine Oil Drain Bolt 29 N m 3 0 kgf m 21 ft Ib e Pour in the specified type and amount of oil Recommended Engine Oil Type API SG SH SJ SL or SM with JASO MA MA1 or MA2 Viscosity SAE 10W 40 SAE 20W 40 SAE 100 50 Capacity 3 2 L 3 4 US qt when filter is not 3 8 L 4 0 US qt when filter is removed SAE 10W 30 4 0 L 4 2 US qt when engine is 20 10 0 10 20 30 406 completely dry 8509011881 C 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 for most conditions the oil viscosity may need to be changed to
84. Equipped Models ELECTRICAL SYSTEM 16 91 Not Verified OThe red warning indicator light LED and the immobilizer warning symbol A blink to display the collation error Immobilizer Amplifier Failure Registered Ignition Key Collation Error e Turn to OFF the ignition switch and remove the new igni tion key 1 OThe immobilizer warning symbol B disappears OThe red warning indicator light LED A then blinks for 15 seconds it means the ECU is in the registration mode OAfter 15 seconds the ECU ends the registration mode and stops blinking the red warning indicator light LED e Disconnect the antenna lead connector of the current ig nition switch and connect the antenna lead connector of the new ignition switch A e Insert the ignition key 1 B again into the new ignition switch and turn it to ON NOTE Olnsert and turn on the ignition key within 15 seconds that the ECU is in the registration mode OWhen a registration mode was ended do the registered ignition key verification procedure over again to restart it This applies to all ignition key registration OKeep other ignition keys away from the immobilizer an tenna hnnnnnnnni 0 3second hnnnnnn LIL LU GP300260S1 16 92 ELECTRICAL SYSTEM Immobilizer System Equipped Models Olf there is any problem in the registration the red warning indicator light LED
85. IX 5 Joint Connector D Frame Ground 2 Frame Ground 3 Engine Ground Battery 12 V 8 Ah Starter Relay Main Fuse 30 ECU Fuse 15 A Fuel Pump Relay Box Fuel Pump Relay ECU Main Relay Fuse Box 1 lgnition Fuse 15 A Joint Connector F lgnition Switch Engine Stop Switch FUEL SYSTEM DFI 3 109 Fuel Injectors 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 side cover see Side Cover 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 xIf 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 with the connectors in stalled see Throttle Body Assy Removal e Disconnect the injector connector e Co
86. L 50 mm 1 97 in C Torque Crank Case Bolts M7 20 N m 2 0 kgf m 15 ft Ib OLasty tighten the M6 bolts 68 mm 2 69 in D L 40 mm 1 57 in E Torque Crank Case Bolts M6 12 1 2 kgf m 106 in Ib 6104389851 C CRANKSHAFT TRANSMISSION 9 15 Crankcase Splitting e After tightening all crankcase bolts check the following items OWipe up the liquid gasket that seeps out around the crankcase mating surface OCrankshaft and transmission shafts turn freely OWhile spinning the output shaft gears shift smoothly from the 1st to 6th gear and 6th to 1st OWhen the output shaft stays still the gear can not be shifted to 2nd gear or other higher gear positions e Install the removed parts see appropriate chapters 9 16 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods Crankshaft Removal e Split the crankcase see Crankcase Splitting e Remove Balancer see Balancer Removal Crankshaft A Crankshaft Installation If the crankshaft bearing inserts or crankcase halves are replaced with new ones select the bear ing inserts and check clearance with a plastigage press gauge before assembling engine to be sure the correct bearing inserts are installed e Apply molybdenum disulfide oil solution to the crankshaft main bearing inserts e Install the crankshaft with the camshaft chain A hanging on it e Install the balancer see Balancer Installation
87. 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 other foreign materials entering into sealed areas during 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 i cident Visually inspect removed parts for corrosion discol IN oration or other damage Refer to the appropriate sections IN of this manual for service limits on individual parts Replace YS AN the parts if any damage has been found or if the part is be yond its service limit 68020098 Replace
88. Oil Passage Plugs 20 2 0 15 L 8 Passage Plug 9 8 1 0 87 9 Starter Motor Clutch Bolts 12 1 2 106 in Ib L 10 Crankcase Bolts M7 20 2 0 15 S 11 Crankcase Bolts M9 42 4 3 31 S MO 12 Crankcase Bolts M6 12 1 2 106 S 13 Crankcase Bolts M8 27 2 8 20 S 14 Do not apply any grease or oil EO Apply engine oil G Apply grease HG Apply high temperature 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 9 4 CRANKSHAFT TRANSMISSION Exploded View 61023688W5 C CRANKSHAFT TRANSMISSION 9 5 Exploded View Torque pe Famer ae em Gear Positioning Lever Bolt pu 106 2 Shift Drum Cam Bolt 1 2 106 L 3 Neutral Switch 15 1 5 11 4 Shift Shaft Return Spring Pin 39 4 0 29 L 5 Shift Pedal Mounting Bolt 25 2 5 18 EO Apply engine oil G Apply grease MO Apply molybdenum disulfide oil mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 L Apply a non permanent locking agent R Replacement Parts 9 6 CRANKSHAFT TRANSMISSION Specifications Item Standard Service Limit C
89. Vehicle down Sensor Input Voltage Output Voltage 1 100 x50 r min rpm Dual throttle valve 38 mm 1 42 in 40 7 1 3 kPa 305 10 mmHg 2 1 2 for reference DENSO Digital memory type with built in IC igniter sealed with resin 294 kPa 3 0 kgf cm 43 psi with engine idling In tank friction pump 50 mL 1 7 US oz or more for 3 seconds INP 289 Fine atomizing type with 8 holes About 11 7 12 3 O at 20 C 68 F 4 75 5 25 V DC 1 02 1 06 V at idle throttle opening DC 4 22 4 42 V atfull throttle opening for reference 4 6 DC 4 75 5 25 V DC 3 80 4 20 V at standard atmospheric pressure About DC 2 25 2 50 V at 20 C 68 F 5 4 6 6 at 0 C 32 F 0 29 0 39 kQ 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 V With sensor arrow mark pointed up DC 3 55 4 45 V Specifications FUEL SYSTEM DFI 3 19 Item Standard Subthrottle Sensor Input Voltage 4 75 5 25 V Output Voltage DC 1 08 1 12 V at subthrottle valve full close position DC 4 2 4 4 V at subthrottle valve full open position for reference Resistance 4 6kO Immobilizer Antenna Equipped Model Resistance About 3 0 4 6 O Subthrottle Valve Actuator Resistance About 5 2 7 8 Input Voltage About DC 11 5 13 5 V Oxygen Sensor Output Voltage Rich Output Voltage Lean Heat
90. 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 8 V repeat charging cycle OTo ensure maximum battery life and customer satisfac tion it is recommended the battery be load tested at three times its amp hour rating for 15 seconds Re check voltage and if less than 12 8 V repeat the charging cycle and load test If still below 12 8 V the battery is defective Precautions 1 No need of topping up No topping up is necessary in this battery until it ends its life under normal use Forcibly prying off the seal cap to add water is very dangerous Never do that 2 Refreshing charge If an engine will not start a horn sounds weak or lamps are dim it indicates the battery has been discharged Give refresh charge for 5 to 10 hours with charge current shown in the specification see Refreshing Charge When a fast charge is 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 ch
91. and the immobilizer warning symbol A blink 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 the immobilizer warning symbol A blink 3 times and stop for 1 second and then repeat this cycle e Turn to OFF the ignition switch and remove the ignition key 1 OThe immobilizer warning symbol B disappears OThe red warning indicator light LED A then blinks for 15 seconds OAfter 15 seconds the ECU ends the registration mode and stops blinking the red warning indicator light LED NOTE OThis procedure registered the registered ignition key and one ignition key If more keys registration is needed go to next procedures within the registration mode e Insert the ignition key 2 into the ignition switch and turn it to ON 0 ON OF F 3second UUU GP30026CS1 8 300270651 Immobilizer System Equipped Models ELECTRICAL SYSTEM 16 93 Olf there is any problem in the registration the red warning indicator light LED and the immobilizer warning symbol A blink to display the collation error Immobilizer Amplifier Failure When Registered Ignition Key is Inserted Ignition Key Collation Error e The ignition key
92. cables and hose correctly see Cable Wire and Hose Routing section in the Appendix chap ter Exploded Seals usd euis Seat Seat Installation oie de tetti RM IARE Lower Fairing Remowval Lower Fairing Installation Middle Fairing Removal Middle Fairing Installation Upper Fairing Removal Upper Fairing Installation Upper Side Fairing Removal Upper Side Fairing Installation Meter Cover Meter Cover Installation Windshield Removal Windshield Installation Upper Fairing Bracket Removal Upper Fairing Bracket Installation Side Side Cover Removal Side Cover Installation Seat COVersS Seat Cover Remowval Seat Cover Installation FRAME 15 1 Frame Table of Contents 15 2 15 8 15 8 15 8 15 9 15 9 15 9 15 9 15 13 15 14 oio ce i ee ede eee ua 15 16 Carrier Removal 15 16 Carrier Installation 15 16 Fenders s et e Een 15 17 Front Fender Remowval 15 17 Front Fender Installation 15 17 Flap
93. ciency e Remove Radiator Fan Mounting Bolts A Radiator Fan B Radiator and Radiator Fan Installation e Installation is the reverse of removal e Install the rubber dampers A and radiator bracket collars B as shown in the figure C Larger D Smaller 41 ANS P 2 68007104842 C 4 16 COOLING SYSTEM Radiator e Fit the slits on the heat insulation rubber plate A to the upper mounting brackets B and fan motor bracket C e Insert the upper right mounting bracket to the frame pro jection D e Make sure the throttle and clutch cables are routed cor rectly see Cable Wire and Hose Routing section in the Appendix chapter e Install the radiator upper bolt A e Connect the lower radiator hose B e Install the radiator lower bolt C and tighten the radiator upper and lower bolts securely e Tighten the lower radiator hose clamp screw D e Install the cap E on the radiator upper bolt e Connect the radiator fan motor lead connector e Install the removed parts see appropriate chapter Radiator Inspection e Check the radiator core x If there are obstructions to air flow remove them the corrugated fins A are deformed carefully straighten them x If the air passages of the radiator core are blocked more than 2096 by unremovable obstructions or irreparably de formed fins replace the radiator wi
94. 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 the right lower fairing see Lower Fairing Re moval in the Frame chapter e Support the fuel tank with a suitable bar see Fuel Tank Removal in the Fuel System DFI chapter e Pull up the connector bracket A e Disconnect the crankshaft sensor lead connector B e Clear the crankshaft sensor lead from the clamps A e Remove Crankshaft Sensor Cover Bolts B Crankshaft Sensor Cover C e Remove Crankshaft Sensor Bolts A Crankshaft Sensor B Crankshaft Sensor Installation e Tighten 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 GP108955 16 40 ELECTRICAL SYSTEM Ignition System e Apply silicone sealant to the circumference of the alterna tor lead grommet A and fit the grommet into the notch B of the lower crankcase securely Sealant Liquid Gasket TB1
95. e Tighten the fuel pump bolts C to a snug fit e Tighten the fuel pump bolts alternating diagonally Torque Fuel Pump Bolts 9 8 1 0 kgf m 87 in Ib e Tighten the pump bolts again to check the tightness 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 check the operating voltage see Fuel Pump Operating Voltage Inspection 3 106 FUEL SYSTEM Fuel Pump Fuel Pump Operating Voltage Inspection NOTE sure the battery is fully charged e Turn the ignition switch to OFF e Remove the front seat see Front Seat Removal in the Frame chapter e Disconnect the fuel pump lead connector and connect the measuring adapter A between these connectors as shown 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 R pump BK Y lead Digital Meter BK pump R W lead e Measure the operating voltage with engine stopped and with the connector joined e Turn the engine stop switch to run position e Turn the ignition switch to ON Operating Voltage
96. motorcycle held perpendicular Do not use the side stand x If the coolant level is lower than the L level line B un screw the reserve tank cap and add coolant to the F level line C L low full For refilling add the specified mixture of coolant and soft water Adding water alone dilutes the coolant and degrades its anticorrosion properties The diluted coolant can attack the aluminum en gine parts In an emergency soft water alone can be added But the diluted coolant must be returned to the correct mixture ratio within a few days If coolant must be added often or the reservoir tank has run completely dry there is probably leakage in the cooling system Check the system for leaks Coolant ruins painted surfaces Immediately wash away any coolant that spills on the frame engine wheels or other painted parts PERIODIC MAINTENANCE 2 21 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 deterioration Squeeze the hoses A hose should not be hard and brittle nor should it be soft or swollen Replace the hose if any fraying cracks B or bulges C are noticed 0506080851 C e Check that the hoses are securely connected and clamps are
97. necessary Cylinder compression Carbon accumulation on piston and in is higher than usable combustion chamber possibly due to range damaged valve stem oil seal and or damaged piston oil rings This may be indicated by white exhaust smoke Incorrect cylinder head gasket thickness Cylinder compression Gas leakage around cylinder head is lower than usable range Replace the gasket with a standard part Replace damaged check gasket and cylinder head warp Bad condition of valve seating Repair if necessary Incorrect valve clearance Adjust the valve clearance Incorrect piston cylinder clearance Replace the piston and or cylinder Piston seizure Inspect the cylinder and replace repair the cylinder and or piston as necessary Bad condition of piston ring and or piston ring grooves Replace the piston and or the piston rings 5 26 END Cylinder Head Cylinder Head Removal e Remove Coolant Drain see Coolant Change in the Periodic Maintenance chapter Camshafts see Camshaft Removal Throttle Body Assy see Throttle Body Assy Removal in the Fuel System DFI chapter Exhaust Pipe see Exhaust Pipe Removal e Disconnect the water temperature sensor connector A e Remove Tube B Water Hose C e Remove Timing Rotor see Timing Rotor Removal in the Electrical System chapter Front Camshaft Chain Guide Bolts A Front Camshaft Chain Guide
98. the Frame chapter Front Wheel see Front Wheel Removal in the Wheels Tires chapter e Loosen the upper front fork clamp bolt A and lower front fork clamp bolts B Olf fork leg C is to be disassembled loosen the upper front fork clamp bolt Then loosen the top plug D beforehand NOTE OLoosen the top plug after loosening the upper front fork clamp bolt OLoosen the lower front fork clamp bolts e With a twisting motion work the fork leg down and out Front Fork Installation e Install the fork so that the length A is 218 mm 8 58 in from the top end B of the outer tube to upper surface C of the lower front fork clamp 218 mm 8 58 in A e Tighten Torque Lower Front Fork Clamp Bolts 20 5 N m 2 09 kgf m 15 1 ft Ib Front Fork Top Plugs 22 5 Nm 2 29 kgf m 16 6 ft Ib Upper Front Fork Clamp Bolts 20 N m 2 0 kgf m 15 ft Ib NOTE OTighten the top plug before tightening the upper front fork clamp bolt OTighten the two clamp bolts lower alternately two times to ensure even tightening torque e Install the removed parts see appropriate chapters e Adjust Spring Preload see Spring Preload Adjustment Rebound Damping Force see Rebound Damping Force Adjustment Fork Oil Change e Remove the front fork see Front Fork Removal e Hold the inner tube lower end in a vice e Unscrew the top plug A out of the outer tube GM04730BS1 SUSPENSION 13 11 Front
99. 004 in Cylinder Head Cylinder Compression Cylinder Head Warp Usable Range 770 1 198 kPa 7 9 12 2 kgf cm 112 174 psi at 236 r min rpm 0 05 mm 0 002 in Valves Valve Clearance Exhaust Intake Exhaust Intake Valve Stem Bend Valve Stem Diameter Exhaust Intake Exhaust Intake Valve Valve Guide Exhaust Intake Width Exhaust Intake Outside Diameter Exhaust Intake Exhaust Intake Valve Head Thickness Valve Guide Inside Diameter Clearance Wobble Method Valve Seat Cutting Angle Valve Seating Surface Valve Spring Free Length 0 22 0 31 mm 0 0087 0 0122 in 0 15 0 24 mm 0 0059 0 0094 in 0 8 mm 0 031 in 0 5 mm 0 020 in TIR 0 01 mm 0 0004 in or less 4 455 4 470 mm 0 1754 0 1760 in 4 475 4 490 mm 0 1762 0 1768 in 4 500 4 512 mm 0 1772 0 1776 in 4 500 4 512 mm 0 1772 0 1776 in 0 09 0 16 mm 0 0035 0 0063 in 0 03 0 10 mm 0 0012 0 0039 in 32 45 60 0 8 1 2 mm 0 031 0 047 0 5 1 0 mm 0 020 0 039 in 24 7 24 9 mm 0 972 0 980 28 9 29 1 mm 1 138 1 146 in 35 9 mm 1 41 in 35 9 mm 1 41 in 0 6 mm 0 024 in 0 3 mm 0 012 in TIR 0 05 mm 0 002 in 4 44 mm 0 175 in 4 46 mm 0 176 in 4 58 mm 0 180 in 4 58 mm 0 180 in 0 36 mm 0 014 in 0 29 mm 0 011 in 34 7 mm 1 37 in 34 7 mm 1 37 in ENGINE END 5 9 S
100. 1 0 2 0 11 2 14 8 Steering Stem Warp Inspection 14 9 Stem Cap Deterioration Damage Inspection 14 9 PIANGIGD AR ERR ILE REOR DITE REUNIR 14 10 Handlebar Removal nie eet eee tte ever pe eee tu a 14 10 Handlebar Installation 2 14 11 14 2 STEERING Exploded View STEERING 14 3 Exploded View No Fastener Torque Nm kgfm fttb 1 Hendiebar Hoider Bos 28 18 2 Switch Housing Screws 35 035 Simb 3 Steering Stem Head Bok 106 4 Upper Front Fork Clamp Bats 29 20 1 5 Handlebar Holder Mounting nus 34 38 25 R 6 SerngSemNt _ s 8 AD Apply adhesive AL Tighten the two clamp bolts alternately two times to ensure even tightening torque G Apply grease R Replacement Parts L Apply a non permanent locking agent 14 4 STEERING Special Tools Head Pipe Outer Race Press Shaft 57001 1075 875710755 C Head Pipe Outer Race Driver 654 5 57001 1077 875710775 C Steering Stem Bearing Driver 42 5 57001 1344 Steering Stem Nut Wrench 57001 1100 o 875711005 C 7571344ST C Steering Stem Bearing Driver Adapter 541 5 57001 1345 875713455 C Head Pipe Outer Race Driver 555 57001 1446 875714465 C Steering STEERING 14 5
101. 1 system fails the signal is out of the usable range wiring short or open the ECU sets the DFI in the a N method 2 Intake Air Temperature Intake Air Temperature 47 178 C If the intake air temperature sensor system fails the signal is out of the usable range wiring short or open the ECU sets Ta at 40 C Temperature Sensor Intake Air Pressure Sensor 2 Water Temperature Tw 30 120 C Atmospheric Pressure Absolute Pa 100 900 mmHg If the water temperature sensor system fails the signal is out of the usable range wiring short or open the ECU sets Tw at 80 C and radiator fan operates If the intake air pressure sensor 2 system fails the signal is out of the usable range wiring short or open the ECU sets Pa at 760 mmHg the standard atmospheric pressure Crankshaft Sensor Rear Wheel Rotation Sensor Crankshaft sensor must send 22 signals to the ECU at the 1 cranking Rear wheel rotation sensor must send 45 signals to the ECU at the 1 rotation of the wheel If the crankshaft sensor generates less than 22 or more signals the engine stops by itself If the rear wheel rotation sensor system fails the signal is missing wiring open the ECU stops the KTRC control Front Wheel Rotation Sensor Signal Vehicle down Sensor Front wheel rotation sensor must send 48 signals to the ECU at the 1 rotation of the wheel Output Voltage 0
102. 10 4 84 V If the front wheel rotation sensor system fails the signal is missing wiring open the ECU stops the KTRC control If the vehicle down sensor system has failures the output voltage is out of the usable range wiring short or open the ECU shuts off the fuel pump relay the fuel injectors and the ignition system Subthrottle Sensor Output Voltage 0 15 4 85 V If the subthrottle sensor system fails the output voltage is out of the usable range wiring short or open the ECU drive the subthrottle valve to the full closed position and it stops the current to the subthrottle valve actuator Oxygen Sensor 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 3 42 FUEL SYSTEM DFI Self Diagnosis Service Output Signal Usable Codes parte Range or Criteria Backups Dy EGU Immobilizer 35 Amplifier _ If the immobilizer system fails no signal wiring Equipped short or open the vehicle is no start and run Model 36 ads The ignition key must use If the blank key or broken key is used the Model register key vehicle is no start and run The ECU send the data 39 ECU for service code and key registration to the meter unit The ECU sends If the stick coil 1 primary winding has failures 51 Stick Coil 1 signals output v
103. 10 km h 6 2 mph or above for one minute or more Check the battery voltage Check the power source wiring and meter unit When the motorcycle is running does the yellow ABS indicator light LED go off Count the number of times the yellow ABS indicator ASk the rider if th bl light LED blinks in the self diagnosis mode to find happens again the service code GL14621B F Self diagnosis Outline When the indicator light has blinked or come on the ABS hydraulic unit memorizes and stores the service code 19 codes including Normal Code for the service person to troubleshoot easily The service code memory is powered directly by the battery and cannot be canceled by the ignition switch The ABS hydraulic unit can memorize up to all service codes 19 codes Further service codes are memorized after erasing the preceding all service codes 19 codes If there is no fault only the start code 12 is shown indicating that The ABS is normal Self diagnosis Procedures OWhen a problem occurs with the ABS system the yellow ABS indicator light LED A lights NOTE OUse a fully charged battery when conducting self diagnosis Otherwise the light blinks very slowly or doesn t blink OThe motorcycle is stopped OKeep the self diagnosis terminal grounded during self 8L14580B81 0 diagnosis with an auxiliary lead 12 38 5 Anti Lock System e Remove the seat see Seat
104. 2 is successfully registered in the ECU OThe red warning indicator light LED and the immobilizer warning symbol A blink 4 times and stop for 1 second and then repeat this cycle OThis procedure has registered the registered ignition key and 2 ignition keys e Turn to OFF the ignition switch and wait for period of more than 15 seconds e The registration mode automatically ends e The red warning indicator light LED A goes off hnnnnnnnni us i N m 8 30024651 0 3second poge FU 6230026651 C 0 30 30 30 3 0 30 30 3 15 LU UL GP30029CS1 GP30030CS1 16 94 ELECTRICAL SYSTEM Immobilizer System Equipped Models e Remove the key registration unit key registration adapter and install the immobilizer Kawasaki diagnostic system connector cap NOTE OTurn 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 ECU is faulty and has to be replaced e Prepare a new ECU A and current ignition key s B NOTE OThe 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 e Replace EC
105. 28 C G lead ECU terminal 49 D xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see Removal Installation GC17127FS1 FUEL SYSTEM DFI 3 75 Subthrottle Sensor Service Code 32 Subthrottle Sensor Resistance Inspection e Turn the ignition switch to OFF e Remove the right side cover see Side Cover Removal in the Frame chapter e Disconnect the subthrottle sensor connector ODisconnect the subthrottle sensor connector and connect the throttle sensor setting adapter A to the sensor con nector only Special Tool Throttle Sensor Setting Adapter 57001 1538 Subthrottle Sensor Output Resistance Connections to Adapter Digital Meter W sensor BL lead Digital Meter BK sensor lead Standard 4 6 xIf the reading is out of the standard replace the throttle body assy x If the reading is within the standard but the problem still exists replace the ECU see ECU Removal Installation Subthrottle Sensor Circuit 6617087212 C 1 ECU 2 Subthrottle Sensor 3 76 FUEL SYSTEM DFI Oxygen Sensor not activated Service Code 33 Oxygen Sensor Removal Installation e Refer to the Oxygen Sensor Removal Installation in the Electrical System chapter Oxygen Sensor Inspection e Warm up the engine
106. 2xx az BL vow g BL W 8L Ge WR W L BL R Immobilizer Kawasaki Sensor 5 252526 22555 ABS Self ABS Kawasaki Diagnosis Self Terminal Diagnosis System Connector Regulator Rectifier Diagnostic System Connector Frame 9 Frame Frame Ground Ground 55 2 Starter Notor BK Y BK Y 2o ax Alternator Starter Relay 1 ECU Fuse 15 2 Main Fuse 304 Fan Fuse 15 Meter Fuse 7 5 Accessory Fuse 5A ABS Motor Relay Fuse 254 ABS Solenoid Valve Relay Fuse 15 TGNITION SWITCH CONNECTIONS Batterylsnitio Signal OFF Loch BR BL Rear Brake Light Switch BK Y BK Y BK Y BK Y BK Y BK Y por Joint Connector B RIGHT SWITCH HOUSING CONNECTIONS Front Brake Light Switch Engine Stop_Switeh Starter Button Color Y R R olor Joint Connector F EGU Joint Connector D Rear Wheel Rotation Sensor Rear Right Turn Signa Light 12V10W License Plate Light 12V5W Rear Left Turn Signal Light 12V10W Color Code BK Black BL Blue BR Brown Green ey Gray LB Light Blue LG Light Green Orange P Pink PU Purple R Red v
107. 3 Light Horn Fuse 7 4 Torn Signal Relay Accessory Connectors CD ww DC 120 LS S 000 90 9 Accessory Left Switch Housing Relay Box Relay Left Switch Housing Relay Box i Horn Button S Dimmer Switch 1 Radiat 3 ECU Wain Rel 2 Hazard Button B Starter Lockout Fan Relay 4 Fual Pump Relay 3 Turn Signal Switeh Switch 2 Headlight Girevit 5 Starter Girouit SEL Button Upper and Lower Button 4 Passing Button Relay Relay c LEFT SWITCH HOUSING CONNECTIONS Horn Button Hazard Button Turn Signal Switch Passing Burton 0 mmer Sw re chy Starter Os ich M Lever Push Released Released R Lo Pulled In Lower W2L0687CW5 C ELECTRICAL SYSTEM 16 17 Wiring Diagram BR Model Crank shaft Sansor Fuel Injectors si 2 3 4 ya ey BL BK WR BL R WR BL 0 WR wR Sub Oxygen Intake peek Main Sub lotake Air Air Throttle throttle Pressure Pressure etuator Sensor Sensor Sensor 2 Sensor 1 Nevers Water Switch Pressure Sidestand Sensor Temperature 2 Switch Switch Sensor y oFF Hl 28 5 det as BK Y BK Y BK Y Joint Ed Connector E BK BL ECU v a R BLAY w 8k BR N BR Y
108. 4 0 kgf cm 57 psi GJ05041BS1 6J05030781 6J05044BS1 C 10 14 WHEELS TIRES Tires e Check to see that the rim lines A on both sides of the tire sidewalls are parallel with the rim flanges x If the rim flanges and tire sidewall rim lines are not parallel remove the valve core e Lubricate the rim flanges and tire beads e Install the valve core and inflate the tire again e After the tire beads seat in the rim flanges check for air leakage Olnflate the tire slightly above standard inflation OUse a soap and water solution or submerge the tire and check for bubbles that would indicate leakage e Adjust the air pressure to the specified pressure see Air Pressure Inspection in the Periodic Maintenance chap ter e Install the air valve cap e Adjust the wheel balance see Balance Adjustment Tire Repair Currently two types of repair for tubeless tires have come into wide use One type is called a temporary external re pair which can be carried out without removing the tire from the rim and the other type is called permanent internal repair which requires tire removal It is generally under stood that higher running durability is obtained by perma nent internal repairs than by temporary external ones Also permanent internal repairs have the advantage of permitting a thorough examination for secondary damage not visible from external inspection of the tire For these r
109. 53 Stick coil 3 malfunction wiring open or short 54 FI KTRC Stick coil 4 malfunction wiring open or short 56 FI Radiator fan relay malfunction wiring open or short 62 FI KTRC Subthrottle valve actuator malfunction wiring open or short 64 FI Air switching valve malfunction wiring open or short 67 FI Oxygen sensor heater malfunction wiring open or short 94 Fl Oxygen sensor malfunction wiring open or short Notes OThe ECU may be involved in these problems If all the parts and circuits checked out good be sure to check the ECU for ground and power supply If the ground and power supply are checked good replace the ECU OWhen no service code is displayed the electrical parts of the DFI system has no fault and the mechanical parts of the DFI system and the engine are suspect Self Diagnosis FUEL SYSTEM DFI 3 41 Backups OThe ECU takes the following measures to prevent engine damage when the DFI ignition or immo bilizer system parts have troubles Output Signal Usable Range or Criteria Main Throttle Output Voltage Sensor Backups by ECU If the main throttle sensor system fails the output voltage is out of the usable range wiring short or open the ECU locks ignition timing into the ignition timing at closed throttle position and sets the DFI in the D J method 1 Intake Air Pressure Sensor 1 Intake Air Pressure Absolute Pv 100 900 mmHg If the intake air pressure sensor
110. 57 Headlight Cover Installation 16 57 Headlight Removal Installation 16 58 Tail Brake Light LED Removal 16 58 Tail Brake Light LED Installation 16 58 License Plate Light Bulb Replacement 16 58 Turn Signal Light Bulb Replacement 16 61 Turn Signal Relay Inspection 16 61 Air Switching Valve 16 64 Air Switching Valve Operation UC Air Switching Valve Unit Test Radiator Fan System Fan Motor Inspection Meter Gauge Indicator Unit Meter Unit Removal Installation Meter Unit Disassembly Meter Operation Inspection Meter System Inspection Meter Unit Inspection Fuel Level Sensor Line Self Diagnosis Mode 16 82 Immobilizer System Models one 16 84 Operational Cautions 16 84 Key Registration 16 84 Immobilizer System Parts Replacement 16 102 Immobilizer System Inspection 16 104 Switches and Sensors 16 106 Brake Light Timing Inspection 16 106 Brake Light Timing Adjustment 16 106 16 2 ELECTRICAL SYSTEM Switch Inspection Water Temperature Sensor
111. A 12 1 2 kgf m 106 in Ib GE14153BS1 C e Tighten the upper adjusting collar A Torque Upper Adjusting Collar 9 8 N m 1 0 kgf m 87 in Ib e Tighten the right and left upper engine mounting bolts B C Torque Upper Engine Mounting Bolt 44 N m 4 5 kgf m 32 ft lb e Tighten the upper adjusting collar locknut D Torque Upper Adjusting Collar Locknut 49 Nm 5 0 kgf m 36 ft Ib Special Tool Engine Mount Nut Wrench E 57001 1450 e Install the right and left engine brackets see Engine In stallation in the Engine Removal Installation chapter 5 28 END Cylinder Head e Install Front Camshaft Chain Guide A Rear Camshaft Chain Guide B New O rings C Collar D OApply grease to the new O ring e Tighten Torque Front Camshaft Chain Guide Bolt Upper E 25 2 5 18 ft Ib Front Camshaft Chain Guide Bolt Lower F 12 1 2 kgf m 106 in Ib Rear Camshaft Chain Guide Bolt G 25 N m 2 5 kgf m 18 ft lb e Install the removed parts see appropriate chapters Cylinder Head Warp Inspection e Clean the cylinder head Lay a straightedge across the lower surface of the cylinder head at several positions e Use a thickness gauge A to measure the space between the straightedge B and the head Cylinder Head Warp Standard Limit 0 05 mm 0 002 x If the cylinder head is warped more than the service limit
112. A so that the OUTSIDE mark B faces outward e Replace the clutch hub nut with a new one e Holding the clutch hub tighten the clutch hub nut Special Tool Clutch Holder 57001 1243 Torque Clutch Hub Nut 135 N m 13 8 kgf m 100 ft Ib e Install the spring seat A and spring B as shown in the figure Clutch Hub C B GF06144BS1 6 12 CLUTCH e Install the friction plates and steel plates starting with a friction plate and alternating them NOTE Olnstall the both ends marked two friction plates at dis assembled to the their original position OWhen replace the friction plates with new ones mark the both ends two friction plates so that the two kinds of friction plates do not mix up at opening the package NOTICE If new dry friction plates and steel plates are in stalled apply engine oil to the surfaces of each plate to avoid clutch plate seizure Olnstall the last friction plate A fitting the tangs in the grooves in the housing as shown in the figure e Apply molybdenum disulfide grease to the pusher shaft A e Apply engine oil to the needle bearing B e Install the pusher C needle bearing and washer D in the clutch spring plate E GF06203BS1 e Install the clutch spring plate so that there are no gap A f it has gap B turn the clutch spring plate to install it again C Correct D Wrong e Install Clut
113. Air Cleaner Housing Installatiom nnne 3 121 UNI cr 3 122 Fuel Tank 3 122 Fuel Tank Installation i tere te e i e ee ep pe e eg eins 3 124 Fuel Tank and Cap 3 126 Fuel Tank Cleaning 3 126 3 4 FUEL SYSTEM Exploded View 6002540BW5 C FUEL SYSTEM DFI 3 5 Exploded View mE kgfm fttb Switch Housing Screws 5 0 36 31 in Ib 2 Upper Air Cleaner Housing Screws 10 in Ib 3 Body Assy Holder Clamp Bolts 26 in Ib 4 Throttle Body Assy Holder Bolts 106 in Ib 5 Cleaner Duct Clamp Bolts 2 0 0 20 18 in Ib 6 Delivery Pipe Assy Mounting Screws 3 4 0 35 30 in Ib 7 Throttle Cable Accelerator 8 Throttle Cable Decelerator 9 Air Cleaner Element 10 Intake Air Pressure Sensor 2 11 Intake Air Pressure Sensor 1 12 Fuel Injectors Air Switching Valve Apply cable lubricant Apply engine oil Apply grease Apply a non permanent locking agent Replacement Parts 3 6 FUEL SYSTEM Exploded View FUEL SYSTEM 3 7 Exploded View 2 Bolts 0 60 a in Ib 3 Intake Air Temperature Sensor Mounting 12 0 42 11 in lb Screw 12 1 2 106 in Ib 4 Water Temperature Sensor 5 Crankshaft Sensor 6 Intake Air Temperature Sensor 7 Stick Coils 8 Rear Wheel Ro
114. Air Pressure Sensor 2 Service Code 16 3 59 Intake Air Pressure Sensor 2 emen 3 59 Intake Air Pressure Sensor 2 Installation 3 59 Intake Air Pressure Sensor 2 Input Voltage 3 60 Intake Air Pressure Sensor 2 Output Voltage 3 61 Crankshaft Sensor Service Code 21 22 1 1111 3 63 Crankshaft Sensor Removallnstallatigon 9 3 63 Crankshaft Sensor Resistance Inspection 3 63 Crankshaft Sensor Peak Voltage Inspectionm pp 3 63 Rear Wheel Rotation Sensor Signal Service Code 24 3 64 Rear Wheel Rotation Sensor Signal 3 64 Front Wheel Rotation Sensor Signal Service Code 27 ssseeeeseseessereerrrrssssrrrrerrressserereee 3 66 Front Wheel Rotation Sensor Signal 3 66 Vehicle down Sensor Service Code 31 eene nnne 3 68 Vehicle down Sensor Removal cesses e e eee men ren rene ene ese ese sre 3 68 3 2 FUEL SYSTEM DFI Vehicle down Sensor Installation pp 3 68 Vehicle down Sensor Input Voltage renren een 3 69 Vehicle down Sensor Output Voltage
115. B Rear Camshaft Chain Guide Bolt C Rear Camshaft Chain Guide D Upper Engine Brackets Both Sides E see Engine Re moval in the Engine Removal Installation chapter e Loosen Upper Engine Mounting Bolts Left A e Remove Upper Engine Mounting Bolts Right B e Loosen Upper Adjusting Collar Locknut C Special Tool Engine Mount Nut Wrench D 57001 1450 e Loosen Upper Adjusting Collar E e Remove the M6 cylinder head bolts A e Loosen the M10 cylinder head bolts as shown sequence 1 10 in the figure and remove them with washers e Remove the cylinder head GE14151BS1 C 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 END 5 27 Cylinder Head e Replace the cylinder head gasket A with new one e Install the dowel pins B and cylinder head gasket e Replace the cylinder head bolt washers A with new ones e Apply molybdenum disulfide oil solution to both sides B of the cylinder head bolt washers and threads C of the bolts e Tighten the M10 cylinder head bolts following the tighten ing sequence 1 10 Torque Cylinder Head Bolts M10 First 20 2 0 kgf m 15 ft Ib Final 54 5 5 kgf m 40 ft Ib e Tighten Torque Cylinder Head Bolts M6
116. Balance Weight Installation e Check if the weight portion has any play on the blade A and clip B x lf it does discard it A WARNING Unbalanced wheels can create an unsafe riding condition If the balance weight has any play on the rib of the rim the blade and or clip have been stretched Replace the loose balance weight Do not reuse used balance weight Balance Weight Part Number Weight 41075 0007 10 g 0 35 oz 41075 0008 20 0 71 oz 41075 0009 30 g 1 06 oz NOTE OBalance weights are available from Kawasaki dealers in 10 20 and 30 grams 0 35 0 71 and 1 06 oz sizes An imbalance of less than 10 grams 0 35 oz will not usually affect running stability ODo not use four or more balance weight more than 90 gram 3 2 oz If the wheel requires an excess balance weight disassemble the wheel to find the cause e Slip the balance weight A onto the rib B by pushing or lightly hammering C the clip D Left Side E Right Side F e Be sure to install the balance weight OCheck that the blade A and clip B are fully seated on the rim C and that the clip is hooked over the rib D Left Side E Right Side F 6J04088BS1 C 6J04074BS1 C 6J04088BS1 C 10 12 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 Wh
117. Bolts 8 mm E 27 2 8 kgf m 20 ft Ib e Tighten the stay mount bolt F e Install Left Lower Fairing Stay A Right Lower Fairing Stay B e Install the engine ground cable terminal vertically and tighten the bolt A Torque Engine Ground Cable Terminal Bolt 9 8 1 0 kgf m 87 in Ib e Install the engine sprocket B see Engine Sprocket In stallation in the Final Drive chapter e Run the leads cables and hoses correctly see Cable Wire and Hose Routing section in the Appendix chapter e Install the removed parts see appropriate chapters e Adjust Throttle Cables see Throttle Control System Inspection in the Periodic Maintenance chapter Clutch Cable see Clutch Operation Inspection in the Pe riodic Maintenance chapter Drive Chain see Drive Chain Slack Inspection in the Periodic Maintenance chapter 8 10 ENGINE REMOVAL INSTALLATION Engine Removal Installation e Fill the engine with engine oil see Engine Oil Change in the Periodic Maintenance chapter e Fill the engine with coolant see Coolant Change in the Periodic Maintenance chapter Crankshaft Transmission Table of Contents Exploded Specifications Special Tools and Sealants Crankcase Splitting Crankcase Splitting Crankcase Assembly Cranksha
118. Box Removal in the Electrical System chapter ECU Main Relay Inspection e Refer to the Relay Circuit Inspection in the Electrical Sys tem chapter Fuel Line FUEL SYSTEM DFI 3 101 Fuel Pressure Inspection NOTE OBe sure the battery is fully charged e Remove Fuel Hose see Fuel Hose Replacement in the Periodic Maintenance chapter e Support the fuel tank with a suitable bar see Fuel Tank Removal 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 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 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 Connect the pressure gauge C to the fuel pressure gauge adapter Special Tools Oil Pressure Gauge 5 kgf cm 57001 125 Fuel Pressure Gauge Adapter 57001 1593 Fuel Hose 57001 1607 A WARNING Fuel is extremely flammable and can be explosive under certain conditions resulting in serious injury or death Do not try to s
119. Cover Removal e Remove Left Side Cover see Side Cover Removal in the Frame chapter Left Lower Fairing see Lower Fairing Removal in the Frame chapter e Disconnect the alternator lead connector A e Place a suitable container under the alternator cover A e Loosen the water hose clamp B and move it upward to clear the alternator lead if necessary ODo not remove the water hose e Remove Alternator Cover Bolts C Alternator Cover Alternator Cover Installation 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 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 B are in place on the crankcase e Install a new gasket and the alternator cover e Tighten Torque Alternator Cover Bolts 12 1 2 106 in Ib e Run the alternator lead correctly see Cable Wire and Hose Routing section in the Appendix chapter e Confirm that the drain hose and clamp are installed se curely and run the hose correctly see Cable Wire and Hose Routing section in the Appendix chapter System ELECTRICAL SYSTEM 16 31 Stator Coil Removal e Remove Alternator Cover see Alternator Cover Removal Holding Plate Bolt A and Plate Alternator Lead Gro
120. D and middle en gine mounting nut E Torque Lower Engine Mounting Nut 44 N m 4 5 kgf m 32 ft lb Middle Engine Mounting Nut 44 N m 4 5 kgf m 32 ft lb Remove the right upper engine mounting bolt L 65 A e Tighten the upper adjusting collar B Torque Upper Adjusting Collar 9 8 N m 1 0 kgf m 87 ft lb OBe careful not to overtighten the adjusting collar e Tighten the upper adjusting collar locknut C Torque Upper Adjusting Collar Locknut 49 N m 5 0 kgf m 36 ft Ib Special Tool Engine Mount Nut Wrench D 57001 1450 Tighten the right upper engine mounting bolt L 65 Torque Right Upper Engine Mounting Bolt 44 N m 4 5 kgf m 32 ft lb REMOVAL INSTALLATION 8 9 Engine Removal Installation e Install the left engine bracket A and tighten the mounting bolts evenly Torque Upper Engine Bracket Bolts 10 mm B 59 6 0 kgf m 44 ft Ib Lower Engine Bracket Bolts C 59 N m 6 0 kgf m 44 ft lb Rear Engine Bracket Bolts D 59 N m 6 0 kgf m 44 ft lb Upper Engine Bracket Bolts 8 mm E 27 2 8 kgf m 20 ft lb e Tighten the stay mount bolt F e Install the right engine bracket A and tighten the mount ing bolts evenly Torque Upper Engine Bracket Bolts 10 mm B 59 N m 6 0 kgf m 44 ft lb Lower Engine Bracket Bolts C 59 N m 6 0 kgf m 44 ft lb Rear Engine Bracket Bolts D 59 6 0 kgf m 44 ft lb Upper Engine Bracket
121. Ignition tere 1 1 Switch 0 6s 0 3 0 930 35 0 6 0 35 ON 0 9s 0 9s How to Erase Service Codes OEven if the ignition switch is turned to 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 68114584842 C 12 42 BRAKES Anti Lock System Service Code Table Service Light Code Yellow ABS Indicator Light LED Problems State After 12 ee Start code not fault starts turn off Rear inlet solenoid valve trouble shorted L J LUUL or open stuck valve ON Rear outlet solenoid valve trouble shorted 14 ON or open stuck valve Front inlet solenoid valve trouble shorted 17 ON or open stuck valve Front outlet solenoid valve trouble shorted 18 ON or open stuck valve ABS solenoid valve relay trouble wiring 19 ON shorted or open stuck relay Front rear tire abnormal substandard 25 tire deformation wheel sensor rotor teeth ON number wrong ABS motor relay trouble wiring shorted 35 J UU LIU ON open or lock stuck relay Front wheel rotation sensor signal abnormal sensor or rotor missing too 42 ON large clearance rotor tooth worn or missing Front wheel rotation sensor wiring 43 a ON abnormal wiring shorted or open Rear wheel rotation sensor signal
122. Immo bilizer Warning Indicator Light Blinking Mode x If the meter function does not work replace the meter unit Check 3 4 Green Left Turn Signal Indicator Light LED Inspection Connect the leads in the same circuit as Check 3 1 Connect the terminal 8 to the battery terminal GP17846CS1 GP17918CS1 GP17847C81 Meter Gauge Indicator Unit ELECTRICAL SYSTEM 16 77 e Check that the green left turn signal indicator light LED A goes on x If the green left turn signal indicator light LED does not go on replace the meter unit Check 3 5 Blue High Beam Indicator Light LED In spection e Connect the leads in the same circuit as Check 3 1 e Connect the terminal 3 to the battery terminal e Check that the blue high beam indicator light LED A goes on x If the blue high beam indicator light LED does not go on replace the meter unit Check 3 6 Green Right Turn Signal Indicator Light LED Inspection e Connect the leads in the same circuit as Check 3 1 e Connect the terminal 4 to the battery terminal e Check that the green right turn signal indicator light LED A goes on x If the green right turn signal indicator light LED does not go on replace the meter unit GP17848CS1 QOD xx WU lt n D ps 8 17850051 8 17852051 16 78 ELECTRICAL SYS
123. Input Voltage Standard Battery Voltage FUEL SYSTEM DFI 3 83 Stick Coils 1 2 3 4 Service Code 51 52 53 54 e Turn the ignition switch to OFF If the input voltage is out of the standard check the wiring for continuity see Stick Coil Circuit xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection the input voltage is within the standard check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation Stick Coil Circuit Joint Connector D Frame Ground 2 Engine Ground Battery 12 V 8 Ah Starter Relay Main Fuse 30 Fuse Box 1 Ignition Fuse 15 A Joint Connector F Ignition Switch Engine Stop Switch Stick Coils GCci7091FW2 C 3 84 FUEL SYSTEM DFI Radiator Fan Relay Service Code 56 Radiator Fan Relay Removal Installation OThe radiator fan relay is built in the relay box A e Refer to the Relay Box Removal in the Electrical System chapter Radiator Fan 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 see Radiator Fan Relay Circuit xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection
124. KTRC Warning Red Warning Indicator Light LED INSPECTION P 3 95 EQUI Sta cU 3 96 Id ntifiCatiOri rre rat beoe rin Ee 3 96 Removal ie etre ied 3 96 ECU InstallatiOPi airo e T O 3 97 ECU Power Supply 3 97 Tc 3 100 ECU Fuse Removal br eor N d d ee Er des 3 100 EGU Euse InstallatiOn te ett emt ua eua 3 100 Fuse Inspection re 3 100 ECU Main Relay Removal Installation pp 3 100 EGU Main Relay Inspection 4 3 100 EE 3 101 Fuel Pressure Inspection 3 101 Fuel Flow Rate Inspection 3 102 FUEL SYSTEM DFI 3 3 HI D IIT 3 104 etie tre Ig e a ne eg e Pe adea 3 104 Fuel Pump Installation P tt e t a Or n PP ge ets 3 105 Fuel Pump Operation 3 105 Fuel Pump Operating Voltage Inspection 0 3 106 Pressure Regulator Removal rd I Usa tev p fe dac det 3 106 Pump Screen Fuel Filter Cleaning pp 3 107 Fuel Pump Relay Removal Installation pp 3 107 Fuel Pump Relay
125. Locknut 13 Rear Caliper Pin Bolt 20 Si Rear Brake Pad Pin Plug 22 in lb Rear Brake Pad Pin 13 Rear Caliper Mounting Bolt 16 Rear Brake Disc Mounting Bolts 20 L Suspension Upper Front Fork Clamp Bolts 20 2 0 15 Lower Front Fork Clamp Bolts 20 5 2 09 15 1 AL Front Fork Top Plugs 22 5 2 29 16 6 Piston Rod Nuts 15 1 5 11 Cylinder Units 60 6 1 44 AD Front Axle Clump Bolt 20 2 0 15 Rear Shock Absorber Bolt Upper 34 3 5 25 Swingarm Pivot Adjusting Collar Locknut 98 10 72 Swingarm Pivot Shaft 20 2 0 15 Swingarm Pivot Shaft Nut 108 11 0 79 7 Swingarm Pivot Adjusting Collar 20 2 0 15 Tie rod Nuts 34 3 5 25 R Rear Shock Absorber Nut Lower 34 3 5 25 R Rocker Arm Nut 34 3 5 25 R Steering Handlebar Holder Bolts 25 2 5 18 Switch Housing Screws 3 5 0 36 31 Steering Stem Head Bolt 108 11 0 79 7 Upper Front Fork Clamp Bolts 20 2 0 15 Handlebar Holder Mounting Nuts 34 3 5 25 R Steering Stem Nut 25 2 5 18 Lower Front Fork Clamp Bolts 20 5 2 09 15 1 AL Frame Front Fender Mounting Bolts 3 9 0 40 35 in Ib Rear Frame Bolts 44 4 5 32 Front Footpeg Bracket Bolts 25 2 5 18 Sidestand Bracket Bolts 49 5 0 36 L Sidestand Nut 44 4 5 32 R S 2 10 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Sidestand Bolt Sidestand Switch Bolt Carrier Bracket Bolts Carrier Mounting Bolts Rear Frame Guard Bolts Rear Footpeg Bracket Bolts Lower Rear Footpeg Bracket Nuts Electrical System Switch Housing
126. Mounting Bolt 25 Muffler Body Clamp Bolt 15 Muffler Body End Cover Bolts 87 in lb Premuffler Chamber Guard Bolts 87 in lb Clutch Clutch Lever Assembly Clamp Bolts 69 in Ib S Clutch Cover Bolts 87 in lb Oil Filler Plug Hand tighten Clutch Spring Bolts 80 in Ib Clutch Hub Nut 100 R Engine Lubrication System Oil Filler Plug Hand tighten Oil Cooler Bolts 106 in Ib Oil Plugs 15 L Radiator Water Hose Clamp Screws 27 in lb Oil Pressure Switch 11 SS Oil Pressure Switch Terminal Bolt 18 in Ib Oil Pressure Relief Valve 11 L Filter 13 G R Filter Pipe 18 L Oil Pan Bolts 106 in Ib Engine Oil Drain Bolt 21 Lower Fairing Bracket Bolts 106 in Ib Engine Removal Installation Upper Engine Bracket Bolts M10 44 S Upper Engine Bracket Bolt M8 20 5 Lower Bracket Bolts 44 5 Upper Adjusting Collar 87 in lb 5 Upper Mounting Bolt L 65 32 S Upper Adjusting Collar Locknut 36 5 Upper Engine Mounting Bolt L 54 32 Bracket Bolts 44 5 Middle Bracket Bolts 18 L S 2 8 PERIODIC Torque and Locking Agent Fastener Remarks Middle Engine Mounting Nut 32 Lower Mounting Nut 32 Lower Adjusting Collar Locknut 36 Lower Adjusting Collar 87 in lb Crankshaft Transmission Balancer Shaft Clamp Bolt 9 8 87 in Ib Balancer Shaft Lever Bolt 25 18 Breather
127. OHolding the outer tube A by hand pull the inner tube B several times to pull out the outer tube Remove the inner tube guide bushing A outer tube guide bushing B washer C oil seal D from the inner tube e Hold the inner tube lower end in a vice e Using the fork cylinder holder A loosen the cylinder unit Special Tool Fork Cylinder Holder 57001 1443 e Take the cylinder unit A out of the inner tube B ODo not disassemble the cylinder unit and inner tube 13 22 SUSPENSION Front Front Fork Assembly e Using a high flash point solvent clean off any oil or dirt that may be on the adhesive coating area Dry them with a clean cloth e Apply adhesive ThreeBond 1344 or equivalent to the threads of the cylinder unit A e Install the cylinder unit into the inner tube e Tighten the cylinder unit with the specified torque using the fork cylinder holder A and a suitable bar B Special Tool Fork Cylinder Holder 57001 1443 Torque Cylinder Unit 60 N m 6 1 kgf m 44 ft Ib OTo tighten the cylinder unit with the specified torque pull the bar with 200 N 20 4 kgf 45 0 Ibf C force at the point of 300 mm 11 8 in D from the center E of the fork cylinder holder in the direction as shown e Replace the following parts with new one Oil Seal A Outer Tube Guide Bushing B Inner Tube Guide Bushing C Dust Seal D Retaining Ring E e Install the following parts o
128. Over Voltage Service Code 53 12 49 ABS Solenoid Valve Relay Supply Voltage Inspection Low Voltage Service Code 54 12 49 ECU Inspection Service Code 55 12 49 Output Fluid Pressure Sensor Front Brake Wiring Inspection Service Code 83 12 50 Output Fluid Pressure Sensor Front Brake Offset Abnormal Service Code 84 12 50 Fluid Pressure Sensor Supply Voltage Inspection Service Code 89 12 50 ABS Hydraulic Unit Removal oae ettet ente eter tine 12 50 ABS Hydraulic Unit IristallatlQni oerte cio ron beet I etna tre seu 12 52 ABS Hydraulic Unit 12 52 Front Wheel Rotation Sensor Removal 12 53 Front Wheel Rotation Sensor Installation 12 53 Rear Wheel Rotation Sensor Removal sees ene 12 54 Rear Wheel Rotation Sensor Installation pp 12 54 Wheel Rotation Sensor Inspectiom 12 55 Wheel Rotation Sensor Air Gap Inspection 4 0 04400000 0000 00000000 12 55 Wheel Rotation Sensor Rotor 2 2 12 56 ABS Solenoid Valve Relay Fuse 15 A 12 56 ABS Motor Relay Fuse 25 A Removal pp 12 56 Fuse Installations deett t ete e E eed cadat ae 12
129. RUE UI a qm i F 9 M d wre 6C17077FW5 C FUEL SYSTEM DFI 3 13 DFI System Part Names 1 Joint Connector E 2 ECU 3 Joint Connector D 4 Rear Wheel Rotation Sensor 5 Joint Connector B 6 Frame Ground 2 7 Frame Ground 3 8 Frame Ground 1 9 Engine Ground 10 Battery 12 V 8 Ah 11 Starter Relay 12 Main Fuse 30 A 13 ECU Fuse 15 A 14 Fuse Box 2 15 Fan Fuse 15 A 16 Meter Fuse 7 5 A 17 Fuel Pump Fuel Level Sensor 18 ABS Hydraulic Unit 19 Relay Box 20 Starter Circuit Relay 21 Fuel Pump Relay 22 ECU Main Relay 23 Radiator Fan Relay 24 Fuse Box 1 25 Ignition Fuse 15 A 26 Joint Connector C 27 Meter Unit 28 Red Warning Indicator Light LED Battery Oil Pressure Water Temperature Immobilizer Equipped Model 29 Yellow Engine Warning Indicator Light LED 30 Joint Connector F 31 Front Wheel Rotation Sensor 32 Vehicle down Sensor 33 Immobilizer Antenna Equipped Model 34 Immobilizer Amplifier Equipped Model 35 Ignition Switch 36 Engine Stop Switch 37 Starter Button 38 Air Switching Valve 39 Fan Motor 40 Spark Plugs 41 Intake Air Temperature Sensor 42 Crankshaft Sensor 43 Fuel Injectors 44 Subthrottle Valve Actuator 45 Main Throttle Sensor 46 Subthrottle Sensor 4
130. Rear shock absorber adjustment too hard Tire air pressure too high Battery Trouble Battery discharged 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 adjustment too soft Front fork rear shock absorber spring weak Rear shock absorber oil leaking 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 Brake Doesn t Hold Air in the brake line Pad or disc worn Brake fluid leakage Disc warped Battery overcharged Alternator trouble Regulator rectifier trouble Battery faulty MODEL APPLICATION Year Model Beginning Frame No JKALZCA10CA000001 Sue KLZ1000AC JKALZTOOAAA000001 L1 This digit in the frame number changes from one machine to another Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Motorcycle amp Engine Company Part No 99924 1449 01 Printed in Japan
131. 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 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 Head Pipe Outer Race Driver 054 5 B 57001 1077 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 042 5 C 57001 1344 Steering Stem Bearing Driver Adapter 41 5 D 57001 1345 e Install the lower ball bearing A onto the stem e Grease the following Inner and Outer Races Lower and Upper Ball Bearings OThe lower and upper ball bearings are identical 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 01058657 P 90058655 GNO5146BS1 C 14 8 STEERING Steering Stem e Settle the bearings in place as follows OTighten the steering stem nut with 55 N m 5 6 kgf m 41 ft Ib of torque first and loosen it a fraction of a turn unt
132. Sensor B Crankshaft Sensor A Oxygen Sensor B Ignition Key Transponder Equipped Model A Ignition Switch B Immobilizer Antenna C Equipped Model Red Warning Indicator Light LED D Stick Coils A Air Switching Valve B Intake Air Pressure Sensor 1 C Intake Air Pressure Sensor 2 D Subthrottle Valve Actuator E Fuel Injectors F Water Temperature Sensor A Engine Ground B FUEL SYSTEM DFI 3 17 DFI Parts Location Immobilizer Amplifier A Equipped Model Vehicle down Sensor B Intake Air Temperature Sensor A Frame Ground B Battery 12 V 8 Ah A ECU Fuse 15 A B Relay Box ECU Main Relay Radiator Fan Relay Fuel Pump Relay C ECU D Immobilizer Equipped Model Kawasaki Diagnostic System Connector E Fuel Pump A Rear Wheel Rotation Sensor A 3 18 FUEL SYSTEM DFI Specifications Item Standard Digital Fuel Injection System Idle Speed Throttle Body Assy Throttle Valve Bore Throttle Body Vacuum Bypass Screws Turn Out ECU Make Type Fuel Pressure High Pressure Line Fuel Pump Type Discharge Fuel Injectors Type Nozzle Type Resistance Main Throttle Sensor Input Voltage Output Voltage Resistance Intake Air Pressure Sensor 1 Intake Air Pressure Sensor 2 Input Voltage Output Voltage Intake Air Temperature Sensor Output Voltage Resistance Water Temperature Sensor Output Voltage
133. Set the neutral position e Turn the engine stop switch to run position A e Push the starter button and run the engine e Turn the engine stop switch to stop position e Immediately the engine should be stop x If the engine does not stop inspect or replace the follow ing item Engine Stop Switch see Switch Inspection in the Elec trical System chapter PERIODIC MAINTENANCE 2 47 Periodic Maintenance Procedures Others Chassis Parts Lubrication e Before lubricating each part clean off any rusty spots with rust remover and wipe off any grease oil dirt or grime e Lubricate the points listed below with indicated lubricant NOTE OWhenever the vehicle has been operated under wet or rainy conditions or especially after using a high pressure water spray perform the general lubri cation Pivots Lubricate with Grease Brake Lever Brake Pedal Clutch Lever Rear Brake Joint Pin Sidestand Points Lubricate with Grease Clutch Inner Cable Upper and Lower Ends A Throttle Inner Cable Upper and Lower Ends Cables Lubricate with Rust Inhibitor Clutch Cable Throttle Cables e Lubricate the cables by seeping the oil between the cable and housing OThe cable may be lubricated by using a commercially available pressure cable lubricator with an aerosol cable lubricant 6004011481 C 2 48 PERIODIC Periodic Maintenance Procedures e With the cable disconnected at both ends the
134. Spring Preload Adjustment e To adjust the spring preload turn in the adjuster A until you fee a click to the desired position OThe standard adjuster setting is the 1 click from the fully counterclockwise position x If the spring action feels too soft adjust it Spring Preload Adjustment Adjuster Position Damping Setting T 24 Strong Rear Shock Absorber Removal e Support the motorcycle with the stand e Remove Bolts A Sidestand Bracket B with the Sidestand Counterclockwise Clockwise Sof ter gt Harder 3 1 Seated position adjuster turned fully clockwise GM05484BS1 C Clockwise Counterclockwise Harder Softer STD 24 12 11109 8 7 6 5 4 3 2 1 Seated position adjuster turned fully counter clockwise GMO54B8BS1 C SUSPENSION 13 25 Shock Absorber e Squeeze the brake lever slowly and hold it with band A e Raise the rear wheel off the ground with the jack Special Tools Jack A 57001 1238 Jack Attachment B 57001 1608 A WARNING Be sure to hold the front brake when removing the shock absorber or the motorcycle may fall over It could cause an accident and injury e Remove Rear Shock Absorber Bolts A and Bracket
135. Standard Battery Voltage for 3 seconds and then 0 V e Turn the ignition switch to OFF x If the reading is not the standard check the ECU main relay and fuel pump relay see Relay Circuit Inspection in the Electrical System chapter x If the main relay and pump relay are normal check the wiring for continuity see Fuel Pump Circuit 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 Pressure Regulator Removal OThe pressure regulator A is built into the fuel pump B and can not be removed GC17138FS1 FUEL SYSTEM DFI 3 107 Fuel Pump Pump Screen Fuel Filter Cleaning OThe pump screen A and fuel filter B are built into the pump and can not be cleaned or checked xIf the pump screen or fuel filter is suspected of clogging or being damaged replace it with the fuel pump as a set 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 3 108 FUEL SYSTEM Fuel Pump Fuel Pump Circuit TGNITION G3 0505 signal Jee 6617097282
136. T Toothed Washer 34 4th 3rd Gear 30 T 26 T Bushing Toothed Washer 940 5 Toothed Washer 37 Steel Balls bth Gear 25 T Low Gear 35 T Washers 31 x 20 5 Races Needle Bearings Circlips 622 2 x 18 7 Needle Bearing Low Gear 13 T Drive Shaft Bushing oth Gear 22 Toothed Washer 31 Circlip 29 x 22 6 3rd 4th Gear 17 T 23 Bushing Top Gear 24 T Toothed Washer 934 2 Toothed Washer 32 2nd Gear 20 T Washer 30 x 20 5 9 38 CRANKSHAFT TRANSMISSION Transmission Shift Drum and Fork Removal e Remove Lower Crankcase Half see Crankcase Splitting Transmission Shafts see Transmission Shaft Removal Gear Positioning Lever see External Shift Mechanism Removal Bolts A Shift Drum Bearing Holder B e Pull out the shift rods C and take off the shift forks e Pull out the shift drum D Shift Drum and Fork Installation e Apply engine oil to the shift drum forks and rods e Install the shift rods A noting the groove position OThe rods are identical OPosition the one with shortest ears B on the drive shaft and place the pin in the center groove in the shift drum C OThe two forks D on the output shaft are identical e Install the forks so that its 0061 and 0062 side faces engine left side e Apply a non permanent locking agent to the threads of the shift drum bearing holder bolts and tight
137. Throttle Cables Right Switch Housing Lead Hold the right switch housing lead and horn lead with the clamp Horn Lead Hold the horn lead with the clamp on the air switching valve Air Switching Valve Engine Subharness Before clamping face the locking portion of the clamp in direction as shown 17 12 APPENDIX Cable Wire and Hose Routing APPENDIX 17 13 Cable Wire and Hose Routing NOOR 1 Main Harness 2 3 Run the left switch housing lead ignition switch lead and immobilizer antenna lead equipped Insert the clip on the main harness to the rib on the frame to hold the main harness models through from outside of the main harness to under the left engine bracket and throttle cables then run them to outside of the frame Left Switch Housing Lead Ignition Switch Lead Immobilizer Antenna Lead Equipped Models Run the radiator fan motor lead to front of the air switching valve lead to under the left engine bracket and throttle cables and to upside of the engine subharness then run it to outside of the frame Run the radiator fan motor lead to front of the throttle cables Throttle Cables Right Switch Housing Lead Horn Lead Run the right switch housing lead to the rear of the air switching valve lead to under the left engine bracket and throttle cables to upside of the engine subharness then run it to outside of the frame Run the main harness between
138. 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 4 5 C 57001 1330 For Exhaust Valve Seat Valve Seat Cutter 45 527 5 57001 1114 Valve Seat Cutter 32 628 57001 1119 Valve Seat Cutter 60 627 57001 1409 For Intake Valve Seat Valve Seat Cutter 45 532 57001 1115 Valve Seat Cutter 32 633 57001 1199 Valve Seat Cutter 60 533 57001 1334 xIf the manufacturer s instructions are not available use the following procedure Seat Cutter Operation Care 1 This valve seat cutter is developed to grind the valve for repair Therefore the cutter must not be used for other purposes than seat repair 2 Do not drop or shock the valve seat cutter or the dia mond particles may fall off 3 Do not fail to apply engine oil to the valve seat cutter before grinding the seat surface Also wash off ground particles sticking to the cutter with washing oil NOTE ODo not use a wire brush to remove the metal particles from the cutter It will take off the diamond particles 4 Setting the valve seat cutter holder in position operate the cutter in one hand Do not apply too much force to the diamond portion NOTE OPrior to grinding apply engine oil to the cutter and dur ing the operation wash off any ground particles sticking to the cutter with washing oil 5 After use wash it with washing oil and appl
139. Violet W White ON Y Yellow P PARK 98052 0650E W2ROGSOEWS C 16 22 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems Learn and ob serve all the rules below ODo not reverse the battery cable connections This will burn out the diodes on the electrical parts OAlways check battery condition before condemning other parts of an electrical system A fully charged battery is a must for conducting accurate electrical system tests OThe electrical parts should never be struck sharply as with a hammer or allowed to fall on a hard surface Such a shock to the parts can damage them OTo prevent damage to electrical parts do not disconnect the battery cables or any other electrical connections when the ignition switch is ON or while the engine is running OBecause of the large amount of current never keep the starter button pushed when the starter motor will not turn over or the current may burn out the starter motor wind ings OTake care not to short the cables that are directly con nected to the battery positive terminal to the chassis ground OTroubles may involve one or in some cases all items Never replace a defective part without determining what CAUSED the failure If the failure was caused by some other item or items they must be repaired or replaced or the new replacement will soon fail again OMake sure all
140. Wheel Rotation Sensor Removal in the Brakes chapter Cotter Pin A Rear Axle Nut B Washer C Axle D from Right Side 10 8 WHEELS TIRES Wheels Rims e Remove the drive chain A from the rear sprocket toward the e Move the rear wheel back and remove it NOTICE Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground Rear Wheel Installation e Apply high temperature grease to the grease seal lips e Fit the collars on the both sides of the hub Left Side Collar A 40 x 35 Right Side Collar B 41 x 28 e Engage the drive chain with the rear sprocket e Install the caliper bracket A onto the stopper B of the swingarm e Insert the axle from the right side of the wheel e Adjust the drive chain slack before tightening the axle nut see Drive Chain Slack Inspection in the Periodic Mainte nance chapter e Tighten Torque Rear Axle Nut 108 N m 11 0 79 7 ft Ib e Insert a new cotter pin A NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle tighten the nut clockwise B up to next alignment Olt should be within 30 degrees OLoosen once and tighten again when the slot goes past the nearest hole HJ07007BS1 e Bend the cotter pin A over the nut B A W
141. 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 108 11 0 kgf m 79 7 ft Ib e Turn the wheel measure the chain slack again at the tight est position and readjust if necessary e Insert a new cotter pin A NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle tighten the nut clockwise B up to next alignment Olt should be within 30 degrees OLoosen once and tighten again when the slot goes past the nearest hole e Bend the cotter pin A over the nut B A WARNING 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 HJ07007BS1 HJ07008BS1 C 2 32 PERIODIC Periodic Maintenance Procedures Wheel Alignment Inspection e Check that the notch A on the left alignment indicator B aligns with the same swingarm mark or position C that the right alignment indicator notch aligns with x If they are not adjust the chain slack and align the wheel alignment see Drive Chain Slack Adjustment NOTE OWheel alignment can be also checked using the straightedge or string method A WARNING Misalignment of the wheel will result in abnormal wear a
142. above parts is good replace the meter unit 8 17825051 8 17824 652 16 72 ELECTRICAL SYSTEM Gauge Indicator Unit Meter System Inspection Check 2 1 Outside Temperature Inspection e Disconnect the outside temperature sensor connector A see Outside Temperature Sensor Removal e Connect the variable rheostat B to the BK Y lead C and BL R lead D terminals Temperature Resistance kQ 0 32 F 5 4 6 6 80 C 176 F 0 29 0 39 Turn the ignition switch to ON Read the temperature in the display OThe display range is 20 140 C 4 284 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 If the wiring is good replace the meter unit Check 2 2 Water Temperature Inspection e Disconnect the water temperature sensor connector A see Water Temperature Sensor Removal in the Fuel Sys tem DFI chapter e Connect the variable rheostat B to the W R lead C and W BL lead D terminals Temperature Resistance kQ 20 4 F 18 80 2 37 0 C 32 F about 6 544 40 C 104 F 1 136 0 095 100 C 212 F 0 1553 0 0070 Reference Info
143. accommodate atmospheric conditions in your riding area e Check the oil level see Oil Level Inspection in the Engine Lubrication System chapter Oil Filter Replacement e Remove the left lower fairing see Lower Fairing Removal in the Frame chapter e Drain the engine oil see Engine Oil Change e Remove the oil filter with the oil filter wrench A Special Tool Oil Filter Wrench 57001 1249 e Replace the filter with a new one e Apply grease to the gasket A before installation e Tighten the filter with the oil filter wrench Torque Oil Filter 17 N m 1 7 13 ft Ib NOTE OHand tightening of the oil filter can not be allowed since it does not reach to this tightening torque e Pour in the specified type and amount of oil see Engine 2 56 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Hose Replacement e Remove Brake Hose Fitting Bolt A NOTICE Brake fluid quickly ruins painted plastic surfaces any spilled fluid should be completely washed away immediately e 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 the end of the brake hose to some high place to keep fluid loss to a minimum e Immediately wash away any brake fluid that spills OThere are washers on each side of the brake hose fitti
144. air pressure sensor 1 trouble Inspect see chapter 3 Inspect and adjust see chapter 2 Inspect see chapter 3 Intake air pressure sensor 2 trouble Inspect see chapter 3 Water temperature sensor trouble Intake air temperature sensor trouble Inspect see chapter 3 Inspect see chapter 3 Engine stalls easily Spark plug dirty broken or gap maladjusted Inspect and replace see chapter 2 Stick coil trouble Inspect see chapter 16 Main throttle sensor trouble Inspect see chapter 3 Subthrottle sensor trouble Inspect see chapter 3 Subthrottle valve actuator trouble Inspect see chapter 3 Intake air pressure sensor 1 trouble Inspect see chapter 3 Intake air pressure sensor 2 trouble Water temperature sensor trouble Inspect see chapter 3 Intake air temperature sensor trouble Inspect see chapter 3 Fuel pump trouble Inspect see chapter 3 Fuel injector trouble Fuel pressure too low or too high Fuel pressure regulator trouble Fuel line clogged Poor acceleration Fuel pressure too low Water or foreign matter in fuel Fuel filter or pump screen clogged 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 Change fuel Inspe
145. and Rear Fender Removal 15 17 Flap and Rear Fender Installation 15 18 ETAITIG 15 19 Frame Inspection 15 19 Rear Frame Remowval 15 19 Rear Frame Installation 15 19 Rear Footpeg Bracket Removal 15 19 Rear Footpeg Bracket Installation 15 19 15 20 Upper Mud Guard 15 20 Upper Mud Guard Installation 15 20 Lower Mud Guard Removal 15 21 Lower Mud Guard Installation 15 21 Sidestand 15 22 Sidestand Remowval 15 22 Sidestand Installation 15 22 Rear View 15 23 Rear View Mirror Removal 15 23 Rear View Mirror Installation 15 23 1 5 2 Exploded View OBL 4 lt lt gt NDS 9 WD AD y 8002551885 FRAME 15 3 Exploded View memi ee Nm km fb Front Fender Mounting Bots 39 040 2 CA and AU Models 15 4 FRAME Exploded View k liae gt 9 3 15 5 Exploded View Torque Remarks kgf m ft Ib 6 Sidestand Switch Bok _ es 090 Bn L L Carrier Bracket Bolts 34 3 5 25 8 Carrier Mounting Bolts 8 8 0 90 78 9 Rear Frame Guard Bolts 8 8 0 90 78 in lb 10 Rear Footpeg Bracket Bolts
146. 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 Liquid fuel is caught by a vapor separator and returned to the fuel tank The Clean Air Act which is the Federal law covering motor vehicle pollution contains what is commonly referred to as the Act s tampering provisions Sec 203 a The following acts and the causing thereof are prohibited 3 A for any person to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title prior to its sale and delivery to the ultimate purchaser or for any manufacturer or dealer knowingly to remove or render inoperative any such device or element of design after such sale and delivery to the ultimate purchaser 3
147. and face its open side in direction as shown Hold the front wheel rotation sensor lead to the brake hose with the clip at the white mark on the lead placed approx 10 mm 0 4 mm above the clamp Install the clip so that the lead is placed at rear of the hose and face its open side in direction as shown Hold the brake hose at the rubber protector to the front fender with the clamp Before clamping face the locking portion of the clamp to backward Do not hold the front wheel rotation sensor lead with this clamp Front Wheel Rotation Sensor Lead Brake Hose Hold the front wheel rotation sensor lead to the brake hose with the clip at the white mark on the lead Install the clip so that the lead is placed at outside of the hose and face its open side in direction as shown Front Wheel Rotation Sensor 17 40 APPENDIX Cable Wire and Hose Routing 68092000 G APPENDIX 17 41 Cable Wire and Hose Routing 1 Rear Brake Reservoir Hose 2 Clamp Hold the rear brake reservoir hose and rear shock absorber adjuster hose together as 12 13 Hold the rear shock absorber adjuster hose and rear brake light switch lead to the frame with 15 16 Before clamping face the locking portion of the clamp in direction as shown shown Rear Shock Absorber Adjuster Hose Hold the rear wheel rotation sensor lead to the brake hose with the clip at the white
148. as shown in the figure e Tighten Torque Air Cleaner Duct Clamp Bolts 2 0 0 20 kgf m 18 in Ib e Tighten the air cleaner housing mounting bolts C e Install the breather hose D and clamp e Run the leads and hoses correctly see Cable Wire and Hose Routing section in the Appendix chapter e Install the removed parts see appropriate chapters 5 5 2 5 Cy MEAM We ET SONY By DOT vos GC07066BS2 C 3 122 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 to OFF Disconnect the battery terminal To avoid fuel spills draw it from the tank when the engine is cold Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately e Turn the ignition switch to OFF e Wait until the engine cools down e Disconnect the battery terminal see Battery Removal in the Electrical System chapter e Remove Middle Fairing see Middle Fairing Removal in the Frame chapter Meter Cover see Meter Cover Removal in the Frame chapter Seat see Seat Removal in the Frame chapter Front Fuel Tank Bolts A e Disc
149. bearing Transmission Shaft Assembly e Install the new ball bearing A and collar B output shaft on the each shaft using the bearing driver Spacial Tool Bearing Driver 032 57001 382 e Apply engine oil to the bushings ball bearings and shafts e Install the gear bushings A on the shaft with their holes B aligned e Replace any circlips removed with new ones e Install the circlips A so that the opening B is aligned with a spline groove C 9113413851 9113267851 6113040851 6113010251 9 34 CRANKSHAFT TRANSMISSION Transmission e The drive shaft gears can be recognized by size the gear with the smallest diameter is 1st gear and the largest one is 6th gear Be sure that all parts are put back in the cor rect sequence and all circlips and washers are properly in place e Install the 3rd 4th gear onto the drive shaft with their oil holes aligned e Install the 6th gear bushing onto the drive shaft with their oil holes aligned e The output shaft gears can be recognized by size the gear with the largest diameter is 1st gear and the small est one is 6th gear Be sure that all parts are put back in the correct sequence and all circlips and washers are properly in place e Install the 6th gear onto the output shaft with their oil holes aligned e Install the 3rd 4th gear bushings onto the output shaft with their oil holes aligned NOTE OWhen the toothed washers a
150. body GE P FUEL SYSTEM 3 119 Throttle Body Assy e Pull out the fuel injectors A from the delivery pipe assy B NOTE ODo not damage the insertion portions of the injectors when they are pulled out from the delivery pipe assy Never drop the primary fuel injector especially on a hard surface Such a shock to the injector can damage it Throttle Body Assy Assembly e Before assembling blow away dirt or dust from the throttle body and delivery pipe assy by applying compressed air e 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 assy C and confirm whether the injectors turn smoothly or not 9 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 assy to the throttle body e Tighten Torque Delivery Pipe Assy Mounting Screws 3 4 Nm 0 35 kgf m 30 in Ib e Install the throttle body assy see Throttle Body Assy In stallation 17 102 3 120 FUEL SYSTEM Air Cleaner Air Cleaner Element Removal Installation e Refer to the Air Cleaner Element Replacement in the Pe riodic Maintenance chapter Air Cleaner Element Inspection e Remove the air cleaner element see Air Cleaner Element Replacement in the Periodic Maintenance chapter e Visually check the element A fo
151. brake pipe temporarily and then tighten them to the specified torque OTighten the brake pipe joint nuts with the flare nut wrench e Install the brake pipes at the specified angle see Cable Wire and Hose Routing section in the Appendix chapter e Tighten Torque Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft lb Brake Pipe Joint Nuts 18 1 8 kgf m 13 ft lb e When installing the hoses avoid sharp bending kink ing flatting or twisting and route the hoses according to Cable Wire and Hose Routing section in the Appendix chapter e Fill the brake line after installing the brake hose see Brake Fluid Change 2 58 PERIODIC Periodic Maintenance Procedures Brake Fluid Change NOTE OThe procedure to change the front brake fluid is as fol lows Changing the rear brake fluid is the same as for the front brake Level the brake fluid reservoir e Remove the reservoir cap e Remove the rubber cap from the bleed valve A on the caliper e Attach a clear plastic hose B to the bleed valve and run the other end of the hose into a container e Fill the reservoir with fresh specified brake fluid e Change the brake fluid ORepeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes 1 Open the bleed valve A 2 Apply the brake and hold it B 3 Close the bleed valve C 4 Release the brake D NOTE OThe fluid
152. by an arrow B on the wheel spoke 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 front axle e Tighten Torque Front Axle 127 N m 13 0 kgf m 93 7 ft Ib e Before tightening the axle clamp bolt A on the right front fork leg pump the front fork up and down 4 or 5 times to allow the right front fork leg to seat on the front axle NOTE OPut a block in front of the front wheel to stop moving e Tighten Torque Front Axle Clamp Bolt 20 N m 2 0 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 e Remove the muffler body see Muffler Body Removal in the Engine Top End chapter e Raise the rear wheel off the ground with the stand A e Remove Chain Cover see Drive Chain Removal in the Final Drive chapter Rear Wheel Rotation Sensor see Rear
153. 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 80904020152 C PERIODIC MAINTENANCE 2 49 Periodic Maintenance Procedures Bolts Nuts and Fasteners Tightness Inspection e Checkthe 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 xIf there are loose fasteners retighten them to the spec ified torque following the specified tightening sequence Refer to the appropriate chapter for torque specifications If torque specifications are not in the appropriate chapter see the Standard Torque Table For each fastener first loosen it by 1 2 turn then tighten it x If cotter pins are removed replace them with new ones Bolt Nut and Fastener to be checked Engine Clutch Lever Pivot Bolt Locknut Engine Mounting Bolts and Nuts Exhaust Pipe Manifold Holder Nuts Exhaust Pipe Mounting Bolt Muffler Body Clamp Bolt Muffler Body Mounting Bolt and Nut Radiator Upper and Lower Bolts Subframe Bolts Wheels Front Axle Front Axle Clamp Bolt Rear Axle Nut Brakes Brake Lever Pivot Nut Brake Pedal Bolt Brake Rod Joint Cotter Pin Caliper Mounting Bolts Front Master Cylinder Clamp Bolts Rear Master Cylinder Mounting B
154. 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 terminal Do not pull the lead only the con nector Conversely make sure that all the DFI electrical connections are firmly reconnected before starting the en gine OConnect these connectors until they click A ODo not turn the ignition switch to ON while any of the DFI electrical connectors are disconnected The ECU memo rizes service codes 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 n
155. clutch plate as sembly length Torque Clutch Spring Bolts 9 0 N m 0 92 kgf m 80 in Ib GF06202BS2 C 6 14 CLUTCH Clutch 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 If any plates show signs of damage or if they have worn past the service limit replace them with new ones Friction Plate Thickness Standard 2 72 2 88 mm 0 107 0 113 in Service Limit 2 4 mm 0 094 in Clutch Plate Warp Inspection e Place each friction plate or steel plate on a surface plate and measure the gap between the surface plate A and each friction plate or steel plate B with a thickness gauge C The gap is the amount of friction or steel plate warp x If any plate is warped over the service limit replace it with a new one Friction and Steel Plate Warp Standard 0 15 mm 0 0059 in or less Service Limit 0 3 mm 0 012 in Clutch Spring Free Length Measurement e Measure the free length of the clutch springs A xIf any spring is shorter than the service limit it must be replaced Clutch Spring Free Length Standard 64 6 mm 2 54 in Service Limit 61 6 mm 2 43 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 wo
156. code of Self Diagnosis see Fuel System chapter It is the service code of the meter communication line error OThe number 39 in the display disappear when the meter unit is connected to main harness of the normal motor cycle Check 3 3 Immobilizer Blinking Mode Inspection Equipped Models e Connect the leads in the same circuit as Check 3 1 e Disconnect the terminal 6 X GP17844CS1 GP17845CS1 GP17843CS1 16 76 ELECTRICAL SYSTEM Meter Gauge Indicator Unit e Check that the red warning indicator light LED A starts blinking Immobilizer Warning Indicator Light Blinking Mode e Push the upper B and lower C buttons more than 2 second within 20 seconds after the terminal 6 discon nected e Check that the red warning indicator light LED goes on one second and then the light goes off Immobilizer Warning Indicator Light No Blinking Mode NOTE OFor this inspection be sure the battery is 12 2 V or more Immobilizer Warning Indicator Light Blinking Mode does not work when the battery voltage is less than 12 0 2 V e Connect the terminal 6 to the battery terminal e And then disconnect the terminal 6 e Push the upper A and lower B buttons more than 2 second within 20 seconds after the terminal 6 discon nected e Check that the red warning indicator light LED C goes on one second and then the light starts blinking
157. 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 e Secure the fuel hose with 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 Do not drive the fuel pump 3 seconds or more with out the fuel in the fuel tank If the fuel pump is driven without the fuel it may be damaged e Measure the discharge for 3 seconds ORepeat this operation several times Amount of Fuel Flow Standard 50 mL 1 7 US oz or more for 3 seconds e Turn the ignition switch to OFF x If 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 Confirm that the drain hose and clamp are installed se curely and run the hose correctly see Cable Wire and Hose Routing section in the Appendix chapter e Start the engine and check for fuel leakage 3 104 FUEL SYSTEM Fuel Pump Fuel Pump Removal A WARNING Gasoline is extremely flammable and ca
158. connectors as shown 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 Intake Air Temperature Sensor Output Voltage Connections to Adapter Digital Meter R sensor R BK lead Digital Meter gt BK sensor 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 25 2 50 V at 20 C 68 F NOTE OThe output voltage changes according to the intake air temperature 62172564 6517076 R R BK BK 1 SO 8017115 81 C FUEL SYSTEM DFI 3 55 Intake Air Temperature Sensor Service Code 13 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 xIf the reading is out of the standard remove the ECU and check the wiring for continuity between main harness connectors ODisconnect the ECU and sensor connectors Wiring Inspection ECU Connector A Intake Air Temperature Sensor Connector B R BK lead ECU terminal 16 C G lead ECU terminal 49 D x If the wiring is good check the intake air temperature s
159. connectors in the circuit are clean and tight and examine wires for signs of burning fraying etc Poor wires and bad connections will affect electrical system op eration OMeasure coil and winding resistance when the part is cold at room temperature Electrical Wiring ELECTRICAL SYSTEM 16 23 Wiring Inspection e Visually inspect the wiring for signs of burning fraying etc xIf any wiring is poor replace the damaged wiring e Pull each connector A apart and inspect it for corrosion dirt and damage x If the connector is corroded or dirty clean it carefully If it is damaged replace it e Check the wiring for continuity OUse the wiring diagram to find the ends of the lead which is suspected of being a problem OConnect the hand tester between the ends of the leads Special Tool Hand Tester 57001 1394 OSet the tester to the x 1 O range and read the tester x If the tester does not read 0 the lead is defective Re place the lead or the wiring harness B if necessary GPO7002BS1 C GP07056BS1 16 24 ELECTRICAL SYSTEM Battery Battery Removal e Turn the ignition switch to OFF e Remove Seat see Seat Removal in the Frame chapter e Disconnect the negative cable A NOTICE sure to disconnect the negative cable first e Slide out the positive terminal cap B and disconnect the positive cable C e Remove the band D and the battery Batt
160. cover F and circlip G Special Tool Inside Circlip Pliers 57001 143 e Pull out the piston assembly H e Replace Diaphragm C Dust Cover F Circlip G Piston Assembly H 9817150852 C Rear Master Cylinder Disassembly e Remove the rear master cylinder see Rear Master Cylin der Removal in the Brakes chapter e e Remove the circlip A connector B and O ring C Special Tool Inside Circlip Pliers 57001 143 e e Slide the dust cover D out of place and remove the cir e Pull out the push rod assy e Take off the piston assy G and return spring H d NOTICE Do not remove the secondary cup from the piston since removal will damage it Replace Circlip A O ring C Na Circlip E E A 8 Push Rod Assy F Piston Assy 8513318852 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 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 2 60 PERIODIC Peri
161. drive chain slack after installing the engine sprocket see Drive Chain Slack Adjustment in the Pe riodic Maintenance chapter Rear Sprocket Removal e 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 the rear sprocket nuts A e Remove the rear sprocket B Rear Sprocket Installation e Install the sprocket facing the tooth number marking A outward e Replace the rear sprocket nuts with new ones e Tighten Torque Rear Sprocket Nuts 59 N m 6 0 kgf m 44 ft Ib e Install the rear wheel see Rear Wheel Installation in the Wheels Tires chapter Sprocket Coupling FINAL DRIVE 11 13 Coupling Installation e Apply high temperature grease to the following parts Coupling Grease Seal Lip A Coupling Internal Surface B e Install Collar A Coupling B Coupling Bearing Removal e Remove Coupling Grease Seal Circlip A Special Tool Inside Circlip Pliers 57001 143 e Remove the bearing A by tapping from the wheel side Special Tool Bearing Driver Set B 57001 1129 Coupling Bearing Installation e Replace the bearing with a new one e Press in the bearing A until it is bottomed Special Tool Bearing Driver Set B 57001 1129 e Pack the bearing with high temperature grea
162. e Remove Water Hose C Water Pipe Bolt D Water Pipe E Remove the mounting bolts A e Pull out the starter motor B with the cable connected e Slide the rubber cap A Remove the starter motor cable terminal nut B and ca ble Starter Motor Installation Do not tap the starter motor shaft or body Tapping the shaft or body could damage the motor e When installing the starter motor clean the starter mo tor legs A and crankcase B where the starter motor is grounded Electric Starter System ELECTRICAL SYSTEM 16 49 e Install the starter motor cable A as shown B Upward e Tighten Torque Starter Motor Cable Terminal Nut C 5 9 N m 0 60 kgf m 52 in Ib e Slide back the rubber cap to the original position Replace the O ring A with a new one e Apply grease to the O ring Tighten Torque Starter Motor Mounting Bolts 9 8 N m 1 0 kgf m 87 in Ib e Install the water hose and pipe see Water Pump Instal lation in the Cooling System chapter e Install the removed parts 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 out the armature A out of the yoke B NOTE ODo not remove the circlip C from the shaft e Remove the starter motor terminal locknut A GP11203BS1 62118587
163. force can be left soft for average riding But Counterclockwise Clockwise it should be adjusted harder for high speed riding or riding Softer Harder with a passenger If the damping feels too soft or too stiff STD adjust it in accordance with the following table i 1211109 876 554 32 1 Rebound Damping Force Adjustment UP LC im Adjuster Damping i Position Force Seated position adjuster turned fully clockwise 0M04729B 1 C 12 clicks Weak Spring Preload Adjustment e Turn the spring preload adjuster A to change spring preload setting OThe standard adjuster setting is the 12 mm 0 47 in B from top as shown in the figure Adjuster Protrusion from top Standard 12 mm 0 47 in Usable Range 4 19 mm 0 16 0 75 in A WARNING GO4C262 If both adjusters 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 Action Adjuster Damping Position Force 19 mm Weak Soft Setting 13 10 SUSPENSION Front Front Fork Removal Each Fork Leg e Remove Upper Side Fairing see Upper Side Fairing Removal in
164. front wheel pointing straight ahead alternately tap each end of the handlebars 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 pushing and pulling A the forks If you feel looseness the steering is too loose NOTE OThe cables and wiring will have some effect on the mo tion of the fork which must be taken into account OBe sure the leads and cables are properly routed OThe bearings must be in good condition and properly lubricated in order for any test to be valid 2 40 PERIODIC Periodic Maintenance Procedures Steering Play Adjustment e Remove Upper Fairing Bracket see Upper Fairing Bracket Re moval in the Frame chapter Handlebars and Lower Handlebar Holder see Handle bar Removal in the Steering chapter Steering Stem Head Bolt Plug A Steering Stem Head Bolt B Upper Front Fork Clamp Bolts C Loosen Stem Head D e Bend the claws A of the claw washer back e Remove the steering stem locknut B and claw washer e Adjust the steering Special Tool Steering Stem Nut Wrench A 57001 1100 x If the steering is too tight loosen the stem nut a fraction of a turn x If the steering is too loose tighten the stem nut a fraction of a turn NOTE OTurn the stem nut 1 8 turn at time maximum e Install the
165. hose clamp in direction as shown 17 34 APPENDIX Cable Wire and Hose Routing C pS do 08809897045 C APPENDIX 17 35 Cable Wire Hose Routing Engine Subharness Install the fuel hose with protective mesh side toward the fuel tank Starter Motor Cable Battery Ground Cable Idle Adjusting Cable Hold the idle adjusting screw with the holder on the clutch cover Breather Hose Hold the sidestand switch lead with the clamp Install the harness holder at the places where higher than the branching point of the water pipe to hold the engine subharness to the water pipe Water Pipe Upper View A Run the alternator lead between the water pipe and crankcase Hose Clamp Water Hose Engine Subharness Connector Air Hose Air Switching Valve Run the engine subharness to under the air hose Run the engine subharness between the 1 and 2 throttle body assy holders as shown Be careful not to pinch the engine subharness with the throttle body Face the tabs of the hose clamp in direction as shown 17 36 APPENDIX Cable Wire and Hose Routing IAF a A 1 x OO D c id 2 Aw Yo _ y APPENDIX 17 37 Cable Wire and Hose Routing Run the brake hose right switch housing lead and throttle cables into the guide Hold t
166. in Spark plug incorrect the Owner s Manual Replace it with the correct plug see chapter 2 Stick coil trouble Inspect see chapter 16 ECU trouble Inspect see chapter 3 Engine vacuum not synchronizing Inspect and adjust see chapter 2 Intake air pressure sensor 1 trouble Inspect see chapter 3 Intake air pressure sensor 2 trouble Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 FUEL SYSTEM DFI 3 35 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions chapter 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 Rear wheel rotation sensor trouble Inspect see chapter 12 Throttle valves will not fully open Inspect throttle cables and lever linkage see chapter 3 Engine overheating Water temperature sensor see Overheating of Troubleshooting Guide crankshaft sensor or speed sensor trouble chapter 17 Air switching valve trouble Inspect and replace see chapter 16 Air suction valve trouble Inspect and replace see chapter 5 Air cleaner element clogged Clean element see chapter 2 Fuel pressure too high Inspect see chapter 3 Fuel injector trouble Inspect see chapter 3 spect see chapter 3 Fuel
167. light LED and the immobilizer warning symbol A blink to display the collation error code Immobilizer Amplifier Failure 0 3second D Mec EEEFECEPEEUBEELFEFBREENT 6230026651 0 2second 6230027651 I hnnnnnnnni 6230025651 ELECTRICAL SYSTEM 16 97 Immobilizer System Equipped Models When Registered Ignition Key is Inserted 0 5second 0 5second Ignition Key Collation Error 0 3second 6230026651 e The ignition key 1 is successfully registered the ECU OThe red warning indicator light LED and the immobilizer warning symbol A blink 3 times and stop for 1 second and then repeat this cycle OThis procedure has registered the registered ignition key and 2 ignition keys e Turn to OFF the ignition switch and wait for period of more than 15 seconds e The registration mode automatically ends Dm AAS e The red warning indicator light LED A goes off GP30030CS1 NOTE OTurm the ignition switch to ON with the registered ignition key OCheck that the engine can be started using all regis tered ignition keys 16 98 ELECTRICAL SYSTEM Immobilizer System Equipped Models Case 4 When all re
168. marks on the lead Install the clips so that the lead is placed at under the hose and face its open side in direction as shown Rear Brake Hose Hold the brake hose at the rubber protector with the clamps Run the rear brake reservoir hose to outside of the rear brake hose Rear Wheel Rotation Sensor Hold the rear wheel rotation sensor lead at the rubber protector with the clamps Rear Wheel Rotation Sensor Lead Hold the rear wheel rotation sensor lead to the brake hose with the clip at the white mark on the lead Install the clip so that the lead is placed at outside of the hose and face its open side in direction as shown Run the rear brake light switch lead and rear wheel rotation sensor lead to outside of the brake pipes Rear Brake Light Switch Lead clamp Hold the rear shock absorber adjuster hose and rear brake light switch lead to the rear frame with clamp Brake Pipes 17 42 APPENDIX Cable Wire and Hose Routing 6B09901D G APPENDIX 17 43 Cable Wire and Hose Routing 68097030 6 0 x 0 Hold the oxygen lead rear wheel rotation lead rear brake light switch crankshaft sensor lead to the frame with clamp Hold the oxygen sensor lead rear wheel rotation sensor lead rear brake light switch lead and crankshaft sensor lead with clamp Run the fuel tank drain hose along the air cle
169. mm 1 357 in x If any crankpin has worn past the service limit replace the crankshaft with a new one x If the measured crankpin diameters not less than the service limit but do not coincide with the original diameter markings on the crankshaft make new marks on it Crankpin Diameter Marks None 34 484 34 492 mm 1 3576 1 3579 in 34 493 34 500 1 3580 1 3583 Crankpin Diameter Marks or no mark 9105236851 6105041751 9105316851 C 9 22 CRANKSHAFT TRANSMISSION Crankshaft and Connecting Rods e Measure the connecting rod big end inside diameter and mark each connecting rod big end in accordance with the inside diameter e Tighten the connecting rod big end nuts to the specified torque see Connecting Rod Installation NOTE OThe mark already on the big end should almost coincide with the measurement Connecting Rod Big End Inside Diameter Marks None 37 500 37 508 mm 1 4764 1 4766 in 37 509 37 516 mm 1 4767 1 4770 in Big End Cap A Connecting Rod B Weight Mark Alphabet C Diameter Mark Around Weight Mark D or no mark e Select the proper bearing insert A in accordance with the combination of the connecting rod and crankshaft coding Size Color B Con rod Big End Crankpin Inside Diameter Diameter Marking Marking Size Color Part Number None None Black 92139 0123
170. no drag inspect Brake fluid level inspect 8 e 2 36 months Brake pad wear inspect 9 e 2 37 light switch operation 1 2 2 37 inspect Suspension Front forks rear shock absorber operation damping and smooth e e e 2 38 stroke inspect Front forks rear shock absorber 2 5 2 2 38 leak inspect y 2 39 Rocker arm operation inspect e 2 39 Tie rods operation inspect e 2 39 Steering Steering play inspect year e 2 39 Steering stem bearings lubricate 2 years e 2 41 Electrical System Lights and switches operation year 1 2 42 inspect Headlight aiming inspect year e 2 44 Sidestand switch operation year 2 45 inspect Engine stop switch operation year 2 2 46 inspect Others Chassis parts lubricate year e 2 47 Bolts and nuts tightness inspect e e e e 2 49 Service more frequently when operating in severe conditions dusty wet muddy high speed or frequent starting stopping For higher odometer readings repeat at the frequency interval established here PERIODIC MAINTENANCE 2 5 Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY Whichever ODOMETER READING comes yy x 1 000 km first 1 000 mile See 1 12 24 36 48 Page ITEM Every 0 6 7 5 15 22 5 30 Air cleaner element replace Every 18 000 km 11 250 mile 2 50 Fuel hose replace 5 years 2 50 Coolant change 3 years
171. of the outer tube Left Front Fork 114 2 mm 4 49 0 08 in from the top of the outer tube NOTE OFork oil level 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 outer tube D OSet the gauge stopper E so that its lower side shows the oil level distance specified F OPull the handle slowly to pump out the excess oil until the oil no longer comes out x 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 e Screw the rod nut A onto the piston rod B as shown in the figure 15 mm 0 59 in or more C e Screw the fork piston rod puller onto the end of the piston rod Special Tool Fork Piston Rod Puller M10 x 1 0 57001 1298 e Install the spring seat A with the flat surface B facing upward e Install the fork spring C with the smaller end D facing upward e Install Collar A Washer B GM04733BS2 C GMO4511BS1 C GM04734BS1 C Front SUSPENSION 13 15 e Check the distance between the lower end A of the top plug B and lower end C of the rebound damping ad juster with a vernier caliper D Right Front Fork Only 14 5 mm 0 571 in or more E
172. or a low flash point solvent to clean the screen NOTE OWhile cleaning the screen check for any metal particles that might indicate internal engine damage e Check the screens carefully for any damage x If the screen is damaged replace the oil screen ENGINE LUBRICATION SYSTEM 7 11 Oil Pressure Relief Valve Oil Pressure Relief Valve Removal e Remove Oil Screen see Oil Screen Removal Oil Pressure Relief Valve A Oil Pressure Relief Valve Installation e Apply a non parmanent locking agent to the threads of the oil pressure relief valve and tighten it Torque Oil Pressure Relief Valve 15 1 5 11 ft Ib Oil Pressure Relief Valve Inspection e 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 change 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 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 pilo
173. quantity and ignition timing according to engine rpm and throttle opening Input Terminal A Output Terminal B Ground Terminal C 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 sure the battery is fully charged e Turn the ignition switch to OFF e Remove the right side cover see Side Cover Removal in the Frame chapter e Disconnect the main throttle sensor connector and con nect the throttle sensor setting adapter A between these connectors Special Tool Throttle Sensor Setting Adapter 57001 1538 e Connect a digital meter to the throttle sensor setting adapter leads Main Throttle 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 Main Throttle Sensor Output Voltage Inspec tion OBO 6C17127BS1 Throttle Sensor Service Code 11
174. roughness of the rear wheel bearing by push ing and pulling A the wheel e Spin B the rear wheel lightly and check for smoothly turn roughness binding or noise xIf roughness binding or noise is found remove the rear wheel and inspect the wheel bearing see Rear Wheel Re moval Hub Bearing Inspection in the Wheels Tires chap ter and coupling see Coupling Bearing Inspection in the Final Drive chapter 65118218 P 2 30 PERIODIC 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
175. service limit replace the con necting rod with new one and then check clearance again If clearance is too large after connecting rod replacement the crankshaft also must be replaced 6105040881 C 6105040781 CRANKSHAFT TRANSMISSION 9 21 Crankshaft and Connecting Rods Connecting Rod Big End Bearing Insert Crankpin Wear Inspection e Measure the bearing insert crankpin A clearance with plastigage press gauge B e Tighten the big end nuts to the specified torque see Con necting Rod Installation NOTE ODo not move the connecting rod and crankshaft during clearance measurement NOTICE After measurement replace the connecting rod bolts Connecting Rod Big End Bearing Insert Crankpin Clearance Standard 0 030 0 060 mm 0 0012 0 0024 in Service Limit 0 10 mm 0 0039 in x If the clearance is within the standard no bearing replace ment is required xIf the clearance is between 0 061 mm 0 0024 in and the service limit 0 10 mm 0 0039 in replace the bearing inserts A with inserts painted blue B Check insert crankpin clearance with the plastigage press gauge The clearance may exceed the standard slightly but it must not be less than the minimum in order to avoid bearing seizure xIf the clearance exceeds the service limit measure the diameter of the crankpins Crankpin Diameter Standard 34 484 34 500 mm 1 3576 1 3583 Service Limit 34 47
176. stops at the bottom of its housing OThe new needle bearings must be pressed into the crankcase so that the end is flush with the end of the hole Special Tool Bearing Driver Set 57001 1129 Ball and Needle Bearing Wear Inspection Do not remove the bearings for inspection Re moval may damage them e Check the ball bearings OSince the ball bearings are made to extremely close toler ances the wear must be judged by feel rather than mea surement Clean each bearing in a high flash point sol vent dry it do not spin the bearing while it is dry and oil it with engine oil OSpin A the bearing by hand to check its condition x If the bearing is noisy does not spin smoothly or has rough spots replace it e Check the needle bearings OThe rollers in a needle bearing normally wear very little and wear is difficult to measure Instead of measuring inspect the bearing for abrasion color change or other damage x If there is any doubt as to the condition of a needle bear ing replace it Oil Seal Inspection e Inspect the oil seals Replace it if the lips are misshapen discolored indicating that the rubber has deteriorated hardened or otherwise damaged 6114060551 9114000851 WHEELS TIRES 10 1 Wheels Tires Table of Contents Exploded View selera aa Ea a t 10 2 Specifications LE 10 4 teya RIK OTe T A
177. the ABS Hydraulic Unit Therefore the relay cannot be checked directly e Recheck the service code indication erase the service code perform the pre diagnosis inspection 1 and 2 and retrieve the service code x If the yellow ABS indicator light LED A lights the ABS hydraulic unit has trouble Replace the ABS hydraulic unit x If the yellow ABS indicator light LED does not light ABS system is normal service code is not stored 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 see Wheel Rotation Sensor Air Gap Inspection e Check the front wheel rotation sensor see Wheel Rota tion Sensor Inspection x both inspections are good go to next step e Check that there is iron or other magnetic deposits be tween the sensor A and sensor rotor B and the sensor rotor slots for obstructions e Check the installation condition of the sensor for loose ness e Check the sensor rotor tip for deformation or damage e g chipped sensor rotor teeth x If the sensor rotor in bad condition remove the any de posits Install the proper part or replace faulty part x lf the all items are good go to next step e Recheck the service code indication erase the service code perform the pre diagnosis inspection 1 and 2 and retrieve the service code x If the yellow ABS indicator light LED A lights the A
178. the bearing seal B for tears or leakage x If the seal is torn or is leaking replace the bearing Swingarm Bearing Lubrication NOTE OSince the bearings are packed with grease and sealed lubrication is not required Chain Guide Inspection e Refer to the Chain Guide Wear Inspection in the Periodic Maintenance chapter SUSPENSION 13 31 Tie Rod Rocker Arm Tie Rod Removal e Remove Upper Mud Guard see Upper Mud Guard Removal in the Frame chapter e Squeeze the brake lever slowly and hold it with a band A e Raise the rear wheel off the ground with the jack see Rear Shock Absorber Removal Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Remove Upper Tie Rod Bolt and Nut A Lower Tie Rod Bolt and Nut B Tie Rod C Tie Rod Installation e Apply grease to the inside of the grease seals e Install the tie rod e Replace the tie rod nuts with new ones e Tighten Torque Tie Rod Nuts 34 3 5 kgf m 25 ft Ib Rocker Arm Removal e Remove Upper Mud Guard see Upper Mud Guard Removal in the Frame chapter e Squeeze the brake lever slowly and hold it with a band e Raise the rear wheel off the ground with the jack see Rear Shock Absorber Removal Special Tools Jack 57001 1238 Jack Attachment 57001 1608 e Remove Lower Rear Shock Absorber Bolt and Nut A Upper Tie Rod Bolt and Nut B Rocker Arm Bolt and Nut C Rocker Arms D Gomes
179. the left engine bracket and the frame then run it to outside of the frame Detail A Stick Coil Lead for Cylinder Hold the throttle sensor lead and throttle body tube with the clamp at white mark on the tube White Mark Air Switching Valve Lead Connector Hold the horn lead with the clamp on the air switching valve Horn Lead Run the air switching valve hose to the upside of the throttle sensor lead Intake Air Pressure Sensor 2 Lead Connector Subthrottle Valve Actuator Lead Connector Intake Air Pressure Sensor 1 Lead Connector Section B B Hold the injector lead with the clamps Fuel Pipe Run the injector lead to under the projection on the fuel pipe as shown Run the intake air temperature sensor lead to under the crankshaft sensor lead Intake Air Temperature Sensor Run the injector lead to front of the engine breather hose Hose Clamp Injector Lead Face the tabs of the hose clamp in direction as shown 17 14 APPENDIX Cable Wire and Routing APPENDIX 17 15 Cable Wire and Hose Routing Reserve Tank Overflow Hose Run the reserve tank overflow hose to inside of the frame Water Hose Cylinder Head to Radiator Filler Neck Water Hose Thermostat Housing to Radiator Filler Neck Hose Clamps Radiator Hose Hold the clutch cable and horn read with the clamps Insert the clamp on the l
180. the piston with its dent mark facing forward e Fit a new piston pin snap ring into the side of the piston so that the ring opening A does not coincide with the slit B of the piston pin hole OApply molybdenum disulfide oil solution to the piston pins and piston journals OWhen installing the piston pin snap ring compress it only enough to install it and no more NOTICE Do not reuse snap rings as removal weakens and deforms them They could fall out and score the cylinder wall e Install the cylinder see Cylinder Installation Cylinder Wear Inspection e Since there is a difference in cylinder wear in different di rections take a side to side and a front to back measure ment at each of the two locations total of four measure ments as shown in the figure xIf any of the cylinder inside diameter measurements ex ceeds the service limit replace the cylinder 10 mm 0 39 in A 60 mm 2 36 in B Cylinder Inside Diameter Standard 76 990 77 006 mm 3 0311 3 0317 in Service Limit 77 09 mm 3 035 in GE16044BS1 C GE16061BS1 C GE16062BS1 C GE16282BS1 5 40 END Pistons Piston Wear Inspection e Measure the outside diameter A of each piston 11 mm 0 43 in B up from the bottom of the piston at a right angle to the direction of the piston pin If the measurement is under ser
181. the seating surface correctly to prevent the bolt heads from hitting the crankcase 9 18 CRANKSHAFT TRANSMISSION Crankshaft 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 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 x If the connecting rod assy was replaced use the bolts and nuts attached to the new connecting rod assy e Apply a small amount of molybdenum disulfide oil solution to the following portions Threads A of Bolts and Nuts Seating Surfaces B of Nuts and Connecting Rod Caps 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
182. the slit A on the sidestand switch to the pin B on the sidestand e Apply a non permanent locking agent to the thread of the switch bolt and tighten it Torque Sidestand Switch Bolt 8 8 N m 0 90 kgf m 78 in Ib 6020057BS1 15 23 Rear View Mirrors Rear View Mirror Removal e Slide the dust cover A e Loosen the rear view mirror locknut upper B and re move the rear view mirror stay C from the rear view mir ror nut lower D OThe rear view mirror locknut upper and rear view mirror stay are left hand thread e Loosen the rear view mirror nut lower and remove it Rear View Mirror Installation e Tighten the rear view mirror nut lower A e Tighten the rear view mirror stay B until the fully position e Adjust the rear view mirror stay to assure the safe condi tions of the rear with the rider sitting on the motorcycle OThe rear view mirror locknut upper and rear view mirror stay are left hand thread e Tighten the rear view mirror locknut upper C e Install the dust cover D e Adjust the rear view mirror E by slightly moving only the mirror portion of the assembly Olnstallation and adjustment of the left side are common with those of the right side Follow the procedure speci fied at the right side ELECTRICAL SYSTEM 16 1 Electrical System Table of Contents Exploded 16 3 Specifications
183. the washer A e Replace the circlip B with a new one and install it Special Tool Out side Circlip Pliers 57001 144 External Shift Mechanism Inspection e Examine the shift shaft A for any damage x If the shaft is bent straighten or replace it x If the serration B are damaged replace the shaft x If the springs C are damaged in any way replace them x If the shift mechanism arm D is damaged in any way replace the shift shaft e Check the return spring pin A is not loose x If it is loose unscrew it apply a non permanent locking agent to the threads and tighten it Torque Shift Shaft Return Spring Pin 39 N m 4 0 kgf m 29 ft lb CRANKSHAFT TRANSMISSION 9 31 External Shift Mechanism Check the gear positioning lever A and its spring for breaks or distortion xIf the lever or spring are damaged in way replace them e Visually inspect the shift drum cam B x If it is badly worn or shows any damage replace it 9 32 CRANKSHAFT TRANSMISSION Transmission Transmission Shaft Removal e Split the crankcase see Crankcase Splitting e Remove the drive shaft A and output shaft B Transmission Shaft Installation e Check to see that the set pins A and set rings B are in place e Install the drive shaft and output shaft into the upper crankcase half e Apply engine oil to the bearings OThe bearing set pins and rings must match properly with the holes o
184. thoroughly until the radiator fan starts e Turn the ignition switch to OFF e Remove the right side cover see Side Cover Removal in the Frame chapter e Open the clamp A and pull out the oxygen sensor lead connector B e Disconnect the oxygen sensor lead connector 4 pins con nector and connect the measuring adapter A between these connectors B Main Harness C Oxygen Sensor 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 R sensor BL Y lead Digital Meter BK sensor lead e Remove Air Cleaner Housing see Air Cleaner Housing Removal e Disconnect the stick coil connectors A e Pull up the rubber cover B forward ODo not disconnect the air switching valve connector C FUEL SYSTEM DFI 3 77 Oxygen Sensor not activated Service Code 33 e Separate the air switching valve hoses A from the air suction valve covers e Install the suitable plugs A on the fitting of the air suction valve covers and shut off the secondary air e Reposition the rubber cover and connect the stick coil connectors e Install the air cleaner housing temporarily see Air Cleaner Housing Installation e Remove the fuel hose see Fuel Hose Replacement in the Periodic Maintenance chapter e Connect the following parts temporary Fue
185. 07BS1 PERIODIC MAINTENANCE 2 29 Periodic Maintenance Procedures Tread Depth Standard Front 4 4 mm 0 17 in Rear 6 6 mm 0 26 in Service Limit Front 1 mm 0 04 in AT CH DE 1 6 mm 0 06 in Rear 2 mm 0 08 in Up to 130 km h 80 mph 3 mm 0 12 in Over 130 km h 80 mph A WARNING Some replacement tires may adversely affect han dling and cause an accident resulting in serious in jury or death To ensure proper handling and sta bility use only the recommended standard tires for replacement inflated to the standard pressure NOTE countries may have their own regulations a mini mum tire tread depth be sure to follow them OCheck and balance the wheel when a tire is replaced with a new one Wheel Bearing Damage Inspection e Raise the front wheel off the ground with the jack see Front Wheel Removal in the Wheels Tires chapter e Turn the handlebars all the way to the right or left e Inspect the roughness of the front wheel bearing by push ing and pulling A the wheel e Spin B the front wheel lightly and check for smoothly turn roughness binding or noise x If roughness binding or noise is found remove the front wheel and inspect the wheel bearing see Front Wheel Removal Hub Bearing Inspection in the Wheels Tires chapter e Raise the rear wheel off the ground with the stand see Rear Wheel Removal in the Wheels Tires chapter e Inspect the
186. 0806053842 ENGINE LUBRICATION SYSTEM 7 9 Cil Pan NOTE OMake the application finish within 7 minutes when the liquid gasket to the mating surface of the oil pan is ap plied OMoreover fit the oil pan and tighten the bolts just after application of the liquid gasket e Tighten the oil pan bolts following sequence 1 20 Torque Oil Pan Bolts 12 N m 1 2 kgf m 106 in Ib 80806063842 C e Install the removed parts see appropriate chapters 7 10 LUBRICATION SYSTEM Oil Screen Oil Screen Removal e Remove Oil Pan see Oil Pan Removal Oil Screen A Oil Screen Installation e Clean the oil screen see Oil Screen Cleaning e Replace the O ring A with a new one and install it e Apply grease to the O ring e Install the rubber damper B to the oil pressure relief valve e Install the oil screen Oil Screen Cleaning e Remove the oil screen see Oil Screen Removal e Clean the oil screen with a high flash point solvent and remove the particles stuck e Blow away the particles by applying compressed air A from the inside to the outside from the clean side to the dirty side A WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the screen 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
187. 1 C GK04093BS1 C Drive FINAL DRIVE 11 9 e Turn the pin holder A by wrench clockwise until two pins of link come into groove of plate holders B e Take off the plate holder e Set the plate holder B A and cutting and riveting pin B as shown in the figure e Turn the pin holder until riveting pin touches link pin e Turn the wrench clockwise until tip of riveting pin hits to the link pin e Rivet it e Same work for the other link pin GK04094BS1 GK04026BS1 C 11 10 FINAL DRIVE Drive Chain e After staking check the staked area of the link pin for cracks e Measure the outside diameter A of the link pin and link plates width B Link Pin Outside Diameter Standard 5 6 6 0 mm 0 22 0 24 in Link Plates Outside Width Standard 19 35 19 55 mm 0 7618 0 7697 in x If the reading exceeds the specified length cut and rejoin the chain again e Check Movement of the Rollers e Adjust the drive chain slack after installing the chain see Drive Chain Slack Adjustment in the Periodic Mainte nance chapter GK04028BS1 Sprocket Coupling FINAL DRIVE 11 11 Engine Sprocket Cover Removal e Remove Left Lower Fairing see Lower Fairing Removal in the Frame chapter Engine Sprocket Inner Cover Bolts A Engine Sprocket Inner and Outer Cover B e Remove the engine sprocket outer cover screws A to separate the outer and inn
188. 1 C ELECTRICAL SYSTEM 16 29 Battery Terminal Voltage 11 5 less than 12 8 V Standard Charge 0 9 A x 5 10 h see following chart Quick Charge 4Ax1h NOTICE If possible do not quick charge If quick charge is done unavoidably do standard charge later on Terminal Voltage less than 11 5 V Charging Method 0 9 20 h Olncrease the charging voltage to a maximum voltage of 25 V if the battery will not accept current initially Charge for no more than 5 minutes at the increased voltage then check if the battery is drawing current If the battery will accept current decrease the voltage and charge by the standard charging method described on the battery case If the battery will not accept current after 5 min utes replace the battery Battery A Battery Charger B Standard Value C Current starts to flow D e Determine the battery condition after refresh charge ODetermine the condition of the battery left for 30 minutes after completion of the charge by measuring the terminal voltage according to the table below 12 0 lower than 12 8 V Charge insufficient Recharge lower than 12 0 V Unserviceable Replace Charge Time h 11 10 9 1 1 11 6 11 8 12 0 12 2 12 4 12 6 12 8 13 0 Battery Terminal Voltage V 4208021851 v B afa ig 8 08022851 C 16 30 ELECTRICAL SYSTEM Charging System Alternator
189. 12 7 Fastener N m Torque kgf m R k ftlb emarks 1 Brake Pipe Joint Nuts 8 1 8 2 Brake Hose Banjo Bolts 5 2 5 5 2 5 Rear Master Cylinder Mounting Bolts Brake Pedal Bolt Rear Master Cylinder Push Rod Locknut 1 7 Rear Caliper Pin Bolt 2 8 Bleed Valve i 17 27 7 8 1 2 2 8 8 0 90 0 80 Rear Brake Pad Pin Plug 2 5 0 25 22 17 Rear Brake Pad Pin 1 7 Rear Caliper Mounting Bolt 22 2 2 i 27 2 8 11 Brake Disc Mounting Bolts 12 ABS Hydraulic Unit 13 Rear Wheel Rotation Sensor B Apply brake fluid G Apply grease R Replacement Parts Si Apply silicone grease ex PBC grease NOTE OWhen disassembling the brake hose and pipe disassemble them by the unit as shown in the exploded view 12 8 BRAKES Specifications Item Standard Service Limit Brake Lever Brake Pedal Brake Lever Position Brake Lever Free Play Pedal Free Play Pedal Position Brake Pads Lining Thickness Front Rear 5 way adjustable to suit rider Non adjustable Non adjustable About 54 mm 2 1 in below footpeg top 4 0 mm 0 16 in 5 0 mm 0 20 in 1 mm 0 04 in 1 mm 0 04 in Brake Discs Thickness Front Rear Runout Brake Fluid Grade ABS Wheel Rotation Sensor Air Gap Front Rear 4 8 5 2 mm 0 19 0 20 in 5 8 6 2 mm 0 23 0 24 in TIR 0 15 mm 0 006 in or less 0 4 1 6 mm 0 02 0 06 in 0 4 1 6 mm 0 02 0 06 in
190. 12V108 R City Light Gr 1254 Headlight Low 12 55 Headlight High 12 55 Front Left Turn Signal Light 12V108 Accessory lt O avy Connectors py Relay Box 1 iur Cv den DC 12 4 BR 1 1 22 5 1 zz 1 CoeoeQd erates Housing Relay Box Horn Button i fuge Box 2 Hazard Button se aa Ignition Fuse Left Switch Housing 3 Turn Signal Switch M even 2 Headlight Relay 4 Passing Button 2 Headlight Circuit Fuse 15 5 Dimmer Switch Relay 3 Brake Light 6 Starter Lockout 3 ECU Main Relay Horn Fuse 7 94 goes sory Switch 4 Fuel Pump Relay 4 Turn Signal Relay Relay 7 SEL Button 5 Starter Circuit Fuse 7 5 B Upper and Lower Relay Button ABS Hydraulic Unit LEFT SWITCH HOUSING CONNECTIONS Horn Button Hazard Button Turn Signal Switch Passing Button Dimmer Switch Starter Lockout Switch Multifunction Button fester BR YBK AlGerer o ey e toler R Y R Y Clutch Lever Push Released Released R Lo Pulled In Lower W2L0694885 C Wiring Model ELECTRICAL SYSTEM 16 19 Crank shaft Sensor Sub throttle Fuel Injectors Valve Actuator BL 8K WR BL R WR BL O WR WAR 18888 Sub throttle Sensor Main Intake Air Throttle Pressure Sensor Sensor 2 t a dot utem Neutral 011 Oxygen Temperatura S
191. 13 6 SUSPENSION Specifications Item Standard Front Fork Per One Unit Fork Inner Tube Diameter Air Pressure Rebound Damper Setting Right Front Fork Only Fork Spring Preload Setting Fork Oil Recommend Oil Amount When Changing Oil for reference Right Front Fork Left Front Fork After Disassembly and Completely Dry Right Front Fork Left Front Fork Fork Oil Level Fully Compressed without Spring below from the Top of the Outer Tube Right Front Fork Left Front Fork Fork Spring Free Length 43 mm 1 7 in Atmospheric pressure non adjustable 7 clicks from the fully clockwise position Usable range 0 12 clicks Adjuster protrusion is 12 mm 0 47 in Usable range 4 19 mm 0 16 0 75 in KHL 15 10 or equivalent Approx 450 mL 15 2 US oz Approx 455 mL 15 4 US oz 528 4 mL 17 9 0 1 US oz 535 4 mL 18 1 0 1 US oz 115 2 mm 4 53 0 08 in 114 2 mm 4 49 0 08 in 282 mm 11 1 in Service Limit 276 mm 10 9 in Rear Shock Absorber Rebound Damper Setting Spring Preload Setting Position Gas Pressure 2 turns out from the fully clockwise position Usable Range 0 lt gt 3 3 4 turns out 1 click from the fully counterclockwise position Usable Range 0 lt gt 24 clicks 1 270 kPa 13 kgf cm 184 psi Non adjustable Special Tools Inside Circlip Pliers 57001 143 7570143ST C Oil Seal amp Bearing Remover
192. 130 08 1 3 5 92139 0032 92139 0217 1 3 5 The bearing inserts for Nos 2 and 4 journals have oil groove respectively 9 8 CRANKSHAFT TRANSMISSION Special Tools and Sealants Bearing Puller 57001 135 7570135ST C Outside Circlip Pliers 57001 144 7570144ST C Bearing Puller Adapter 57001 317 7570317ST C Bearing Driver 32 57001 382 875703825 C Bearing Driver Set 57001 1129 Flywheel Holder 57001 1313 875711295 C ST571313ST C Liquid Gasket TB1216B 92104 1064 879210645 6 Liquid Gasket TB1207B 92104 2068 879220685 CRANKSHAFT TRANSMISSION 9 9 Crankcase Splitting Crankcase Splitting e Remove the engine see Engine Removal in the Engine Removal Installation chapter e Set the engine on a clean surface and hold the engine steady while parts are being removed e Remove Cylinder see Cylinder Removal in the Engine Top End chapter Clutch see Clutch Removal in the Clutch chapter External Shift Mechanism see External Shift Mecha nism Removal Starter Motor see Starter Motor Removal in the Electri cal System chapter Oil Pump see Oil Pump Removal in the Engine Lubri cation System chapter Alternator Rotor see Alternator Rotor Removal in the Electrical System chapter Oil Filter see Oil Filter Replacement in the Periodic Maintenance chapter Oil Coo
193. 15 15 Seat Covers Seat Cover Removal e Remove Seat see Seat Removal Carrier see Carrier Removal Bolts A and Washers e Pull up the seat cover B to clear the hook portions C from the slots of the rear fender and remove it Seat Cover Installation e Installation is the reverse of removal note the following OFit the craws A into the slits B on the rear fender 15 16 FRAME Carrier Carrier Removal e Remove Seat see Seat Removal Carrier Bracket Bolts A and Collars Carrier Assembly B e Remove Carrier Mounting Bolts A and Washers Carrier B Right and Left Carrier Brackets C Carrier Installation e Installation is the reverse of removal note the following OApply a non parmanent locking agent to the thread of the carrier bracket bolts and carrier mounting bolts OTighten Torque Carrier Mounting Bolts 8 8 0 90 kgf m 78 in Ib Carrier Bracket Bolts 34 N m 3 5 kgf m 25 ft Ib FRAME 15 17 Fenders Front Fender Removal e Remove Brake Hose Clamp A Both Sides Reflectors Both Sides AU and CA Models Bolts B with Washers Both Sides Front Fender C Front Fender Installation e Installation is the reverse of removal note the following OlInstall the front fender to the front fork OTighten Torque Front Fender Mounting Bolts 3 9 N m 0 40 kgf m 35 in Ib Olnstall the brake hose clamps to the front fender holes OFace the lock portio
194. 16 trouble Immobilizer system trouble Equipped Model 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 gap maladjusted Inspect and replace see chapter 2 Spark plug incorrect Replace it with the correct plug see chapter 2 ECU ground and power supply trouble Inspect see chapter 3 ECU trouble No or little fuel in tank Fuel injector trouble Fuel pump not operating Fuel pump relay trouble Inspect and replace see chapter 16 Fuel filter or pump screen clogged Inspect and replace fuel pump see chapter 3 Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump see chapter 3 Fuel line clogged Inspect and repair see chapter 3 Poor Running at Low Speed Symptoms or Possible Causes Actions chapter Spark weak Ene Stick coil shorted or not in good contact Inspect or reinstall see chapter 16 Stick coil trouble Inspect see chapter 16 Spark plug dirty broken or gap maladjusted Inspect and replace see chapter 2 Spark plug incorrect Replace it with the correct plug see chapter 2 ECU trouble Inspect see chapter 3 Fuel air mixture incorrect Litt
195. 2 and retrieve the service code x If the yellow ABS indicator light LED A light the sole noid valve in the ABS hydraulic unit has trouble Replace the ABS hydraulic unit x If the yellow ABS indicator light LED does not light ABS system is normal service code is not stored temporary failure ABS Solenoid Valve Relay Inspection Service Code 19 e Remove Seat see Seat Removal in the Frame chapter e Check the ABS solenoid valve relay fuse 15 A A see Fuse Inspection in the Electrical System chapter x If the fuse is good check the wiring continuity between the positive terminal A of the battery and R BK lead terminal B in the ABS Hydraulic Unit Lead Connector C Special Tool Hand Tester 57001 1394 the wiring is open replace or repair the harness see ABS System Wiring Diagram x If the wiring is good go to next step GL14585BS1 Anti Lock System BRAKES 12 45 5 solenoid valve relay is built in the 5 Hydraulic Unit Therefore the relay cannot be checked directly Recheck the service code indication erase the service code perform the pre diagnosis inspection 1 and 2 and retrieve the service code x If the yellow ABS indicator light LED A lights the ABS hydraulic unit has trouble Replace the ABS hydraulic unit x If the yellow ABS indicator light LED does not light ABS system is normal service code is not stored
196. 2 5 kgf m 18 ft lb Brake Pipe Joint Nuts 18 N m 1 8 kgf m 13 16 e Inspect the brake hose routing If any brake hose routing is incorrect route the brake hose according to Cable Wire and Hose Routing section in the Appendix chapter 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 2 36 PERIODIC Periodic Maintenance Procedures Brake Fluid Level Inspection e Check that the brake fluid level in the front brake reservoir A is above the lower level line B NOTE OHold the reservoir horizontal by turning the handlebars when checking brake fluid level x If the fluid level is lower than the lower level line fill the reservoir to the upper level line C in the reservoir e 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
197. 211F 92104 0004 e Apply silicone sealant A to the crankshaft sensor lead grommet and crankcase halves mating surface on the front and rear sides of the crankshaft sensor cover mount Sealant Liquid Gasket TB1211F 92104 0004 e Replace the O ring A in the crankshaft sensor cover with a new one OApply grease to the O ring e Install Crankshaft Sensor Cover A e Tighten Torque Crankshaft Sensor Cover Bolts B 12 N m 1 2 kgf m 106 in Ib e Run the crankshaft sensor lead correctly see Cable Wire and Hose Routing section in the Appendix chapter e Install the removed parts see appropriate chapters ELECTRICAL SYSTEM 16 41 Ignition System Crankshaft Sensor Inspection e Support the fuel tank with a suitable bar see Fuel Tank Removal in the Fuel System DFI chapter e Disconnect the crankshaft sensor A see Crankshaft Sensor Removal e Set the hand tester B to the x 10 O range and connect lead to the yellow lead and lead to the black lead in the connector Special Tools Hand Tester 57001 1394 Needle Adapter Set C 57001 1457 Crankshaft Sensor Resistance 376 564 x If there is more resistance than the specified value the coil has an open lead and must be replaced Much less than this resistance means the coil is shorted and must be replaced e Using the highest resistance range of the tester measure the resistance between the crankshaft sensor leads an
198. 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 2 12 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Fuel System DFI Throttle Grip Free Play Idle Speed Bypass Screws Turn Out Throttle Body Vacuum Air Cleaner Element Cooling System Coolant Type Recommended Color Mixed Ratio Freezing Point Total Amount Engine Top End Valve Clearance Exhaust Intake Clutch Clutch Lever Free Play Engine Lubrication System Engine Oil Type Viscosity Capacity Wheels Tires Tread Depth Front Rear Air Pressure when Cold 2 3 0 08 0 12 in 1 100 50 r min rpm 2 1 2 for reference 40 7 1 3 kPa 305 10 mmHg at idle speed Viscous paper element Permanent type of antifreeze Green Soft water 5096 Coolant 5096 35 31 F 2 6 L 2 7 US qt 0 22 0 31 mm 0 0087 0 0122 in 0 15 0 24 mm 0 0059 0 0094 in 2 mm 0 08 0 12 in API SG SH SJ SL or SM with JASO MA1 or 2 SAE 10W 40 3 2 L 3 4 US qt when filter is not removed 3 8 L 4 0 US qt when filter is removed 4 0 L 4 2 US qt when engine is completely dry 4 4 mm 0 17 in 6 6 mm 0 26 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
199. 56 aee 12 57 BRAKES 12 3 Exploded View This page intentionally left blank 12 4 BRAKES Exploded 08102493845 C Exploded View BRAKES 12 5 Fastener Torque kgf m R k ftlb emarks Front Master Cylinder Reservoir Cap Screws 1 5 0 15 13 in Ib 1 0 0 10 8 9 in lb Si 2 Brake Lever Pivot Bolt 3 Lever Pivot Bolt Locknut 5 9 0 60 52 in lb Front Master Cylinder Clamp Bolts 11 1 1 97 inb S 1 2 0 12 11 in Ib 5 Front Brake Light Switch Screw 6 Hose Banjo Bolts 25 18 7 Brake Pipe Joint Nuts 18 Front Brake Pad Spring Bolts 2 9 0 30 26 inb Bleed Valve 7 8 0 80 69 inb 2 1 8 5 Hydraulic Unit Bracket Bolts 8 8 0 90 78 inb L 9 Front Brake Disc Mounting Bolts 27 1 1 8 20 Front Caliper Assembly Bolts 22 2 2 16 713 Front Brake Pad Pin 15 5 18 Front Caliper Mounting Bolts 25 15 Face the lock portion of the clamp backward 16 Front Wheel Rotation Sensor 17 ABS Hydraulic Unit B Apply brake fluid L Apply a non permanent locking agent R Replacement Parts S Follow the specified tightening sequence Si Apply silicone grease ex PBC grease NOTE OWhen disassembling the brake hose and pipe disassemble them by the unit as shown in the exploded view 12 6 BRAKES Exploded View 6L02494BW5 C Exploded View BRAKES
200. 57001 1058 7571058ST C Bearing Driver Set 57001 1129 7571129ST C Jack 57001 1238 7571238ST C Bearing Remover Head 15 x 17 57001 1267 875712675 C SUSPENSION 13 7 Fork Oil Level Gauge 57001 1290 875712905 C Fork Piston Rod Puller M10 x 1 0 57001 1298 7571298ST C Fork Spring Stopper 57001 1374 lt gt Bearing Remover Shaft 13 57001 1377 875713745 6 875713775 C Fork Cylinder Holder 57001 1443 7571443ST C 13 8 SUSPENSION Special Tools Fork Oil Seal Driver 43 57001 1530 875715305 C Fork Spring Compressor 57001 1540 7571540ST C Fork Spring Compressor 57001 1587 875715875 C Swingarm Pivot Nut Wrench 57001 1597 7571597ST C Jack Attachment 3 7571608ST C Needle Bearing Driver 517 018 57001 1609 Needle Bearing Driver 528 57001 1610 7571609ST C 8 5716105 C Bar 57001 1694 875716945 Fork Spring Compressor 57001 1771 ST5717718T 6 SUSPENSION 13 9 Front Rebound Damping Force Adjustment Right Front Fork Only e To adjust the rebound damping force turn the rebound damping adjuster A until you feel a click OThe standard adjuster setting is the 7 clicks from the fully clockwise position OThe damping
201. 6 PERIODIC Periodic Maintenance Procedures e Connect vacuum gauge special tool and hoses A to the fittings on the throttle body Special Tool Vacuum Gauge 57001 1369 e Connect a highly accurate tachometer B to one of the Stick coil primary leads e Plug the air switching valve hose end A and air cleaner housing fitting B e Install the air cleaner housing see Air Cleaner Housing Installation in the Fuel System DFI chapter e Remove the fuel hose see Fuel Hose Replacement e Connect the following parts temporary Fuel Pump Lead Connector A Fuel Hose B Special Tool Fuel Hose 57001 1607 e Start the engine and warm it up thoroughly e Check the idle speed using a highly accurate tachometer A Idle Speed Standard 1 100 50 r min rpm x If the idle speed is out of the specified range adjust it with the adjusting screw see Idle Speed Adjustment 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 40 7 1 3 kPa 305 10 mmHg at idle speed PERIODIC MAINTENANCE 2 17 Periodic Maintenance Procedures xIf any vacuum is not within specifications first synchro nize the balance of the left 1 2 throttle valves and right 3 4 throttle valves assemblies Example 311 260 mmHg 2 300 mmHg 3 250 mmHg
202. 6 in Ib e Install the water hoses A and clamps as shown in the figure e Tighten Torque Radiator Water Hose Clamp Screws B 3 0 0 31 27 in Ib e Install the removed parts see appropriate chapters LUBRICATION SYSTEM 7 15 Cil Pressure Measurement Oil Pressure Measurement e Remove the right lower fairing see Lower Fairing Re moval in the Frame chapter e Remove the oil passage plug A e 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 e Start the engine and warm up the engine e Run the engine at the specified speed and read the oil pressure gauge x the oil pressure is much lower than the standard check the oil pump relief valve and or crankshaft bearing insert wear immediately If the reading is much higher than the standard check the oil passages for clogging Oil Pressure Standard 255 304 kPa 2 6 3 1 kgf cm 37 44 psi at 4 000 r min rpm oil temperature 50 C 122 F Stop the engine Remove the oil pressure gauge and adapter A WARNING Take care against burns form hot engine oil that will drain through the oil passage when the gauge adapter is removed e Apply a non permanent locking agent to the oil passage plug and tighten it Torque Oil Passage Plug 20 N m 2 0 kgf m 15 ft Ib 7 16
203. 7 Intake Air Pressure Sensor 2 48 Intake Air Pressure Sensor 1 49 Water Temperature Sensor 50 Oxygen Sensor 3 14 FUEL SYSTEM DFI System OColor Codes BK Black GY Gray PU Purple BL Blue LB Light Blue R Red BR Brown LG Light Green V Violet CH Chooolate O Orange W White DG Dark Green P Pink Y Yellow G Green Terminal Numbers of ECU Connectors ri a C 44143142141 39 38 37 36 35 34 55 54 53 52 50 49 48 47 46 45 66 65 64 63 62 61 60 59 58 57 56 1110 9 11615 1413 1211 22121120 18 17 16 15 14 13 12 EEJCYEEICEIEEIEEIEEIHDIEEL 089 Terminal Names 1 Subthrottle Valve Actuator P BL 2 Unused 3 Unused 4 Power Supply to Sensors BL 5 Fuel Pump Relay BR Y 6 Power Supply to ECU from ECU Main Relay BR W 7 Power Supply to ECU from Battery W BK 8 Oxygen Sensor BL Y 9 KTRC Indicator Light G R 10 Front Wheel Rotation Sensor Signal G Y 11 Immobilizer Amplifier Equipped Model V 12 Subthrottle Valve Actuator Y BK 13 Unused 14 Unused 15 Unused 16 Intake Air Temperature Sensor R BK 17 Intake Air Pressure Sensor 2 G W 18 Intake Air Pressure Sensor 1 Y BL 19 Vehicle down Sensor Y G 20 Rear Wheel Rotation Sensor Output P 21 Rear Wheel Rotation Sensor Signal R Y 22 Immobilizer Amplifi
204. 961 1 4967 in 38 009 38 016 mm 1 4964 1 4967 in 38 000 38 008 mm 1 4961 1 4963 in TIR 0 2 100 mm 0 008 3 94 in TIR 0 2 100 mm 0 008 3 94 in 0 58 mm 0 023 in 0 10 mm 0 0039 in 34 47 mm 1 357 in 0 39 mm 0 0153 in TIR 0 05 mm 0 0020 in 0 06 mm 0 0024 in 34 96 mm 1 3764 in CRANKSHAFT TRANSMISSION 9 7 Specifications Item Standard Service Limit Crankshaft Main Bearing Insert Thickness Brown 1 491 1 495 mm 0 0587 0 0589 in Black 1 495 1 499 mm 0 0589 0 0590 in Blue 1 499 1 503 mm 0 0590 0 0592 in Transmission Shift Fork Ear Thickness 5 9 6 0 mm 0 232 0 236 in 5 8 mm 0 228 in Gear Groove Width 6 05 6 15 mm 0 238 0 242 in 6 25 mm 0 246 in Shift Fork Guide Pin Diameter 6 9 7 0 mm 0 272 0 276 in 6 8 mm 0 268 in Shift Drum Groove Width 7 05 7 20 mm 0 278 0 283 in 7 3 mm 0 287 in Connecting Rod Big End Bearing Insert Selection Con rod Big End Inside Diameter Crankpin Diameter Marking Marking Size Color Part Number None J ooo 925991 None m a Black 92139 0123 o 321390122 Crankshaft Main Bearing Insert Selection Crankcase Main Crankshaft Main Bearing Insert Bearing Inside Journal Diameter Diameter Marking Marking Bearing Insert Size Color Part Number Journal Nos 92139 0034 2 4 1 Brown 92139 0219 1 3 5 92139 0033 2 4 Black 02
205. A while holding the alter nator rotor steadily with the holder B temporarily Special Tool Rotor Holder 57001 1757 Torque Alternator Rotor Bolt 70 N m 7 0 kgf m 52 ft Ib e Remove the rotor bolt and washer see Alternator Rotor Removal e Check the tightening torque with flywheel puller A Special Tool Flywheel Puller Assembly M38 x 1 5 M35 x 1 5 57001 1615 x the rotor is pulled out with under 20 N m 2 0 15 ft lb of drawing torque clean off any oil dirt or flaw of the crankshaft and rotor tapered portion and dry them with a clean cloth Then confirm that it is not pulled out with above torque xIf the rotor is not pulled out with 20 N m 2 0 kgf m 15 ft lb of drawing torque it is installed correctly Tighten the alternator rotor bolt with specified torque as follows 16 34 ELECTRICAL SYSTEM Charging System 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 1690 Stopper D 57001 1679 Torque Alternator Rotor Bolt 155 Nm 15 8 kgf m 114 ft Ib If using rotor holder 57001 1757 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 Tool Rotor Holder 57001 1757 Torque Alternator Rotor Bolt 155 Nm 15 8 kgf m 114 ft Ib
206. ARNING 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 HJ07008BS1 C Wheels Rims WHEELS TIRES 10 9 e Install rear wheel rotation sensor see Rear Wheel Rota tion 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 which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the motorcycle until a firm brake pedal is obtained by pumping the pedal until the pads are against the disc Wheel Inspection e Raise the front rear wheel off the ground Special Tools Jack 57001 1238 Jack Attachment 57001 1608 Attachment Jack 57001 1252 e Spin the wheel lightly and check for roughness or binding x If roughness or binding is found replace the hub bearings see Hub Bearing Removal Installation e Inspect the wheel for small cracks dents bending or warp x If there is any damage to the wheel replace the wheel e Remove the wheel and support it with the tire by the axle e Measure the rim runout axial A and radial B with a dial gauge If rim runout exceeds the service limit check the hub bear ings see Hub B
207. Air Cleaner Duct Clamp Bolts 2 0 0 20 18 in Ib Delivery Pipe Assy Mounting Screws 3 4 0 35 30 in Ib Oxygen Sensor 44 4 5 32 Crankshaft Sensor Bolts 5 9 0 60 52 Intake Air Temperature Sensor Mounting Screw 1 2 0 12 11 in Ib Water Temperature Sensor 12 1 2 106 in Ib Fuel Pump Bolts 9 8 1 0 87 in Ib L Cooling System Radiator Water Hose Clamp Screws 26 in Ib Coolant By pass Fitting Bolt 78 Thermostat Housing Bolts 52 Water Pipe Bolts 1 106 in Ib Water Pump Impeller Bolt 87 in Ib Water Pump Cover Bolts 97 in lb Coolant Drain Bolt 97 in lb Air Suction Valve Cover Bolts 87 in lb Spark Plugs 115 in Ib Cylinder Head Cover Bolts 87 in lb Camshaft Sprocket Bolts 11 Upper Camshaft Chain Guide Bolts 106 in Ib Camshaft Cap Bolts 106 in Ib Cylinder Head Bolts 10 First 15 Cylinder Head Bolts 10 Final 40 Cylinder Head Bolts M6 106 in Ib PERIODIC MAINTENANCE 2 7 Torque and Locking Agent Fastener Remarks Throttle Body Assy Holder Bolts 106 in Ib L Plugs 14 5 L Throttle Body Assy Holder Clamp Bolts 26 in Ib Front Camshaft Chain Guide Bolt Upper 18 Rear Camshaft Chain Guide Bolt 18 Front Camshaft Chain Guide Bolt Lower 106 in Ib Coolant Fitting Bolt 78 in lb L Camshaft Chain Tensioner Cap Bolt 15 Camshaft Chain Tensioner Mounting Bolts 97 in lb Muffler Body Mounting Bolt 25 Chamber
208. BS hydraulic unit has trouble Replace the ABS hydraulic unit x If the yellow ABS indicator light LED does not light ABS system is normal service code is not stored temporary failure GL14586BS1 GL14580BS1 GL14580BS1 Anti Lock System BRAKES 12 47 Front Wheel Rotation Sensor Wiring Inspection Service Code 43 e Disconnect ABS Hydraulic Unit Connector see ABS Hydraulic Unit Removal Front Wheel Rotation Sensor Connector see Front Wheel Rotation Sensor Removal e Check the wiring continuity of the BK W lead and W BK lead Special Tool Hand Tester 57001 1394 Front Wheel Rotation Sensor Lead Connector A ABS Hydraulic Unit Lead Connector B BK W Lead Terminals C W BK Lead terminals D xIf the wiring is open replace or repair the harness see ABS System Wiring Diagram x If the wiring is good go to next step e Recheck the service code indication erase the service code perform the pre diagnosis inspection 1 and 2 and retrieve the service code the yellow ABS indicator light LED A lights replace the front wheel rotation sensor see Front Wheel Rotation Sensor Removal Still when it is not good replace the ABS hydraulic unit x If the yellow ABS indicator light LED does not light ABS system is normal service code is not stored temporary failure Rear Wheel Rotation Sensor Signal Abnormal Service Code 44 e
209. CI 2 oz L 5 0 C zoo No b cde rani cd 3 5 o 0 vc oo O Ce cote Ow oan gt gn TES Qoo L 15 Blowby Gas 7 Oil Pipe 8 Oil Screen Specifications ENGINE LUBRICATION SYSTEM 7 5 Item Standard Engine Oil Type Viscosity Capacity Oil Pressure Measurement Oil Pressure API SG SH SJ SL or SM with JASO MA MA1 or MA2 SAE 10W 40 3 2 L 3 4 US gt when filter is not removed 3 8 L 4 0 US gt when filter is removed 4 0 L 4 2 US gt when engine is completely dry Between upper and lower level lines Wait several minutes after idling or running 255 304 kPa 2 6 3 1 kgf cm 37 44 psi at 4 000 r min rpm Oil Temperature 50 C 122 F 7 6 ENGINE LUBRICATION SYSTEM Special Tools and Sealants Liquid Gasket TB1211 Oil Pressure Gauge Adapter PT3 8 56019 120 57001 1233 875601205 6 875712335 Outside Pliers Liquid Gasket TB1207B 57001 144 92104 2068 7570144ST C 879220685 Oil Pressure Gauge 10 kgf cm 57001 164 7570164ST C LUBRICATION SYSTEM 7 7 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 level befo
210. CTRICAL SYSTEM 16 83 Meter Circuit GPi7819CW3 C OO LO doo NI LX XA lx X 15 Ignition Switch Crankshaft Sensor Water Temperature Sensor Neutral Switch Oil Pressure Switch ECU Joint Connector D Rear Wheel Rotation Sensor Frame Ground 1 Frame Ground 4 Frame Ground 2 Engine Ground Battery 12 V 8 Ah Starter Relay Main Fuse 30 A ECU Fuse 15 A Fuse Box 2 Meter Fuse 7 5 A Fuel Level Sensor ABS Hydrauric Unit Upper and Lower Button SEL Button Fuse Box 1 lgnition Fuse 15 A Outside Temperature Sensor to Turn Signal Switch Left to Turn Signal Switch Right to Dimmer Switch and Passing Button Meter Unit Joint Connector F 16 84 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 transpon der and ECU Electronic Control Unit If the code does not match ignition system injectors and subthrottle 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 red warning indica
211. Clamp B e Remove Lower Rear Shock Absorber Nut and Bolt A Upper Rear Shock Absorber Bolt B Clamp C e Remove the rear shock absorber D from rearside Rear Shock Absorber Installation e Replace the rear shock absorber nut lower with a new one e Tighten Torque Rear Shock Absorber Bolt and Nut Upper and Lower 34 N m 3 5 kgf m 25 ft Ib 13 26 SUSPENSION Shock Absorber Rear Shock Absorber Inspection e Remove the rear shock absorber see Rear Shock Ab sorber Removal e Visually inspect the following items Smooth Stroke Oil Leakage Crack or Dent x If there is any damage to the rear shock absorber replace it e Visually inspect the rubber bushing x If it show any signs of damage replace it Rear Shock Absorber Scrapping A WARNING Since the rear shock absorber contains nitrogen gas do not incinerate the rear shock absorber with out first releasing the gas or it may explode Before arear shock absorber is scrapped drill a hole at the point A shown to release the nitrogen gas com pletely Wear safety glasses when drilling the hole as the gas may blow out bits of drilled metal when the hole opens Rear Shock Absorber Bearing Removal e Remove Rear Shock Absorber see Rear Shock Absorber Re moval Sleeve A Grease Seals B e Remove the needle bearing A using the bearing re mover head B and bearing remover shaft C Special Tools Bearin
212. Code 55 e Recheck the service code indication erase the service code perform the pre diagnosis inspection 1 and 2 and retrieve the service code x If the yellow ABS indicator light LED A lights the ABS hydraulic unit has trouble Replace the ABS hydraulic unit If the yellow ABS indicator light LED does not Igiht ABS system is normal service code is not stored temporary failure GL14580BS1 GL14580BS1 GL14580BS1 12 50 BRAKES Anti Lock System Output Fluid Pressure Sensor Front Brake Wiring Inspection Service Code 83 OThe Output Fluid Pressure Sensor is built in the ABS Hy draulic Unit Therefore the sensor cannot be checked di rectly e Perform the Pre Diagnosis Inspection 1 and 2 see In quiries to Rider x If the yellow ABS indicator light LED A lights the ABS hydraulic unit has trouble Replace the ABS hydraulic unit x If the yellow ABS indicator light LED does not Igiht ABS system is normal service code is not stored temporary failure Output Fluid Pressure Sensor Front Brake Offset Abnormal Service Code 84 OThe Output Fluid Pressure Sensor is built in the ABS Hy draulic Unit Therefore the sensor cannot be checked di rectly e Perform the Pre Diagnosis Inspection 1 and 2 see In quiries to Rider x If the yellow ABS indicator light LED A lights the ABS hydraulic unit has trouble Replace the ABS hydraulic uni
213. 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 e Remove the pressure tester replenish the coolant and install the radiator cap 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 e Fill the cooling system with fresh water mixed with a flush ing compound NOTICE Do not use a flushing compound which is harmful to the aluminum engine and radiator Carefully follow the instructions supplied by the manufacturer of the cleaning product e Warm up the engine and run it at normal operating tem perature for about ten minutes e Stop the engine and drain the cooling system e Fill the system with fresh water e Warm up the eng
214. ER CES DE E EXT E E CES EKZ ENT ENT EKT DIT roro 542551 oe oda ada a2 do ofa oo ofa 1 a 23 0 even rne sir eds ede ri odo up ed odo ds ws dos eds o o do olosan sdz odz edz oe 192 oe oa oe ofp ods ida fo ep aa ao aga 2 60 2 65 2 702 75 2 80 2 8512 9012 9513 00 3 10 3 15 3 203 25 3 30 3 3513 40 3 45 3 50 2 65 2 70 2 75 2 80 2 85 2 9012 9513 0013 0 03 1513 2013 2513 30 3 35 3 40 3 45 3 50 3 20 3 25 3 30 3 35 3 40 3 4513 50 2 70 2 75 2 802 85 2 90 2 9513 00 3 05 3 10 PETENS DET DNI ONT DET DS DT 50 0 4850 52 4513 0 58v0 62 2 902 9913 oq 3 os 0 18 3 zola 2913 sola 35 0 5 5o 0 6350 67 3 3 53 0 73 0 77____ 3 08 3 10 3 1913 203 25 3 3053 353 4of3 453 50 INSTALL THE SHIM THIS THICKNESS mm 6GS07122BW3 C Measure the clearance when engine is cold Check present shim size Match clearance in vertical column with present shim size in horizontal column Install the shim specified where the lines intersect This shim will give the proper clearance Example Present shim is 2 95 mm Measured clearance is 0 45 mm Replace 2 95 mm shim with 3 20 mm shim 5 Remeasure the valve clearance and readjust if necess
215. F NOTE OThe output voltage changes according to the coolant temperature in the engine 1 910 GC17117FS1 3 58 FUEL SYSTEM DFI 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 Removal Installation 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 Water Temperature Sensor Connector B W G lead ECU terminal 30 C G lead ECU terminal 49 D x If the wiring is good check the water temperature sensor resistance see Water Temperature Sensor Resistance Inspection 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 GC17118FS1 eT WR 1 ECU 2 Water Temperature Sensor 6617081212 FUEL SYSTEM DFI 3 59 Intake Air Pressure Sensor 2 Service Code 16 Intake Air Pressure Sensor
216. Fairing Removal in the Frame chapter 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 A and turn the balancer shaft B clockwise C until the balancer gear makes a whining sound OTurn the shaft counterclockwise D until the balancer gear whining sound disappears and tighten the clamp bolt Torque Balancer Shaft Clamp Bolt 9 8 N m 1 0 kgf m 87 in Ib Balancer Damper Inspection e Remove the balancer and disassemble the weight and gear assembly e Visually inspect the rubber dampers A x If they appear damaged or deteriorated replace them 61068167 P CRANKSHAFT TRANSMISSION 9 27 Starter Motor Clutch Starter Motor Clutch Removal Installation e Refer to the Alternator Rotor Removal Installation in the Electrical System chapter Starter Motor Clutch Inspection e Remove Alternator Cover see Alternator Cover Removal in the Electrical System chapter Starter Idle Gear and Shaft e Turn the starter motor clutch gear A by hand The starter motor clutch gear should turn clockwise B freely but should not turn counterclockwise C x If the starter motor clutch does not operate as it should or if it makes noise go to the next step e Disassemble the starter motor clutch and visuall
217. Ground GL145828W2 C 12 40 BRAKES Anti Lock System Self diagnosis Flow Chart Turn the ignition switch to OFF Connect the ABS self diagnosis terminal to the ground terminal Turn the ignition switch to ON Self diagnosis mode starts The yellow ABS indicator light LED blinks to display the service code in about 3 seconds after entering the self diagnosis mode 1 If no service code is shown drive at 20 km h 12 mph or more for one minute stop and try self diagnosis again Check the faulty point with the service code table and repair according to fault inspection 1 to 19 Erase the service code memorized in the ABS hydraulic unit Start the self diagnosis mode to confirm that erasing has been completed Disconnect the ABS self diagnosis terminal to the ground terminal ending the self diagnosis mode Activate the ABS by driving the motorcycle at 20 km h 12 mph NG lit above in order to confirm that the ABS is normal Repeat self diagnosis OK Unlit Activate the ABS at a safe place in order to confirm that it operates normally 2 OK 1 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 the brake lever
218. HC 4 cylinder Liquid cooled 77 0 x 56 0 mm 3 03 x 2 20 in 1 043 63 64 cu in 10 3 1 86 8 kW 118 PS 99 000 r min rpm WVTA 78 2 H 78 2 kW 106 PS 39 000 r min rpm 102 Nm 10 4 kgf m 75 ft lb 7 700 r min rpm WVTA 78 2 H 96 Nm 9 8 71 ft lb 6 800 r min rpm FI Fuel Injection KEIHIN TTK38 x 4 Electric starter Battery and coil transistorized Electronically advanced digital igniter From 10 BTDC 1 100 r min rpm to 40 22 BTDC 5 200 r min rpm CR9EIA 9 Left to right 1 2 3 4 1 2 4 3 24 BTDC 44 ABDC 248 45 BBDC 19 ATDC 244 Forced lubrication wet sump General Specifications GENERAL INFORMATION 1 9 ltems KLZ1000AC Engine Oil Type Viscosity Capacity Drive Train Primary Reduction System Type Reduction Ratio Clutch Type Transmission Type Gear Ratios 1st 2nd 3rd 4th 5th 6th Final Drive System Type Reduction Ratio Overall Drive Ratio API SG SH SJ SL or SM with JASO MA MA1 or MA2 SAE 10W 40 4 0 L 4 2 US qt Gear 1 627 83 51 Wet multi disc 6 speed constant mesh return shift 2 692 1 950 1 529 1 304 1 136 0 958 35 13 39 20 26 17 30 23 25 22 23 24 Chain drive 2 867 43 15 4 471 Top gear Frame Type Caster Rake Angle Trail Front Tire Type Size Rim Size Rear Tire Type Size Rim Size Front Suspensi
219. INE TOP END 5 17 e Install Air Suction Valves A see Air Suction Valve Installation Air Switching Valve B see Air Switching Valve Installa tion Hoses C e Position the rubber cover on the cylinder head cover 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 Do not tap 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 Reposition the rubber cover A and connect the stick coil connectors B e Run the hoses and harness correctly see Cable Wire and Hose Routing section in the Appendix chapter NOTE OBe careful not to tight the stick coil leads e Install the removed parts see appropriate chapters SIN LIOLL SAN 2 LES iA 1 ime 5 18 END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal This is a non return type camshaft chain tensioner The push rod does not return to its original position once it moves out to take up camshaft chain slack Observe all the rules listed below When removing the tensioner do not take out the mounting bolts only halfway Retightening the mounting bolts from this position could damage the tensioner and the camshaft chain Once the bolts are loosened the t
220. If any diode shows low or high in both directions the diode is defective and the relay box must be replaced NOTE OThe actual meter reading varies with the meter or tester used and the individual diodes but generally speaking the lower reading should be from zero to one half the scale Tester Connection Relay Box Internal Circuit 090902030 PONDO GPi90108W2 C A Headlight Circuit Relay B ECU Main Relay C Fuel Pump Relay D Starter Circuit Relay E Radiator Fan Relay ELECTRICAL SYSTEM 16 113 30 Main Fuse Removal e Remove Starter Cable Terminal Cover see Starter Relay Inspec tion e Pull out the main fuse A from the starter relay with a needle nose pliers 15 A ECU Fuse Removal e Remove Starter Cable Terminal Cover see Starter Relay Inspec tion e Pull out the fuse A Fuse Box Fuse Removal e Remove Seat see Seat Removal in the Frame chapter e Unlock the hooks A to lift up the lids B e Pull the fuses A straight out of the fuse box with needle nose pliers Fuse Installation e 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 16 114 ELECTRICAL SYSTEM Fuse Fuse Inspection e Remove the fuse e Inspect the fuse element x If it is blown out replace the fu
221. Inspection pp 11 14 Rear Sprocket Warp Inspection RN 11 15 11 2 FINAL DRIVE Exploded View FINAL DRIVE 11 3 Exploded View Fastener Engine Sprocket Nut Drive Chain Guide Bolts Rear Sprocket Nuts Rear Axle Nut HG Apply high temperature grease HO Apply heavy oil L Apply a non permanent locking agent MO Apply molybdenum disulfide oil mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts 11 4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain Drive Chain Slack Drive Chain Wear 20 link Length Standard Chain Make Type Link Link Pin Outside Diameter When drive chain replacing Link Plates Outside width When drive chain replacing 25 35 mm 1 0 1 4 in 317 5 318 2 mm 12 50 12 53 in ENUMA 525 116 links 5 6 6 0 mm 0 22 0 24 in 19 35 19 55 0 7618 0 7697 319 12 6 Sprockets Rear Sprocket Warp 0 4 mm 0 016 in or less 0 5 mm 0 020 in FINAL DRIVE 11 5 Special Tools Inside Circlip Pliers Bearing Driver Set 57001 143 57001 1129 7570143ST C 7571129ST C 11 6 FINAL DRIVE Drive Chain Drive Chain Slack Inspection e Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter Drive Chain Slack Adjustment e Refer to the Drive Chain Slack Adjustment in th
222. J06093BS1 C 6J06008BS1 C 10 16 WHEELS TIRES Hub Bearing the circlip with new Special Tool Inside Circlip Pliers 57001 143 e Replace the grease seals with new ones e Press in the grease seals A so that the seal surface 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 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 Hub Bearing Lubrication NOTE OSince the hub bearings are packed with grease and sealed lubrication is not required 6J06008BS1 C 6J06002BS1 C FINAL DRIVE 11 1 Final Drive Table of Contents ubdolere oi 11 2 DPCCINGALONS EL 11 4 219121615 Bc 11 5 atri e OR EE OR e RE a tA Ree eet ea ey RR kas 11 6 Drive Chain Slack Inspection
223. KTRC indicator light LED A goes on xIf the yellow KTRC indicator light LED does not go on replace the meter unit 8 17887051 Check 3 11 Fuel Gauge Inspection e Connect the leads in the same circuit as Check 3 1 OThe all segments of the fuel gauge in the display will blink e Connect the variable rheostat A to the terminal 12 and the battery terminal e Check that the segments number of the fuel level gauge A matches the resistance value of the variable rheostat OWhen the terminal 12 is connected one segment in the fuel level gauge should appear about every 15 seconds Variable Rheostat Resistance Q Display Condition 20 6 segments go on about 175 1 segment goes on 210 1 segment and Fuel Symbol B blink EPI xIf the display function does not work replace the meter unit 16 80 ELECTRICAL SYSTEM Gauge Indicator Unit Check 3 12 Speedometer Inspection the leads in the same circuit as 3 1 e The speed equivalentto the input frequency is indicated the oscillator A if the square wave is input into terminal 10 Olndicates approximately 60 km h if the input frequency is approximately 388 4 Hz Olndicates approximately 60 mph if the input frequency is approximately 621 5 Hz x If the meter function does not work replace the meter unit NOTE OThe input frequency of the oscillator adds the integrated value of th
224. L When brake pedal is pushed down When brake pedal is released Sidestand Switch Connections Sidestand Switch Connections Color BK G When sidestand is down aa ERR When sidestand is up O O Neutral Switch Connections Neutral Switch Connections Color SW Terminal Ground When transmission is in neutral When transmission is not in neutral Oil Pressure Switch Connections Oil Pressure Switch Gonnections Color SW Terminal Ground When engine is running Engine lubrication system is in good condition ELECTRICAL SYSTEM 16 107 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 e Suspend an accurate thermometer B with temperature sensing 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 the hand tester does not show the specified values place the sensor GP18055B 2 C Water Temperature Senso
225. Lower 28 2 9 21 L 11 Footpeg Bracket Nuts 25 2 5 18 R G Apply grease L Apply a non permanent locking agent R Replacement Parts S Follow the specified tightening sequence 15 6 Exploded FRAME 15 7 Exploded View 1 Other than GB WVTA FULL WVTA 78 2 Models 2 AU Model 3 CA Model L Apply a non permanent locking agent R Replacement Parts 15 8 FRAME Seats Seat Removal e Insert the ignition key A into the seat lock turning the key clockwise pulling up on the rear of the seat B and pull the seat forward Seat Installation e Slip the seat hooks A under the brace B on the fuel tank bracket e Insert the seat hooks C into the latch hole D e Push down the front part of the seat until the lock clicks Fairings FRAME 15 9 Lower Fairing Removal e Remove Bolts A Lower Fairing B Lower Fairing Installation e Installation is the reverse of removal note the following OBe sure install the grommets A and dampers B Right Lower Fairing C Left Lower Fairing D Middle Fairing Removal e Remove Quick Rivet A 15 10 Fairings e Remove the bolt A e Pull the middle fairing B evenly outward to clear the pro jections C and remove the fairing forward Middle Fairing Installation e Installation is the reverse of removal note the following s
226. Maintenance chapter 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 damaged P Anti Lock System BRAKES 12 53 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 xIf the ABS hydraulic unit connector is clogged with mud or dust blow it off with compressed air Front Wheel Rotation Sensor Removal NOTICE The wheel rotation sensor should be handled care fully never struck sharply as with a hammer or al lowed to fall on a hard surface since the wheel rota tion sensor is precision made Be careful not to get water or mud on the wheel rotation sensor Do not try to disassemble or repair the wheel rota tion sensor Remove Right Upper Side Fairing see Upper Side Fairing Re moval in the Frame chapter Connector A Disconnect Grommet B Clear the sensor lead from the clamps C e Clear the sensor lead from the clamps A e Remove Bolt B Front Wheel Rotation Sensor C Front Wheel Rotation Sensor Insta
227. Measure the air gap between the rear wheel rotation sen sor and sensor rotor see Wheel Rotation Sensor Air Gap Inspection e Check the rear wheel rotation sensor see Rear Wheel Rotation Sensor Inspection x If both inspections are good go to next step e Check that there is iron or other magnetic deposits be tween the sensor A and sensor rotor B and the sensor rotor slots for obstructions e Check the installation condition of the sensor for loose ness e Check the sensor rotor tip for deformation or damage e g chipped sensor rotor teeth xIf the sensor rotor in bad condition remove the any de posits Install the proper part or replace faulty part x lf the all items are good go to next step 9114587851 9114580851 12 48 BRAKES Anti Lock Brake System e Recheck the service code indication erase the service code perform the pre diagnosis inspection 1 and 2 and retrieve the service code x If the yellow ABS indicator light LED A lights the ABS hydraulic unit has trouble Replace the ABS hydraulic unit x If the yellow ABS indicator light LED does not light ABS system is normal service code is not stored temporary failure Rear Wheel Rotation Sensor Wiring Inspection Service Code 45 e Disconnect ABS Hydraulic Unit Connector see ABS Hydraulic Unit Removal Rear Wheel Rotation Sensor Connector see Rear Wheel Rotation Sensor Removal e Check the wiring conti
228. 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 dry e Checkthe wheel alignment see Wheel Alignment Inspec tion e Rotate the rear wheel to find the position where the chain is tightest e Measure the vertical movement chain slack A midway between the sprockets x If the chain slack exceeds the standard adjust it Chain Slack Standard 25 35 mm 1 0 1 4 in GK04060781 C 6512021851 PERIODIC MAINTENANCE 2 31 Periodic Maintenance Procedures Drive Chain Slack Adjustment e Raise the rear wheel off the ground with the stand e Remove the cotter pin A and loosen the axle nut B e Loosen the both chain adjuster locknuts C xIf the chain is too loose turn out the right and left chain adjusters D evenly xIf 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 left wheel alignment indicator F should align with the same swingarm mark or position G that the right indicator notch aligns with A WARNING Misalignment of the wheel will result in
229. OWhen installing the inserts A be careful not to damage the insert surface with the edge of the connecting rod B or the cap C One way to install inserts is as follows Installation D to Cap Installation E to Connecting Rod Push F Spare Dowel Pin G Connecting Rod Bolts H e Install the cap on the connecting rod aligning the weight and diameter marks e Remove debris and clean the surface of inserts e Apply molybdenum disulfide oil solution MO to the threads and seating surfaces of the big end nuts and bolts e Install the crankshaft see Crankshaft Installation e Install each connecting rod on its original crankpin OThe connecting rod big end is bolted using the plastic region fastening method OThis method precisely achieves the needed clamping force without exceeding it unnecessarily allowing the use of thinner lighter bolts further decreasing connecting rod weight OThere are two types of the plastic region fastening One is a bolt length measurement method and other is a rotation angle method Observe one of the following two but the bolt length measurement method is preferable because this is a more reliable way to tighten the big end nuts 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 NOTICE Be careful not to overtighten the nuts The bolts must be positioned on
230. R sensor BL lead Digital Meter BK sensor G lead e Measure the input voltage with the engine stopped and with the connector joined e Turn the ignition switch to ON 9617123251 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 Vehicle down Sensor Output Voltage Inspec tion xIf the reading is out of the standard remove the ECU and check the wiring for continuity between main harness connectors ODisconnect the ECU and sensor connections Wiring Inspection ECU Connector A Vehicle down Sensor Connector B BL lead ECU terminal 4 C G lead ECU terminal 49 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 8017124 81 3 70 FUEL SYSTEM DFI Vehicle down Sensor Service Code 31 Vehicle down Sensor Output Voltage Inspection e Remove the vehicle down sensor see Vehicle down Sensor Removal e Connect the measuring adapter A to the vehicle down sensor connectors as shown 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 Mete
231. Removal Installation chapter e Remove Water Hose Clamp Screw Loosen A Water Hose B e Remove Upper Engine Mounting Bolts Left A e Remove Cylinder A NOTE Olf it is hard to remove it tap lightly using a plastic mallet Cylinder Installation NOTE Olf a new cylinder is used use new piston ring e Replace the cylinder gasket A with a new one e Install the dowel pins B and new cylinder gasket e Apply molybdenum disulfide oil solution to the cylinder bore 5 38 END Cylinder Pistons 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 Position the crankshaft at 2 3 piston TDC Prepare two auxiliary head bolts with their head cut Olnstall the two cylinder head bolts A diagonally in the crankcase e Install the cylinder block B Pistons C OFirst insert the 2 3 pistons and then rotate the crank shaft at 90 angle then insert the 1 4 pistons e Tighten the upper engine mounting bolts and engine bracket bolts after cylinder head bolts tightend see Cylinder Head Installation Piston Removal e Remove the cylinder see Cylinder Removal e Place a clean cloth u
232. Removal in the Frame chap ter e Turn the ignition switch to ON e Ground the self diagnosis terminal A Gray to the bat tery terminal using a suitable lead OCount the blinks of the light to read the service code Keep the auxiliary lead ground until you finish reading the service code Service Code Clearing Procedures e Start the service code erase mode with the following pro cedure OThe erase mode starts when the ABS self diagnosis ter minal is disconnected from the ground terminal after start ing the self diagnosis mode OThe service code can be erased by grounding and un grounding each time for at least one second the ABS self diagnosis terminal three times within about 12 5 sec onds after starting the erase mode OThe yellow ABS indicator light LED remains lit during the erase mode OAfter 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 only start code 12 will be shown Anti Lock System BRAKES 12 39 Erasing of Service Code Yellow ABS End of Service Code Erase ON Indicator 1 1 Light LED OFF IService code lerase starts ABS Self open E ul 10 45 0 46 0 46 a The signal to inform of the erase completion of service code diagnosis Terminal
233. S mL x 0 02816 02 IMP Units of Speed mL x 0 06102 cu in km h x 06214 mph Units of Force Units of Power N 0 1020 kg kW x 1 360 PS N x 02248 kW x 1341 HP kg N 5 x 0 7355 kW kg 7209 de dB PS 0 9863 HP Units of Temperature 9 C 40 40 F 5 F 40 ee oF oF 32 68 104 248 284 4 20 10 20 i40 320 40 60 20 i i 26 7 48 9 176 212 80 100 120 140 160 180 200 220 240 260 280 300 i i 400 714 93 3 116 1120 1140 138 160 PERIODIC 2 1 Periodic Maintenance Table of Contents Periodic Maintenance 20 2 2 3 Torque and Locking oo eil 2 6 Specifications cce fr tent n 2 12 Special Tools as mna te ee ee dt eee p ERN ET 2 14 Periodic Maintenance 2 15 System ud dao 2 15 Throttle Control System Inspectigm cessent eene nnne 2 15 Engine Vacuum Synchronization 2 15 Idle Speed Inspection 2 19 Idle Speed Nd jUslImienl 2 del ees Due t dena eng 2 19 Fuel Hose Inspection fuel leak damage installation condition 2 19 SY SUC IV mm 2 20 Coolant Level 1 0 0
234. S 4 Camshaft Sprocket Bolts 15 1 5 11 L 5 Upper Camshaft Chain Guide Bolts 12 1 2 106 in Ib S 6 Camshaft Cap Bolts 12 1 2 106 in Ib S 7 Cylinder Head Bolts M10 First 20 2 0 15 S MO Cylinder Head Bolts M10 Final 54 5 5 40 S MO 8 Oylinder Head Bolts 6 12 1 2 106 in Ib S 9 Throttle Body Assy Holder Bolts 12 1 2 106 in Ib L 10 Plugs 19 6 2 00 14 5 L 11 Throttle Body Assy Holder Clamp Bolts 2 9 0 30 26 in Ib 12 Front Camshaft Chain Guide Bolt Upper 25 2 5 18 13 Rear Camshaft Chain Guide Bolt 25 2 5 18 14 Front Camshaft Chain Guide Bolt Lower 12 1 2 106 E Coolant By pass Fitting Bolt 0 90 78 L Camshaft Chain Tensioner Cap Sot 2 15 97 inib EO Apply engine oil G Apply grease L Apply a non permanent locking agent LG Apply liquid gasket M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts S Follow the specified tightening sequence WL Apply soap and water solution or rubber lubricant 5 4 END Exploded View GE02536BW5 C END 5 5 Exploded View Torque Fastener Nm 1 Muffler Body Mounting Bolt 34 3 5 25 2 Premuffler Chamber Mounting Bolt 34 3 5 25 3 Muffler Body Clamp Bolt 21 2 1 15 4 Muffler Body End Cover Bolts 9 8 1 0 87
235. S hydraulic unit has trouble Replace the ABS hydraulic unit If the yellow ABS indicator light LED does not light ABS system is normal service code is not stored temporary failure Power Supply Voltage Abnormal 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 go to next step e Recheck the service code indication erase the service code perform the pre diagnosis inspection 1 and 2 and retrieve the service code x If the yellow ABS indicator light LED A lights the ABS hydraulic unit has trouble Replace the ABS hydraulic unit x If the yellow ABS indicator light LED does not light ABS system is normal service code is not stored temporary failure ABS Solenoid Valve Relay Supply Voltage Inspection Low Voltage Service Code 54 e Check the charging voltage see Charging Voltage In spection in the Electrical System chapter xIf the charging voltage is good go to next step e Recheck the service code indication erase the service code perform the pre diagnosis inspection 1 and 2 and retrieve the service code x If the yellow ABS indicator light LED A lights the ABS hydraulic unit has trouble Replace the ABS hydraulic unit x If the yellow ABS indicator light LED does not light ABS system is normal service code is not stored temporary failure ECU Inspection Service
236. SYSTEM Gauge Indicator Unit Meter Unit Removal Installation e Refer to the Meter Cover Removal Installation in the Frame chapter Meter Unit Disassembly e Remove Meter Unit see Meter Unit Removal Installation Screws A Lower Meter Cover B e Separate the meter assembly A and upper meter cover B Meter Operation Inspection Check 1 1 Meter Unit Switching Inspection e Turn the ignition switch to ON and check the following e By pushing the upper button A each time check that the display B changes as follows OThis display is ordinary indication 000 gt TRIP A TRIP B Km L CLOCK RANGE AV Km L GP17821CN3 e By pushing the lower button each time check that the display changes water temperature A and outside tem perature B x If the meter does not work replace the meter unit 62178575 P 8 17887051 EU GP17822CS1 Meter Gauge Indicator Unit ELECTRICAL SYSTEM 16 69 e Indicate the ODO mode e Check that the display A changes to the km h and mph display each time by pushing the lower button while upper button pushed in NOTE OMile Km Display can alternate between English and metric modes mile and km in the digital meter Make sure that km or mile according to local regulations is correctly displayed before riding xIf the display function does not work replace the meter unit e S
237. Screws Oxygen Sensor Front Brake Light Switch Screw Licence Plate Light Mounting Screws Intake Air Temperature Sensor Mounting Screw Spark Plugs Crankshaft Sensor Cover Bolts Water Temperature Sensor Timing Rotor Bolt Crankshaft Sensor Bolts Starter Motor Cable Terminal Nut Starter Motor Terminal Locknut Starter Motor Mounting Bolts Alternator Rotor Bolt Stator Coil Bolts Starter Motor Through Bolts Brush Holder Screw Oil Pressure Switch Oil Pressure Switch Terminal Bolt Alternator Cover Bolts Alternator Lead Holding Plate Bolt Engine Ground Cable Terminal Bolt Neutral Switch Sidestand Switch Bolt 21 78 in Ib 25 78 in Ib 78 21 18 31 in Ib 32 11 in lb 8 11 in ib 87 106 in Ib 106 in Ib 29 52 in Ib 52 97 87 114 106 in ib 44 in lb 34 in ib 11 18 in ib 106 in Ib 106 in ib 87 11 78 Remarks PERIODIC 2 11 Torque Locking Agent The table below relating tightening torque to thread diameter lists the basic torque for the bolts and nuts Use this table for only the bolts and nuts which do not require a specific torque value All of the values are for use with dry solvent cleaned threads Basic Torque for General Fasteners Threads Diameter Torque mm N m ft Ib 5 3 4 4 9 0 35 0 50 30 43 in lb 6 5 9 7 8 0 60 0 80 52 69 8 14 19 1 4 1 9 10 0 13
238. Side Plate Bolt 5 9 52 in lb Connecting Rod Big End Nuts SM Breather Plate Bolts 9 8 87 in lb Shift Drum Bearing Holder Bolts 12 3 106 in lb Oil Passage Plugs 20 15 Oil Passage Plug 9 8 87 in Ib Starter Motor Clutch Bolts 12 106 in Ib Crankcase Bolts 7 20 j 15 Crankcase Bolts M9 42 31 Crankcase Bolts M6 12 106 in Ib Crankcase Bolts M8 27 20 Gear Positioning Lever Bolt 12 106 in Ib Shift Drum Cam Bolt 12 106 in Ib Neutral Switch 15 11 Shift Shaft Return Spring Pin 39 29 Shift Pedal Mounting 25 18 Wheels Tires Front Axle Clamp Bolt 20 15 Front 93 7 Rear Sprocket Nuts 59 44 Rear Axle Nut 79 7 Final Drive Engine Sprocket Nut Drive Chain Guide Bolts Rear Sprocket Nuts Rear Axle Nut Brakes Front Master Cylinder Reservoir Cap Screws 13 in Ib Brake Lever Pivot Bolt f 8 9 in Ib Brake Lever Pivot Bolt Locknut 52 in lb Front Master Cylinder Clamp Bolts 97 in lb Front Light Switch Screw 11 in Ib Brake Hose Banjo Bolts 18 Brake Pipe Joint Nuts 13 ABS Hydraulic Unit Bracket Bolts 78 Torque and Locking Agent PERIODIC MAINTENANCE 2 9 Fastener Remarks Front Brake Disc Mounting Bolts L Front Brake Pad Spring Bolts 26 in lb Bleed Valve 69 in Ib Front Caliper Assembly Bolts 16 Front Brake Pad Pin 11 Front Caliper Mounting Bolts 18 Rear Master Cylinder Mounting Bolts 18 Brake Pedal Bolt 78 in Ib Rear Master Cylinder Push Rod
239. Starter Relay Battery 12 V 8 Ah 11 Rear Brake Light Switch 12 Regulator Rectifier 13 Water Temperature Sensor 14 Alternator 15 Stator Coil 16 Radiator Fan Motor 16 14 ELECTRICAL SYSTEM Parts Location 17 Neutral Switch 18 Sidestand Switch 19 Oil Pressure Switch 20 Air Switching Valve 21 Stick Coils 22 Spark Plugs 23 Immobilizer Amplifier Equipped Models 24 Turn Signal Relay 25 Starter Lockout Switch 26 Ignition Switch Immobilizer Equipped Model Including Immobilizer Antenna 27 Meter Unit 28 Front Brake Light Switch 29 Rear Wheel Rotation Sensor ELECTRICAL SYSTEM 16 15 Wiring Diagram BR Model This page intentionally left blank 16 16 ELECTRICAL SYSTEM Wiring Diagram BR Model 6 1 2 Turn Light RH 1 3 Turn Light LH 4 Negative Supply GND 5 Block 6 Block 7 Unused 8 Ignition 9 Unused 1 10 Unused 11 Unused 12 Siren Output 3 GPS PS Positive Supply 12V 8 G 9 9 5 3 9 9 Right Switch Housing i Front Brake f NEN Light Switch 4 gt an 1 2 3 44 71 2 Engine Stop Switch Right Switch Housing ps Motor Hd s TA Switching tick S Starter Button n Valve Coils B 5 1 Intake e anak 1 Tenperature 55 Sensor Spark Plugs R BR W Y R Immobilizer
240. TEM Gauge Indicator Unit Check 3 7 Green Neutral Indicator Light LED Inspec tion e Connect the leads in the same circuit as Check 3 1 e Connect the terminal 2 to the battery terminal e Check that the green neutral indicator light LED A goes on x If the green neutral indicator light LED does not go on replace the meter unit Check 3 8 Yellow ABS Indicator Light LED Inspection e Connect the leads in the same circuit as Check 3 1 OThe yellow ABS indicator light LED goes on e Connect the terminal 1 to the battery terminal e Check that the yellow ABS indicator light LED A goes off If the yellow ABS indicator light LED does not go off replace the meter unit Check 3 9 Red Oil Pressure Warning Indicator Light LED Inspection e Connect the leads in the same circuit as Check 3 1 e Connect the terminal 13 to the battery terminal GP17854CS1 8 17856051 17857051 ELECTRICAL SYSTEM 16 79 Meter Gauge Indicator Unit e Check that the oil symbol A and red oil pressure warning indicator light LED B goes on x If the oil symbol and red warning indicator light LED do not go on replace the meter unit GP17858CS1 Check 3 10 Yellow KTRC Indicator Light LED e Connect the leads in the same circuit as Check 3 1 e Connect the terminal 5 to the battery terminal e Check that the yellow
241. TEM DFI 3 47 Main Throttle Sensor Service Code 11 Main Throttle Sensor Resistance Inspection e Turn the ignition switch to OFF e Disconnect the main throttle sensor connector ODisconnect the main throttle sensor connector and con nect the throttle sensor setting adapter A to the sensor connector only Special Tool Throttle Sensor Setting Adapter 57001 1538 Main Throttle Sensor Resistance Connections to Adapter Digital Meter W sensor BL lead Digital Meter BK sensor lead Standard 4 6kQ xIf the reading is out of the standard replace the throttle body assy x If the reading is within the standard but the problem still exists replace the ECU see ECU Removal Installation Main Throttle Sensor Circuit o9 6GC17078FW2 1 ECU 2 Main Throttle Sensor 3 48 FUEL SYSTEM DFI 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 Air Cleaner Housing see Air Cleaner Housing Removal Intake Air Pressure Sensor 1 Connector A e Remove the intake air pressure sensor 1 A from the rubber damper B in the bracket and separate the vac uum hose C Intake Air Pressure Sensor 1 Installation NOTE OThe intake air pressure sensor 1 is the same part as the intake air pres
242. Tank see Fuel Tank Installation e Confirm that the drain hose and clamp are installed se curely and run the hose correctly see Cable Wire and Hose Routing section in the Appendix chapter e Start the engine and check for fuel leakage Fuel Flow Rate 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 to OFF Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately NOTE 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 e Support the fuel tank with a suitable bar see Fuel Tank Removal Fuel Line FUEL SYSTEM DFI 3 103 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
243. U see Immobilizer System Parts Replacement e Insert the current registered ignition key into the ignition switch and turn it to ON Olf there is any problem in the registration the red warning indicator light LED and the immobilizer warning symbol A blink to display the collation error Immobilizer Amplifier Failure Registered Ignition Key Collation Error 0 du OF F GP30746BS1 3second UUU GP300260S1 ELECTRICAL SYSTEM 16 95 Immobilizer System Equipped Models e The registered ignition key is successfully registered in the ECU OThe red warning indicator light LED and the immobilizer warning symbol A blink 1 time and stop for 1 second and then repeat this cycle e Turn to OFF the ignition switch and remove the registered ignition key OThe immobilizer warning symbol B disappears OThe red warning indicator light LED A then blinks for 15 seconds it means the ECU is in the registration mode OAfter 15 seconds the ECU ends the registration mode and stops blinking the red warning indicator light LED NOTE Olnsert and turn on the next key between 15 seconds that the ECU is in the registration mode OWhen a registration mode was ended do the registered ignition key verification procedure over again to restart it This applies to all ignition key registration e Insert the other remaining registered ignition key into the ignit
244. Vertical Adjustment e Refer to the Headlight Aiming Inspection in the Periodic Maintenance chapter Headlight Bulb Replacement e Remove Headlight Assy see Headlight Removal Installation Headlight Bulb Dust Covers A e Remove Hook A Headlight Bulb B When handling the quartz halogen bulb never touch the glass portion with bare hands Always use a clean cloth Oil contamination from hands or dirty rags can reduce bulb life or cause the bulb to explode NOTE OClean off any contamination that inadvertently gets on the bulb with alcohol or soap and water solution Replace the headlight bulb e Fit the projection A of the bulb in the hollow B of the headlight e Install the hook C Lighting System ELECTRICAL SYSTEM 16 57 e Fit the dust cover A onto the bulb B firmly as shown Good C Bad D e After installation adjust the headlight aim see Headlight Aiming Inspection in the Periodic Maintenance chapter OOther Bulb Repeat the above steps City Light Bulb Replacement e Remove the headlight assy see Headlight Removal In stallation e Turn the socket A counterclockwise and remove it e Pull the bulb A out of 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 then the specified valve e Replace the bulb with a new one Headlight Cover Removal e Remove Upper Fairing see Upper F
245. abnormal sensor or rotor missing too 44 ON large clearance rotor tooth worn or missing Rear wheel rotation sensor wiring 45 A ON abnormal wiring shorted or open 52 supply voltage abnormal ON low voltage 53 supply voltage abnormal ON low voltage 54 5 solenoid valve relay supply voltage ON low voltage 55 trouble operation abnormal ON Output fluid pressure sensor front brake 83 TWA trouble voltage abnormal wiring shorted ON or open BRAKES 12 43 Anti Lock Brake System Yellow ABS Indicator Light LED Problems Output fluid pressure sensor front brake trouble offset abnormal JUUUUUUULIUUUL Power supply voltage for fluid pressure Iuuuuuuuimnnnnnni sensor abnormal voltage abnormal wiring shorted or open 12 44 5 Anti Lock System 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 Solenoid Valve Inspection Service Code 13 14 17 18 OThe solenoid valve is built in the ABS Hydraulic Unit Therefore the solenoid valve cannot be checked directly e Recheck the service code indication erase the service code perform the pre diagnosis inspection 1 and
246. acket C 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 NOTICE To avoid damaging the electrical connections in side the switch be sure that the switch body does not turn during adjustment 2 38 PERIODIC Periodic Maintenance Procedures x If it does not go on inspect or replace the following items Battery see Charging Condition Inspection in the Elec trical System chapter Brake Light see Tail Brake Light Removal in the Electri cal System chapter Main Fuse 30 A and Brake Light HornFuse 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 e Tighten Torque Front Footpeg Bracket Bolt 25 N m 2 5 kgf m 18 ft Ib Rear Master Cylinder Mounting Bolts 25 N m 2 5 kgf m 18 ft Ib 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 ti
247. aged replace the mechani cal seal as a unit Impeller Sealing Seat Surface A Rubber Seal B Mechanical Seal C 6006015851 C 6006016851 C GD06017BS1 4 14 COOLING SYSTEM Radiator Radiator and Radiator Fan Removal e Remove the middle fairing see Middle Fairing Removal in the Frame chapter e Remove the side cover see Side Cover Removal in the Frame chapter e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Remove the bolts A and right and left radiator side cov ers B e Slide the connector cover A and disconnect the radiator fan motor lead connector B e Release the fan motor lead from the clamp C e Loosen the clamps A to move them forward e Remove the bolt B and collar e Disconnect the radiator hose C from the filler neck D e Loosen the radiator hose clamp screw A and disconnect the lower radiator hose B from the radiator e Remove the radiator lower bolt C e Remove the cap D and radiator upper bolt D Radiator COOLING SYSTEM 4 15 e Move the radiator A rightward to clear it from the frame projection B e Clear the heat insulation rubber plate C from the radiator upper mounting brackets D and fan motor bracket e Remove the radiator from the frame NOTICE Do not touch the radiator core This could damage the radiator fins resulting in loss of cooling effi
248. ain Throttle Sensor Output Voltage Connections to Adapter Digital Meter W sensor Y W lead Digital Meter gt BK sensor lead Standard DC 1 02 1 06 V at idle throttle opening x If 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 6505015851 C PERIODIC MAINTENANCE 2 19 Periodic Maintenance Procedures Idle Speed Inspection e Start the engine and warm it up thoroughly e With the engine idling turn the handlebars to both sides A xIf handlebars 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 make sure to correct any of these conditions Check the idle speed Idle Speed Standard 1 100 50 r min rpm x If the idle speed is out of the specified range adjust it Idle Speed Adjustment Start the engine and warm it up thoroughly e Turn the adjusting screw A unt
249. ain bearing inside diameter and mark the upper crankcase half in accordance with the inside diam eter Crankcase Main Bearing Inside Diameter Marks or no mark e Tighten the crankcase bolts to the specified torque see Crankcase Assembly NOTE OThe mark already on the upper crankcase half should almost coincide with the measurement Crankcase Main Bearing Inside Diameter Marks O 38 000 38 008 mm 1 4961 1 4963 in None 38 009 38 016 mm 1 4964 1 4967 in e Select the proper bearing insert A in accordance with the combination of the crankcase and crankshaft coding Size Color B 5 4 3 2 1 8105319 52 C 8105041751 Crankcase Main Crankshaft Main Bearing Insert Bearing Inside Journal Diameter Diameter Marking Marking Size Color Part Number Journal Nos 92139 0034 2 4 1 Brown 92139 0219 1 3 5 1 92139 0033 2 4 Black 92139 0218 1 3 5 92139 0032 2 4 4 n 92139 0032 LE ui 92139 0217 1 3 5 bearing inserts for Nos 2 and 4 journals an groove respectively e Install the new inserts in the crankcase halves check insert journal clearance with the plastigage press gauge CRANKSHAFT TRANSMISSION 9 25 Balancer Balancer Removal e Split the crankcase see Crankcase Splitting e Remove the balancer A from the upper crankcase half e Remove the oil seal B Bal
250. ain harness to regulator rectifier with clamp Regulator Rectifier Hold the oxygen sensor lead rear wheel rotation sensor lead rear brake light switch lead and crankshaft sensor lead to the frame with clamp Hold the rear brake light switch lead at both sides of the connector with the clamp Do not hold the rear brake light switch lead at the connector Hold the oxygen sensor lead rear wheel rotation sensor lead rear brake light switch lead and crankshaft sensor lead with clamp Hold the oxygen sensor lead and rear wheel rotation sensor lead to the frame with clamp Rear Wheel Rotation Sensor Lead Hold the rear shock absorber adjuster hose and rear brake light switch lead to the frame with clamp Rear Shock Absorber Adjuster Hose Rear Brake Light Switch Lead Hold the oxygen sensor lead and rear wheel rotation sensor lead by bending the clamp rearward 17 30 APPENDIX Cable Wire and Hose Routing 08809895045 C APPENDIX 17 31 Cable Wire Hose Routing Install the hose clamps so that its screw head face direction as shown White Paint Mark Install the water hose so that the white paint mark faces upside Water Hose Water Pipe Upper White Paint Mark Install the water hose so that the white paint mark faces outside Water Hose with Protective Mesh Water Pipe Lower Align the white paint mark on the water hose with white paint mark on th
251. ain hose as shown Water Hoses Radiator Hose Hose Clamp Rear Brake Reservoir Hose Rear Shock Absorber Adjuster Hose Rear Wheel Rotation Sensor Lead Rear Brake Hose Hold the rear wheel rotation sensor lead to the brake hose Run the rear brake light switch lead to outside of the rear brake hose and rear wheel rotation sensor lead and inside of the rear frame pipe Before clamping face the locking portion of the clamp in direction as shown Face the tabs of the hose clamp in direction as shown 17 20 APPENDIX Cable Wire and Hose Routing APPENDIX 17 21 Cable Wire Hose Routing 12 13 14 15 16 17 19 ma CN Fuel Tank Breather Hose Clamp Hold the clamp on the main harness to the rib of the frame as shown Run the sidestand switch lead to inside of the brake pipe Run the fuel hose battery ground cable fuel tank drain hose starter motor cable and brake pipe in order from the inside of the frame Run the fuel tank breather hose to outside of the frame Run the idle adjusting cable to under the starter motor cable Run the sidestand switch lead to outside of the starter motor cable Fuel Tank Drain Hose Fuel Tank Breather Hose Run the fuel tank breather hose fuel tank drain hose and sidestand switch lead to inside of the drive chain cover Detail A 20 30 Hold the harness to th
252. airing Removal in the Frame chapter Upper Side Fairings see Upper Side Fairing Removal in the Frame chapter Meter Cover see Meter Cover Removal in the Frame chapter Screws A e Clear the hook portions B Headlight Cover Installation Olnsert the hook portions A of the left and right into the ribs B e Tighten the screws 16 58 ELECTRICAL SYSTEM Lighting System Headlight Removal Installation e Remove Upper Fairing see Upper Fairing Removal in the Frame chapter Upper Side Fairings see Upper Side Fairing Removal in the Frame chapter Meter Cover see Meter Cover Removal in the Frame chapter Headlight Cover see Headlight Cover Removal Mounting Bolts A Mounting Nuts B e Disconnect the headlight connectors A and city light con nector B e Remove the headlight assy e Installation is the reverse of removal Tail Brake Light LED Removal e Remove Seat Cover see Seat Cover Removal in the Frame chapter Tail Brake Light Mounting Bolts A e Disconnect the tail brake light lead connector B to re move the tail brake light LED Tail Brake Light LED Installation e Installation is the reverse of removal e Tighten the tail brake light mounting bolts securely License Plate Light Bulb Replacement e Remove Screws A License Plate Light Cover B and Lens Lighting System ELECTRICAL SYSTEM 16 59 e Push and turn the bulb A counterclockwise and r
253. ake Hose Bracket Bolt A e Remove Quick Rivet A Upper Mud Guard Bolts B Upper Mud Guard C Upper Mud Guard Installation e Installation is the reverse of removal note the following OApply a non parmanent locking agent to the thread of the upper mud guard bolts and brake hose bracket bolt OTighten Torque Front Footpeg Bracket Bolts 25 N m 2 5 kgf m 18 ft Ib FRAME 15 21 Guard Lower Mud Guard Removal e Remove Upper Mud Guard see Upper Mud Guard Removal Lower Mud Guard Bolts A Lower Mud Guard B Lower Mud Guard Installation e Installation is the reverse of removal note the following OApply a non parmanent locking agent to the thread of the two lower mud guard bolts A 15 22 Sidestand Sidestand Removal e Raise the rear wheel off the ground with the stand e Remove Sidestand Switch Bolt A Nut B Sidestand Switch C e Remove Spring A Sidestand Nut B Sidestand Bolt C Sidestand D Sidestand Installation e Apply grease to the sliding area A of the sidestand B e Replace the sidestand nut C with a new one e Tighten the sidstand bolt D first and then the sidestand nut Torque Sidestand Bolt 29 N m 3 0 kgf m 21 ft Ib Sidestand Nut 44 N m 4 5 kgf m 32 ft Ib e Hook the spring E so that the long spring end faces up ward Olnstall the spring hook direction as shown in the figure e Install the sidestand switch OFit
254. all new bolts and nuts in reused connecting rods x If the connecting rod assy was replaced use the bolts and nuts attached to the new connecting rod assy e Apply a small amount of molybdenum disulfide oil solution to the following portions Threads A of Bolts and Nuts Seating Surfaces B of Nuts and Connecting Rod Caps 6105040481 C e First tighten the nuts to the specified torque See the table below e Next tighten the nuts 120 5 OMark A the connecting rod big end caps and nuts so that nuts can be turned 120 B properly OTighten the hexagon nut by 2 corners Connecting Torque Angle Nut Rod Assy kgf m ft Ib Attached to 22 2 2 16 8105040551 Use the bolts new con rod 120 attached to new con rod New 20 2 0 15 120 26 2 7 19 Replace the Used 120 bolts with new ones Kew 26 2 7 19 120 9 20 CRANKSHAFT TRANSMISSION 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 e Remove the connecting rod big end bearing inserts and reinstall the connecting rod big end cap e Select an arbor A of the same diameter as the connect ing rod big end and insert the arbor t
255. allation 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 xIf the air switching valve is normal check the wiring for continuity see Air Switching Valve Circuit xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see Removal Installation Air Switching Valve Circuit BR W w BK GCci7094FW2 C 1 ECU 8 Relay Box 2 Frame Ground 3 9 ECU Main Relay 3 Engine Ground 10 Fuse Box 1 4 Battery 12 V 8 Ah 11 Ignition Fuse 15 A 5 Starter Relay 12 Joint Connector F 6 Main Fuse 30 13 Ignition Switch 7 ECU Fuse 15 A 14 Air Switching Valve Oxygen Sensor Heater Service Code 67 FUEL SYSTEM DFI 3 89 Oxygen Sensor Heater Removal Installation The oxygen sensor heater is built in the oxygen sensor So the heater itself can not be removed Remove the oxy gen sensor see Oxygen Sensor Removal in the Electrical System chapter Oxygen Sensor Heater Resistance Inspection e Turn the ignition switch to OFF e Remove the right side cover see Side Cover Removal in the Frame chapter e Open the clamp A and pull out the oxygen sensor lead connector B e Disconnect the oxygen sensor lead connector e Connect a di
256. ancer Installation e Check that the rubber dampers A are in place as shown in the figure e Apply molybdenum disulfide oil solution to the damper contact portions of the balancer weight e Install the balancer weight A into the gear B OAlign the punch mark C of the balancer weight with the groove D of the gear e Apply molybdenum disulfide oil solution to the needle bearings Insert the needle bearings e Fit the copper washers A on both ends of the weight and gear assembly The projected sides B face inward e Insert the pin A as shown in the figure e Set the 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 6106040551 9 26 CRANKSHAFT TRANSMISSION Balancer e Assemble the crankcase see Crankcase Assembly e Fill the oil seal lips with grease e Install the new oil seal A so that its surface is flush with the surface of the crankcase Turn the balancer shaft so that its mark B faces down ward This photo is shown with the upside down e Install the balancer shaft lever A e Apply a non parmanent locking agent to the threads of the balancer shaft lever bolt B e Tighten Torque Balancer Shaft Lever Bolt 25 N m 2 5 kgf m 18 ft Ib Balancer Shaft Clamp Bolt C 9 8 N m 1 0 kgf m 87 in lb Balancer Adjustment Remove the lower fairing see Lower
257. and Tester 57001 1394 OSet the tester to the x 1 O range and read the tester x If the tester does not read 0 the lead is defective Re place the lead or the main harness or the subharness OIf both ends of a harness A are far apart ground B the one end C using a jumper lead D and check the con tinuity between the end E and the ground F This en ables to check a long harness for continuity If the harness is open repair or replace the harness OWhen checking a harness A for short circuit open one end B and check the continuity between the other end C and ground D If there is continuity the harness has a short circuit to ground and it must be repaired or re placed e Narrow down suspicious locations by repeating the con tinuity tests from the ECU connectors 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 xIf an abnormality is found replace the affected DFI part If no abnormality is found in the wiring connectors and DFI parts replace the ECU GC17234FS1 6017029281 3 28 FUEL SYSTEM DFI Troubleshooting the DFI System DFI Diagnosis Flow Chart Yellow engine warning indicator Yellow engine warning Red warning indicator light light LED and yellow KTRC indicator light LED goes LED and Immobi
258. and pedal GL14583B F BRAKES 12 41 Anti Lock System How to Read Service Codes OService codes are shown by a series of long and short blinks of the yellow ABS indicator light LED as shown below ORead 10th digit and unit digit as the yellow ABS indicator light LED blinks OWhen there are a number of faults a maximum of all service codes 19 codes can 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 19 codes starting with the last one stored then the display is repeated from the smallest number code once again Service Service Service Service gt gt code 13 code 14 53 code 55 08114454841 C Olf there is no fault the yellow ABS indicator light LED lights as shown in the figure Indication of Service Code Ex 1 Start Code 12 ABS is normal is shown Start Code 12 Yellow ABS 10th a Indicator digit digit Start Start Start Light 0 er 0 34 Code 12 Code 12 Code 12 LED Lp pem ON OFF ees Ignition 13 08 11113 38 Switch 0 65 0 35 0 0 95 2 Service Code 13 42 shown Yellow 5 Service Service Indicator Start Code 13 Code 42 1f Light Code 12 0 6s 0 3s 0 6s 0 3s four or more service codes 1 1 1 LED ON 71 LL 3 gs MHAI g 1 en
259. andard 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 6C17127BS1 C Subthrottle Sensor Service Code 32 FUEL SYSTEM DFI 3 73 xIf the reading is out of the standard remove the ECU and check the wiring for continuity between main harness connectors ODisconnect the ECU and sensor connectors Wiring Inspection ECU Connector A Subthrottle Sensor Connector B BL lead ECU terminal 4 C G lead ECU terminal 49 D x lf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see ECU Removal Installation Subthrottle Sensor Output Voltage Inspection e Measure the output voltage at the subthrottle sensor in the same way as input voltage inspection note the fol lowing ODisconnect the subthrottle sensor connector and connect the throttle sensor setting adapter A between these con nectors Special Tool Throttle Sensor Setting Adapter 57001 1538 Subthrottle Sensor Output Voltage Connections to Adapter Digital Meter R sensor BL W lead Digital Meter BK sensor lead e Remove the air cleaner housing see Air Cleaner Housing Removal e Disconnect the subthrottle valve actuator harness con nector A
260. aner cover as shown Brake Pipes Run the brake pipes to under the starter motor cable battery ground cable alternator lead and main harness Main Harness Frame Ground Terminal Main Harness to Regulator Rectifier ECU Battery Ground Cable Hold the alternator subharness and main harness to regulator rectifier with clamp ABS Hydraulic Unit Main Harness to ABS Hydraulic Unit Fuel Hose Alternator Lead Before clamping face the locking portion of the clamp in direction as shown 17 44 APPENDIX Cable Wire and Hose Routing 08809923045 C APPENDIX 17 45 Cable Wire Hose Routing Brake Hose between ABS Hydraulic Unit and Front Calipers about 40 Clamps Brake Hose between Front Master Cylinder and ABS Hydraulic Unit about 3 Brake Hose between Rear Master Cylinder and ABS Hydraulic Unit Brake Hose between ABS Hydraulic Unit and Rear Caliper about 9 ABS Hydraulic Unit Fit the projection on the brake hose to the stopper on the master cylinder Hold the front wheel rotation sensor lead to the meter bracket Clamp Clips Brake Hose between ABS Hydraulic Unit and Left Front Caliper Clamps Brake Hose between ABS Hydraulic Unit and Right Front Caliper Hold the brake hose with the clamp at the rubber protector Fit the projection on the brak
261. ankshaft 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 xIf 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 If the reading is within the standard remove the ECU and check the wiring for continuity between main harness con nectors ODisconnect the ECU and sensor connectors Wiring Inspection ECU Connector A Crankshaft Sensor Connector B YIBK lead ECU terminal 37 C Y lead ECU terminal 48 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 8017122 51 Y Y BK GCi7083FW2 C 1 ECU 2 Crankshaft Sensor 3 64 FUEL SYSTEM DFI 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 OThe ECU uses the rear wheel rotation sensor
262. arance see Valve Clearance Inspection in the Periodic Maintenance chapter GE15012081 C 5 36 END 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 ee of 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 opera 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 END 5 37 Cylinder Pistons Cylinder Removal e Remove Radiator A see Radiator and Radiator Fan Removal in the Cooling System chapter Radiator Bracket B Cylinder Head C see Cylinder Head Removal Upper Engine Bracket see Engine Removal in the En gine
263. arged 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 28 ELECTRICAL SYSTEM Battery A DANGER tention for more severe burns Interchange Batteries produce an explosive gas mixture of hydrogen and oxygen that can cause seri ous injury and burns if ignited Keep the battery away from sparks and open flames during charging When using a battery charger connect the battery to the charger before turning on the charger This procedure prevents sparks at the battery terminals which could ignite any battery gases The electrolyte contains sulfuric acid Be careful not to have it touch your skin or eyes If touched wash it off with liberal amount of water and seek medial at A sealed battery can fully display its perfor
264. aring Removal seen eee 13 32 Tie Rod and Rocker Arm Bearing Installation esee 13 33 Rocker Arm Tie Rod Bearing Sleeve Inspection 13 33 Rocker Arm Tie Rod Bearing Lubrication 22 13 33 13 2 SUSPENSION Exploded View s 8 VIY OY 20007 Gy 02 0 AN D 272 C9 0 00 gt GLO e 9 6102352815 C Exploded View SUSPENSION 13 3 No Upper Front Fork Clamp Bolts 20 Lower Front Fork Clamp Bolts 20 5 Fastener Remarks Piston Rod Nuts Cylinder Units AD Apply adhesive Th Front Fork Top Plugs 22 5 Front Axle Clump Bolt reeBond TB1344N or equivalent AL Tighten the two clamp bolts alternately two times to ensure even tightening torque G Apply grease R Replacement Parts 13 4 SUSPENSION Exploded View GMO2353BW5 C SUSPENSION 13 5 Exploded View No Fastener Torque Remarks Nm ft lb Rear Stock Absorber Bot as m 2 Swingarm Pivot Adjusting ems Locknut 10 72 3 Swingarm Pivot Shaft 20 2 0 15 4 Swingarm Pivot Shaft Nut 108 11 0 79 7 5 Pivot Adjusting Collar 20 2 0 15 6 Tie rod Nuts 34 3 5 25 R 7 Shock Absorber Nut Lower 34 3 5 25 R 8 Rocker Arm Nut 34 3 5 25 R G Apply grease R Replacement Parts
265. ark plug TU 2 e Measure the gap D with wire type thickness gauge SS x If the is incorrect replace the spark plug PME Spark Plug Gap 0 8 0 9 mm 0 031 0 035 in e Use the standard spark plug or its equivalent Spark Plug NGK CR9EIA 9 Interlock Operation Inspection e Raise the rear wheel off the ground with stand e Turn the engine stop switch to ON run position 1st Check e Start the engine to the following conditions Condition Transmission Gear 1st Position Clutch Lever Release Sidestand Down or Up OTurn the ignition switch to ON and push the starter button OThen the starter motor should not turn when the starter system circuit is normality xIf the engine is start inspect the starter lockout switch sidestand switch neutral switch and relay box ELECTRICAL SYSTEM 16 45 Ignition System 2nd Check e Start the engine to the following conditions Condition Transmission Gear 1st Position Clutch Lever Pulled in Sidestand Up OTurn the ignition switch to ON and push the starter button OThen the starter motor should turn when the starter sys tem circuit is normality xIf the starter motor is not turn inspect the starter lockout 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
266. ary PERIODIC MAINTENANCE 2 25 Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE ga Do cx PRESENT SHIM Example PART No 92180 1018 1020 1022 1024 1026 1028 01103211034 1036 1038 1042 1044 1046 1048 1050 1052 60 65 70 75 80 85 95 00 05 10 20 25 30 35 40 45 0 00 0 04 2 502 55 2 60 2 6 2 702 75 2 802 85 2 90 2 953 00 3 05 3 10 3 15 3 2013 25 ashe oa 12 12 eoz os a o oo oa vos o 2 290 09 owes e oole se oa ena rf ale edo on no ex d sla fo al as 8 rade sla oe voa nda esp do os oo o o afa 18 4 asf see eda esa roa vfs o eda ofa edo ofa oro ola 18 29 25 n a to SPECIFIED CLEARANCE NO CHANGE REQUIRED 2 55 2 60 2 65 2 70 2 75 2 8012 85 2 90 2 9 03 05 3 10 3 15 3 20 3 2513 3013 3513 4013 45 3 50 2 60 2 65 2 702 7512 80 2 85 2 90 2 95 3 00 3 103 15 3 2013 25 3 30 3 35 3 40 3 45 3 50 2 65 2 702 752 80 2 8512 90 2 9513 00 3 0 03 15 3 20 3 25 3 30 3 35 3 4013 4513 50 oso 40 E EE NT DES DESERE ER NE ENT ERES DIS 0 50 0 54 2 7512 80 2 852 9012 95 3 00 3 0513 1013 15 3 20 3 2513 30 3 3513 40 3 45 3 50 osoasa EN DES ERS DES ERE DIES ERES ERES 0 650 69 2 90 2 95 3 0013 05 3 15 3 20 3 25 3 30 3 35
267. ater 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 Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Remove Left Side Cover see Side Cover Removal in the Frame chapter Connector A Water Temperature Sensor B e Replace the water temperature sensor gasket with a new one and apply soap and water solution or rubber lubricant 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 sure the battery is fully charged e Turn the ignition switch to OFF e Disconnect the water temperature sensor connector 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 W G 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 Output Voltage Standard About DC 2 80 2 97 V at 20 C 68
268. ator cable has a clamp C e Install the clamp securely e Turn the throttle grip and make sure that the throttle pulley moves smoothly and return by spring force 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 Idle Speed see Idle Speed Adjustment in the Periodic Maintenance chapter 3 118 FUEL SYSTEM DFI Throttle Body Assy Throttle Body Assy Disassembly DKA Ay SEN OTIS oN 2 SS ON g Y SS 1 Subthrottle Valve Actuator 2 Subthrottle Sensor 3 Main Throttle Sensor 4 Throttle Body Assy 5 Fuel Injectors 6 Delivery Pipe Assy 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 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 6GC17235FW2 C e Remove the delivery pipe assy mounting screws A to pull out the fuel injectors B from the throttle body assy together with the delivery pipe assy C NOTE ODo not damage the insertion portions of the injectors when they are pulled out from the throttle
269. ator rectifier leads are loose or open x If the charging voltage does not rise as the engine speed increases then the regulator rectifier is defective or the alternator output is insufficient for the loads Check the alternator and regulator rectifier to determine which part is defective 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 36 ELECTRICAL SYSTEM Charging System e To check the alternator output voltage do the following procedures OTurn the ignition switch to OFF ORemove the left side cover see Side Cover Removal in the Frame chapter ODisconnect the alternator lead connector A see alterna tor Cover Removal OConnect the hand tester as shown in the table 1 OStart the engine ORun it at the rpm given in the table 1 ONote the voltage readings total 3 measurements Table 1 Alternator Output Voltage Tester Connections Reading Range Tester to Tester at 4 000 rpm Another White 44 8 V or lead more 250 V AC One White lead x If the output voltage shows the value in the table the al ternator operat
270. auge OCheck the intake air pressure sensor 1 output voltage using the following formula and chart Suppose Pg Vacuum Pressure Gauge of Throttle Body PI 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 2 70 cmHg Barometer Reading Vv 3 2 V Digital Meter Reading then Pv 70 8 62 cmHg Absolute Plot this Pv 62 cmHg at a point 1 on the chart and draw a vertical line through the point Then you can get the usable range 2 of the sensor output voltage Usable range 3 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 x 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 supply are good replace the ECU see ECU Removal Installation 3 52 FUEL SYSTEM DFI Intake Air Pressure Sensor 1 Service Code 12 fs 7 1 0 7 P4 7 P4 T NE ded rU yt ou 7 10 20 30 40 50 60 70 7680 90 cmHg Ps 2 1 1 1 1 20 40 60 80 101 32 120
271. aulic unit and the rear master cylinder because dirt around the banjo bolts could contaminate the brake fluid in the line during removal installation Spread over a shop towel around the ABS hydraulic unit before removing the brake line so that brake fluid does not leak on the parts e Open the clamp A e Slide the covers B to disconnect the regulator rectifier connectors C e Remove the bolts A e Pull the lever A forward to disconnect the ABS hydraulic unit connector B e Pull up the ABS hydraulic unit C 12 52 5 Anti Lock System e Remove Regulator Rectifier see Regulator Rectifier Removal in the Electrical System chapter Bolts A Bracket B ABS Hydraulic Unit C NOTICE The ABS hydraulic unit A has been adjusted and set with precision at the factory Do not try to dis assemble and repair the ABS hydraulic unit ABS Hydraulic Unit Installation e Install the ABS hydraulic unit to the bracket NOTICE Brake fluid quickly ruins painted plastic surfaces any spilled fluid should be completely washed away immediately e Apply a non permanent locking agent to the thread of the bolts A and tighten them e Tighten Torque ABS Hydraulic Unit Bracket Bolts 8 8 N m 0 90 kgf m 78 in Ib e Pull the lever A backward to connect the ABS hydraulic unit connector B e Install the brake hoses correctly see Brake Hose Re placement in the Periodic
272. ay 12 Turn Signal Switch 13 Hazzard Button 14 Front Left Turn Signal Light 12 V 10 W 15 Fuse Box 1 16 Turn Signal Relay Fuse 7 5 A 17 Front Right Turn Signal Light 12 V 10 W 18 Joint Connector A 19 Meter Unit 20 Green Right Turn Signal Indicator Light LED 21 Green Left Turn Signal Indicator Light LED 00 00 amp oN2o 16 64 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 O 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 18 22 at 20 C 68 F the tester does not read as specified value replace it with a new one e Connect the 12 V battery A 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 If the air switching valve does not operate as described replace it with a new one NOTE OTo check air flow through the air switching valve
273. ay will blink This function is Fuel Level Sensor Line Self Diagnosis Mode Refer to Fuel Level Sensor Line Self Diagnosis Mode Inspection x If the meter unit does not work replace the meter unit e Refer to the following indicator light inspection for other indicator lights LED inspection NOTE OCurrently the wiring that relates to blinking has been disconnected for the meter is removed from main har ness Therefore the above blink has occurred e Disconnect the terminal 6 the LCD segments and LED warning indicator lights disappear x If the meter unit does not work replace the meter unit GP17842CS1 GP17843CS1 Meter Gauge Indicator Unit ELECTRICAL SYSTEM 16 75 Check 3 2 Meter Communication Line Service Code 39 Check e Connect the leads in the same circuit as Check 3 1 e Wait 10 seconds and the yellow engine warning indicator light LED goes on e Set the ODO mode A by pushing the upper button B e Push the upper button for more than 2 seconds e Check the following items OThe yellow engine warning indicator light LED A re mains on and the number 39 B in the display appears e Push the upper button for more than 2 seconds e Check the following items OThe display returns ODO mode from number 39 OThe yellow engine warning indicator light LED remains on x If the meter unit does not work replace the meter unit NOTE OThe number 39 is service
274. blue high beam indicator light LED C should go on x If the high beam headlight and or blue high beam indicator light LED does not go on inspect or replace the following item Headlight Blue High Beam Bulb see Headlight Bulb Re placement in the Electrical System chapter Meter Unit for Blue High Beam Indicator Light LED see Meter Unit Inspection in the Electrical System chapter Dimmer Switch see Switch Inspection in the Electrical System chapter e Turn the engine stop switch to stop position e The low beam and high beam headlights should stay go ing on x If the headlights and blue high beam indicator light LED does go off inspect or replace the following item Headlight Relay in Relay Box see Relay Circuit Inspec tion in the Electrical System chapter e Turn the ignition switch to OFF e The headlights and blue high beam indicator light LED should go off Headlight Aiming Inspection e Inspect the headlight beam for aiming x If the headlight beam is off the point adjust the headlight aiming Headlight Beam Horizontal Adjustment e Remove the left middle fairing see Middle Fairing in the Frame chapter e Turn the horizontal adjuster A on the headlight with the phillips tip screwdriver B in or out until the beam points straight ahead f the headlight beam points too low or high adjust the vertical beam Headlight Beam Vertical Adjustment e Remove the right middle fairing see Middle Fairing in
275. but the type and brand of the brake fluid that is already in the reservoir are unidentified Recommended Disc Brake Fluid Grade DOT4 e Follow procedure below to install the front rear brake fluid reservoir cap correctly OFirst tighten the rear brake fluid reservoir cap B clock wise C by hand until slight resistance is felt indicating that the cap is seated on the reservoir body then tighten the cap an additional 1 6 turn D while holding the brake fluid reservoir body A PERIODIC MAINTENANCE 2 37 Periodic Maintenance Procedures Brake Pad Wear Inspection e Remove the brake pads see Front Rear Brake Pad Re moval in the Brakes chapter e Check the lining thickness A of the pads in each caliper x If the lining thickness of either pad is less than the service limit B replace both pads in the caliper as a set C Front Brake Pad D Rear Brake Pad 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 x If it does not adjust the brake light switch as follows e Remove Rear Master Cylinder Mounting Bolts A Footpeg Bracket Bolts B and Washers Footpeg Br
276. ch Springs e Tighten Torque Clutch Spring Bolts 9 0 N m 0 92 kgf m 80 in Ib e Install the clutch cover see Clutch Cover Installation 6 13 Clutch Clutch Plate Assembly Inspection e Inspect the friction plate thickness see Clutch Plate Wear Damage Inspection e Measure the length A of the clutch plate assembly as shown in the figure OAssemble Clutch Hub B Spring Seat C Spring D Friction Plates E Steel Plates F Clutch Spring Plate C Clutch Springs H Clutch Spring Bolts I NOTE Olnstall the both ends marked two friction plates at dis assembled to the their original position Torque Clutch Spring Bolts 9 0 N m 0 92 kgf m 80 in Ib Clutch Plate Assembly Length Standard 51 1 51 7 mm 2 01 2 04 in x If the length is not within the specified range adjust the length see Clutch Plate Assembly Adjustment Clutch Plate Assembly Adjustment e Inspect the clutch plate assembly length and then re place the steel plate s which brings the length within the specified range e Remove Clutch Spring Bolts Clutch Springs Clutch Spring Plate e Replace the following steel plate s Thickness Part Number 2 3 mm 0 091 in 13089 0008 2 6 mm 0 102 in 13089 0009 2 9 mm 0 114 in 13089 1093 NOTE ODo not use the steel plate of 2 3 mm 0 091 in and 2 9 mm 0 114 in thickness at the same time e Install the removed parts and inspect the
277. chometer Pulse 12 Fuel Level Sensor 13 Red Warning Indicator Light LED Oil Pressure Warning 14 Left Switch Housing Upper Button 15 Left Switch Housing Lower Button 16 Ground 8 17817652 not drop the meter unit Place the unit so that it faces upward If the meter unit is left upside down or sideways for a long time or dropped it will malfunction Do not short each terminals Check 3 1 Meter Unit Primary Operation Check e Using the auxiliary leads the 12 V battery A to the meter unit connector as follows OConnect the battery positive terminal to the terminal 7 OConnect the battery negative terminal to the terminal 16 GP17840CS1 16 74 ELECTRICAL SYSTEM Meter Gauge Indicator Unit e Connect the terminal 6 to the battery terminal e Check the following items OThe tachometer needle A momentarily points their last readings and back to the minimum position OAII the LCD Liquid Crystal Display segments B appear for about 1 second OThe red warning indicator light LED C goes on for 2 seconds OThe yellow engine warning indicator light LED D goes on for 2 seconds OThe yellow ABS warning indicator light LED E goes on OThe yellow KTRC indicator light LED F goes on for 2 seconds OThe yellow KTRC warning indicator light LED G goes on OThe all segments of the fuel gauge in the displ
278. ci17086FW2 1 ECU 2 Vehicle down Sensor 3 72 FUEL SYSTEM DFI 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 Output Terminal B Ground Terminal C 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 subthrottle sen sor can damage it Subthrottle Sensor Input Voltage Inspection NOTE sure the battery is fully charged e Turn the ignition switch to OFF e Remove the right side cover see Side Cover Removal in the Frame chapter e Disconnect the subthrottle sensor and connect the throttle sensor setting adapter A between these connectors Special Tool Throttle Sensor Setting Adapter 57001 1538 Connect a digital meter to the throttle sensor setting 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 St
279. ck 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 If 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 9617131251 C Stick Coil Input Voltage Connections to ECU Connector For Stick Coil 1 Digital Meter BK lead terminal 44 Digital Meter gt BK Y lead terminal 65 For Stick Coil 2 Digital Meter BK R lead terminal 55 Digital Meter BK Y lead terminal 65 For Stick Coil 3 Digital Meter gt BK O lead terminal 66 Digital Meter gt BK Y lead terminal 65 For Stick Coil 4 Digital Meter BK G lead terminal 43 Digital Meter gt BK Y lead terminal 65 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
280. 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 the claw washer touches the steering stem nut 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 Tighten Torque Steering Stem Head Bolt 108 11 0 kgf m 79 7 ft lb Upper Front Fork Clamp Bolts 20 N m 2 0 kgf m 15 ft lb e Check the steering again x If the steering is still too tight or too loose repeat the ad justment e Install the removed parts see appropriate chapters 65158374 P 9515050851 PERIODIC MAINTENANCE 2 41 Periodic Maintenance Procedures Steering Stem Bearing Lubrication e Remove the steering stem see Stem Stem Bearing Re moval in the Steering chapter e Using a high flash point solvent wash the upper and lower ball bearings 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 65158376 P 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 I
281. ct and clean fuel system see chapter 3 Inspect and replace fuel pump see chapter 3 Fuel pump trouble Inspect see chapter 3 Fuel injector trouble Inspect see chapter 3 Main throttle sensor trouble Inspect see chapter 3 FUEL SYSTEM DFI 3 33 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions chapter 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 2 Stick coil trouble Inspect see chapter 16 Stumble Fuel pressure too low Inspect see chapter 3 Fuel injector trouble Inspect see chapter 3 Main throttle sensor trouble Inspect see chapter 3 nspect see chapter 3 Subthrotte valve actuator rouble inspect see chapter 3 intake air pressure sensor 2 trouble Inspect see chapter 3 Water temperature sensor rouble inspect see chapter 3 sug Unstable fuel pressure Fuel pressure regulator trouble Inspect and replace fuel pump or kinked fuel line Inspect and replace fuel pump see chapter 3
282. ct the drive chain wear see Drive Chain Wear Inspection in the Periodic Maintenance chapter Worn Tooth Engine Sprocket A Worn Tooth Rear Sprocket B Direction of Rotation C NOTE Olf a sprocket requires replacement the chain is proba bly worn also When replacing a sprocket inspect the chain 6J06002BS1 C GK05017BS1 C Sprocket Coupling FINAL DRIVE 11 15 Rear Sprocket Warp Inspection e 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 x If the runout exceeds the service limit replace the rear sprocket Rear Sprocket Warp Standard 0 4 mm 0 016 in or less Service Limit 0 5 mm 0 020 in GK05000BS1 C BRAKES 12 1 Table of Contents udolere Tod 12 3 PEEL 12 8 Special H 12 9 Brake Lever Brake Pedal ertt tt obe 12 10 Brake Lever Position Adjustment pp 12 10 Brake Pedal Position Inspection 8 12 10 Brake Pedal Position 2 2 1 1 tennis 12 10 Bra
283. ction e Check that the throttle grip A moves smoothly from full open to close and the throttle closes quickly and com pletely by the return spring in all steering positions x If the throttle grip does not return properly check the throt tle cable routing grip free play and cable damage Then lubricate the throttle cable e Check the throttle grip free play B Throttle Grip Free Play Standard 2 3 mm 0 08 0 12 in xIf the free play is incorrect adjust the throttle cable as follows e Loosen the locknuts A 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 e 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 xIf the free play can not be adjusted with the adjusters replace the cable Engine Vacuum Synchronization Inspection NOTE OThese 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 the air cleaner housing see Air Cleaner Housing Removal in the Fuel System DFI chapter e Pull off the rubber caps A and vacuum hose B from the fittings of each throttle body e Plug the vacuum hose end A 2 1
284. d Install the clip so that the lead is placed at rear of the hose and face its open side in direction as shown 14 Hold the front wheel rotation sensor lead to the brake hose with the clip at the white mark on the lead placed approx 10 mm 0 4 mm above the clamp Install the clip so that the lead is placed at rear of the hose and face its open side in direction as shown 15 Hold the front wheel rotation sensor lead to the brake hose with the clip at the white mark on the lead Install the clip so that the lead is placed at outside of the hose and face its open side in direction as shown Before clamping face the locking portion of the clamp in direction as shown Face the tabs of the hose clamp in direction as shown 17 18 APPENDIX Cable Wire and Hose Routing NN APPENDIX 17 19 Cable Wire and Hose Routing WD Fuel Tank Breather Hose Clamp Starter Motor Cable Battery Ground Cable Air Cleaner Drain Hose Engine Subharness Run the alternator lead to the outside of air cleaner drain hose and sidestand switch lead and to inside of the engine subharness water pipe fuel tank drain hose and fuel tank breather hose Run the sidestand switch lead to inside of the fuel tank breather hose fuel tank drain hose and alternator lead Hold the sidestand switch lead with the clamp on the water pump cover Run the end of fuel tank dr
285. d chassis ground Any tester reading less than infinity indicates a short necessitating replacement of the crankshaft sensor as sembly Crankshaft Sensor Peak Voltage Inspection NOTE OBe sure the battery is fully charged e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Crankshaft Sensor Lead Connector A see Crankshaft Sensor Removal e Set the hand tester B to the DC 10 V range e Connect the peak voltage adapter C to the hand tester and crankshaft sensor leads in the connector Special Tools Hand Tester 57001 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Needle Adapter Set D 57001 1457 Connections Crankshaft Peak Voltage Sensor Lead Adapter Hand Tester Yellow Red y Black lt Black y e Turn the ignition switch and engine stop switch to ON e Pushing the starter button turn the engine 4 5 sec onds with the transmission gear in neutral to measure the crankshaft sensor peak voltage e Repeat the measurement 5 or more times Crankshaft Sensor Peak Voltage Standard 2 0 V or more x If the tester reading is not specified one inspect the crank shaft sensor see Crankshaft Sensor Inspection 16 42 ELECTRICAL SYSTEM Ignition System 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 rot
286. d brake fluid temperature e Check to see that the rear caliper pin bolt and the sleeve are not badly worn or stepped and that the rubber boots are not damaged xIf the rear caliper pin bolt is damaged replace the rear caliper pin bolt xIf the sleeve is damaged replace the sleeve x If the rubber boots are damaged replace the rubber boot GLO5298BS1 C 12 16 BRAKES Brake Pads Front Brake Pad Removal e Remove Pad Spring Bolts A Pad Spring B Pad Pin C e Remove the brake pads A Front Brake Pad Installation e Push the caliper pistons in by hand as far as they will go e Install Brake Pads Pad Pin e Tighten Torque Front Brake Pad Pins 15 1 5 kgf m 11 ft Ib e Install the pad spring and bolts e Tighten Torque Front Brake Pad Spring Bolts 2 9 N m 0 30 kgf m 26 in 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 Rear Brake Pad Removal e Remove the muffler body see Muffler Body Removal in the Engine Top End chapter e Remove Rear Brake Pad Pin Plug A Rear Caliper Mounting Bolt B Pads BRAKES 12 17 e Pull up the caliper rem
287. d cover e Remove the air switching valve A see Air Switching Valve Removal e Remove the air suction valves B see Air Suction Valve Removal e Remove Cylinder Head Cover Bolts A Cylinder Head Cover Cylinder Head Cover Installation e Install Dowel Pins A Plug Hole Gaskets B G098244 P m E A LIA OO 97 n LLL 8 09089851 C 5 16 END Cylinder Head Cover 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 Sealant Liquid Gasket TB1216B 92104 1064 e Replace the head cover gasket A with a new one e Install the gasket to the cylinder head cover B e Install the cylinder head cover from the left side e Position the cylinder head cover properly while pulling up the water hose on the right side e Apply sorp and water solution or rubber lubricant to the both surface of the washers e Install the washers with the metal side A faces upward e Tighten the cover bolts following the specified tightening sequence Torque Cylinder Head Cover Bolts 9 8 1 0 kgf m 87 in Ib A HT al p HE EM 8 09090851 Cylinder Head Cover ENG
288. d 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 BRAKES 12 25 Brake Hose Removal Installation Refer to the Brake Hose 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 26 5 Anti Lock System Parts Location Front Wheel Rotation Sensor A Front Wheel Rotation Sensor Rotor B Rear Wheel Rotation Sensor A Rear Wheel Rotation Sensor Rotor B Yellow ABS Indicator Light A ABS Hydraulic Unit A Fuse Box 2 A BRAKES 12 27 Anti Lock Brake System ABS Kawasaki Diagnostic System Connector A ABS Self diagnosis Terminal B 12 28 BRAKES Anti Lock Brake System ABS System Wiring Diagram
289. ddle Fairing see Middle Fairing Removal in the Frame chapter Radiator Cap e Check the radiator filler neck A for signs of damage e Check the condition of the top and bottom sealing seats A in the filler neck They must be smooth and clean for the radiator cap to function properly GD07001BS1 C 4 18 COOLING SYSTEM Thermostat Thermostat Removal e Remove Coolant Drain see Coolant Change in the Periodic Maintenance chapter Engine Sprocket Cover see Engine Sprocket Removal in the Final Drive chapter Harness Holder A Water Hose Clamp B Water Hose C Water Pipe Bolts D Water Pipe E e Disconnect the connector A from the water temperature sensor e Loosen the water hose clamp screw B and disconnect the water hose C from the cylinder e Remove Thermostat Housing Bolts A Thermostat Housing Cover B Thermostat Thermostat Installation e Install the thermostat A in the housing so that the air bleeder hole B is on top Thermostat COOLING SYSTEM 4 19 e Replace the O ring A with a new one e Apply grease to the O ring and install it e Install the thermostat housing cover B NOTE ONote that the thermostat does not move at the place when installing the thermostat housing cover e Apply non parmanent locking agent to the threads of the thermostat housing bolts Tighten Torque Thermostat Housing Bolts 5 9 N m 0 60 kgf m 52 in Ib e Apply non parma
290. de 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 65128233 2 34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brakes Brake Fluid Leak Brake Hose and Pipe Inspection e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Rear Fender see Flap and Rear Fender Removal in the Frame chapter e Apply the brake lever or pedal and inspect the brake fluid leak from the brake hoses A pipes B and fittings C x If the brake fluid leaked from any position inspect or re place the problem part PERIODIC MAINTENANCE 2 35 Periodic Maintenance Procedures Brake Hose and Pipe Damage and Installation Condition Inspection e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Rear Fender see Flap and Rear Fender Removal in the Frame chapter e Inspect the brake hoses and fittings for deterioration cracks and signs of leakage OThe high pressure inside the brake line can cause fluid to IAM leak A or the hose pipe to burst if the line is not properly maintained Bend and twist the rubber hose while exam ining it Replace the hose and pipe if any crack B bulge C or leakage is noticed Tighten any brake hose banjo bolts and brake pipe joint nuts Torque Brake Hose Banjo Bolts 25 N m
291. ditions 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 Even when the DFI system is operating normally the yel low engine warning indicator light LED may blink under strong electrical interference Additional measures are not required Turn the ignition switch OFF to stop the indicator light and symbol If the yellow engine warning indicator light LED of the motorcycle brought in for repair still blinks check the service code When the repair has been done the yellow engine warn ing indicator light LED goes off But the service codes stored in memory of the ECU are not erased to preserve the problem history The problem history can be referred using the KDS Kawasaki Diagnostic System when solv ing unstable problems When the motorcycle is down the vehicle down sensor operates and the ECU shuts off the fuel pump relay fuel in jectors and ignition system The ignition switch is left ON If the starter button is pushed the electric starter turns but the engine does not start When the starter button is pushed the yellow engine warning indicator light LED blink but the service code is not displayed To start t
292. e tween the journal and camshaft cap Camshaft Journal Camshaft Cap Clearance Standard 0 038 0 081 mm 0 0015 0 0032 in Service Limit 0 17 mm 0 0067 in xIf any clearance exceeds the service limit measure the diameter of each camshaft journal with a micrometer Camshaft Journal Diameter Standard 23 940 23 962 mm 0 9425 0 9434 in Service Limit 23 91 mm 0 9413 in xIf the camshaft journal diameter is less than the service limit replace the camshaft with a new one and measure the clearance again xIf the clearance still remains out of the limit replace 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 runout with a dial gauge at the specified place as shown in the figure x If the runout exceeds the service limit replace the shaft Camshaft Runout Standard TIR 0 02 mm 0 0008 in or less Service Limit TIR 0 1 mm 0 004 in GE11337BS1 5 24 END Camshaft Camshaft Chain Cam Wear Inspection e 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 Height Standard Exhaust 32 943 33 057 1 2970 1 3015 Intake 32 943 33 057 1 2970 1 3015 GE11012281 0 Ser
293. e common difficulties Engine Doesn t Start Starting Difficulty Starter motor not rotating Ignition and engine stop switch not ON Starter lockout switch or neutral switch trou ble 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 spark spark weak Vehicle down sensor DFI coming off Ignition switch not ON Engine stop switch turned OFF Clutch lever not pulled in or gear not in neu tral Battery voltage low 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 Neutral starter lockout or sidestand switch trouble Crankshaft se
294. e Fit the collar C on the grease seal of the left side e Screw the swingarm pivot adjusting collar A into the frame B so that the collar does not project the swingarm mating surface 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 NOTE OTighten the swingarm pivot shaft until the clearance C between the ball bearing D and collar comes to 0 mm 0 in Torque Swingarm Pivot Shaft 20 N m 2 0 kgf m 15 ft Ib eUsing the swingarm pivot nut wrench tighten the swingarm pivot adjusting collar locknut E Special Tool Swingarm Pivot Nut Wrench 57001 1597 Torque Swingarm Pivot Adjusting Collar Locknut 98 10 kgf m 72 ft Ib e Tighten the swingarm pivot shaft nut Torque Swingarm Pivot Shaft Nut 108 N m 11 0 kgf m 79 7 ft lb Move the swingarm up and down to check for abnormal friction e Install the removed parts see appropriate chapters GMO6193BS1 C GMO6194BS1 C Swingarm SUSPENSION 13 29 Swingarm Bearing Removal e Remove Swingarm see Swingarm Removal Collar A Grease Seals B Sleeve C Circlip Right Side D 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 needle bearings A ball bearing B
295. e Insert a thin blade screwdriver A into the slit B on the joint lock C e Turn the driver to disconnect the joint lock e Pull the fuel hose joint A out of the delivery pipe A WARNING Fuel is flammable and explosive under certain con ditions and can cause severe burns Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is dis connected fuel spills out from the hose and the pipe Cover the hose connection with a clean shop towel to prevent fuel spillage e Replace the fuel hose with a new one e Run the fuel hose correctly see Cable Wire and Hose Routing section in the Appendix chapter e Insert the fuel hose joint A straight onto the delivery pipe until the hose joint clicks e Push B the joint lock C e Push and pull A the fuel hose joint B back and forth more than two times and make sure it is locked and does not come off A WARNING Leaking fuel can cause a fire or explosion resulting in severe burns Make sure the fuel hose joint is installed correctly on the delivery pipe and that it doesn t leak x If it comes off reinstall the hose joint e Run the fuel hose correctly see Cable Wire and Hose Routing section in the Appendix chapter e Install the fuel tank see Fuel Tank Installation in the Fuel System DFI chapter e Start the engine and check the fuel hose for leaks 2 52 PERIODIC
296. e Install the new inserts in the connecting rod and check insert crankpin clearance with the plastigage press gauge Crankshaft Side Clearance Inspection e Insert a thickness gauge A between the crankcase main bearing and the crank web at the No 3 journal to deter mine clearance the clearance exceeds the service limit replace the crankcase halves as a set NOTE OThe upper and lower crankcase halves are machined at the factory in the assembled state so the crankcase halves must be replaced as a set Bearing Insert Crankshaft Side Clearance Standard 0 09 0 19 mm 0 0035 0 0075 in Service Limit 0 39 mm 0 0153 in 6105060181 6105041781 CRANKSHAFT TRANSMISSION 9 23 Crankshaft and Connecting Rods Crankshaft Runout Inspection e Measure the crankshaft runout x If the measurement exceeds the service limit replace the crankshaft Crankshaft Runout Standard TIR 0 02 mm 0 0008 in or less Service Limit TIR 0 05 mm 0 0020 in Crankshaft Main Bearing Insert Journal Wear Inspection e Using a plastigage press gauge A measure the bear ing insert journal B clearance NOTE OTighten the crankcase bolts to the specified torque see Crankcase Assembly ODo not turn the crankshaft during clearance measure ment OJournal clearance less than 0 025 mm 0 00098 in can not be measured by plastigage press gauge however using genuine part
297. e 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 e Remove Upper Mud Guard see Upper Mud Guard Removal in the Frame chapter Rear Wheel see Rear Wheel Removal in the Wheels Tires chapter Chain Cover Bolt A e Remove Clamp A Chain Cover B Swingarm see Swingarm Removal in the Suspension chapter e Remove Engine Sprocket Cover see Engine Sprocket Cover e Remove the drive chain A from the engine sprocket B and take it off the chassis FINAL DRIVE 11 7 Drive Chain Drive Chain Installation e Install the drive chain to the engine sprocket e Install Swingarm see Swingarm Installation in the Suspension chapter Rear Wheel see Rear Wheel Installation in the Wheels Tires chapter Engine Sprocket Cover see Engine Sprocket Cover In stallation e Insert the projection A on the chain cover into the swingarm hole B e Adjust the drive chain slack after installing the chain see Drive Chain Slack Adjustment in the Periodic Mainte nance chapter Drive Chain Replacement e Remove Chain Cover see Drive Chain Removal Engine Sprocket Cover see Engi
298. e Procedures x If the sidestand switch operation does not work inspect or replace the following item Battery see Charging Condition Inspection in the Elec trical System chapter Main Fuse 30 A see Fuse Inspection in the Electrical System chapter Ignition Fuse 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 Engine Stop Switch see Switch Inspection in the Elec trical System chapter Starter Button see Switch Inspection in the Electrical System chapter Neutral Switch see Switch Inspection in the Electrical System chapter Starter Relay see Starter Relay Inspection in the Elec trical System chapter Relay Box see Relay Circuit Inspection in the Electrical System chapter Harness see Wiring Inspection in the Electrical System chapter x If the all parts are good condition replace the ECU see ECU Removal Installation in the Fuel System DFI chap ter Engine Stop Switch Operation Inspection First Step e Turn 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 e The engine does not start x If the engine starts inspect or replace the following item Engine Stop Switch see Switch Inspection in the Elec trical System chapter Second Step e Turn the ignition switch to ON e
299. e Sensor 2 Output Voltage Connections to Adapter Digital Meter Y sensor G W lead 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 Ir 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 x If the reading is out of the usable range replace the sen sor If the reading is within the usable range remove the ECU and check the wiring for continuity between main harness connector Special Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Intake Air Pressure Sensor 2 Connector B G W lead ECU terminal 17 C ROMERO G lead ECU terminal 49 D xIf the wiring is good check the sensor for various vac uum see Intake Air Pressure Sensor 1 Output Voltage Inspection 3 62 FUEL SYSTEM DFI Intake Air Pressure Sensor 2 Service Code 16 Intake Air Pressure Sensor 2 Circuit 6617082212 1 ECU 2 Intake Air Pressure Sensor 2 Crankshaft Sensor Service Code 21 FUEL SYSTEM DFI 3 63 The crankshaft sensor has no power source and when the engine stops the cr
300. e Warp 1 1 1 0 0 00000 00000000000000000000 6 14 Clutch Spring Free Length Measurement sss 6 14 Clutch Housing Finger Inspection teh rer uie bao tek 6 14 Clutch Housing Spline Inspection pp 6 14 6 2 Exploded View GF022018W5 C 6 3 Exploded View 2 Cover Bolts 9 8 1 0 87 in lb 3 Filler Plug Hand tighten 4 Clutch Spring Bolts 9 0 0 92 80 in Ib 5 Clutch Hub Nut 135 13 8 100 R CL Apply cable lubricant EO Apply engine oil G Apply grease L Apply a non permanent locking agent M Apply molybdenum disulfide grease R Replacement Parts S Follow the specified tightening sequence WL Apply soap and water solution or rubber lubricant 6 4 CLUTCH Specifications ltem Standard Service Limit Clutch Lever Free Play 2 3mm 0 08 0 12 in E Clutch Clutch Plate Assembly Length 51 1 51 7 mm 2 01 2 04 in Plate Thickness 2 72 2 88 mm 0 107 0 113 2 4 mm 0 094 in Friction and Steel Plate Warp 0 15 mm 0 0059 in or less 0 3 mm 0 012 in Clutch Spring Free Length 64 6 mm 2 54 in 61 6 mm 2 43 in 6 5 Special Tool Sealant Clutch Holder Liquid Gasket TB1211F 57001 1243 92104 0004 gt 7571243ST C 879200045 6 6 CLUTCH
301. e 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 e Measure coil winding resistance when the DFI part is cold at room temperature e Make sure all connectors in the circuit are clean and tight and examine leads for signs of burning fraying short etc Deteriorated leads and bad connections can cause reappearance of problems and unstable operation of the DFI system If any wiring is deteriorated replace the wiring 9617572051 6617037351 Troubleshooting the DFI System FUEL SYSTEM DFI 3 27 e Pull each connector A apart and inspect it for corrosion dirt and damage x If the connector is corroded or dirty clean it carefully If it is damaged replace it Connect the connectors securely e Check the wiring for continuity OUse the wiring diagram to find the ends of the lead which is suspected of being a problem OConnect the hand tester between the ends of the leads Special Tool H
302. e connector joined e Turn the ignition switch to ON Input Voltage Standard DC 4 75 5 25 V e Turn the ignition switch to OFF x If the reading is within the standard check the output volt age see Intake Air Pressure Sensor 2 Output Voltage Inspection xIf the reading is out of the standard remove the ECU and check the wiring for continuity between main harness connectors Special Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Intake Air Pressure Sensor 2 Connector B BL lead ECU terminal 4 C G lead ECU terminal 49 D xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see Removal Installation 8017119 51 C 8017111 81 C FUEL SYSTEM DFI 3 61 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 Pressur
303. e frame with clamps Run the sidestand switch lead to inside of the brake hose Run the frame ground cable to the upside of the alternator lead battery ground cable and brake hose Run the battery ground cable between the fuel hose and brake hose 18 Hold the battery ground cable and starter motor cable to the main harness with the band at the front of the branching point on the main harness After tying them cut the band excess length and face its knot downward Run the starter motor cable to outside of the fuel hose to upside of the alternator lead brake pipes and battery ground cable to under the frame ground cable Hold the rear wheel rotation sensor lead connector and crankshaft sensor lead connector to the air cleaner housing with the holder Intake Air Temperature Sensor Frame Ground Terminal Fuel Hose Hold the main harness with the clamp so that it positions away from the bracket KLZ1000AC early model only Before clamping face the locking portion of the clamp in direction as shown 17 22 APPENDIX Cable Wire and Hose Routing 9 Y me a Aa Nosa We a m WT NIC NN PT V M A T 1 2 a Ch MEE I 1 A ES dere 68098900 6 APPENDIX 17 23 Cable Wire and Hose Routing QI CN Oo Sidestand Switch Lead
304. e hose to the stopper on the caliper Front Wheel Rotation Sensor Lead Front Wheel Rotation Sensor 17 46 APPENDIX Cable Wire and Hose Routing 6G OOO amo BEL x di GA DEL 27 pe zie Ts NE un uM 08809924045 C APPENDIX 17 47 Cable Wire Hose Routing WN ABS Hydraulic Unit Brake Hose see 17 45 page for direction between ABS Hydraulic Unit and Rear Caliper Brake Hose see 17 45 page for direction between Rear Master Cylinder and ABS Hydraulic Unit Fit the brake hose end pipe to the groove on the caliper Clips Hold the brake hose at the rubber protector with the clamps Rear Brake Reservoir Rear Shock Absorber Adjuster Hose Hold the rear brake reservoir hose and rear shock absorber adjuster hose together with the clamp Clamp Rear Wheel Rotation Sensor Lead Hold the rear wheel rotation sensor lead at the rubber protector with the clamps Rear Brake Reservoir Hose Fit the brake hose end pipe to the stopper on the master cylinder Clamp Rear Wheel Rotation Sensor 17 48 APPENDIX Troubleshooting Guide NOTE ORefer to the Fuel System chapter for most of DFI troubleshooting 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 mor
305. e odometer OThe integrated value of the odometer cannot be reset Check 3 13 Odometer Check e Check the odometer with the speedometer check in the same way value indicated in the odometer is not added replace the meter unit NOTE OThe data is maintained even if the battery is discon nected OWhen the figures come to 999999 they are stopped and locked OThe integrated value of the odometer cannot be reset Check 3 14 Trip A B Meter Check e Check the trip meter with the speedometer in the same Way x If value indicated in the trip meter is not added replace the meter unit NOTE OThe integrated value of the odometer cannot be reset e Check that when the lower button is pushed for more than two seconds the figure display turns to 0 0 x If the figure display does not indicate 0 0 replace the me ter unit duty t TX100 50 0V 17861652 C B ib 9 897 17 GP17882CS1 00 GP17883CS1 ELECTRICAL SYSTEM 16 81 Meter Gauge Indicator Unit Check 3 15 Tachometer Inspection e Connect the leads in the same circuit as Check 3 1 e The engine speed rpm equivalent to the input frequency is indicated in the oscillator A if the square wave is input into terminal 11 Olndicates approximately 6 000 rpm if the input frequency is approximately 200 Hz x If the meter function does not work replace the meter unit d
306. e shape of the current ignition key e Remove Seat see Seat Removal in the Frame chapter e Remove the immobilizer Kawasaki diagnostic system connector cap A e Connect the key registration adapter A and key registra tion unit B Special Tools Key Registration Unit 57001 1582 Key Registration Adapter 57001 1746 Immobilizer System Equipped Models ELECTRICAL SYSTEM 16 85 e Insert the registered ignition key into the ignition switch and turn it to ON Verified OThe red warning indicator light LED and the immobilizer warning symbol A blink to display the registration mode go to the next step Not Verified OThe red warning indicator light LED and the immobilizer warning symbol A blink to display the collation error re fer to the following failure illustrations Immobilizer Amplifier Failure Registered Ignition Key Collation Error e Turn to OFF the ignition switch and remove the registered ignition key x If there are other registered ignition keys they should all do the procedure above OThe red warning indicator light LED A then blinks for 15 seconds it means the ECU is in the registration mode OThe immobilizer warning symbol B disappears OAfter 15 seconds the ECU ends the registration mode and stops blinking the red warning indicator light LED NOTE Olnsert and turn on the next key between 15 seconds that the ECU is in the registration mode OWhen a registration mode
307. e 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 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 right side cover see Side Cover Removal in the Frame chapter e Pull the air switching valve hose A out of the air cleaner housing e Start the engine and run it at idle speed e Plug A the air switching valve hose end with your finger and feel vacuum pulsing in the hose x If there is no vacuum pulsation check the hose line for leak If there is no leak check the air switching valve see Air Switching Valve Unit Test in the Electrical Sys tem chapter or air suction valve see Air Suction Valve Inspection in the Engine Top End chapter PERIODIC MAINTENANCE 2 27 Periodic Maintenance Procedures Clutch Clutch Operation Inspection e Pull the clutch lever just enough to take up the free play A e Measure the gap between the lever and the lever holder x If the gap is too wide the clutch not release fully If the gap is too narrow the clutch may not engage fully In either case adjust it Clutch Lever Free Play Standard 2 3 mm 0 08 0 12 in A WARNING The engine and exhaust system get e
308. e water pipe Insert the radiator hose to the water pipe until it stops against the stopper on the water pipe Radiator Hose Water Hose Detail A 2 places O ring Apply soapy water to protect the O ring from damage during installation Oil Cooler Engine Subharness Battery Ground Cable Harness Holder Install the harness holder at the places where higher than the branching point of the water pipe to hold the engine subharness to the water pipe Hold the sidestand switch lead with the clamp on the water pump cover Neutral Switch Lead Do not pull the lead after connected Run the oil pressure switch lead to the inside of the water pipe Cover the oil pressure switch with the switch cover 17 32 APPENDIX Cable Wire and Hose Routing ees NS 4 JP tS vd La n 6809896015 C APPENDIX 17 33 Cable Wire Hose Routing Water Hose Cylinder Head to Radiator Filler Neck Hose Clamp Hose Clamp Water Hose Thermostat Housing to Radiator Filler Neck Tab Insert the water hose to the thermostat housing cover until it stops against the tab Breather Hose from Upper Crankcase to Air Cleaner Case White Paint Mark Install the breather hose so that the white paint mark faces rearward Hose Clamp Bracket Clamp Crankshaft Sensor Lead Face the tabs of the
309. e 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 Lower Fairing see Lower Fairing Removal in the Frame chapter Radiator see Radiator and Radiator Fan Removal in the Cooling System chapter Exhaust Pipe see Exhaust Pipe Removal in the Engine Top End chapter Air Switching Valve see Air Switching Valve Removal in the Engine Top End chapter Throttle Body Assy see Throttle Body Assy Removal in the Fuel System DFI chapter Shift Lever see Shift Pedal Removal in the Crank shaft Transmission chapter e Remove Clamps A Water Hoses B e Remove the connector A from the bracket on the air suc tion valve cover and disconnect the connector e Disconnect Starter Motor Cable see Starter Motor Removal in the Electrical System chapter Alternator Lead Connector see Alternator Cover Re moval in the Electrical System chapter Crankshaft Sensor Lead Connector see Crankshaft Sensor Removal in the Electrical System chapter 8 6 ENGINE REMOVAL INSTALLATION Engine Removal Installation e Remove Engine Ground Cable Terminal Bolt A Engine Sprocket B see Engine Sprocket Removal in the Final Drive chapter e Remove the drive chain from the output shaft e Remove Left Lower Fairing Stay A Right Low
310. ead to the hole on the engine bracket Clutch Cable Crankshaft Sensor Lead Oxygen Sensor Lead Hold the crankshaft sensor lead and oxygen sensor lead with clamp Run the reserve tank overflow hose to behind of the adjusting bolt and between the adjusting bolt and frame and directs it to under the frame Run the clutch cable at this point View Z Horn Lead Connect the horn lead connectors so that its lead comes from inside Tip the outer horn terminal slightly toward rear to avoid the lead from contact with another connector Before clamping face the locking portion of the clamp in direction as shown Face the tabs of the hose clamp in direction as shown 17 16 APPENDIX Cable Wire and Hose Routing 3702 05 7 m 4 QC n 4 Oty e 652 lt V sf 4 SS i R 68098870 6 APPENDIX 17 17 Cable Wire and Hose Routing Reserve Tank Return Hose Clip the return hose to the reserve tank Reserve Tank Overflow Hose Hose Clamps Reserve Tank Radiator Hose Water Hose Clamps Throttle Cables Clutch Cable 10 Front Wheel Rotation Sensor Lead 11 Brake Hose 12 Hold the brake hose at the rubber protector to the front fender with the clamp 13 Hold the front wheel rotation sensor lead to the brake hose with the clip at the white mark on the lea
311. earing Inspection xIf 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 GJ04130BS1 10 10 WHEELS TIRES Wheels Rims Axle Inspection e Remove the front and rear axles see Front Rear Wheel Removal e Visually inspect the front and rear axle for damages x If the axle is damaged or bent replace it e Place the axle in V blocks that are 100 mm 3 94 in A apart and set a dial gauge B on the axle at a point halfway between the blocks Turn C the axle to mea sure the runout The difference between the highest and lowest dial readings is the amount of runout If axle runout exceeds the service limit replace the axle Axle Runout 100 mm 3 94 in Standard TIR 0 1 mm 0 004 in or less Service Limit TIR 0 2 mm 0 008 in Balance Inspection e Remove the front and rear wheels see Front Rear Wheel Removal e Support the wheel so that it can be spun freely e Spin the wheel lightly and mark A the wheel at the top when the wheel stops ORepeat this procedure several ti
312. easons 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 15 Hub Bearing Removal e Remove the wheels see Front Rear Wheel Removal and take out the following Collars A Coupling B Out of rear hub Grease Seals C Special Tool Inside Circlip Pliers 57001 143 e Use the bearing remover to remove the hub bearings A Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground Special Tools Bearing Remover Head 020 x 022 B 57001 1293 Bearing Remover Shaft 13 C 57001 1377 Hub Bearing Installation e Before installing the hub bearings blow any dirt or foreign particles out of the hub with compressed air to prevent contamination of the bearings e Replace the bearings with new ones e Install the bearings by using the bearing driver set which does not contact the bearing inner race NOTE Olnstall the bearings so that the marked side faces out e Press in each right the bearing A until they are bottomed Special Tool Bearing Driver Set B 57001 1129 GJ06109BS2 C G
313. ection 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 GNO5060481 C GNO5130BS1 C Steering Stem STEERING 14 9 Steering Stem Warp Inspection e Whenever the steering stem is removed or if the steering can not be adjusted for smooth action check the steering stem for straightness x If the steering stem A is bent replace the steering stem Stem Cap Deterioration Damage Inspection Replace the stem cap if its oil seal A shows damage GN05147BS1 14 10 STEERING Handlebar Handlebar Removal e Remove Clamp A Clutch Lever Clamp Bolts B Clutch Lever Assembly C Left Switch Housing D Handlebar Weight E Handlebar Grip F e Remove Front Master Cylinder A see Front Master Cylinder Re moval in the Brakes chapter Clamp B Right Switch Housing C Handlebar Weight D Throttle Grip E e Remove Handlebar Holder Bolts A Handlebar Holder B Handlebars C e Remove Middle Fairing see Middle Faring Removal in the Frame chapter Handlebar Holder Mounting Nut A Both Sides e Remove Caps and Bolts A Lower Handlebar Holder Assembly B Handlebar STEERING 14 11 e Remove Bolts A Both Sides Lower Handlebar Holders B Lower Handlebar Holder Brace C Handlebar Ins
314. ed 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 Gauge incorrect Water temperature gauge broken Water temperature sensor broken Coolant incorrect Coolant level too low Coolant deteriorated Wrong coolant mixed ratio Cooling system component incorrect Radiator fin damaged Radiator clogged Thermostat trouble Radiator cap trouble Radiator fan relay trouble Fan motor broken Fan blade damaged Water pump not turning Water pump impeller damaged Over Cooling Gauge incorrect Water temperature gauge broken Water temperature sensor broken Cooling system component incorrect Thermostat trouble Clutch Operation Faulty Clutch slipping Friction plate worn or warped Steel plate worn or warped Clutch spring broken or weak Clutch hub or housing unevenly worn No clutch lever play Clutch inner cable trouble Clutch release mechanism trouble Clutch not disengaging properly Clutch plate warped or too rough Clutch spring compression uneven Engine oil deteriorated Engine oil viscosity too high Engine oil level too high Clutch housing frozen on drive shaft Clutch hub nut loose Clutch hub spline damaged Clutch friction plate installed wrong Clutch l
315. eed to disassemble or repair them Replace the ABS hydraulic unit The basic troubleshooting procedures are listed below e Carry out pre diagnosis inspections as a preliminary in spection e Determine the fault using the self diagnosis function e Check wiring and connections from the ABS hydraulic unit connector to the suspected faulty ABS part using the hand tester Special Tool Hand Tester 57001 1394 e Visually inspect the wiring for signs of burning or fraying xIf any wiring is poor replace the damaged wiring e Pull each connector A apart and inspect it for corrosion dirt and damage x If the connector is corroded or dirty clean it carefully If it is damaged replace it 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 the tester does not read 0 the lead is defective Re place the main harness B if necessary e Narrow down suspicious parts and close in on the faulty ABS part by repeating the continuity tests If no abnormality is found in the wiring or connectors the ABS parts are the next likely suspects Check each part one by one x If an abnormality is found replace the affected ABS part GL14614BS1 12 34 BRAKES Anti Lock Brake System ABS D
316. eel 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 e To maintain wheel balance mark the valve stem position on the tire with chalk so that the tire can be reinstalled in the same position Chalk Mark or Yellow Mark A Air Valve B Align C e Lubricate the tire beads and rim flanges on both sides with a soap and water solution or rubber lubricant This helps the tire beads slip off the rim flanges NOTICE Never lubricate with engine oil or petroleum distil lates because they will deteriorate the tire e Remove the tire from the rim using a suitable commer cially available tire changer NOTE OThe tires cannot be removed with hand tools because they fit the rims too tightly Tire Installation A WARNING 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 ofthe 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
317. egistration mode OAfter 15 seconds the ECU ends the registration mode and stops blinking the red warning indicator light LED NOTE Olnsert and turn on the next key between 15 seconds that the ECU is in the registration mode OWhen a registration mode was ended do the registered ignition key verification procedure over again to restart it This applies to all ignition key registration e Insert the second ignition key into the ignition switch and turn it to ON NOTE OKeep other ignition keys away from the immobilizer an tenna Olf there is any problem in the registration the red warning indicator light LED and the immobilizer warning symbol A blink to display the collation error Immobilizer Amplifier Failure When Registered Ignition Key is Inserted GP30027C81 0 5second 0 Sees baa GP30024CS1 16 100 ELECTRICAL SYSTEM Immobilizer System Equipped Models Ignition Key Collation Error 0 3second D Mec EEEFECEPEEUBEELFEFBREENT 6230026651 e The second ignition key is registered the ECU OThe red warning indicator light LED and the immobilizer warning symbol A blinks 2 time and stops for 1 second and the repeats this cycle to indicate successful registra tion of the second ignition key e Turn to OFF the ignition switch and wait for period more than 15 seconds e The re
318. el 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 outer tube D OSet the gauge stopper E so that its lower side shows the oil level distance specified F OPull the handle slowly to pump out the excess oil until the oil no longer comes out x 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 GM04733BS2 C e Screw the rod nut A onto the piston rod B as shown in the figure 15 mm 0 59 in or more C 8 04511 51 C e Screw the fork piston rod puller onto the end of the piston rod D ine Special Tool Fork Piston Rod Puller M10 x 1 0 57001 1298 e Install the spring seat A with the flat surface B facing upward B e Install the fork spring C with the smaller end D facing upward A GM04734BS1 e Install Collar A Washer B 13 20 SUSPENSION Front e Check the distance between the lower end A of the top plug B and lower end C of the rebound damping ad juster with a vernier caliper D Right Front Fork Only 14 5 mm 0 571 in or more E e Set the fork spring compressor on the washer A using the outer tube as a guide
319. el 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 Close the fuel tank cap e Remove the bar which supported fuel tank e Remove the rear fuel tank bolt A e Remove the fuel tank and place it on a flat surface not apply the load to the fuel pipe of the fuel pump Fuel Tank Installation e Note the above WARNING see Fuel Tank Removal e Check that the dampers A pad B and trim C are in place on the frame and the fuel tank x If the dampers pad or trims are damaged or deteriorated replace them FUEL SYSTEM 3 125 Fuel Tank e Install the breather hose A and clamp securely e 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 does not come off A WARNING Make sure the hose joint is installed correctly on the delivery pipe or the fuel could leak x lf it comes off reinstall the hose joint Connect the fuel pump lead connector and the battery terminal see Battery Installation in the Electrical System chapter OBe careful not to pinch the leads cables or harnesses around rear part of the fuel tank A e Run the hoses cor
320. em to determine the cause and then replace it with a new fuse of proper amperage see Fuse Installation in the Electrical System chapter Anti Lock System BRAKES 12 57 Fuse Inspection e Remove the fuses see ABS Solenoid Valve Relay Fuse 15 AJABS Motor Relay Fuse 25 A Removal e Refer to the Fuse Inspection in the Electrical System chapter SUSPENSION 13 1 Suspension Table of Contents Exploded 13 2 Specifications Ota eI RD Wirt 13 6 Speclal TOONS e Pe ERE eta 13 7 FROME de 13 9 Rebound Damping Force Adjustment Right Front Fork 13 9 o o eiae 13 9 Front Fork Removal Each Fork Leg on 13 10 Eront Eork Installation ion cete reet ete tette tes ee d e e te p e e ee bu eat 13 10 KARS me EE 13 10 Front Fork Disassembly rtr 13 20 Front Fork Assembly utes lace titan tate ran Race cad aan S t 13 22 Inner Tube Outer Tube Inspection 000000 1101 13 23 Dust Seal Inspection nece te ee deor ee tee et 13 23 Spring Tension 13 23 Rear Shock ADSOFDGF 3 E D P Et
321. emove Clutch see Clutch Removal in the Clutch chapter Oil Pan see Oil Pan Removal Circlip A and Washer B Special Tool Outside Circlip Pliers 57001 144 e Remove Oil Pump Drive Gear A Washer B Oil Pump Drive Gear Installation e Apply molybdenum grease to the journal portion A on the oil pump drive gear shaft B e Install the washer C to the shaft e Apply molybdenum disulfide oil solution to the hole A of the oil pump drive gear shaft in the crankcase e Insert the oil pump drive gear shaft B to the lower crankcase e Replace the circlip C with a new one e Install the washer D and circlip Special Tool Outside Circlip Pliers 57001 144 e Align the projection on the shaft with the oil water pump shaft slot by turning the oil pump drive gear e Set the circlip original position 7 14 LUBRICATION SYSTEM Cil Cooler Oil Cooler Removal e Remove Left Lower Fairing Assembly see Lower Fairing Assem bly Removal in the Frame chapter Coolant Drain see Coolant Change in the Periodic Maintenance chapter Engine Oil Drain see Engine Oil Change in the Periodic Maintenance chapter Water Hose Clamp Screws Loosen A Water Hoses B Cooler Bolts C Oil Cooler D Oil Cooler Installation e Replace the O ring A with a new one Apply grease to the O ring and install it e Install the oil cooler e Tighten Torque Oil Cooler Bolts 12 N m 1 2 kgf m 10
322. emove 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 Fit the projections A on the lens to the cover grooves B e Tighten the license plate light cover screws Torque Licence Plate Light Mounting Screws 1 2 N m 0 12 kgf m 11 in Ib 16 60 ELECTRICAL SYSTEM Lighting System Headlight Tail Light Circuit Y R GPi2604BW3 C lgnition Switch Tail Brake Light LED License Plate Light 12 V 5 W Joint Connector B Frame Ground 3 Frame Ground 1 Engine Ground Battery 12 V 8 Ah Starter Relay Main Fuse 30 A Alternator Relay Box 5 A N Headlight Circuit Relay Dimmer Switch Passing Button Fuse Box 1 Turn Signal Relay Fuse 7 5 A Headlight Relay Fuse 15 A Headlight High 12 V 55 Headlight Low 12 V 55 City Light 12 V 5 W Joint Connector A Meter Unit Blue High Beam Indicator Light LED Lighting System ELECTRICAL SYSTEM 16 61 Turn Signal Light Bulb Replacement e Unscrew the screw A and remove the lens e Push and turn the bulb A counterclockwise and remove it e Insert the new bulb A by aligning its upper and lower pins B with the upper and lower
323. en sor resistance see Intake Air Temperature Sensor Resis tance Inspection GC17116FS1 Intake Air Temperature Sensor Resistance Inspection e Remove the intake air temperature sensor see Intake Air Temperature Sensor Removal Installation e Suspend the sensor A in a container of machine oil so that the heat sensitive portion is submerged e Suspend a thermometer B with the heat sensitive por tion C located in almost the same depth with the sensor NOTE OThe sensor and thermometer must not touch the con tainer side or bottom e Place the container over a source of heat and gradually raise the temperature of the oil while stirring the oil gently for even temperature e Using a digital meter measure the internal resistance of the sensor across the terminals at the temperatures shown in the following Intake Air Temperature Sensor Resistance Standard 5 4 6 6 at 0 C 32 F 68617608682 C 0 29 0 39 at 80 C 176 F x If the reading is out of the standard replace the sensor x If the reading is within the standard but the problem still exists replace the ECU see ECU Removal Installation 3 56 FUEL SYSTEM DFI Intake Air Temperature Sensor Service Code 13 Intake Air Temperature Sensor Circuit 2Y 6617080282 C 1 ECU 2 Intake Air Temperature Sensor Water Sensor Service Code 14 FUEL SYSTEM DFI 3 57 W
324. en it loosely e Unscrew the caliper mounting bolts C and detach the caliper D from the disc Do not loosen the caliper assembly bolts E Take out only the caliper mounting bolts for caliper re moval Loosening the caliper assembly bolts will cause brake fluid leakage e Unscrew the banjo bolt and remove the brake hose F from the caliper see Brake Hose and Pipe Replacement in the Periodic Maintenance chapter 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 Caliper Rubber Parts Replacement in the Periodic Maintenance chap ter Rear Caliper Removal e Remove the muffler body see Muffler Body Removal in the Engine Top End chapter e Loosen the banjo bolt A at the brake hose lower end and tighten it loosely e Unscrew the caliper mounting bolt B and rear caliper pin bolt C and detach the caliper D from the disk e Unscrew the banjo bolt and remove the brake hose from the caliper see Brake Hose and Pipe Replacement in the Periodic Maintenance chapter 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 Caliper Rubber Parts Replacement in the Periodic Maintenance chap ter
325. en them Torque Shift Drum Bearing Holder Bolts 12 N m 1 2 kgf m 106 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 shift drum cam bolt A e Remove Shift Drum Cam B Dowel Pin C Bearing D Shift Drum Assembly e Be sure to install the dowel pin e Apply a non permanent locking agent to the threads of the shift drum bearing holder bolt and tighten it Torque Shift Drum Cam 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 6113482851 9113483851 C CRANKSHAFT TRANSMISSION 9 39 Transmission Shift Fork Gear Groove Wear Inspection e Measure the thickness of the shift fork ears A and mea sure the width of the gear grooves B x If the thickness of a shift fork ear is less than the service limit the shift fork must be replaced Shift Fork Ear Thickness Standard 5 9 6 0 mm 0 232 0 236 Service Limit 5 8 mm 0 228 in x If the gear groove is worn over the service limit the gear must be replaced Gear Groove Width Standard 6 05 6 15 mm 0 238 0 242 in Service Limit 6 25 mm 0 246 in Shift Fork Guide Pin Drum Groove Wear Inspecti
326. ensioner must be removed and reset as described in Camshaft Chain Ten sioner Installation Do not turn over the crankshaft while the tensioner is removed This could upset the camshaft chain timing and damage the valves e Remove Right Side Cover see Side Cover Removal in the Frame chapter Cap Bolt A Washer B Spring C Rod D Mounting Bolts E Camshaft Chain Tensioner F Camshaft Chain Tensioner Installation e Replace the O ring A with a new one e Apply grease to the new O ring e Release the stopper B and push the push rod C into the tensioner body D e Install the tensioner body so that the stopper faces up ward e Install the mounting bolts A e Tighten Torque Camshaft Chain Tensioner Mounting Bolts 11 1 1 kgf m 97 in Ib e Install the rod spring and washer e Tighten Torque Camshaft Chain Tensioner Cap Bolt B 20 2 0 kgf m 15 ft Ib e Turn the crankshaft 2 turns clockwise to allow the ten sioner to expand END 5 19 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 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 Crankcase Halves Mating Surface B e Remove the camshaf
327. ensor 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 4 1 6 mm 0 02 0 06 in Rear 0 4 1 6 mm 0 02 0 06 in NOTE O The sensor air gap cannot be adjusted x If the air gap is not within the specification inspect the hub bearing see Hub Bearing Inspection in the Wheels Tires chapter sensor installation condition and sensor see Wheel Rotation Sensor Inspection 12 56 5 Anti Lock System Wheel Rotation Sensor Rotor Inspection e Remove Wheels see Front Rear Wheel Removal in the Wheels Tires chapter Brake Disc Mounting Bolts A Sensor Rotor B Front Wheel C Rear Wheel D e Visually inspect the wheel rotation sensor rotor x If 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 GL14006BS1 GL14110BS1 C ABS Solenoid Valve Relay Fuse 15 A Removal e Refer to the Fuse Box Fuse Removal in the Electrical Sys tem chapter ABS Motor Relay Fuse 25 A Removal e Refer to the Fuse Box Fuse Removal in the Electrical Sys tem chapter Fuse Installation e fuse fails during operation inspect the electrical sys t
328. er Equipped Model P BK 23 Subthrottle Valve Actuator BK O 24 Subthrottle Valve Actuator G 25 Unused 6GCc17074FW2 FUEL SYSTEM DFI 3 15 DFI System 26 27 Subthrottle Sensor BL W Unused Water Temperature Sensor W G Outside Temperature Sensor BL R Unused Sidestand Switch G BK Left Switch Housing Upper Button P BL Starter Button R BK Neutral Switch LG Crankshaft Sensor Y BK Ground for ECU BK BL Ground for Fuel System BK Y Fuel Injector 3 BL O Fuel Injector 2 BL R Fuel Injector 1 BL BK Stick Coil 4 BK G Stick Coil 1 BK Left Switch Housing Lower Button Y R Starter Lockout Switch R G External Communication Line Immobilizer Equipped Model KDS LG BK Crankshaft Sensor Y Ground for Sensors G Unused Unused Fuel Injector 4 BL G Unused Unused Stick Coil 2 BK R Left Switch Housing SEL Button G W Engine Stop Switch R Ground P Unused External Communication Line Immobilizer Equipped Model KDS GY BL Meter Unit Tachometer LB Radiator Fan Relay Y BL Air Switching Valve R BL Oxygen Sensor Heater P BK Ground for Ignition System BK Y Stick Coil 3 BK O KDS Kawasaki Diagnostic System External Communication Line Meter Unit BL O Main Throttle Sensor Y W 3 16 FUEL SYSTEM DFI DFI Parts Location Main Throttle Sensor A Subthrottle
329. er Fairing Stay B e Remove Left Side Stay Mount Bolt A Upper Engine Bracket Bolts M8 B and Washer Upper Engine Bracket Bolts M10 C and Washer Rear Engine Bracket Bolt D Lower Engine Bracket Bolt E Left Engine Bracket F e Remove Right Side Stay Mount Bolt A Upper Engine Bracket Bolts M8 B and Washer Upper Engine Bracket Bolts M10 C and Washer Rear Engine Bracket Bolt D Lower Engine Bracket Bolt E e Disconnect the clutch cable lower end F see Clutch Ca ble Removal in the Clutch chapter e Free the clutch cable and horn lead from the clamps on the right engine bracket G e Remove the right engine bracket e Support the engine with a suitable stand A OPut a plank B onto the suitable stand for engine balance REMOVAL INSTALLATION 8 7 Engine Removal Installation e Remove Upper Engine Mounting Bolt A Both Sides Middle Engine Mounting Nut B Bolt and Collar Lower Engine Mounting Nut C e Using the nut wrench A loosen the upper adjusting collar locknut B Special Tool Engine Mount Nut Wrench 57001 1450 e Using the Hexagon Wrench turn the adjusting collar C counterclockwise to make the gap between the engine and adjusting collar e Using the nut wrench A loosen the lower adjusting collar locknut B Special Tool Engine Mount Nut Wrench 57001 1450 e Remove the lower engine mounting bolt C e Using the Hexagon W
330. er Mounting Bolts 25 N m 2 5 kgf m 18 ft Ib Brake Hose Banjo Bolt 25 N m 2 5 kgf m 18 ft Ib NOTE ODepress the brake pedal A and then align the bolts holes of the master cylinder B 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 12 20 BRAKES Master Cylinder Master Cylinder Inspection Visual Inspection e 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 B 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
331. er Resistance Throttle Grip and Cables Throttle Grip Free Play DC 0 7 V or more DC 0 2 V or less 11 7 14 5 O at 20 C 68 F 2 mm 0 08 0 12 in Air Cleaner Element Viscous paper element 3 20 FUEL SYSTEM DFI Special Tools and Sealant Oil Pressure Gauge 5 kgf cm 57001 125 875701255 C Carburetor Drain Plug Wrench Hex 3 57001 1269 875712695 Fork Oil Level Gauge 57001 1290 7571290ST C Vacuum Gauge 57001 1369 225 222 875713695 C Tester 57001 1394 7571394ST Peak Voltage Adapter 57001 1415 875714155 C Needle Adapter Set 57001 1457 Throttle Sensor Setting Adapter 57001 1538 T571457ST C 7571538ST C Fuel Pressure Gauge Adapter 57001 1593 7571593ST C Fuel Hose 57001 1607 e 7571607ST C FUEL SYSTEM 3 21 Special Tools and Sealant Measuring Adapter Liquid Gasket TB1211 57001 1700 56019 120 875717005 6 875601205 3 22 FUEL SYSTEM DFI DFI Servicing Precautions DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system OThis DFI system is designed to be used with 12 V sealed battery as its power source Do not use any other battery except for a 12 V sealed battery as a power source ODo not reverse the battery
332. er cover B Engine Sproket Cover Installation e Be sure to install the drive chain guide A e Tighten Torque Drive Chain Guide Bolts B 9 8 N m 1 0 kgf m 87 in Ib e Install the engine sprocket outer cover to the inner cover e Be sure to install the dowel pins A e Install the engine sprocket inner cover Engine Sprocket Removal e Remove Engine Sprocket Cover see Engine Sprocket Cover Re moval e Flatten out the bended washer A e Remove the engine sprocket nut B and washer NOTE OWhen loosening the engine sprocket nut hold the rear brake on 11 12 FINAL DRIVE Sprocket Coupling e Raise the rear wheel off the ground with the stand e Loosen the drive chain see Drive Chain Slack Adjust ment in the Periodic Maintenance chapter e Remove the drive chain from the rear sprocket toward the right e Disengage the drive chain A from the engine sprocket B e Pull the engine sprocket off the output shaft C Engine Sprocket Installation e Replace the sprocket washer e Install the engine sprocket so that OUT SIDE letters A face outward e Apply molybdenum disulfide oil solution to the threads and the seating surface of the engine sprocket nut e Tighten Torque Engine Sprocket Nut 125 N m 12 7 kgf m 92 2 ft Ib NOTE OTighten the nut while applying the rear brake e After torquing the engine sprocket nut bend the one side of the washer over the nut e Adjust the
333. er to the reser voir for more complete bleeding OFront Brake First bleeding the right caliper then repeat the above steps for the left calper e Remove the clear plastic hose e Check the fluid level see Brake Fluid Level Inspection in the Periodic Maintenance chapter e Install the diaphragm and reservoir cap e Tighten Torque Brake Reservoir Cap Screws 1 5 0 15 kgf m 13 in Ib 12 24 BRAKES Fluid A WARNING When working with the disc brake observe the pre cautions listed below 2 3 reuse old brake fluid Do not use fluid from that has left unsealed or that has been open for a long time Do not mix two types and brands of fluid for use in the brake This lowers the brake fluid boiling point and could cause the brake to be ineffective It may also cause the rubber brake parts to deteriorate Don t leave the reservoir cap off for any length of time to avoid moisture contamination of the fluid Don t change the fluid in the rain or when a strong wind is blowing Except for the disc pads and disc use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning of the brake parts Do not use any other fluid for cleaning these parts Gasoline engine oil or any other petroleum distillate will cause deterio ration of the rubber parts Oil spilled on any part will be difficult to wash off completely an
334. erent adjust it as follows OTo adjust the pedal position loosen the front locknut C left hand threads and rear locknut D and then turn the tie rod E External Shift Mechanism Removal e Remove Shift Lever see Shift Pedal Removal Circlip A Washer B Clutch see Clutch Removal in the Clutch chapter Special Tool Outside Circlip Pliers 57001 144 CRANKSHAFT TRANSMISSION 9 29 External Shift Mechanism e Pull out the shift shaft assembly A e Remove Gear Positioning Lever Bolt A Gear Positioning Lever B Collar and Spring C e Remove Shift Drum Cam Bolt A Shift Drum Cam B External Shift Mechanism Installation e Be sure to install the dowel pin A e Align the dowel pin with the hollow B of the shift drum cam Apply a non permanent locking agent to the threads of the shift drum cam bolt and tighten it Torque Shift Drum Cam Bolt 12 N m 1 2 kgf m 106 in Ib e Assemble the following parts as shown A Gear Positioning Lever B Spring C Collar D Gear Positioning Lever Bolt OHang the spring end E to the gear positioning lever 9 30 CRANKSHAFT TRANSMISSION External Shift Mechanism e While prying the gear positioning lever A tighten the gear positioning lever bolt B Torque Gear Positioning Lever Bolt 12 N m 1 2 kgf m 106 in Ib e Install the shift shaft A so that the return spring pin B fits between the spring C e Install
335. ery Installation e Turn the ignition switch to OFF e Put the battery into the rear fender e Install the band A e Connect the positive cable B red to the positive terminal first and then the negative cable C to the negative terminal e Apply a light coat of grease on the terminals to prevent corrosion e Cover the Positive terminal with the cap D 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 KLZ1000A YTX9 BS Each battery comes with its own specific elec trolyte container using the wrong container may overfill the battery with incorrect electrolyte which can shorten battery life and deteriorate battery per formance Be sure to use the electrolyte container with the same model name as the battery since the electrolyte volume and specific gravity vary with the battery type GP08135BS1 C Battery ELECTRICAL SYSTEM 16 25 Do not remove the aluminum sealing sheet A from the filler ports B until just prior to use Be sure to the dedicated electrolyte container for correct electrolyte volume DANGER Sulfuric acid in battery electrolyte can cause severe burns To prevent burns wear protective clothing and safety glasses when handling electrolyte the electrolyte comes in c
336. es properly x If the output voltage shows a much higher than the value in the table the regulator rectifier is damaged A much lower reading than that given in the table indicates that the alternator is defective e Check the stator coil resistance as follows OStop the engine OConnect the hand tester as shown in the table 2 ONote the readings total 3 measurement Table 2 Stator Coil Resistance at 20 C 68 F Tester Connections Reading Range Tester to Tester to One White lead Another White lead 0 17 0 25 Q x If there is more resistance than shown in the table or no hand tester reading infinity for any two leads the stator has an open lead and must be replaced Much less than this resistance means the stator is shorted and must be replaced e Using the highest resistance range of the hand tester measure the resistance between each of the black leads and chassis ground Any hand tester reading less than infinity lt indicates a short necessitating stator replacement x If the stator coils have normal resistance but the voltage check showed the alternator to be defective then the rotor magnets have probably weakened and the rotor must be replaced Special Tool Hand Tester 57001 1394 System ELECTRICAL SYSTEM 16 37 Regulator Rectifier Inspection e Remove ABS Hydraulic Unit see ABS Hydraulic Unit Removal in the Brakes chapter Bolts A Regulator Rectifie
337. et the CLOCK mode A by pushing the upper button B e Push the lower button C for more than two seconds OThe clock setting menu hour and minute D should blink e Push the lower button OThe hour display A starts blinking e By pushing the upper button each time check that the hour display changes e By pushing the lower button check that the hour display decides and minute display A starts blinking e By pushing the upper button each time check that the minute display changes e By pushing the lower button check that the hour and minute display start blinking e By pushing the upper button check that the hour and minute display decide e When both hour and minute display is blinking by pushing the lower button check that the hour display start blinking This blinking returns the hour setting display xIf the display function does not work replace the meter unit OIf the terminal 15 disconnected when the clock is setting clock is set at time of that time GP17891CS1 C GP17808BS1 C GP17809BS1 HS DEW N GP17810BS1 16 70 ELECTRICAL SYSTEM Meter Gauge Indicator Unit Check 1 2 Left Switch Housing Switching Inspection Turnthe ignition switch to 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
338. eter tete ets 10 16 10 2 WHEELS TIRES Exploded 6402197885 C WHEELS TIRES 10 3 Exploded View Front Axle Clamp Bolt 20 Front Axle 127 Rear Sprocket Nuts 59 Rear Axle Nut 108 HG Apply high temperature grease R Replacement Parts WL Apply soap and water solution or rubber lubricant 10 4 WHEELS TIRES Specifications ltem 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 0 1 mm 0 004 in or less TIR 0 2 mm 0 008 in 3 94 in Wheel Balance Balance Weights 10 g 0 35 oz or less 10 g 0 35 oz 20 g 0 71 oz 30 g 1 06 oz Rim Size Front J17M C x MT3 50 cx Rear J17M C x MT5 50 Tires Air Pressure when Cold Front Rear Tread Depth Up to 220 kg 485 Ib load 250 kPa 2 5 kgf cm 36 psi Up to 220 kg 485 Ib load 290 kPa 2 9 kgf cm 42 psi Front 4 4 mm 0 17 in 1 mm 0 04 in AT CH DE 1 6 mm 0 06 in Rear Up to 130 km h 80 mph 6 6 mm 0 26 in 2 mm 0 08 in Over 130 km h 80 mph 3 mm 0 12 in Standard Tires Make Type Size Front PIRELLI SCORPION TRAIL 120 70 ZR17 M C 58 W Rear PIRELLI SCORPION TRAIL K 180 55 ZR17 M C 73 W A WARNING Some replacement tires may adversely affect handling and cause an accident resulting in serious injur
339. ever play excessive Clutch release mechanism trouble Gear Shifting Faulty Doesn t go into gear shift pedal doesn t return Clutch not disengaging Shift fork bent or seized Gear stuck on the shaft Gear positioning lever binding Shift return spring weak or broken Shift return spring pin loose Shift mechanism arm spring broken Shift mechanism arm broken Shift pawl broken Jumps out of gear Shift fork ear worn bent Gear groove worn Gear dogs and or dog holes worn Shift drum groove worn Gear positioning lever spring weak or bro ken Shift fork guide pin worn Drive shaft output shaft and or gear splines worn Overshifts Gear positioning lever spring weak or bro ken Shift mechanism arm spring broken Abnormal Engine Noise Knocking ECU trouble Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Overheating Piston slap Cylinder piston clearance excessive Cylinder piston worn Connecting rod bent Piston pin piston pin hole worn Valve noise Valve clearance incorrect Valve spring broken or weak Camshaft bearing worn Valve lifter worn Other noise Connecting rod small end clearance exces sive Connecting rod big end clearance exces sive Piston ring groove clearance excessive Piston ring worn broken or stuck Troubleshooting Guide Piston ring groove worn Piston seizure damage Cylinder head gasket leaking Exhaust pipe leaking at cylinder head con nection Crankshaft
340. f 1 and 2 Cylinders Measuring Valve A lf the valve clearance is not within the specified range first record the clearance and then adjust it Valve Clearance Adjustment e To change the valve clearance remove the camshaft chain tensioner camshafts and valve lifters Replace the shim with one of a different thickness NOTE OMark and record the locations of the valve lifters and shims so that they can be reinstalled in their original positions 6507024851 C OQ etm 9507131851 GH es SOO 9507132851 7102172 6507022851 Maintenance Procedures PERIODIC MAINTENANCE 2 23 OBesides the standard shims in the valve clearance adjust ment charts the following shims may be installed at the factory Although they are not available as spare parts they can be used to adjust valve clearance Adjustment Shims Thickness 3 225 3 275 mm mm 3 325 mm 2 675 2 725 mm mm 2 775 2 825 mm mm 2 875 2 925 2 975 mm mm mm 3 025 3 075 mm mm 3 125 3 175 mm mm Clean the shim to remove any dust or oil e Measure the thickness of the removed shim A 2 24 PERIODIC Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART INTAKE VALVE PRESENT Examp D nn inane MARK 0 00 0 02 BE EI
341. ff the ground Special Tools Jack 57001 1238 Attachment Jack 57001 1252 Jack Attachment 57001 1608 OFor front disc inspection turn the handlebars 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 x If 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 GL08042BS1 CN 9108018851 C 12 22 BRAKES Fluid Brake Fluid Level Inspection e Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter Brake Fluid Change e Refer to the Brake Fluid Change in the Periodic Mainte nance chapter Brake Line Bleeding The brake fluid has a very low compression 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 n
342. filled up on the grooves B ODo not apply liquid gasket to the inside of the groove C Ll OY OOTY 6194386812 Do not apply liquid gasket around the crankshaft main bearing inserts and oil passage holes e Fit the lower crankcase to the upper crankcase NOTE OMake the application finish within 20 minutes when the liquid gasket to the mating surface of the crankcase half is applied OMoreover fit the case and tighten the bolts just after application of the liquid gasket e The 9 bolts have copper plated washers replace them with new ones 9 14 CRANKSHAFT TRANSMISSION Crankcase Splitting e Apply molybdenum disulfide oil solution to the lower seating surface A on the copper plated washer B and threads C of the M9 bolts D e Tighten the lower crankcase bolts using the following steps OFollowing the sequence numbers on the lower crankcase half tighten the M9 bolts 1 10 with copper plated wash ers Torque Crankcase Bolts M9 42 N m 4 3 kgf m 31 ft Ib OTighten the M7 bolts A Torque Crankcase Bolts 7 20 2 0 kgf m 15 ft Ib 5 2 6104387851 6194388812 e Tighten the upper crankcase bolts follow the specified sequence OFirst tighten the M8 bolts A Torque Crank Case Bolts 8 27 N m 2 8 kgf m 20 ft Ib OSecond tighten the M7 bolts L 85 mm 3 35 in B
343. fingers in front of the piston 65130182 P 9513152851 PERIODIC MAINTENANCE 2 61 Periodic Maintenance Procedures 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 9513261851 C 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 brake pads see Front Brake Pad Removal in the Brakes chapter OPump the brake lever until the pistons come out of the cylinders and then disassemble the caliper Front 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 valve and rubber cap Torque Bleed Valves 7 8 N m 0 80 kgf m 69 in Ib e Replace the fluid seals A with new ones OApply silicone grease to the fluid seals and install them into the cylinders by hand e Replace the dust seals B with new ones OApply silicone grease to the dust seals and install them into the cylinders by hand 6105040251 e Replace the O ring A with a new one OApply grease to the O ring e Apply brake fluid to the outside of the
344. flywheel puller A remove the alternator rotor B from the crankshaft Special Tool Flywheel Puller Assembly M38 x 1 5 M35 x 1 5 57001 1615 Do not attempt to strike the alternator rotor itself Striking the rotor can cause the magnets to lose their magnetism Alternator Rotor Installation e Apply a thin coat of molybdenum disulfide grease to the crankshaft A and the outer surface B of the starter clutch gear C e Install the starter clutch gear A 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 B Alternator Rotor Tapered Portion C e Fit the woodruff key D securely in the slot in the crank shaft before installing the alternator rotor System ELECTRICAL SYSTEM 16 33 e Install the alternator rotor A while turning B the starter clutch gear C clockwise NOTE OConfirm the alternator rotor fit or not to the crankshaft before tightening it with specified 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 temporarily Special Tools Grip C 57001 1591 Rotor Holder 57001 1690 Stopper D 57001 1679 Torque Alternator Rotor Bolt 70 N m 7 0 kgf m 52 ft Ib If using rotor holder 57001 1757 e Install the washer and rotor bolt e Tighten the alternator rotor bolt
345. form the work efficiently and to avoid costly mistakes read the text thor oughly familiarize yourself with the procedures before starting work and then do the work care fully in a clean area Whenever special tools or equipment are specified do not use makeshift tools or equipment Precision measurements can only be made if the proper instruments are used and the use of substitute tools may ad versely affect safe operation For the duration of the warranty period we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty To get the longest life out of your vehicle e Follow the Periodic Maintenance Chart in the Service Manual e Be alert for problems and non scheduled maintenance e Use proper tools and genuine Kawasaki Mo torcycle parts Special tools gauges and testers that are necessary when servicing Kawasaki motorcycles are introduced by the Service Manual Genuine parts provided as spare parts are listed in the Parts Catalog e Follow the procedures 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
346. ft and Connecting Rods Crankshaft Removal Crankshaft Installation Connecting Rod Removal Connecting Rod Installation Crankshaft Connecting Rod 1 sioe Connecting Rod Bend Inspection Connecting Rod Twist Inspection Connecting Rod Big End Side Clearance Inspection Connecting Rod Big End Bearing Insert Crankpin Wear Crankshaft Side Clearance Crankshaft Runout Inspection Crankshaft Main Bearing Insert Journal Wear Inspection used Balancer Remowval Balancer Installation Balancer Adjustment Balancer Damper Inspection Starter Motor Clutch Starter Motor Clutch Removal Installation Starter Motor Clutch Inspection 9 21 9 22 9 23 9 23 9 25 9 25 9 25 9 26 9 26 9 27 9 27 9 27 Starter Motor Clutch Disassembly Starter Motor Clutch Assembly External Shift Shift Pedal Removal Shift Pedal Installation External Shift Mechanism External Shift Mechanism Installation External Shift Mechanism
347. g Remover Head 15 x 17 57001 1267 Bearing Remover Shaft 013 57001 1377 GM05404BS1 Rear Shock Absorber Bearing Installation e Replace the needle bearing A and grease seals B with new ones e Apply plenty of grease to the lips of the grease seals e Install the needle bearing position as shown C 8 7 mm 0 34 in e Install the grease seals and sleeve D GMO5405BS1 C Swingarm SUSPENSION 13 27 Swingarm Removal e Remove Rear Brake Hose Lower End see Rear Caliper Removal in the Brakes chapter Rear Wheel see Rear Wheel Removal in the Wheels Tires chapter Mud Guard see Mad Guard Removal in the Frame chapter Rocker Arm see Rocker Arm Removal e Unscrew the swingarm pivot shaft nut A e Using the swingarm pivot nut wrench A loosen the swingarm pivot adjusting collar locknut B Special Tool Swingarm Pivot Nut Wrench 57001 1597 e Turn the swingarm pivot shaft A counterclockwise to free the adjusting collar from the swingarm OMake the gap between the adjusting collar and swingarm Pull out the pivot shaft to the right side and remove the swingarm Swingarm Installation e Visually inspect the chain guide A Replace the chain guide if it shows any signs of abnormal wear or damage 13 28 SUSPENSION Swingarm e Apply grease to the lips of the grease seals A e Be sure to install the grease seals and sleeve B to the swingarm
348. gh 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 Permanent type of antifreeze soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators Green Soft water 50 coolant 50 35 31 F 2 6 L 2 7 US qt reserve tank full level including radiator and engine Radiator Cap Relief Pressure 93 123 kPa 0 95 1 25 kgf cm 13 18 psi Thermostat Valve Opening Temperature Valve Full Ope
349. gine Ground Battery 12 V 8 Ah Starter Relay Main Fuse 30 ECU Fuse 15 A Relay Box ECU Main Relay Fuse Box 1 Ignition Fuse 15 Joint Connector F lgnition Switch Oxygen Sensor 6617088282 C FUEL SYSTEM DFI 3 95 Warning Indicator Light LED Yellow Engine Warning Yellow KTRC Warning Red Warning Indicator Light LED Inspection Yellow Engine Warning Indicator Light A Yellow KTRC Warning Indicator Light B Red Warning Indicator Light C e Refer to the Meter Unit Inspection in the Electrical System chapter for the warning indicator light LED inspection GC17248FS1 Red Warning Indicator Light LED Immobilizer Circuit 6617249212 C 1 ECU 2 Frame Ground 1 3 Meter Unit 4 Yellow Engine Warning Light LED 5 Yellow KTRC Warning Light LED 6 Red Warning Indicator Light LED Battery Oil Pressure Water Temperature Immobilizer Equipped Model 3 96 FUEL SYSTEM DFI ECU ECU Identification countries have their own regulations so each 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 WVTA Full H with immobilizer 21175 0735 GB WVTA Full H with immobilizer Australia with immobilizer Southeast Asia B2 wi
350. gistered 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 e Prepare a new ECU A and 2 new ignition keys B NOTE OThe key registration unit is not required OThe key registration process is same as the case 3 e Insert the first 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 the immobilizer warning symbol A blink to display the collation error Immobilizer Amplifier Failure Ignition Key Collation Error GP30746BS1 0 3second Hhnnnnnn UUU GP30026CS1 C Immobilizer System Equipped Models ELECTRICAL SYSTEM 16 99 e The first ignition key is successfully registered in the ECU OThe red warning indicator light LED and the immobilizer warning symbol A blink 1 time and stops for 1 second and the repeats this cycle to indicate successful registra tion of the first ignition key e Turn to OFF the ignition switch and remove the first igni tion key OThe immobilizer warning symbol B disappears OThe red warning indicator light LED A then blinks for 15 seconds it means the ECU is in the r
351. gistration mode automatically ends Dri e The red warning indicator light LED A goes off GP30030CS1 NOTE the ignition switch ON with the registered ignition key OCheck that the engine can be started using all regis tered ignition keys ELECTRICAL SYSTEM 16 101 Immobilizer System Equipped Models All Keys Initial Registration Flow Chart rendi Cm First ignon Key Red warning indicator light LED and symbol binking Pattern 2 OFF and remove first ignition Red warming indicator light LED and symbol blinking Pattern 3 Registration of Y 5 Turn OFF and remove fist ignition key Key2 Red warning indicator light LED and Turn OFF and remove second ignition key ECU checks NG Red warning idicator light LED NOTE and symbol blinking NOTES ECU checks second ignition NOTES Temporary registry of second ignition key Red warning indicator light LED and symbol biniung Pattern 4 Turn OFF and remove second ignition key NOTET Red warring indicator ight LED and symbol goes of Cw N Blinking Patterns and Number 0 2second 0 gp 0 3 8 0 Seesend 2 8 0 3596056 isecend 38 1 44 1 4 3 0 5 8 NOTE 1 Key Substitute Time Insert next key and tum ON within 15 seconds after previous key is turned OFF Amplif
352. gital meter A to the oxygen sensor lead con nector B e Measure the oxygen sensor heater resistance Oxygen Sensor Heaters Resistance Connections BK lead C BK lead D Standard 11 7 14 5 at 20 C 68 F x If 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 Oxygen Sensor Heater Power Source Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch to OFF e Remove the right side cover see Side Cover Removal in the Frame chapter e Open the clamp A and pull out the oxygen sensor lead connector B 80178140651 3 90 FUEL SYSTEM DFI Oxygen Sensor Heater Service Code 67 e Disconnect the oxygen sensor lead connector and con nect the measuring adapter A between these connec tors B Main Harness C Oxygen Sensor Special Tool Measuring Adapter 57001 1700 e Connect a digital meter D to the measuring adapter lead Oxygen Sensor Power Source Voltage Connections to Adapter Digital Meter Y sensor P BK lead Digital Meter gt Battery terminal Measure the power source voltage with the engine stopped and with the connector joined 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 specif
353. gnition Switch Right Switch HousingHorn Spark Plugs SUPE Fan Stick tt hi Wotor 1 2 3 f46oils ir EJ intake l oun Temperature T Sensor Y R Tum BR W R BL BK Y BL W R BK R BK R R BK 0 R BK G R BK BK Y Immobilizer Amplifier Mor Vehicle down Immobilizer Sensor Antenna EEk Front Wheel Rotation Sensor ME Meter Unit 1 Yellow Engine Warning Indicator Light LED 2 Yellow ABS Indicator Light LED 3 Yellow KTRC Indicator Light LED ORME Stee any 4 Yellow KTRG Warning BR Indicator Light LED Green Neutral Indicator Light LED a 6 Blue High Beam Indicator a Meter Unit Light LED 7 Green Left Turn Signal Indicator Light LED 8 Green Right Turn Signal Indicator Light LEB 9 Red Warning Indicator Light LED Battery Oil Pressure Water Temperature Immobilizer 10 peedoneter 11 Tachometer or 12 Qdometer Trip Meter a Glock 3 Fuel Level Gauge 14 Water Temperature Outside Temperature Gauge 15 Illumination Light LED Outside Temperature Sensor o 5A ft Front Right HLED Light Emitting Diode Turn Signal Light Joint Connector Joint Connector
354. grooves C in the socket and turn the bulb clockwise OTurn the bulb about 15 e Fit the projection A on the lens to the groove B on the socket Tighten the screw Turn Signal Relay Inspection e Remove Right Upper Side Fairing see Upper Side Fairing Re moval in the Frame chapter e Pull up the turn signal relay A e Disconnect the turn signal relay connector Oln this photo the meter cover has been removed for clearly 16 62 ELECTRICAL SYSTEM Lighting System e Connect one 12 V battery and turn signal lights as indi cated in the figure and count how many times the lights blink for one minute Turn Signal Relay A Turn Signal Lights B 12 V Battery C x If the lights do not blink as specified replace the turn sig nal relay Testing Turn Signal Relay GP12040281 Load The Number of Turn Blinking Times Signal Lights Wattage W 1 10 140 250 2 20 75 95 Cycle s per minute Correspond to one light burned out ELECTRICAL SYSTEM 16 63 Lighting System Turn Signal Light Circuit a QU m LOO 5 N bk er OP GP12605BW3 C Ignition Switch Rear Right Turn Signal Light 12 V 10 W Rear Left Turn Signal Light 12 V 10 W Joint Connector B Frame Ground 3 Frame Ground 1 Engine Ground Battery 12 V 8 Ah Starter Relay 10 Main Fuse 30 A 11 Turn Signal Rel
355. he brake hose with the clamp at the rubber protector Hold the front wheel rotation sensor lead to the meter bracket Run the brake hoses to inside of the throttle cables Brake Hose Front Wheel Rotation Sensor Lead Brake Hose Fitting Hold the front wheel rotation sensor lead to the brake hose with the clip at the white mark on the lead Install the clip so that the lead is placed at front of the hose and face its open side in direction as shown Hold the front wheel rotation sensor lead to the brake hose fitting with the clip at the white mark on the lead Install the clip so that the lead is placed at front of the hose and face its open side in direction as shown Hold the front wheel rotation sensor lead with clamp Brake Hose Brake Pipes Clamp Hold the brake pipes to the frame with clamps Run the brake pipes to under the other leads Run the rear wheel rotation sensor lead to the outside of the main harness upside of the intake air temperature sensor lead and under the crankshaft sensor lead Clamp Before clamping face the locking portion of the clamp in direction as shown 17 38 APPENDIX Cable Wire and Hose Routing APPENDIX 17 39 Cable Wire and Hose Routing 15 Hold front wheel rotation lead brake hose with at the white the lead Install the clip so that the lead is placed at rear of the hose
356. he engine again raise the motorcycle turn the ignition switch OFF and then ON Much of the DFI system troubleshooting work consists of confirming continuity of the wiring The DFI parts assembled and adjusted with precision and it is impossible to disassemble or repair them 8017201 51 3 26 FUEL SYSTEM DFI Troubleshooting the DFI System 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 terminal Special Tool Needle Adapter Set 57001 1457 Insert the needle adapter straight along the terminal in the connector to prevent short circuit between terminals e Make sure that measuring points are correct in the con nector noting the 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 ON and measure the voltage with the connector joined NOTICE Incorrect reverse connection or short circuit by needle adapters could damage the DFI or electrical system parts OAfter measurement remove the needl
357. 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 won t fully open Brake dragging Clutch slipping Engine overheating Engine oil level too high Engine oil viscosity too high Drive train trouble Camshaft cam worm 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 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 Fuel air mixture incorrect Throttle body assy holder loose 17 50 APPENDIX Troubleshooting Guide Air cleaner duct loose Air cleaner poorly sealed or missing Air cleaner clogg
358. hickness Standard Top A 0 77 0 79 mm 0 0303 0 0311 in Second B 0 77 0 79 mm 0 0303 0 0311 in Service Limit Top A 0 70 mm 0 028 in Second B 0 70 mm 0 028 in xIf any of the measurements is less than the service limit on either of the rings replace all the rings NOTE OWhen using new rings in a used piston check for un even groove wear The rings should fit perfectly parallel to the groove sides If not replace the piston Piston Ring End Gap Inspection e Place the piston ring A inside the cylinder using the pis ton to locate the ring squarely in place Set it close to the bottom of the cylinder where cylinder wear is low e Measure the gap B between the ends of the ring with a thickness gauge Piston Ring End Gap Standard Top 0 20 0 30 mm 0 0079 0 0118 in Second 0 38 0 48 mm 0 0150 0 0189 in Service Limit Top 0 6 mm 0 024 in Second 0 8 mm 0 031 in xIf the end gap of either ring is greater than the service limit replace all the rings 8 16070851 GE16283BS1 5 42 END Throttle Body Assy Holder Throttle Body Assy Holder Removal e Remove Throttle Body Assy see Throttle Body Assy Removal in the Fuel System DFI chapter Clamps A Bolts B Throttle Body Assy Holders C Throttle Body Assy Holder Installation e Replace the O rings A with new ones e Apply grease to the O rings and insta
359. hrough the connect ing rod big end e Select an arbor of the same diameter as the piston pin and at least 100 mm 3 94 in long and insert the arbor B through the connecting rod small end e On a surface plate set the big end arbor on V block C e With the connecting rod held vertically use a height gauge to measure the difference in the height of the arbor above the surface plate over a 100 mm 3 94 in length to determine the amount of connecting rod bend connecting rod bend exceeds the service limit the con necting rod must be replaced Connecting Rod Bend Service Limit TIR 0 2 100 mm 0 008 3 94 in 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 If connecting rod twist exceeds the service limit the con necting rod must be replaced Connecting Rod Twist Service Limit TIR 0 2 100 mm 0 008 3 94 in Connecting Rod Big End Side Clearance Inspection e Measure connecting rod big end side clearance Olnsert a thickness gauge A between the big end and ei ther crank web to determine clearance Connecting Rod Big End Side Clearance Standard 0 13 0 38 mm 0 0051 0 0150 in Service Limit 0 58 mm 0 023 in x If the clearance exceeds the
360. iagnosis Flow Chart Problem occurs Confirm problems Gather information from rider Conduct pre diagnosis inspection 1 2 Conduct self diagnosis Check by other than self diagnosis Check by self diagnosis If harness or connector is faulty If ABS part is faulty Repair or replace Check ABS parts NG Final inspection OK End GLI4011B BRAKES 12 35 Anti Lock Brake System Inquiries to Rider OEach rider reacts to problems in different ways so it is important to confirm what kind of condition the rider is dissatisfied with OTry to find out exactly what problem occurs under exactly what conditions by asking the rider know ing this information may help you reproduce the problem in the shop OThe diagnosis sheet will help prevent you from overlooking any keys so always use it Sample Diagnosis Sheet Rider name Registration No license plate No Model Frame No Frequency Mileage Brake Yellow O Braking Abnor 5 not 5 ABS L1 ABS op lever ABS distance working works erating vibration indicator too long but too fre or noise light yellow quently LED ABS blinks indicator Pedal Yellow Abnor light vibration ABS mal LED ornoise indicator pedal doesn t light move light up LED ment remains lit up L1 At start up Year of initial registration Engine No Date problem occurred Weather
361. ial Tool Fork Piston Rod Puller M10 x 1 0 B 57001 1298 e Hold the fork tube upright press the outer tube A and the piston rod all the way down e Pour in the type and amount of fork oil specified Fork Oil Recommended Oli KHL15 10 or equivalent Amount Per Side When changing oil for reference Right Front Fork Approx 450 mL 15 2 US oz Left Front Fork Approx 455 mL 15 4 US oz After disassembly and completely dry Right Front Fork 528 4 mL 17 9 0 1 US oz Left Front Fork 535 4 mL 18 1 0 1 US oz 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 M10 x 1 0 57001 1298 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 outer tube to the oil UM 9 My D GM04382BS1 C Wy 8 04042851 C 6 04021351 C SUSPENSION 13 19 Front Oil Level fully compressed without spring Standard Right Front Fork 115 2 mm 4 53 0 08 in from the top of the outer tube Left Front Fork 114 2 mm 4 49 0 08 in from the top of the outer tube NOTE OFork oil lev
362. ibly causing an accident resulting in injury or death If the frame is bent dented cracked or warped replace it Rear Frame Removal e Remove Rear Fender see Rear Fender Removal Rear Frame Bolts A Both Sides Rear Master Cylinder Reservoir Bracket Bolt B Rear Footpeg Bracket Bolt Caps Both Sides Rear Footpeg Bracket Bolts Upper C and Nuts Both Sides Rear Frame D Rear Frame Installation e Replace the rear footpeg bracket nuts with new ones e Tighten Torque Rear Frame Bolts 44 N m 4 5 kgf m 32 16 Rear Footpeg Bracket Nuts 25 2 5 kgf m 18 ft Ib Rear Footpeg Bracket Removal e Remove Rear Shockabsorber Adjuster Bolts A Right Side Only Muffler Body Mounting Bolt B and Washer Rear Footpeg Bracket Bolt Caps Rear Footpeg Bracket Bolts Upper C and Nuts Rear Footpeg Bracket Bolt Lower D and Washer Remove the brake hose E from the clamp F Right Side Only Remove the rear footpeg bracket Rear Footpeg Bracket Installation e Apply non parmanent locking agent to the thread of the rear footpeg bracket bolt lower e Replace the rear footpeg bracket nuts with new ones e Tighten Torque Rear Footpeg Bracket Bolts Lower 28 2 9 kgf m 21 ft Ib Rear Footpeg Bracket Nuts 25 2 5 kgf m 18 ft Ib 15 20 FRAME Guard Upper Mud Guard Removal e Remove Right Front Footpeg Bracket Bolts A e Remove Quick Rivets A e Remove Br
363. ic Maintenance chapter FUEL SYSTEM DFI 3 115 Throttle Body Assy Idle Speed Inspection Adjustment e Refer to the Idle Speed Inspection Adjustment in the Pe riodic Maintenance chapter 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 to OFF Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately NOTICE Never drop the throttle body assy especially on a hard surface Such a shock to the body assy can damage it e Remove Side Cover see Side Cover Removal in the Frame chap ter Air Cleaner Housing see Air Cleaner Housing Removal Fuel Hose see Fuel Hose Replacement in the Periodic Maintenance chapter e Clear the adjusting screw A from the bracket e Disconnect Intake Air Pressure Sensor 1 Connector A Intake Air Pressure Sensor 2 Connector B Subthrottle Valve Actuator Connector C Main Throttle Sensor Connector D Subthrottle Sensor Connector E 3 116 FUEL SYSTEM DFI Throttle Body Assy e Loosen the locknuts A e Turn the adjusters B to gi
364. ication 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 Fuse 15 A see Fuse Inspection in the Electrical 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 main harness con nectors ODisconnect the ECU and sensor connectors Wiring Inspection ECU Connector A Oxygen Sensor Connector B P BK lead ECU terminal 64 C xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see Removal Installation 6617134251 C 6617135251 C FUEL SYSTEM 3 91 Oxygen Sensor Heater Service Code 67 Oxygen Sensor Circuit 6617088282 C ECU Frame Ground 3 Engine Ground Battery 12 V 8 Ah Starter Relay Main Fuse 30 ECU Fuse 15 A Relay Box ECU Main Relay 10 Fuse Box 1 11 Ignition Fuse 15 A 12 Joint Connector F 13 Ignition Switch 14 Oxygen Sensor 3 92 FUEL SYSTEM DFI Oxygen Sensor Incorrect Output Voltage Service Code 94 Oxygen Sensor Removal Installation e Refer to the Oxygen Sensor Removal Installation in the Electrical System chapter
365. ier Time of Transmitting and Receiving Messages 3 ECU confirms the following immobilizer Failure Pattem 1 Ignition Key Collation Error Pattern 5 4 ECU confirms the following Ignition Key Not Match the Unique Code 5 ECU confirms the O Not Registered ignition Key 7 When the ECU registered key is tumed OFF ECU keeps the power for two seconds And then in two seconds after the key is OFF ECU tums the power 62300526 16 102 ELECTRICAL SYSTEM Immobilizer System Equipped Models Immobilizer System Parts Replacement Ignition Switch Immobilizer Antenna Replacement e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Lower Handlebar Holder Assembly see Handlebar Re moval in the Steering chapter Left Side Cover see Side Cover Removal in the Frame chapter e Slide the dust cover A and clear the clamp B e Disconnect the ignition switch lead connector C and im mobilizer antenna lead connector D e Remove the steering stem see Stem Stem Bearing Re moval in the Steering chapter e Using a small chisel or punch A turn out the Torx bolts e Remove the ignition switch B e Tighten a new Torx bolt A until the bolt head B is broken C e Run the leads correctly see Cable Wire and Hose Rout ing section in the Appendix chapter Immobilizer Amplifier Replacement e Remove Meter Cover see Meter Cover Re
366. ifier connector A with needle adapter set Special Tool Needle Adapter Set 57001 1457 Amplifier Input Voltage Connections to Amplifier Connector Digital Meter BR W lead Digital Meter gt BK Y 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 xIf the reading is within the standard check the wiring to ECU see ECU Power Source Circuit xIf the wiring is good replace the amplifier see Immobi lizer System Parts Replacement in the Electrical System chapter 3 80 FUEL SYSTEM DFI Blank Key Detection Service Code 36 Equipped Model e This code appears in the following conditions OThe transponder A in the ignition key is malfunction OWhen the spare ignition 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 If the service code 36 appears again the transponder in the key is malfunction replace it Immobilizer System Circuit GCi7089FW3 C 1 Joint Connector E 7 Battery 12V 8 Ah 13 Fu
367. il it turns lightly Afterward tighten it again with specified torque using a steering stem nut wrench A Special Tool Steering Stem Nut Wrench 57001 1100 Torque Steering Stem Nut 25 N m 2 5 kgf m 18 ft Ib e Install the claw washer A so that its bent side B faces upward and engage the bent claws with the grooves of stem locknut C e Hand tighten the stem locknut until the claw washer touches the steering stem nut 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 steering stem head bolt e Install the front forks see Front Fork Installation in the Suspension chapter NOTE OTighten the lower front fork clamp bolts first next the stem head bolt last the upper front fork clamp bolts OTighten the lower front fork clamp bolts alternately two times to ensure even tightening torque Torque Upper Front Fork Clamp Bolts 20 2 0 kgf m 15 ft Ib Steering Stem Head Bolt 108 N m 11 0 kgf m 79 7 ft lb Lower Front Fork Clamp Bolts 20 5 N m 2 09 kgf m 15 1 ft lb AWARNING 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 Hose Routing s
368. il the idle speed is correct OOpen and close the throttle a few times to make sure that the idle speed is within the specified range Readjust if necessary 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 Support the fuel tank with a suitable bar see Fuel Hose Replacement and check the fuel hoses Replace the 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 9505240851 2 20 PERIODIC Periodic Maintenance Procedures e Check that the hose joints are securely connected OPush pull A the hose joint B back and forth more than two times and make sure it is locked and does not come off Fuel Pump Side C Throttle Body Assy Side D 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 Cooling System Coolant Level Inspection NOTE OCheck the level when the engine is cold room or ambi ent temperature e Check the coolant level in the reserve tank A with the
369. inder Removal eese enne entran nnne etn nnn 12 18 Rear Master Cylinder hn o tatc 12 19 Front Master Cylinder Disassembly pp 12 19 Rear Master Cylinder 2 2 24 4 2 241000 nennen nnn 12 19 Master Cylinder Assembly nsss ico oerte tron ir tape P 12 19 Master Cylinder Inspection Visual 12 20 DISC E MM RNC EE 12 21 Brake Disc Rermoval 25 12 21 12 21 Brake Disc Wear om DE e b RAE eed 12 21 prake C oT 12 21 altre 12 22 Brake Fluid Level Inspection isai eena a aA E ERA EE Ra a 12 22 Brake Fluid Change 12 22 Brake Line Bleeding 12 22 Brake ME 12 25 Brake Hose Removallnstallation pp 12 25 Brake Hose and Pipe Inspection 12 25 Anti Lock Brake Sy Stem nenii eoe tropaea due re bep on ud Ua ede Abd 12 26 Parts EoCaliObbs zo E TE 12 26 12 2 BRAKES ABS Servicing IM CUT etin ex ides 12 30 ABS Troubleshooting eur tte pacer ede eee 12 32 Inquiries to RIdOF nito tid dur edt fei iet oie dnt 12 35 Self diagnosis Outlirie
370. ine and drain the system e Repeat the previous two steps once more e Fill the system with a permanent type coolant and bleed the air from the system see Coolant Change in the Peri odic Maintenance chapter Coolant Reserve Tank Removal Installation e The coolant reserve tank is removed and installed dur ing coolant change see Coolant Change in the Periodic Maintenance chapter 4 10 COOLING SYSTEM Water Pump Water Pump Removal e Drain Coolant see Coolant Change in the Periodic Mainte nance chapter Engine Oil see Engine Oil Change in the Periodic Main tenance chapter e Remove Left Side Cover see Side Cover Removal in the Frame chapter Left Lower Fairing see Lower Fairing Removal in the Frame chapter Engine Sprocket Cover see Engine Sprocket Cover Re moval in the Final Drive chapter Remove the water pipe bolts A to pull out the water pipes B from the water pump cover e Loosen the clamp bolt C to remove the water hose D e Remove Water Pump Cover Bolts A Clamp B Water Pump Cover C e Remove Water Pump Impeller Bolt A and Washer Water Pump Impeller B Dowel Pins C e Disconnect the neutral switch connector D e Remove the water pump housing E Water Pump Installation e Replace the O ring A with a new one and install it COOLING SYSTEM 4 11 Water Pump Be sure to install the dowel pins e Install Water Pump Housing A Water Pump Impeller
371. ing 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 Electrical System chapter ECU Main Relay see Relay Circuit Inspection in the Electrical System chapter Power Source Wiring see ECU Power Source Circuit the fuse wiring and relay are good replace the ECU see Removal Installation GC17137FS1 FUEL SYSTEM DFI 3 99 ECU ECU Power Source Circuit GCci7096FW2 C Joint Connector E ECU Joint Connector D Frame Ground 2 Frame Ground 3 Engine Ground Battery 12 V 8 Ah Starter Relay Main Fuse 30 A 10 ECU Fuse 15 A 11 Frame Ground 1 12 Relay Box 13 ECU Main Relay 14 Fuse Box 1 15 Ignition Fuse 15 A 16 Joint Connector F 17 Ignition Switch 3 100 FUEL SYSTEM DFI DFI Power Source ECU Fuse Removal e Refer to the 15 A 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
372. ion switch and turn it to ON NOTE OKeep other ignition keys away from the immobilizer an tenna Olf there is any problem in the registration the red warning indicator light LED and the immobilizer warning symbol A blink to display the collation error Immobilizer Amplifier Failure When Registered Ignition Key is Inserted on GP30027C81 0 2second gt gt GP30024CS1 16 96 ELECTRICAL SYSTEM Immobilizer System Equipped Models Ignition Key Collation Error e The other remaining ignition key is registered in the ECU OThe red warning indicator light LED and the immobilizer warning symbol A blink 2 times and stop for 1 second and then repeat this cycle e Turn to OFF the ignition switch and remove the other re maining ignition key OThe immobilizer warning symbol B disappears OThe red warning indicator light LED A then blinks for 15 seconds OAfter 15 seconds the ECU ends the registration mode and stops blinking the red warning indicator light LED NOTE OThis procedure registered the registered ignition key and one ignition key If more keys registration is needed go to next procedures within the registration mode e Insert the ignition key 1 into the ignition switch and turn it to ON Olf there is any problem in the registration the red warning indicator
373. isconnect the front brake light switch connectors C Immediately wash away any brake fluid that spills Front Master Cylinder Installation e Set the front master cylinder to match its mating surface A to the punch mark B of the handlebars e The master cylinder clamp must be installed with the ar row mark C upward 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 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 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 Cotter Pin A Joint Pin B NOTE OPull off the joint pin while pressing down the brake pedal e Unscrew the brake hose banjo bolt A on the master cylin der see Brake Hose Replacement in the Periodic Main tenance chapter e Remove the master cylinder mounting bolts B e Slide the reservoir hose lower end clamp C e Pull off the reservoir hose lower end and drain the brake fluid into a container BRAKES 12 19 Master Cylinder Rear Master Cylinder Installation e Replace the cotter pin A with a new one e Replace the washers on each side of hose fitting with new ones e Tighten Torque Rear Master Cylind
374. iscosity 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 cleaner duct loose Air cleaner poorly sealed or missing Handling and or Stability Unsatisfactory Handlebars 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 Handlebars shakes or excessively vibrates Tire worn Swingarm pivot bearing worn Rim warped or not balanced Wheel bearing worn Handlebar holder bolt loose Steering stem nut loose Front rear axle runout excessive Engine mounting bolt loose Handlebars pulls to one side Frame bent Wheel misalignment Swingarm bent or twisted Swingarm pivot shaft runout excessive Steering maladjusted 17 52 APPENDIX Troubleshooting Guide Front fork bent Contaminated pad Right and left front fork oil level uneven Brake fluid deteriorated Shock absorption unsatisfactory Primary or secondary cup damaged in master Too hard cylinder Front fork oil excessive Master cylinder scratched inside Front fork oil viscosity too high
375. ive by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in 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 intake system by cutting drilling or other means if such modifications result in increased noise levels Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop However it contains enough detail and basic in formation to make it useful to the owner who de sires to perform his own basic maintenance and repair work A basic knowledge of mechanics the proper use of tools and workshop proce dures must be understood in order to carry out maintenance and repair satisfactorily When ever the owner has insufficient experience or doubts his ability to do the work all adjust ments maintenance and repair should be car ried out only by qualified mechanics In order to per
376. 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 65 Air Switching Valve Air Switching Valve Circuit GPiB8619BW3 C ooxooRoM2 Ignition Switch Air Switching Valve Joint Connector E ECU Frame Ground 1 Frame Ground 3 Engine Ground Battery 12 V 8 Ah Starter Relay Main Fuse 30 A ECU Fuse 15 A ECU Main Relay Relay Box Fuse Box 1 Ignition Fuse 15 A Joint Connector F 16 66 ELECTRICAL SYSTEM Radiator Fan System Fan Motor Inspection e Remove the left side cover see Side Cover Removal in the Frame chapter e Slide the dust cover A e Disconnect the connector B e Using an auxiliary leads supply battery power to the fan motor x If the fan does not rotate the fan motor is defective and must be replaced Radiator System ELECTRICAL SYSTEM 16 67 Radiator Fan Circuit GPi5i20BW3 C gt gnition Switch Fan Motor Water Temperature Sensor Joint Connector E ECU Frame Ground 1 Frame Ground 3 Engine Ground Battery 12 V 8 Ah Starter Relay Main Fuse 30 A Fuse Box 2 Fan Fuse 15 A Relay Box Radiator Fan Relay Fuse Box 1 Ignition Fuse 15 A Joint Connector C Joint Connector F 16 68 ELECTRICAL
377. justing Nut Caps A e Remove Bolts A and Washers Adjusting Nuts B Bolts and Washers Windshield Assembly C Fairings FRAME 15 13 e Remove Bolts A Washers B Brackets C Windshield D Windshield Installation e Installation is reverse of removal Upper Fairing Bracket Removal e Remove Middle Fairing see Middle Fairing Removal Upper Fairing see Upper fairing Removal Upper Side Fairing see Upper Side Fairing Removal Meter Cover see Meter Cover Removal Coolant Reserve Tank see Coolant Change in the Peri odic Maintenance chapter Bands A Front Wheel Rotation Sensor B Turn Signal Relay C e Disconnect Outside Temperature Sensor D Vehicle down Sensor E Immobilizer Amplifier F Equipped Model e Remove Bolt A Both Sides Bolts B Upper Fairing Bracket C Upper Fairing Bracket Installation e Installation is the reverse of removal note the following ORun the cables and leads correctly see Cable Wire and Hose Routing section in the Appendix chapter 15 14 FRAME Side Covers Side Cover Removal e Remove Seat see Seat Removal Upper Side Fairing see Upper Side Fairing Removal Bolts A with Washers e Pull the side cover B outward to clear the stoppers C Side Cover Installation e Be sure to install the pads A and grommet B e Insert the projections A into the holes B e Install the bolts and washers FRAME
378. ke Pedal Bemoval ite eie veto btt v db net adu oat 12 10 Brake Pedal Installation 2 2 20200 0000000000000 000000000000 000000000000 12 11 Calipers se 12 12 Front Caliper 12 12 Rear Caliper iiti ree rh e a vere FEY ELE EC seve 12 12 Caliper Installation 12 13 Front Caliper Disassemb y 3 6 adeo 12 13 58 dte acit cal 12 13 Rear Caliper Disassembly pp 12 13 Rear Caliper ASSembly sia cp tir tr TEE ieu 12 13 Caliper Fluid Seal Damage Inspectigom 12 14 Rear Caliper Dust Boot and Friction Boot Damage 12 14 Caliper Piston and Cylinder Damage Inspection 12 14 Rear Caliper Holder Wear Inspection 12 15 Blake PAGS MMC EET Front Brake Pad 2 Front Brake Pad Installation Rear Brake Pad Rear Brake Pad Installation Brake Pad Wear Inspection Master usi usce Front Master Cylinder Removal pp 12 18 Front Master Cylinder Installations d esie odo 12 18 Rear Master Cyl
379. ke 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 1 Oct 4 2011 LIST 5 ABDC ABS Ah ATDC BBDC BDC BTDC cmHg CU cu in DC DFI DOHC DOT ECU ampere s after bottom dead center antilock brake system 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 central prcessing unit cubic inch s direct current digital fuel injection double overhead camshaft department of transportation electronic control unit farad s degree s Fahrenheit foot feet gram s gallon s hour s horsepower s integrated circuit in km h KTRC L LCD LED Ib m min mmHg mph OZ Pa PS psi dt rpm TDC TIR mx inch s kilometers per hour Kawasaki traction control system liter s liquid crystal display light emitting diode pound s meter s minute s millimeters of mercury miles per hour newton s ounce s pa
380. ket bolts and tighten them Torque Camshaft Sprocket Bolts 15 Nm 1 5 kgf m 11 41 e Apply molybdenum disulfide oil solution to all cam parts and journals e Using a wrench on the timing rotor bolt A turn the crank shaft clockwise until the line B TDC mark for 1 4 pis tons on the timing rotor is aligned with the timing mark C Crankcase Halves Mating Surface 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 GE11382BS1 ENGINE END 5 21 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 OUse the one punch mark on the sprocket as IN mark the two punch marks as EX mark OThe timing marks must be aligned with the cylinder head upper surface B EX mark Tow punch marks C IN mark One punch mark D 1 pin E 2 pin F 29 pin G 30 H GE113638W2 5 22 END Camshaft Camshaft Chain e Before installing the camshaft caps and upper chain guide install the camshaft chain tensioner body tem porarily see Camshaft Chain Tensione
381. l e Check conductivity of the following numbered terminals by connecting the hand tester and one 12 V battery to the relay box as shown see Relay Box Internal Circuit in this section x If the tester does not read as specified replace the relay box Relay Circuit Inspection with the battery disconnected 2222 2101 Tester Connection Tester Reading Headlight Circuit 1 3 eo Relay ECU Main Relay Not 7 Fuel Pump Relay 9 10 Not A 11 16 Starter Circuit Relay 11 12 eo 17 20 eo Radiator Fan Relay 18 19 Not The actual reading varies with the hand tester used Relay Circuit Inspection with the battery connected Tester Tester Connection Reading Q 2 11 1 3 0 ECU Main Relay 4 5 7 6 0 Fuel Pump Relay 9 10 7 8 0 Radiator Fan 18 19 17 20 0 Relay Battery Tester Connection Connection DC 25 V Range Reading V s Starter Battery Circuit Relay 1 12 Tite Voltage Apply positive lead Apply negative lead 16 112 ELECTRICAL SYSTEM Relay Box 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 resistance should be low in one direction and more than ten times as much in the other direction
382. l inspect Coolant leak water hose and pipe inspect Water hose damage inspect year Water hose installation condition year year inspect Engine Top End CA Model Valve clearance inspect Other than CA Models Air suction system damage inspect Clutch Clutch operation play disengagement engagement inspect Wheels and Tires Tire air pressure inspect Wheel tire damage inspect Tire tread wear abnormal wear inspect Wheel bearing damage inspect Final Drive Drive chain lubrication condition inspect Drive chain slack inspect Every 1 000 km 600 mile 2 30 Every 600 km 400 mile 2 30 2 4 Periodic Maintenance Chart FREQUENCY Whichever ODOMETER READING comes 5 x 1 000 km first x 1 000 mile See lal 18 24 Page Every 0 6 3 75 7 5 11 25 15 18 75 22 5 Drive chain wear inspect e o e 2 32 Drive chain guide wear inspect e e e 2 33 Brakes Brake fluid leak brake hose and year e e e e e e 2 34 pipe inspect Brake hose and pipe damage year E gt 2 35 inspect Brake hose and pipe installation year 2 5 A i 2 35 condition inspect Brake operation effectiveness year gt 5 M 2 35 play
383. l Pump Lead Connector A Fuel Hose B Special Tool Fuel Hose 57001 1607 e Start the engine and let it idle e Measure the output voltage with the connector joined Output Voltage with Plugs Standard DC 0 7 V or more e Next remove the air cleaner housing and pull up the rub ber cover to take out the plugs from the fittings A of the air suction valve covers e Reposition the rubber cover and install the air cleaner housing e Start the engine and let it idle e Measure the output voltage with the connector joined Output Voltage without Plugs Standard DC 0 2 V or less e Turn the ignition switch to OFF 3 78 FUEL SYSTEM DFI Oxygen Sensor not activated Service Code 33 x If the reading is out of the standard with plugs DC 0 7 V or more without plugs DC 0 2 V or less remove the ECU and check the wiring for continuity between main harness connectors ODisconnect the ECU and sensor connectors Wiring Inspection ECU Connectors Oxygen Sensor Connector B BL Y lead ECU terminal 8 C 601712981 G lead ECU terminal 49 D x If the wiring is good replace the sensor x If the reading is within the standard with plugs DC 0 7 V or more without plugs DC 0 2 V or less check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see Removal Installation
384. le fuel in tank Supply fuel see Owner s Manual Air cleaner clogged poorly sealed or missing Clean element or inspect sealing see chapter 2 Air duct loose Reinstall see chapter 3 Throttle body assy holder loose Reinstall see chapter 3 Throttle body assy dust seal damage Replace see chapter 3 Fuel injector O ring damage Replace see chapter 3 Fuel filter or pump screen clogged Inspect and replace fuel pump see chapter 3 3 32 FUEL SYSTEM DFI DFI System Troubleshooting Guide Symptoms or Possible Causes Actions chapter 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 Inspect see chapter 3 Water temperature sensor trouble Inspect see chapter 3 Intake air temperature sensor 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 Unstable rough idling Fuel pressure too low or too high 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 Engine vacuum not synchronizing Intake
385. le 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 maladjusted 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 0101010101010101010101010 1010109101010 0 other FUEL SYSTEM DFI 3 31 DFI System Troubleshooting Guide NOTE OThis is not an exhaustive list giving every possible cause for each problem listed It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties in DFI system OThe ECU may be involved in the DFI electrical and ignition system troubles If these parts and circuits are checked out good be sure to check the ECU for 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 Neutral starter lockout or sidestand switch Inspect each switch see chapter
386. ler see Oil Cooler Removal in the Engine Lubri cation System chapter Oil Pipe see Oil Pipe Removal in the Engine Lubrication System chapter Oil Pressure Relief Valve see Oil Pressure Relief Valve Removal in the Engine Lubrication System chapter x If the crankshaft is to be removed remove the pistons see Piston Removal in the Engine Top End chapter e Remove Balancer Shaft Clamp Bolt A Balancer Shaft Lever Bolt B e Remove the upper crankcase bolts following the specified sequence OFirst loosen the M6 bolts A OSecond loosen the M7 bolts B OLasty loosen the 8 bolts C 6104381851 C 9 10 CRANKSHAFT TRANSMISSION Splitting e Remove the lower crankcase bolts following the specified sequence OFirst loosen the M7 bolts A OLastly loosen the M9 bolts as shown sequence 1 10 in the figure e Tap lightly around the crankcase mating surface with a plastic mallet and split the crankcase Pi SS OTake care not to damage the crankcase C ir ipe tL FN p 61043828W2 Crankcase Assembly The upper and lower crankcase halves 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 e Using compressed air blow out the oil pas
387. ler plug B with a new one e Apply grease to the O ring e Tighten Torque Filler Plug Hand tighten GFO5018BS1 C 65058416 6 10 CLUTCH Clutch Clutch Removal e Remove Clutch Cover see Clutch Cover Removal Clutch Spring Bolts A Clutch Springs Clutch Spring Plate B with Washer Needle Bearing and Pusher C e Remove Friction Plates and Steel Plates Spring and Spring Seat NOTE OThe two plates at both ends are different from the plate installed between these plates However it is impossible to identify it on externals OMark and record the locations of the friction plates so that they can be reinstalled in their original positions e Holding the clutch hub A remove the nut B and wash ers Special Tool Clutch Holder C 57001 1243 e Remove Clutch Hub Spacer 47 x 925 5 e Using the two 4 bolts or screws A pull out the sleeve B and then remove the needle bearing C and clutch housing e Remove the spacer 56 x 25 Clutch Installation e Install the spacer 56 x 25 A so that the tapered side B faces inward 6 11 Clutch e Install the clutch housing A to the drive shaft e While holding the clutch housing install the needle bear ing B and sleeve C OThe holes D of the sleeve face outward e Install the following parts to the drive shaft Spacer 47 x 25 5 A Clutch Hub e Install the washer
388. 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 Tighten Torque Front Master Cylinder Reservoir Cap Screws 1 5 N m 0 15 13 in Ib e Follow the procedure below to install the front rear brake fluid reservoir cap correctly OFirst tighten the rear brake fluid reservoir cap B clock wise C by hand until slight resistance is felt indicating that the cap is seated on the reservoir body then tighten the cap an additional 1 6 turn D while holding the brake fluid reservoir body A e Tighten the bleed valve and install the rubber cap Torque Bleed 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 x If necessary bleed the air from the lines p OT T PERIODIC MAINTENANCE 2 59 Periodic Maintenance Procedures Master Cylinder Rubber Parts Replacement Front Master Cylinder Disassembly e Remove the front master cylinder see Front Master Cylin der Removal in the Brakes chapter e Remove Reservoir Cap A Diaphragm Plate B Diaphragm C e Unscrew the locknut D and pivot bolt E and remove the brake lever e Remove the dust
389. liest convenience change the oil completely Engine Oil Change e Refer to the Engine Oil Change in the Periodic Mainte nance chapter Oil Filter Replacement e Refer to the Oil Filter Replacement in the Periodic Main tenance chapter 7 8 ENGINE LUBRICATION SYSTEM Cil Pan Oil Pan Removal e Remove Exhaust Pipe see Exhaust Pipe Removal in the Engine Top End chapter Oil Filter A see Oil Filter Replacement in the Periodic Maintenance chapter Oil Pan Bolts B Oil Pan C e Remove the following parts if necessary Oil Screen see Oil Screen Removal Oil Pipe see Oil Pipe Removal Oil Pressure Relief Valve see Oil Pressure Relief Valve Removal Oil Pan Installation e Install the following parts if removed Oil Pressure Relief Valve see Oil Pressure Relief Valve Installation Oil Pipe see Oil Pipe Installation Oil Screen see Oil Screen Installation e Replace the O rings A with new ones e Apply grease to the O rings and install them e Install the dowel pins B 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 oil pan Sealant Liquid Gasket TB1207B 92104 2068 NOTE OEspecially apply liquid gasket so that it shall be filled up on the grooves B E Xe SS ONS QS ASS Sd SV GS M 72932 8
390. lizer warning indicator light LED do on or yellow engine warning warning symbol blink not go on or Immobilizer indicator light LED and warning symbol and red warning yellow KTRC warning indicator light LED do not blink indicator light LED go on Conduct non self diagnosis Conduct self diagnosis Conduct self diagnosis inspection inspection DFI system inspection immobilizer System Conduct general fuel system inspection General fuel system throttle body assy air cleaner fuel tank etc 06171066 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 DFI system problem or a general engine problem FUEL SYSTEM DFI 3 29 Troubleshooting the DFI System Sample Diagnosis Sheet Rider name Registration No license plate No Year of initial registration Model Engine No Frame No Date problem occurred Mileage Environment when problem occurred Weather fine cloudy rain snow always O other Temperature O hot O warm cold O very cold O always O other
391. ll them e Apply a non parmanent locking agent to the throttle body assy holder bolts e Tighten Torque Throttle Body Assy Holder Bolts 12 Nm 1 2 kgf m 106 in Ib e Install the clamps A so that their projections B fit on the holes C of the holders OBe sure that the clamp bolt heads A face as shown in the figure Muffler ENGINE TOP END 5 43 A WARNING The exhaust pipe or muffler body can become ex tremely hot during normal operation and cause se vere burns Do not remove the exhaust pipe or muf fler body while it is hot Muffler Body Removal e Remove Muffler Body Clamp Bolt A Loosen Muffler Body Mounting Bolt B and Nut Muffler Body C 5 44 END Muffler Muffler Body Installation e Replace the muffler body gaskets A with new ones e Install the muffler body gaskets until it is bottomed so that the inside chamfer side faces rear B e Install the muffler body clamp C so that the insert the projection D into the clamp slit E e Install the muffler body until it stops at the bottom surface of the exhaust pipe e Install the muffler body mounting bolt and nut e Tighten Torque Muffler Body Mounting Bolt F 34 N m 3 5 kgf m 25 ft lb Turn the muffler body clamp outward until it stops at the slit ends Inside G Viewed from Rear H Outward I Tighten Torque Muffler Body Clamp Bolt J 21 N m 2 1 kgf m 15 ft lb
392. llation e Installation is the reverse of removal note the following ORun the lead correctly see Cable Wire and Hose Rout ing section in the Appendix chapter 12 54 5 Anti Lock System Rear Wheel Rotation Sensor Removal The wheel rotation sensor should be handled care fully never struck sharply as with a hammer or al lowed to fall on a hard surface since the wheel rota tion sensor is precision made Be careful not to get water or mud on the wheel rotation sensor Do not try to disassemble or repair the wheel rota tion sensor e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Connector A Disconnect Grommet B e Clear the sensor lead from the clamps C e Clear the sensor lead from the clamps A e Remove Grommet B Bolt C Rear Wheel Rotation Sensor D Rear Wheel Rotation Sensor Installation e Installation is the reverse of removal note following ORun the lead correctly see Cable Wire and Hose Rout ing section in the Appendix chapter BRAKES 12 55 Anti Lock Brake System 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 otherwise damaged Wheel Rotation S
393. lor and then the stripe color Unless instructed otherwise electrical Y R wires 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 GB02082BS1 C GENERAL INFORMATION 1 7 Model Identification KLZ1000AC Europe Left Side View 68038622 P KLZ1000AC Europe Right Side View 62038623 Frame Number 1 8 GENERAL INFORMATION General Specifications Items KLZ1000AC Dimensions Overall Length Overall Width Overall Height High Position Wheelbase Road Clearance Seat Height Curb Mass Front Rear 21 0 L 5 55 US gal Fuel Tank Capacity Performance Minimum Turning Radius Engine Type Cooling System Bore and Stroke Displacement Compression Ratio Maximum Horsepower Maximum Torque Carburetion System Starting System Ignition System Timing Advance Ignition Timing Spark Plug Cylinder Numbering Method Firing Order Valve Timing Intake Open Close Duration Exhaust Open Close Duration Lubrication System 2 235 mm 87 99 in 900 mm 35 4 in 1 405 mm 55 31 1 430 mm 56 3 in 1 520 mm 59 84 in 155 mm 6 10 in 845 mm 33 3 in 239 kg 527 Ib 117 kg 258 Ib 122 kg 269 Ib 3 0 m 9 8 ft 4 stroke DO
394. ltage Replace bad parts or inspect them with KAWASAKI Hand Tester Replace bad parts ECU is defective Replace ECU GP10679B F Ignition System ELECTRICAL SYSTEM 16 47 Ignition System Circuit 9 l qwe 3 m L EM Hi SONS m LG BL W 22 Y a H BL 86 l L3 9 0 17 KD M r1 9 1 Ignition Switch 14 Engine Ground 2 Engine Stop Switch 15 Battery 12 V 8 Ah 3 Spark Plugs 16 Starter Relay 4 Stick Coils 17 Main Fuse 30 5 Crankshaft Sensor 18 ECU Fuse 15 A 6 Main Throttle Sensor 19 Relay Box 7 Subthrottle Sensor 20 ECU Main Relay 8 Neutral Switch 21 Starter Lockout Switch 9 Sidestand Switch 22 Fuse Box 1 10 Joint Connector E 23 Ignition Fuse 15 A 11 ECU 24 Joint Connector F 12 Frame Ground 3 25 Vehicle down Sensor Frame Ground 1 16 48 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 Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Remove Left Lower Fairing see Lower Fairing Removal in the Frame chapter Engine Sprocket Cover see Engine Sprocket Cover Re moval in the Final Drive chapter Harness Holder A e Loosen the water hose clamp screw B
395. mance 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 be checked by measuring battery terminal voltage with a digital voltmeter A e Remove Seats see Seats section in the Frame chapter e Disconnect the battery terminals sure to disconnect the negative cable first e Measure the battery terminal voltage NOTE OMeasure with a digital voltmeter which can be read one decimal place voltage x If the reading is 12 8 V or more no refresh charge is re quired however if the read is below the specified refresh charge is required Battery Terminal Voltage Standard 12 8 V or more Terminal Voltage V A Battery Charge Rate 96 B Good C Refresh charge is required D Refreshing Charge e Remove the battery A see Battery Removal e Do refresh charge by following method according to the battery terminal voltage A WARNING This battery is sealed type Never remove sealing cap B even at charging Never add water Charge with current and time as stated below 8 08010851 C 8 0900125
396. ment 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 2 In most cases assembly order is the reverse of disassem T bly however if assembly order is provided this Service cu Om i Manual follow the procedures given x S DE gt SS WX 2 N 68020118 S 1 4 GENERAL INFORMATION Before Servicing Tightening Sequence Generally when installing a part with several bolts nuts or screws start them all in their holes and tighten them to a snug fit Then tighten them according to the specified se quence to prevent case warpage or deformation which can lead to malfunction Conversely when loosening the bolts nuts or screws first loosen all of them by about a quar ter turn and then remove them If the specified tightening sequence is not indicated tighten the fasteners alternating diagonally Tightening Torque Incorrect torque applied to a bolt nut or screw may lead to serious damage Tighten fasteners to the specified torque using a good quality torque wrench Force Use common sense during disassembly and assembly excessive force can cause expensive or hard to repair dam age When necessary remove screws that have a non permanent locking agent applied using an impact driver Use a pla
397. mes 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 If the wheel always stops in one position provisionally attach a balance weight A on the rim at the marking using adhesive tape e Rotate the wheel 1 4 turn B and see whether or not the wheel stops in this position If it does the correct balance weight is being used x If the wheel rotates and the weight goes up replace the weight with the next heavier size If the wheel rotates and the weight goes down replace the weight with the next lighter size Repeat these steps until the wheel remains at rest after being rotated 1 4 turn e Rotate the wheel another 1 4 turn and then another 1 4 turn to see if the wheel is correctly balanced e Repeat the entire procedure as many times as necessary to achieve correct wheel balance e Permanently install the balance weight Balance Weight Removal e Insert a standard tip screwdrivers A B between the C and weight D as shown in the figure e Pry the balance weight with two standard tip screwdrivers and remove the balance weight e Discard the used balance weight NOTICE Do not tap the screwdrivers The rim could be dam aged 6J04043BS1 C 6J04076BS1 C 6J04077BS1 6J04073BS1 C Wheels Rims WHEELS TIRES 10 11
398. mes 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 65148746 Front Fork Oil Leak Inspection e Visually inspect the front forks A for oil leakage Replace or repair any defective parts if necessary PERIODIC MAINTENANCE 2 39 Periodic Maintenance Procedures Rear Shock Absorber Oil Leak Inspection e Visually inspect the shock absorber A for oil leakage If the oil leakage is found on it replace the shock absorber with a new one Rocker Arm Operation Inspection e Pump the seat down and up 4 or 5 times and inspect the smooth stroke xIf the rocker arms A do 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 65148749 Tie Rod Operation Inspection e Pump the seat down and up 4 or 5 times and inspect the smooth stroke xIf the tie rod A does not smoothly stroke or noise is found inspect the fasteners and tie rod bearings see Rocker Arm Tie Rod Bearing Sleeve Inspection in the Suspension 65148750 Steering Steering Play Inspection e Remove the lower fairing see Lower Fairing Removal in the Frame chapter e Raise the front wheel off the ground with the jack see Front Wheel Removal in the Wheels Tires chapter e With the
399. 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 background before starting the repair work Ask the rider abou
400. minals of the main harness connectors are dam aged replace the main harness x If the terminals of the ECU connectors are damaged re place the ECU e Turn the ignition switch to OFF e Disconnect the ECU connectors 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 1 BK BL lead ECU terminal 38 BK Y leads ECU terminal 39 65 G lead ECU terminal 49 P lead ECU terminal 58 Engine Ground lt Battery Terminal lt Battery Terminal Criteria Both 0 Q x If no continuity check the connectors the engine ground lead or main harness and repair or replace them if nec essary GC17136FS1 3 98 FUEL SYSTEM DFI ECU x If the wiring is good check the power source voltage of the ECU NOTE sure the battery is fully charged e Connect the ECU and relay box connectors e Connect a digital meter A to the connectors B with the needle adapter set Special Tool Needle Adapter Set 57001 1457 ECU Power Supply Inspection Connections 1 Digital Meter Terminal 6 BR W Digital Meter gt Battery terminal Digital Meter Terminal 7 W BK Digital Meter gt Battery terminal Ignition Switch OFF Terminal 6 BR W 0 V Terminal 7 W BK Battery Voltage Ignition Switch ON Both Battery Voltage x If the read
401. mmet B Stator Coil Bolts C e Remove the stator coil D from the alternator cover Stator Coil Installation e Apply a non permanent locking agent to the threads of the stator coil bolts and tighten them Torque Stator Coil Bolts 12 N m 1 2 kgf m 106 in Ib e Secure the alternator lead with a holding plate e Apply a non permanent locking agent to the threads of the plate bolt and tighten it Torque Alternator Lead Holding Plate Bolt 12 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 silicone sealant coating area Dry them with a clean cloth e Apply silicone sealant to the circumference of the alterna tor lead grommet A and fit the grommet into the notch B of the cover securely Sealant Liquid Gasket TB1211F 92104 0004 e Install the alternator cover see Alternator Cover Installa tion Alternator Rotor Removal e Remove Alternator Cover see Alternator Cover Removal Starter Idle Gear A 16 32 ELECTRICAL SYSTEM Charging System e Hold the alternator rotor steady with the rotor holder A and stopper B e Remove the rotor bolt C and washer Special Tools Grip D 57001 1591 Stopper 57001 1679 Rotor Holder 57001 1690 If using the rotor holder 57001 1757 e Hold the alternator rotor steady with the rotor holder A e Remove the rotor bolt B and washer Special Tool Rotor Holder 57001 1757 e Using the
402. moval in the Frame chapter Immobilizer Amplifier connector A Immobilizer Amplifier B Immobilizer System Equipped Models ELECTRICAL SYSTEM 16 103 e Fit the slit A on the damper to the bracket projection B Both Sides ECU Replacement Never drop the ECU especially on a hard surface Such a shock to the ECU can damage it e Remove Seat see Seat Removal in the Frame chapter e For WVTA 78 2 H and GB WVTA FULL H Models us ing a small chisel or other suitable tool remove the screws A washers B and ECU guard C e Remove Relay Box see Relay Box Removal ECU Connectors A ECU B e Connect the connectors to the ECU e For WVTA 78 2 H and GB WVTA FULL H Models in stall the ECU guard A and washers B Do not pinch the leads e For WVTA 78 2 H and GB WVTA FULL H Models tighten the new screws C using the Kawasaki genuine screws of which threads are coated with locking agent 16 104 ELECTRICAL SYSTEM Immobilizer System Equipped Models Immobilizer Relational Parts Replacement Chart Failed or Lost Part Ignition Key Black Ignition Switch Amplifier ECU Ignition Key Black Ignition Switch ECU Replacement Part e Main Replacement Part Additional Replacement Part Immobilizer System Inspection e Refer to the Immobilizer Amplifier and Blank Key Detec tion section in the Fuel System DFI chapter
403. move ignition 2 3 Matching Unique Code O Not Registered Ignition Key O Ignition key or not 62300516 16 90 ELECTRICAL SYSTEM Immobilizer System Equipped Models Case 2 When the ignition switch is faulty and has to be replaced e Prepare a new ignition switch A and two new ignition keys B OThese parts are available as a set Prepare the current registered ignition key C e Remove Ignition Switch see Immobilizer System Parts Replace ment Seat see Seat Removal in the Frame chapter e Remove the immobilizer Kawasaki diagnostic system connector cap e Connect the key registration adapter A and key registra tion unit 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 of Current Ig nition Switch NOTE OKeep the antenna C more than 15 cm 5 9 in from the new ignition switch D e Insert the current registered ignition key A into the cur rent ignition switch B e Insert the new ignition key 1 C into the new ignition switch D and turn it to ON Verified OThe red warning indicator light LED and the immobilizer warning symbol A blink to display the ECU is in the reg istration mode go to the next step CNET 0 5second 0 5second GP30024CS1 Immobilizer System
404. mulation in the water passages and consider ably reduces the efficiency of the cooling system Water and Coolant Mixture Ratio Recommended Soft Water 50 Coolant 50 Freezing Point 35 31 F Total Amount 2 6 L 2 7 US qt e Fill the radiator up to the filler neck A with coolant NOTE OPour in the coolant slowly so that it can expel the air from the engine and radiator e Check the cooling system for leaks e Tap the radiator hoses to force any air bubbles caught inside e Fill the radiator up to the filler neck with coolant e Fill the reserve tank up to the F full level line A with coolant and install the cap B e Start the engine warm it up thoroughly until the radiator fan turns on and then stop the engine e Check the coolant level in the reserve tank after the en gine cools down If the coolant level is lower than the L low level line C add coolant to the F level line NOTICE Do not add more coolant above the level line 2 54 PERIODIC Periodic Maintenance Procedures Radiator Hose and O ring Replacement e Drain the coolant see Coolant Change e Remove Thermostat Housing A see Thermostat Removal in the Cooling System chapter Water Pump Cover B see Water Pump Removal in the Cooling System chapter Oil Cooler C see Oil Cooler Removal in the Engine Lubrication System chapter e Replace the hoses D and O rings
405. n A of the brake hose clamp back ward Flap and Rear Fender Removal e Remove Seat see Seat Removal Seat Cover see Seat Cover Removal Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Battery see Battery Removal in the Electrical System chapter ECU Guard see Immobilizer System Parts Replace ment in the Electrical System chapter GB WVTA FULL H and WVTA 78 2 H Models Screws A Bands B Starter Relay C Fuse Box 1 D Fuse Box 2 E Bracket F Clamp G Bolts H Immobilizer Equipped Model Kawasaki Diagnostic System Connector I 15 18 FRAME Fenders Remove Bands A Nuts B e Disconnect Turn Signal Light Lead Connectors A Licence Plate Light Lead Connector B Tail Light Lead Connector C e Remove Bolts D Clamps E e Pull up A front side of the rear fender B remove the rear fender rearward C e Remove Nut A Washer B Bolt C Flap D Flap and Rear Fender Installation e Installation is the reverse of removal note the following OReplace the rear fender mounting nuts A with new ones ORun the cables leads harness and hose correctly see Cable Wire and Hose Routing section in the Appendix chapter FRAME 15 19 Frame Inspection e Visually inspect the frame for cracks dents bending or warp Olf there is any damage to the frame replace it A WARNING A repaired frame may fail in use poss
406. n be ex plosive under certain conditions creating the potential for serious burns Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Turn the ignition switch to OFF Disconnect the battery terminal To avoid fuel spills draw it from the tank when the engine is cold Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately Never drop the 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 careful of fuel spillage from the fuel tank since fuel still remains in the fuel tank and fuel pump Plug the fuel pipe of the fuel tank e Turn the fuel tank upside down e Remove the fuel pump bolts A and take out the fuel pump B Do not pull the leads of the fuel pump If they are pulled the lead terminals may be damaged e Discard the fuel pump gasket A FUEL SYSTEM 3 105 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 terminal A and band B are in place e Apply a non permanent locking agent to the threads of the fuel pump bolts
407. n 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 Carbon accumulating on valve seating sur face Camshaft cam worm Run on dieseling Ignition switch trouble Engine stop switch trouble Fuel injector trouble Loosen terminal of battery cable ECU ground lead Carbon built up in combustion chamber 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 sealed or miss ing Air cleaner duct loose Water or foreign matter in fuel Throttle body assy holder loose Fuel to injector insufficient Fuel tank air vent obstructed Fuel line clogged Fuel pump trouble APPENDIX 17 49 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
408. n the figure Special Tool Hand Tester 57001 1394 x If the relay does not work as specified the relay is defec tive Replace the relay Testing Relay Tester Range x 1 range Criteria When battery is connected 0 When battery is disconnected gt GP11202BS1 Electric Starter System ELECTRICAL SYSTEM 16 55 Electric Starter Circuit GP11227BW3 Ignition Switch Engine Stop Switch Starter Button Neutral Switch Sidestand Switch Joint Connector E ECU Joint Connector B Frame Ground 3 Engine Ground Battery 12 V 8 Ah Main Fuse 30 A Starter Relay Starter Motor Frame Ground 1 Relay Box Starter Circuit Relay Starter Lockout Switch Fuse Box 1 Ignition Fuse 15 A Joint Connector F 16 56 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
409. nance chapter e Connect the following parts temporary Fuel Pump Lead Connector A Fuel Hose B Special Tool Fuel Hose 57001 1607 e Start the engine and let it idle e Measure the output voltage with the connector joined Output Voltage with Plugs Rich Standard DC 0 7 V or more e Next remove the air cleaner housing and pull up the rub ber cover to take out the plugs from the fittings A of the air suction valve covers e Reposition the rubber cover and install the air cleaner housing 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 2 V or less e Turn the ignition switch to OFF 3 94 FUEL SYSTEM Oxygen Sensor Incorrect Output Voltage Service Code 94 the reading is out of the standard with plugs DC 0 7 V or more without plugs DC 0 2 V or less check the following Fuel Pressure see Fuel Pressure Inspection Fuel Injector see Fuel Injectors section the fuel pressure and fuel injectors are good replace the sensor x If the reading is within the standard with plugs DC 0 7 V or more without plugs DC 0 2 V or less check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see Removal Installation Oxygen Sensor Circuit ECU Frame Ground 3 En
410. nd Hose Routing 68098910 G APPENDIX 17 25 Cable Wire Hose Routing ds 2 Hold the oxygen sensor lead rear wheel rotation sensor lead rear brake light switch lead and crankshaft sensor lead to the frame with clamp Hold the rear brake light switch lead at both sides of the connector with the clamp Do not hold the rear brake light switch lead at the connector Hold the oxygen sensor lead rear wheel rotation sensor lead rear brake light switch lead and crankshaft sensor lead with clamp Hold the oxygen sensor lead and crankshaft sensor lead with clamp Hold the alternator subharness to the rear frame pipe with band After tying them cut the band excess length and face its knot downward Hold the main harness to the ECU bracket with clamp Hold the main harness to the rear fender with the blade clips on the main harness Section A A Starter Motor Cable Main Harness to Rear Lights Main Harness to ECU Battery Ground Cable Hold the main harness to ECU with clamp Alternator Lead Connectors Relay Box Leads Run the battery ground cable to under the relay box Run the starter motor cable to under the fuse box Fuse Box Starter Relay Accessory Relay Hold the accessory relay and battery positive lead connector to the rear fender with bracket Battery Positive Lead Connector Battery Positive Cable Position the battery positive
411. nd and power supply are good replace the ECU see Removal Installation FUEL SYSTEM DFI 3 65 Rear Wheel Rotation Sensor Signal Service Code 24 Rear Wheel Rotation Sensor Circuit GCci7084FW2 C 1 ECU 2 Rear Wheel Rotation Sensor 3 ABS Hydraulic Unit 3 66 FUEL SYSTEM DFI 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 OThe ECU uses the 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 in the Fuel System DFI chapter Front Wheel Rotation Sensor Lead Connector see Front Wheel Rotation Sensor Removal in the Brakes chapter ABS Hydraulic Unit Connector see ABS Hydraulic Unit Removal in the Brakes chapter e Check the wiring for continuity between harness connec tors Special Tool Hand Tester 57001 1394 Wiring Continuity Inspection ECU Connector lt
412. nd immobilizer warning symbols go off and service code is not displayed But the service codes stored in memory of the ECU are not erased to preserve the problem history In this model the problem history can not be erased 3 40 FUEL SYSTEM DFI Self Diagnosis Service Code Table Service Code System Problems 11 Main throttle sensor malfunction wiring open or short 12 FI KTRC Intake air pressure sensor 1 malfunction wiring open or short 13 Fl Intake air temperature sensor malfunction wiring open or short 14 Fl Water temperature sensor malfunction wiring open or short 16 Fl Intake air pressure sensor 2 malfunction wiring open or short 21 FI KTRC Crankshaft sensor malfunction wiring open or short 24 FI KTRC Rear wheel rotation sensor malfunction wiring open or short 27 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 KTRC Subthrottle sensor malfunction wiring open or short 33 Fl Oxygen sensor inactivation wiring open or short 35 Immobilizer Immobilizer amplifier malfunction Equipped Model 36 Immobilizer Blank Key detection Equipped Model 39 ECU Wiring communication error 51 FI KTRC Stick coil 1 malfunction wiring open or short 52 Stick coil 2 malfunction wiring open or short
413. nd 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 Lubricate the drive chain if it appears dry e Stretch 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 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 A WARNING A chain that breaks or jumps off the sprockets could snag on the engine sprocket or lock the rear wheel severely damaging the motorcycle and causing it to go out of control Inspect the chain for damage and proper adjustment before each ride If chain wear exceeds the service limit replace it with the standard chain Standard Chain Make ENUMA Type EK525RMX Link 116 Links 6 04060651 C PERIODIC MAINTENANCE 2 33 Periodic Maintenance Procedures Chain Gui
414. nder the pistons and remove the pis ton pin snap ring A from the outside of each piston e Remove the piston pins Olf difficult to remove the piston pin use the piston pin puller assembly A to remove the piston pin Special Tool Piston Pin Puller Assembly A 57001 910 e Remove the pistons e Carefully spread the ring opening with your thumbs and then push up on the opposite side ofthe ring A to remove it e Remove the 3 piece oil ring with your thumbs in the same manner GE16178BS1 GE16013BS1 C Cylinder Pistons ENGINE TOP END 5 39 Piston Installation e 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 Do not mix up the top and second ring e Install the top ring A so that the 1T mark B faces up e Install the second ring C so that the 2T mark D faces up OApply molybdenum disulfide oil solution to the piston rings NOTE Olf a new piston is used use new piston ring e Install
415. ne Sprocket Removal 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 Body A Handlebar B Cutting and Riveting Pin C For Cutting D For Riveting E Plate Holder A F Plate Holder B G Gauge H e Grind A the pin head to make it flat e Set the cutting and riveting pin B as shown in the figure GK04016BS1 C GK04017BS1 C 11 8 FINAL DRIVE Drive Chain Screw the holder until it touches chain e Be sure that the cutting pin hits center of chain pin e Screw the handlebar A into body e Turn the pin holder with wrench B clockwise to extract chain pin e Replace the link pin link plate and grease seals e Apply grease to the link pins A and grease seals B 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 C so that the mark faces out e Push the link plate by hand or plier to fix it e n case of grease seals chain be sure to set the grease seals correctly e Set the plate holder A A and plate holder B B on the body e Fit the plate holder A A to link plate e Turn the pin holder by hand until plate holder B B touches the other link plate GK04018BS1 C GKO4019BS1 C GK04103BS1 C GK04021BS
416. nent locking agent to the threads of the water pipe bolt Tighten Torque Water Pipe Bolt 12 N m 1 2 kgf m 106 in Ib Radiator Water Hose Clamp Screws 2 9 N m 0 30 kgf m 26 in Ib e Run the hoses correctly see Cable Wire and Hose Rout ing section in the Appendix chapter 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 at room temperature xIf the valve is open replace the thermostat with a new one e To check valve opening temperature suspend the ther mostat A in a container of water and raise the tempera ture of the water OThe thermostat must be completely submerged and must not touch the container sides or bottom Suspend an ac curate thermometer B in the water so that the heat sen sitive portions C are located in almost the same depth It must not touch the container either x If the measurement is out of the specified range replace the thermostat with a new one Thermostat Valve Opening Temperature 58 62 C 136 144 F 6009000851 C 6009020252 C 4 20 COOLING SYSTEM Hose and Pipes Hose Installation e Install the hoses and pipes being careful to follow bend DD A wg ing direction Avoid sharp bending kinking flattening or twisting e Run the hoses see Cable Wire and Hose Routi
417. ners Tightness Replacement Parts Air Cleaner Element Repl Fuel Hose Replacement Coolant Change IT I T UTEM Radiator Hose and O ring een Engine Oil Change Oil Filter Replacement Brake Hose Brake Fluid Change Master Cylinder Rubber Parts Replacement Caliper Rubber Parts Replacement pp Spark Plug Replacement 2 42 2 44 2 45 2 46 2 47 2 47 2 49 2 50 2 50 2 50 2 52 2 54 2 55 2 55 2 56 2 58 2 59 2 60 2 63 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 gt x 1 000 km first x 1 000 mile See Every 0 6 3 75 7 5 11 25 15 18 75 22 5 Fuel System Throttle control system year e 5 2 15 smooth return no drag inspect Engine vacuum synchronization inspect Idle speed inspect Fuel leak fuel hose and pipe inspect Fuel hose and pipe damage inspect Fuel hose and pipe installation condition inspect Cooling System Coolant leve
418. ng e Replace them with new ones when installing e Fitthe projection of the brake hose end to the calipers and master cylinders and tighten the brake hose banjo bolts to the specified torque Torque Brake Hose Banjo Bolts 25 2 5 kgf m 18 ft lb e When installing the hoses avoid sharp bending kink ing flatting or twisting and route the hoses according to Cable Wire and Hose Routing section in the Appendix chapter e Fill the brake line after installing the brake hose see Brake Fluid Change PERIODIC MAINTENANCE 2 57 Periodic Maintenance Procedures e For the brake hoses of the ABS note the following NOTE OWhen removing the brake pipes and hoses on the hy draulic unit remove them according to each assembly of the exploded view in the Brakes chapter e Remove Air Cleaner Housing see Air Cleaner Housing Removal in the Fuel System DFI chapter Rear Fender see Flap and Rear Fender Removal in the Frame chapter Brake Pipe Joint Nuts A Bolts B Clamps C e Open the band D e Clear the brake pipe from the holder E e There are washers on each side of the brake hose fitting Replace them with new ones when installing 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 tighten the brake pipe joint nuts at both ends of the
419. ng 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 8 15011951 C GE15012181 5 34 END x If the outside diameter A of the seating surface is too large make the 32 grind described below x If the outside diameter of the seating surface is within the specified range measure the seat width as described be low e Grind the seat at a 32 angle B until the seat outside diameter is within the specified range OTo make the 32 grind fit a 32 cutter into the holder and slide it into the valve guide OTurn the holder one turn at a time while pressing down very lightly Check the seat after each turn NOTICE The 32 cutter removes material very quickly Check the seat outside diameter frequently to pre vent overgrinding OAfter making the 327 grind return to the seat outside di ameter measurement step above e To measure the seat width use a vernier caliper to mea sure the width of the 45 angle portion of the seat at sev eral places around the seat x If the seat width is too narrow repeat the 45 grind until the seat is slightly too wide and then return t
420. ng sec tion in the Appendix chapter e Install the clamp A as near as possible to the hose end to clear the raised rib of the fitting This will prevent the hoses from working loose OThe clamp screws should be positioned correctly to pre ico vent the clamps from contacting the other parts Torque Radiator Water Hose Clamp Screws 2 9 N m 0 30 kgf m 26 in Ib Hose Inspection e Refer to the Radiator Hose Damage and Installation Con dition Inspection in the Periodic Maintenance chapter COOLING SYSTEM 4 21 Water Temperature Sensor The water temperature sensor should never be al lowed to fall on a hard surface Such shock to the water temperature sensor can damage it Water Temperature Sensor Removal Installation e Refer to the Water Temperature Sensor Removal Instal lation in the Fuel System DFI chapter Water Temperature Sensor Inspection e Refer to the Water Temperature Sensor Inspection in the Electrical System chapter END 5 1 Engine Top End Table of Contents Exploded View 5 2 Cylinder Head Warp Inspection 5 28 Exhaust System Identification 5 6 EN NV A 5 29 Specifications 5 8 Valve Clearance Inspection 5 29 Special Tools and Sealant 5 10 Valve Clearance Adjustment 5 29 Clean Air System
421. ning Lift 58 62 C 136 144 F 8 mm 0 31 in or more at 75 C 167 F COOLING SYSTEM 4 7 Special Tools Bearing Driver Set Oil Seal Driver 37 5 57001 1129 57001 1660 7571129ST C ST571660ST 6 4 8 COOLING SYSTEM Coolant Coolant Deterioration Inspection e Remove the right middle fairing see Middle Fairing Re moval in the Frame chapter e Visually inspect the coolant A in the reserve tank If whitish cotton like wafts are observed aluminum parts in the cooling system are corroded If the coolant is brown iron or steel parts are rusting In either case flush the cooling system xIf 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 in the Periodic Maintenance chapter Coolant Draining e Refer to the Coolant Change in the Periodic Maintenance chapter Coolant Filling e Refer to the Coolant Change in the Periodic Maintenance chapter Pressure Testing e Remove the right middle fairing see Middle Fairing Re moval in the Frame chapter e Remove the radiator cap and install a cooling system pressure tester A on the filler neck B NOTE OWet the cap sealing surfaces with water or coolant to prevent pressure leaks e Build up pressure in the system carefully until the pres sure reaches 123 kPa 1 25 kgf cm 18 psi NOTICE
422. nnect a digital meter to the terminals A of the injector e Measure the fuel injector resistance Fuel Injector Resistance Connections For Fuel Injector 1 W R lt BL BK terminal For Fuel Injector 2 W R BL R terminal For Fuel Injector 3 W R BL O terminal For Fuel Injector 4 W R BL G terminal Standard About 11 7 12 3 O at 20 C 68 F x If the reading is out of the standard replace the injector 3 110 FUEL SYSTEM Fuel Injectors Fuel Injector Power Source Voltage Inspection NOTE sure the battery is fully charged e Remove the air cleaner housing see Air Cleaner Housing Removal e Turn the ignition switch to OFF e Disconnect the injector connector and connect the mea suring adapter A between these connectors as shown Main Harness B Fuel Injector 1 C Special Tool Measuring Adapter 57001 1700 e 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 Battery 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 If the reading is not the standard check the ECU main relay and f
423. nnectors Wiring Continuity Inspection ECU Connector A Intake Air Pressure Sensor 1 Connector B BL lead ECU terminal 4 C G lead ECU terminal 49 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 9617111251 C 3 50 FUEL SYSTEM DFI 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 lead Digital Meter gt BK sensor lead e Measure the output voltage with the engine stopped and with the connector joined Turn the ignition switch to ON 6c17112FS1 Output Voltage Usable Range DC 3 80 4 20 at standard atmospheric 101 32 76 cmHg OThe output voltage changes according to local atmo spheric pressure e Turn the ignition switch t
424. nsor 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 and or idle adjusting screw maladjusted 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 air mixture incorrect Bypass screw maladjusted Air passage clogged Air bleed pipe bleed holes 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 cleaner duct loose Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Pisto
425. nstal lation in the Steering chapter e Adjust the steering see Steering Play Adjustment 2 42 PERIODIC Maintenance Procedures Electrical System Lights Switches Operation Inspection First Step e Set the gear position in the neutral position e Turn the ignition switch to ON e Thefollowing lights should go on according to below table City Light A goes on Taillight B goes on License Plate Light C Meter Panel LCD D Green Neutral Indicator Light LED E Warning Symbol and Red Warning Indicator Light LED F Yellow ABS Indicator Light LED G If the light does not go on inspect or replace the following item Battery see Charging Condition Inspection in the Elec trical System chapter Main Fuse 30 A and Brake Light Horn Fuse 10 A see Fuse Inspection in the Electrical System chapter Applicable Bulb see Wiring Diagram in the Electrical System chapter Meter Unit for Meter Panel LCD see Electronic Com bination Meter Unit Inspection in the Electrical System chapter Meter Unit for Green Neutral Indicator Light LED see Meter Unit Inspection in the Electrical System chapter Meter Unit for Red Warning Indicator 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 Neutral Swi
426. nto the impeller by pressing them by hand until the seat stops at the bottom of the hole e Install the water pump impeller see Water Pump Instal lation Water Pump Impeller Inspection e Remove the water pump cover see Water Pump Re moval e Visually inspect the water pump impeller A x If the surface is corroded or if the blades are damaged replace the impeller Water Pump COOLING SYSTEM 4 13 Water Pump Housing Disassembly NOTICE Do not damage the hole wall of the water pump housing e Insert a bar A into the pump housing B and hammer evenly around the circumference of the mechanical seal bottom C e Take the oil seal A out of the housing B with a hook C Water Pump Housing Assembly Do not reuse the mechanical seal and oil seal e Apply high temperature grease to the oil seal lips A e Press the new oil seal into the housing with a bearing driver B until it stops at the bottom surface C of the housing Special Tool Bearing Driver Set 57001 1129 Be careful not to damage the sealing surface of the mechanical seal e Press the new mechanical seal into the housing with the oil seal driver A until its flange B touches the surface C of the housing Special Tool Oil Seal Driver 37 5 57001 1660 Mechanical Seal Inspection e Remove the water pump impeller see Water Pump Re moval e Visually inspect the mechanical seal x If any one of the parts is dam
427. nto the inner tube Dust Seal Retaining Ring Oil Seal Washer F Outer Tube Guide Bushing Inner Tube Guide Bushing e Insert the inner tube to the outer tube e Fit the new outer tube guide bushing A into the outer tube NOTE OWhen assembling the new outer tube guide bushing hold the washer against the new outer tube guide bush ing and tap the washer with the fork oil seal driver B until it stops Special Tool Fork Oil Seal Driver 643 57001 1530 e Install the oil seal by using the fork oil seal driver Special Tool Fork Oil Seal Driver 643 57001 1530 e Install the retaining ring and dust seal into the outer tube e Pour the specified type of oil see Fork Oil Change Front SUSPENSION 13 23 Inner Tube Outer Tube Inspection e Visually inspect the inner tube A and repair any dam age e Nick or rust damage can sometimes be repaired by using a wet stone to remove sharp edges or raised areas which cause seal damage xIf the damage is not repairable replace the inner tube Since damage to the inner tube damages the oil seal replace the oil seal whenever the inner tube is repaired or replaced NOTICE If the inner tube is badly bent or creased replace it Excessive bending followed by subsequent straightening can weaken the inner tube e Temporarily assemble the inner tube A and outer tube B and pump C them back and forth manually to check fo
428. nuity of the BK O lead and W G lead Special Tool Hand Tester 57001 1394 Rear Wheel Rotation Sensor Lead Connector A ABS Hydraulic Unit Lead Connector B BK O Lead Terminals C W GK Lead terminals D x If the wiring is open replace or repair the harness see ABS System Wiring Diagram x If the wiring is good go to next step e Recheck the service code indication erase the service code perform the pre diagnosis inspection 1 and 2 and retrieve the service code x If the yellow ABS indicator light LED A lights replace the rear wheel rotation sensor see Rear Wheel Rotation Sensor Removal x Still when it is not good replace the ABS hydraulic unit x If the yellow ABS indicator light LED does not light ABS system is normal service code is not stored temporary failure Power Supply Voltage Abnormal Low Voltage Service Code 52 e Check Battery Condition see Charging Condition Inspection in the Electrical System chapter Charging Voltage see Charging Voltage Inspection in the Electrical System chapter x If the battery and charging voltage are good condition go to next step GL14580BS1 GL14588BS1 C GL14580BS1 Anti Lock System BRAKES 12 49 e Recheck the service code indication erase the service code perform the pre diagnosis inspection 1 and 2 and retrieve the service code x If the yellow ABS indicator light LED A lights the AB
429. o OFF x If the reading is out of the usable range replace the sen Sor x If the reading is within the usable range remove the ECU and check the wiring for continuity between main harness connector Special Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor connectors Wiring Continuity Inspection ECU Connector A Intake Air Pressure Sensor 1 Connector B YIBL lead ECU terminal 18 C G lead ECU terminal 49 D 9617113251 C FUEL SYSTEM 3 51 Intake Air Pressure Sensor 1 Service Code 12 x If the wiring is good check the sensor for various vacuum e Remove the intake air pressure sensor 1 A and discon nect the vacuum hose from the sensor e 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 57001 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 9617114732 the fork oil level g
430. o the seat outside diameter measurement step above x If the seat width is too wide make the 60 A grind de scribed below x If the seat width is within the specified range lap the valve to the seat as described below e Grind the seat at a 60 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 the 60 grind return to the seat width mea surement step above Correct Width B GE15012281 GE15012381 C ENGINE TOP END 5 35 Valves e Lap the valve to the seat once the seat width and outside diameter are within the ranges specified above OPut a little coarse grinding compound on the face of the valve in a number of places around the valve head OSpin the valve against the seat until the grinding com pound produces a smooth matched surface on both the seat and the valve ORepeat the process with a fine grinding compound Lapper A Valve Seat B Valve C e The seating area should be marked about in the middle of the valve face x If the seat area is not in the right place on the valve check to be sure the valve is the correct part If it is it may have been refaced too much replace it e Be sure to remove all grinding compound before assem bly e When the engine is assembled be sure to adjust the valve cle
431. odic Maintenance Procedures brake fluid to the new parts to the inner wall of the cylinder e Take care not to scratch the piston or the inner wall of the cylinder e Apply silicone grease to the contact portion of the push rod and brake lever pivot bolt e Tighten Torque Brake Lever Pivot Bolt 1 0 0 10 kgf m 8 9 in Ib Brake Lever Pivot Bolt Locknut 5 9 0 60 kgf m 52 in Ib Caliper Rubber Parts Replacement Front Caliper Disassembly e Loosen the front caliper assembly bolts A and tighten it loosely e Remove Front Caliper see Front Caliper Removal in the Brakes chapter Front Brake Pads see Front Brake Pad Removal in the Brakes chapter e Remove the front caliper assembly bolts A and split the caliper e Remove the O ring B on the oil passage of the caliper half 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 39 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 rubber gasket Block the hose joint opening E during this operation if the caliper half has the opening Bolt F and Nut Push down A WARNING The piston in the brake caliper can crush hands and fingers Never place your hand or
432. of clean cloth to prevent fuel spillage e Check the injector fuel line for leakage as follows OConnect a commercially available vacuum pressure pump A to the nipple of the delivery pipe B with the fuel hose C both ends with the clamps D as shown in the figure Lower Side View E OApply soap and water solution to the areas F as shown in the figure OWatching the pressure gauge squeeze the pump lever G and build up the pressure until the pressure reaches the maximum pressure 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 fuel line is leaking Replace the delivery pipe assy injectors and related parts ORepeat the leak test and check the fuel line for no leak age e Install Fuel Hose see Fuel Hose Replacement in the Periodic Maintenance chapter Fuel Tank see Fuel Tank Installation e Confirm that the drain hose and clamp are installed se curely and run the hose correctly see Cable Wire and Hose Routing section in the Appendix chapter e Start the engine and check for fuel leakage 8017614 52 C Fuel Injectors FUEL SYSTEM DFI 3 113 Fuel Injector Circuit
433. oing 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 62118997 118918 P 62118919 Electric Starter System ELECTRICAL SYSTEM 16 53 Brush Lead Inspection e Using the x 1 O hand tester range measure the resis tance as shown Right hand End Cover and Negative Brushes A Terminal Bolt and Positive Brushes B Special Tool Hand Tester 57001 1394 x If there is not close to zero ohms the brush lead has an open Replace the brush plate assy Right hand End Cover Inspection e Using the highest hand tester range measure the resis tance as shown Terminal Bolt and Right hand End Cover A Terminal Bolt and Negative Brushes B Special Tool Hand Tester 57001 1394 If there is any reading the brush assy and or terminal bolt assy have a short Replace the starter motor Starter Relay Inspection e Remove Battery Negative Cable see Battery Removal e Remove the cable terminal cover A e Disconnect Connector A Cable Terminals B e Remove Starter Relay C 16 54 ELECTRICAL SYSTEM Electric Starter System e Connect the hand tester A and 12 V battery B to the starter relay C as shown i
434. oltage no signal wiring short or open the ECU continuously to the stick shuts off the injector 1 to stop fuel to the coil cylinder 1 though the engine keeps running The ECU sends If the stick coil 2 primary winding has failures 52 Stick Coil 2 signals output voltage no signal wiring short or open the ECU continuously to the stick shuts off the injector 2 to stop fuel to the coil cylinder 2 though the engine keeps running The ECU sends If the stick coil 3 primary winding has failures 53 Stick Coil 3 signals output voltage no signal wiring short or open the ECU continuously to the stick shuts off the injector 3 to stop fuel to the coil cylinder 3 though the engine keeps running The ECU sends If the stick coil 4 primary winding has failures 4 4x Signals output voltage no signal wiring short or open the ECU 92 Stick Golya continuously to the stick off the injector 4 to stop fuel to the Coil cylinder 4 though the engine keeps running When the relay OFF 56 ran condition the fan relay is y open Subthrottle The actuator operates If the subthrottle valve actuator fails the 62 Valve open and close of the signal is out to the usable range wiring short Actuator subthrottle valve by the or open the ECU stops the current to the pulse signal from the ECU actuator The air switching valve Air Switchin controls the flow of the 64 Valve 9 secondary air by opening and shu
435. olts Suspension Front Fork Clamp Bolts Rear Shock Absorber Bolt and Nut Swingarm Pivot Shaft Locknut Swingarm Pivot Shaft Nut Tie Rod Nuts Rocker Arm Nut Steering Handlebar Holder Bolts Handlebar Holder Mounting Bolts and Nuts Steering Stem Head Bolt Others Footpeg Bracket Bolts Front Fender Bolts Sidestand Bolt 2 50 PERIODIC Periodic Maintenance Procedures 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 e Remove Fuel Tank see Fuel Tank Removal in the Fuel System DFI chapter Connector Bracket A Screws B Upper Air Cleaner Housing C e Discard the air cleaner element A e Install a new element so that flat side faces forward e Tighten Torque Upper Air Cleaner Housing Screws 1 1 N m 0 11 kgf m 1 0 in Ib Fuel Hose Replacement e Remove the fuel tank see Fuel Tank Removal in the Fuel System DFI chapter PERIODIC MAINTENANCE 2 51 Periodic Maintenance Procedures e Be sure to place a piece of cloth around the fuel hose joint
436. on Measure the diameter of each shift fork guide pin A and measure the width of each shift drum groove B xIf the guide pin any shift fork is less than the service limit the fork must be replaced Shift Fork Guide Pin Diameter Standard 6 9 7 0 mm 0 272 0 276 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 Service Limit 7 3 mm 0 287 in 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 9113484851 9113485851 9113486851 9 40 CRANKSHAFT TRANSMISSION Ball Bearing Needle Bearing and Oil Seal Ball and Needle Bearing Replacement Do not remove the ball or needle bearings unless it is necessary Removal may damage them e Using a press or puller remove the ball bearing and or needle bearings NOTE the absence of the above mentioned tools satisfac tory results may be obtained by heating the case to ap proximately 93 C 200 F max and tapping the bearing in or out NOTICE Do not heat the case with a torch This will warp the case Soak the case in oil and heat the oil e Using a press and the bearing driver set A install the new ball bearing until it
437. on Type Wheel Travel Rear Suspension Type Wheel Travel Brake Type Front Rear Tubular diamond 27 107 4 21 Tubeless 120 70 ZR17 M C 58W J17M C x MT3 50 Tubeless 180 55 ZR17 M C 73W J17M C x MT5 50 Telescopic fork upside down 150 mm 5 91 in Swingarm 150 mm 5 91 in Dual discs Single disc 1 10 GENERAL INFORMATION General Specifications Items KLZ1000AC Electrical Equipment Battery 12V8 Ah Headlight Type Semi sealed beam High Beam 12V 55 W Low Beam 12 V 55 W Tail Brake Light LED Alternator Type Three phase AC Specifications are subject to change without notice and may not apply to every country for Units GENERAL INFORMATION 1 11 Unit Conversion Table Units of Length Tun E km x 0 6214 mile mega x 1 000 000 m EM c PEE kilo x 4 000 mm x 0 03937 in centi x 0 01 milli x 0 004 Units of Torque micro x 0 000001 Nim we AOE N m x 07376 ftlb N m x 8 851 Units of Mass 9 807 Nm kg x 2 205 Ib x 7 233 9 0 03527 OZ 86 80 in Ib Units of Volume Units of Pressure L x 0 2642 05 0 01020 kgf cm L x 0 2200 gal IMP kPa x 0 1450 psi L x 1 057 qt US kPa x 0 7501 cmHg L x 0 8799 qt IMP kgf cm x 98 07 kPa L x 2 113 pint US kgf cm x 14 22 L x 1 816 pint IMP cmHg x 1 333 kPa mL x 0 03381 oz U
438. onnect the fuel pump lead connector A e Remove the breather hose A and clamp Fuel Tank FUEL SYSTEM DFI 3 123 e Open the fuel tank cap A to lower the pressure in the tank ODuring tank removal keep the tank cap open to release pressure in the tank This makes fuel spillage less e Draw the fuel out from the fuel tank with a commercially available pump A OUse a soft plastic hose B as a pump inlet hose in order to insert the hose smoothly OPut the hose through the fill opening C into the tank and draw the fuel out A WARNING Spilled fuel is flammable and can be explosive un der certain conditions The fuel can not be removed completely from the fuel tank Be careful for re mained fuel spillage e Remove the both side cover see Side Cover Removal in the Frame chapter e Lift up the fuel tank and support it with a suitable bar A e Be sure to place a piece of cloth around the fuel hose joint e Insert a thin blade screwdriver A into the slit B on the joint lock C e Pry the screwdriver to disconnect the joint lock 6609100851 C 3 124 FUEL SYSTEM Fuel Tank e Pull A the fuel hose joint B out of the 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 fu
439. ontact 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 e Remove the electrolyte container from the vinyl bag e Detach the strip of caps A from the container and set aside these will be used later to seal the battery NOTE ODo not pierce or otherwise open the sealed cells B of the electrolyte container Do not attempt to separate individual cells e Place the electrolyte container upside down with the six sealed cells into the filler ports of the battery Hold the container level push down to break the seals of all six cells You will see air bubbles rising into each cell as the ports fill NOTE ODo not tilt the electrolyte container ME02112BS1 GP08139BS1 C ffe L 8 09000751 C 16 26 ELECTRICAL SYSTEM Battery e Check the electrolyte flow If no air bubbles A are coming up from the filler ports or if the container cells have not emptied completely tap the container B a few times NOTE OBe careful not to have the battery fall down e Keep the container in place Don t remove the container from the battery the battery
440. or Input Voltage Inspection 3 44 Main Throttle Sensor Output Voltage Inspection 3 45 Main Throttle Sensor Resistance Inspection 3 47 Intake Air Pressure Sensor 1 Service Code 12 3 48 Intake Air Pressure Sensor 1 3 48 Intake Air Pressure Sensor 1 3 48 Intake Air Pressure Sensor 1 Input Voltage 3 49 Intake Air Pressure Sensor 1 Output Voltage 3 50 Intake Air Temperature Sensor Service Code 13 3 54 Intake Air Temperature Sensor 3 54 Intake Air Temperature Sensor Output Voltage 3 54 Intake Air Temperature Sensor Resistance 3 55 Water Temperature Sensor Service Code 14 3 57 Water Temperature Sensor Removal Installation 1 3 57 Water Temperature Sensor Output Voltage 3 57 Water Temperature Sensor Resistance 3 58 Intake
441. or bolt C Special Tool Flywheel amp Pulley Holder 57001 1605 Timing Rotor Installation e Install the timing rotor A with the their theeth B aligned e Tighten Torque Timing Rotor Bolt 39 N m 4 0 kgf m 29 ft Ib Special Tool Flywheel amp Pulley Holder 57001 1605 Stick Coil Removal Never drop the stick coils especially hard sur face Such a shock to the stick coils can damage it e Remove Air Cleaner Housing see Air Cleaner Housing Removal in the Fuel System DFI chapter e Disconnect the stick coil connectors A e Pull the stick coils B NOTICE Do not pry the connector part of the coil while re moving the coil Stick Coil Installation e Pull up the rubber cover forward 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 Do not tap 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 Reposition the rubber cover and connect the stick coil connectors e Run the hoses and harness correctly see Cable Wire and Hose Routing section in the Appendix chapter NOTE careful not to tight the stick coil leads NW s e Install the removed parts see approp
442. ot 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 and 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 6517036851 DFI Precautions FUEL SYSTEM DFI 3 23 OIf the motorcycle is not properly handled the high pres sure inside the fuel line can cause fuel to leak or the hose to burst Remove the fuel tank see Fuel Tank Removal and check the fuel hose A Replace the fuel hose if any fraying cracks or bulges are noticed 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 3 24 FUEL SYSTEM DFI Troubleshooting the DFI System The red warning indicator light LED A is used for the immobilizer indicator equipped model battery wa
443. ot operate the vehicle and service the brake system immediately NOTE OThe procedure to bleed the front brake line is as follows Bleeding the rear brake line is the same as for the front brake e Remove the reservoir cap A and diaphragm e Fill the reservoir with fresh brake fluid to the upper level line in the reservoir e Slowly pump the brake lever several times until no air bubbles can be seen rising up through the fluid from the holes at the bottom of the reservoir OBleed the air completely from the master cylinder by this operation e Remove the rubber cap from the bleed valve A on the caliper e Attach a clear plastic hose B to the bleed valve and run the other end of the hose into a container Fluid BRAKES 12 23 e Bleed the brake line and the caliper ORepeat this operation until no more air can be seen com ing out into the plastic hose 1 Pump the brake lever until it becomes hard and apply the brake and hold it A 2 Quickly open and close B the bleed valve while hold ing the brake applied 3 Release the brake C NOTE OThe fluid level must be checked often during the bleed ing operation and replenished with fresh brake fluid as necessary If the fluid in the reservoir runs completely out any time during bleeding the bleeding operation must be done over again from the beginning since air will have entered the line OTap the brake hose lightly from the calip
444. ove the pad A and brake pads B Rear Brake Pad Installation e Check that the pad springs A B are in place on the caliper or bracket e Push the caliper piston in by hand as far as it will go e Pull up the caliper install the brake pads A and pad pin B OFit the projections C of the brake pad into the recesses D of the caliper bracket e Tighten Torque Rear Caliper Mounting Bolt 22 2 2 kgf m 16 ft Ib Rear Brake Pad Pin 17 N m 1 7 kgf m 13 ft lb Rear Brake Pad Pin Plug 2 5 N m 0 25 kgf m 22 in Ib A WARNING After servicing it takes several applications of the brake pedal before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the motorcycle until a firm brake pedal is obtained by pumping the pedal until the pads are against the disc Brake Pad Wear Inspection e Refer to the Brake Pad Wear Inspection in the Periodic Maintenance chapter 12 18 BRAKES Master Cylinder Front Master Cylinder Removal e Remove the rear view mirror see Rear View Mirror Re moval in the Frame chapter e Remove the banjo bolt to disconnect the brake hose from the master cylinder see Brake Hose Removal Installa tion e Unscrew the clamp bolts A and take off the master cylin der B as an assembly with the reservoir brake lever and brake switch installed e D
445. ow Chart Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corro sion 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 100 C 212 F the radiator fan relay conducts to operate the radiator fan The radiator fan draws air through the radiator core when there is not suffi cient air flow such as at low speeds This increases up the cooling action of the radiator When the coolant temperature is below 97 5 C 208 F the fan relay opens and the radiator fan stops In this way this system controls the engine temperature within narrow limits where the engine op erates most efficiently even if the engine load varies The system is pressurized by the radiator cap to suppress boiling and the resultant air bubbles which can cause engine overheating As the engine warms up the coolant in the radiator and the water jacket expands The excess coolant flows throu
446. pecifications Standard Service Limit Cylinder Pistons Cylinder Inside Diameter 76 990 77 006 mm 3 0311 3 0317 in 77 09 mm 3 035 in Piston Diameter 76 974 76 984 mm 3 0305 3 0309 in 76 82 mm 3 024 in Piston Cylinder Clearance 0 010 0 032 mm 0 0004 0 0013 in Piston Ring Groove Clearance Top 0 03 0 07 mm 0 0012 0 0028 in 0 17 mm 0 0067 in Second 0 02 0 06 mm 0 0008 0 0024 in 0 16 mm 0 0063 in Piston Ring Groove Width Top 0 82 0 84 mm 0 0323 0 0331 in 0 92 mm 0 0362 in Second 0 81 0 83 mm 0 0319 0 0327 in 0 91 mm 0 0358 in Piston Ring Thickness Top 0 77 0 79 mm 0 0303 0 0311 in 0 70 mm 0 028 in Second 0 77 0 79 mm 0 0303 0 0311 in 0 70 mm 0 028 in Piston Ring End Gap Top 0 20 0 30 mm 0 0079 0 0118 in 0 6 mm 0 024 in Second 0 38 0 48 mm 0 0150 0 0189 in 0 8 mm 0 031 in 5 10 END Special Tools Sealant Compression Gauge 20 kgf cm 57001 221 7570221ST C Valve Spring Compressor Assembly 57001 241 7570241ST C Piston Pin Puller Assembly 57001 910 7570910ST C Valve Seat Cutter 45 627 5 57001 1114 875711145 C Valve Seat Cutter 45 532 57001 1115 ST571115ST C Valve Seat Cutter 32 528 57001 1119 Valve Seat Cutter Holder Bar 57001 1128 ST571119ST C 7571128ST C Valve Seat Cut
447. pection 2 34 Brake Hose and Pipe Damage and Installation Condition Inspection 2 35 Brake Operation Inspection pp 2 35 Brake Fluid Level nemen 2 36 Brake Pad Wear Inspection pp 2 37 Brake Light Switch Operation Inspection 2 0440 49 0 6 00 2 37 RII IE 2 38 Front Forks Rear Shock Absorber Operation Inspection 2 38 Front Fork Oil Leak 2 38 Rear Shock Absorber Oil Leak Inspection 2 39 Rocker Arm Operation 2 39 Tie Rod Operation Inspection 1 0206 0 000000000000000000000000000000000000000044443 2 39 Inge DES 2 39 Steering ay Inspectionm m 2 39 Steering Play Adjustment ianei e aaaea aaae daaa iE AEEA iaai Tenai ie 2 40 Steering Stem Bearing Lubrication 2 4 1111 111 2 41 ey Te fe estu peer PCT 2 42 2 2 PERIODIC MAINT ENANCE Lights and Switches Operation Headlight Aiming Inspecti op TED Sidestand Switch Operation Engine Stop Switch Operation Inspection pp de coiere RE Chassis Parts Lubrication Bolts Nuts and Faste
448. pening A of the reed faces the front and downward e Install the bracket A as shown in the figure 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 GE04099BS1 C Clean Air System ENGINE TOP END 5 13 Air Suction Valve Inspection e Remove the air suction valve see Air Suction Valve Re moval e Visually inspect the reeds A for cracks folds warps heat damage or other damage x If there is any doubt as to the condition of the reeds re place the air suction valve as an assembly e Check the reed contact areas B of the valve holder for grooves scratches any signs of separation from the holder or heat damage x If there is any doubt as to the condition of the reed contact areas replace the air suction valve as an assembly If any carbon or other foreign particles have accumulated between the reed and the reed contact area wash the valve assembly clean with a high flash point solvent 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 NOTICE Never drop the air switching valve especially on a hard surface Such a shock to the air switching valve can damaged it e Remove the stick coils see Stick Coil Removal in the Electrical System chap
449. pistons and push them into each cylinder by hand e Be sure to install the O ring e Tighten Torque Front Caliper Assembly Bolts 22 N m 2 2 kgf m 16 ft Ib 9513262851 e Install the brake pads see Front Brake Pad Installation in the Brakes chapter e Wipe up any spilled brake fluid on the caliper with wet cloth 2 62 PERIODIC Periodic Maintenance Procedures Rear Caliper Disassembly e Remove Brake Pads see Rear Brake Pad Removal in the Brakes chapter Rear Caliper see Rear Caliper Removal in the Brakes chapter e Remove the pad spring A 65130350 e Remove Dust Boot A Sleeve B e Using compressed air remove the piston OCover the caliper opening with a clean heavy cloth C ORemove the piston by lightly applying compressed air D to where the brake line fits into the caliper A WARNING The piston in the brake caliper can crush hands and 65130351 P fingers Never place your hand or fingers in front of the piston e Remove the dust seal and fluid seal e Remove the bleed valve and rubber cap NOTE Olf compressed air is not available do as follows with the brake hose connected to the caliper OPrepare a container for brake fluid and perform the work above it ORemove the 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 part
450. pply to Rear Wheel Rotation Sensor W G Rear Wheel Rotation Sensor Signal Input BK O Unused Rear Wheel Rotation Sensor Signal Output R Y Yellow ABS Warning Indicator Light BL Y Power Supply to ABS Motor Relay R W 12 30 BRAKES Anti Lock Brake System 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 to ON while any of the ABS electrical connectors are disconnected The ABS hydraulic unit memorizes service codes ODo not spray water on the electrical parts ABS parts con nectors leads and wiring olf a transceiver is installed on the motorcycle make sure that the operation of the ABS system is not influenced by electric wave radiated from the antenna Locate the antenna as far as possible away from the ABS hydraulic unit OWhenever the ABS electrical connections are
451. procedures within the registration mode 0 2second Ahn OHF MAAA 8 30025651 C gt gt ON LILI LILI 8 30024651 C 0 3second UUU GP30026CS1 0 5second 0 pe 19 GP30024CS1 Immobilizer System Equipped Models ELECTRICAL SYSTEM 16 87 e Insert the ignition key 2 to the ignition switch and turn it to ON Olf there is any problem in the registration the red warning indicator light LED and the immobilizer warning symbol A blink 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 the immobilizer warning symbol A blink 4 times and stop for 1 second and then repeat this cycle OThis procedure has registered the 2 ignition keys e Continue with the procedure if neccesary to register an additional one ignition key NOTE OThe ECU can store up the five key codes Ignition Key Indicator Blinks Indicator Light Stops 1 second Indicator Light Blinks 5 times Remarks Ignition Key 3 Repeat e Turn to OFF the ignition switch and wait for period of more than 15 seconds The registration mode automatically ends
452. r W sensor Y G lead Digital Meter gt BK sensor lead e 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 NOTE Olf you need to test again turn the ignition switch OFF and then ON e Turn the ignition switch to OFF x If the reading is out of the standard replace the sensor 8017125 81 C 9017786652 C Vehicle down Sensor Service Code 31 FUEL SYSTEM DFI 3 71 If the reading is within the standard remove the ECU and check the wiring for continuity between main harness con nectors ODisconnect the ECU and sensor connectors Wiring Inspection ECU Connector A Vehicle down Sensor Connector B lead ECU terminal 19 C G lead ECU terminal 49 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 Vehicle down Sensor Circuit GC17126FS1 GC
453. r B e Set the hand tester to the x 1 kO range and make the measurements shown in the table Special Tool Hand Tester 57001 1394 e Connect the hand tester to the regulator rectifier xIf the tester readings are not as specified replace the regulator rectifier Use only Kawasaki Hand Tester 57001 1394 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 regulator rectifier will be damaged Regulator Rectifier Resistance Unit Tester Lead Connection Terminal W BK1 BK2 BK3 BK Y 20 200 20 750 20 200 20 750 20 200 20 750 BK1 0 5 BK2 0 5 20 300 0 5 20 300 20 300 Tester Lead Connection e Install the regulator rectifier 62090132 P BK Y GP09184BS1 BK3 BK2 BK 1 W o 16 38 ELECTRICAL SYSTEM Charging System Charging System Circuit sili BATTERY j w GP093388W2 C lgnition Switch Frame Ground 2 Engine Ground Battery 12 V 8 Ah Starter Relay Main Fuse 30 Alternator Regulator Rectifier Load Ignition System ELECTRICAL SYSTEM 16 39 A WARNING The ignition system produces extremely high volt age Do nottouch the spark plug ignition coil or ig nition coil lead while the engine is running or you
454. r Installation e Install the camshaft caps and upper camshaft chain guide A as shown in the figure Identification No 1 4 Camshaft Cap B eFirst tighten the all camshaft cap bolts and upper camshaft chain guide bolts evenly to seat the camshaft in place then tighten all bolts following the specified tightening sequence Torque Camshaft Cap Bolts 1 18 12 1 2 kgf m 106 in Ib Upper Camshaft Chain Guide Bolts 19 20 12 N m 1 2 kgf m 106 in Ib 9 5 8 6 G 0 2 9 07 jim LM cy DR Dy 20 00 0 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 cylinder head cover see Cylinder Head Cover Installation GE113368W2 Camshaft Camshaft Chain ENGINE TOP END 5 23 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 Measure each clearance between the camshaft journal and the camshaft cap using plastigage A e Tighten the camshaft cap bolts see Camshaft Installa tion NOTE ODo not turn the camshaft when the plastigage is b
455. r Resistance HB80 2237 about 6 544 1 136 0095 0 1553 10 0070 Reference Information Oxygen Sensor Removal Never drop the sensor especially on a hard surface Such a shock to the sensor can damage it NOTICE Do not pull strongly twist or bend the oxygen sen sor lead This may cause the wiring open e Clear the oxygen sensor lead from the clamp A e Disconnect the oxygen sensor lead connector B e Remove the right lower fairing see Lower Fairing Re moval in the Frame chapter e Clear the oxygen sensor lead from the clamp A e Remove the oxygen sensor B 16 108 ELECTRICAL SYSTEM Switches and Sensors Oxygen Sensor Installation Never drop the oxygen sensor A especially on a hard surface Such a shock to the unit can damage it Do not touch the sensing part B and filter holes C of the sensor to prevent oil contact Oil contami nation from hands can reduce sensor performance e Tighten Torque Oxygen Sensor 44 N m 4 5 kgf m 32 ft Ib e Run the oxygen sensor lead correctly see Cable Wire and Hose Routing section in the Appendix chapter Oxygen Sensor Inspection e Referto the Oxygen Sensor Inspection in the Fuel System DFI chapter Outside Temperature Sensor Removal e Remove Left Upper Side Fairing see Upper Side Fairing Re moval in the Frame chapter Connector A Disconnect Screw B Outside Temperature Sensor C Ou
456. r Resistance Outside Temperature Sensor Resistance Fuel Level Sensor Resistance Full Position Empty Position ON after about 10 mm 0 39 in pedal travel When engine is stopped ON When engine is running OFF in the text 5 4 6 6 at 0 C 32 F 0 29 0 39 at 80 C 176 F 9 6 12 4 Q 222 228 ELECTRICAL SYSTEM 16 11 Special Tools and Sealant Hand Tester 57001 1394 7571394ST C Peak Voltage Adapter 57001 1415 875714155 C Lead Wire Peak Voltage Adapter 57001 1449 7571449ST C Needle Adapter Set 57001 1457 T571457ST C Key Registration Unit 57001 1582 N 875715825 C Grip 57001 1591 875715915 C Flywheel amp Holder 57001 1605 1571605 C Flywheel Assembly 38 x 1 5 35 1 5 57001 1615 8 5716155 C 875716795 6 57001 1679 Rotor Holder 57001 1690 ST571690ST 16 12 ELECTRICAL SYSTEM Special Tools and Sealant Key Registration Adapter 57001 1746 Rotor Holder 57001 1757 e 8757174697 6 875717575 6 Liquid Gasket TB1211F 92104 0004 879200045 Location ELECTRICAL SYSTEM 16 13 Timing Rotor Crankshaft Sensor Oxygen Sensor Horn BROWN Relay Box ECU Fuse Box 1 Fuse Box 2
457. r grooves in the bearing outer races When they are properly matched there is no clearance A be tween the crankcase and the bearing outer races e Assemble the crankcase see Crankcase Assembly e Using a high flash point solvent clean off any oil or dirt from the outer circumference of the oil seal A and its matching surfaces of the crankcases Wipe the solvent with a clean cloth e Apply high temperature grease to the oil seal lips e Insert the collar B into the oil seal e Press in the oil seal into the crankcase so that the surface of the oil seal is flush with the surface C of the crankcase Transmission Shaft Disassembly e Remove the transmission shafts see Transmission Shaft Removal e Remove the circlips and disassemble the transmission shafts Special Tool Outside Circlip Pliers 57001 144 e The 5th gear A on the output shaft has three steel balls assembled into it for the positive neutral finder mecha nism Remove the 5th gear OSet the output shaft in a vertical position holding the 3rd gear B OSpin the 5th gear quickly C and pull it off upward lt fie J ey MW SML 6113082B CRANKSHAFT TRANSMISSION 9 33 Transmission e Remove the ball bearing A from each shafts Special Tools Bearing Puller C 57001 135 Bearing Puller Adapter D 57001 317 e Discard the bearing OFor output shaft remove the collar B together with the ball
458. r head with a torch This will warp the cylinder head Soak the cylinder head in oil and heat the oil Special Tool Valve Guide Arbor 4 5 57001 1331 GE15043BS1 C GE15028BS1 C GE15045BS1 C 5 30 END Valve Guide Installation e Apply oil to the valve guide outer surface before installa tion e Heat the area around the valve guide hole to about 120 150 C 248 302 F Do not heat the cylinder head with a torch This Will warp the cylinder head Soak the cylinder head and heat the oil e Using the valve guide driver A and two washers B press and insert the valve guide in until the valve guide driver surface C touches the head surface D 12 8 13 0 mm 0 504 0 512 in E Special Tools Valve Guide Driver 57001 1564 Washer 57001 1612 e Ream the valve guide with valve guide reamer A even if the old guide is reused Special Tool Valve Guide Reamer 4 5 57001 1333 GE15046BS1 C ENGINE END 5 31 Valves Valve to Guide Clearance Measurement Wobble Method If a small bore gauge is not available inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below e Insert a new valve A into the guide B and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface e Mo
459. r smooth operation x If 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 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 282 mm 11 1 in Service Limit 276 mm 10 9 in GM04732BS1 GM04128BS1 C 8 04011851 C 13 24 SUSPENSION Shock Absorber Rebound Damping Force Adjustment e To adjust the rebound damping force turn the lower damping adjuster A to the desired position until you feel a click OThe standard adjuster setting is the 2 turns out from the fully clockwise position Rebound Damping Force Adjustment sne Load 3 3 4 turns out l 0
460. r tears or breaks x If the element has any tears or breaks replace the ele ment Air Cleaner Oil Draining A drain hose is connected to the bottom of the air cleaner to drain water or oil accumulated in the cleaner part e Visually check the catch tank A of the drain hose if the water or oil accumulates in the tank x If any water or oil accumulates in the catch tank remove the catch tank from the drain hose and drain it A WARNING Oil on tires will make them slippery and can cause an accident and injury Be sure to reinstall the catch tank after draining Air Cleaner Housing Removal e Remove Fuel Tank see Fuel Tank Removal Connector Bracket A Breather Hose B and Clamp e Disconnect the intake air temperature sensor connector C e Remove the bolt A FUEL SYSTEM 3 121 Air Cleaner e Loosen the air cleaner duct clamp bolt A both sides e Lift up the air cleaner housing and remove the air switch ing valve hose B e After removing the air cleaner housing cover the clean cloth on the throttle body assy A WARNING If dirt or dust is allowed to pass through into the throttle body assy the throttle may become stuck possibly causing accident Air Cleaner Housing Installation e Install the air switching valve hose A to the air cleaner housing e Install the air cleaner housing on the throttle body assy Olnstall the clamp bolt heads B outside
461. rankcase Crankshaft Connecting Rods Connecting Rod Bend Connecting Rod Twist Connecting Rod Big End Side Clearance Connecting Rod Big End Bearing Insert Crankpin Clearance Crankpin Diameter Marking None Connecting Rod Big End Inside Diameter Marking None Connecting Rod Big End Bearing Insert Thickness Brown Black Blue Connecting Rod Bolt Stretch Crankshaft Side Clearance Crankshaft 3 Main Journal Width Crankshaft Runout Crankshaft Main Bearing Insert Journal Clearance Crankshaft Main Journal Diameter Marking None 1 Crankcase Main Bearing Inside Diameter Marking None 0 13 0 38 mm 0 0051 0 0150 0 030 0 060 mm 0 0012 0 0024 34 484 34 500 mm 1 3576 1 3583 in 34 484 34 492 mm 1 3576 1 3579 in 34 493 34 500 mm 1 3580 1 3583 in 37 500 37 516 mm 1 4764 1 4770 in 37 500 37 508 mm 1 4764 1 4766 in 37 509 37 516 mm 1 4767 1 4770 in 1 478 1 483 mm 0 05819 0 05839 in 1 483 1 488 mm 0 05839 0 05858 in 1 488 1 493 mm 0 05858 0 05878 in Usable Range 0 20 0 32 mm 0 0079 0 0126 in 0 09 0 19 mm 0 0035 0 0075 in 23 49 23 54 mm 0 9248 0 9267 in TIR 0 02 mm 0 0008 in or less 0 010 0 034 mm 0 0004 0 0013 in 34 984 35 000 mm 1 3773 1 3780 in 34 984 34 992 mm 1 3773 1 3776 in 34 993 35 000 mm 1 3777 1 3780 in 38 000 38 016 mm 1 4
462. re assembled onto the out put shaft note the following OWhen the tangs A of the toothed washer shall be as sembled they should be installed into the notch B of the toothed washer see Page 9 36 e Fit the steel balls into the 5th gear holes in the output shaft aligning the hole as shown in the figure Gear A Output Shaft B Steel Balls C Hole D Do not apply grease to the balls to hold them in place This will cause the positive neutral finder mechanism to malfunction OAfter assembling the 5th gear with steel balls in place on the output shaft check the ball locking effect that the 5th gear doesn t come out of the output shaft when moving it up and down by hand e Check that each gear spins or slides freely on the trans mission shafts without binding after assembly 6113505851 C CRANKSHAFT TRANSMISSION 9 35 Transmission This page intentionally left blank 9 36 CRANKSHAFT TRANSMISSION Transmission CO 2 3 4 5 6 7 8 7 49 74249 0 9 00509 0902 9 19 ro aN 20 49 8 G3 62 G1 GO 69 8 29 52700609 000902 amp amp Transmission CRANKSHAFT TRANSMISSION 9 37 Output Shaft Collar Bearing Bushing 2nd Gear 39 T Washer 34 x 28 1 Circlips 633 x 25 9 Top Gear 23
463. re each use and change the oil and filter according to the periodic maintenance chart Oil Level Inspection e 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 warning indicator light LED and oil pressure warning symbol will blink If this blink stays on when the engine is running above idle speed stop the engine immediately and find the cause x If the oil level is too high remove the excess oil using a 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 ear
464. re peak voltage adapter R 8 10011952 C GP10283BS1 16 44 ELECTRICAL SYSTEM Ignition System A WARNING To avoid extremely high voltage shocks do not touch the spark plugs or tester connections e Turn the ignition switch and the engine stop switch 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 100 V or more e Repeat the test for the other stick coil 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 Spark Plug Condition Inspection N Remove the spark plugs see Spark Plug Replacement oa e Visually inspect the spark plugs x If the spark plug center electrode A and or side elec 7 trode B corroded damaged or if the insulator C is cracked replace the plug E the spark plug is dirtied or the carbon is accumulated replace the sp
465. rectly see Cable Wire and Hose Rout ing section in the Appendix chapter 3 126 FUEL SYSTEM DFI Fuel Tank Fuel Tank and Cap Inspection e Open the tank cap e Visually inspect the gasket A on the tank cap for any damage Replace the tank cap if gasket 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 If they are clogged remove the tank and drain it and then blow the breather free with compressed air Do not apply compressed air to the air vent holes D in the tank cap This could cause damage and clogging of the labyrinth in the cap Fuel Tank 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 COOLING SYSTEM 4 1 Cooling System Table of Contents Exploded
466. rench turn the adjusting collar D counterclockwise to make the gap between the engine and adjusting collar 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 Screw the upper adjusting collar A and lower adjusting collar B into the frame all the way e Apply a non parmanent locking agent to the threads of the middle engine bracket bolts C e Install the middle engine bracket D and tighten the bolts Torque Middle Engine Bracket Bolts 25 2 5 kgf m 18 ft lb GH04172BS2 C 8 8 ENGINE REMOVAL INSTALLATION Engine Removal Installation e Insert the lower engine mounting bolt A from the left e Insert the middle engine mounting bolt B from the left placing the collar C between the engine and frame e Install and tighten the left upper engine mounting bolts L 54 A Torque Upper Engine Mounting Bolts 44 N m 4 5 kgf m 32 ft lb Temporarily install the right upper engine mounting bolt L 65 B Tighten the lower adjusting collar A Torque Lower Adjusting Collar 9 8 1 0 kgf m 87 ft lb OBe careful not to overtighten the adjusting collar Tighten the lower adjusting collar locknut B Torque Lower Adjusting Collar Locknut 49 Nm 5 0 kgf m 36 ft lb Special Tool Engine Mount Nut Wrench C 57001 1450 Tighten the lower engine mounting nut
467. renew the cups e Check the dust covers E for damage x If they are damaged replace them e Check the piston return springs F for any damage x If the springs are damaged replace them e Check that relief port G and supply port H are not plugged x 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 ff GLO7133BS2 C Brake Disc BRAKES 12 21 Brake Disc Removal e Remove the wheels see Front Rear Wheel Removal in the Wheels Tires chapter e Unscrew the mounting bolts A and take off the disc B e Remove the gaskets Front Only Brake Disc Installation e Replace the gaskets with new ones Front Only e Install the brake disc on the wheel so that the marked side A faces out e Apply a non permanent locking agent to the threads of the front and rear brake disc mounting bolts and tighten them Torque Brake Disc Mounting Bolts 27 N m 2 8 kgf m 20 ft lb Brake Disc Wear Measure the thickness of each disc at the point where it has worn the most x If the disc has worn past the service limit replace it Measuring Area A 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 Service Limit Front 4 5 mm 0 18 in Rear 5 5 mm 0 22 in Brake Disc Warp e Raise the front rear wheel o
468. 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 e Make sure that the container cells have emptied com pletely and remove the container from the battery e Place the strip of caps A loosely over the filler ports press down firmly with both hands to seat the strip of caps into the battery don t pound or hammer When properly installed the strip of caps will be level with the top of the battery NOTICE Once the strip of caps is installed onto the battery never remove the caps nor add water or electrolyte to the battery NOTE OCharging the battery immediately after filling can shorten service life ME02114BS1 e Hm LJ LJ LJ L3 Tf GPO8012BS1 C 8 08010851 C ELECTRICAL SYSTEM 16 27 Battery Initial Charge e Newly activated sealed batteries require an initial charge Standard Charge 0 9 A x 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
469. riate chapters ELECTRICAL SYSTEM 16 43 Ignition System 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 O range and read the tester e Measure the secondary winding resistance B as follows OConnect the tester between the plug terminal and coil terminal OSet the tester to the x 1 kO range and read the tester Stick Coil Winding Resistance Primary Windings 1 1 1 50 Secondary Windings 10 8 16 2 x If the tester does not read as specified replace the coil Stick Coil Primary Peak Voltage NOTE OBe sure the battery is fully charged e Remove the stick coils see Stick Coil Removal but do not remove the spark plugs e Measure the primary peak voltage as follows Olnstall the new spark plug A into each stick coil B and ground them onto the engine OConnect the peak voltage adapter C into the hand tester D which is set to the DC 250 V range OConnect the adapter to the lead wire peak voltage adapter E which is connected between the stick coil connector and stick coil ECU F Battery Special Tools Hand Tester 57001 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Lead Wire Peak Voltage Adapter 57001 1449 Primary Lead Connection Adapter R to lead wire peak voltage adapter W Adapter BK to lead wi
470. ring seat OPump the piston rod A up and down at least ten times to expel the oil from the fork Special Tool Fork Piston Rod Puller M10 x 1 0 B 57001 1298 e Hold the fork tube upright press the outer tube A and the piston rod all the way down e Pour in the type and amount of fork oil specified Fork Oil Recommended Oli KHL15 10 or equivalent Amount Per Side When changing oil for reference Right Front Fork Approx 450 mL 15 2 US oz Left Front Fork Approx 455 mL 15 4 US oz After disassembly and completely dry Right Front Fork 528 4 mL 17 9 0 1 US oz Left Front Fork 535 4 mL 18 1 0 1 US oz 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 M10 x 1 0 A 57001 1298 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 outer tube to the oil GM04382BS1 i My lt d D Wy 8 04042851 C 6 04021351 C 13 14 SUSPENSION Front Oil Level fully compressed without spring Standard Right Front Fork 115 2 mm 4 53 0 08 in from the top
471. rmation e Turn the ignition switch to ON e Read the temperature in the display OThe display range is 40 119 C 104 247 F x If the temperature is out of the range the indication fixes the minimum value or maximum value e Disconnect the variable rheostat the water temperature symbol A and red warning indicator B blinks x If the display function does not work check the wiring see Meter Unit Circuit x If the wiring is good replace the meter unit 8 17826051 8 17826051 GP17868CS1 ELECTRICAL SYSTEM 16 73 Meter Gauge Indicator Unit Check 2 3 Battery Warning Indicator Inspection e When the battery condition is low voltage 10 8 11 2 V or less the battery symbol A and red warning indicator light LED B goes on If the battery symbol and red warning indicator light LED goes on charge the battery see Refreshing Charge xIf the battery condition is good replace the meter unit Meter Unit Inspection e Remove the meter unit see Meter Unit Removal 1 Yellow ABS Indicator Light LED 2 Green Neutral Indicator Light LED Ground 3 Blue High Beam Indicator Light LED 4 Green Right Turn Signal indicator Light LED 5 Yellow KTRC Indicator Light LED 6 Ignition 7 Battery 8 Green Left Turn Signal indicator Light LED 9 ECU Communication Pulse 10 Speed Sensor Pulse 11 Ta
472. rminal G B Output Terminal Y G C Power Source Terminal BL D Vehicle down Sensor Removal Never drop the vehicle down sensor especially on a hard surface Such a shock to the sensor can damage it e Remove Left Upper Side Fairing see Upper Side Fairing Re moval in the Frame chapter Connector A Bolts B and Nuts Vehicle down Sensor C Vehicle down Sensor Installation e Be sure to install the rubber dampers A and collars B on the upper fairing bracket GC17355BS1 C FUEL SYSTEM DFI 3 69 Vehicle down Sensor Service Code 31 e The UP mark A of the sensor should face upward 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 on the upper fairing bracket Vehicle down Sensor Input Voltage Inspection NOTE OBe sure the battery is fully charged e Turn the ignition switch to OFF e Disconnect the vehicle down sensor connector and con nectthe measuring adapter A between these connectors as shown 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
473. rn or if there are groove cuts where the tangs hit replace the housing Also replace the friction plates if their tangs are damaged Clutch Housing Spline Inspection e Visually inspect where the teeth A on the steel plates wear against the clutch hub splines B there are notches worn into the splines replace the clutch hub Also replace the steel plates if their teeth are damaged GF06060281 GF06060381 C GF06209BS1 C ENGINE LUBRICATION SYSTEM 7 1 Engine Lubrication System Table of Contents Oke Nice ET E 7 2 Engine Oil Flow dee 7 4 rd s 7 5 Special Tools and Sealants 7 6 AM 7 7 Oil Level INSpectiOn 7 7 Engine Oil rene aa e ere eee eee 7 7 Oil Filter 7 7 Bla t 7 8 OilPar ere ue 7 8 Qil Pan Installation eee Ee ee ete eee eed reet estre rere o ere eL ak 7 8 1 AT RING 7 10 Gil Screen
474. rning in dicator oil pressure warning indicator and water tempera ture warning indicator Outline When a problem occurs with DFI system the yellow en gine warning indicator light LED A goes on to alert the rider In addition the condition of the problem is stored in the memory of the ECU 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 OFor models equipped with an immobilizer system the red warning indicator light LED D and immobilizer warning symbol E blinks when a problem occurs in the system With the engine stopped and turned in the self diagnosis mode the service code A is displayed on the LCD Liquid Crystal Display by the number of two digits If the problem is with the following parts the ECU can not recognize these problem Therefore the yellow engine warning indicator light LED goes off or the red warning indicator light LED and immobilizer warning symbol do not blinks and service code is not displayed LCD for Meter Unit Fuel Pump Fuel Pump Relay Fuel Injectors Stick Coil Secondary Wiring and Ground Wiring ECU Main Relay ECU Power Source Wiring and Ground Wiring 8017099 51 C 8017209 52 C 8017101 52 C Troubleshooting the DFI System FUEL SYSTEM DFI 3 25 When the service code A is displayed for first ask the rider about the con
475. runout excessive Engine mount loose Crankshaft bearing worn Primary gear worn or chipped Camshaft chain tensioner trouble Camshaft chain sprocket guide worn Air suction valve damaged Air switching valve damaged Alternator rotor loose Catalytic converter melt down due to muffler overheating KLEEN 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 insufficient Rear wheel misaligned Abnormal Frame Noise Front fork noise Oil insufficient or too thin Spring weak or broken Rear shock absorber noise Shock absorber damaged Disc brake noise Pad installed incorrectly Pad surface glazed Disc warped Caliper trouble Other noise Bracket nut bolt etc mounted or tightened not properly APPENDIX 17 51 Red Oil Pressure Warning Indicator Light LED Goes On Engine oil pump damaged Engine oil pump incorrect assembly Engine oil screen clogged Engine oil filter clogged Engine oil level too low Engine oil v
476. s 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 Valve 7 8 0 80 kgf m 69 in Ib PERIODIC MAINTENANCE 2 63 Periodic Maintenance Procedures e Replace the fluid seal A with a new one OApply silicone grease to the fluid seal and install it into the cylinder by hand e Replace the dust seal B with a new one OApply silicone grease to the dust seal and install it into the cylinder by hand e Install the pad spring A in the caliper as shown in the figure e Apply brake fluid to the outside of the piston B and push it into the cylinder by hand e Replace the dust boot C e Install the sleeve D with dust boot OApply silicone grease to the sleeve Spark Plug Replacement e Remove the stick coils see Stick Coil Removal in the Electrical System chapter e Remove the spark plugs A using the plug wrench B vertically Special Tool Spark Plug Wrench Hex 16 57001 1262 e Replace the spark plug with a new one Standard Spark Plug Type NGK CR9EIA 9 e Insert new spark plug in the plug wrench e Using the plug wrench vertically tighten the plug NOTICE The insulator of the spark plug may break if when the wrench is inclined during tightening Torque Spark Plugs 9 8 N m 1 0 kgf m 87 in Ib e Install the stick coils properly see Stick Coil Installa
477. s maintains the minimum standard clearance Crankshaft Main Bearing Insert Journal Clearance Standard 0 010 0 034 mm 0 0004 0 0013 in Service Limit 0 06 mm 0 0024 in x If the clearance is within the standard no bearing replace ment is required x If the clearance is between 0 035 0 0014 in and the service limit 0 06 mm 0 0024 in replace the bearing in serts A with inserts painted blue B Check insert journal clearance with the plastigage press gauge The clear ance may exceed the standard slightly but it must not be less than the minimum in order to avoid bearing seizure xIf the clearance exceeds the service limit measure the diameter of the crankshaft main journal Crankshaft Main Journal Diameter Standard 34 984 35 000 mm 1 3773 1 3780 in Service Limit 34 96 mm 1 3764 in x If any journal has worn past the service limit replace the crankshaft with a new one xIf the measured journal diameters are not less than the service limit but do not coincide with the original diameter markings on the crankshaft make new marks on it Crankshaft Main Journal Diameter Marks None 34 984 34 992 mm 1 3773 1 3776 in 1 34 993 35 000 mm 1 3777 1 3780 in Crankshaft Main Journal Diameter Marks 1 or no mark 9105317851 6105041751 9105318851 C 9 24 CRANKSHAFT TRANSMISSION Crankshaft Connecting Rods e Measure the m
478. sages in the crankcase halves 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 breather plate mating surface A 1 mm 0 04 in or more thick and then install the breather plate Sealant Liquid Gasket TB1207B 92104 2068 NOTE OMake the application finish within 7 minutes when the liquid gasket to the mating surface of the breather plate is applied OMoreover fit the plate and tighten the bolts just after application of the liquid gasket 9104383851 CRANKSHAFT TRANSMISSION 9 11 Crankcase Splitting e Apply a non permanent locking agent to the threads of the breather plate bolts A and tighten them Torque Breather Plate Bolts 9 8 1 0 kgf m 87 in lb e Install the breather side plate A so that the plate hole B fit the projection C of the upper crankcase e Apply a non parmanent locking agent to the threads of the breather side plate bolt D and tighten it Torque Breather Side Plate Bolt 5 9 N m 0 60 kgf m 52 in Ib e Press and insert the fitting A in the upper crankcase B until it is bottomed Special Tool Bearing Driver Set 57001 1129 e Press and insert the plug C in the upper crankcase so that the plug is deeper than crankcase surface e Press and insert the new needle bearing A for the shift shaft so that its marked side faces ou
479. scal s horsepower pound s per square inch quart s revolution revolution s per minute second s top dead center total indicator reading volt s watt s ohm s COUNTRY AND AREA CODES AT AU BR CA CH DE Austria Australia Brazil Canada Switzerland Germany EUR GB SEA B2 WVTA FULL H GB WVTA FULL H WVTA 78 2 H Europe United Kingdom Southeast Asia B2 WVTA Model with Honeycomb Catalytic Converter Full Power WVTA Model with Honeycomb Catalytic Converter Left Side Traffic Full Power WVTA Model with Honeycomb Catalytic Converter 78 2 Kw Power EMISSION CONTROL To protect the environment in which we all live Kawasaki has incorporated crankcase emis sion 1 and exhaust emission 2 control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board Addi tionally Kawasaki has incorporated an evaporative emission control system 3 in compliance with applicable regulations of the California Air Resources Board on vehicles sold in California only 1 Crankcase Emission Control System This system eliminates the release of crankcase vapors into the atmosphere Instead the vapors are routed through an oil separator to the intake side of the engine While the engine is operating the vapors are drawn into combustion chamber where they are burned along with the fuel
480. se e Replace the circlip with a new one Special Tool Inside Circlip Pliers 57001 143 GK05085BS1 C GK05038BS1 C 11 14 FINAL DRIVE Sprocket Coupling e Replace the grease seal with a new one e Press in the grease seal so that the seal surface is flush with the end of the hole OApply high temperature grease to the grease seal lip Special Tool Bearing Driver Set 57001 1129 Coupling Bearing Inspection Since the coupling bearing is made to extremely close tolerances the clearance can not normally be measured NOTE Olt is not necessary to remove the coupling bearing for inspection If the bearing is removed it will need to be replaced with a new one e Turn the bearing in the coupling back and forth A while checking for plays roughness or binding x If the bearing play roughness or binding is found replace the bearing e Examine the bearing seal B for tears or leakage x If the seal is torn ot is leaking replace the bearing Coupling Bearing Lubrication NOTE OSince the coupling bearing is packed with grease and sealed lubrication is not required Coupling Damper Inspection e Remove the rear wheel coupling and inspect the rubber dampers A e Replace the damper if it appears damaged or deterio rated Sprocket Wear Inspection e Visually inspect the engine and rear sprocket teeth for wear and damage x If the teeth are worn as illustrated replace the sprocket and inspe
481. se Before replacing a blown fuse always check the amperage in the affected circuit If the amperage is equal to or greater than the fuse rating check the wiring and related components for a short circuit Housing A Fuse Element B Terminals C Blown Element D When replacing a fuse be sure the new fuse matches the specified fuse rating for that circuit Installation of a fuse with a higher rating may cause damage to wiring and components GP20000181 C APPENDIX 17 1 Appendix Table of Contents Cable Wire and Mose Routing Ne 17 2 Troubleshooting 17 48 17 2 APPENDIX Cable Wire Hose Routing T gt 4 m i3 MINIS 5 k 1 1 1 mdt pP g 5 n o 97 ls aan CAT oe m P TRE if 7 2 LIR z 0O t E ADS LR 4 lt Wi o 8 07 a Ex L3 Jy a 0 e 68095800 6 APPENDIX 17 3 Cable Wire and Hose Routing 17 18 19 20 21 22 23 24 Before clamping face the locking portion of the clamp in direction as shown Hold the right switch housing lead and throttle cables to the handlebars with the clamp Turn Signal Relay Immobilizer Amplifier equipped models Run the me
482. se Box 1 2 ECU 8 Starter Relay 14 Ignition Fuse 15 A 3 Immobilizer Kawasaki Diag 9 Main Fuse 30A 15 Joint Connector F nostic System Connector 10 ECU Fuse 15 A 16 Immobilizer Antenna 4 Frame Ground 3 11 Relay Box 17 Immobilizer Amplifier 5 Frame Ground 1 12 ECU Main Relay 18 Ignition Switch 6 Engine Ground ECU Communication Error Service Code 39 FUEL SYSTEM DFI 3 81 ECU Communication Line Inspection OWhen the data is not sent from the ECU to the meter unit for more than about 10 seconds the service code 39 is displayed OThe service code 39 is detected with meter unit e Remove the ECU and meter unit check the wiring for continuity between main harness connector ODisconnect the ECU and meter unit connectors Wiring Inspection ECU Connector Meter Unit Connector B BL O lead ECU terminal 26 C x If 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 ECU Communication Line Circuit 8017130 51 1 ECU 2 Frame Ground 1 3 Meter Unit 4 Yellow Engine Warning Indicator Light LED 5 Yellow KTRC Warning Indicator Light LED GCci7090FW2 C 3 82 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 Sti
483. see Brake Light Switch Operation Inspection in the Periodic Maintenance chapter Brake Pedal Removal e Remove Right Front Footpeg Bracket Bolts A Rear Master Cylinder Mounting Bolts B Lever Pedal BRAKES 12 11 Cotter Pin A Joint Pin B Rear Brake Light Switch Spring C Return Spring D Brake Pedal Bolt E Brake Pedal F Brake Pedal Installation e Apply grease to the footpeg pivot shaft A e Install Washer B Brake Pedal C Washer D e Apply a non permanent locking agent to the threads of the brake pedal bolt E and tighten it Torque Brake Pedal Bolt 8 8 N m 0 90 kgf m 78 in Ib e Hook the shorter end of the rear brake light switch spring A on the brake light switch e Hook the upper end of the return spring B on the footpeg bracket hook OFace the both lower spring ends as shown e Replace the cotter pin A with a new one e Insert the cotter pin and bend the pin ends B e Install the front footpeg bracket and rear master cylinder e Tighten Torque Front Footpeg Bracket Bolts 25 2 5 kgf m 18 ft Ib Rear Master Cylinder Mounting Bolts 25 N m 2 5 kgf m 18 ft Ib e Check the brake pedal position see Brake Pedal Position Inspection GL04081BS1 C 12 12 BRAKES Calipers Front Caliper Removal e Remove the clamp A Left Side Only e Loosen the banjo bolt B at the brake hose lower end and tight
484. see Meter Unit Inspection in the Electrical System chap ter Turn Signal Relay Fuse 7 5 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 green 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 Fourth Step e Set the dimmer switch A to low beam position e Start the engine e The low beam headlight 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 Fuse 15 A see Fuse Inspection in the Electri cal System chapter Dimmer Switch see Switch Inspection in the Electrical System chapter Headlight Relay in Relay Box see Relay Circuit Inspec tion in the Electrical System chapter Harness see Wiring Inspection in the Electrical System chapter 65178849 P 2 44 PERIODIC Periodic Maintenance Procedures e Set the dimmer switch to blue high beam position e The low beam A and high beam B headlights should go on e The
485. 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 Abnormal 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 ABS Hydraulic Unit Connector see ABS Hydraulic Unit Removal in the Brakes chapter e Check the wiring for continuity between harness connec tors Special Tool Hand Tester 57001 1394 Wiring Continuity Inspection ECU Connector lt ABS Hydraulic Unit Connector B R Y lead ECU terminal 21 ABS Hydraulic Unit terminal 16 C Wiring Continuity Inspection ABS Hydraulic Unit Connector Rear Wheel Rotation Sensor Connector B BK O lead ABS Hydraulic Unit Connector terminal 14 C W G lead ABS Hydraulic Unit Connector terminal 13 D 99999970 OX XXX X XO 9617143251 C xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the grou
486. sing Switch HousingHorn Spark Plugs gi oy 1 Front Brake tt Fan 35 ar ai GAP Light Switeh e Air Hoorn ayer CN 2 Engine Stop Switch Switching SS SS NS intake 3 8tarter Button Valve S 4 Sensor BR W R BL BK Y BL W R BK R R BK 0 R 6 R BK down Sensor Front Wheel Rotation Sensor Meter Unit 1 Yellow Engine Marning Indicator Light LED 2 Yellow ABS Indicator Light LED o Yellow KTRO Indicator Light LED 4 Yellow KTRC Warning Indicator Light LED gt Green Neutral Indicator Light LED Blue High Beam Indicator Connector F 8R W o Meter Unit Light LED See ui 7 Green Left Turn Signal Indicator Light LED 8 Green Right Turn Signal UI Indicator Light LEB BL R 9 Red Warning Indicator Light LED P BL Battery Oil Pressure ah Water Temperature eL Y LG 10 Speedometer R BK 11 Tachometer n 12 0dometer Trip Meter BR W Glock 13 Fuel Level Gauge 14 Water Temperature Outside Temperature Gauge 15 Illumination Light LED E Dutside ALED Eight Emitting Diode H Temperature ES Sensor Front Right Ture sienai Joint Connector Joint Connector
487. sing lead to the left engine bracket with the clamp Right Switch Housing Lead Main Harness to Engine Subharness Run the right switch housing lead ignition switch lead radiator fan motor lead immobilizer an tenna lead equipped models and left switch housing lead to the inside of the left engine bracket Before clamping face the locking portion of the clamp in direction as shown 17 10 APPENDIX Cable Wire and Routing APPENDIX 17 11 Cable Wire Hose Routing Hold the right switch housing lead to the frame with the clamp Hold the brake hose with the clamp at the rubber protector Throttle Cables Hold the right switch housing lead and throttle cables to the handlebars with the clamp Right Switch Housing Lead Brake Hose Run the brake hose right switch housing lead and throttle cables into the guide Run the meter unit lead to front of the meter bracket Run the right switch housing lead through this point to the inside of the frame Run the throttle cables through this point to the inside of the frame Run the throttle cables and right switch housing lead through inside of the right fork tube Run the throttle cables and right switch housing lead to the inside of the brake hose Clutch Cable Run the clutch cable to the upside of the radiator fan motor lead Run the clutch cable to the upside of the throttle cables
488. stic 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 68020128 68020138 68020148 2 68020158 5 68020168 GENERAL INFORMATION 1 5 Before Servicing Press For items such as bearings or oil seals that must be r pressed into place apply small amount of oil to the con D uua tact area Be sure to maintain proper alignment and use dai d smooth movements when installing gt 68020178 Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary Replace with new ones whenever m removed Press bearings with the manufacturer and size marks facing out Press the bearing into place by putting RSs pressure on the correct bearing race as shown 2 B Bh B
489. sure sensor 2 e Installation is the reverse of removal OPosition the intake air pressure sensor 1 A between the projections B on the rubber damper FUEL SYSTEM DFI 3 49 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 air cleaner housing see Air Cleaner Housing Removal e Disconnect 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 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 sensor BL lead Digital Meter BK sensor G lead e Measure the intake voltage with the engine stopped and with the connector joined e Turn the ignition switch to ON GC17110FS1 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 1 Output Voltage Inspection xIf the reading is out of the standard remove the ECU and check the wiring for continuity between main harness connectors Special Tool Hand Tester 57001 1394 ODisconnect the ECU and sensor co
490. t x If the yellow ABS indicator light LED does not Igiht ABS system is normal service code is not stored temporary failure Fluid Pressure Sensor Supply Voltage Inspection Service Code 89 OThe Fluid Pressure Sensors are built in the ABS Hydraulic Unit Therefore the voltage cannot be checked directly e Perform the Pre Diagnosis Inspection 1 and 2 see In quiries to Rider x If the yellow ABS indicator light LED A lights the ABS hydraulic unit has trouble Replace the ABS hydraulic unit x lf the yellow ABS indicator light LED does not Igiht ABS system is normal service code is not stored 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 as with a hammer or allowed to fall on a hard surface Be careful not to get water or mud on the ABS hy draulic unit e Drain the brake fluid from the front and rear brake lines ODrain the brake fluid through the bleed valve by pumping the brake lever and pedal GL14580BS1 GL14580BS1 BRAKES 12 51 Anti Lock System Remove Rear Fender see Flap and Rear Fender Removal in the Frame chapter Brake Hose Lower Ends see Brake Hose Replacement in the Periodic maintenance chapter e Clean the ABS hydraulic unit NOTICE Clean all fittings on the ABS hydr
491. t chain tensioner see Camshaft Chain Tensioner Removal e Loosen the upper chain guide bolts and camshaft cap bolts as shown sequence 1 20 in the figure and re move them e Remove Upper 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 SUN ya 19 9 09 47 9 2 er eee 27 oh Op Gow BAN S SL SI iN 2 il Es o CTL Q 6 1 1333812 Camshaft Sprocket Mounting Bolts A Camshaft Sprockets B The crankshaft may be turned while the camshafts are removed Always pull the chain taut while turn ing the crankshaft This avoids kinking the chain on the lower crankshaft sprocket A kinked chain GE11381BS1 C could damage both the chain and the sprocket 5 20 END Camshaft Camshaft Chain Camshaft Installation e Be sure to install the following parts Plug Hole Gaskets A Dowel Pins B NOTE OThe exhaust camshaft has a 1169 EX mark A and the intake camshaft has a 1169 IN mark B Be careful not to mix up these shafts e Install the camshaft sprockets so that position the timing marks A outside OThe intake camshaft sprocket and exhaust camshaft sprocket are identical e Apply a non permanent locking agent to the threads of the camshaft sproc
492. t light Do not use gasoline or a low flash point solvent to clean the oil pressure relief valve x If 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 6008060251 7 12 ENGINE LUBRICATION SYSTEM Oil Pump Oil Pump Removal e Remove Water Pump see Water Pump Removal in the Cooling System chapter e Pull the water pump shaft A to remove the oil pump cover B e Remove Oil Water Pump Shaft A with Inner Rotor B Outer Rotor C Oil Pump Installation e Assemble the pin A inner rotor B and oil water pump shaft C e Apply engine oil to the sliding surfaces of the inner rotor and shaft e Apply engine oil to the sliding surfaces of the outer rotor A and install it into the crankcase e Turn the pump shaft so that the slot B in its shaft fits onto the projection C of the pump drive gear shaft e Pack grease into the cavity A between the inner rotor and outer rotor for improve the oil pump initial priming e Install the dowel pin B e Install the oil pump cover C so that the dowel pin fits into the hole D of the oil pump cover e Install the water pump see Water Pump Installation in the Cooling System chapter LUBRICATION SYSTEM 7 13 Oil Pump Oil Pump Drive Gear Removal e R
493. t the conditions B under which the problem occurred and try to determine the cause C Do not rely solely on the ABS self diagnosis function use common sense check the brakes for proper braking power and brake fluid level search for leaks etc If the yellow ABS indicator light LED blinks when the ignition switch is turned to ON or the motorcycle is running ABS system does not function In this case the voltage of the battery is extremely low 8017201 51 C Anti Lock System BRAKES 12 33 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 n
494. tallation e Install Lower Handlebar Holders A Bolts B Both Sides e Install Lower Handlebar Holder Assembly A Bolts B and Caps e Replace the handlebar holder mounting nuts A with new ones Torque Handlebar Holder Mounting Nuts 34 3 5 kgf m 25 ft lb e Align the punch mark A on the handlebars and the corner edge B on the lower handlebar holder Tighten the front holder bolts first and then the rear holder bolts There will be a gap C at the rear part of the holder after tightening Torque Handlebar Holder Bolts 25 N m 2 5 kgf m 18 ft Ib 14 12 STEERING Handlebar Install Throttle Grip Throttle Cable Tips A Right Switch Housing OFit the projection B into a hole C in the handlebars e Tighten Torque Switch Housing Screws 3 5 0 36 kgf m 31 in Ib e Apply a non permanent locking agent to the right handle bar weight bolt e Install the front brake master cylinder see Front Master Cylinder Installation in the Brakes chapter e Apply adhesive cement to the inside of the left handlebar grip e Apply a non permanent locking agent to the left handlebar weight bolt e Install the left switch housing OFit the projection A into a hole B in the handlebars e Tighten 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 Run the leads
495. tart the engine with the fuel hoses disconnected e Connect the fuel pump lead connector e Turn the engine stop switch 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 NOTICE Do not drive the fuel pump 3 seconds or more with out the fuel in the fuel tank If the fuel pump is driven without the fuel it may be damaged 3 102 FUEL SYSTEM Fuel Line e Start the engine and let it idle e Measure the fuel pressure with the engine idling Fuel Pressure with Engine Idling Standard 294 kPa 3 0 kgf cm 43 psi 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 x If 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
496. tation Sensor 9 Front Wheel Rotation Sensor 10 ECU 11 Relay Box 12 Vehicle down Sensor R Replacement Parts SS Apply silicone sealant WL Apply soap and water solution or rubber lubricant 3 8 FUEL SYSTEM DFI Exploded View 08002542845 C FUEL SYSTEM DFI 3 9 Exploded View ref remm Ds ue nmt Nm ftib 98 10 i G Apply grease L Apply a non permanent locking agent R Replacement Parts 3 10 FUEL SYSTEM DFI DFI System DFI System 6 2 6 2 ng DFI System FUEL SYSTEM DFI 3 11 Battery 12 V 8 Ah Vehicle down Sensor Fuel Filter Pressure Regulator Fuel Pump Fuel Flow Delivery Pipe Assy Intake Air Temperature Sensor Subthrottle Sensor Subthrottle Valve Actuator Fuel Injectors Main Throttle Sensor Water Temperature Sensor Rear Wheel Rotation Sensor Oxygen Sensor Crankshaft Sensor Intake Air Pressure Sensor 2 Intake Air Pressure Sensor 1 Air Switching Valve Air Flow 3 12 FUEL SYSTEM DFI DFI System DFI System Wiring Diagram PH lj 1 II 1 w BL 6 8 Et zai TR HIS Es aiii EH DES m mr m Bi mE
497. tch see Switch Inspection in the Electrical System chapter Harness see Wiring Inspection in the Electrical System chapter Yellow ABS Indicator Light LED see Yellow ABS Indi cator Light LED Inspection in the Brakes chapter e Turn the ignition switch to OFF e The all lights should go off OFor models equipped with an immobilizer system red warning indicator light LED and immobilizer symbol will blinks Refer to the Immobilizer System Equipped Mod els section in the Electrical System chapter x If the light does not go off replace the ignition switch Second Step Other then CA Model e Turn the ignition switch to P Park position e The city light taillight and license plate light should go on x If the light does not go on inspect or replace the following item Ignition Switch see Switch Inspection in the Electrical System chapter PERIODIC MAINTENANCE 2 43 Periodic Maintenance Procedures Third Step e Turn on the turn signal switch A left or right position e The left or right turn signal lights B front and rear ac cording to the switch position should blink e The green turn signal indicator light LED C in the meter unit should blink x If 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 System chapter 65178846 Meter Unit for Green Turn Signal Indicator Light LED
498. tch to run position e Turn the ignition switch to ON Output Voltage Standard Battery Voltage for 3 seconds and then 0 V Turn the ignition switch to OFF x lf the reading is not the standard check the ECU main relay and fuel pump relay see Relay Circuit Inspection in the Electrical System chapter xIf the main relay and pump relay are normal check the wiring see Fuel Injector Circuit 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 lf there is still no battery voltage check the fuel injector resistance see Fuel Injector Resistance Inspection and wiring see Fuel Injector Circuit GC17140FS1 3 112 FUEL SYSTEM DFI Fuel Injectors Fuel Injector Fuel Line Inspection e Remove Fuel Tank see Fuel Tank Removal Fuel Hose see Fuel Hose Replacement in the Periodic Maintenance chapter OBe sure to place a piece of cloth around the fuel outlet pipe of the fuel pump and the delivery pipe of the throttle body assy A WARNING Fuel is flammable and explosive under certain con ditions and can cause severe burns Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately When the fuel hose is dis connected fuel spills out from the hose and the pipe because of residual pressure Cover the hose connection with a piece
499. temporary failure Front Rear Wheel Rotation Difference Abnormal Service Code 25 e Check 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 and Clogging with Foreign Matter of Sen sor Rotor see Wheel Rotation Sensor Inspection xIf the all parts correct recheck the service code indica tion erase the service code perform the pre diagnosis inspection 1 and 2 and retrieve the service code x If the yellow ABS indicator light LED A lights the ABS hydraulic unit has trouble Replace the ABS hydraulic unit If the yellow ABS indicator light LED does not light ABS system is normal service code is not stored temporary failure ABS Motor Relay Inspection Service Code 35 e Remove Seat see Seat Removal in the Frame chapter e Check the ABS motor relay fuse 25 A A see Fuse Inspection in the Electrical System chapter GL14580BS1 12 46 BRAKES Anti Lock System x If the fuse is good check the wiring continuity between the positive terminal A of the battery and R W lead terminal B in the ABS hydraulic unit lead connector C Special Tool Hand Tester 57001 1394 the wiring is open replace or repair the harness see ABS System Wiring Diagram x If the wiring is good go to next step OThe ABS motor relay is built in
500. ter e Disconnect the connector A and the hose B e Clear the harness C from the clamp D e Pull up the rubber cover A forward e Disconnect the hoses B from the air switching valve C and remove the air switching valve Air Switching Valve Installation e Install the air switching valve A as shown in the figure B Viewed Left Side C About 40 Air Switching Valve Operation Test e Refer to the Air Suction System Damage Inspection in the Periodic Maintenance chapter GE04100BS1 5 14 END Clean Air System Air Switching Valve Unit Test e Refer to the Air Switching Valve Unit Test in the Electrical System chapter Clean Air System Hose Inspection e Be certain that all the hoses are routed without being flat tened or kinked and are connected correctly to the air cleaner housing air switching valve and air suction valve covers xIf they are not correct them Replace them if they are damaged Cylinder Head Cover ENGINE TOP END 5 15 Cylinder Head Cover Removal e Remove Side Cover see Side Cover Removal in the Frame chap ter Air Cleaner Housing see Air Cleaner Housing Removal in the Fuel System DFI chapter e Remove Radiator Cap Mounting Bolt A and Collar e Remove the stick coils A from the spark plugs see Stick Coil Removal in the Electrical System chapter e Pull up the rubber cover B forward so that it clears from the cylinder hea
501. ter 32 33 57001 1199 875711995 C Valve Seat Cutter Holder 4 5 57001 1330 Valve Guide Arbor 4 5 57001 1331 875713305 C 875713315 C Special Tools Sealant Valve Guide Reamer 4 5 57001 1333 7571333ST C Valve Seat Cutter 60 633 57001 1334 C Nunc 875713345 6 Valve Seat Cutter 60 627 57001 1409 7571409ST C Engine Mount Nut Wrench 57001 1450 875714505 C Valve Guide Driver 57001 1564 875715645 C ENGINE TOP END 5 11 Valve Spring Compressor Adapter 24 57001 1586 ST571586ST Compression Gauge Adapter M10 x 1 0 57001 1601 7T571601ST C L Shape Hose 57001 1606 7571606ST C Washer 57001 1612 Liquid Gasket TB1216B 92104 1064 8 5716125 C 879210645 5 12 END Clean Air System Air Suction Valve Removal e Remove Air Cleaner Housing see Air Cleaner Housing Removal in the Fuel System DFI chapter Air Switching Valve see Air Switching Valve Removal Stick Coil Connector see Stick Coil Removal in the Elec trical System chapter Connector A from Bracket B at Left Side Air Suction Valve Cover Bolts C and Bracket Air Suction Valve Covers D Both Sides e Remove the air suction valve A on both sides Air Suction Valve Installation e Install the air suction valve so that o
502. ter unit lead to front of the meter bracket Hold the main harness to the meter bracket Hold the left turn signal light lead to the handlebars with the clamp Left Switch Housing Lead Run the left turn signal light lead to front of the meter bracket Run the left switch housing lead and clutch cable into the guide Vehicle down Sensor Run the clutch cable into the clamp Outside Temperature Sensor Hold the main harness to the meter bracket Main Harness Clamp Hold the front wheel rotation sensor lead to the brake hose fitting with the clip at the white mark on the lead Install the clip so that the lead is placed at front of the hose and face its open side in direction as shown Hold the front wheel rotation sensor lead to the brake hose with the clip at the white mark on the lead Install the clip so that the lead is placed at front of the hose and face its open side in direction as shown Front Wheel Rotation Sensor Lead Hold the front wheel rotation sensor lead to the meter bracket Hold the brake hose with the clamp at the rubber protector Run the brake hose right switch housing lead and throttle cables into the guide Run the right turn signal light lead to front of meter bracket Viewed from A behind the steering stem head Position the guides with its tabs into the grooves on the steering stem head 17 4 APPENDIX Cable Wire and Hose Routing gt a w 7 c y 2
503. th a new one When cleaning the radiator with steam cleaner be careful of the following to prevent radiator damage Keep the steam gun A away more than 0 5 m 1 6 ft B from the radiator core Hold the steam gun perpendicular C not oblique D to the core surface Run the steam gun following the core fin direction Radiator Cap Inspection e Remove Right Middle Fairing see Middle Fairing Removal in the Frame chapter Radiator Cap e Check the condition of the bottom A and top B valve seals and valve spring C x If any one of them shows visible damage replace the with a new one 8007010451 C 6007013851 C COOLING SYSTEM 4 17 Radiator e Install the cap A on a cooling system pressure tester B NOTE OWet the cap sealing surfaces with water or coolant to prevent pressure leaks e Watching the pressure gauge pump the pressure tester to build up the pressure until the relief valve opens the gauge needle flicks downward Stop pumping and mea sure leak time at once The relief valve must open within the specified range in the table below and the gauge hand must remain within the same range at least 6 seconds Radiator Cap Relief Pressure Standard 93 123 kPa 0 95 1 25 kgf cm 13 18 psi x the cap can not hold the specified pressure or if it holds too much pressure replace it with a new one Radiator Filler Neck Inspection e Remove Right Mi
504. th immobilizer 21175 0753 WVTA 78 2H with immobilizer 21175 0754 Brazil with immobilizer 21175 0781 Canada without immobilizer Full Full Power H Honeycomb Type Catalyst 78 2 Maximum Horsepower 78 2 kW 106 3 PS ECU Removal Never drop the ECU especially on a hard surface Such a shock to the ECU can damage it e Remove Seat see Seat Removal in the Frame chapter e For WVTA 78 2 H and GB WVTA FULL H Models us ing a small chisel or suitable tool remove the screws A washers B and ECU guard C e Remove Relay Box see Relay Box Removal in the Electrical Sys tem chapter ECU Connectors A ECU B 8017095 51 C ECU FUEL SYSTEM DFI 3 97 ECU Installation e Connect the ECU connectors A e Install the ECU B into the rubber protector C e Install the relay box see Relay Box Installation in the Electrical System chapter e For WVTA 78 2 H and GB WVTA FULL H Models in stall the ECU guard A and Washers B Do not pinch the leads e For WVTA 78 2 H and GB WVTA FULL H Models tighten the new screws C using the Kawasaki genuine screws of which threads are coated with locking agent ECU Power Supply Inspection e Visually inspect the ECU connectors xIf 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 connectors xIf the ter
505. the Frame chapter e Turn the vertical adjuster A on the headlight with the phillips tip screwdriver B 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 PERIODIC MAINTENANCE 2 45 Periodic Maintenance Procedures NOTE OFor CA model the proper angle is 0 4 degrees below horizontal This is 50 mm 2 in drop at 7 6 m 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 Sidestand Switch Operation Inspection e Inspect the sidestand switch A operation accordance to the following table Sidestand Switch Operation Engine Engine Position Lever Start Run Up Neutral Released Starts Continue running Up Neutral Pulledin starts Continue running Up In Gear Released eect start running Up In Gear Pulled in Starts running Down Neutral Released Starts running Down Neutral Pulled in Starts running Down In Gear Released Stops Start Doesn t Down In Gear Pulled in Stops start 2 46 PERIODIC Periodic Maintenanc
506. the clutch cover e Apply molybdenum disulfide grease to the pusher holding portion A on the release shaft e Install the washer B and spring C e Insert the release shaft straight into the upper hole of the clutch cover NOTICE When inserting the release shaft be careful not to remove the spring of the oil seal e Fit the spring A as shown in the figure Viewed from Rear B Release Shaft C Clutch Cover D Clutch Cover Disassembly e Remove Clutch Cover see Clutch Cover Removal Release Lever and Shaft Assembly see Release Shaft Removal Oil Seal A e Remove Needle Bearings A Oil Level Inspection Window B Oil Filler Plug C 6205058851 C 6 9 Clutch Cover Assembly e Replace the needle bearings and oil seal with new ones NOTE Olnstall the needle bearings so that the manufacture s mark face out e Install the needle bearings A and oil seal B position as shown in the figure Press the needle bearing until the bottom C Press the needle bearing so that the bearing surface D is flush with the housing end of clutch cover E Apply a soapy water to outside of the oil seal and press it until the bottom e Apply a soapy water to the rubber portion A of the oil level inspection window e Press the gauge until the bottom so that its projection B faces inside of the clutch cover C e Replace the O ring A of the oil fil
507. the following parts SEL Button 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 or lower button B each time check that the display C changes as follows OThis display is ordinary indication 000 gt TRIP TRIP gt Km L CLOCK RANGE Km L GP17889CN3 x If the display function does not work check the following parts Upper Button or Lower Button see Switch Inspection Wiring see Meter Unit Circuit x If the above parts is good replace the meter unit om GP17888CS1 GP17890CS1 Meter Gauge Indicator Unit ELECTRICAL SYSTEM 16 71 e Select the power mode e By pushing the upper button A or lower button B each time check that the power mode symbol changes to going on x If the display function does not work check the following parts Upper Button or Lower Button see Switch Inspection Wiring see Meter Unit Circuit x If the above parts is good replace the meter unit e Select the KTRC mode e By pushing the upper button A or lower button B each time check that the KTRC indicator symbol changes to going on x If the indicator symbol does not work check the following parts Upper Button or Lower Button see Switch Inspection Wiring see Meter Unit Circuit x If the
508. tightened correctly Torque Radiator Water Hose Clamp Screws 2 9 0 30 kgf m 26 in Ib Engine Top End Valve Clearance Inspection NOTE OValve clearance must be checked and adjusted when the engine is cold 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 align the 1 4 mark on the timing rotor with the crankcase timing mark Mark A for 1 4 Pistons Timing Mark B Crankcase Halves Mating Surface e Using the thickness gauge A measure the valve clear ance between the cam and the valve lifter Valve Clearance Standard Exhaust 0 22 0 31 mm 0 0087 0 0122 Intake 0 15 0 24 mm 0 0059 0 0094 in 2 22 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTE OThickness gauge is 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 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 OWhen positioning 1 piston TDC at the end of the compression stroke Intake Valve Clearance of 1 and 3 Cylinders Exhaust Valve Clearance o
509. tion in the Electrical System chapter OBe sure the stick coils are installed by pulling up it lightly NOTE OBe careful not to tight the stick coil leads 8105040251 C FUEL SYSTEM DFI 3 1 Fuel System DFI Table of Contents Exploded VIeW ee eet hee eR epe ted rea HER P Death 3 4 DOE SUI pe 3 10 DEL Parts Location iie teat en tec b a RESP RERUMS 3 16 Specifications ici rh tek e ERR CR ek ee a De een eR RR ER e 3 18 Special Tools and Sealant i niece iet pori e e e epe noe A aO ee t e e RE e va en 3 20 DFI Servicing Precautions pp 3 22 DFIServieng Iecalto iuit undue tne ne petuo mime o a 3 22 Troubleshooting the DFI Systerr ait RR px ba Ree uin BER 3 24 OUTING E 3 24 ere P TIT TORIC GS TL 3 28 DFI System Troubleshooting Guide It cadre tre e roe Ove todo 3 31 SNB pM ET 3 36 Self diagnoSisS cm 3 36 Self diagnosis Procedures 3 37 Service Code Reading ret aerei td re E Cen Enn FR oa eR ODE 3 39 Service Code M eo es tondeuse tdi aai 3 39 eru 3 41 Main Throttle Sensor Service Code 11 41 iine 3 44 Main Throttle Sensor 3 44 Main Throttle Sens
510. tion switch to OFF e Measure the output voltage with the engine stopped and with the connector joined e Turn the ignition switch to ON Output Voltage Standard DC 1 02 1 06 V at idle throttle opening DC 4 22 4 42 V at full throttle opening for reference NOTE OOpen the throttle confirm the output voltage will be raise OThe standard voltage refers to the value when the volt age reading at the Input Voltage Inspection shows 5 V exactly OWhen the input voltage reading shows other than 5 V derive a voltage range as follows Example In the case of a input voltage of 4 75 V 1 02 x 4 75 5 00 0 969 V 1 06 x 4 75 5 00 1 007 V Thus the valid range is 0 969 1 007 V Turn the ignition switch to OFF x If the reading is out of the standard check the main throt tle sensor resistance see Main Throttle Sensor Resis tance Inspection x If the reading is within the standard remove the ECU and check the wiring for continuity between main harness side connectors ODisconnect the ECU and sensor connectors Wiring Inspection ECU Connector A Main Throttle Sensor Connector B Y W lead ECU terminal 27 C G lead ECU terminal 49 D xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see Removal Installation 8017109 51 C FUEL SYS
511. 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 nottry to disassemble and repair the ABS parts replace it OThe ABS has many brake lines pipes and leads And the ABS cannot detect problems with the conventional braking system brake disc wear unevenly worn brake pad and other mechanical faults To prevent trouble check the brake lines and pipes for correct routing and connection the wiring for correct routing and the brakes for proper braking power Be sure to check for fluid leak age and bleed the brake line thoroughly BRAKES 12 31 Anti Lock System 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 NOTICE Do not ride the motorcycle with air in the brake line or the ABS could malfunction OThe Yellow ABS indicator light LED
512. tor 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 left and right buttons down for two seconds within twenty seconds of switching the ignition off e all coded keys are lost the ECU and ignition 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 a 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 key is lost the user should go to his dealer and have a new ECU installed and register the ignition keys GUT x 9 and 10 are strongly recommended to the customer to ensure security of the motorcycle Key Registration Case 1 When additional spare ignition key is required e Prepare a new spare ignition key e Cut the key in accordance with th
513. tside Temperature Sensor Installation e Check that the O ring A is in place on the outside tem perature sensor B e Tighten the screw securely e Install Left Upper Side Fairing see Upper Side Fairing Instal lation in the Frame chapter 62188433 Switches and Sensors ELECTRICAL SYSTEM 16 109 Outside Temperature Sensor Inspection e Remove the outside temperature sensor see Outside 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 Outside Temperature Sensor Resistance Standard 5 4 6 6 at 0 C 32 F 0 29 0 39 at 80 176 F x If the reading is out of the standard replace the sensor Fuel Level Sensor Inspection e Remove Fuel Pump see Fuel Pump Removal in the Fuel System DFI chapter e Check that the float moves up and down smoothly without binding It should go down under its own weight x If the float does not mo
514. tside and its surface B is flush with the end of the hole e Install the new oil seal C so that its surface D is flush with the end of the hole e Apply grease to the oil seal lips 6104385851 9 12 CRANKSHAFT TRANSMISSION Crankcase Splitting Apply a non parmanent locking agent to the oil passage plugs A and tighten them Torque Oil Passage Plugs 20 N m 2 0 kgf m 15 ft Ib e Install the oil passage plug B in the lower crankcase and tighten it Torque Oil Passage Plug 9 8 1 0 kgf m 87 in Ib e Install Crankshaft see Crankshaft Installation Connecting Rods see Connecting Rod Installation Camshaft Chain A Transmission Shafts and Gears see Transmission Shaft Installation Dowel Pins B Shift Drum see Shift Drum and Fork Installation Shift Forks and Shift Rods see Shift Drum and Fork In stallation e Before fitting the lower case on the upper case check the following OBe sure to hang the camshaft chain on the crankshaft OCheck to see that the shift drum and transmission gears are in the neutral position CRANKSHAFT TRANSMISSION 9 13 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 Sealant Liquid Gasket TB1216B 92104 1064 NOTE OEspecially apply a sealant so that it shall be
515. tting the solenoid valve The oxygen sensor heater If the oxygen sensor heater fails wiring short 67 uu raise temperature of or open the ECU stops the current to the the sensor for its earlier heater and it stops the feedback mode of the activation oxygen sensor The oxygen sensor must If the oxygen sensor output voltage is incorrect 94 2 Senp signale the ECU stops the feedback mode of the ensor voltage continuously to the ECU oxygen sensor FUEL SYSTEM DFI 3 43 Self Diagnosis Note 1 D J Method The DFI control method from medium to heavy engine load When the engine load is light like at idling or low speed the ECU determines the injection quantity by calculating from the throttle vacuum intake air pressure sensor output voltage and engine speed crankshaft sensor output voltage This method is called D J method 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 main throttle sensor output voltage and the engine speed This method is called a N method This depends on the number of stopped cylinders 3 44 FUEL SYSTEM DFI Main Throttle Sensor Service Code 11 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
516. uble Inspect see chapter 3 Fuel air mixture incorrect 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 Water or foreign matter in fuel Replace see chapter 3 Change fuel Inspect and clean fuel system see chapter 3 Fuel injector O ring damage Replace see chapter 3 Fuel injector clogged Inspect and repair see chapter 3 Fuel line clogged Inspect and repair see chapter 3 Fuel pump operates intermittently and often ECU fuse blows Fuel pump bearings may wear Replace the fuel pump see chapter 3 Fuel pump 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 Cracked or obstructed intake air pressure sensor 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 poor quality or incorrect Fuel change Use the gasoline recommended
517. uel pump relay see Relay Circuit Inspection in the Electrical System chapter If the main relay and pump relay are normal check the wiring see Fuel Injector Circuit xIf the wiring is good check the ECU for its ground and power supply see ECU Power Supply Inspection x If the ground and power supply are good replace the ECU see Removal Installation 8017139 51 C Fuel Injectors FUEL SYSTEM DFI 3 111 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 OConnect the relay box connectors e Connect a digital meter A to the connectors 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 ECU terminal 42 Digital Meter gt Battery terminal For Fuel Injector 2 Digital Meter BL R lead ECU terminal 41 Digital Meter gt Battery terminal For Fuel Injector 3 Digital Meter BL O lead ECU terminal 40 Digital Meter Battery terminal For Fuel Injector 4 Digital Meter BL G lead ECU terminal 52 Digital Meter gt Battery terminal e Measure the output voltage with the engine stopped and with the connector joined Turn the engine stop swi
518. up the outer tube E to hold it by the clamps and then tighten the two bolts The outer tube is used as a guide Special Tools Fork Spring Compressor 57001 1587 Fork Spring Compressor 57001 1540 e Insert the holder bar A into the axle hole of the front fork B Special Tool Bar 57001 1694 For Left Fork Leg OPosition the bar left and right and evenly e Insert the compression shaft and install the nut e Insert the lower end of the compression shaft A into the hole B of the holder bar e Screw the adjust nut A onto the compression shaft as shown in the figure e Screw the locknut B e Set the other side compression shaft same process SUSPENSION 13 17 Front e Set the holder bar A and compression shafts B e Screw in the nuts A until the piston rod nut comes out e While holding up the top plug A insert the fork spring stopper B between the piston rod nut C and the slider Special Tool Fork Spring Stopper 57001 1374 e Holding the top plug A with a wrench B loosen the piston rod nut C e Remove Top Plug Rebound Damping Adjuster Rod Right Front Fork Only Washer A Collar B Fork Spring C GM04731BS1 13 18 SUSPENSION Front e Drain the fork into a suitable container and remove the spring seat OPump the piston rod A up and down at least ten times to expel the oil from the fork Spec
519. ure install the grommet A OHang the hook portion A into the grommet B Olnsert the projection C into the grommet D Olnsert the projections A into the grommets B Upper Fairing Removal e Remove Windshield Assembly see Windshield Removal Quick Rivets A Upper Fairing B 00058581 Upper Fairing Installation e Installation is the reverse of removal FRAME 15 11 Fairings Upper Side Fairing Removal e Remove Middle Fairing see Middle Fairing Removal Upper Fairing see Upper Fairing Removal Quick Rivet A e Remove Quick Rivet A Bolts B e Disconnect the turn signal light lead connector A and remove the upper side fairing B Upper Side Fairing Installation e Installation is the reverse of removal note the following Olnsert the tabs A into the slots B Meter Cover Removal e Remove Upper Side Fairing see Upper Side Fairing Removal Bolts A e Slide the dust cover B and disconnect the connector 15 12 Fairings e Clear the projection A both sides and remove the meter cover assembly B e Remove Screws A and Washers Meter Unit B Meter Cover C NOTICE Place the meter unit so that the face is up If a meter unit is left upside down or sideways for any length of time it will malfunction Meter Cover Installation e Installation is the reverse of removal Windshield Removal e Remove Ad
520. urn signal light lead to upside of the main harness Hold the main harness with clamp Rear Left Turn Signal Light Lead Run the rear left turn signal light lead to under the main harness Hold the main harness and rear left turn signal light leads with clamp Insert the tail brake light LED lead connector into the hole on the guard to hold it Run the license plate light lead through the hole on the guard Hold the rear right turn signal light lead and license plate light lead with clamp Run the tail brake light LED lead to upside of the main harness Hold the main harness to the rear fender with the blade clips on the main harness 17 28 APPENDIX Cable Wire and Hose Routing APPENDIX 17 29 Cable Wire and Hose Routing BONA NOOO 11 12 13 14 15 16 17 18 Before clamping face the locking portion of the clamp in direction as shown Alternator Lead Run the alternator lead between the brake pipes above the ABS hydraulic unit Alternator Lead Connectors Hold the alternator subharness to the rear frame with band After tying them cut the band excess length and face its knot downward Alternator Subharness between Alternator Lead and Regulator Rectifier Main Harness to Regulator Rectifier Run the alternator subharness and main harness to regulator rectifier through the inside of the rear frame pipe Hold the alternator subharness and m
521. ut Voltage 8 3 82 Radiator Fan Relay Service Code 56 3 84 Radiator Fan Relay Removalllnstallationm 3 84 Radiator Fan Relay Inspection ecrire erede e enu en see toa Rete paints 3 84 Subthrottle Valve Actuator Service Code 62 nennen 3 85 Subthrottle Valve Actuator Removal 9 3 85 Subthrottle Valve Actuator Inspection 3 85 Subthrottle Valve Actuator Resistance Inspection 9 3 85 Subthrottle Valve Actuator Input Voltage Inspection 3 86 Air Switching Valve Service Code 64 nnn nnne tenen 3 88 Air Switching Valve Removal Installation 3 88 Air Switching Valve Inspection 2 3 88 Oxygen Sensor Heater Service Code 67 3 89 Oxygen Sensor Heater Removal Installation 3 89 Oxygen Sensor Heater Resistance 3 89 Oxygen Sensor Heater Power Source Voltage Inspection 3 89 Oxygen Sensor Incorrect Output Voltage Service Code 94 3 92 Oxygen Sensor Removal lnstallation pp 3 92 Oxygen sensor Inspectlgpizsiun ses So a Podio et abe teet Eine Rus 3 92 Warning Indicator Light LED rrt bete da 3 95 Yellow Engine Warning Yellow
522. uty t TX100 50 8 17864 652 e Disconnect the terminal 6 e Check that the tachometer needle A back to the mini mum 0 position x If the meter unit does not work replace the meter unit GP17818CS1 Check 3 16 Other Inspection OThe following items are displayed while running AVERAGE CURRENT RANGE e When the above item is faulty indication check the follow ing items Wiring see Meter Circuit Fuel Injectors see Fuel Injectors Service Code 41 42 43 44 section in the Fuel System DFI chapter Speed Sensor see Speed Sensor Service Code 24 section the Fuel System DFI chapter Crankshaft Sensor see Crankshaft Sensor Inspection x If the above items are good replace the meter unit and or ECU 16 82 ELECTRICAL SYSTEM Gauge Indicator Unit Fuel Level Sensor Line Self Diagnosis Mode Inspection NOTE OUsually when the open or short of the fuel level sensor circuit is detected it becomes the Fuel Level Sensor Line Self Diagnosis Mode OThe all segments of the fuel gauge A in the display will blink This function is Fuel Level Sensor Line Self Diagnosis Mode x If the meter enters the self diagnostic mode when the me ter is installed in the motorcycle check the fuel level sen sor see Fuel Level Sensor Inspection and wiring x If the fuel level sensor and wiring are good replace the meter unit GP17885CS1 Meter Gauge Indicator Unit ELE
523. ve smoothly replace the fuel pump Float in Full Position A Float in Empty Position B Float Arm Stoppers C 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 xIf the tester readings are not as specified do not change smoothly according as the float moves up and down replace the fuel pump Fuel Level Sensor Resistance Standard Full position 9 6 12 4 O Empty position 222 228 6617608652 C GP18620BS1 16 110 ELECTRICAL SYSTEM Relay Box The relay box A has relays and diodes relays 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 Fuel Tank A see Fuel Tank Removal in the Fuel Sys tem DFI Chapter Bolts B Bracket C Cross Member D e For WVTA 78 2 H and GB WVTA FULL H Models re move the ECU guard see Immobilizer System Parts Re placement e Remove Screws A Band B Connector C e Pull up the bracket assembly A e Disconnect the connectors B and remove the relay box C Relay Box Installation e Installation is the reverse of removal ELECTRICAL SYSTEM 16 111 Relay Box Relay Circuit Inspection e Remove the relay box see Relay Box Remova
524. ve the more free play e Remove Throttle Cable Holder Clamp A Throttle Cable Lower Ends B e Loosen the throttle body assy holder clamp bolts A Special Tool Carburetor Drain Plug Wrench Hex 3 57001 1269 Throttle Body Assy FUEL SYSTEM DFI 3 117 e Remove the throttle body assy A from the throttle body assy holders e Disconnect the injector connectors B e Remove the clamps C e After removing the throttle body assy stuff pieces of lint free clean cloth into the throttle body assy holders A WARNING If dirt or dust is allowed to pass through into the throttle body assy the throttle may become stuck possibly causing accident NOTICE If dirt gets into the engine excessive engine wear and possible engine damage will occur Throttle Body Assy Installation e Be sure to position the throttle body assy holder clamp in original position see Throttle Body Assy Holder Installa tion in the Engine Top End chapter e Connect the injector connectors A e Install the throttle body assy to the throttle body assy hold ers e Install the clamps B e Tighten Torque Throttle Body Assy Holder Clamp Bolts 2 9 Nm 0 30 kgf m 26 in Ib Special Tool Carburetor Drain Plug Wrench Hex 3 57001 1269 e Apply a thin coat of grease to the throttle cable lower ends e Fitthe accelerator cable end A and the decelerator cable end B into the throttle pulley OThe acceler
525. ve 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 If the reading exceeds the service limit replace the guide NOTE OThe reading is not actual valve valve guide clearance because the measuring point is above the guide Valve Valve Guide Clearance Wobble Method Standard Exhaust 0 09 0 16 mm 0 0035 0 0063 in Intake 0 03 0 10 mm 0 0012 0 0039 in Service Limit Exhaust 0 36 mm 0 014 in Intake 0 29 mm 0 011 in Valve Seat Inspection e Remove the valve see Valve Removal e Check the valve seating surface A between the valve B and valve seat C OMeasure the outside diameter D of the seating pattern on the valve seat x If the outside diameter is too large or too small repair the seat see Seat Repair Valve Seating Surface Outside Diameter Standard Exhaust 24 7 24 9 mm 0 972 0 980 in Intake 28 9 29 1 mm 1 138 1 146 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 H 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 Intake 0 5 1 0 mm 0 020 0 039 GE15007BS2 C 8 15011752 C 5 32 END
526. vice Limit Exhaust 32 84 mm 1 293 in Intake 32 84 mm 1 293 in Camshaft Chain Removal e Split the crankcase see Crankcase Splitting in the Crank shaft Transmission chapter e Remove the camshaft chain A from the crankshaft sprocket END 5 25 Cylinder Head Cylinder Compression Measurement NOTE OUse the battery which is fully charged e Warm up the engine thoroughly e Stop the engine e Remove Stick Coils see Stick Coil Removal in the Electrical Sys tem chapter Spark Plugs see Spark Plug Replacement in the Peri odic Maintenance chapter e Attach the compression gauge A adapter B and hose C firmly into the spark plug hole OUsing the starter motor turn the engine over with the throt tle fully open until the compression gauge stops rising the compression is the highest reading obtainable Special Tools Compression Gauge 20 kgf cm 57001 221 Compression Gauge Adapter M10 x 1 0 57001 1601 L Shape Hose 57001 1606 Cylinder Compression Usable Range 770 1 198 kPa 7 9 12 2 kgf cm 112 174 psi at 236 r min rpm e Repeat the measurement for the other cylinders e Install the spark plugs Torque Spark Plugs 13 N m 1 3 kgf m 115 in Ib OThe following table should be consulted if the obtainable compression reading is not within the us able range Problem Diagnosis Remedy Action Remove the carbon deposits and replace damaged parts if
527. vice limit replace the pis ton Piston Diameter Standard 76 974 76 984 mm 3 0305 3 0309 in Service Limit 76 82 mm 3 024 in 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 Standard Top 0 03 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 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 82 0 84 mm 0 0323 0 0331 Second B 0 81 0 83 mm 0 0319 0 0327 in Service Limit Top A 0 92 mm 0 0362 in Second B 0 91 mm 0 0358 in x If the width of any of the two grooves are wider than the service limit at any point replace the piston GE16064BS1 C GE16065BS1 C GE16070781 Cylinder Pistons ENGINE TOP END 5 41 Piston Ring Thickness Inspection e Measure the piston ring thickness OUse the micrometer to measure at several points around the ring Piston Ring T
528. w B to assemble the yoke and end cover e Align the marks A to assemble the yoke and the end cover B 16 52 ELECTRICAL SYSTEM Electric Starter System e Tighten Torque Starter Motor Through Bolts A 5 0 N m 0 51 kgf m 44 Brush Inspection e Measure the length of each brushes A If any is worn down to the service limit replace the brush assy Starter Motor Brush Length Standard 12 mm 0 47 in Service Limit 6 5 mm 0 26 in Commutator Cleaning and Inspection e Clean the metallic debris off the between commutator segments A NOTE ODo not use emery or sand paper on the commutator e Check the commutator for damage or abnormal wear Replace the starter motor with a new one if there is damage or wear e Visually inspect the commutator segments for discol oration Replace the starter motor with a new one if discoloration is noticed Armature Inspection e Using the x 1 O hand tester range measure the resis tance between any two commutator segments A Special Tool Hand Tester 57001 1394 x If there is a high resistance or no reading 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 foreg
529. was ended do the regis tered ignition key s verification procedure over again to restart it This applies to all ignition key registration e Insert the ignition key 1 into the ignition switch and turn it to ON NOTE OKeep other ignition keys away from the immobilizer an tenna 0 5second 0 5second 0 3second LIL LU 8 300260651 8 30027051 16 86 ELECTRICAL SYSTEM Immobilizer System Equipped Models Olf there is any problem in the registration the red warning indicator light LED and the immobilizer warning symbol A blink 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 the immobilizer warning symbol A blink 3 times and stop for 1 second and then repeat this cycle Turn to OFF the ignition switch and remove the ignition key 1 OThe immobilizer warning symbol A disappears OThe red warning indicator light LED then blinks for 15 seconds OAfter 15 seconds the ECU ends the registration mode and stops blinking the red warning indicator light LED NOTE OThis procedure registered the registered ignition key and one ignition key If more keys registration is needed go to next
530. witch Pressure Sensor Sensor 2 E TIT S Switch Intake Air Pressure Sensor 1 BK Y BK Y BK Y K 8L Regulator Rectifier Alternato Diagnostic System Connector 5 555555 22 0 4 EIS 224222 25 RA Frame 3 WW Eround Joint 4 Rear Connector B Frame Frame round Ground Brake 2 5 Light Switch Starter 1 ECU Fuse 2 Main Fuse 304 ABS Self ABS Kawasaki Fuse Box 2 Diagnosis Self i Fan Fuse 154 Terminal Diagnosis 2 Meter Fuse 7 5 System 3 Accessory Fuse 5A Connector 4 ABS Motor Relay Fuse 25 5 ABS Solenoid Valve Relay Fuse 15 Relay 154 RIGHT SWITCH HOUSING CONNECTIONS Front Brake Light Switch Engine Stop Switch Joint Connector F EGU Joint Connector D Rear Wheel Rotation Sensor Rear Right Turn Signa Light 12V10W License Plate Light 12V5W Rear Left Turn Signal Light 12V10W Color Code BK Black BL Blue BR Brown Green Orange P Pink PU Purple R Red W White Y Yellow 98052 0694B W2RO6948W5 C 16 20 ELECTRICAL SYSTEM Wiring Diagram Other than BR and CA Models Right Switch Housing i Front Brake Light Switch 2 Engine Stop Switch a Starter Button Ton Bard e ignition Go I
531. with an immobilizer system when a problem occurs with the system the red warning indicator light LED D and immobilizer warning symbol E blink NOTE OUse a fully charged battery when conducting self diagnosis Otherwise the yellow engine warn ing light LED or red warning indicator light LED and symbol blink very slowly or do not blink e Turn the ignition switch to ON e Push the upper button A to display the odometer e Push the upper button A for more than two seconds The service code B is displayed on the LCD by the num ber of two digits 8017209 52 GCci7103FS1 C 8017104 52 C 3 38 FUEL SYSTEM DFI Self Diagnosis e Any of the following procedures ends self diagnosis OWhen the service code is displayed on the LCD push the upper button for more than two seconds OWhen the ignition switch is turned OFF Self Diagnosis Flow Chart Turn the ignition switch to OFF Turn the ignition switch to ON Display the odometer and push the upper button for more than two seconds Then self diagnosis mode starts The service code s is displayed on the LCD Liquid Crystal Display i Turn the ignition switch to OFF Locate the problem with the service code table and inspect and repair DFI ignition and immobilizer system equipped models according to inspection procedure on all the service codes i Turn the ignition switch to ON
532. ws the Table of Contents In these illustrations you will find the instructions indicating which parts require spec ified tightening torque oil grease or a locking agent during assembly GENERAL INFORMATION 1 1 General Information Table of Contents T Model IdentifICatiOn EE rte ren agr General Specifications Unit Conversion Table 1 2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera tion on a motorcycle read the precautions given below To facilitate actual operations notes illustra tions photographs cautions and detailed descriptions have been included in each chapter wherever necessary This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts Especially note the following Battery Ground Before completing any service on the motorcycle discon nect the battery cables from the battery to prevent the en S gine from accidentally turning over Disconnect the ground 2 qe cable first and then the positive When completed Wa with the service first connect the positive cable to the e 4 positive terminal of the battery then the negative ca A ble to the negative terminal DISASSEMBLY ASSEMBLY 68020248 Edges of Parts
533. xtremely hot during normal operation and can cause serious burns Never touch the engine or exhaust pipe during clutch adjustment Turn the adjuster A so that 5 6 mm 0 20 0 24 in B of threads are visible e Slide the dust cover A at the clutch cable lower end out of place e Loosen both adjusting nuts B at the clutch cover as far as they will go e Pull the clutch outer cable C tight and tighten the adjust ing nuts against the clutch cover D e Slip the dust cover back onto place e Turn the adjuster at the clutch lever until the free play is correct e Push the release lever A toward the front of the motor cycle until it becomes hard to turn OAt this time the release lever should have the proper an gle shown 60 B xIf the angle is wrong check the clutch and release parts for wear A WARNING Too much cable play can prevent clutch disengage ment and cause an accident resulting in serious in jury or death When adjusting the clutch or replac ing the cable be sure the upper end of the clutch outer cable is fully seated in its fitting or it could slip into place later creating enough cable play to prevent clutch disengagement e After the adjustment start the engine and check that the clutch does not slip and that it releases properly 65088289 2 28 PERIODIC Periodic Maintenance Procedures Wheels Tires Air Pressure Inspection
534. y inspect the clutch parts x If there is any worn or damaged part replace it NOTE OExamine the starter motor clutch gear as well Replace it if it worn or damaged Starter Motor Clutch Disassembly e Remove Alternator Rotor see Alternator Rotor Removal in the Electrical System chapter e Hold the alternator rotor with the flywheel holder A Special Tool Flywheel Holder 57001 1313 e Remove the starter motor clutch bolts B e Remove Starter Motor Clutch Housing A Starter Motor Clutch B Starter Motor Clutch Assembly e Install the starter motor clutch to the housing so that the flange A fit to the housing groove B e Apply a non permanent locking agent to the threads of the starter motor clutch bolts and tighten them Torque Starter Motor Clutch Bolts 12 N m 1 2 kgf m 106 in Ib 9 28 CRANKSHAFT TRANSMISSION External Shift Mechanism Shift Pedal Removal e Remove Shift Lever Bolt A Shift Lever B Shift Pedal Mounting Bolt C Shift Pedal D with Tie rod E Shift Pedal Installation e Tighten Torque Shift Pedal Mounting Bolt A 25 2 5 kgf m 18 ft lb Shift Pedal B Washer C e Align the punch mark the shift shaft with the slit B of the shift lever e Tighten the shift lever bolt C e After installation confirm that the shift pedal A is posi tioned as shown in the figure About 90 B x If the pedal position is diff
535. y or death To ensure proper handling and stability use only the recommended standard tires for replacement inflated to the standard pressure Special Tools Inside Circlip Pliers 57001 143 7570143ST C Bearing Driver Set 57001 1129 7571129ST C Jack 57001 1238 7571238ST C Attachment Jack 57001 1252 875712525 6 WHEELS TIRES 10 5 Bearing Remover Head 20 x 22 57001 1293 7571293ST C Bearing Remover Shaft 13 57001 1377 875713775 Jack Attachment 33 UL 7571608ST C 10 6 WHEELS TIRES Wheels Rims Front Wheel Removal e Remove Lower Fairing see Lower Fairing Removal in the Frame chapter Front Fender A see Front Fender Removal in the Frame chapter Front Caliper Mounting Bolts B Both Sides Front Calipers C Both Sides Bolt D Front Wheel Rotation Sensor E e Loosen Front Axle Clamp Bolt A Front Axle B e Raise the front wheel off the ground Special Tools Jack A 57001 1238 Attachment Jack B 57001 1252 Jack Attachment C 57001 1608 e Pull out the axle to the right and drop the front wheel out of the forks UR NOTICE Do not lay the wheel down on one of the discs This can damage or warp the disc Place blocks un der the wheel so that the disc does not touch the ground Front Wheel Installation NOTE OThe direction of the wheel rotation A is shown
536. y 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 STOD istis ios Outer diameter of cutter C GE15133BS1 C 8 15011851 C Valves ENGINE TOP END 5 33 Operating Procedures e Clean the seat area carefully e Coat the seat with machinist s dye e Fit a 45 cutter into the holder and slide it into the valve guide e Press down lightly on the handle and turn it right or left Grind the seating surface only until it is smooth 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 e Measure the outside diameter of the seating surface with a vernier caliper x If the outside diameter of the seating surface is too small repeat the 45 grind until the diameter is within the spec ified range Widened Width A of engagement by machining with 45 cutter Ground Volume B by 32 cutter 32 C Correct Width D Ground Volume E by 60 cutter 60 F e Measure the outside diameter of the seating surface with a vernier caliper If the outside diameter of the seating surface is too small repeat the 45 grind A until the diameter is within the specified range Original Seati

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